Information about Proton rocket

Stan Black

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Information about Proton rocket

« on: 06/22/2009 07:42 am »

Morning all,

Here is what I think I know about the Proton rocket.

Proton-K 336-02 for Mir and 337-01 for Kvant featured the RD-253 engines enhanced to 106½% thrust and the RD-0210/0211 to 101½%.

The RD-253 were enhanced to 102% as standard on Proton-K from serial 353-01, but the first to fly was 356-02 with Fobos-1 (65 flew and one serial number is unallocated).

Proton-K 386-01 introduced the next major change; a new engine was introduced, the RD-275 with 107% thrust of the RD-253.

For use in the Proton-M the RD-275 were enhanced to 102% with the goal of achieving 105% upgrade in the future (that is 112% above the original thrust levels of the RD-253). The RD-0210/0211 to 105%. Proton-K 395-02 for PAS-8 in November 4, 1998 tested these engines.

Another feature of Proton-M is they vent propellent from the expended 1st and 2nd stages to prevent contamination of the ground. At the time of the second Proton failure in 1999 three had already flown that year with this feature on their first stage. I assume such a change was introduced sequentially into the Protons so they would be 396-01 with Telstar-6, 396-02 with Nimiq-1 and 397-01 with Astra-1H.

I have the impression (but no hard facts) that Proton-K 395-01 for Zarja introduced the first stage venting as a standard feature, and also tested the enhanced engines.

The enhanced Proton-M RD-0210/0211 led to the Phase II engines in Proton-K; with no change in thrust.

Proton-Ms 535-01 and 535-02 featured additional telemetry instrumentation; this was removed from 535-03 onwards. From 535-05 mass was further reduced by using isogrid design and high-strength aluminium alloys. (Both 535-04 and 535-05 remain unflown; assume storage life is the same as a Proton-K of five years).

Stan

References:-

DEVELOPMENT STATUS AND OPERATIONAL USE OF “PROTON-M” LAUNCHER WITH UPGRADED MAIN ENGINES

Novosti Kosmonavtiki

ILS website and Proton mission planner’s guide

« Last Edit: 25 November 2011 10:45:33 AM by anik »

« Last Edit: 08/03/2014 06:35 am by Stan Black »

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Nicolas PILLET

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		207-01	N-4	Proton-1
		208-01
		209-01	N-4	Proton-2
		210-01
1965	У10721101	211-01	N-4
	У10721201	212-01	N-4	Proton-3
1966	Н10722701	227-01	11F91 2P	Kosmos-146
	Н10722801	228-01	11F91 3P	Kosmos-154
1967	Я10722901	229-01	11F91 4L
	Я10723001	230-01	11F91 5L
	Я10723101	231-01	11F91 6L	Zond-4
	Я10723201	232-01	11F91 7L
	Я10723301	233-01	11F91 8L and М-69 522
1968	В10723401	234-01	11F91 9L	Zond-5
	В10723501	235-01	11F91 12L	Zond-6
		236-01	N-6	Proton-4
	В10723701	237-01	11F91 13L
	В10723801	238-01	E-8-5 402
	В10723901	239-01	E-8 201
	В10724001	240-01	М-69 521
1969	Ю10724101	241-01	E-8-5 404	Kosmos-305
	Ю10724201	242-01	E-8-5 401
	Ю10724301	243-01	11F91 11L	Zond-7
	Ю10724401	244-01	E-8-5 403	Kosmos-300
	Ю10724501	245-01	L1-E
		246-01	82EV LVE
	Ю10724701	247-01	E-8-5 405
		248-01	E-8-5 406	Luna-16
		249-01	М-71 172	Mars-3
		250-01	11F91 14L	Zond-8
		251-01	E-8 203	Luna-17
		252-01	L1-E	Kosmos-382
		253-01	М-71 170	Kosmos-419
	4922425401	254-01	17К 12101	Salyut
		255-01	М-71 171	Маrs-2
	4922425601	256-01	E-8-5 407	Luna-18
	5112425701	257-01	E-8LS 202	Luna-19

Platform	Period of initial launch complex operation	Overhaul period	Renewed launch complex operation	Launches before overhaul	Launches after overhaul to 31st August 2000 [2]	Launches after overhaul to 2001 [3]	Total launches as of 1st January 2000 [1]	Total to 31st August 2000 [2]	Total launches to 2001 [3]
23	1967-1979	1979-1989	1989-2004	32	59	63 64	89	91	95 96
24	1965-1978 or 1979?	1978-1999	April 1999 to date	35	4	5 4	36	39	40 39
39	1980 to date	No major overhaul					78	82	82
40	1977-1991	1991 - now dismantled		66			66	66	66
						Totals	269	278	283

Proton Serial	Date Of Launch	Issues
У10721101	24.03.1966	2nd stage engine failure. [Novosti Kosmonavtiki] 2nd stage engine failure at 122·85 seconds. Possible cause: destruction of engine chambers or discharge fuel lines of the second stage caused by external impact of the 1st stage. [ESA Document]
Н10722701	10.03.1967	208 reworks/223 discrepancies. [Encyclopedia Astronautica]
Н10722801	08.04.1967	70 reworks/194 discrepancies. [Encyclopedia Astronautica]
Я10722901	28.09.1967	Assembly completed in 71 days. 138 reworks/120 discrepancies. [Encyclopedia Astronautica] Ignition failure of engine 11Д43 number У233011 of side module G-1. Flight termination at 97·4 seconds. [Novosti Kosmonavtiki] Failure of engine number 1 to ignite at lift-off due to a low fuel flow in the pre-burner. Cause: ingestion of a rubber plug into the fuel pump high-pressure cavity. At 97·4 seconds the vehicle safety controller generated the 1st stage engine ECOC and initiated the payload escape system of the 7K-L1 spacecraft. The vehicle fell down 20-30 km off the launch pad. [ESA Document]
Я10723001	22.11.1967	Failure of 2nd stage 4th engine 8Д412K to reach norminal thrust due to the engine nozzle failure at 125·5 seconds. Vehicle destruction at 129·9 by command. [Novosti Kosmonavtiki] A malfunction of 1st stage tank draining system was observed since the moment of lift-off. It did not result in an accident. A slower shift to pre-nominal thrust was registered for engines No. 2 & 3 of the 2nd stage. The cause was improper selection of the engine start sequence. Engine No. 4 of the 2nd stage failed to accelerate to nominal thrust due to nozzle destruction at 125·5 seconds. The reason of the failure was a drastic pressure drop down stream of the nozzle at ignition of propellants beyond the nozzle section during engine ignition. At 130sec the LV safety controller initiated the 2nd stage ECOC and initiated the payload escape system of the 7K-L1 spacecraft. The vehicle fell down 110 km south-west of the town of Jezkazgan. [ESA Document]
В10723701	20.01.1969	Spontaneous shutdown of 2nd stage 4th engine 8Д411К at 313·66 seconds. Spontaneous shutdown of 3rd stage engine 8Д48 of the 8Д49 main block due to a failed pre-burner supply line at 500·03 seconds. [Novosti Kosmonavtiki] Uncontrolled cut-off of the 2nd stage 4th engine at 313·66 seconds. Cause: significant rotor imbalance and beating of the MTU bearings, to result in the MTU gas seal backlash being taken up and followed by MTU fire. The flight continued on three intact engines. At 338 seconds those engines were cut-off in accordance with the nominal flight sequence. An emergency main engine cut off of the 3rd stage occurred at 500·03 seconds due to a failure of the pre-burner fuel supply line. The vernier engine of the 3rd stage was cut-off at 595 seconds in accordance with the nominal flight sequence. [ESA Document]
В10724001	27.03.1969	Spontaneous shutdown of the 3rd stage engine 8Д48 of the 8Д49 main block. [Novosti Kosmonavtiki] At 438·66 seconds the 3rd stage MECO occurred due to MTU bearings imbalance and beating. [ESA Document]
Я10723301	02.04.1969	Failure of engine 11Д43 number Я233021 of the 1st stage side module G-2 at 0·02 seconds. The vehicle crashed in the vicinity of the launch pad. [Novosti Kosmonavtiki] Post lift-off failure of the 1st stage block number 2 engine at 0·02-0·03 seconds. Cause: lack of the hydraulic lock plug in the drain port of the oxidiser pump cover, ingress of the oxidiser gas to the drain port cavity and inflammation of the MTU pump shaft. At 30 seconds the vehicle fell down and exploded 1·5 km off the launch pad. [ESA Document] http://www.videocosmos.com/images/mars-69/2nd_mars-69_launch.jpg
Ю10724501	28.11.1969	Failure of 3rd stage engine 8Д48 at 556·5 seconds. Explosion in the area of the fuel tank lower bulkhead at 556·6 seconds. The 3rd stage and the payload compartment L1E disintegrated during re-entry to fall down 200 km north of Harbin (China). [Novosti Kosmonavtiki] Failure of the 3rd stage main engine due to insufficient vibration resistance of the engine fuel line. The vehicle and the 7K-L1E spacecraft fell down in China 200 km north of Harbin. [ESA Document]
Ю10724701	06.02.1970	Shutdown of the 2nd stage engine at 127 seconds by a false command from SBN. [Novosti Kosmonavtiki] The false command was induced by erroneous reading of an engine No. 2 sensor. The vehicle fell down 80 km south-west of the town of Dzhezkazgan. [ESA Document] After 128·3 seconds of flight, 1st stage engine cutoff due to false alarm from the LV safety system activated by the engine pressure gauge. Manufacturing defect. Additional check of gauges introduced at point of installation. [Proton Mission Planner’s Guide]
26001	29.07.1972	Vehicle disintegration at 180 seconds. [Novosti Kosmonavtiki] Emergency cut-off of the 2nd stage engines at 181·9 seconds by the vehicle safety controller due to vehicle instability caused by abnormal operation of the auto-stabiliser. The vehicle fell down 536km off the launch pad. [ESA Document] After 181·9 seconds of flight, 2nd stage automated stabilisation system failure due to a relay short circuit in the "pitch" and "yawing" channels caused by elastic deformation of the device housing (which operates in vacuum). Design defect. Design of instruments upgraded and additional testing undertaken. [Proton Mission Planner’s Guide]
28301	03.04.1973	Third stage exploded.
29301	05.08.1977	1st stage engine failure at 53·68 seconds. [Novosti Kosmonavtiki] Emergency MECO of the 1st stage engines at 53·68 seconds by the vehicle safety controller. The cause was a failure of block number 4 engine actuator due to a jammed slide valve. [ESA Document] After 40·13 seconds of flight, spontaneous deflection of 1st stage engine, loss of stability and engine cutoff at 53·68 seconds into the flight safety system command. Steering failure due to spool-and-sleeve pair manufacturing defect (faulty liner), which caused penetration of hard particles under liner rim and resulted in spool-and-sleeve seizure. [Proton Mission Planner’s Guide]
29402	27.05.1978	Launch termination at 119·51 seconds by SBN because of the vehicle attitude instability caused by an abnormal skew of the 1st stage engine 11Д43 of side module G-2. [Novosti Kosmonavtiki] The flight was terminated at 119·51 seconds by the safety controller due to the vehicle’s abnormal pitching and rolling caused by unauthorised gimballing of block number 2 engine. The vehicle fell down 600 km off the launch pad. [ESA Document] After 87 seconds of flight, loss of stability commenced due to error of 1st stage second combustion chamber steering gear. High temperature impact on cables due to heptyl leak into second block engine compartment. Leak likely developed at heptyl feed coupling to gas generator. Coupling upgraded. [Proton Mission Planner’s Guide]
29702	17.08.1978	2nd stage engine failure. [Novosti Kosmonavtiki] Failure of the 2nd stage engine at 242 seconds. The vehicle fell down 136 km south-east of Karaganda. [ESA Document] Flight terminated after 259·1 seconds due to loss of LV stability. Automatic stabilisation system electric circuit failure in rear compartment of 2nd stage caused by hot gases leaking from second engine gas inlet due to faulty sealing of pressure gauge. gauge attaching point upgraded. [Proton Mission Planner’s Guide]
29801	17.10.1978	Disintegration of the 2nd stage engine 8Д411K. [Novosti Kosmonavtiki] Failure of a 2nd stage engine at 236 seconds due to ingress of foreign particles (aluminium or steel), which caused in flammation of MTU components. The vehicle fell down 86 km south-east of Karaganda. [ESA Document] After 235·62 seconds of flight, 2nd stage engine shutoff and loss of stability caused by a turbine part igniting in turbo pump gas tract followed by gas inlet destruction and hot air ejection into 2nd rear section. Engine design upgraded. [Proton Mission Planner’s Guide]
30002	20.04.1979	Engines ignited then shutdown. [Encyclopedia Astronautica]
30702	23.07.1982	Failure of the 1st stage engine at 8 seconds. [Novosti Kosmonavtiki] Actuator failure in one of the 1st stage side blocks at 8 seconds. The vehicle fell down 55 km off the launch pad. [ESA Document] At 45·15 seconds into the flight, major malfunctioning of 1st stage engine fifth chamber. Flight terminated by LV safety system command. Failure caused by steering motor malfunctioning: first stage of hydraulic booster got out of balance coupled with booster dynamic excitation at resonance frequencies. Hydraulic booster design redefined. [Proton Mission Planner’s Guide]
31401	24.12.1982	Failure of the 2nd stage engine at 230 seconds. [Novosti Kosmonavtiki] Failure of the 2nd stage engine at 230 seconds. [ESA Document] 2nd stage engine failure caused by high-frequency vibrations. Engine design upgraded. [Proton Mission Planner’s Guide]
33801	29.11.1986	Failure of the 2nd stage engine caused by high-frequency vibrations. [Novosti Kosmonavtiki] Failure of the 2nd stage engine caused by high-frequency vibrations. [ESA Document] Control system failure due to brief relay contact separation caused by engine vibration. Upgrading included introduction of self-latching action capability for program power distributor shaft. [Proton Mission Planner’s Guide]
34102	18.01.1988	Failure of 3rd stage engine at 540 seconds. [Novosti Kosmonavtiki] Failure of 3rd stage engine at 540 seconds. [ESA Document] 3rd stage engine failure caused by destruction of fuel line leading to mixer. Unique manufacturing defect. Inventory rechecked. [Proton Mission Planner’s Guide]
34502	09.08.1990	Vehicle failure. [Novosti Kosmonavtiki] Emergency cut-off of the 3rd stage engine at 349 seconds due to the premature oxidiser depletion. The vehicle fell down in the Pacific in the area 25·7N and 161E. [ESA Document] 3rd stage engine shutoff due to termination of oxidiser supply. Fuel line clogged by a piece of textile (wiping rag). Remedial program introduced to prevent wiping rags from being left inside engine and LV. [Proton Mission Planner’s Guide]
36402	27.05.1993	A violation of the fuel storage life requirement resulted in an enhanced concentration of copper in the fuel to change the fuel heat expansion properties. This entailed an erroneous prediction of the 2nd stage fuel volume (the stage was not fully tanked). As a result, the payload failed to reach LEO. [Novosti Kosmonavtiki] Vehicle failure due to degraded fuel quality. A violation of the fuel storage life requirement resulted in an enhanced concentration of copper in the fuel to change the fuel heat expansion properties. This entailed an erroneous prediction of the 2nd stage fuel volume (the stage was not fully tanked). [ESA Document] 2nd and 3rd stage engine failures. Multiple engine combustion chamber burn-through caused by propellant contaminants. Remedial program introduced to modify propellant specifications and testing procedures. All launch site propellant storage, transfer, and handling equipment purged and cleaned. [Proton Mission Planner’s Guide] 27 мая 1993 г. у Протона № 36402 в полёте преждевременно остановился двигатель второй ступени, а затем при работе двигателя третьей ступени произошла аналогичная ситуация с ДУ-3. КА «Горизонт» не был выведен на нужную орбиту. Причиной этого оказалась некондиционность заправленного горючего - излишек содержания меди, что ухудшило охлаждающую способность гептила и привело к прогоранию охлаждаемых гептилом огневых стенок камер сгорания ДУ-2,-3 и, следовательно, к преждевременному расходованию горючего. Несколько лет после этого предприятие РНЦ ПХ пыталось создать штатные установки для проверки параметра фактической охлаждающей способности гептила перед заправкой по определённому критерию, но нехватка финансирования заставила найти другой способ. [Электронная Газета Гкнпц Им.М.В.Хруничева]
37801	14.12.1995	Of three redundant control channels in Proton vehicle control system, the first one failed at launch on 14th December 1995 and the second one in flight. Only the third channel helped the launch to succeed. The next Proton launch with Gorizont comsat in December was delayed to investigate the near-accident. [Novosti Kosmonavtiki]
38901	05.07.1999	2nd stage engine failure at 277 seconds [ESA Document] 2nd stage engine failure due to foreign particles in gas turbine pump. Implemented inspection of internal cavities of second and third stage engines, improved work processes and changed filter design in the ground portion of the fuelling system. [Proton Mission Planner’s Guide]
38602 4922122122	27.10.1999	2nd stage engine failure at 222 seconds. [ESA Document] 2nd stage engine failure due to foreign particles in gas turbine pump. Installed additional filters in the on-board portion of the fuelling system. Developed and implemented new design of the turbo pump unit with increased combustion resistance. [Proton Mission Planner’s Guide] At 221.96 seconds, off-the-nominal behaviour was recorded of the 8D411K engine ser. no. 5358161741 installed in Stabilisation Plane I of Stage II. This manifested itself in the unsealing of the engine’s exhaust duct followed by spontaneous shutdown of the remaining engines. The most likely cause of the failure of the Proton LV ser. no. 38602 on October 27, 1999 is the presence of metallic or mineral particulate matter inside the engine resulting in the ignition of the turbopump's engine assembly in Stage II engine #1 (P/N 8D411K, ser. no. 5358161741). The most likely cause for the particulate matter to find its way into the engine is poor workmanship at the Voronezh Mechanical Plant in 1992/93. []*
40402	15.02.2000	Oxidiser tank weld failure during pressure test. [Novosti Kosmonavtiki]
41010	29.03.2005	Разработка и реализация мероприятий в связи с аномальным поведением параметров рулевого блока РД-0214 двигателя РД-0213 №1208860552 III ступени РН «Протон-К» №410-10 30марта 2005 г. (самопроизвольные изменения режима рулевого блока из-за снижения расхода окислителя, поступающего из стабилизатора в оба газогенератора рулевого блока) Работы ведутся в соответствии с рекомендациями МВК по повышению динамической стабильности и защищенности стабилизатора при попадании частиц. [KBKhA 2005 Annual Report]
53513	29.12.2005	Разработка и реализация мероприятий а связи с имевшимся случаем самопроизвольного, скачкообразного снижения до 51% режима работы двигателя РД-0211 №5355365421 при пуске РН «Протон-М» №535-13. [KBKhA 2005 Annual Report]
53522	05.09.2007	LV stage 1/stage 2 stage separation failure. Burn-through of the LV stage 1/stage 2 separation pyrobolt actuation cable. Corrective action is to over-wrap the pyrobolt wiring harness by two layers of asbestos tape with 50% overlap. This increases the heat resistance to well over 400°C, the harness melting point. Additionally the ring and harness are jointly over-wrapped with two layers of tape with 50% overlap impregnated with glue, and the harness was re-routed away from the exhaust gas. [Proton Mission Planner’s Guide]

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