Near disaster for ExoMars

The Russian jinx for going to Mars might not be over yet: New data suggests that the Briz-M upper stage to the Proton rocket exploded shortly after it has propelled ExoMars on its way to Mars and then separated from it.

There appears to be a cloud of debris near the probe, thought to have been caused when the Briz-M stage was to fire its rockets one last time to take it away from ExoMars as well as prevent it from following it to Mars. Instead, it is thought (though not confirmed) that the stage blew up at that moment.

Though so far ExoMars appears to be functioning properly, but they have not yet activated all of its most sensitive instruments. Only when they turn them on in April will we find out if they were damaged in any way by the Briz-M failure.

ExoMars blasts off

The European-Russian Mars orbiter/lander ExoMars was successfully launched on a Proton rocket this morning from Baikonur.

It will still take most of today for the rocket’s Briz-M upper stage to complete several additional engine burns to send the spacecraft on its path to Mars, but the most difficult part of the launch has now passed.

The article does a nice job of summing up Russia’s most recent track record in trying to send spacecraft to Mars, thus illustrating the significance of today’s success:

For Russian scientists, the launch marks the resumption of a cooperative effort with Europe to explore the Solar System, after the failure of the Phobos-Grunt mission in 2011.The launch of the ExoMars-2016 spacecraft will be Proton’s first “interplanetary” assignment in almost two decades. During its previous attempt in November 1996, Proton’s upper stage failed, sending the precious Mars-96 spacecraft to a fiery desmise in the Earth’s atmosphere and effectively stalling Russia’s planetary exploration program for a generation.

Further in the past, during the Soviet era, the Russians tried numerous times to either orbit or land on Mars. Every mission failed. If this mission successfully reaches Mars and lands it will mark the first time the Russians played a major role in a mission to Mars that actually reached its goal and worked.

Another Falcon Heavy customer switches to different rocket

The competition heats up: Afraid of more delays in SpaceX’s Falcon Heavy rocket, Inmarsat has booked a Russian Proton rocket for a 2017 commercial satellite launch.

London-based Inmarsat is the second Falcon Heavy commercial customer to have sought a Plan B given the continued uncertainties in the launch schedule of Falcon Heavy, whose inaugural flight has been repeatedly delayed. Carlsbad, California-based ViaSat Inc. in February moved its ViaSat-2 consumer broadband satellite from the Falcon Heavy to Europe’s Ariane 5 rocket for an April 2017 launch, securing what may be launch-service provider Arianespace’s last 2017 slot for a heavy satellite.

ExoMars ready for launch

The European ExoMars Mars orbiter and lander mission, set for launch on March 14, is assembled on its Proton rocket and is ready for launch.

This European project was originally going to be in partnership with NASA, but the Obama administration pulled out of the deal. The Russians then offered to come in and provide a rocket for the mission.

Russian Proton rocket successfully launches commercial satellite

The competition heats up: The Russians successfully put a European commercial communications satellite into orbit today their Proton rocket.

It was the sixth successful Proton launch since their May failure. The key quote from the article however was this:

ILS owner Khrunichev State Research and Production Space Center of Moscow has said it would give ILS leeway to reduce prices to work its way back into the regular commercial-launch rotation alongside SpaceX and Europe’s Arianespace. The decline of the Russian ruble against the U.S. dollar has made that task easier as most commercial launch contracts are priced in dollars.

In other words they are going to cut prices to compete, and the falling ruble has given them more leeway to do it.

Proton successfully launches satellite

The competition heats up: A Russian Proton rocket successfully placed a commercial communications satellite in orbit today, the fifth successful launch in a row since a May launch failure and the second launch in only 10 days.

For the Russians the Proton successes during the second half of 2015 are encouraging. Whether they have solved their chronic quality control problems, however, remains unknown. I remain doubtful, especially because they have eliminated competition within their industry and folded everything into a single government entity that runs it all.

Proton launch success

The competition heats up: Russia’s Proton rocket successfully launched a military communications satellite on Sunday.

The link provides a lot of interesting information about the satellite as well as some recent upgrades the Russians have installed in Proton, but for context the last two paragraphs are probably the most important:

Sunday’s launch was the seventy ninth orbital launch attempt of 2015 and the seventh Proton launch of the year. Five of the six previous launches were successful, with May’s launch of Mexsat-1 failing to achieve orbit. Proton has had eleven failures in the last ten years, with 2009 the only year since 2005 in which it has not suffered at least one anomaly.

The next Proton launch is scheduled for 23 December, with another Proton-M/Briz-M carrying the Ekspress-AMU1 communications satellite. Details of any future Garpun launches are not available.

The launch reliability for Proton has seriously fallen since 2005, and to compete in the changing launch market they will need to fix this.

Eutelsat signs a multi-launch Proton rocket deal

The competition heats up: Satellite maker Eutelsat has signed a seven year multi-launch deal with International Launch Services (ILS) using the Proton rocket.

The ILS press release does not state how many launches this contract covers, which makes me suspect that ILS was forced due to competition with SpaceX to give Eutelsat a great deal of flexibility about which launcher it uses with each satellite down the road. The ILS release even admits this. ““With their selection of ILS Proton for this Multi-Launch Agreement Eutelsat has made a clear statement that flexibility and schedule assurance are key discriminators.”

This is still a good thing for the Russians, as it insures them a share in the launch market for almost the next decade.

New launch contracts for SpaceX and ILS

The competition heats up: Launch competitors SpaceX and ILS announced new contracts today for launching commercial satellites into orbit.

SpaceX announced two new contracts, one from the Spanish communications company Hispasat, who signed them up to use a Falcon 9, and a second from the Saudia Arabian communications company Arabsat for a Falcon Heavy launch.

ILS meanwhile got its own contract from Hispasat to use a Proton to put another Hispasat communcations satellite into orbit.

The two Hispasat contracts show the advantages of competition for satellite makers. They now have more than one company to choose from, and are spreading their business around to give them options while encouraging these companies to compete against each other by lowering prices.

Proton failure investigation finds quality control the root problem

In the heat of competition: The Russian investigation into the most recent Proton rocket launch failure has now found that the cause of the turbo pump failure was because of significant management failures.

The investigation into the MexSat-1 failure established that a fast spinning shaft inside a turbine of the RD-0212 engine propelling the third stage can break easily due to excessive vibrations. (The turbine is designed to pump propellant into four thrusters which steer the rocket in flight.) Yet, despite the problem lingering in the engine’s design for decades, the fact that two of these three accidents had happened in the past 15 months was itself is not an accident!

In an interview with the Russian business web site BFM.ru, the head of Roskosmos Igor Komarov disclosed that due to recent easing of requirements for the quality of metal that had gone into the production of the shaft, the turbine became more vulnerable to vibrations. Additional fascinating details on the same issue had surfaced on the online forum of the Novosti Kosmonavtiki magazine.

As it turned out, dangerously low requirements for the turbine shaft were set in the design documentation during the development of the rocket. However the issue was identified early during testing and the production team self-imposed extra margins for the affected components to remedy the problem. However in 2013, the new management began questioning why so much manufactured parts had been disqualified during production, even when they had met lowest requirements set in the design documentation. By that time, the new generation of workers and mid-level production managers no longer saw a reason to fight for more stringent requirements, which were actually making their own work more difficult. As a result, the hardware which was barely making through the quality control was certified for the installation on the engine, thus giving the old design flaw more chances to surface. [emphasis mine]

The description above reminds me strongly of the circumstances that took place prior to the Challenger failure in 1986: Engineers trying to fix a problem that managers don’t want to see.

Angara to launch commercial payload on next launch

The competition heats up: Russia has decided to accelerate use of its heavy Angara rocket by launching a commercial payload on its next launch in 2016.

They had initially planned to do more test flights. The technical problems with Proton, combined with increased competition from SpaceX and others, is forcing them to move at a less leisurely pace.

In the meantime, they have concluded their investigation into the Progress/Soyuz rocket failure, issuing an incredibly vague press release that only stated the following:

The damage to the ship during its abnormal separation from the third stage of the Soyuz-2-1a launch vehicle resulted from a particular property of the joint use of the cargo spacecraft and the launch vehicle. This design property was related to frequency and dynamic characteristics of joint vehicles. This design property was not fully accounted for during the development of the rocket and spacecraft complex.

Limitations on further flights of the Soyuz-2-1a rocket with other spacecraft had not been found.

It sounds to me as if they don’t know exactly what caused the abnormal separation between the rocket and the spacecraft, and that they have decided to move on regardless.

I think it would be very wise for the U.S. to get its own manned spacecraft operational as fast as possible.

Criminal charges against Russian workers who caused Proton failure

The three Russian technicians and their supervisor whose sloppy work caused the spectacular 2013 crash of a Proton rocket immediately after launch have now been indicted on criminal charges and will face trial.

According to investigators, Grishin, Nikolayev and Gudkova in 2011 were tasked with installing the angular rate sensors on the Proton rocket that are responsible for yaw control. “As a result of their violation of technical discipline envisaged by engineering and technological documentation, these sensors were installed incorrectly / at 180 degrees from their correct position/,” Markin said.

The installation error accounted for the vehicle’s wild trajectory, causing its crash and destruction. During the investigation, Grishin and Nikolayev partly admitted their guilt in committing the crime, he said.

In his turn, Nasibulin guided by the fact that over a long time no violations had been found during the installation process and also amid the job cuts withdrew the control operation from a respective list. He did not monitor the process and the sensors were installed without the due control.

Note that they didn’t sabotage anything intentionally. They only did bad work. In the U.S. such incompetence would certainly get them fired, but no one would dream of prosecuting them under these circumstances. It appears that Putin’s government has decided to make them scapegoats and an example to everyone else: Do your work right or else!

Along these lines, Russian government officials have also indicated they are considering imposing fines on manufacturers for any future failures or delays.

Both the criminal indictments and the fines would surely work to prevent further disasters. They will also work very effectively in preventing any risk-taking or innovation from anyone. Who wants to build something new and untested if there is a strong possibility its failure will get you in prison?

Do not expect much creativity from the Russian aerospace industry in the coming years.

Corruption in the Russian space industry

A slew of stories in the Russian press today illustrate again the deeply ingrained problems that country has, both in corruption and in its ability to produce a quality product.

The last story describes the overall scale of the corruption, which is not confined just to the space sector, but can be found in many industries. The aerospace industry just happens to be the most visible outside Russia, and thus the most embarrassing. Yet,
» Read more

Russians delay next Angara launch to replace Briz upper stage

The competition heats up? The Russians have delayed until late 2016 the first test flight of the heavy-lift version of their new Angara rocket so that they can fly it with its own new upper stage, rather than using the trouble-plagued Briz upper stage used on Proton.

In other words, they want to dump all the components of the Proton as soon as possible. Whether this will solve the quality control problems that seem to be systemic to their aerospace industry however remains questionable. If I was a commercial satellite company I would have as little faith in Angara, until it has proven itself through a number of launches.

Rogozin pins Proton failure on “moral degeneration”

In a speech before the State Duma, Russian deputy prime minister Dmitry Rogozin blamed the “moral degeneration” of the top leaders of their county’s aerospace industry for Saturday’s Proton launch failure.

“With such degeneration in the leadership of the enterprises, there’s no surprise at such a high degree of accidents,” said Rogozin who said that “space bosses have long gone into their own space.” … The vice premier expressed those that the force of “legal gravitation will lead them [those responsible for the failure of the Progress and the Proton] to where they should be,” RIA Novosti quoted him as saying.

In other words, expect more arrests and prosecutions. Meanwhile, there is little evidence that Rogozin or Putin are doing anything to make their space industry more competitive and thus capable of generating the profits necessary to keep it afloat.

Update on Saturday’s Proton launch failure

Link here. The failure was in the third stage, which was the cause of a previous Proton failure last May.

Note that the Proton also put a commercial satellite in the wrong orbit in October when the upper stage underperformed.

Overall, the Russians are doing a very poor job in eliminating the serious quality control problems that have plagued their aerospace industry in recent years. If anything, the problems appear to be worsening.

Proton launches successfully

The competition heats up: Russia’s Proton successfully launched an Inmarsat commercial satellite into orbit today.

Considering the problems the Proton has had in recent years, this launch success is significant. It suggests that they are back in business.

In related news, a Russian space expert was fired from his job at a hi-tech operation outside Moscow after he publicly criticized the Putin government’s consolidation of Russia’s entire space industry into a single government-run corporation.

Vadim Lukashevich worked at the Skolkovo Innovation Center, a high-tech business park outside Moscow intended as Russia’s answer to Silicon Valley that has partnerships with Western research universities such as MIT. “As I understand it, they [fired me] for a series of interviews in which I criticize the recent decision to liquidate the Federal Space Agency and create a new state corporation called Roscosmos,” Lukashevich told The Moscow Times on Friday.

…Lukashevich, a prominent voice in the Russian space scene, told the BBC the reform would remove any industry accountability and would foster corruption — all while failing to provide Russia with a long-term direction in space.

On Wednesday, a day after the interview was published, he said someone at Skolkovo’s Space Cluster called him to say he had been fired. The caller “apologized several times, saying the decision was imposed on them from above — by a phone call from URSC in the middle of the night,” Lukashevich said

I think that Lukashevich is right, that creating a single government-run corporation will encourage corruption and in the long run will be a disaster for Russia’s space industry. We will see a rebirth of the same problems that destroyed the Soviet Union. In fact, Lukashevich’s firing is illustrative of this.

I also think that in the short term it will likely energize their space program. But only for a short period of time. After they achieve some Soviet-style stunts that appear impressive, the weight of corruption and the lack of competition will cause the industry to collapse in bankruptcy again.

A new Russian heavy lift rocket amid Russian budget woes

The competition heats up: Even as Russia today successfully placed a commercial satellite in orbit on the 400th successful Proton rocket launch, Russian sources indicate that — despite budget woes fueled by the drop in oil prices — Russia is moving ahead with the design and construction of a heavy-lift rocket capable of competing with NASA’s Space Launch System (SLS).

From the last link above:

By 2013, Roskosmos drafted a very preliminary roadmap toward the development of heavy and super-heavy launch vehicles. Not surprisingly, it matched closely the strategy that NASA had followed since 2011 within the Space Launch System, SLS, project.

…As the American SLS project, Russian super-heavy launcher plans envisioned building a rocket with a payload of 80-85 tons in the first phase of the program. A pair of such rockets would be enough to mount a lunar expedition. In the second phase of development, the rocket would be upgraded to carry unprecedented 130-180 tons of payload in order to support, permanent lunar bases, missions to asteroids and expeditions to Mars.

As much as I remain a skeptic of SLS, it has apparently struck so much competitive fear in the Russian leadership that they are now willing to try to copy it. Much like the 1980s, when the Soviet rulers bankrupted their nation trying to duplicate American projects like the Strategic Defense Initiative and the Space Shuttle, Putin is now repeating that error all over again. His country has experienced almost a quarter-century of strong economic growth since the fall of communism because, during that time, they focused on capitalism, private enterprise, freedom, and a bottom-up economic structure. Now, they are beginning to abandon that approach and return to the top-down, centralized system of government planning.

As it did in previous century, it will bankrupt them again in this century. Though the Russian government is denying the reports that they are going to trim their space budget, their government’s budget is going to suffer from the drop in the price of oil. Something will have to give.

Update: This review of a book about modern Russia is definitely pertinent: The Land of Magical Thinking: Inside Putin’s Russia

Proton launch postponed

The heat of competition: Russian engineers have scrubbed Friday’s commercial Proton launch due to a gyro issue with the rocket’s Briz upper stage.

They have begun to destack the rocket to get at the upper stage in order to repair the problem, with the new launch date expected to be no earlier than mid-December.

The problem once again raises questions about the quality control generally within the Russian aerospace industry and specifically in the companies that build Proton and its upper stage. At the same time, it is a good thing they spotted the problem before launch, allowing them to correct it. That is what a company with good quality control does.

Another failure for Russia’s Proton rocket?

Unconfirmed sources today are suggesting that Tuesday’s Proton launch of a Russian communications satellite placed the satellite in the wrong orbit.

A report appearing on NASASpaceFlight (NSF) has indicated that while the initial phase of the launch of the Russian Ekspress AM-6 telecommunications satellite might have gone off as planned – the later stages of the mission were less than perfect. NSF’s Chris Bergin reported via Twitter that, although the spacecraft had been placed into the wrong orbit – it should be able to be placed into the correct orbit over time. How much time and what the exact cause as to why the satellite may have been placed into an improper orbit – have yet to emerge. In fact, officials within the Russian space industry have stated that the spacecraft is, in actuality, in the correct orbit.

If these sources are correct it will be a very bad problem for Russia’s aerospace industry, now consolidated into a single giant corporation run by the central government. Proton has had numerous failures in the past three years, all caused by serious quality control problems in Russia’s entire space industry. Another failure here will only add weight to this conclusion.

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