Tank sensing
- Replace certain fittings with welds inside tank
Aft end cavity environment failure
- Increase fire suppression capacity by 15x
Booster leak mitigation
– Replace certain manifolds with dedicated drain per corresponding valve
Replace certion flanges with better seals and improve joint design
Replace certion fittings with welds in specific location
- Replace accessible valves of a certain type with new design
- Replace certain flange bolts with higher strength bolts and increase torque
- Disallow certain seal re-use, and add cameras to monitor all engines during ground operations
- Increased scrutiny on leak checks
- 90+ cameras added to detect leakage during operations
Raptor leak mitigation
- Add leak capture and drain hardwarev for valves of a certain type
- leak check and screen for porosity on igniter units
- Improved igniter seal design
- Weld certain alignment bolt holes shut
- Reassess k-factor and torque for engine hot joint #1, add leak capture and route overboard
- Reassess k-factor and torque for engine hot joint #2
- Add safety cable to certain fluid lines on high risk locations
- Add one methane sensor per engine bay
- Ground test campaign to better characterize typical engine leakage
- Improve structural FEA/fatigue analysis for all medium to high criticality lines
Collateral damage from fire
- Add insulation to engine lines sensitive to thermally driven loads
- Add insulation to avionic harnessing
- Add backup wire to specific harness
- Improve thermal protection of avionics tray
- Change routing to flight computers
Booster reliability improvement
- Replace sensor with more reliable units
- Coat gimbal assembly with lubricant
- Add pump pressure sensors to certain location
- Add pump temperature sensors to certain location
- Replace certain bolts, and increase torque for certain flanges
- New seal design for certain areas of booster
- Add electric actuation system
- Better manage engine bay pressure by increasing fire suppression capacity by
- Replace sensor with more reliable units
- Coat gimbal assembly with lubricant
- Add pump pressure sensors to certain location
- Add pump temperature sensors to certain location
- Replace certain bolts, and increase torque for certain flanges
- New seal design for certain areas of booster
- Add electric actuation system
- Better manage engine bay pressure by increasing fire suppression capacity by 15x
- Change certain booster valve timing
Raptor reliability improvement
- Add final leak checks for critical joints
- Add support bracket for certain sensor
- Add support bracket for certain sensor
- Add check valves to certain areas of engine
- Improve oxygen valve design
- Improve oxygen valve seal design
- Improve design of hot manifold
- Change nitrogen shutdown usage
- Change engine shutdown logic
- Increase capability for ground leakage mitigation
- Redesign fire suppression system
- Change conditions around bolts
- Change timing of specific valve actuation
Avionics reliability
- Eliminate certain type of connector improvement
- Redesign network architecture
Risk Process
- Improve risk tracking process
Safety System
- Implement improvements to safety system
- Verify flight safety system design improvements using additional type of test article
- Verify flight safety system design improvements via analysis
- Perform component testing
N
- Review and improve operations surrounding flight safety system
Change Control
- Improve CAD controls
- Add engineering walkdown
- Improve use of change management system
Pad Design
-Redesign of launch pad deck
- Improve assumptions for new pad deck design
- Add water cooled pad deck
Pad Design Process
- Improve pad deck design documentation
- Improve pad design process
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