Tag Archives: Command Module

[March 16, 1969] Flight of the Space Spider (Apollo 9)



by Kaye Dee

Riding on Apollo's Coat-tails
The Traveller recently referred to President Nixon’s 8-day European tour, but it would seem Mr. Nixon deliberately decided to pave the way by riding on the coat-tails of the general international applause accorded to the historic Apollo-8 mission. Shortly before he announced his own trip to Europe, the President personally dispatched Apollo-8 commander Colonel Frank Borman and his family on an eight-nation European goodwill tour. (The other Apollo-8 crewmembers, already in training as part of the Apollo-11 backup crew, were not available to participate in the tour.)


Departing on 2 February, Col. Borman, his wife Susan, and two sons undertook a 19-day tour, visiting the UK, France, Belgium, the Netherlands, West Germany (including West Berlin), Italy (including Vatican City), and Spain (like Australia, home to an Apollo Manned Space Flight Network station and a Deep Space Network facility): an itinerary very closely paralleling that later followed by President Nixon!

The Borman family meets the Royal Family and Col. Borman presents a picture of the Moon to the Pope during his goodwill tour of Europe

Col. Borman said that he was particularly gratified to make the journey because of a conviction that space efforts “can be a very positive force for creating better relations among the people of the world”.

A Long-Delayed Mission
But while Colonel Borman was embarking on his diplomatic mission, the crew of the long-delayed first test flight of the Lunar Module (LM) in Earth orbit were in the final stages of preparations for the Apollo-9 mission, which splashed down just a few days ago with all its objectives successfully completed. Intended to be Apollo-8, the mission was bumped later in the sequence due to a succession of technical delays in the development of the LM, the first manned spacecraft designed solely for operations in space.


Apollo-9’s main task was to qualify the LM for manned lunar flight, demonstrating that the craft could perform all the necessary manoeuvres required for a landing on the Moon. The flight was therefore intended to be very much a mission of “firsts” that would finally fully test-out the entire suite of hardware needed to accomplish a Moon landing mission. It would see the first flight of the complete Apollo Saturn vehicle – Saturn V launcher (AS-504 for this mission), Command Service Module (CSM-104) and Lunar Module (LM-3) – as well as the first docking and extraction of a LM from the Saturn S-IVB stage.


 
Putting the LM through its paces would involve the first flight tests of its upper and lower stages, with the first firings of their engines in space, and include the first rendezvous and docking between with the CSM and LM. The mission would also undertake the first spacewalk of the Apollo programme, to test the reliability of the Apollo A-7L space suit and the Portable Life Support System (PLSS) backpack, essential for lunar surface operations.

The Crew Who Waited
Original 1966 crew photo of Astronauts Scott, McDivitt and Schweickart. Their training for the flight that eventually became Apollo-9 commenced in January 1967, even before the Apollo-1 fire

Probably the best prepared mission crew to date, the Apollo-9 crew originally came together in January 1966, as the back-ups for Apollo-1, before being assigned as the first crew to fly the LM. Their 1,800 hours of mission-specific training was equivalent to about seven hours for every hour of their eventual flight!

With so much riding on a successful LM test flight, Apollo-9’s crew comprised two veteran Gemini astronauts and one rookie. Mission Commander Air Force Col. James McDivitt previously commanded the Gemini-IV mission, during which the first US EVA was conducted. Command Module Pilot Lt.-Col. David Scott, also with the US Air Force, was Pilot of Gemini-VIII, its flight cut short by the first US in-flight space emergency, but for which he undertook considerable EVA training.

Finally Go for launch! Astronauts McDivitt, Scott and Schweickart in their official Apollo-9 pre-flight crew portrait

The new kid on the block for Apollo-9 was LM Pilot Mr. Russell Schweickart, originally selected in the third group of astronauts in 1963. An experienced fighter pilot, serving with the U.S. Air Force and the Massachusetts Air National Guard between 1956 and 1963, Mr. Schweickart joined NASA as a civilian, from a position as a research scientist at the Experimental Astronomy Laboratory of the Massachusetts Institute of Technology (MIT). Mr. Schweickart is nicknamed “Rusty” for his red hair (but in Australia, with our sense of humour, we’d have called him “Bluey”!).

Introducing Gumdrop and Spider
Because Apollo-9 would have two spacecraft from the same mission operating independently for the first time (unlike the Gemini VI-VII rendezvous, in which the two spacecraft were separate missions with their own callsigns), they each required separate callsigns for easy communications identification. NASA Administrators therefore finally lifted the ban on spacecraft names, which has been in operation since the beginning of the Gemini programme, permitting the crew to select their own names for the CM and LM.

The Apollo-9 CSM and LM being prepared for launch at Kennedy Space Centre

The astronauts chose “Gumdrop” for the CM, based on the shape of the capsule, which resembles the popular sweet, and “Spider” for the LM, given the spider-like appearance of the lander, with its four spindly legs. Unfortunately, it seems that certain NASA officials were not happy with these choices, feeling they were not dignified enough, so I hope they will not place restrictions on the names that can be selected for future missions, or force the crews to revert to dull numerical callsigns.

Patching Up
North American Rockwell artist Allen Stevens seems to be quite a favourite with the Apollo astronauts as a mission patch designer. He has designed the patches for Apollo-1, 7 and Apollo-9, and seems to have had a strong influence on the design of the Apollo-8 patch.

Stevens’ Apollo-9 patch evolved from a design he originally developed when Apollo-9 was still anticipated to be Apollo-8. The relatively simple concept depicts all the vehicle elements of the Apollo mission – the Saturn V in launch configuration, with the CSM and the LM flying separately as they would do during orbital test manoeuvres. In the final version of the design they appear against a mottled blue background that could represent either the Earth’s oceans or orbital space. Rather than show the CSM and LM docked together in orbit, as we often see them in NASA illustrations, Stevens chose to depict them in their on orbit ‘station-keeping’ positions, with the CSAM and LM facing each other, although this does give the impression that the CM is attempting to dock with the front of the LM!

Completing the design, the names of the crew and mission circle just inside the red-bordered edge of the patch, with the “D” in McDivitt’s name also filled in red. This is a nod to Apollo-9 being originally designated as the “D” mission in the sequence of Apollo flights prior to the Moon landing.

A Busy Moonport
Due to the long delay with the LM, preparations for Apollo-9 initially overlapped those of Apollo-7 and 8. By February, while the astronauts were spending long hours in mission simulators preparing for their flight, Kennedy Space Centre (KSC) was a hive of activity with Apollo-9 in the final stages of pre-launch testing, and advance preparations for Apollo 10 and Apollo 11 also underway (Apollo 10 is currently due for launch in May and Apollo 11 in July).  

In addition to Apollo-9’s launch preparations, the Apollo 10 spacecraft was moved from the Manned Spacecraft Operations Building (MSOB) to the Vehicle Assembly Building (VAB) for mating with its Saturn V launcher (above left); the first and second stages for the Apollo 11 Saturn V arrived, with the stacking of that launcher commencing in the VAB (above right); and the upper and lower stages of the Apollo 11 LM were also mated in the MSOB, in preparation for testing in the altitude chamber. NASA is really moving at a cracking pace to achieve a manned lunar landing this year!

An Unexpected Delay
The countdown for Apollo-9 commenced on 26 February, for a planned launch on the 28th. But fate stepped in to delay the crew’s trip to space just a bit longer! Ironically, despite their years of training for this mission, the astronauts pushed themselves so hard in their final weeks that, as launch day approached, they developed cold-like symptoms such as sore throats and nasal congestion.

Apollo-9's LM crew, McDivitt and Schweickart, training in the Lunar Module simualator

For NASA’s most complex manned mission to date, senior managers and flight surgeons wanted the crew to be in the best possible health for the 10-day flight. (They were probably also mindful of preventing a recurrence of the issues with the Apollo-7 crew, due to in-flight health problems). Consequently, the launch was rescheduled to 3 March to give the astronauts time to recover.

Finally on their Way!

 

 

 

 

 

 

 

 

 

 

 

 

 

Once KSC medical director Dr Charles Berry finally cleared the crew for launch, Apollo-9 left the pad exactly on time at 16:00GMT on 3 March. Hopefully the smooth launch impressed Vice President Spiro Agnew (on right in the picture below), who was present in the Launch Control Centre in his new role as Head of the National Space Council, especially as President Nixon has asked his science adviser, Dr Lee Dubridge, to report on possible cost reductions within the US space programme.

To maximize the chances of accomplishing them, in case any problems forced an early return to Earth, the most critical mission tasks were scheduled for the first five days of the flight. So once the Saturn rocket’s S-IVB third stage and the CSM were safely in orbit, things moved quickly. During the second orbit, CM Pilot Scott turned the CSM and successfully docked with the Lunar Module, nestled in the Spacecraft-Lunar Module Adapter of the S-IVB stage. The linked spacecraft were ejected from the S-IVB, which was then remotely controlled to simulate Trans-Lunar Injection and eventually be sent into a solar orbit.

Demonstrating that the “probe and drogue” CM-LM docking assembly worked properly is another crucial step towards enabling the future Moon landing. If this system didn’t work, a lunar landing would not be possible.

Once the probe is inserted in the drogue it retracts and pulls the two spacecraft together so that a series of twelve latches locks them tight.

Burning Along
Six hours into the mission, the next task was to establish that the docked CSM-LM could be manoeuvred using the Service Module’s Service Propulsion System (SPS) engine. A five-second burn placed the CSM in an orbit of 125 by 145 miles, to improve its orbital lifetime. This short firing demonstrated the CSM guidance and navigation system’s ability to control the burn and showed that the LM’s relatively light structure could withstand thrust, acceleration and vibration.

Following the first sleep period on an Apollo mission during which all three astronauts slept at the same time, Apollo-9’s second day focussed on putting the SPS engine, and the CSM, to the test, through a series of three burns. The first burn, lasting 110 seconds, raised Apollo 9’s orbit to 213 miles and tested the structural dynamics of the docked spacecraft under conditions simulating a lunar mission. This involved gimballing (swivelling) the SPS engine to determine whether the spacecraft’s guidance and navigation autopilot could dampen the induced oscillations. The CSM remained very stable, with the oscillations damped within just five seconds.

Apollo spacecraft diagram key. CSM (right) and LM (launch configuration) docked. I – Lunar module descent stage; II – Lunar module ascent stage; III – Command module; IV – Service module. 1 LM descent engine skirt; 2 LM landing gear; 3 LM ladder; 4 Egress platform ("porch"); 5 Forward hatch; 6 LM reaction control system quad; 7 S-band inflight antenna (2); 8 Rendezvous radar antenna; 9 S-band steerable antenna; 10 Command Module crew compartment; 11 Electrical power system radiators; 12 SM reaction control system quad; 13 Environmental control system radiator; 14 S-band steerable antenna

The second SPS burn lasted 280 seconds, changing the orbit to 126 by 313 miles, while the short third burn, just 28.2 seconds, changed the plane of the spacecraft’s orbit. These orbital changes were designed to position Apollo-9 for better ground tracking and lighting conditions during upcoming mission activities.

Space Sickness Strikes
Entering the LM and checking out its systems was scheduled for flight day three, but planned operations were initially disrupted when space sickness reared its head. Flight surgeons still know little about this condition, which seems to affect some astronauts but not others, and some more than others.

A view inside Command Module Gumdrop

Both Col. McDivitt and Mr. Schweickart were affected, with McDivitt apparently experiencing some mild nausea. Mr. Schweickart, however, vomited in the CM and again later in the LM. When Col. McDivitt contacted the flight surgeons from the LM to report the medical situation, they were less than happy that the earlier incident had not been initially reported, as they could have treated Schweickart’s symptoms sooner.

Opening Up the LM
Although the initial bout of space sickness delayed the start of operations to clear the docking tunnel and access the LM, the astronauts were able to continue with the day’s activities, and both Commander and LM Pilot used the docking tunnel to make the first ever transfer between manned spacecraft without needing to spacewalk. With Lt.-Col. Scott remaining in the CM, and hatches between the Gumdrop and Spider closed, the LM’s communications and life support systems demonstrated that they were operating independently from the CM. Schweickart also deployed Spider’s landing legs (which had been folded for launch) into the position they would assume for landing on the Moon, giving the LM the appearance of its namesake!


A Jumping Spider!
During the nine hours they inhabited Spider, still docked to the CSM, Col. McDivitt and Mr. Schweickart conducted a major test of the Lunar Module’s descent engine, firing it for 367 seconds to simulate the pattern of throttling planned for a descent to the lunar surface. For the final 59 seconds of the burn McDivitt controlled the throttling, varying the thrust from 10 to 40 percent and shutting it off manually, marking the first manual throttling of an engine in space.

This burn, which demonstrated that the LM descent engine could manoeuvre the combined LM-CSM stack, was followed by an additional SPS firing after the LM crew returned to the CM. Together, these burns placed Apollo 9 into an orbit of 142 by 149 miles, ahead of the rendezvous exercises to be performed on day five.

Red Rover (Doesn’t Quite) Cross Over
The step-by-step testing program for Apollo-9 earmarked the fourth day of the mission for a spacewalk to test the reliability of the Apollo EVA suit and the PLSS backpack, necessary because it would be impractical and dangerous for astronauts to move across the Moon’s surface trailing umbilical lines connected to the LM. As the only EVA scheduled before the Moon landing, it was the single opportunity to test the PLSS operationally in space.

Astronaut Schweickart training for his planned EVA

Using the call sign “Red Rover”, “Rusty” Schweickart was originally scheduled to perform a two-hour EVA to simulate a space rescue technique in the event that a CM-LM docking could not be made, crossing from Spider to Gumdrop. This would have involved him exiting the hatch on the LM and making his way along the outside of the spacecraft to the CM hatch, where Lt.-Col. Scott would be standing by to assist access to the CM. However, the LM Pilot’s bout of space sickness led Col. McDivitt to initially cancel the EVA, due to the flight surgeons’ concerns about the dangers of vomiting in a spacesuit. This also meant the cancellation of a planned TV broadcast of the spacewalk itself, which would have been another first.

Wearing Golden Slippers
But with Mr. Schweickart feeling somewhat better by day four, a modified short EVA was substituted to enable the EVA equipment test to be carried out. After McDivitt and Schweickart again transferred to Spider, Mr. Schweickert climbed out onto the LM porch for a 37.5-minute EVA, exclaiming “Hey, this is like spectacular” as he stood in the void. For much of this time, the astronaut’s feet were held in gold-coloured restraints, nicknamed the “Golden Slippers”, but he was also able to move around the LM’s exterior using handholds to retrieve some experiments.

At the same time, David Scott, wearing a bright red helmet, made a stand-up EVA in Gumdrop’s hatch and both astronauts photographed each. Scott, too, retrieved experiments from outside the CM. Mr. Schweickart has said that he found moving around easier than it had been in simulations and was confident that he could have completed the spacewalk to the CM had it gone ahead.

The Spider Takes Flight

The key event in Apollo -9’s programme was the undocking and rendezvous tests scheduled for the fifth day of the mission. These manoeuvres would simulate all the activities required for a successful lunar landing and return to lunar orbit. With McDivitt and Schweickart in Spider, and Scott remaining in Gumdrop, the two craft undocked to commence a complex set of manoeuvres and burns of both the LM descent and ascent engines. These tests also carried a new element of danger. The Lunar Module has no ability to return to Earth on its own, since it lacks a heatshield: if something went seriously wrong its crew could end up stranded in space with no way home.

After 45 minutes separated but station keeping, an initial 24.9-second LM descent engine burn placed Spider into a 137 by 167 mile orbit; a second 24.4-second firing circularized the orbit around 154 by 160 miles, approximately 12 miles higher than Gumdrop. Over the next four hours, McDivitt fired the LM’s descent engine at several throttle settings, before lowering Spider’s orbit to begin a two-hour ‘chase’ to catch-up with Gumdrop. The LM descent stage was then jettisoned, and the ascent stage engine fired for the first time, lowering the LM’s orbit still further and placing Spider 75 miles behind and 10 miles below Gumdrop for the rendezvous manoeuvre.

Although it is planned that in future Moon missions, the Command Module pilot will conduct the rendezvous with a returning LM, for Apollo-9 Spider carried out the rendezvous, to demonstrate that the manoeuvre could be performed by either craft. Apart from this difference, the approach and rendezvous hewed as closely as possible to the current plans for lunar missions. Mission Commander McDivitt flew the LM close to Gumdrop, manoeuvring Spider so that CM Pilot Scott could see each side of the vehicle and inspect it for any damage. As he photographed the ascent stage, Scott joked “You’re the biggest, friendliest, funniest looking Spider I’ve ever seen.”

McDivitt then docked to the CM, guided by Scott, as Sun glare was interfering with his vision. Once Spider’s crew returned to Gumdrop, the ascent stage was jettisoned and remotely commanded to fire its engine to fuel depletion, simulating an ascent stage’s climb from the lunar surface. With the approach and rendezvous operation complete, the only major LM system that had not been fully tested during Apollo-9 was the lunar landing radar.

A Bit Camera Shy
Unlike the previous two missions, Apollo 9’s packed programme restricted the television broadcasts made by the astronauts. Spider was equipped with a Westinghouse b/w Lunar Surface Lunar TV Camera, identical to the one taken to be carried to the Moon’s surface on the first landing, as another equipment trial. This low-light “slow scan” camera produced a 320 line, 10 frames per second non-interlaced picture.

Only two broadcasts were from Spider. The first, seven minutes’ long, occurred on day three and showed Mr. Schweickart and Col. McDivitt working in the confined space of the LM. The second broadcast occurred shortly after the end of the EVA on the fourth day, with Spider’s crew still wearing their spacesuits.

The quality of this 15-minute transmission was much better than the previous day, and the crew treated viewers to a scene of Col. McDivitt eating. The camera was then pointed out the LM’s top window to show Gumdrop, then through one of the forward windows to glimpse one of Spider’s attitude control thruster quads and a landing leg. Finally, the view switched back into the cabin to show the LM’s instrument panel and a radiation detector. Once the LM ascent stage was jettisoned, on day five, there were no further broadcasts as the CM did not carry a television camera.

Cruisin' in Orbit
Once the crowded test schedule of the first five days was complete, the second five days of Apollo-9’s flight, intended to test the endurance of the CSM for the total length of a Moon landing mission, were quiet and relaxed by comparison.

Col. McDivitt thanked the Mission Control team for their work during the hectic first half of the mission and jokingly mused: “Might give you the impression that it might work, huh?” The crew sang a belated “Happy Birthdays” to Christopher C. Kraft, Jr., Director of Flight Operations at the Manned Spacecraft Centre, and Apollo 9 crew secretary Charlotte Maltese.

There were additional SPS burns on days six and eight to change the spacecraft’s orbit, with no major activities scheduled for the ninth day, although the astronauts made observations of the Pegasus 3 satellite, passing within 1,000 miles and 700 miles of Apollo 9 during two successive orbits. They also observed the LM ascent stage from about 700 miles away.

Observing the Earth
The main activity of the second half of the Apollo-9’s flight was the mission’s only formal scientific investigation, a programme of multi-spectral terrain photography, using four Hasselblad 70 mm cameras pointed out the CM’s round hatch window. This allowed photographs to be taken in four specific wavelengths of the visible and near infrared spectrum simultaneously.

Multi-spectral images. The same view of San Diego and parts of California in four different wavelengths

This experiment was designed to determine whether multi-spectral photography can be effectively utilised for earth resources programmes such as agriculture, forestry, geology, oceanography, hydrology, and geography. The results will help to refine the instruments for the Earth Resources Technology Satellite (ERTS), due for launch in 1972, Landsat, and techniques for multi-spectral photography to be conducted aboard the Skylab space station in the early 1970s.

Altogether 127 complete four-frame sets of photographs were taken over California, Texas, other areas of the southern United States, Mexico, the Caribbean and the Cape Verde Islands. Astronauts also took more than 1,100 standard Earth observation photographs of targets around the world, using colour and colour infrared film and a handheld Hasselblad camera.

Apollo-9 astronauts' colour photograph of the North Carolina coast and a colour infra-red view of California's Salton Sea

Coming Home
Apollo -9 returned to Earth on 13 March (the 14th for us here in Australia), the tenth day of the mission. Re-entry was delayed by one revolution due to heavy seas in the primary recovery area, but Gumdrop splashed down safely in the Atlantic, within three miles of the recovery ship, the USS Guadalcanal, after a mission totalling 241 hours, 53 seconds – just 10 seconds longer than planned!

On board the recovery ship, the crew were treated to a share of a 350-pound cake baked in their honour. Now safely back in Houston for their flight debriefings, NASA’s attention – and the world’s – is already turning to Apollo-10, due to fly in May to test the LM around the Moon!

Ready for the Next Steps
While Apollo-9 might not have seemed as exciting a mission as Apollo-8’s epic lunar voyage, it was critical because it has simulated in Earth orbit, as far as possible, many of the conditions that the astronauts and their equipment will face when the lunar landing attempt is made. Beyond that first landing and its successors, there is the Apollo Applications Programme, and other developments such as the Skylab manned earth orbiting workshop. Everything that has been learned in space with Apollo-9 will be useful sooner or later in future space activities!

And you can bet we'll be covering each and every one of them here on the Journey…

Apollo-9 view of the Moon


[January 28, 1967] "Fire in the cockpit!" (The AS-204 Accident)


by Kaye Dee

As I write this, I’m still in shock. It’s only a few hours since the news broke here in Australia of the tragic loss of the crew of Apollo 204 in a fire on the launchpad at Cape Kennedy, during a launch rehearsal. Spaceflight is difficult and dangerous – we know that. Astronauts Freeman, Bassett and See were killed in plane crashes during training; Armstrong and Scott had a narrow escape from inflight disaster during Gemini VIII.

Unconfirmed rumours abound of Soviet cosmonauts who died in unsuccessful space missions before Gagarin, and the Russians have probably had training accidents to which they have not yet admitted. When I wrote about Gemini VIII’s aborted mission, I asked if spaceflight was moving too fast. There’s certainly been a headlong rush on NASA’s part to get to the Moon ahead of the Soviet Union, so perhaps this tragedy is the answer to my rhetorical question.


The first image available showing the fire-ravaged interior of the Apollo 204 spacecraft

Details are still sketchy at this time, although no doubt more information about the accident will emerge in the coming days and weeks as investigations take place. But right now, let’s explore the background to the mission and what we know about the catastrophe.

The Lost Crew
Apollo 204 (AS-204) was intended to be the first manned test flight of the new Apollo Command and Service Modules, the spacecraft that will be used to carry the first NASA astronauts to the Moon within the next few years. As such, two experienced astronaut test pilots were assigned to the flight: USAF Lt. Colonels Virgil “Gus” Grissom, the Command Pilot, and Senior Pilot Edward White. Grissom was the United States’ second space traveller, flying the Mercury MR-4 mission. He also commanded the first manned Gemini mission, Gemini III. Rumour even has it that Grissom was already under possible consideration to command NASA’s first lunar landing mission. Lt. Col. White is famous as the first American to make a spacewalk, during Gemini IV. These veteran astronauts were joined for this mission by rookie US Navy Lt. Commander Roger Chaffee. Chaffee was selected as a member of the third astronaut group and specialised in communications: he had been a CapCom for both Gemini III and IV.


Official Apollo 204 crew portrait, including a model of the new Apollo Command Module which their mission was intended to test. Left to right Ed White, "Gus" Grissom and Roger Chaffee

The Apollo 204 back-up crew consists of experienced Mercury and Gemini astronaut Walter Schirra and first-time fliers Donn Eisele and Walter Cunningham. Astronaut Eisele had originally been assigned in Lt. Commander Chaffee’s role for the Apollo 204 mission but had to be replaced when he needed shoulder surgery in early 1966. I assume that once Apollo missions resume after the accident investigation, this crew will fly the first orbital mission that should have been accomplished by AS-204.

What’s in a Name?
The design for the official Apollo 204 patch, developed by the crew and illustrated by North American Rockwell artist Allen Stevens, carries the designation Apollo 1. At the time that it was approved by NASA, in June 1966, this was the flight’s official name. However, it seems that only recently some doubt arose as to whether the formal designation of the mission would be Apollo 1 after all, which is why it is presently being referred to as Apollo 204, or AS-204. I’ve heard from the Australian liaison officer at NASA, that just last week approval for the patch was withdrawn and that, if this accident had not occurred, the patch might have had to be redesigned, depending on the final mission designation.

But as it stands, the mission patch uses the American flag for a background, with a central image depicting an Apollo spacecraft in Earth orbit. The Moon appears to the right of the Earth, reminding us of the eventual goal of Project Apollo. The designation Apollo 1 and the names of the crew appear in a border around the central image, while the patch is edged with a black border – a touch that is poignantly even more appropriate in view of the loss of the crew. I do hope that this patch, and the designation Apollo 1, will be re-instated as the official insignia of this mission in honour of its lost crew.

The Mission that Should Have Been
The fire that has killed the Apollo 204 crew occurred during a preflight test ahead of a launch scheduled for 21 February. It was planned to be the first manned orbital test flight of the Apollo Command and Service Modules, launched on a Saturn IB rocket. The mission was to have tested launch operations, ground tracking and control facilities, as well as the performance of the Apollo-Saturn launch vehicle. Depending on how well the spacecraft performed, the mission might have lasted up to two weeks, perhaps equalling Gemini VII's record spaceflight and demonstrating that the Apollo spacecraft could function successfully for the duration of the longest Moon flights currently in planning.


The Apollo 204 crew in front of Pad 34, from which they should have launched, and where they have been killed

The Command Module allocated to Apollo 204, CM-012, was a so-called “Block I” version, originally designed before the lunar orbit rendezvous landing strategy was selected. Block 1 spacecraft aren’t able to dock with a lunar module, but future “Block II” versions will.

Was It a Lemon?
The Apollo Command and Service Modules are undoubtedly far more complex than any previously-built spacecraft, so it isn’t surprising that their development has had many teething problems. Over the last few months, I’ve heard from my former colleagues at the WRE that many issues with the Command Module became evident last year, especially when CM-012 was delivered to Kennedy Space Centre in August to be prepared for its flight. Even before it arrived, the Apollo 1 crew had expressed concerns to Apollo Spacecraft Program Office manager Joseph Shea about the quantity of flammable materials, such as nylon netting and Velcro, being used in the spacecraft cabin to hold tools and equipment in place. It seems that, even though Shea ordered these flammable materials removed, this may not have happened.


The Apollo 204 crew sent Program manager Jospeh Shea a parody of their crew portrait to express their concernes about the spacecraft. They are shown praying, and the picture carried the inscription: "It isn't that we don't trust you, Joe, but this time we've decided to go over your head"

When CM-012 arrived at Kennedy Space Center, there were still 113 significant planned engineering changes to be completed, and another 623 engineering change orders were made following delivery! This suggests that many issues with the spacecraft design were still being resolved. Apparently, the engineers in charge of the spacecraft training simulators just couldn’t keep up with all these changes, and I’ve heard that Lt. Colonel Grissom expressed his frustration about this by bringing a lemon from a tree at his home and hanging it on the simulator.


CM-012, at that time designated Apollo 1, arriving at Kennedy Space Centre

There were several problems with the environmental control unit in the Command Module, which was twice returned to the manufacturer for designed changes and repairs. During a high-speed landing test, when the Command Module was dropped into a water tank to simulate splashdown, its heat shield split wide open, and the ship sank like a stone! There were also apparently concerns about a propellant tank in the Service Module that had ruptured during pre-delivery testing. NASA had it removed and tested at Kennedy Space Centre to be sure there were no further problems. 

CM-012 finally completed a successful altitude chamber test on 30 December and was mated to its Saturn IB launch vehicle on Pad 34 at Cape Kennedy on 6 January. So, was this particular spacecraft a lemon – an accident waiting to happen? Or has this tragedy shown that the design of the Apollo Command Module is inherently flawed? We’ll undoubtedly have to wait for the results of the accident investigation before we know the answer.

Countdown to Disaster
At this point, we still know very little about the disastrous fire or what led to its breakout, but my WRE colleagues have helped me put together some information accident from their contacts at NASA. The fire broke out during what had apparently been a trouble-plagued launch simulation known as a "plugs-out" test. This kind pre-flight simulation is intended to demonstrate that the spacecraft will operate as it should on internal power, detached from all cables and umbilicals, and successfully carrying out this test was essential for confirming the 21 February launch date.


The AS-204 crew in the CM simulator on 19 January, as part of their preparations ahead of the "plugs out" test

Almost as soon as the astronauts entered the Command Module, there were problems when Grissom experienced a strange odour in his oxygen supply from the spacecraft, which delayed the start of the test. Problems with a high oxygen flow indication that kept triggering the master alarm also caused delays. There were also serious communications issues: at first, it was Command Pilot Grissom experiencing difficulty speaking with the control room, but the problems spread to include communications between the operations and checkout building and the blockhouse at complex 34, forcing another hold in the simulated countdown.

Fire Erupts
It was not until five and a half hours after the simulation began that the countdown finally resumed, and when it did instruments apparently showed an unexplained rise in the oxygen flow into the crew’s spacesuits. Within seconds, there were calls from the spacecraft indicating that a fire had broken out in the cabin and that the astronauts were facing a serious emergency, trying to escape. The final transmission from inside the spacecraft ended with a cry of pain.

Of course, there are emergency escape procedures for the Command Module, but with the triple spacecraft hatch, it requires at least 90 seconds to get it open, and it seems that the crew had never been able to accomplish the escape routine in that minimum time. There is some evidence that Lt. Col. White was trying to carry out his assigned emergency task of opening the hatch, but in the pure oxygen atmosphere of the spacecraft, the fire became incredibly intense very rapidly and rising internal pressure would have made it difficult, if not impossible to open the inward-opening hatch.


Picture taken shortly after the fire was extinguished showing the external damage to the Command Module caused by the hull rupture resulting from the fire

In less than 20 seconds from the first detection of the fire, the pressure inside CM-012 rose to the point where it actually ruptured the hull of the spacecraft, sending flame, heat and dense smoke into the pad service structure. The ground crew bravely tried to rescue the astronauts, but the dangerous conditions and unsuitable emergency equipment made it virtually impossible. Many were later treated for smoke inhalation. There were fears the CM had exploded, and that the fire might ignite the solid fuel rocket in the launch escape tower above it. If this happened, it could set fire to the entire service structure.

It took about five minutes for the ground crew to finally get the spacecraft hatch open, but their efforts were in vain, as the astronauts were already dead. The exact cause of death has yet to be determined: it may have been physical burns from the fire, or carbon monoxide asphyxia, from the fire's by-products.

Whatever the cause, three brave men have died, and an exhaustive investigation of the fire and its causes will now take place as part of the accident investigation. Exactly what effect this tragedy will have on the future of the Apollo programme will very much depend upon the findings of that investigation. If the design of the Command Module is found to be intrinsically flawed, the necessary redesigns could delay the programme for years, causing NASA to miss President Kennedy’s deadline for a Moon landing, and allowing the Soviet Union to overtake the United States again in the Space Race.

Grissom and White have both said in past interviews that they recognized the possibility that there could be catastrophic failures and accidents in spaceflight and that they accepted that possibility and continued with their work. I’d just like to give the last word in this article to Astronaut Frank Borman, who said in a 1965 interview "I hope that the people in the US are mature enough that when we do lose our first crews they accept this as part of the business". It would not honour the loss of the Apollo 204 crew if this tragedy led to the termination of the Apollo programme.