Independent Arianespace investigation cites design error as cause of Russian launch failure

A just released independent investigation by Arianespace of the Soyuz rocket launch failure that put two European Galileo GPS satellites in the wrong orbits has concluded that the design of the Fregat upper stage, not an assembly error, was at fault for the failure.

The upper stage was not oriented correctly because fuel lines to thrusters had become frozen.

The freezing resulted from the proximity of hydrazine and cold helium feed lines, these lines being connected by the same support structure, which acted as a thermal bridge. Ambiguities in the design documents allowed the installation of this type of thermal “bridge” between the two lines. In fact, such bridges have also been seen on other Fregat stages now under production at NPO Lavochkin. The design ambiguity is the result of not taking into account the relevant thermal transfers during the thermal analyses of the stage system design.

That the Russian investigation found that this arrangement of feed lines happened once in every four stages that were assembled still suggests sloppiness, if not in assembly then in design. The Arianespace investigation, though thorough, thus appears to me to be trying to provide cover for thier Russian partners here.

More quality control problems in Russia

The investigation into the failure of a Russian Soyuz rocket to place two European Galileo GPS satellites into the correct orbit has found that it was caused by the faulty installation of fuel lines on the Fregat upper stage.

The failure was as simple as clamping together a cold helium line with the hydrazine fuel line, causing the hydrazine to freeze long enough to upset the Fregat stage’s orientation and cause the two satellites’ release into an orbit that is both too low and in the wrong inclination, officials said. One official said the Euro-Russian board of inquiry into the failure discovered that one in four Fregat upper stages at prime contractor Moscow-based NPO Lavochkin had the same faulty installation. ,,,,

Government and officials said the commission is debating how to proceed now that it knows that, as expected, the Fregat failure was not one of design, but of assembly and quality control. [emphasis mine]

In other words, 1 in 4 Fregat upper stations were routinely assembled improperly and no one noticed. The investigation also found that this assembly problem had existed on several past launches but because of the orbital requirements it had fortunately not caused any problems.

I want to emphasize that these kind of sloppy assembly issues have been occurring at a number of different Russian factories and different Russian companies. It seems to be systemic to the entire Russian aerospace industry, and it also appears to be getting worse.

Soyuz docks successfully with ISS

Despite the failure of one solar array to deploy, a Soyuz capsule carrying three astronauts successfully docked with ISS today.

The solar array issue, still unresolved, needs to be figured out, as this Soyuz spacecraft must serve as one of ISS’s lifeboats for the next few months. Without that array the spacecraft will have limited power, and will definitely not be considered the best way home should something go wrong on the station.

A solar panel on manned Soyuz fails to deploy

One of the two solar panels on the manned Soyuz capsule transporting three astronauts to ISS has failed to deploy.

“According to our data, one of the solar panels is still unable to unfold for reasons unknown. But preliminary data suggest that it will not impede [the spacecraft] from docking to the ISS. They have carried out a maneuver just now which involved all of the spacecraft’s engines, all systems are running smoothly, the crew is OK,” the source in the agency said.

Because they are flying the fast route to ISS a shortage of power is not as critical. However, this failure once again indicates the increasing quality control problems faced by the Russian aerospace industry. In past decades these problems simply did not happen, especially on their manned missions. Now they are happening with increasing frequency.

Russia announces plans to fund its share of ISS through 2025

In a somewhat unexpected development today, Russian Deputy Prime Minister Dmitry Rogozin revealed today that Russia intends to spend $8.2 billion (321 billion rubles) on research and development at the International Space Station through 2025.

“The 2016-2025 draft of the target federal program provides for allocating 321 billion rubles for the ISS development and operation, including the creation of new modules for unmanned spacecraft,” Rogozin said during a visit to a cosmonaut training center. “Russia channels considerable funds into development of this area of Russian space science. We are now thinking of research projects designed to explore outer space, as well as new projects in manned cosmonautics,” Rogozin said.

Up until now the Russians have been unclear about what they intend to do at ISS. NASA had asked them to extend the partnership to 2024. Their initial response was almost hostile, with Rogozin even threatening to stop flying American astronauts to ISS on Russian Soyuz rockets/capsules. Now it appears that they have decided to up their participation with new modules and agree to the extension.

Moreover, Rogozin’s statement suggests they are going to take a more independent position when it comes to human research in space. Up until now, they have allowed NASA a veto on flying any long manned missions on ISS, which is why no yearlong expeditions prior to next year’s have taken place. NASA kept saying no. This report suggests that once we have our own methods for getting astronauts to ISS they are going to go their own way and begin flying their own long term missions to ISS. We will fly our astronauts there on our schedule, and they will fly their astronauts there on their schedule.

Should make for some interesting news stories, eh? Will Russian and American astronauts even be allowed in each other’s modules? I am reminded of stories of messy divorces where the couples still had to live in the same house.

Blue Origin to build rocket engine for Atlas 5

The competition heats up: Jeff Bezos’s company Blue Origin has signed a contract with the United Launch Alliance to build a rocket engine for the Atlas 5 rocket so that it will no longer have to depend on Russian engines.

Neither executive [of either company] would discuss a dollar figure, although it’s likely somewhat less than $1 billion. Bruno said a typical liquid-fueled rocket engine takes seven years and $1 billion to develop, but Blue Origin is already several years along on the BE-4. Bruno said the engine could be ready within four years to serve as the main engine on the company’s Atlas V rockets.

This is excellent news, because it shows that ULA is being pro-active in solving this problem, rather then waiting for Congress to act.

Russia to match SpaceX launch prices

The competition heats up: The head of Russia’s United Rocket and Space Corporation (URSC), which now controls that country’s entire space industry, said today that they intend to compete with SpaceX’s Falcon 9 much cheaper launch prices.

They intend to do it with both the Proton rocket as well as their new family of Angara rockets. The heavy version of Angara will allow them to compete with SpaceX’s Falcon Heavy, and in fact might even put more payload into orbit for less.

Putin threatens management at Vostochny with criminal prosecution

In a statement today in the Russian press Vladimir Putin proposed initiating a criminal investigation into the management of the new Vostochny spaceport.

[Putin] admitted that “although the project is in the focus of our special attention, problems abound. … I will have to hand over some issues to law enforcement agencies to get them sorted out and clarified,” Putin said. Funding is provided regularly but the funding procedure itself needs special attention, he said, referring to “quasi and semi-criminal schemes”.

It appears that funds have not been used as efficiently as he likes and his solution is to threaten prosecution of those involved. This is becoming a standard Putin technique. He used it to guarantee his control over the Russian aerospace company Energia, and now he is using it here to guarantee the Vostochny project moves forward fast and efficiently.

Its use also illustrates the limitations of Russia’s top down approach to everything. Such threats can prevent corruption in a specific project, but that such treats are necessary so frequently points out how easily such corruption grows in a government-run centralized bureaucracy. We see it here in the U.S. as well. Take away the profit motive and private ownership and there remains nothing to naturally focus the efforts of management towards success and efficiency.

The Russian takeover of Crimea once again threatens American access to space

A decision by the Russians to possibly shift astronaut training back to a base in the Crimea, now under their control, could lock American astronauts from future Soyuz flights.

Shifting the survival training to Russian-occupied Crimea will require foreign cosmonauts to accept travel there without Ukrainian visas, an explicit acquiescence to the new diplomatic status of the province. Refusal to attend survival training is equivalent to failing the training, which by existing training regulations is an automatic disqualification for flight certification. No Crimea trip, no space trip.

The Russians have not yet made this shift official, so it is possible it will not become a problem. However, the article outlines many reasons why it makes good sense for the Russians to do it.

Sarah Brightman, astronaut

The competition heats up: The start of Sarah Brightman’s astronaut training has been delayed from this fall to the beginning of 2015.

I suspect this delay has more to do with accommodating her schedule and the fact that she is very enthusiastic and well-prepared than any negative issues related to her or the mission. They have probably decided that she just needs less time to train.

Her actual flight to ISS is scheduled for the fall of 2015.

Vladimir Putin, space cadet

Two news stories today demonstrate without question that Russia’s newly reorganized aerospace industry and its project to build a new spaceport are not merely the efforts of mid-level bureaucrats in that aerospace industry.

No, these efforts have been instituted and are being pushed at the very top of the Russian government, by Vladmir Putin himself. It appears that he has decided, or has always believed, that Russia deserves a strong and vibrant space program, run from Moscow, and is doing everything he can to make it happen, as part of his personal vision for Russia.

The first story described a visit on Tuesday that Putin made to Russia’s new space port, Vostochny, in the far eastern end of Russia. While there he noted that construction is several months behind schedule and that this slack must be made up. He then endorsed the proposal put to him by space agency officials that the number of people working on construction should be doubled.

The second story described Putin’s endorsement of the construction of a new Russian heavy lift rocket, capable of putting 150 tons into orbit. Such a rocket would be comparable in power to the largest version of the U.S.’s SLS rocket, not due to be launched, if ever, until the 2020s.
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All geckos lost from Foton-M4

Upon the return to Earth today of Russian biology satellite Foton-M4 biologists discovered that all the geckos on board had died sometime during the mission.

The cause of death has not yet been announced. The mission itself had some problems, and returned to Earth about two weeks early. Nonetheless, the Russians also announced that flies on board were still alive upon landing.

Russian military abandons Rokot

Beginning in 2016, the Russian military will stop using its Rokot launcher, switching to Soyuz and Angara rockets instead.

The reason? Rokot relies on some imported parts, while Soyuz and Angara are build entirely in Russia.

It is interesting how fast the Russians are moving to stop their dependence on foreign parts, compared to the United States. Rather than try to build Russian-built parts for Rokot, they have taken the simplest and fastest approach and simply switched rockets.

In the U.S. Congress is instead demanding that a new rocket engine be build for Atlas 5 to replace the Russian engine, an expensive and time-consuming process. Wouldn’t it make more sense to say buy-buy to Atlas 5 and just switch to the Falcon 9?

Russia to continue on ISS past 2020?

A Russian news story today suggests that they are leaning strongly to continuing their partnership with the United States on ISS beyond 2020.

“The issue of Russia’s participation at the ISS after 2020 remains open, but there is a 90-percent chance that the state’s leadership will agree to participate in the project further,” [Izvestia] wrote, citing a source at Russia’s Federal Space Agency Roscosmos.

This report gives a better overview of the debate going on with Russia’s government and space agency. If they abandon ISS the work they have already done on new modules for the station will have to be written off, and it appears assembling their own station from those modules will be too expensive and take too long.

It also looks like NASA offered them a second year long mission if they stuck around.

Soyuz puts two satellites in wrong orbit

A Russian-made Soyuz rocket launched from French Guiana for Arianespace has placed two European Galileo GPS satellites into the wrong orbit.

Russianspaceweb suggests that the problem was caused by the rocket’s Russian Fregat upper stage. (Scroll down about halfway to read their report on this launch.)

Multiple independent sources analyzing the situation suggested that the Fregat upper stage had fired its engine for the right duration, however the stage’s orientation in space during the second or both maneuvers had probably been wrong. According to Jonathan McDowell, an astronomer at the Harvard-Smithsonian Center for Astrophysics and a veteran space historian, the Fregat’s angular orientation error during engine firing could reach as much as 145 degrees.

This failure is a triple whammy. It hits both Arianespace and Russia since the Soyuz was part of a partnership between the two. It also hits Europe’s Galileo GPS satellite, which after many years of development was beginning to move towards full operation.

Sea Launch has suspended all operations until 2015

Russian competition cools down: The mostly Russian-owned rocket company Sea Launch has suspended all operations until mid-2015.

I suspect that the Russian government, now in control of almost all Russian aerospace efforts, is not interested in building this company up as the rocket it uses is partly made in Ukraine and is a competitor to Russia’s new Angara rocket. Everything the Russian government has done for the past year has indicated a desire to shut down all cooperative efforts with other countries and focus everything towards all-Russian efforts.

Thus, Sea Launch dies.

Two additional Russian rocket engines arrive in the U.S.

Despite tensions over the Ukraine, a Russian cargo plane on Wednesday delivered two more Russian rocket engines to Alabama for their refurbishment and use in ULA’s Atlas 5 rocket.

This delivery gives ULA some additional breathing room. It the additional deliveries scheduled for later this year and early in 2015 happen, they will have even more breathing room for more Atlas 5 launches. Even so, their dependence on Russian engines is something that limits the company’s competitiveness in the emerging aggressive launch market.

Russia to build new satellite communications cluster

The competition heats up: The Putin government’s newly released draft plan for Russia’s space industry includes the development of a new communications satellite constellation.

In addition to encrypted mobile communications, the Ellips satellites will support air-traffic control and traditional fixed communications. Reflecting its dual (civilian and military) application, the Ellips project would be funded jointly by the Russian space agency, Roskosmos, and by the Russian Ministry of Defense at a price tag of 65.6 billion rubles to develop and deploy the constellation.

The article then goes on to detail at length the problems the Russian communications satellite industry has had for the past two decades, including their inability to build satellites that will last in orbit as long as their competitors.

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