Unethical Decisions - The Causes of the Space Shuttle Challenger Disaster Roger Boisjoly — Transcript
Full transcript
- 0:45I'm eating I don't know whether this is
- 0:49because professor black shares lunches
- 0:52are you a little longer than usual this
- 0:53quarter but we'll be starting from 335
- 0:57from now on the questions related to
- 1:03ethics are being raised in a number of
- 1:06arenas today in education we see this in
- 1:09the proposal for the liberal education
- 1:13of the University of Minnesota where
- 1:15there are strong recommendations for
- 1:17courses and ethics we see this in the
- 1:19requirements of the Accreditation Board
- 1:21for Engineering and Technology where is
- 1:24a strong push for engineering ethics
- 1:28courses for engineers and it's fine to
- 1:32do this in what we sometimes call an
- 1:34academic manner in terms of reading
- 1:36about ethical problems and ethical
- 1:38issues and and decisions made on ethics
- 1:41and either from a textbook or from a
- 1:43faculty member but today we'll have a
- 1:45living example of an issue in
- 1:48engineering ethics and the person that
- 1:50played a key role in in in a very
- 1:53important manner it's been said that the
- 1:56engineering advances often as a result
- 1:59of failures that we learn from the
- 2:02analysis of failures of systems what one
- 2:05might do in the future and what one must
- 2:08do in the future and that's fine and and
- 2:11there's a certain more than grain of
- 2:13truth to that perhaps but one thing is
- 2:15to learn from failures that one could
- 2:17not predict before the failure occurred
- 2:19it's another thing when people were
- 2:21predicting a particular failure and then
- 2:23it occurs and and that latter issue is
- 2:25the one which we'll hear about today and
- 2:27it's truly a an ethical issue which will
- 2:30go down in the history of engineering in
- 2:32the history of the u.s. the failure that
- 2:35led to the disaster of the of the space
- 2:39shuttle Challenger is one that was well
- 2:40known to everybody here today it's an
- 2:44issue that raised problems related to
- 2:47engineering decisions versus what were
- 2:49called some extent management decisions
- 2:51brings rise to questions of the need for
- 2:54having technical leadership at
- 2:57proper levels and industry and that
- 2:59technical leadership making decisions on
- 3:01technical grounds as well the speaker
- 3:04today is one who has been called with
- 3:07the good reason a whistleblower and has
- 3:12suffered all of the the bad as well as
- 3:15some of the good that occurs to
- 3:17whistleblowers as you'll hear about
- 3:19today I think it's a rare opportunity
- 3:21for us to hear the firsthand about the
- 3:24key issues related not only to what has
- 3:28become a very tragic incident but also
- 3:30key issues related to what engineers
- 3:32must do and consider when practicing in
- 3:36industry Roger Beaujolais is a graduate
- 3:39of what is now the University of Lowell
- 3:42he received an engineering degree there
- 3:43in 1960 he worked for a number of
- 3:47companies generally related to aerospace
- 3:51industry from July 1980 he started to
- 3:56work for Morton Thiokol in Utah he
- 3:59worked there through of course the
- 4:00incident on the Challenger which was in
- 4:02January 86 and left the company later on
- 4:06in 1986 he's been giving lectures at
- 4:09some other educational institutions I
- 4:12heard him a few years ago speak at the
- 4:14American Society of Mechanical Engineers
- 4:15meeting I'm sure you'll all be impressed
- 4:18with the knowledge he'll in part today
- 4:21and the sincerity in which he'll deliver
- 4:23mr. Poli
- 4:38oh I can come on lightboxes off there we
- 4:52go okay good afternoon what I'm going to
- 4:57do is define to you the circumstances
- 5:00leading to the challenge of disaster and
- 5:02give you a factual chronology of what
- 5:05happened that led to the decision-making
- 5:08process before I start I'd like to give
- 5:11you somewhat of a familiar familiar
- 5:14ization process here well looking at
- 5:16here is that what we call the stack on
- 5:17the shuttle the solid rocket boosters
- 5:19the external tank and the orbiter itself
- 5:21and I'm going to be primarily focusing
- 5:26on the solid rocket booster phase the
- 5:30booster is actually made up of four
- 5:32segments that are transported to Cape
- 5:34Canaveral and assembled ready for launch
- 5:36we're looking at the forward section
- 5:39forward Center the App Center in the aft
- 5:43section containing the nozzle itself the
- 5:45reason I show you this is because I want
- 5:47to point out a full booster and show you
- 5:48this is the joint that failed and this
- 5:51is the configuration of that particular
- 5:53joint I have a full-size set of pictures
- 5:56of that in the moment another joint that
- 5:58I will be discussing is part of the
- 6:00escalation of the problem is this nozzle
- 6:02joint that looks like so and again I
- 6:04have a full-size graph of that that I
- 6:06want to show you what really started
- 6:12with like what the concerns was the fact
- 6:16that when we assemble this this filled
- 6:19joint you can see we have vacuum putty
- 6:23located between the two interfaces on
- 6:26either side of this joint the joint is
- 6:28configured with a clevis and a tang the
- 6:32tank fits into the clevis with two
- 6:33o-rings we refer to the first o-ring
- 6:36that the hot gas had the potential of
- 6:38reaching through this path right here as
- 6:40their primary or ring seal and then the
- 6:43redundant secondary seal behind it was
- 6:46the flight rate man rating of this
- 6:50basically this was our backup seals
- 6:52should anything ever occur in hot gas
- 6:54get past this primary seal now the gas
- 6:57that this system was to protect against
- 6:59was approximately 5700 degrees
- 7:01Fahrenheit and it was never intended to
- 7:03have any holes in this party it was
- 7:05never intended for this gas to ever come
- 7:07down and penetrate and even reach a seal
- 7:09but unfortunately the mechanism of
- 7:12assembly caused and trapped air to occur
- 7:14and occasionally and quite frequently in
- 7:17fact we'd get bore holes in this putty
- 7:19which would then provide a path during
- 7:22ignition for the hot gas to come down
- 7:23and attack the o-ring seals just to show
- 7:27you well I guess not on a more vivid
- 7:29detail I had a full scale model here but
- 7:31I think I will forego that the joints
- 7:34were actually put together like I said
- 7:36Tang in clevis and pinned in a hundred
- 7:39and seventy seven locations these pens
- 7:41one inch diameter actually carried the
- 7:43structural load as the internal pressure
- 7:45was generated as you can see here this
- 7:48is a propellant outline and there's
- 7:50actually a hole down the centerline of
- 7:52the motor so large in fact that you
- 7:54could actually stoop down and walk down
- 7:55the full length of this motor these
- 7:57components were twelve foot in diameter
- 7:59and contained 1.1 million pounds of
- 8:03propellant when they were fully
- 8:04assembled ready for flight at the Cape
- 8:06the problem really started to escalate
- 8:09in January of 1985 in January of 1985 I
- 8:13was at the Cape and when the boosters
- 8:16were recovered for reuse and
- 8:18refurbishment and disassembled at the
- 8:21Cape I inspected them and I found two
- 8:23failed joints of the character that I
- 8:25just showed you had massive leaks in
- 8:27them we had compromised the primary seal
- 8:30and two filled joints in fact they were
- 8:32compromised so bad that in one joint
- 8:34we actually had eighty degrees of
- 8:37blackened grease between these two seals
- 8:39which indicated the products of
- 8:40combustion had actually blown by this
- 8:42first primary seal and fortunately were
- 8:45actually stopped by the secondary seal
- 8:47one joint had 80 degrees arc length and
- 8:49the other joint had 110 degrees arc
- 8:51length was postulated after this launch
- 8:53that these seals had a temperature of 53
- 8:55degrees Fahrenheit well in by March
- 8:58early late March late February early
- 9:02March of 1985
- 9:03I had brought this information back and
- 9:06one of my colleagues former supervisor
- 9:08in fact had devised what we referred to
- 9:09as a resiliency test to actually test
- 9:12the capability of these seals to perform
- 9:14in an environment that we had not
- 9:17previously tested for namely alloy the
- 9:19normal launch temperature we found out
- 9:22for these pulmonary Orange resiliency
- 9:24tests that we were in severe problem
- 9:28area at 50 degrees Fahrenheit the seals
- 9:31had a distinct problem with them at that
- 9:33temperature we presented this
- 9:35information to engineering management if
- 9:37I call but they felt it was just too
- 9:39sensitive to release to anybody and so
- 9:41they just kept it secret the only people
- 9:44that really know about it was the
- 9:45individuals who had actually worked and
- 9:47knew about the tests and and were privy
- 9:49to the results well and I will I will
- 9:53give you this data later on in the
- 9:55presentation so you know precisely what
- 9:57the data encompassed in June of 1985 the
- 10:01problem escalated once again we opened
- 10:05up a a nozzle joint this time and the
- 10:09nozzle joint is made up of a joint that
- 10:11looks like so this is what we call the
- 10:14nozzle fixed housing and a nozzle cone
- 10:17actually lays across the exit like so
- 10:19and so what we have here is a piece of
- 10:23metal that supports the gimballed nozzle
- 10:26that actually is attached to the F
- 10:27closure dome and the metal parts are
- 10:30heavily insulated because of the
- 10:32turbulence of the gas in this area and
- 10:34again we find a gap between the
- 10:36insulation which was filled with vacuum
- 10:37putty again the primary seal would be in
- 10:40this location the first seal designated
- 10:42as the primary is that is the seal that
- 10:44would first be attacked by hot gas
- 10:46should it ever occur now in this joint
- 10:48we have a different characteristic in
- 10:50that we have a very very safe secondary
- 10:52seal which is a face seal around the
- 10:55corner it's actually squeezed between
- 10:56two massive pieces of metal this
- 10:58represents almost the full-scale
- 11:00cross-section of what we're looking at
- 11:01we have a hundred one in an eighth inch
- 11:03diameter bolts that actually clamp this
- 11:05face together
- 11:06now what I'm about to show you when we
- 11:09is what we found when we opened up this
- 11:11joint in June of 1985 from an actual
- 11:15flight that occurred in April
- 11:17this particular segment was actually
- 11:18sent back to psych all in Utah with the
- 11:21nozzle intact on this particular
- 11:23assembly and we just assembled it at
- 11:25Utah cause it was much easier to do it
- 11:27that way back at our plant now what I'm
- 11:29about to show you is the condition of
- 11:31the seal that actually came out of that
- 11:34joint and I'd like to point out to
- 11:36people this is not a cartoon this is an
- 11:39actual photographic cross-sections of
- 11:42the seal that will remove from that
- 11:43joint and as you can see the seal had
- 11:46three heat-affected notches in it from
- 11:48the hot gas each of these cross-section
- 11:51refers to a notch as shown in the plan
- 11:54view now what we're looking at side view
- 11:56what we're looking at here is this
- 11:58highlighted the dark highlighted outline
- 12:00is the amount of seal material that
- 12:02remained as opposed to the round
- 12:05circular cross-section that should have
- 12:06been there and if you look at this worse
- 12:08cross-section I would estimate that
- 12:11somewhere between 75 and 80 percent of
- 12:12the cross section has been vaporized by
- 12:14the hot gas we postulated that this
- 12:17cross section in this seal had never
- 12:20sealed for the full two minutes of
- 12:22booster flight and so we really had a
- 12:25brand-new ballgame here because if
- 12:27whatever happened to this joint and we
- 12:30come up with several postulations as to
- 12:32what it might have been but after all we
- 12:34don't have crystal balls but whatever
- 12:36happened to this joint if it should
- 12:37happen to a filled joint then all bets
- 12:39are off because the filled joint might
- 12:41fail because both of those seals bore
- 12:43seals on the same surface and it's not
- 12:46difficult to predict that whatever
- 12:48happened to one could happen to the next
- 12:50one in line now at the same time this
- 12:52was going on in this joint
- 12:53the secondary seal around the corner
- 12:55that very safe seal that I spoke to you
- 12:57about was also eroded 30 mm of an inch
- 13:01and so we really had a new problem on
- 13:05our hands and another miss Ann Ennis
- 13:08well this was so serious that for the
- 13:11next flight right in this review we had
- 13:14to go down and present a complete status
- 13:19of all the booster seals on the shuttle
- 13:21program to NASA at the Marshall Space
- 13:22Flight Center so we did this and because
- 13:25of the seriousness of this what we just
- 13:27found on this seal it was decided
- 13:30engineering management that they would
- 13:31now release the information that they
- 13:33had been keeping secret up to this time
- 13:34and they presented that information to
- 13:37NASA now everybody on the program knew
- 13:39about the seriousness of these seals and
- 13:42they're serious functional capabilities
- 13:45at 53 degrees Fahrenheit actually at 50
- 13:47because that was the whole limit we
- 13:49tested well as you can imagine I waited
- 13:52for some action to take place and I
- 13:53waited two four weeks and virtually
- 13:56nothing was done they had formed an
- 13:58unofficial task force team but virtually
- 14:00nothing was being done after two weeks
- 14:03of frustration with this activity I
- 14:05wrote a memo on a 31st of July 1985 to
- 14:10the vice president of engineering at
- 14:11Morton Thiokol and I'd like to give you
- 14:13a sense of that memo in quote one
- 14:16paragraph the memo ended by saying quote
- 14:19it is my honest and very real fear that
- 14:21if we do not take immediate action to
- 14:24dedicate a team to solve the problem
- 14:26with the field joints having a
- 14:27number-one priority then we stand in
- 14:29jeopardy of losing a flight along with
- 14:32all the launchpad facilities I also
- 14:34mentioned in that memo that we were
- 14:37going to experience a failure the
- 14:38highest order loss of human life on
- 14:41August 15th a seal task force team was
- 14:44officially formed I believe is the
- 14:46direct result of that memo although no
- 14:48one ever talked to me about that memo
- 14:51the Vice President engineering never
- 14:53wrote me a memo back or never talked to
- 14:55me about the contents of that memo but
- 14:57he published a memo officially forming
- 14:59this team which had five of us
- 15:02designated as full-time members out of
- 15:05approximately 2,500 people working on
- 15:06the program not all of whom were
- 15:08engineers of course unfortunately for us
- 15:10they were assigned to this team we
- 15:12received virtually no management support
- 15:14whatsoever the major production program
- 15:17dominated all available resources as we
- 15:20struggle to get changes tested and
- 15:25implemented in the program itself well
- 15:28on August 19th NASA headquarters was
- 15:30getting a little antsy so they asked for
- 15:31presentation from Morton Thiokol again
- 15:33on the status of the booster seals on
- 15:35the shuttle program and that's the
- 15:38management was assured by thiokol senior
- 15:40people that it was safe to continue fine
- 15:43well January 27th was the concluding
- 15:45major event that was in front of us
- 15:49prior to the challenge of disaster on
- 15:51that day we got a rather benign
- 15:52telephone call asking if we were
- 15:55concerned about the predicted overnight
- 15:56temperature low of 18 degrees Fahrenheit
- 15:59and of course being the only technical
- 16:02person that had seen the joints
- 16:03disassembled via before I bought went
- 16:05into orbit without any booster assist at
- 16:07all and very very concerned along with
- 16:09my colleagues we mustered up a group of
- 16:12engineers that were extremely concerned
- 16:13with what we were faced with we
- 16:16convinced thiokol engineering management
- 16:18and also the business side of the house
- 16:19on my dad that day that it was not safe
- 16:22to launch under these conditions based
- 16:24on our previous years experience and the
- 16:26experience during the year in the
- 16:28escalation of the problem we were asked
- 16:30by and we transmitted this informally to
- 16:33the Marshall Space Flight Center NASA
- 16:34Massa Marshall Space Flight Center we
- 16:36were asked to give a formal presentation
- 16:38that evening to express our concerns so
- 16:40a formal talk on was convened and we
- 16:43were at Morton Thiokol in Utah where we
- 16:46were gathered there were 14 of us there
- 16:49were a group at the Kennedy Space Center
- 16:50and then there was a group at the
- 16:52Marshall Space Flight Center which was a
- 16:54technical branch that had oversight for
- 16:55the shuttle solid rocket boosters
- 16:57we started our presentation and what I'd
- 17:00like to show you is a sampling or the
- 17:03view graphs that we presented that night
- 17:04and I'd like to point out to people that
- 17:07we had precisely about 45 minutes to
- 17:09present prepare this formal presentation
- 17:12and we as individuals went to our own
- 17:14offices and prepared prepared these view
- 17:16graphs and none of us knew what the
- 17:19other people were presenting except we
- 17:21saw it in real time but I hope that you
- 17:24understand after you see them that what
- 17:25we presented was enough information from
- 17:27an engineering standpoint to stop the
- 17:29flight what this was was a sheet in a
- 17:32cartoon that I had torn right out of an
- 17:34October 85 presentation to SAE that I
- 17:37gave to 130 technical experts in this
- 17:39nation concerning the sales in this
- 17:41joint in how they operate as I solicited
- 17:43help from their expert opinions so I had
- 17:47this at my fingertips so I included this
- 17:49I thought this would be another neat way
- 17:51to drive the point home once again what
- 17:53the problem was
- 17:54if you look at this top view with this
- 17:56centerline of the segment being here
- 17:58relative to this piece here you'll find
- 18:00that everything is as it should be when
- 18:03it's assembled you see how the o-rings
- 18:04are touching both sides of the surfaces
- 18:06that's how or ings are really supposed
- 18:08to work but you'll find in in the
- 18:11pressurized view down below with the
- 18:14same criteria this is the centerline
- 18:15relative to this view that as pressure
- 18:18is applied to this cylinder in the walls
- 18:20actually bulge out radially the joint
- 18:23doesn't deflect quite as far because it
- 18:25has a largest stiffness well the effect
- 18:27of that differential deflection is to
- 18:29cause this inboard clevis leg to deflect
- 18:32in towards the centerline of the motor
- 18:33at the same time that the Tang is
- 18:35deflecting outboard with the resulting
- 18:37effect that this gap opens tremendously
- 18:39on the order of 42 to 60 thousandths of
- 18:43an inch the 42 thousandths of an inch is
- 18:45a measured maximum number conducted in
- 18:4712 tests with hydraulic oil as we had
- 18:50measured over the period of time this is
- 18:52my best estimate of 60,000 switch may be
- 18:55a practical upper limit since we had
- 18:57only run 12 tests and I wasn't about to
- 18:59stand up and say that we had screened
- 19:01out the maximum at that point in time
- 19:02and so this was my best estimate now
- 19:05when I presented this to seal experts in
- 19:07San Diego at sae nobody said a word and
- 19:11I know why they didn't say a word
- 19:12because these are more than an order of
- 19:13magnitude beyond the accepted industrial
- 19:16standards for the uses of o-ring design
- 19:18these should be on the order of a
- 19:20thousand so it's two thousandths of an
- 19:22inch
- 19:23and we're talking 42 to 60 thousandths
- 19:25of an inch in a pressurized condition
- 19:27with an o-ring of that size now the
- 19:29problem is exacerbated even further
- 19:32because you'll see that the secondary
- 19:34o-ring has lifted off its seal see
- 19:37that's the problem with this joint when
- 19:40the joint opens that much this small
- 19:42diameter seal with with the 20,000th
- 19:44minimum squeeze on it does not have the
- 19:47margin to allow it to stay seated on its
- 19:50mating surface and so this is a
- 19:52misapplication of o-ring technology and
- 19:55if you want to look at what happened to
- 19:56challenge it just picture both o-ring
- 19:58seals looking like the secondary seal
- 20:01position both o-rings will lift it off
- 20:03in hot gas won't roaring by eating the
- 20:05seals that will lift
- 20:06off alive as it went out the case
- 20:08continued a slow leak until it reached
- 20:10about 50 seconds then it started to flow
- 20:12more rapidly and the trace on the
- 20:14pressure transducer at the head end
- 20:16showed the the the pressure drop falling
- 20:18at the same time the hole was growing at
- 20:2073 seconds the hole is analytically
- 20:23predicted to be about 25 inches in
- 20:25diameter when they found the pieces it
- 20:27was about 25 inches in diameter I had
- 20:32also taken this right out of the August
- 20:3519th presentation though
- 20:36NASA headquarters I had prepared this
- 20:38chart for that presentation although I
- 20:40didn't present it at that time you can
- 20:42see way back in August my primary
- 20:45concern was at the field units that had
- 20:47the highest concern the erosion
- 20:49penetration of the primary si requires a
- 20:51reliable secondary seal for pressure
- 20:53integrity and I've broken it down into
- 20:55two conditions ignition transient and
- 20:58steady-state in a 0 to 600 millisecond
- 21:01region is the time it takes to go from
- 21:03zero pressure to a thousand for PS I
- 21:07broke that down into three regimes 0 to
- 21:09170 milliseconds we have a high
- 21:12probability of having a secondary co in
- 21:16other words the secondary seal will be
- 21:17contacting like the primary seal because
- 21:19we have really not experienced any joint
- 21:22rotation yet because nothing is really
- 21:24happening it's just starting to be
- 21:26pressurized in the 170 to 330
- 21:29millisecond region we have somewhat a
- 21:31reduced probability because now motion
- 21:33is is starting and then 330 to 600 we
- 21:36have a high probability that we might
- 21:38not have secondary seal capability now
- 21:41how did we know this well we had done
- 21:44bench testing that actually showed us
- 21:45this and bench testing also showed us
- 21:47that the initial phase of 100 and 0 to
- 21:50170 milliseconds was safe and if we
- 21:53should ever penetrate the seal primary
- 21:56seal after the initial ignition
- 21:58transient we had a high probability that
- 22:01we would have no secondary seal
- 22:02capability because it would be lifted
- 22:04off and so what we were talking about
- 22:06here is timing function if you'll find
- 22:09this referred to later on as timing
- 22:11function and
- 22:15this was nothing new they had seen this
- 22:18before but this was just kind of
- 22:19reinforce what we had already presented
- 22:22to them what this chart was was a chart
- 22:26made up and you see it's hand printed we
- 22:28didn't have the time to get it typed up
- 22:29I just hand printed this so you have to
- 22:31excuse some of the the words and you can
- 22:33see I just stuck things in as
- 22:36appropriate I did this specifically for
- 22:39Challenger that other chart had nothing
- 22:41to do a challenger that was a general
- 22:42chart and the program itself and you'll
- 22:45notice that I had no mention of
- 22:46temperature in the other chart I was
- 22:47afraid of these joints even at room
- 22:49temperature in the middle of summer
- 22:50because that joint was simply a lousy
- 22:53design a temperature lower than the
- 22:56current database results in changing the
- 22:57primary no ring sealing timing function
- 23:00those are the three zones that I
- 23:01described previously that was my fear
- 23:03that we'd slide from that first safe
- 23:05zone to one of those two other zones and
- 23:08heaven forbid the last zone nearing 330
- 23:12milliseconds this is the January 85
- 23:15launch designated as the 15th white
- 23:17where we had 80 and 110 degrees of arc
- 23:19length of black and grease luring
- 23:22squeeze would result in would be at the
- 23:25result of lower temperature I'd actually
- 23:26run a calculation that day which showed
- 23:28the cross section of the O ring to
- 23:29shrink by one thousandth of an inch not
- 23:31very much but we didn't have very much
- 23:33to spare and it's in a wrong direction
- 23:34higher o range short hardness that
- 23:37material gets just like a brick when it
- 23:40freezes we were just slightly above the
- 23:42glass transition temperature which is
- 23:44defined as the temperature of an
- 23:46elastomer at which all the way the
- 23:47spaces disappear and it is now like a
- 23:49piece of metal thicker grease viscosity
- 23:53not the best wording in the world but
- 23:54what I'm referring to is the
- 23:56slipperiness or the quality of the
- 23:57grease to allow the o-ring to slide into
- 23:59position it would impede that someone
- 24:02higher or ring pressure actuation time
- 24:04is a result of lower temperature than we
- 24:07had experienced previously now the
- 24:09bottom two bullets sum up the whole
- 24:12discussion that evening in the whole
- 24:15fear if the actuation time increases the
- 24:17threshold of secondary seal
- 24:19pressurization capability is approached
- 24:21that was what we were really afraid of
- 24:23if the threshold is reached then it's
- 24:26really a jump ball
- 24:27we might not be able to seal these
- 24:29joints we were not talking about these
- 24:31joints sealing once the seals are
- 24:33sealing and working and being attacked
- 24:35by hot gas we were talking that night
- 24:37about them even functioning as being
- 24:40able to function as seals before the hot
- 24:41gas ate them alive this is the infamous
- 24:45data that we obtained in the February
- 24:46March timeframe in 1985 and as you can
- 24:48see by the data when we ran these tests
- 24:51now let me first explain what we
- 24:53actually did we actually took an o-ring
- 24:55between two steel plates and and we
- 24:59squeezed down to two steel plates to
- 25:02actually represent this action right
- 25:05here on the on the actual joint and what
- 25:10we were doing is squeezing it down
- 25:12squeezing an o-ring down let me just
- 25:15actually make it perfectly clear by
- 25:17putting an o-ring seal in there we
- 25:18actually squeezing the o-ring down 40
- 25:20thousands of an inch and then removing
- 25:2330 thousandths of that squeeze so we
- 25:26should have had a residual squeeze of
- 25:27ten thousandths of an inch and measuring
- 25:30and you know by optical means and white
- 25:32means whether or not the o-ring still
- 25:35maintained contact with both metal parts
- 25:37well we did that at a hundred degrees
- 25:39Fahrenheit and we found that at a
- 25:42hundred degrees the o-ring maintained
- 25:45contact with the metal parts we did it
- 25:48in 75 degrees Fahrenheit and we found
- 25:50that it separated for 2.4 seconds and at
- 25:5350 degrees the same tests produced the
- 25:56results of separation for an excess of
- 25:5810 minutes we start measuring after 10
- 26:00minutes because it was ridiculous to to
- 26:02proceed with with further measurement
- 26:04because 10 minutes and 2.4 seconds
- 26:07compared to 200 milliseconds actually I
- 26:10designated it as a hundred and 70
- 26:11milliseconds now that 170 milliseconds
- 26:14was my best estimate post-disaster
- 26:16testing was literally thousands of tests
- 26:18pointed to real number being 200
- 26:21milliseconds so I missed it by a few
- 26:23ticks if you can see that this also was
- 26:27a unconservative test but we had fixed
- 26:30machine settings at the time and this
- 26:32was only preliminary set of data we
- 26:34actually separated to inches a minute in
- 26:36the flight rate was 3.2 inch inches per
- 26:38minute so this was slightly
- 26:39unconservative
- 26:40but I I point to this and tell everybody
- 26:44that's in engineering I only need one
- 26:46piece of negative data to shut something
- 26:47down I can't necessarily say the same
- 26:50thing to go forward with a project but I
- 26:52only need one negative piece of data to
- 26:54shut something down that was a very bad
- 26:56piece of data to continue going forward
- 27:00with this program and yet and this is
- 27:03the data we presented and had in our
- 27:04possession that evening and I was asked
- 27:06during of course a telephone
- 27:07conversation to produce other data and
- 27:09how to share frustration from being
- 27:11badgered I basically blurted it out that
- 27:14I'm sorry I don't have anything other
- 27:15than what I presented because I've been
- 27:17trying to get other data since last
- 27:19October and in the system just would not
- 27:21allow me to get it and when I said that
- 27:23the general manager Bob Plant just about
- 27:25come out of his chair the conclusions
- 27:28and the next chart the recommendations
- 27:30chart were actually written and
- 27:31presented by the vice president
- 27:32engineering at Mullen cycle based on our
- 27:34input up to up to the meeting time the
- 27:38temperature of the o-ring is not the
- 27:39only parameter controlling buh-bye well
- 27:41absolutely that's a given statement
- 27:42because we had blow-by at various
- 27:44temperatures but the characteristic of
- 27:46the Bulova is the important thing to
- 27:47understand the January flight had blow
- 27:51by with an o-ring temperature about 53
- 27:53degrees we had for development motors
- 27:55with no blow by in the range of 47 to 52
- 27:58degrees but there's a caveat to that
- 27:59right away the development mortis had
- 28:02party packing which resulted in better
- 28:03performance now let me explain that to
- 28:05you there tested in a horizontal
- 28:06position and it's a very difficult
- 28:08assembly and so when they were assembled
- 28:10and they walked down the joint after
- 28:12assembling looked at the putty in the
- 28:13character of the joint from the inside
- 28:15they found that they were like little
- 28:16fall kennels volcanoes in the putty
- 28:18holes and they attributed that to the
- 28:21very difficult in severe assembly in the
- 28:23horizontal position and so they just
- 28:25slammed them shut with the handle of a
- 28:28broom for instance or shove some more
- 28:30putty in and tapped it shut so they
- 28:32didn't really represent what they had in
- 28:34flight but they and it was okay the
- 28:37rationale was okay up to that point but
- 28:39they should have investigated the flip
- 28:40side of that coin which was does it do
- 28:42the same thing when we assemble it
- 28:43vertically because they're assembled
- 28:46vertically at the Cape now when they
- 28:50finally got around to doing that it was
- 28:52in the middle
- 28:53part of 1985 middle to latter part in
- 28:561985 what do you think they found they
- 28:58found that when they assembled it
- 28:59vertically it also blew holes and putty
- 29:01so by not doing those tests early on in
- 29:04the program they essentially voided the
- 29:05development qualification testing
- 29:07relative to oring erosion due to heart
- 29:09gas impingement so we really couldn't
- 29:12use that data that night even though it
- 29:13was stated at about 50 degrees
- 29:15Fahrenheit we expect blow by the current
- 29:17it's a reasonable assumption we headed
- 29:19at 53 the year before well with
- 29:21inexperienced base we expect the
- 29:24temperature to be 29 degrees at 9:00
- 29:26a.m. and 38 degrees at 2 o'clock in the
- 29:29afternoon for lunchtime those were
- 29:31options that we were concerning that
- 29:33night we have no data other than
- 29:36temperature that would make these joints
- 29:39any different than anything else we have
- 29:41ever flown in fact from a geometry
- 29:42standpoint we presented that that
- 29:44evening but to keep it somewhat in hand
- 29:46here
- 29:46I don't present it anymore we add
- 29:48geometry joints that had better
- 29:50overhangs squeeze on them then most of
- 29:52the joints we had previously flown so we
- 29:54have a better set of joints from a
- 29:55geometry standpoint recommendations
- 29:58basically state don't fly it and if you
- 30:00have to fly it for heaven's sakes back
- 30:03out the conditions of ambient
- 30:04temperature and wind to produce a sealed
- 30:07temperature of no more than 53 degrees
- 30:10Fahrenheit and that basically was the
- 30:12end of our presentation it lasted about
- 30:14an hour as questions were batted back
- 30:17and forth and in discussion at times got
- 30:20very heated so we sat down and now it
- 30:24was management's turn our manager was
- 30:27asked by the project manager at the
- 30:30Kennedy Space Center who was actually a
- 30:31Marshall Space Flight Center in type for
- 30:34his launch decision and our project
- 30:38manager responded that he did not
- 30:40recommend launching based on the
- 30:42engineering presentation just made now
- 30:44pay attention that's the first no vote
- 30:46many of you probably don't even know
- 30:47that the original decision was made not
- 30:49to launch but it was and so that dispels
- 30:52all this garbage about we were too
- 30:56technical in our presentation and the
- 30:58managers didn't understand they
- 30:59understand fully they understood fully
- 31:01the original decision was made not to
- 31:03launch then Larry Malloy who was the man
- 31:05asking the questions asked his
- 31:06essentially his chief engineer at the
- 31:08Marshall Space Flight Center for his
- 31:09launch decision hey George Hardy
- 31:12responded that he did not he was
- 31:14appalled at the high calls
- 31:15recommendation but he would not
- 31:17recommend launching over the contractors
- 31:19objection that's the second no vote then
- 31:22Larry Malloy who was the man asking the
- 31:24questions went into a summary mode and
- 31:26that's when he made some of his famous
- 31:28comments about when do you want me to
- 31:31launch thiokol next April and this
- 31:34remember this was January and they had a
- 31:36very aggressive launch schedule that was
- 31:39George Hardy statement about being apart
- 31:41was the start of the pressure I know it
- 31:43because I felt that George Hardy was a
- 31:45highly respected individual in the
- 31:47program and worked for NASA for many
- 31:49many years and when George Hardy says
- 31:50he's appalled I'll tell you he damn well
- 31:52gets the attention or everybody
- 31:53listening and I felt the pressure and I
- 31:56felt the pressure about the comments
- 31:57from Irene Molloy and I was very very
- 32:00nervous about it he concluded with a
- 32:04statement that he was his opinion that
- 32:06the data we presented was inconclusive
- 32:07now think about that statement for a
- 32:09moment we're at this meeting Flight
- 32:11Readiness review meeting to prove that
- 32:12it's safe to launch his statement about
- 32:15our data being inconclusive actually
- 32:17violates
- 32:18NASA's long-standing conditions of
- 32:21forcing contractors and themselves to
- 32:22prove that it's safe to launch his
- 32:25statement about the data being
- 32:26inconclusive is actually an automatic
- 32:27default or no launch condition if you
- 32:29think about it so that's three no votes
- 32:31including man asking questions as soon
- 32:35as he gets finished speaking our program
- 32:37manager asked for five-minute offline
- 32:40carcass to reevaluate the data now it's
- 32:45the caucus that actually constitutes the
- 32:46unethical decision-making for him in my
- 32:48opinion because if they had done nothing
- 32:51except hang up the phone they'd have
- 32:53been great shape they claims the
- 32:55Presidential Commission I manages claim
- 32:57that they felt no pressure at all but I
- 32:58submit to you if they didn't feel any
- 33:00pressure why they asked for the caucus
- 33:01the decision had already been made not
- 33:03to launch so I know they felt the
- 33:05pressure because I felt the pressure and
- 33:06I was there they started to have a
- 33:09meeting amongst themselves because the
- 33:11first word spoken when the mute button
- 33:12button was pushed on mute was spoken by
- 33:15a general manager
- 33:16he said in a soft voice we have to make
- 33:18a management decision and I emphasize
- 33:20soft voice because he wasn't speaking to
- 33:22me he wasn't speaking of my colleagues
- 33:24on the other end of the table I was less
- 33:26than five feet away from them so I heard
- 33:28I heard every word spoken he was
- 33:30speaking to his other three senior
- 33:32executives who were all vice presidents
- 33:33three of which were gathered right
- 33:35around the table one of which was
- 33:36sitting up against the wall
- 33:38never did but the man against wall never
- 33:40did participate in anything except shook
- 33:42its head yesterday's gonna launch in the
- 33:44ultimate decision anyways they were
- 33:46trying and struggling trying to make a
- 33:49list on a piece of paper that would
- 33:51justify a decision to launch when my
- 33:53colleague Ani Thompson came from way
- 33:54down the other end of the table up place
- 33:56the pad of paper down and once again
- 33:58sketched out the joint with the
- 34:00explanation verbally why we should not
- 34:02attempt the launch under such adverse
- 34:04conditions Arnie was summarily ignored
- 34:06got the vilest looks you can ever ever
- 34:08ever imagine he went back to his place
- 34:11because he had no way of getting them
- 34:15engaged in conversation with him when he
- 34:18gave up and went back to his seat I
- 34:19grabbed eight-by-ten colour glossy
- 34:21photographs that showed the 1985 launch
- 34:26and the heart gasps buh-bye in the
- 34:28blackened condition between the seals I
- 34:31also had a comparative photograph of a
- 34:34room-temperature launch which showed the
- 34:36same type of blow-by but with a totally
- 34:38different characteristic it was gray
- 34:40sort of modelling splotchy in
- 34:42characteristic and it was like night and
- 34:44day between the two all you had to do to
- 34:46say to anybody a person on the street
- 34:48was that the color black is bad and
- 34:51tells you that you're in worse shape
- 34:52now which pick pick one that's in worse
- 34:54shape and a hundred times out of a
- 34:56hundred times they could pick the right
- 34:57photograph when I made that pitch to our
- 35:00managers they just did not want to hear
- 35:03it
- 35:03they didn't want to look at the
- 35:04photographs they didn't want me to talk
- 35:05to them they just Summerlee ignored me
- 35:07also I was told by my colleagues after
- 35:09the meeting that I was literally
- 35:11screaming at the managers to look at the
- 35:13photographs and not ignore what they
- 35:15were telling him namely that more hot
- 35:16gas blow-by occurred at a lower
- 35:18temperature but they didn't want to hear
- 35:19that and so I got the same works as
- 35:21Arnie and I went back to my seat also as
- 35:24they continue their discussion just
- 35:26before they took the vote poll Dave I
- 35:28sprint the vice-president senior vice
- 35:29president and general
- 35:30manager turn third vice president of
- 35:32engineering and said it said to him take
- 35:34off your engineering hat and put on your
- 35:36management hat
- 35:37real subtle threat huh well
- 35:40vice-president engineering capitulated
- 35:42unfortunately they took the vote poll
- 35:44shortly thereafter it was four votes to
- 35:47launch Presidential Commission asked
- 35:49them why they didn't pull us and the
- 35:52general manager said we already knew the
- 35:54position of the engineers and it was
- 35:56fruitless to pull them because we knew
- 35:58we would not be unanimous now see that's
- 36:00what they're supposed to do and if
- 36:02anybody is not unanimous that's a
- 36:04default when no launch but yet we
- 36:06weren't given the opportunity they were
- 36:08back on the telephone conversation told
- 36:11NASA that and they read from this list
- 36:13that they had generated told NASA that
- 36:14they wanted the launch but this was the
- 36:16new decision there was very little
- 36:18questioning no probing discussion NASA
- 36:20promptly accepted the decision telephone
- 36:23telecon was basically terminated now I
- 36:27was very angry when I left that room
- 36:28believe you if I had had a box of
- 36:30grenades that evening cycle would have
- 36:32been leveled this is the decision-making
- 36:36chart that they actually based their
- 36:39decision on now you ask yourself as I go
- 36:41down these statements one of the time if
- 36:43these are actual statements that support
- 36:46a decision to launch the calculations
- 36:49show that SRM 25 o-rings will be 20
- 36:51degrees colder than SRM 15 this is the
- 36:54Challenger Challenger will be 25 degrees
- 36:5620 degrees colder excuse me than the
- 36:58January 85 o-rings remember the name is
- 37:02temperature data not conclusive there's
- 37:05that word again
- 37:05not conclusive on predicting primary
- 37:08o-ring bull by the engineering
- 37:11assessment is that that is a why an
- 37:15outright bull face lie there was no
- 37:18engineering assessment that carcass the
- 37:20only two engineers who spoke were myself
- 37:22in Arnie Thompson and we were not
- 37:23allowed to be engaged in discussion and
- 37:25so that that is a absolute falsehood
- 37:29colder ol rings will have increased
- 37:31effective durometer in other words
- 37:33they'll be harder do you remember that
- 37:34on my chart is a reason for changing the
- 37:37timing function in the fear of launching
- 37:39harder o rings will take longer to see
- 37:41that's another way of saying timing
- 37:44function but this look makes it look
- 37:45like it's a positive attribute instead
- 37:47of a negative attribute more gas may
- 37:50pass the primary o-ring before the
- 37:52primary seal seats
- 37:53that's the magic wand trick you had 24
- 37:57successful voice and you just declare
- 37:58it's going to work it's going to see you
- 38:01can't do that people you we don't know
- 38:03what's going on inside those joints in
- 38:05real time the demonstrated sealing
- 38:07threshold is three times greater than a
- 38:0938 thousands of Rochin experience on a
- 38:11january flight that is a true statement
- 38:14but it does not apply
- 38:16we were not discussing oring erosion
- 38:19that night we were discussing if the
- 38:22seals would function first as seals
- 38:24before the hot gas ate him alive and
- 38:27then we had a comfortable three factor
- 38:31of safety of three on margin we had
- 38:32tested many subscale tests and that was
- 38:35a real number but it didn't apply that
- 38:37night we were afraid that the seals
- 38:39weren't even function as seals first if
- 38:42the primary seal does not seat the
- 38:44secondary will the magic wand trick
- 38:46again I don't know how you can do that
- 38:48pressure will get that a secondary seal
- 38:51before the metal parts rotate I don't
- 38:53know how they knew that I'd it was the
- 38:56closest person and Ronny was the second
- 38:58closest person all those joints and we
- 38:59certainly didn't know that there had
- 39:01never been never been one test dynamic
- 39:05test run on pressure temperature or
- 39:07deflection running these motors why
- 39:09because in order to run those tests you
- 39:11have to drill holes in a case and drill
- 39:13hole in a joint you void 1 million
- 39:16dollars worth of hardware for flight
- 39:18that's why I didn't run tests but I'll
- 39:20show you after the Challenger disaster
- 39:22they drilled holes like you can't
- 39:25believe in a joint they took flight
- 39:27hardware out of the stream like it was
- 39:29popcorn but yet before the disaster we
- 39:33could never get that information the
- 39:35o-ring pressure leak check places the
- 39:37secondary seal in the output position
- 39:39which minimizes sealing time that
- 39:41doesn't say anything it's just filler
- 39:43that's a fact of physics if I put
- 39:45pressure on one side of an o-ring it
- 39:47will move to the opposite side of the
- 39:48groove and it will do it a thousand
- 39:49times out of a thousand times ragazza
- 39:51what the temperature is unless it's
- 39:52frozen solid to the deck it doesn't say
- 39:55anything it's like pushing a cable with
- 39:56casters it's going
- 39:57move as opposed to being grounded its
- 40:00just filler morton-thiokol recommends at
- 40:03the launch proceeded on the 28th now
- 40:05does anybody in the audience see
- 40:07anything after that statement I sure
- 40:09don't see the CEO Morton Thiokol was
- 40:12late as the spring of 1988 said in an
- 40:14interview with Businessweek magazine as
- 40:16he was still trying to protect his
- 40:18corporate hind side that Morton Thiokol
- 40:20never agreed to launch at the
- 40:22temperature at the time of launch and I
- 40:24maintain to you oh yes they did right
- 40:26there it doesn't there's no caveat
- 40:30there's no exceptions there's nothing on
- 40:32that that says they can't launch and
- 40:33quite frankly if it had dropped to 20
- 40:35below zero NASA what this chart has the
- 40:38authority to launch the last poet
- 40:41actually contradicts the first bullet
- 40:43the Challenger will not be significantly
- 40:46different from the January 85 launch it
- 40:48just said it'd be 20 degrees colder and
- 40:50we had met I thought we had made a
- 40:52pretty good case for the increments from
- 40:54a hundred down to 75 down to 50 degrees
- 40:57Fahrenheit the severity and how they
- 40:59overran responded and that it was very
- 41:01very important in those increments that
- 41:04at the law we got the more serious
- 41:05difficulty we were going to have well
- 41:08when this was this chart was finished
- 41:10NASA asked for a signed copy of this
- 41:12chart as you can see Joakim insta who's
- 41:15the guy our program manager signed it
- 41:17and it was faxed down this is the
- 41:19ultimate cya piece of paper in the
- 41:20program because NASA knew that they
- 41:24needed this signed to protect themselves
- 41:26I have to tell you ladies and gentlemen
- 41:28that the only temperature that anybody
- 41:29knew about in that program including me
- 41:31that night and up to that night and
- 41:33since that night was 40 degrees
- 41:36Fahrenheit period 40 degrees Fahrenheit
- 41:39I wasn't willing to launch neither when
- 41:43my colleagues at 40 degrees Fahrenheit
- 41:44but that is the lowest temperature that
- 41:46any of us on a program even knew about
- 41:48and so they did violate launched with
- 41:52criteria al McDonald told Larry Malloy
- 41:54at the Kennedy Space Center he would
- 41:56hate to be the one that had to stand up
- 41:58in front of a board of inquiry and
- 41:59explain why he launched below the
- 42:01specification temperature of 40 degrees
- 42:03Fahrenheit but he was ignored at that
- 42:05point in time also well I had made up my
- 42:07mind not to watch the launch next day
- 42:09because I was very very
- 42:11afraid that what we were predicting was
- 42:13going to occur but one of the colleagues
- 42:16that was in the room that night had a
- 42:18daughter that I call that day who had
- 42:20never seen the launch and he had another
- 42:21daughter that worked at that call and I
- 42:23knew them as family friends and so I sat
- 42:25in with him as he coaxed me to come in
- 42:27and watch well as the vehicle ignited
- 42:30and cleared the lunch tower I whispered
- 42:32to Bob that we just dodged a bullet
- 42:35because we were told by the ballas
- 42:37ditions the people the engineers who are
- 42:39experts on how propellants burn and how
- 42:41they work and from past experience that
- 42:43they had they told us if we had so much
- 42:45as a tiny pinhole in the case it would
- 42:47blow up on the pad right at ignition
- 42:49well when that didn't happen of course I
- 42:51felt wow we're home free at 60 seconds
- 42:55in the launch he would speed back to me
- 42:57that he had just completed a prayer of
- 42:58thanks for a successful launch thirteen
- 43:01seconds later we both saw the horror of
- 43:03destruction along with our colleagues in
- 43:04a room as the vehicle exploded and there
- 43:07was no mistake in our minds that it had
- 43:09exploded because it was way premature in
- 43:12the separation it should have gone 120
- 43:14seconds and as typical engineers we all
- 43:17got acronym and it's out every time
- 43:18there's the launch and we time it was a
- 43:19stopwatch I always do that
- 43:21and it was 73 seconds when it let go but
- 43:24strangely enough right after the
- 43:25explosion occurred and I was very angry
- 43:29even even knowing this our boost is
- 43:31actually flew out of the explosion still
- 43:33thrusting so it wasn't us but I was
- 43:36still mad in hell because that they had
- 43:38just listened and not launched that
- 43:39sequence of events would not have
- 43:41occurred whatever the cause at that
- 43:43point in time well one of the managers
- 43:46was in that room actually the man that
- 43:48said nothing that night except shook his
- 43:50head yes to vote to launch he went out
- 43:53of that room like he was shot out of a
- 43:54cannon because I think he realized what
- 43:58serious trouble the program was in at
- 44:00that point in time because of what had
- 44:02transpired the evening before well any
- 44:04Johnny Thompson and myself were actually
- 44:07placed on a fairly investigation team in
- 44:09prompt order and sent to the Marshall
- 44:11Space Flight Center in Alabama and what
- 44:14I saw there shocked me and actually made
- 44:17me very very angry and disgusted NASA
- 44:20management at the center was diligently
- 44:22attempting to find a condition other
- 44:23than
- 44:24that caused a disaster I think they knew
- 44:27the seriousness of what they had done
- 44:29and they were trying to actually pin
- 44:32this disaster in something else they had
- 44:34actually closed out photographs of the
- 44:36assembly and and they claimed that there
- 44:39was a twisted o-ring and I swore up and
- 44:41down to them that I just tried a piece
- 44:42of o-ring and twisted it actually put it
- 44:45on put it on a desk you know had about a
- 44:48yard length of it was secretary of white
- 44:50out tape and twisted it full 360 degrees
- 44:54three times and I left it on my desk in
- 44:57it unfold and the white out tape was in
- 44:59a line which says that the stored energy
- 45:02and o-ring was sufficient to avoid a
- 45:04twist in it now it was just on a desktop
- 45:07imagine how I would act and greased on a
- 45:09greased surface would even be dipped
- 45:10more difficult I did with him and argued
- 45:13with him and argued with him that that
- 45:14couldn't possibly happen and what they
- 45:15were seeing was a track that somebody
- 45:18had caused by just wiping inadvertently
- 45:20wiping the surface with a glove or hand
- 45:22they actually sent a team of experts out
- 45:25to if I call in spent two weeks trying
- 45:27to take a photograph over twisted o-ring
- 45:29in a joint of course they couldn't do it
- 45:31after two weeks they came back and said
- 45:33wow I guess you were right
- 45:34well even more important than that we're
- 45:39on a fairly investigation team we never
- 45:41showed this information for a week to
- 45:45ten days later they had actually known
- 45:48within 24 hours of launch what actually
- 45:50caused a disaster but those on a fairly
- 45:52investigation team whenever made privy
- 45:54to it they had 16 millimeter film of it
- 45:56you see this arrow right here that
- 45:59points that is black smoke this is the F
- 46:02joint right here see the black smoke
- 46:04coming out of the F joint this is right
- 46:05at the ignition this is at point six
- 46:08eight seconds this is a slight delay
- 46:11because there was postulated there may
- 46:13have been some frozen water in the joint
- 46:14and it delayed it slightly but that's
- 46:16pretty close to at the beginning
- 46:18ignition if you'd taken that the white
- 46:20time they knew that and they had never
- 46:23told us so we're on a fairly
- 46:24investigation team as they chased us
- 46:25down blind alley after blind alley after
- 46:27blind alley well
- 46:32after al McDonald had made the
- 46:35presidential commission aware that the
- 46:36telecon took place they scheduled a the
- 46:38presidential commission scheduled a
- 46:40closed-door hearing at the Kennedy Space
- 46:41Center on the 14th of February 1986 we
- 46:46were instructed by the company attorneys
- 46:47to go that meeting and answer all
- 46:49questions yes to know and volunteer
- 46:51nothing can you imagine how much
- 46:54information they would have really found
- 46:55out if we had done that well I I wasn't
- 46:57willing to do that and I bared all I was
- 46:59pardon me the first to testify Arnie was
- 47:02second and he basically verified
- 47:04everything I said and add a few words
- 47:05himself then now McDonnell gave his
- 47:07version as he was at the Kennedy Space
- 47:09Center that night what the Commission
- 47:11members heard was so shocking to them
- 47:13that they asked us to all leave close
- 47:14the door
- 47:15placed a call directly to President
- 47:17Reagan and informed him of what had
- 47:19happened they were so afraid that
- 47:21because of what they just heard would
- 47:22never ever last to the end of the day
- 47:24before the press got it that they didn't
- 47:27want the president broadsided and so
- 47:28they made the call one of the aides to
- 47:30the Commission told us this well five
- 47:32days later I was being interviewed by
- 47:34another Commission member and I handed a
- 47:36packet of my activity reports and memos
- 47:40to him as in answer to one of his
- 47:42questions and a company attorney present
- 47:44literally almost fell off his chair I
- 47:47realized at that point in time that I
- 47:49had truly not endeared myself with
- 47:50company management
- 47:52because my memos actually stopped their
- 47:57testimony cold in its tracks and clearly
- 48:00proved that this problem had been around
- 48:02way before that telecon meeting and I
- 48:05had the documented evidence that I had
- 48:07handed over to him to prove it and so
- 48:09from that point on management had a very
- 48:12very difficult time in testifying with a
- 48:14series of half-truths and from that
- 48:17point on the focus of the investigation
- 48:19was not only on the technical failure of
- 48:24the joint but on a management managerial
- 48:26failure of the organization on February
- 48:2825th we got to tell our story in public
- 48:31and I fell into further disfavor by
- 48:34directly rebutting our general managers
- 48:36testimony just before me where he
- 48:37claimed that the engineering position at
- 48:39the talk on meeting that evening was not
- 48:41unanimous and that was simply not true
- 48:43every body in the room that evening was
- 48:46there for the sole and specific purpose
- 48:47of stopping the launch even the general
- 48:49manager believe it or not he anticipated
- 48:52that it would be a highly politicized or
- 48:54potentially criticized problem but he
- 48:58knew what we were striving for before
- 49:01the meeting even started so if he didn't
- 49:03support it he sure as hell didn't in
- 49:05voice voice his opinion against anything
- 49:07and so the default is that everybody
- 49:09that was in that room they remained
- 49:11silent was there for the sole purpose of
- 49:13supporting the launch that's why they
- 49:14were there in all actuality well after
- 49:18my testimony I was off the failure
- 49:20investigation team immediately sent back
- 49:21to Utah and at while I was being told in
- 49:24March that I was a major participant in
- 49:26the redesign I was felt very strange
- 49:28because I was it seemed like I was being
- 49:30isolated from the program I was given
- 49:32technical input but never invited to
- 49:34meetings never knew when they occurred
- 49:35never knew who attended I was told by
- 49:37the grapevine that my technical input
- 49:39was changed from time to time and I had
- 49:42no input essentially I was essentially
- 49:44being isolated it took me about six
- 49:45weeks in real time to really understand
- 49:47that this was happening well in May al
- 49:52McDonnell and I would call back to the
- 49:53Presidential Commission we were asked
- 49:55point-blank about our job assignments
- 49:56and when I answered the question with
- 49:59the fact that I was being isolated from
- 50:00the program and that al and said that he
- 50:03had 30 people that were reporting to him
- 50:05originally now
- 50:07we're not reporting him anymore and he
- 50:08was now reporting to one of them
- 50:10Presidential Commission got very very
- 50:12angry because they said we were being
- 50:14punished for honesty and our testimony
- 50:16well the company took out a lot of flack
- 50:20about this because the Presidential
- 50:22Commission actually at least the
- 50:23closed-door hearings and made it public
- 50:25and thiokol got beat up very severely in
- 50:27the press by the press the Presidential
- 50:30Commission and the Congress of the
- 50:31United States it got so bad that our
- 50:34colleagues at the plant were now blaming
- 50:37us for all of that cause problems
- 50:40we started referred to ourselves at the
- 50:42five lepers there were five of us that
- 50:44testified in one degree or another and
- 50:45we were being ostracized by our
- 50:47colleagues we tried to cause a
- 50:51mitigation of the internal strife by
- 50:52asking for a meeting with the CEO the
- 50:55president of the aerospace division and
- 50:57the person heading a shuttle program at
- 50:58that time because the program was
- 51:01actually coming down around their ears
- 51:02and it was out of control because the
- 51:03original people who were controlling the
- 51:05program made the decision to launch was
- 51:07still controlling the program if you can
- 51:09believe that it was still in their
- 51:10position the meeting unfortunately was
- 51:13one-sided totally one-sided we bared our
- 51:16souls to try and help the program in the
- 51:18company and we were basically ostracized
- 51:20and the CEO made it sound like that if
- 51:23everything worked out okay all would be
- 51:25forgiven and that was basically the tone
- 51:29of the meeting that took place that
- 51:30night well in June we were all called
- 51:33back once again and this time to testify
- 51:34in front of the presidential not
- 51:39presidential but the house cyant House
- 51:41Committee on science and technology when
- 51:44we went back there it was really an a
- 51:47bad experience for me extremely bad
- 51:49experience for me during two days of
- 51:51intensive preparations with attorneys
- 51:53and PR people I and we in general but I
- 51:57specifically were the victims of an
- 51:59attempted PR people brainwashing as they
- 52:02told us that the Congress the United
- 52:04States the people on this committee we
- 52:06were only interested in press coverage
- 52:07and they really didn't give a damn about
- 52:08Challenger how do you think you know
- 52:11that made somebody like me feel it was
- 52:15very distressing because they try to
- 52:17influence my testimony directly but they
- 52:19failed once again
- 52:20and I answered all the questions the
- 52:22best of my ability but it took its toll
- 52:25on me when I'm back to cycle I could no
- 52:27longer endure the hostile day-to-day
- 52:29environment and so by July I went to a
- 52:33company executive explain situation he
- 52:35said you better take some time off and
- 52:37get you head cleared when I did that I
- 52:39went out on medical leave got some
- 52:43professional help
- 52:44got a diagnosis well not diagnosed at
- 52:46that time but I got some professional
- 52:48help to the degree and the point where I
- 52:50knew that the source of my problem was
- 52:52the company and I called him up in
- 52:57September and told him I would never
- 52:58return to work for them they taught me
- 53:01that continue on leave that I had to go
- 53:03and get diagnosed by a psychiatrist
- 53:06which I did I was officially diagnosed
- 53:08by one psychiatrist one psychiatrist and
- 53:11three psychologists is having
- 53:13post-traumatic stress disorder I
- 53:16received long-term disabilities from a
- 53:19medical program which started in January
- 53:21of 87 the day I qualified was the day I
- 53:25got my final noticed that I was
- 53:27terminated I was received my final check
- 53:30and they asked me to send my badges in I
- 53:33did that I received 60% of my former
- 53:35salary for two years and then everything
- 53:39was down to zero now what this really
- 53:43leads to is everyone's Professional
- 53:45Responsibility and I believe it is best
- 53:48explained in this timeless piece by mr.
- 53:52Adolph J Ackerman he wrote in the AAAS
- 53:56he wrote in the I Triple E publication
- 54:00that in 1967 that engineers have a
- 54:05responsibility that goes far beyond the
- 54:07building of machines and systems we
- 54:09cannot leave it to the technical
- 54:11illiterate sorry Ventoux literate and
- 54:12overloaded technical administrators to
- 54:15decide what is safe and for the public
- 54:17good we must tell what we know first or
- 54:20normal administrative channels but when
- 54:22these fails through whatever evidence we
- 54:23can find many claim that it is disloyal
- 54:26to protests sometimes the penalty
- 54:29disapproval loss of status even
- 54:32vilification can be so
- 54:33there today we need more critical
- 54:36pronouncements and public declarations
- 54:38by engineering engineers and high
- 54:40professional responsibilities in some
- 54:42instances such criticism must be severe
- 54:44if we ought to properly serve mankind
- 54:46and preserve our freedom hence it is of
- 54:49the utmost importance that we maintain
- 54:51our freedom of communication in the
- 54:53engineering profession and to the public
- 54:55the decades ahead are bound to be a
- 54:58critical and difficult period and there
- 55:00will be occasions for sharp dissent and
- 55:02strong words if we are to meet our
- 55:05responsibilities
- 55:06close quote I simply recommend
- 55:09practicing the golden rule do unto
- 55:11others as you would have them do unto
- 55:12you
- 55:13unfortunately business in this country
- 55:15especially is has perverted their golden
- 55:17rule and it's called doing to others
- 55:19before they do unto you now don't be
- 55:23expected to protect be protected if you
- 55:25are not willing to protect others from
- 55:26surety professionalism speaking out may
- 55:29or may not extract a price for doing so
- 55:30but I can assure you one thing you will
- 55:33have a clear conscience and a peaceful
- 55:35sleep at night for doing the right thing
- 55:37academia research on whistleblowers
- 55:39provides us some insight actually the
- 55:42industrial government complex strongly
- 55:43discourages whistleblowing
- 55:45if a whistleblower goes outside his
- 55:47organizational culture he is usually
- 55:49severely punished for doing so to send a
- 55:51strong message for others in the
- 55:52organization not to do the same or else
- 55:55they will receive the same end result
- 55:56the industry and government has
- 55:58succeeded very cleverly in deceiving the
- 56:01public about the character and motives
- 56:02of whistle blows the general perception
- 56:04is that whistleblowers are troublemakers
- 56:06and snitches and try to make trouble for
- 56:09their employer while exactly the
- 56:11opposite is the truth extensive research
- 56:13shows that doles has stepped forward
- 56:16with bad news do so to protect the
- 56:18health safety and welfare of the public
- 56:20and their companies but whistleblowers
- 56:24are most often long-term dedicated
- 56:27employees whose only concern is to right
- 56:28or wrong within an organization to
- 56:30prevent somebody from a high-probability
- 56:32injury or death it's really that simple
- 56:35but industry and government has
- 56:36distorted the truth so well that winning
- 56:38vindication for whistleblower is all but
- 56:41impossible I'd like to just quickly
- 56:44summarize just so you have a feel for
- 56:46what
- 56:47happens to people the methods used to a
- 56:49neutralized it whistleblower make the
- 56:51whistleblower instead of the message the
- 56:53issue isolate the whistleblower
- 56:55set the whistleblower up for fall
- 56:57display maximum toughness in selecting
- 57:00charges against the whistleblower you
- 57:02eliminate the whistleblowers job
- 57:04destabilize the whistleblower support
- 57:06base the following some of the methods
- 57:08to neutralize the dissent itself
- 57:10overwhelm the whistleblower by making
- 57:12him or her a struggle for self
- 57:14preservation of career family bank
- 57:17account and even sanity until the point
- 57:19of dissent is put behind waiting way to
- 57:21your survival priorities separate
- 57:24expertise from Authority keep the
- 57:26employees ignorant about what's going on
- 57:28substitute democracy for scientific
- 57:31methods for decision making and last but
- 57:34I believe one of the most important ones
- 57:35is to prevent a written record when a
- 57:38policy is indefensible the goal is to
- 57:40restrict debate to an oral dialogue
- 57:41since it is difficult to accuse somebody
- 57:44of revising an oral dialogue and
- 57:47accountability will be diffused in the
- 57:49event of a tragedy I have to tell you
- 57:51each of the foregoing categories were
- 57:53used against me and my colleagues at
- 57:54various points in times all accept
- 57:57dismissal the conversation I today
- 57:59--tz-- and media made it virtually
- 58:00impossible but I call the dismisses but
- 58:04they did make our lives absolutely
- 58:05miserable on a day-to-day basis now the
- 58:09bottom line in this whole thing and why
- 58:11it's so important is accountability and
- 58:14there's been no accountability to date
- 58:17even today no accountability and more
- 58:19than 500 employees unfortunately will be
- 58:21the ones that have accountability
- 58:23extracted from them at this point in
- 58:25time there have been over 1,000
- 58:27employees laid off at the facility at
- 58:29Morton Thiokol out of about 8,000 people
- 58:31and that's very very severe in northern
- 58:34Utah there are no other jobs to go to
- 58:36and so some of these people are
- 58:38unfortunately actually have to walk away
- 58:39from their homes the lack of
- 58:41accountability has actually produced an
- 58:43incredibly browsing nozzle joint
- 58:46redesign that they're flying today the
- 58:48joint actually begs failure by Murphy's
- 58:50Laura once again just as the original
- 58:52joint that I showed you I have some
- 58:54suggested solutions eirick I suggest
- 58:57that we require the passage of the EIT
- 58:59exam as a
- 59:00requisite for obtaining an engineering
- 59:02degree now don't all moan and groan I'm
- 59:05not asking you to do anything I haven't
- 59:06already done on the I did it the hard
- 59:07way
- 59:08I took the EIT being out of school over
- 59:1230 years so it can be done and then take
- 59:16the the P exam and pass it and get
- 59:19licensed now the reason I am I
- 59:21suggesting is the code of ethics as a
- 59:24very effective club when a manager comes
- 59:26up to you and asked you to do something
- 59:28unethical you can simply refer him to
- 59:30the code of ethics and ask him is he
- 59:33asking you to violate this code of
- 59:34ethics you see the effectiveness that
- 59:36this potentially could have I believe it
- 59:38would really work and put the
- 59:40decision-making process back in the
- 59:41hands of the engineering and the
- 59:43technical people and it would also avoid
- 59:45the current shameful paradox that it
- 59:47exists in this country at the present
- 59:48time really the only people that need to
- 59:50be licensed as civil engineers who build
- 59:52our roads bridges and buildings most of
- 59:54the others of us have a huge industrial
- 59:56exemption and not need to be licensed
- 59:58but consider the paradox
- 1:00:00what does more harm to you as an
- 1:00:02individual the roadbed that you drive a
- 1:00:05car over or the car that you're riding
- 1:00:06in did you ever think about the
- 1:00:08airplanes you fly in I did the stress
- 1:00:10analysis and some of that stuff I'm not
- 1:00:12licensed wasn't licensed at the time
- 1:00:14does that give you a warm feeling it
- 1:00:17doesn't give me a very warm feeling and
- 1:00:19it's a terrible paradox when you really
- 1:00:20look at it as to what it represents the
- 1:00:23huge industrial exemption actually
- 1:00:25provides a huge resource pool of a
- 1:00:28renewable resource of Engineers and
- 1:00:30that's why it's done and it's a way to
- 1:00:32promote cheap labor
- 1:00:33in an overturning business community
- 1:00:37well I hope is that attorneys can make
- 1:00:41inroads into the into the law and cause
- 1:00:43the transfer of the engineering code of
- 1:00:45ethics to management and restore the
- 1:00:47technical decision-making to the
- 1:00:48technical people but if this fails I
- 1:00:50feel that the long term solution really
- 1:00:52rests with university university
- 1:00:54education and it rests with them to
- 1:00:57teach students the benefits of combining
- 1:00:59science technology and society issues
- 1:01:01towards the upgrading of ethical
- 1:01:02decision making within industry and
- 1:01:04government in conclusion I will never
- 1:01:07forget and I hope this nation will never
- 1:01:10forget especially the engineering
- 1:01:11community
- 1:01:12the supreme sacrifice that the seven
- 1:01:14challenge astronauts made for forfeiting
- 1:01:16their lives for such an irresponsible
- 1:01:17launch decision
- 1:01:19maybe we always remember astronauts Kobe
- 1:01:22Smith McNair Onizuka Resnick Jarvis and
- 1:01:30McAuliffe for the dedication and courage
- 1:01:33to this nation's space program
- 1:01:35I implore all of you not to dwell on any
- 1:01:39of the negative aspects that you've just
- 1:01:40heard but use those conditions that
- 1:01:45you've heard as a positive lesson on how
- 1:01:48to recognize and act upon
- 1:01:51confrontational situations that you may
- 1:01:54encounter in your careers and I assure
- 1:01:56you you will encounter them albeit in a
- 1:01:59much lesser visible environment I hope
- 1:02:02we can all learn together from past
- 1:02:04organizational misconduct and bring
- 1:02:07about change toward practicing the
- 1:02:08golden rule in business and government
- 1:02:10to significantly reduce unethical
- 1:02:13decision making practices thank you very
- 1:02:15much
- 1:02:22oh yes yes sir that was a marvelous
- 1:02:31presentation but I want to ask you why
- 1:02:33you think that universities are the
- 1:02:35proper place to teach ethics we think
- 1:02:37that the ethical standards of
- 1:02:39universities are it sufficiently high or
- 1:02:42different from the general community if
- 1:02:44I want to be whistle blown off stand up
- 1:02:46at that desk
- 1:02:47what I can say about universities would
- 1:02:49be just about the same is what you have
- 1:02:51said so I don't believe that the ambient
- 1:02:54at the university is very ethical it's
- 1:02:56just hidden no but you have to
- 1:02:58understand that that the real effect of
- 1:03:02an engineering education is to become
- 1:03:04socially inept we are technically sharp
- 1:03:07but socially inept as hell and if you
- 1:03:09don't give people the rudimentary basics
- 1:03:11on what to expect
- 1:03:12then you're expecting them to respond to
- 1:03:14situations that they've never been
- 1:03:15schooled or even have an inkling of a
- 1:03:18being thrown into the Lions Den and I
- 1:03:21believe that through a case study such
- 1:03:24as that I presented here that there are
- 1:03:25many fruitful areas of discussion not
- 1:03:28that you will make everybody an ethical
- 1:03:29person but you will give them the basic
- 1:03:31tools to make an informed decision but
- 1:03:34now you expect people who are no more
- 1:03:38ethical than others to lead ethical
- 1:03:41discussions I you teach things all the
- 1:03:44time in addition all about engineering
- 1:03:47as well well you use this Epic's how do
- 1:03:51we know Epic's we are the teachers and
- 1:03:54we don't know it are you telling me that
- 1:03:56you can't take what I just gave you
- 1:03:58today and use it as a video tape
- 1:04:00presentation as a segment of your class
- 1:04:02and actually motivate people towards a
- 1:04:05understanding of what they need to
- 1:04:07expect when they get into industry
- 1:04:08whether you're unethical or not if you
- 1:04:10can't do that then you don't have a very
- 1:04:13good rapport with your students I don't
- 1:04:15think that's what have a very good
- 1:04:16rapport with their students we have some
- 1:04:18students here and they can tell us how
- 1:04:20good or up the horrors they have with
- 1:04:21their professors well well I'll tell you
- 1:04:24I've been at many of the major
- 1:04:25universities around this country and the
- 1:04:27student bodies are the ones that are
- 1:04:29actually asking for these courses to be
- 1:04:31taught so that they do not go out with
- 1:04:33blinders on and if the universities
- 1:04:36respond to that then we are in a sad
- 1:04:38state of affairs in this country a point
- 1:04:46I wanted to clear out when you said that
- 1:04:48the engineering group on this meeting
- 1:04:53the night before before the management
- 1:04:55reversed itself the engineering
- 1:04:59participants were unanimous and
- 1:05:01recommending that the launch not take
- 1:05:03place and that this information not this
- 1:05:07recommendation not to launch had been
- 1:05:09transmitted to decision makers within
- 1:05:12NASA is that right that's correct so
- 1:05:14they were clearly appraised of the fact
- 1:05:17that the technical people had
- 1:05:19recommended not to launch that's right
- 1:05:23the other recommendation knew that it
- 1:05:30was not based on the same technical it
- 1:05:35was not repetition but was simply a
- 1:05:39management appraisal of the gamble no no
- 1:05:43you missed the sequence of events what
- 1:05:45we did that day was we as engineers
- 1:05:48convinced our own in-house people not to
- 1:05:50launch and we had the technical
- 1:05:51rationale to support that when we were
- 1:05:54finished convincing our own in-house
- 1:05:55people about that we had informal
- 1:05:57discussions with NASA Marshall Space
- 1:05:59Flight Center we had no view graphs but
- 1:06:01we had informal discussions and
- 1:06:02expressed in verbalized our concerns and
- 1:06:05when they heard our concerns verbalized
- 1:06:07they became very antsy about what we
- 1:06:10were talking about and they asked us to
- 1:06:12formalize our concerns in a formal
- 1:06:14presentation on a telecon that evening
- 1:06:16which we did with a formal hookup
- 1:06:17between three two centers and us at the
- 1:06:20plant we actually gave our engineering
- 1:06:22presentation and the expectation had
- 1:06:25never wavered from the fact that we were
- 1:06:27there for the sole purpose of stopping
- 1:06:28the launch as was the initial result
- 1:06:31what happened at night is we ran into a
- 1:06:33buzzsaw with a customer namely NASA who
- 1:06:36actually reversed their posture in in
- 1:06:38instead of forcing us to prove that it
- 1:06:40was safe to launch which was the normal
- 1:06:42occurrence they were actually put us in
- 1:06:45a posture to prove that it was not safe
- 1:06:46to launch and of course we couldn't do
- 1:06:48that
- 1:06:48all I could speak in is terms of
- 1:06:51probabilities of failure and no numbers
- 1:06:53mind you because I had no numbers but I
- 1:06:56have two eyes and I 20 years at 27 years
- 1:06:59experience and a good feel for what
- 1:07:02these little babies do and everybody
- 1:07:05else knew about it for an engineering
- 1:07:08standpoint too and they listened you see
- 1:07:10we were successful what we what we
- 1:07:12actually ran into that night was a
- 1:07:14totally unexpected customer reaction
- 1:07:18that seems to me to exonerate thiokol
- 1:07:21that if that they have made possible the
- 1:07:25vehicle for communicating the concern of
- 1:07:28the technical people your voice had had
- 1:07:31a hearing and your colleagues had had a
- 1:07:33hearing and your customers chose to
- 1:07:37ignore the technical information and
- 1:07:39recommendations they were receiving from
- 1:07:41the technical people and it seems to me
- 1:07:44that that your company people should
- 1:07:48have been thoroughly protected by no not
- 1:07:51at all because they actually ultimately
- 1:07:53capitulated as manages and gave
- 1:07:56permission to launch
- 1:07:57oh yes it does because what it did was
- 1:08:04it what it did was it showed that the
- 1:08:06people who ran the company were now
- 1:08:08coming up and saying you remember that
- 1:08:11chart I showed you it implied it implied
- 1:08:14that there was a engineering review that
- 1:08:16took place see the implication was that
- 1:08:19the engineering assessment is that it
- 1:08:21implied that the engineers participated
- 1:08:24in that caucus when in fact that was not
- 1:08:26true and so they actually had deceived
- 1:08:31NASA on the receiving end of this
- 1:08:33information as to what happened see we
- 1:08:35were on mute
- 1:08:36they couldn't hear us and we couldn't
- 1:08:38hear them this was a closed hearing a
- 1:08:39closed meeting and so they did and they
- 1:08:43do deserve as as matter of fact the
- 1:08:46signers and manufacturers and producers
- 1:08:47of this booster I assigned 75% of the
- 1:08:50blame for the launch on fire call people
- 1:08:52on a human that you may think that
- 1:08:54that's harsh but dammit it's their
- 1:08:56hardware and they have a fiduciary
- 1:08:58responsibility to justify that the
- 1:09:01that to give the information that their
- 1:09:04hardware is ready for launch and when
- 1:09:06they say that their hardware is ready
- 1:09:07for launch by gosh it should be ready
- 1:09:09for launch without any crap shoot or
- 1:09:12gamble in pressing that button and so
- 1:09:14they should be held and put their feet
- 1:09:16to the fire about 75% of the blame now
- 1:09:19if you internalize that same type of
- 1:09:21percentage within Morton Thiokol I say
- 1:09:23that the general manager of our plant
- 1:09:25should be accorded 75% of the blame
- 1:09:27because he's the one that created the
- 1:09:29ultimate internal pressure in that
- 1:09:30caucus when he and it finalized that
- 1:09:33with his direction to the vice
- 1:09:35presidential era to play ball and so I
- 1:09:38apportion 75% of the blame for that
- 1:09:40launch decision on the general manager
- 1:09:42and in that plant now you can agree or
- 1:09:45disagree with that but the fact is they
- 1:09:46cannot dodge the responsibility for
- 1:09:49making this decision I thought at that
- 1:09:51night and I still think it today at this
- 1:09:53point in time that the reason they did
- 1:09:55what they did is that we were in
- 1:09:57negotiations for fall on sole source
- 1:10:00contract without any competition that
- 1:10:03would keep them making boosters into the
- 1:10:04late 1990s without any competition
- 1:10:06whatsoever yeah but don't you think the
- 1:10:08NASA representatives knew that pressure
- 1:10:10that was on them and that they they had
- 1:10:12a very clear idea of what the technical
- 1:10:14problems were and they used this
- 1:10:18reversal position of your Thiokol
- 1:10:21managers simply to do what they wanted
- 1:10:24to do in the first place well I think
- 1:10:25that's correct and now I think that
- 1:10:26actually is underlined by the fact that
- 1:10:28they didn't ask any deeper probing
- 1:10:29questions during during the receipt of
- 1:10:31that answer and I actually had a
- 1:10:33presidential commission member who will
- 1:10:35remain nameless tell me there Roger it
- 1:10:37didn't make any difference what you guys
- 1:10:38did that night NASA was going to launch
- 1:10:40anyways period and so our guys would
- 1:10:43have come out way ahead if they just
- 1:10:45hung up the telephone conversation I
- 1:10:51know that but I can make just and I
- 1:10:54agree this great circumstantial evidence
- 1:10:56for that for that position but there's
- 1:10:58just as strong and evidence on the other
- 1:11:00side of that coin for NASA creating
- 1:11:01their own pressure this was NASA's
- 1:11:03premier PR opportunity since landing a
- 1:11:06man on the moon think about that
- 1:11:08now after that disaster now seven
- 1:11:11through a major reorganization
- 1:11:14and change our management do you think
- 1:11:17any of this would be prevented by the
- 1:11:20change of Management Center Styles they
- 1:11:22don't know well the floor the floor in
- 1:11:24that statement is major they did not go
- 1:11:26through a major reorganization they went
- 1:11:28through a cosmetic reorganization which
- 1:11:31means absolutely nothing
- 1:11:32the the motivation for Carson's schedule
- 1:11:35is alive and well people it's alive and
- 1:11:38well in and you don't have to take my
- 1:11:40word for it
- 1:11:41just go back and read the newspapers
- 1:11:43since they returned the flight NASA
- 1:11:46rolled out the return to flight vehicle
- 1:11:48on the 4th of July
- 1:11:50rah-rah-rah they no sooner got it out to
- 1:11:53the pad when they developed major fuel
- 1:11:56leaks which they acknowledged an
- 1:11:58oppression in a press release that they
- 1:12:00never ever have fixed on a pad they
- 1:12:02always roll back into the Vehicle
- 1:12:04Assembly Building and then proceeded to
- 1:12:06fix it on the pad there there are
- 1:12:09literally hundreds of examples since the
- 1:12:12return to flight like this that will
- 1:12:13absolutely conclusively prove to you
- 1:12:16that the organization is still badly
- 1:12:18broken over 10 scientific astronauts
- 1:12:22have resigned from the program why I ask
- 1:12:25you would scientific astronauts all PhDs
- 1:12:29all very talented individuals all who
- 1:12:32worked their fingers to the bone to get
- 1:12:34into the astronaut corps program why
- 1:12:36would they give up the premier technical
- 1:12:38opportunity this century if there still
- 1:12:40wasn't something really bad in the
- 1:12:42program and they would see seeing
- 1:12:44themselves you as the sacrificial lambs
- 1:12:46once again why would Sally Ride quit
- 1:12:48shortly after she issued a report
- 1:12:50doesn't make sense doesn't make sense at
- 1:12:54all unless the system is still screwed
- 1:12:56up
- 1:12:56I had numerous phone calls both with
- 1:12:59inside of NASA and with inside Morton
- 1:13:01Thiokol and the message was loud and
- 1:13:03clear
- 1:13:03Roger it is business as usual NASA set
- 1:13:07up a a snitch program an internal snitch
- 1:13:10program that would read that people
- 1:13:13would remain anonymous and it goes
- 1:13:14through the Columbus NASA facility the
- 1:13:17first person that reported a very severe
- 1:13:20problem and it had to do with the
- 1:13:22o-rings somebody had actually slipped
- 1:13:24the o-rings I guess with a razor blade
- 1:13:26and they were hoping to draw attention
- 1:13:28to two problems in a manufacturer the
- 1:13:30o-ring seal that was a hell of a way to
- 1:13:32do it but but that's what they did do
- 1:13:34you know that the first test case
- 1:13:36through this supposedly anonymous system
- 1:13:38they identified the individual what do
- 1:13:40you think that did to the system
- 1:13:42it totally diffused the system as being
- 1:13:44operative do you think that things have
- 1:13:47changed at NASA I just came from the
- 1:13:49nest it's guarded Space Center last week
- 1:13:51I got the ultimate invite to talk to my
- 1:13:53colleagues at NASA at a different center
- 1:13:55of course but the fact that Matt is
- 1:13:57there scared to death about this
- 1:13:59upcoming launch after I talk to them
- 1:14:00about this this incredibly lousy joint
- 1:14:03redesigned you know let me show you you
- 1:14:08want you want to see you want ammunition
- 1:14:10I'll give you an addition this is the
- 1:14:12redesigned joint that I have no problem
- 1:14:15with technically I don't like it as the
- 1:14:17best design but I have no problem safety
- 1:14:19wise you can recognize the original
- 1:14:21configuration of the joint in here see
- 1:14:23the crosshatch section that's the new
- 1:14:24additional piece that's now machined as
- 1:14:27part of the tang and this purpose is a
- 1:14:29capture feature to keep this leg from
- 1:14:30lifting off this is now an interference
- 1:14:33fit right here okay these parts is
- 1:14:36supposed to reuse nineteen times you you
- 1:14:39really think they're going to get
- 1:14:40nineteen uses out of these things
- 1:14:41after this interference fit is gold and
- 1:14:44chewed up every time they assemble this
- 1:14:45thing I don't think so
- 1:14:47but as far as it's or rings occur in
- 1:14:49their level rings they add another
- 1:14:50o-ring it's a vital ring and but this
- 1:14:54seal will always remain compressed and
- 1:14:57always get more compression as the
- 1:14:59vehicle is pressurized so from that
- 1:15:00standpoint it's not bad when all these
- 1:15:06go out this tries to go in but it can't
- 1:15:09anymore because this won't let it
- 1:15:11and as this mutual interface moves it
- 1:15:14just causes this comparing to stay
- 1:15:16compressed now see I had recommended a
- 1:15:18wire mesh elastomeric impregnated seal
- 1:15:23for this position that is used in the
- 1:15:26oil industry it can withstand thirty
- 1:15:28five thousand psi in two thousand
- 1:15:30degrees Fahrenheit for a long period of
- 1:15:33time way in excess of two minutes and
- 1:15:35they put a Viton o-ring seal in there
- 1:15:37you know I'm really ashamed to admit
- 1:15:40that I told them how to make this joint
- 1:15:42they they had this coming down
- 1:15:45originally right here and they could not
- 1:15:47figure out how to get a machining quill
- 1:15:49and they had a machine the slot and like
- 1:15:51a stupid jerk I told them to just had to
- 1:15:53relieve this and it could have machined
- 1:15:54it or else they would had to come up
- 1:15:55with a different design but I have no
- 1:15:57problem with this from a safety
- 1:15:58standpoint no problem at all it's a belt
- 1:16:01and suspenders
- 1:16:02they also have heaters on the joint to
- 1:16:04keep them nice and toasty warm okay this
- 1:16:07is the joint I really have a problem
- 1:16:08with this is a joint that I believe that
- 1:16:12none of you is engineering students or
- 1:16:14engineering professors would even design
- 1:16:16in your home workshop this is an
- 1:16:17abortion what we have here and you
- 1:16:21recognize the joint the nozzle fixed
- 1:16:23housing this is the F dome they've got a
- 1:16:25little bit different character of
- 1:16:27insulation they have what they call
- 1:16:29split flap which it allows the stress to
- 1:16:31be taken off this this opening they have
- 1:16:33and he's have been here and they have
- 1:16:35another ol ring is the level rings again
- 1:16:37right there but this is not used as a
- 1:16:39seal I'll explain that in a minute
- 1:16:41there's the original primary seal the
- 1:16:43original secondary seal and now they've
- 1:16:46drilled 100 radio holes between the
- 1:16:50original primary and secondary seal
- 1:16:52installed 100 bolts and underneath the
- 1:16:55head of these bolts they put the magic
- 1:16:56seals called stato seals they are washes
- 1:17:00and you guessed it o rings on the ID
- 1:17:04it's a blind assembly people by its very
- 1:17:07name stat means statics that o seal this
- 1:17:11piece relative to this piece moves in
- 1:17:14the axial direction roughly 8 to 10
- 1:17:16thousandths of an inch
- 1:17:17this piece moves relative to this piece
- 1:17:20some amount unknown in a circumferential
- 1:17:23plane because when these assembled
- 1:17:25they're not round I assure you they are
- 1:17:27round when they're pressurized to a
- 1:17:29thousand psi and so you have relative
- 1:17:32motion this joint is designed to have a
- 1:17:34gap it's designed to have a gap who in
- 1:17:38their right mind would actually clamp
- 1:17:41against an airspace against the gap that
- 1:17:45was designed a piece of equipment it was
- 1:17:48designed have a gap in it what
- 1:17:49means is that at a hundreds of street
- 1:17:51points you have metal metal contact and
- 1:17:52in between 100 discrete points you have
- 1:17:54a daisy effect with a gap in between the
- 1:17:57bolts it will act very similar not in
- 1:18:00magnitude but very similar in technique
- 1:18:02of deflection as the previous joint now
- 1:18:05remember we had already gotten past a
- 1:18:07primary ring sale in April 1985 flight
- 1:18:10this is not a test it was a real flight
- 1:18:12we ever get past the primary seal again
- 1:18:14we now present 101 potentially pets
- 1:18:18instead of one that we had originally I
- 1:18:20had also proposed a metal seal here
- 1:18:23which would have not only taken the
- 1:18:24temperature but would have been
- 1:18:26impervious to erosion should we ever get
- 1:18:28past my recommendation for this joint
- 1:18:31was to simply take these F domes put
- 1:18:33them up in a vertical turret lathe cut a
- 1:18:35cylindrical true service extend this
- 1:18:38they had to make all these new pieces
- 1:18:39anyways here extend this out import a
- 1:18:42register that would actually keep this
- 1:18:45piece from moving in and out like it had
- 1:18:47done before it would minimize it okay
- 1:18:49now get back to the adhesive I could I
- 1:18:51submit to you that if you had gone
- 1:18:52around and taking a poll with that call
- 1:18:54and asked is anybody ever concerned with
- 1:18:58hockey ass getting past this adhesive
- 1:18:59the answer including me would have been
- 1:19:01not on your life it'll never get past it
- 1:19:04he Civ Clark guys can never even get to
- 1:19:06this first sale this is considered a
- 1:19:08wiper seal and the purpose of this is to
- 1:19:10keep this adhesive from following the
- 1:19:13real seal during assembly
- 1:19:14now let me ask you a question if the
- 1:19:16purpose of this seal is to keep that
- 1:19:17adhesive from following that seal during
- 1:19:19assembly does not it follow that that
- 1:19:22adhesive will follow this seal during
- 1:19:24assembly guess what happened the first
- 1:19:27two development tests of this joint a
- 1:19:29hot gas test and a coal gas test they
- 1:19:32got gas right through here
- 1:19:35passed adhesive one gentleman told me
- 1:19:37that it stopped here and the other
- 1:19:38gentleman told me I went all the way up
- 1:19:40to the primary sale two out of two test
- 1:19:43failures in the redesign of this joint
- 1:19:45and this joint still went forward and is
- 1:19:47flying today now do you think something
- 1:19:50has changed at the agency I sure as hell
- 1:19:52don't think something's changed at the
- 1:19:53agency this is the type of crap that
- 1:19:56they still put out this is a Murphy of
- 1:19:59our type joint this is the joint
- 1:20:01why this disjoint is why I don't watch
- 1:20:04launches anymore
- 1:20:05I am absolutely afraid to watch the
- 1:20:09launch because of the fear of failure in
- 1:20:11real time again I could probably see a
- 1:20:13videotape but not in real time that was
- 1:20:15too much to go through that one time and
- 1:20:17I won't do it again but this is what
- 1:20:18we're faced in a program today thank you
- 1:20:22thank you very much the opportunity to
- 1:20:25talk to mr. Beaujolais again and the
- 1:20:27refreshments and old W building and I
- 1:20:29thank you again I think we all
- 1:20:31appreciated your presentation
- 1:20:33[Applause]
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