Upcoming Starship Flight 3 Prepares for Wet Dress Rehearsal

SpaceX is gearing up for the next Starship flight, with preparations focused on the Orbital Launch Pad (OLP). Booster 10 and Ship 28 are expected to return to the launch site in the next week or so, in anticipation of a Wet Dress Rehearsal (WDR) that will pave the way for the third launch of the world’s largest and most powerful rocket.

The upcoming WDR is of particular significance due to upgrades and changes made to the Orbital Tank Farm (OTF). Following the second flight, SpaceX has added extra pumps and subcoolers, as well as redesigned the plumbing system to separate the ship subcoolers from the booster ones. These improvements will enhance efficiency in fueling the rocket stack at a faster rate.

In preparation for the WDR, SpaceX has undertaken several changes to the OTF and launch site. The old water tank, which had been out of use due to leaks, was removed and scrapped. This tank, like others used for cryogenic storage, lacked additional reinforcement and had to be abandoned. Its role was taken over by repurposed methane tanks, which are essential for heat exchangers in the cryo bunker. These heat exchangers help heat up Liquid Nitrogen, used for purging and pressurizing cryo lines.

To reinforce the cryo shell during static fires and launches, SpaceX is adding large vertical I beams and cross supports to the Liquid Nitrogen Tank and the remaining Water tank exposed to the exhaust plume. Previous cryo shells were damaged by sound waves from engine firings. Other small upgrades include replacing burn plates on the Orbital Launch Mount (OLM) ring, particularly those near the Booster Quick Disconnect. They are more susceptible to damage due to Starship’s pad avoidance maneuver at liftoff.

A concrete wall is being constructed to replace HESCO barriers that previously protected the OTF tank farm. Erosion caused by engine firings necessitated the addition of plates at the base of the tower. The Ship Quick disconnect arm has been repainted, and possible upgrades to the arm are underway. SpaceX is also repairing damage remaining from Flight 1, including weld repairs inside the OLM.

SpaceX is currently dismantling the SpaceX LR11000 crane, which may signal heavy maintenance or relocation plans. Meanwhile, preparations for the second tower at Sanchez are underway, with materials being shipped from the Cape. The exact location of this tower is yet to be confirmed, although older animation suggested it would be situated to the south. Starbase General Manager Kathryn Lueders mentioned that it would serve as a launch tower.

The second Booster transport stand and Ship work stand are still being completed, after which work will commence on the third transport stand and work stand. Ship 26 is undergoing engine installs and having more stringers added to its payload section. Its purpose remains a mystery, but it’s most likely a structural test article.

Significant progress has been made on Starfactory and the New High Bay (Ship Bay). The roof on the new Ship Bay is nearly complete, and lighting and elevator equipment installation are underway. Further construction work is taking place as footings are being dug out for the final section of the factory at Tent 3.

The Ringyard has been cleared out as SpaceX moves towards completing Starfactory. Only select sections have been retained, while others have been relocated to the new scrap yard in Sanchez. Cryo testing of Ship 30 and Booster 12 was carried out, with the construction of a possible flame trench and static fire stand for ships in progress. Approval for such testing at Masseys is uncertain, but paperwork might be underway.

Ship 29 and Booster 11 are being prepared for static fires and flights as part of Flight 4 vehicles. Ship 30 and Booster 12 have completed cryo testing, with Booster 12 currently not on a work stand. Ship 30 is awaiting the installation of the next stand in the Ship Bay. Booster 13’s Methane tank is complete, marking a significant milestone for Flight 6, and adding to the growing number of flight-capable boosters in Mega Bay.

Outside of Starfactory, little evidence suggests the imminent appearance of Version 2 parts. Some components observed in Starfactory may be early test tanks. However, the start of construction on the second tower and the arrival of Version 2 pieces are eagerly anticipated.

To wrap it up, SpaceX is actively preparing for the next Starship flight, with a Wet Dress Rehearsal scheduled. Upgrades and changes have been made to the Orbital Tank Farm and launch site, aimed at improving efficiency and reinforcing infrastructure. Progress is also being made on the construction of the second tower at Sanchez and the New High Bay. As SpaceX continues its steady preparations, the space industry eagerly awaits future groundbreaking missions.