Narrator: SHE'S UNLIKE ANY OTHER 747 ON EARTH...
A FLYING TELESCOPE AND SPACE OBSERVATORY NAMED SOFIA.
Man: EVERYBODY KIND OF CALLS US THE VAMPIRE CREW.
WE ONLY COME OUT AT NIGHT.
Narrator: HER JOB--TO PEER INTO CORNERS OF THE UNIVERSE
NEVER BEFORE SEEN BY MAN.
Man: WE CAN GO PLACES AND SEE THINGS
THAT OTHER TELESCOPES CAN'T DO.
Narrator: BUT SOFIA IS GROUNDED,
AND THE PRESSURE'S ON TO GET HER BACK TO WORK FAST.
Man: YOU COULD ACTUALLY CRASH THE AIRPLANE.
MISTAKES CAN BE DEADLY.
IT MIGHT BE SOME SMALL LITTLE THING THAT KILLS YOU.
Narrator: ON A MISSION THIS PRECISE,
THERE IS NO MARGIN FOR ERROR.
THIS IS PLANT 42 IN THE MOJAVE DESERT.
IT'S A TOP-SECRET MILITARY AIRFIELD
ON THE OUTSKIRTS OF PALMDALE, CALIFORNIA.
HIGHLY CLASSIFIED AIRCRAFT
LIKE THE U-2 SPY PLANE AND THE SR-71 BLACKBIRD
WERE ALL TESTED HERE IN THE SIXTIES AND SEVENTIES.
IN 2002, ANOTHER UNIQUE PROJECT WAS IN THE WORKS.
BEHIND CLOSED HANGAR DOORS
AN INFRARED TELESCOPE WAS CAREFULLY UNVEILED.
IN AN AMAZING FEAT OF ENGINEERING,
THE TELESCOPE WAS INSTALLED INTO A 747--
CREATING WHAT IS CURRENTLY THE WORLD'S ONLY FLYING OBSERVATORY,
ALSO RUN OUT OF PLANT 42.
Steve Robinson: IT'S A ONE-OF-A-KIND ASSET FOR NASA.
THERE'S NOT ANOTHER ONE LIKE IT IN THE WORLD.
Narrator: IT'S CALLED
THE STRATOSPHERIC OBSERVATORY FOR INFRARED ASTRONOMY--
SOFIA FOR SHORT.
WHILE ON THE OUTSIDE SHE LOOKS LIKE A NORMAL 747,
ON THE INSIDE, SOFIA IS ONE OF A KIND.
SHE IS OPERATED JOINTLY
BY THE AMERICAN AND GERMAN SPACE AGENCIES.
Ken Bower: WE CHANGED EVERYTHING.
IT'S NOT YOUR FATHER'S AND GRANDFATHER'S 747 ANYMORE.
Narrator: HER JOB IS TO FERRY SCIENTISTS INTO THE NIGHT SKY
AND LOOK INTO SPACE LIKE NO OTHER TELESCOPE CAN.
FLYING AS HIGH AS 45,000 FEET,
SHE OFFERS ASTRONOMERS A CLEAN LINE OF SIGHT,
WELL ABOVE CLOUDS AND WEATHER, WHICH BLOCK INFRARED LIGHT.
IN 2011, PLUTO ECLIPSED A DISTANT STAR
AND FOR A FEW MINUTES CAST A SHADOW OVER THE PACIFIC OCEAN.
SOFIA WAS THE ONLY OBSERVATORY IN THE WORLD
ABLE TO REACH THE REMOTE LOCATION
AND STUDY THE EVENT.
Ted Dunham: WE ENDED UP HITTING THE CENTER
OF THE SHADOW OF PLUTO WITHIN 100 KILOMETERS,
WHICH IS NOT TOO SHABBY FOR SOMETHING THAT FAR AWAY.
Narrator: THE MISSION ALLOWED ASTRONOMERS A CHANCE
TO STUDY PLUTO'S ATMOSPHERE WITHOUT HAVING TO LEAVE EARTH.
THE PLUTO PROJECT PROVED SOFIA TO BE A VITAL TOOL
IN HELPING TO UNLOCK THE SECRETS
OF HOW OUR SOLAR SYSTEM AND COSMOS WERE FORMED.
BUT SHORTLY AFTER THIS TRIUMPH,
SOFIA WAS GROUNDED FOR A MAJOR UPGRADE
OF HER AVIONICS AND TELESCOPE CONTROL SYSTEMS.
IT'S A COMPLICATED JOB NOW FOUR MONTHS BEHIND SCHEDULE.
HER SCIENTISTS ARE FRUSTRATED.
Ted: THE DELAYS THAT WE'VE BEEN EXPERIENCING
ARE REALLY VERY BAD FOR THE PROJECT.
THERE ARE SCIENCE MISSIONS THAT ARE PROBABLY NOT GOING TO OCCUR.
Narrator: CREW CHIEF STEVE ROBINSON
WILL BE GIVING THE GO-AHEAD FOR SOFIA TO FLY AGAIN,
BUT ONLY AFTER HER DATED 35-YEAR-OLD ANALOG INSTRUMENTS
ARE REPLACED WITH NEW DIGITAL ONES.
Steve: TAKE ALL THE GAUGES OUT,
ALL OF THE WIRING OUT OF THE COCKPIT,
REWIRE IT, PUT ALL NEW INSTRUMENTS IN.
IT'S BEEN QUITE THE UNDERTAKING.
Narrator: ALL THIS ADVANCED TECHNOLOGY CAN BE QUITE HEAVY.
Steve: THE TELESCOPE ITSELF
WEIGHS IN THE NEIGHBORHOOD OF 20 METRIC TONS.
WE HAVE MILES AND MILES OF WIRING.
THE DOOR THAT OPENS FOR THE TELESCOPE TO SEE OUT,
THAT WEIGHS 2,500 POUNDS BY ITSELF.
Narrator: THE TIME HAS COME TO SEE IF SOFIA
IS NOW TOO HEAVY TO FLY SAFELY.
AIRCRAFT SCALES ARE MOVED INTO POSITION.
GETTING SOFIA'S EXACT WEIGHT AND BALANCE IS VITAL.
Steve: IF WE DON'T HAVE THE CENTER OF GRAVITY JUST RIGHT,
IT WILL NOT FLY RIGHT IN THE AIR.
Narrator: IT'S THE MOMENT OF TRUTH.
Steve: THIS ONE RIGHT NOW IS READING 11,920-SOME ODD POUNDS.
Narrator: SOFIA'S WEIGHT AND BALANCE
IS WITHIN THE LIMITS FOR SAFE FLIGHT.
THE PRESSURE IS ON TO FINISH THE UPGRADE
AND GET SOFIA AIRBORNE.
BUT CUTTING CORNERS ISN'T AN OPTION.
Steve: FROM THE SCIENTIFIC COMMUNITY
ALL THE WAY DOWN THROUGH THE PROGRAM OFFICE
THROUGH MY IMMEDIATE BOSSES,
THEY'RE ALL PUSHING TO GET IT DONE, GET IT DONE.
BUT WE WILL NOT DO ANYTHING
THAT WILL COMPROMISE THE SAFETY OF THE AIRPLANE.
Narrator: THE NEXT STEP IS A FULL TEST FLIGHT
TO SEE IF SOFIA'S NEW SYSTEMS ARE WORKING PROPERLY.
CHIEF PILOT TROY ASHER GETS A LOOK AT HIS NEW COCKPIT
FOR THE FIRST TIME.
Troy Asher: STEERING BAR IS FOLLOWING REAL NICE.
Man: RIGHT. Troy: YEAH, OK.
Narrator: TROY'S MAIN CONCERN IS GETTING THE AUTOPILOT
TO MAKE VERY SMALL TURNS IN FLIGHT
TO KEEP THE TELESCOPE STABLE.
Troy: IF I WANT TO JUST DO VERY, VERY SMALL HEADINGS,
LIKE ONE OR TWO DEGREES,
WE JUST WANT IT TO JUST REALLY NOT, NOT TURN.
Man: THAT WE CAN PROBABLY FIX.
Troy: OK.
BECAUSE WE HAVE THAT BIG TELESCOPE IN THE BACK,
IT NEEDS TO BE AS STABLE AS POSSIBLE.
MOST AIRPLANES DON'T REALLY CARE ABOUT HOW MUCH THEY ROLL
WHEN YOU MAKE A HEADING CHANGE.
BUT WE DO BECAUSE WHEN THE AIRPLANE ROLLS,
IT MOVES THE WHOLE TELESCOPE IN SPACE.
SO THEY WANT TO KEEP THAT ROLLING MOTION
DOWN TO AS SMALL AS POSSIBLE.
Man: WHAT, ARE YOU GETTING ROLL THERE?
Troy: ARE YOU SHOWING ZERO ON YOUR SIDE EXACTLY?
ARE THEY CLOSE?
I GET ABOUT A HALF A DEGREE OF YOKE DISPLACEMENT.
Man: OK, I THINK WE CAN CUT THAT IN HALF.
Troy: MY IMPRESSION OF THE NEW AVIONICS SUITE RIGHT NOW,
I'M LIKING IT MORE AND MORE ALL THE TIME.
Man: WE'RE OUT OF HERE..
Troy: ALRIGHT, GUYS, WE'LL SEE YOU GUYS SOON.
Narrator: THE BOEING 747
WAS THE WORLD'S FIRST JUMBO JET AIRLINER.
WITH AN UPPER AND LOWER DECK,
IT WAS DESIGNED TO CARRY OVER 400 PASSENGERS.
SOFIA IS A 747SP, OR SPECIAL PERFORMANCE VERSION,
WITH GREATER RANGE AND ENDURANCE.
Troy: IT WAS BUILT TO, SAY, FLY FROM LOS ANGELES
TO SYDNEY, AUSTRALIA,
OR LOS ANGELES TO TOKYO, BACK IN THE SEVENTIES
WHEN NOT A LOT OF AIRPLANES COULD DO THAT VERY WELL.
Narrator: DESIGNED FOR LONG-DISTANCE FLYING,
SOFIA'S SP MODEL IS SHORTER AND LIGHTER THAN AN ORDINARY 747.
IT MEASURES 177 FEET IN LENGTH
AND STANDS MORE THAN 65 FEET HIGH,
WITH AN IMPRESSIVE WINGSPAN OF 196 FEET.
OUT ON THE RAMP, THE GROUND CREW PUTS SOFIA
THROUGH A SERIES OF ENGINE TESTS.
IT HAS BEEN A YEAR
SINCE HER FOUR PRATT & WHITNEY TURBOFAN ENGINES
HAVE BEEN FIRED UP.
Man: THE AUXILIARY POWER SWITCH IS 4.
Steve: UH, 4 ARE ON.
Narrator: CREW CHIEF STEVE ROBINSON
DIRECTS THE OPERATION FROM THE FLIGHT ENGINEER'S SEAT.
Steve: UH, YES, WE'RE GOING TO DO SOME MAINTENANCE ENGINE RUNS
OVER ON THE NASA RAMP.
WE'LL ADVISE WHEN COMPLETE.
Narrator: AVIATION MECHANIC PAT BANTILAN
IS THE EYES ON THE GROUND FOR THE CREW IN THE COCKPIT.
THEY CAN'T SEE DANGEROUS FUEL LEAKS
THAT COULD CAUSE ENGINE FIRES.
Pat Bantilan: WE'RE GOING TO DO LEAK CHECKS ON ALL OF THE ENGINES.
WE BRING FIRE EXTINGUISHERS OUT HERE,
AND WE DO HAVE THOSE ON STANDBY AS WE'RE STARTING THE ENGINES.
Narrator: STEVE RUNS THROUGH THE ENGINE START CHECKLIST.
Pat: WE'VE GOT GOOD ROTATION.
Steve: START VALVE OPEN.
I HAVE N-2.
I HAVE OIL PRESSURE.
OK, WE'RE AT MAX MOTOR. GIVE ME FUEL.
Man: FUEL FLOW, EGT RISING.
Narrator: A RISING EGT, OR EXHAUST GAS TEMPERATURE,
SHOWS THE ENGINE HAS STARTED AND IS FUNCTIONING PROPERLY.
Pat: OK, YOU'RE CLEAR ON FOUR.
Steve: CLEAR ON FOUR.
Man: I'VE GOT FUEL FLOW.
Steve: I HAVE CST PRESSURE.
Man: I'VE GOT EGT.
Pat: NO LEAKS, EVERYTHING IS WORKING AS ADVERTISED.
Narrator: DESPITE A YEAR OF SITTING INACTIVE,
SOFIA'S ENGINES PERFORM PERFECTLY.
Steve: YES, NASA 747 HEAVY
IS ADVISING TERMINATION OF ENGINE RUNS.
Pat: I'M GOING TO BE OFF HEADSET TO YOU.
Steve: BYE. Pat: BYE.
Steve: TO GET THROUGH THIS FIRST STEP OF ENGINE RUNS
IS JUST SUCH A RELIEF.
IT IS SO IMPORTANT,
IT'S ONE OF THE HUGE MAJOR MILESTONES
TO GET READY TO GO FLY.
Narrator: WITH THE ENGINE TESTS OVER,
SOFIA IS NOW READY FOR HER AVIONICS TEST FLIGHT...
WHEN ANYTHING AND EVERYTHING COULD GO WRONG.
Troy: YOU NEVER REALLY KNOW WHAT'S GOING TO HAPPEN.
YOU COULD ACTUALLY CRASH THE AIRPLANE,
YOU COULD PUT THE AIRPLANE
INTO A SITUATION THAT YOU DIDN'T EXPECT.
IT COULD FLIP UPSIDE DOWN, FOR INSTANCE,
OR YOU COULD GET A LARGE BANK ANGLE
OR A LARGE G FORCE OR SOMETHING LIKE THAT.
AND YOU WANT TO MINIMIZE THE RISK TO HUMANS ON THERE.
Narrator: TROY BRIEFS THE FLIGHT AND GROUND CREW.
NOTHING IS LEFT TO CHANCE.
Troy: ON SCHEDULE, WE TAKE OFF ON TIME.
WE GOT ABOUT AN HOUR LATE TAKEOFF CAPABILITY.
Narrator: STEVE ROBINSON HAS THE FINAL WORD
ON WHETHER SOFIA IS READY TO FLY.
Troy: SO NOTHING IS STOPPING US AS FAR AS YOU KNOW.
Steve: AS FAR AS I KNOW NOTHING IS STOPPING...
WE SHOULD BE GOOD TO GO TODAY.
Troy: OK.
Narrator: FLIGHT ENGINEER TIM SANDON
CONDUCTS A PRE-FLIGHT INSPECTION
TO SPOT ANY FINAL POTENTIAL PROBLEMS.
Tim Sandon: PLANES DO VERY WELL WHEN THEY FLY EVERY DAY.
THEY DON'T DO VERY WELL WHEN THEY SIT.
WE CHECK THE GENERAL CONDITION OF THE TIRES.
MAKE SURE THAT THERE ARE NO CUTS OR ABRASIONS,
NOTHING IN THE TIRE.
CHECK THE STRUTS FOR PROPER EXTENSION.
AND CHECK AND MAKE SURE THAT ALL HARDWARE IS SECURE
ANYWHERE THAT WE CAN SEE IT IN THE WHEEL WELL.
ALL RIGHT, THE WALK-AROUND IS COMPLETE, NO DISCREPANCIES.
I'M HAPPY WITH THE CONDITION OF THE AIRPLANE
AFTER A YEAR OF MAINTENANCE,
LOOKING FORWARD TO TODAY'S FIRST FLIGHT.
Narrator: AT THE LAST MOMENT, CHIEF PILOT TROY ASHER
IS CONCERNED THAT HIS LONG-AWAITED TEST FLIGHT
IS IN TROUBLE.
Troy: THE WEATHER'S NOT LOOKING SO GOOD.
I WAS JUST LOOKING AT THE...
THE COMPUTER SYSTEMS ALL SAY THE WEATHER IS OK,
BUT WHEN YOU COME OUTSIDE IT DOESN'T NECESSARILY AGREE.
AND I'M NOT REALLY LIKING WHAT I SEE RIGHT NOW,
SO I DON'T KNOW.
EARLIER WE AGREED
THAT WE WERE GOING TO HAVE A CERTAIN WEATHER CONDITION,
AND WE DON'T HAVE IT.
SO, WE'LL SEE.
WE MIGHT HAVE TO DELAY A LITTLE BIT.
Narrator: SOFIA, THE WORLD'S ONLY FLYING OBSERVATORY
IS READY FOR TAKEOFF ON A LONG-DELAYED TEST FLIGHT.
NASA IS DESPERATE TO GET THEIR FLYING TELESCOPE
BACK IN OPERATION AFTER A YEARLONG UPGRADE.
CREW CHIEF STEVE ROBINSON
OFFICIALLY TURNS SOFIA OVER TO CHIEF PILOT TROY ASHER.
Steve: I'M RELEASING THE AIRPLANE FOR FLIGHT.
IT'S READY TO GO FLY.
AND I'M CERTIFYING THAT ALL OUR MAINTENANCE IS GOOD
AND THE AIRPLANE IS IN GOOD CONDITION
FOR THE PILOTS TO TAKE IT FOR THIS FLIGHT.
Troy: THERE'S A LOT OF PAPERWORK THAT GOES ALONG WITH THESE,
ESPECIALLY AFTER AN AIRPLANE HAS BEEN MODIFIED.
IT'S BEEN SITTING ON THE GROUND FOR ABOUT A YEAR.
AND THESE BIG MACHINES LIKE THIS,
THE MORE YOU FLY THEM, THE BETTER THEY FLY.
AND IF YOU DON'T FLY THEM AT ALL,
THEY DON'T FLY VERY WELL.
Steve: ALRIGHT, GUYS.
Troy: LOOKS REAL GOOD, ALL THE PAPERWORK'S SIGNED OFF,
SO WE'RE JUST WAITING FOR THE CLOUDS.
Narrator: AFTER MONTHS OF TECHNICAL DELAYS,
THE LATEST COMES FROM MOTHER NATURE.
Troy: THIS WEATHER IS NOT GOING TO GET ANY BETTER TODAY,
PROBABLY NOT UNTIL NEXT WEEK, MAYBE.
Narrator: SAFETY IS PARAMOUNT,
AND THE WEATHER FOR THE TEST FLIGHT
NEEDS TO BE PERFECT.
THE OPERATION IS CANCELLED.
Troy: THE PROBLEM WITH THIS FLIGHT
IS WE JUST RIPPED OUT ALL OF THE INSTRUMENTS
OUT OF THE FRONT OF THE COCKPIT.
THE PILOTS USE THOSE FLIGHT INSTRUMENTS
AND NAVIGATION INSTRUMENTS
TO GET THROUGH THE CLOUDS TO FIND THE AIRPORT TO LAND.
WE DON'T EVEN KNOW IF THEY'RE GOING TO WORK.
BUT IF ALL THOSE NEW INSTRUMENTS COMPLETELY FAIL
AND WE'RE IN THE WEATHER,
WE COULD LOSE THE AIRPLANE.
Troy: WE'RE JUST GOING TO BE A WEATHER CANCEL FOR TODAY.
Woman: OK.
Steve: WE'LL TOW THE PLANE BACK IN AND GET READY FOR MONDAY.
Troy: HOPEFULLY MONDAY.
Narrator: IT'S GOING TO BE AT LEAST THREE OR FOUR DAYS
BEFORE THE WEATHER CLEARS.
THE DELAY ALLOWS THE CREW TO DO SOME FINISHING TOUCHES.
ONE TASK IS TO RECONDITION THE LATCHES ON HER NOSE CONE.
Steve: THERE WAS A LITTLE BIT TOO MUCH FORCE REQUIRED
TO CLOSE THESE WHEN WE PUT THE RADOME ON THE AIRPLANE.
Man: YOU JUST NEED A LOT OF PEOPLE TO HOLD IT UP THERE
AND GET IT INTO POSITION.
THAT'S PROBABLY THE HARDEST PART.
Narrator: IT'S A DELICATE JOB THAT REQUIRES FINESSE, PATIENCE,
AND IN THE END, A LITTLE BIT OF MUSCLE.
Man: ONCE WE'RE LATCHED,
WE'RE ALL DONE, WE'RE GOOD TO GO.
SHE'S ON THERE GOOD.
Narrator: ON THE 747'S MAIN DECK,
THE PANELS ARE OFF,
AND THE MAINTENANCE TEAM WIRES
THE NEW TELESCOPE CONTROL SYSTEM.
Ted Brooks: WE'RE TRYING TO GET READY FOR FLIGHT,
WE'RE REALLY, REALLY TRYING TO PREPARE FOR FLIGHT,
WE'RE A LITTLE BEHIND SCHEDULE AS FAR AS THAT'S CONCERNED,
BUT WE'RE, YOU KNOW, WE'RE MAKING,
WE'RE DOING THE BEST WE CAN.
Narrator: TED NEEDS TO USE HIS OWN JUDGMENT.
THE DRAWINGS AREN'T ALWAYS RIGHT.
Ted: THIS WIRE RIGHT HERE WAS ORIGINALLY SUPPOSED TO COME
UP HERE FROM THE TOP DOWN TO HERE,
BUT IT SOMEHOW GOT OVERLOOKED,
SO WE HAD TO RED LINE THE DRAWINGS
AND BRING THIS WIRE FROM UP HERE,
DOWN THROUGH HERE AND RED LINE IT
TO GO THROUGH THIS CONNECTOR
SO THAT IT COULD COME TO HERE AND STILL FUNCTION PROPERLY.
JUST ONE MISPINNED OR MISPLACED WIRE
OR EVEN AN OVERLOOKED WIRE
CAN CAUSE THINGS NOT TO FUNCTION PROPERLY.
Man: GONNA OPEN THE DOOR? Troy: OPEN THE DOOR.
Narrator: PUTTING A 34,000-POUND TELESCOPE
INTO THE 747 MEANT CUTTING A LARGE HOLE IN THE FUSELAGE.
IN FLIGHT, A PURPOSE-BUILT OBSERVATORY DOOR
OPENS UP TO EXPOSE THE TELESCOPE.
Man: DOOR'S COMING OPEN TO 100%.
THREE, TWO, OPEN.
Narrator: BEHIND THE SCIENCE CABIN,
A BULKHEAD MAINTAINS AIR PRESSURE
AND PROTECTS THE SCIENTISTS FROM THE OPEN TELESCOPE CAVITY.
FOUR DAYS HAVE PASSED.
SKIES ARE CLEAR OVER CENTRAL CALIFORNIA.
[HORN HONKS]
IT'S "GAME ON" FOR SOFIA'S FIVE-HOUR AVIONICS TEST FLIGHT.
PLAGUED BY DELAYS,
THIS FLIGHT HAS BEEN 12 MONTHS IN THE MAKING.
Troy: I GOT UP THIS MORNING WITH RAIN ALL OVER MY HOUSE
AND MY CAR AND MY HEAD,
BUT BY THE TIME WE GOT IN, IT CLEARED OUT,
AND WE'VE GOT NICE, BEAUTIFUL BLUE SKIES.
SO IT LOOKS LIKE WE'RE A GO.
Narrator: THE CREW STARTS THEIR PRE-FLIGHT CHECKS.
Man: FLIGHT RECORDER? Troy: ON.
Man: VOICE RECORDER?
AT NEARBY EDWARDS AIR FORCE BASE,
PILOT NILS LARSON GETS READY TO FLY AN F-18 CHASE PLANE
RIGHT BESIDE THE 747.
WITH ALL THE NEW INSTRUMENTATION IN SOFIA'S COCKPIT,
HE'LL BE CHECKING THE ACCURACY OF HER READOUTS
BY COMPARING THEM TO HIS OWN.
Nils Larson: I'M GOING TO MAKE SURE THAT ALL MY READINGS
ARE THE SAME AS THEIR READINGS IN THE COCKPIT.
SO WHEN THEY CALL FOR A CALL-OUT,
I'LL GIVE THEM MY AIRSPEED, MY ALTITUDE,
MY MACH AND HEADING,
SO THAT THEY CAN COMPARE IT WITH THEIR COCKPIT
TO MAKE SURE THAT THEIR INSTRUMENTS,
SINCE THEY'RE BRAND NEW AND BRAND NEW INSTALLED,
ARE READING THE SAME AS MINE.
Narrator: NILS TAXIS INTO POSITION FOR TAKEOFF
AND IN MINUTES WILL MEET UP WITH SOFIA AT PALMDALE.
Controller: NASA 747 HEAVY, ADVISE WHEN READY.
RUNWAY 2-5 CLEARED FOR TAKEOFF, YOUR DISCRETION.
Troy: 30 SECONDS.
Narrator: CHASE PILOT NILS LARSON
APPROACHES THE RUNWAY TO LINE UP WITH SOFIA
AS SHE READIES FOR TAKEOFF.
Man: BRAKES NOW.
OK, THRUST CHECK, 90 KNOTS.
Narrator: WITH EACH ENGINE PUSHING OUT 50,000 POUNDS OF THRUST,
SOFIA ROLLS DOWN RUNWAY 2-5.
THE F-18 PAIRS UP WITH THE HUGE 747.
Man: V1.
ROTATE.
Narrator: SHE HAS 12,000 FEET OF RUNWAY
BUT NEEDS ONLY 5,000 TO GET AIRBORNE.
[RADIO CHATTER]
Narrator: HER 18 WHEELS ARE SUCCESSFULLY RETRACTED.
Nils: YEAH, I'M PRETTY MUCH IN OBSERVATION POSITION NOW.
Narrator: SLOWING DOWN THE FAST F-18
TO KEEP PACE WITH SOFIA'S ASCENT
IS A CHALLENGE FOR PILOT NILS LARSON.
Nils: THE AIRBORNE PICK-UP IS A LITTLE BIT DIFFERENT.
IT'S A LITTLE BIT MORE CHALLENGING
BETWEEN ME TRYING TO STAY AIRBORNE
AND NOT FALL OUT OF THE SKY
AND, YOU KNOW, BIG AIRPLANE, BIG WING--
THEY CAN GET AIRBORNE AT A SLOWER SPEED.
Narrator: WITH SOFIA'S FOUR ENGINES
PUTTING OUT A COMBINED THRUST OF 200,000 POUNDS,
SHE'S CLIMBING AT 2,300 FEET PER MINUTE.
ONCE THEY'RE IN CLEAR AIRSPACE,
THE CREW DISCOVERS A BIG PROBLEM.
THE AUTOPILOT IS ACTING UP.
[RADIO CHATTER]
Narrator: THEY ASK NILS LARSON
TO VISUALLY CHECK SOFIA'S FLIGHT CONTROLS,
ESPECIALLY THE ELEVATORS AT THE BACK OF THE TAIL,
WHICH CONTROL THE PLANE'S UP AND DOWN MOVEMENT.
Nils: GO AHEAD.
Troy: WE'RE SEEING A LOT OF TWITCHING IN OUR AUTOPILOT.
DO YOU SEE ANYTHING ON OUR FLIGHT CONTROLS?
JUST ITTY BITTY, LITTLE SMALL MOVEMENTS?
Nils: YEAH, THE INTERESTING THING
IS IT LOOKS LIKE THE OUTBOARD SECTION
IS A COUPLE OF DEGREES DOWN,
BUT THE INBOARD SECTION IS UP.
Troy: THAT'S NOT GOING TO BE GOOD FOR THE TELESCOPE.
Narrator: THE AUTOPILOT ISN'T HOLDING ALTITUDE,
AND IT MUST PERFORM PERFECTLY
FOR THE TELESCOPE TO KEEP AN ACCURATE FIX ON THE SKY.
THE TEST FLIGHT CONTINUES WITH THE F-18 IN CLOSE PROXIMITY,
OBSERVING SOFIA'S EVERY MOVE.
Nils: THE CHALLENGING PART IS IF SOMETHING GOES WRONG, THAT'S,
YOU KNOW, TRYING TO CONVEY TO THEM WHAT YOU SEE
AND THAT KIND OF THING.
THAT'S USUALLY THE MOST CHALLENGING.
Narrator: NILS' OTHER BIG PROBLEM
IS THE TURBULENT JET WASH
THAT COMES OFF SOFIA'S FOUR POWERFUL JET ENGINES.
Nils: YOU HAVE TO WATCH GETTING TOO CLOSE WHEN IT COMES TO...
PRIMARILY WHEN YOU'RE TRANSITING BACK AND FORTH
TO LOOK AT ONE SIDE VERSUS THE OTHER.
THOSE ENGINES ARE BIG, THEY PUT OUT A LOT OF THRUST,
SO WATCHING OUT FOR THAT.
Man: NOW WE'RE STARTING OUR LEFT TURN FOR THE 1.2 Gs.
Narrator: WITH THE CHASE PLANE HOLDING POSITION
OFF SOFIA'S WING,
THEY COMPARE AIRSPEEDS.
Troy: OK, NILS, I'M SHOWING .700 MACH NOW.
Nils: SAME.
Troy: AND I DON'T KNOW IF YOU HEARD,
CHASE SAID EVERYTHING WE HAD WAS IDENTICAL TO WHAT THE PILOT HAD.
WE'RE PUSHING UP TO 25.
Narrator: SOFIA'S AIRSPEED INDICATOR MATCHES THAT OF THE F-18.
EXCEPT FOR THE FAULTY AUTOPILOT, THINGS ARE LOOKING GOOD.
BACK IN THE NASA HANGAR...
[AIR HISSING]
LIFE SUPPORT TECHNICIAN ROBERT PETERSON
INSPECTS A SPARE EMERGENCY EVACUATION SLIDE
THAT'S BEEN SALVAGED FROM ANOTHER 747.
Robert Peterson: WE SEE A LITTLE BIT OF DISCOLORATION
ON THE SLIDE AREA DUE TO MILDEW,
AND THAT WILL BE SOMETHING THAT WILL HAVE TO BE ADDRESSED
AT THE RECERTIFICATION PROCESS.
THIS IS AN EASILY REPLACED SURFACE.
NOT INEXPENSIVE, BUT IT'S CERTAINLY
WELL WITHIN RECERTIFICATION AND REPACKING CRITERIA.
AT A GLANCE, WE'RE VERY PLEASED
WITH THE CONDITION OF THIS SLIDE,
ALBEIT A 35-YEAR-OLD SLIDE.
Narrator: HARD-TO-FIND SPARE PARTS LIKE THIS ONE
ARE THE BEST HOPE TO KEEP THE VINTAGE 747 FLYING
FOR MANY YEARS TO COME.
IN THE AIR OVER CENTRAL CALIFORNIA,
SOFIA'S FLIGHT CREW IS STILL WORKING OUT THE BUGS
WITH HER NEW AVIONICS.
SHE'S TAKING A STEEP TURN TO THE LEFT.
Troy: WE'RE ROLLING INTO THE TURN NOW.
Nils: OOH WEE.
THAT'S BIG FOR A BIG AIRPLANE DOING 45 DEGREES BANK.
Troy: DROP OFF OUR CHASE,
AND THEN WE'LL TURN BACK AROUND AND COME BACK TO YOU.
Narrator: WITH HER NEW AVIONICS NOW THOROUGHLY TESTED,
THE F-18 HEADS BACK TO EDWARDS AIR FORCE BASE
AND SOFIA TURNS BACK TO PALMDALE.
Troy: APPROACH INTO RUNWAY 2-5 AT PALMDALE.
Controller: NASA 747 HEAVY, ROGER.
Narrator: HER LANDING GEAR IS DOWN AND FLAPS ARE SET.
SOFIA APPROACHES AT 140 MILES PER HOUR.
Man: 50, 40, 30, 20, 15, 10, 5.
Narrator: SOFIA IS HOME AFTER HER SHAKEDOWN FLIGHT.
Troy: NICELY DONE.
Man: TOWER, NASA 747 HEAVY,
WOULD LIKE TO TURN OFF ON JULIET.
Controller: NASA 747 HEAVY, HAVE A GOOD DAY, SIR.
Narrator: CREW CHIEF STEVE ROBINSON
HAS SPENT THE PAST YEAR WAITING FOR THIS MOMENT.
Steve: TROY, HOW'S MY JET?
Troy: WELL, IT'S IN PRETTY GOOD SHAPE,
IT WAS GREAT TO BE FLYING AGAIN.
Steve: AWESOME.
Troy: ENGINE-WISE AND AIRFRAME-WISE
AND EVERYTHING ELSE, IT'S GOOD TO GO.
Steve: GREAT.
Troy: AND WE'LL HAVE A FEW WRITE-UPS
AND WE'RE GOING TO HAVE TO TALK
ABOUT SOME OF THE AVIONICS STUFF IN THE DEBRIEF.
Narrator: BUT IT'S NOT ALL GOOD NEWS.
Troy: THE BAD PART UNFORTUNATELY
IS THAT THE SYSTEM INTERFACE WITH THE AIRPLANE
ISN'T UP TO WHAT WE HAD EXPECTED.
THERE'S SOME FAIRLY SERIOUS PROBLEMS
THAT WE'RE GOING TO HAVE TO GO FIX
BEFORE WE CAN GO DO SCIENCE WITH THE AIRPLANE.
Narrator: THE BIG PROBLEM IS MAKING THE NEW AVIONICS SYSTEM
COMMUNICATE PROPERLY WITH THE OLD AUTOPILOT.
Steve: SOMETIMES WHEN YOU'RE LOOKING AT TRYING TO FIX
SOME OF THESE ELECTRICAL PROBLEMS,
IT CAN TAKE YOU TEN MINUTES OR IT CAN TAKE YOU TEN WEEKS.
YOU JUST DON'T KNOW TILL YOU GET IN IT
AND START LOOKING AND TRYING FIND OUT WHAT'S WRONG.
AND YOU CAN LOOK AND LOOK AND LOOK,
AND THEN ALL OF A SUDDEN BAM,
YOU FIGURE OUT WHAT IT'S BEEN DOING.
IT JUST CAN BE REALLY EASY OR REALLY DIFFICULT
TO TRACE IT DOWN.
Narrator: THE WORLD'S ONLY FLYING TELESCOPE, CALLED SOFIA,
HAS FAILED HER FLIGHT TEST
AND ISN'T READY FOR SPACE OBSERVATION MISSIONS.
IT'S A FRUSTRATING SETBACK
FOR THE TEAM OF ASTRONOMERS AND SCIENTISTS
WHO HAVE BEEN WAITING A YEAR TO SEE THE 747 BACK IN THE SKIES.
Ted: WORKING ON A BIG PROJECT
IS ALWAYS A HIGH-PRESSURE OPERATION,
EVEN ON A GOOD DAY.
BUT WHEN YOU HAVE A PROBLEM
LIKE THE AVIONICS UPGRADE THAT GOES ON AND ON,
IT'S, UH, THE PRESSURE ONLY MOUNTS.
IT CAN BE PRETTY HARD TO WORK UNDER THOSE CONDITIONS.
Troy: STRESS, PRESSURE, ABSOLUTELY.
TO DISAPPOINT YOUR INTERNATIONAL CUSTOMERS
IS OBVIOUSLY A PRESSURE THAT WE JUST HAVE TO FORCE OURSELVES
TO NOT SUCCUMB TO THAT, I GUESS.
Man: THAT'S WHERE WE'RE AT.
Troy: OK, GOOD. GOOD, GOOD.
Narrator: SOFIA MUST UNDERGO MORE TESTING
TO SOLVE THE BIG PROBLEM--
TO MAKE HER NEW INSTRUMENTS CONNECT WITH THE AUTOPILOT.
HER EXTERNAL AIRSPEED PROBES ARE HOOKED UP
TO A MACHINE THAT SIMULATES FLIGHT.
IT BLOWS AIR INTO THE VARIOUS PROBES
WHICH THE AIRCRAFT'S SYSTEMS CONVERT
INTO AIRSPEED, ALTITUDE, AND VERTICAL SPEED.
Steve: THEY'RE FOOLING THE AIRPLANE
TO THINK IT'S FLYING RIGHT NOW.
THESE TUBES ON THE SIDE OF THE AIRPLANE HERE,
THEY'RE HOOKED UP TO AN AIR DATA TEST SET
THAT WE USE TO SIMULATE THE AIRPLANE FLYING
WHILE WE'RE ON THE GROUND.
AND IT TELLS DIFFERENT INFORMATION
LIKE AIRSPEED AND ALTITUDE.
IF WE DON'T GET IT RIGHT,
WHEN THE PILOT GOES TO PULL BACK ON THE STICK,
EITHER HE'LL HAVE NO CONTROL OR HE'LL HAVE TOO MUCH CONTROL,
AND IT WILL CAUSE HIM TO CRASH.
Narrator: IN THE COCKPIT, THE TEST ISN'T GOING WELL.
STRONG DESERT WINDS SWIRL BETWEEN THE TWO HANGARS
AND MOVE SOFIA'S FLIGHT CONTROLS.
Tom McGregor: WE'RE GOING TO MOVE IT OUT INTO THE RAMP
AND WE'RE GOING TO PUT THE NOSE OF THE AIRCRAFT INTO THE WIND
SO THEN THE WIND WILL COME UP UNDERNEATH THE FLIGHT SURFACES,
AND HOPEFULLY IT WON'T FLUTTER AS MUCH
AND WE CAN GET SOME OF OUR TUNING DONE.
Narrator: SOFIA IS TOWED AND POSITIONED
DIRECTLY INTO THE WIND.
THE SIMPLE PLAN WORKS.
THE FLIGHT CONTROLS ARE NO LONGER POUNDED BY WIND GUSTS.
Tom: BY POINTING THIS INTO THE WIND,
WE WERE ABLE TO PUT SOME PRESSURE
ON THE BOTTOM OF THE AILERONS IN A MANNER THAT IT WAS EVEN.
SO WE DIDN'T HAVE THE FLUTTER ON ONE SIDE VERSUS THE OTHER,
SO THEREFORE WE WERE ABLE TO FINE-TUNE THIS AIRCRAFT.
TESTING IT ON THE GROUND
IS ACTUALLY WAY HARDER THAN IN THE AIR.
Narrator: THE AVIONICS TECHNICIANS NOW GET BACK TO WORK
AND TROUBLESHOOT THE PROBLEMS WITH THE AUTOPILOT.
Tom: I WOULD SAY WE'RE ABOUT 80% DONE WITH THE WHOLE THING.
Steve: FANTASTIC.
SO ANOTHER COUPLE OF DAYS, AND WE'LL BE ALL DONE.
Tom: I'D SAY ANOTHER COUPLE OF DAYS,
AND WE'LL BE READY TO SAY
THEY CAN PUT THE COCKPIT BACK TOGETHER
AND CLEAN IT ALL UP AND GET READY FOR TEST FLIGHT.
Steve: SOUNDS GOOD TO ME. WE'VE BEEN WAITING FOR THAT.
Tom: I KNOW.
Narrator: ADDITIONAL TEST FLIGHTS CONTINUE,
WITH A FRUSTRATED TEAM OF SCIENTISTS ON HOLD.
Ted: I CAN HARDLY WAIT TO GET THE TEST FLIGHTS OUT OF THE WAY
SO WE CAN GET BACK TO THE BUSINESS OF DOING ASTRONOMY.
Narrator: FOUR MORE STRESSFUL WEEKS PASS,
AND FINALLY IT BEGINS TO LOOK LIKE THE PROBLEM IS SOLVED.
THE AUTOPILOT AND THE NEW AVIONICS ARE NOW TALKING.
SOMETIMES THE MOST COMPLEX PROBLEMS
HAVE THE SIMPLEST ANSWER.
Manny Antimisiaris: TURNS OUT IT WAS JUST
THE DIGITAL TO ANALOG CONVERTER,
IT WAS JUST ONE SIMPLE LITTLE BOX.
AS SOON AS THEY SWAPPED THAT OUT,
EVERYTHING WORKED PERFECTLY.
Narrator: IT'S A REMINDER TO EVERYONE
THAT EVEN THE SMALLEST COMPONENTS ARE CRITICAL
ON THE MOST SPECIALIZED 747 IN THE WORLD.
BEFORE SOFIA'S NEXT FLIGHT, SHE GETS A GOOD SCRUB.
DETAIL SPECIALIST ADAM SANCHEZ
REMOVES MONTHS OF DUST AND GRIME.
Adam Sanchez: I'M SPRAYING SG-5.
IT'S A CHEMICAL THAT ACTUALLY CLEANS THE PLANE.
IT DOESN'T AFFECT THE PAINT, IT MAKES IT NICE AND NEAT
SO THAT THE PAINT DOESN'T START CHIPPING OR ANYTHING BAD.
AND IT COMES OFF REALLY NICE AND EASY.
Tony Aguilar: CLEANING A 747, IT TAKES 12 PEOPLE TO CLEAN,
IT CAN TAKE US ANYWHERE FROM 40 HOURS TO 50 HOURS
DEPENDING ON THE, HOW DIRTY THE AIRPLANE IS
AND WHAT WE'RE CLEANING FROM THE AIRPLANE.
Phillip Madison: QUITE A WORKOUT.
IT'S QUITE A WORKOUT.
I DON'T NEED TO GO TO THE GYM, MY SHOULDERS,
I GO HOME, MY SHOULDERS ARE QUITE SORE.
Narrator: A CLEAN AIRPLANE ALSO HELPS WITH THE FUEL BILL
BY REDUCING AIR FRICTION.
Tony: IT IMPROVES ON THE FUEL EFFICIENCY,
IT CREATES LESS DRAG WHEN IT'S FLYING,
IT ACTUALLY FLIES FASTER WHEN IT'S ACTUALLY CLEAN
THAN WHILE IT'S DIRTY.
Narrator: CLEANED AND PREENED, SOFIA IS NOW 24 HOURS AWAY
FROM HER NEXT FLIGHT.
HER MOST VALUABLE ASSET-- THE 34,000-POUND TELESCOPE--
HAS ALSO UNDERGONE AN UPGRADE.
TO CLEAR SOFIA FOR SCIENCE MISSIONS,
IT NEEDS TO BE CALIBRATED AND TESTED IN FLIGHT.
Manny: IT'S NOT ONLY A CHANCE FOR THE TELESCOPE
TO MAKE SURE THAT IT'S WORKING,
BUT IT'S A CHANCE FOR THE TELESCOPE OPERATORS,
MISSION DIRECTORS,
TO INTERACT AND WORK WITH THE FLIGHT CREW
AND MAKE SURE THAT WE CAN ACTUALLY FLY A MISSION.
Narrator: INSIDE SOFIA'S CABIN, THE TELESCOPE IS CALIBRATED
FOR ITS FIRST FLIGHT IN A YEAR.
HER TELESCOPE IS EQUIPPED WITH AN INFRARED CAMERA
SPECIFICALLY DESIGNED TO CAPTURE IMAGES DEEP IN OUTER SPACE.
TO WORK AT OPTIMAL PERFORMANCE,
IT NEEDS TO BE COOLED WITH LIQUID NITROGEN.
Zaheer Ali: BASICALLY WHAT YOU HAVE IN HERE
IS A SYSTEM NOT VERY DIFFERENT
FROM THE MICROCHIP THAT'S IN YOUR DIGITAL CAMERA.
BY COOLING IT, YOU GET EXTREMELY BETTER PERFORMANCE.
Narrator: THE PRESSURIZED TANKS OF LIQUID NITROGEN
ARE HIGHLY EXPLOSIVE.
Zaheer: WE HAVE AN ARRAY OF VALVES
AND, MORE IMPORTANTLY, BLOW-OFF VALVES.
THAT PREVENTS THIS CONTAINER FROM TURNING INTO A BOMB.
Narrator: THE MINUS 320 DEGREE FAHRENHEIT LIQUID NITROGEN
IS ADDED TO THE CAMERA'S COOLING SYSTEM.
Man: READY?
Zaheer: YES, READY.
Man: OK, OPENING VALVE.
Zaheer: WE'RE DONE.
YOU CAN SEE THE LIQUID NITROGEN.
I'M CLOSING THE VALVE.
Narrator: THE CAMERA AND TELESCOPE ARE FINALLY READY.
NASA IS ABOUT TO FIND OUT IF SOFIA,
HER INFRARED TELESCOPE, AND NEW AVIONICS SYSTEMS
WILL ALL WORK TOGETHER.
IN THE PRE-MISSION BRIEF,
CHIEF PILOT TROY ASHER DOES A FULL RUNDOWN
WITH TED DUNHAM AND THE REST OF THE SCIENCE TEAM.
Troy: BASICALLY THREE PARAMETERS WE'RE GOING TO VARY,
AND ASSUME YOU WANT THREE MINUTES AT EACH ONE OF THESE.
Ted: IT'S AN END-TO-END TEST OF EVERYTHING ALL PUT TOGETHER,
FROM THE AIRPLANE ALL THE WAY BACK TO THE SCIENCE INSTRUMENT.
Troy: SO YOUR FOCUS TEST IN THE BEGINNING
IS BASICALLY WE'LL JUST HOLD HER STRAIGHT AND LEVEL
AND YOU'LL DO WHAT YOU NEED TO DO
AND TELL US WHEN YOU'RE DONE.
Ted: OK.
TO MAKE SURE ALL THE SYSTEMS PLAY TOGETHER
THE WAY THEY'RE SUPPOSED TO
AND THE DATA IS RECORDED PROPERLY
SO WE CAN MAKE SENSE OF IT AT THE END.
ALL OF THAT IS FINALLY BEING PUT TOGETHER IN FLIGHT.
Narrator: IT'S 45 MINUTES TO TAKEOFF.
MISSION DIRECTOR NANCY McKOWN
NEEDS EVERYONE ABOARD SOFIA AS SOON AS POSSIBLE.
Nancy McKown: PLEASE BE OUT THERE
15, 20 MINUTES BEFORE THE DOOR CLOSES
SO WE CAN HELP YOU GET SET UP.
Narrator: THE CREW OF 31, WHICH INCLUDES TELESCOPE OPERATORS,
MISSION PLANNERS, AND SCIENCE SPECIALISTS,
ARE BACK IN BUSINESS.
THEIR JOB IS TO MAKE AVIATION AND ASTRONOMY WORK TOGETHER.
TONIGHT'S TEN-HOUR FLIGHT WILL TAKE SOFIA NORTHEAST
FROM PALMDALE, CALIFORNIA, TO RAPID CITY, SOUTH DAKOTA.
THERE, SHE WILL TURN WEST TOWARDS PORTLAND, OREGON,
AND OUT OVER THE PACIFIC OCEAN
BEFORE TURNING BACK TOWARDS SAN FRANCISCO
AND THEN HER FINAL LEG SOUTH BACK TO PALMDALE.
Troy: FIRST TIME ALL NIGHT IN ABOUT YEAR, RIGHT?
Manny: YEAH.
Narrator: SOFIA IS FUELED UP AND ON DECK
FOR HER FIRST MISSION IN A YEAR.
Troy: THE AIRPLANE IS READY TO GO,
AND IT LOOKS LIKE WE'RE READY TO GO FLY
FOR THE FIRST TIME ALL NIGHT LONG IN OVER A YEAR.
SO WE'RE EXCITED.
Narrator: THE CLOSING DOOR SIGNALS WHAT THEY'VE ALL BEEN WAITING FOR.
Paul: HI, EVERYBODY, TO SOFIA FLIGHT 94.
WE ARE THE SAFETY TECHS FOR THE EVENING.
TO BEGIN WITH, ALL THE DOORS ARE NOW SECURED AND ARMED,
SO DON'T TRY TO OPEN THEM, WE'LL TAKE CARE OF IT.
ARE THERE ANY QUESTIONS, CONCERNS?
LET'S GO GET SOME DATA!
Manny: POWER SET. AIRSPEED IS ALIVE.
Narrator: CHIEF PILOT TROY ASHER APPLIES FULL POWER,
AND SOFIA ACCELERATES DOWN RUNWAY 2-5.
NASA'S SPECIALIZED AIRBORNE OBSERVATORY
IS AT 35,000 FEET, TRAVELING AT MACH .86
AND HEADING NORTHEAST TOWARDS SOUTH DAKOTA.
Troy: ALBUQUERQUE CENTER 135.32...
Narrator: TONIGHT'S MISSION IS TO CALIBRATE AND TEST
THE TELESCOPE'S UPGRADED CONTROL SYSTEM.
WITHOUT A FULLY OPERATIONAL TELESCOPE,
THERE WILL BE NO MORE SCIENCE FLIGHTS.
Nancy: WE'RE BASICALLY TRYING TO TAKE SOME MEASUREMENTS
OF HOW WELL THE TELESCOPE IS PERFORMING,
HOW WELL WE CAN SEE, HOW WELL IS IT TRACKING,
HOW WELL CAN WE DO EVERYTHING.
Ted: WE'RE TEST DRIVING THE TELESCOPE.
IT HAS A LOT OF NEW SOFTWARE,
AND WE'LL SEE HOW IT GOES AT THE END.
Narrator: SOFIA IS ON A TEN-HOUR NIGHTTIME MISSION,
POSING A DANGEROUS RISK OF EXHAUSTION TO HER CREW.
Manny: EUPHEMISTICALLY, EVERYBODY KIND OF CALLS US
THE VAMPIRE CREW MEMBERS.
WE DON'T WANT TO SEE DAYLIGHT, WE ONLY COME OUT AT NIGHT.
Narrator: SOFIA REACHES 38,000 FEET
AND IS READY TO BEGIN THE TELESCOPE TESTS.
Nancy: MISSION TO FLIGHT DECK FLIGHT ENGINEER,
WE'RE READY TO OPEN THE DOOR ANYTIME YOU'RE ABLE TO DO THAT.
Man: AND IT SHOULD BE MOVING.
DOOR MOVING.
Nancy: MAYBE EVEN A FOURTH THING IS
WE HAVEN'T FLOWN IN A YEAR,
WE'RE VERY RUSTY IN TERMS OF WHAT, WHAT WE HAVE TO DO,
OUR PROCESSES, OUR PROCEDURES.
AND SO THIS IS A GOOD PRACTICE, PRACTICE FLIGHT FOR US.
Narrator: THE OBSERVATORY DOOR OPENS,
AND THE TELESCOPE CAN SOON START TRACKING STARS.
Nancy: OKAY, IT LOOKS, IT APPEARS THAT THE DOOR
IS ALL THE WAY OPEN, TOM.
SO YOU'LL SEE THE APERTURE GOING TO 35, WHICH IS WHERE I SET IT.
THE DOOR'S OPEN, WE'RE GOOD TO GO.
Narrator: WITH SOFIA ON COURSE AND ON TARGET,
THE TELESCOPE OPERATORS GET BUSY LOCKING ON TO STARS.
HER UNIQUE TELESCOPE WAS DESIGNED AND BUILT IN GERMANY
AND IS OPERATED BY THE GERMAN SPACE AGENCY.
HOLGER JAKOB MONITORS THE TELESCOPE'S PERFORMANCE.
Holger Jakob: THE TELESCOPE IS POINTING ON AN OBJECT RIGHT NOW,
AND THIS IS ACTUALLY A STAR,
AND WE ARE USING THIS CAMERA
TO KEEP THE TELESCOPE STABILIZED ON THIS OBJECT.
Narrator: SOFIA IS FLYING AT MACH .86--
14% BELOW THE SPEED OF SOUND.
FOR SCIENCE FLIGHT PLANNER KEN BOWER,
THAT SPEED MAKES IT A CHALLENGE TO TRACK STARS.
Ken: OUR JOB IS TO TAKE A SET OF TARGETS
WHICH THE SCIENCE COMMUNITY HAS RATED AS VERY VALUABLE
TO BE OBSERVED BY OBSERVATORY.
NOT ONLY DO WE HAVE TO WORRY
ABOUT THE STAR THAT WE WANT TO LOOK AT
BEING UP AND VISIBLE,
AND THE SUN BEING DOWN AND THE MOON NOT BEING IN THE WAY,
BUT IN ORDER TO POINT AT IT,
THE PLANE HAS TO POINT IN A CERTAIN DIRECTION.
Nancy: MISSION TO FLIGHT DECK.
CAN YOU GIVE ME A ONE-DEGREE RIGHT TURN?
YEAH, THERE'S A LOT OF THINGS TO MONITOR
THAT I HAVE TO MONITOR VERY CONTINUOUSLY.
UM, THINGS THAT CHANGE,
AND I'M ALWAYS HAVING TO ASK THE PILOTS TO CHANGE HEADING.
UM, SOME TESTS ARE MORE INTENSE THAN OTHERS.
Narrator: ON THE FLIGHT DECK,
THE NEW INSTRUMENTS SEEM TO BE WORKING,
BUT THAT DOESN'T MAKE TRACKING TARGETS IN SPACE EASIER
IN A 747 FLYING JUST BELOW THE SPEED OF SOUND.
Troy: WE'RE REALLY TRYING TO NAVIGATE
IN RELATION TO SOMETHING THAT'S IN DEEP SPACE
AND HAS NOTHING TO DO WITH THE SURFACE OF OUR EARTH.
THERE'S TIMING ISSUES WITH ROTATING UNIVERSE
AND ALL OF THAT.
IF YOU'RE IN THE WRONG PLACE AT THE WRONG TIME,
THE TELESCOPE DOESN'T KNOW WHERE TO LOOK.
YOU KNOW, EVERYTHING GETS MESSED UP.
Narrator: AND NOW THERE IS A NEW PROBLEM--
HIGH ALTITUDE TURBULENCE
THAT AFFECTS THE TELESCOPE'S PRECISE STABILIZERS.
Holger: THE TELESCOPE ITSELF IS RESTING ON AIR SPRINGS.
THESE AIR SPRINGS ARE DAMPING THE VIBRATION FROM THE AIRCRAFT.
WE USE GYROSCOPE SENSORS THAT GUIDE THE TELESCOPE
EXACTLY INTO THE DIRECTION WE WANT IT TO LOOK AT.
Man: WE'RE STARTING TO PICK UP SOME CONTINUOUS CHOP HERE.
IS IT MORE OF THE SAME UP AHEAD?
Narrator: NOW OVER THE COLORADO ROCKIES,
SOFIA RUNS INTO INCREASED TURBULENCE
THAT PUTS THE TELESCOPE'S STABILIZERS TO THE TEST.
Troy: WE'VE GOT PRETTY MUCH CONTINUOUS MODERATE CHOP RIGHT NOW,
SO WE'RE HAVING A LITTLE TROUBLE GETTING THINGS DONE.
THERE'S GOING TO BE SOME MORE BUMPS UP AHEAD, LOOKS LIKE,
IF THIS MAP IS RIGHT THAT WE'RE LOOKING AT.
Nancy: OK, OK.
Troy: OK.
Narrator: IT LOOKS LIKE THE TELESCOPE IS MOVING.
BUT IT'S ACTUALLY THE AIRCRAFT ITSELF
THAT'S MOVING AROUND THE TELESCOPE.
Manny: WOULD HAVE BEEN NICE TO DO THIS TEST IN SMOOTH AIR.
BUT, OH, WELL.
Troy: WOULD HAVE BEEN.
Narrator: AFTER 30 MINUTES,
THE WORST OF THE TURBULENCE HAS PASSED,
ALLOWING THE SCIENCE CREW TO GET BACK TO WORK.
Troy: THE YOKE AND THE CONTROLS DID JITTER QUITE A BIT.
WE WERE A LITTLE BIT WORRIED ABOUT IT.
IT WAS CAUSING THE WHOLE AIRPLANE
TO MOVE AROUND ENOUGH
THAT THE TELESCOPE PROBABLY WOULDN'T HAVE BEEN ABLE TO FOCUS
ON SOME OF ITS OBJECTS.
Narrator: DESPITE THE BUMPY RIDE,
TROY HOPES THE SCIENTISTS GOT THE RESULTS THEY NEEDED.
Troy: DID YOU GET YOUR FOCUS PART, TOO,
OR DID YOU MISS THAT PART?
YEAH, THE TURBULENCE KNOCKED EVERYTHING OFF.
I GUESS IF YOU GO BACK AND LOOK AT THE DATA
AND IT'S REALLY IMPORTANT, MAYBE WE DO IT AGAIN THEN, HUH?
Ted: I'VE NEVER EXPERIENCED TURBULENCE THAT HEAVY
ON SOFIA BEFORE.
THE TELESCOPE'S VIBRATION ISOLATION SYSTEM
WAS WORKING HARDER THAN I'VE EVER SEEN IT HAVE TO WORK.
AND IN FACT, THE TELESCOPE
WASN'T EVEN OPERABLE FOR A WHILE.
Narrator: TURBULENCE IS ONE PROBLEM--
RESTRICTED AIRSPACE POSES ANOTHER.
Ken: RIGHT NOW WE'RE OFFSHORE, OFF THE SHORE OF OREGON,
AND WE'RE OBSERVING A TARGET.
AND ONE OF THE CHALLENGES OF BEING A SCIENCE FLIGHT PLANNER
IS THAT THERE ARE A LOT OF THINGS
WE CAN'T FLY OVER OR FLY THROUGH.
THERE ARE A VARIETY OF DIFFERENT RESTRICTED AIRSPACES.
YOU CAN SEE OVER HERE A COUPLE OF ORANGE AREAS,
THOSE ARE COASTAL WARNING AREAS.
COMMONLY THOSE WILL BE USED FOR MILITARY FLIGHT PLANNING.
IT IS PREFERRED THAT WE NOT GO THERE.
AND DELAYING BY JUST A MINUTE OR TWO TO MOVE AROUND THEM
COULD COST US A LOT OF VALUABLE SCIENCE DATA.
Narrator: IT'S FIVE HOURS INTO THE TEN-HOUR FLIGHT,
AND CREW FATIGUE IS STARTING TO SET IN.
Manny: I DON'T KNOW WHEN THE LAST TIME WAS
THAT YOU PULLED AN ALL-NIGHTER,
BUT FOR ME IT WAS COLLEGE AND THE OCCASIONAL NIGHT FLIGHT,
BUT PRIMARILY THIS AIRPLANE WILL BE FLOWN
EXCLUSIVELY AT NIGHT.
Troy: WHAT I DO PERSONALLY IS I SLEEP SHIFT
ON A FAIRLY, A FAIRLY QUICK BASIS.
I CAN STAY AWAKE FAIRLY WELL, AND I LIKE COFFEE.
Narrator: BUT THERE'S NO TIME TO REST.
THE TELESCOPE AND ITS COMPUTER CONTROL SYSTEMS
ARE NO LONGER RESPONDING TO COMMANDS.
Walter Miller: WE JUST RECENTLY HAD A CRASH
OF THE COMPUTER SYSTEM THAT RUNS THE TELESCOPE
AND RUNS THE WHOLE AIRPLANE SYSTEM
IN MISSION CONTROL AND COMMUNICATIONS SYSTEM.
Nancy: DO WE NEED TO RE-BOOT?
Narrator: IF THE TELESCOPE DOESN'T COME BACK ONLINE,
THE EXPENSIVE, YEARLONG OVERHAUL WILL SUFFER A CRITICAL SETBACK.
ONBOARD COMPUTERS REBOOT ITS CONTROL SYSTEM.
AND IF THAT DOESN'T MAKE IT FULLY FUNCTIONAL,
THEY'LL HAVE TO CANCEL THE MISSION AND RETURN TO BASE.
Nancy: MISSION TO FLIGHT DECK.
CAN YOU TELL ME WHAT THE STATUS IS?
Man: ACTUALLY, RIGHT AFTER OUR CONVERSATION
IT PRETTY MUCH SMOOTHED OUT.
Nancy: COPY THAT.
OK, WE'RE ON CONDITION.
YEAH, I LIKE THE STRESS,
I LIKE, I LIKE THE FAST PACE, YOU KNOW,
AND THAT YOU HAVE TO, YOU HAVE TO THINK ON YOUR FEET
AND YOU HAVE TO DO SOMETHING RIGHT NOW.
Narrator: IT TAKES 20 MINUTES OF INVESTIGATION
TO DISCOVER THE ROOT OF THE PROBLEM.
Ken: SOMETHING FOULED UP
AND WE HAD TO RESET A WHOLE BUNCH OF OUR COMPUTERS.
IT'S REQUIRED SEVERAL MINUTES FOR US TO CLOSE THE DOOR,
REPOSITION THE TELESCOPE, SHUT DOWN SEVERAL COMPUTERS,
RESTART THE MASTER NETWORK
AND THEN RESTART SEVERAL DIFFERENT SYSTEMS.
Nancy: WE'RE STARTING TO REMEMBER, OH, YEAH,
THIS IS WHAT WE NEED TO DO, THIS IS HOW YOU DO IT.
AND EVERYTHING'S STARTING TO GEL, SO IT'S GOOD.
Narrator: THEY'VE BEEN IN THE AIR FOR EIGHT GRUELING HOURS,
WITH TWO MORE TO GO.
Troy: AS FAR AS OUR POSITION GOES,
WE'VE NOW MADE IT AROUND OUR CIRCUIT.
WE'RE OUT OVER THE PACIFIC OCEAN PROBABLY ABOUT,
OH, I'D SAY 300 MILES WEST OF, SAY, BIG SUR, CALIFORNIA.
Narrator: AFTER MONTHS OF SETBACKS,
THE FLYING TELESCOPE FINALLY WORKS PERFECTLY.
Ted: WE HAD PRETTY GOOD SUCCESS WITH IT.
ALL THE KIND OF WORK THAT INFRARED ASTRONOMERS DO
IS FUNDAMENTALLY BASED ON THIS CAPABILITY.
SO IT'S REALLY IMPORTANT
THAT WE WERE ABLE TO SHOW THAT THIS WORKS.
Nancy: I THINK THAT WENT REALLY WELL.
AT LEAST WE FINISHED THE TEST WHICH WAS,
IT WAS A DIFFICULT TEST TO DO, AND WE FINISHED IT.
AND WE HAVE NEW FUNCTIONS, NEW FUNCTIONALITY WITH IT
THAN WE DID A YEAR AGO.
Narrator: TELESCOPE SOFTWARE ENGINEER HOLGER JAKOB
IS EQUALLY PLEASED.
Holger: TODAY WAS VERY SUCCESSFUL.
THE TELESCOPE SO FAR REALLY BEHAVED FLAWLESS.
I'M PROUD, YEAH, TO WORK HERE ON THIS PROJECT.
Narrator: ON THE FLIGHT DECK, CHIEF PILOT TROY ASHER
BRINGS SOFIA BACK TO EARTH.
Troy: WELL, WE'RE ABOUT, ABOUT 20 MINUTES OUT NOW,
I'M LOADING IN THE APPROACH, COMING BACK INTO PALMDALE.
[RADIO CHATTER]
Computer: 50, 40, 30, 20, 10.
Narrator: IT'S 5 A.M.,
AND THE SLEEP-DEPRIVED CREW IS READY FOR BED,
RELIEVED TO HAVE THIS TEST BEHIND THEM.
Troy: IT WENT GREAT.
I THINK SUCCESSFUL, WE GOT EVERYTHING.
SOFIA'S BACK IN BUSINESS.
WE'RE READY, WERE READY TO,
WE'RE READY TO DO SOME GOOD SCIENCE HERE
FOR THE REST OF THE YEAR.
Narrator: IT TAKES HARD WORK AND DEDICATION
ON THE PART OF THE GROUND CREW, AIR CREW AND SCIENTISTS
TO ALLOW SOFIA TO DO HER JOB.
Ken: SOFIA IS THE LARGEST MOVEABLE TELESCOPE IN THE WORLD.
WE CAN GO PLACES AND SEE THINGS THAT OTHER TELESCOPES CAN'T DO.
Nancy: THERE'S ONLY ONE SOFIA,
AND THERE'S BASICALLY ONLY ONE AIRCRAFT
THAT DOES SOMETHING LIKE THIS.
Ted: WE GET TO LAUNCH SOFIA 120 TIMES A YEAR.
AND IF WE DON'T LIKE WHAT HAPPENED,
WE CAN CHANGE SOMETHING AND LAUNCH IT AGAIN.
Steve: IT'S JUST A LOT OF PRIDE,
TO BE PART OF SOMETHING THIS BIG AND THIS IMPORTANT RIGHT NOW
IS KIND OF AMAZING AND HUMBLING ALL AT THE SAME TIME.
Manny: THAT WAS GREAT.
Troy: VERY GOOD!
Manny: WE'RE BACK IN BUSINESS, BOYS.
Troy: ALRIGHT!
Narrator: SOFIA'S LONG AND CHALLENGING UPGRADE
FINALLY PUTS HER BACK IN THE SKIES.
SHE'LL BE FLYING SPACE OBSERVATION MISSIONS
FOR MANY YEARS TO COME.
WITH HER DEDICATED TEAM,
THIS 747SP WILL HELP UNRAVEL THE MYSTERIES OF THE UNIVERSE.