Author Topic: FAILURE: Sea Launch - Intelsat 27 - February 1, 2013 (0656UTC)  (Read 169203 times)

Offline awbyrdjr

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I trying to picture in my mind, just now, this failure mode finally cropping up just after liftoff of the 20th or so Energia/Buran.  Would this have been the Soviet's "o-ring"?

 - Ed Kyle

I would imagine such a failure on Energia would have been significantly more benign than the o-ring failure on 51-L, if it could have happened at all.  It was mentioned earlier in the thread, though I don't know with what authority, that the BIM turbopump in question is a Zenit-only device that was not used on Energia.  Further, a 2006 thread suggests that the loss of a single booster on Buran would result in an abort-once-around, though I don't know in what phase of flight.  Not a fun day for those involved, but not a LOCV either.

http://forum.nasaspaceflight.com/index.php?topic=2560.0

Offline Jim

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I trying to picture in my mind, just now, this failure mode finally cropping up just after liftoff of the 20th or so Energia/Buran.  Would this have been the Soviet's "o-ring"?

 - Ed Kyle

There are 3 other boosters and the core that could handle the steering.  The booster was still producing thrust.
« Last Edit: 02/07/2013 06:14 pm by Jim »

Offline R7

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Would this have been the Soviet's "o-ring"?

 - Ed Kyle

<propeller hat on>

With all four boosters thrusting nominally and 3/4 still doing TVC properly it might have had a fighting chance for ATO or even better. RD-170 gimbaled only in one axis, how are they oriented, is there redundancy?

</propeller hat on>

Quote
Not a fun day for those involved, but not a LOCV either.

this

Gaaah, Jim beat me to it while I was writing, gotta add something seemingly insightful now: the propeller section applies only if engine with failed TVC doesn't wobble uncontrollably.
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Offline russianhalo117

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pointing the obvious (and speculating): static hotfirings won't reveal the issue if it's root cause is related to the dynamics of actually releasing the vehicle.

The BIM was OK at T-0, was it not, otherwise launch would have been cancelled.
It was fine until it failed to nominally switch completely over to RP-1 (RG-1) and used up the remaining first stage high-pressure helium gas which is used to spin up and start BIM power generation. This resulted in the gradual deceleration of the BIM turbo-pump and increasing loss of TVC and power generation after liftoff.

In essence, that switchover isn't tested before launch commit, correct?  Doesn't that seem like a design flaw?

Seems to me it's more of a pre-launch-commit-testing flaw.  If the switchover occurred prior to T-0, and was not successful, the launch could be halted.  "Timing is everything."
Yes.
Currently, BIM requires an actual flight engine and stage to be tested. AFAIK, BIM would have to be replaced (or certain elements within it) after any testing or abort and would have to be returned home for that work. Not exactly with the BIM in that the process is started at T-10s via ground side helium to start to spin up the BIM then when it reaches a certain RPM and then it switches over to stage one GHe supply around T-3s and then starts switching over RP-1 at T-0 and switches completely when RD-171M commits to flight and lifts off. So in the final steps of the switching process the only real option is launch and abort downrange into the ocean/nearby land so that the pad isn't destroyed.
That is what I understand about the BIM when RD-171M commits to flight liftoff.

Offline owais.usmani

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http://www.vedomosti.ru/companies/news/8867321/rkk_energiya_zayavila_chto_ne_otkazhetsya_ot_morskogo_starta

Quote
However, interest in the acquisition of exclusive floating cosmodrome already showing foreign customers. As the " RIA Novosti "a source close to the negotiations, already at least two organizations, one of which - the largest American space rocket corporation Lockheed Martin, have expressed interest in discussing the possibility of buying a " Sea Launch "at the RSC " Energia ".

Offline Targeteer

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pointing the obvious (and speculating): static hotfirings won't reveal the issue if it's root cause is related to the dynamics of actually releasing the vehicle.

The BIM was OK at T-0, was it not, otherwise launch would have been cancelled.
It was fine until it failed to nominally switch completely over to RP-1 (RG-1) and used up the remaining first stage high-pressure helium gas which is used to spin up and start BIM power generation. This resulted in the gradual deceleration of the BIM turbo-pump and increasing loss of TVC and power generation after liftoff.

In essence, that switchover isn't tested before launch commit, correct?  Doesn't that seem like a design flaw?

Seems to me it's more of a pre-launch-commit-testing flaw.  If the switchover occurred prior to T-0, and was not successful, the launch could be halted.  "Timing is everything."
Yes.
Currently, BIM requires an actual flight engine and stage to be tested. AFAIK, BIM would have to be replaced (or certain elements within it) after any testing or abort and would have to be returned home for that work. Not exactly with the BIM in that the process is started at T-10s via ground side helium to start to spin up the BIM then when it reaches a certain RPM and then it switches over to stage one GHe supply around T-3s and then starts switching over RP-1 at T-0 and switches completely when RD-171M commits to flight and lifts off. So in the final steps of the switching process the only real option is launch and abort downrange into the ocean/nearby land so that the pad isn't destroyed.
That is what I understand about the BIM when RD-171M commits to flight liftoff.

Probably a simple--and maybe dumb--question but does the BIM burn RP-1 or just use it a flowing fluid?
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Offline strangequark

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Probably a simple--and maybe dumb--question but does the BIM burn RP-1 or just use it a flowing fluid?

It just uses it as a working fluid.

Offline anik

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Odyssey platform returned to Long Beach.
« Last Edit: 02/17/2013 05:32 am by anik »

Offline Galactic Penguin SST

Odyssey platform returned to Long Beach.

I assume that the control ship has already been back for some time already?
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Offline anik

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I assume that the control ship has already been back for some time already?

Yes, I think the Sea Launch Commander has returned nine days after Intelsat 27 launch.

Offline owais.usmani

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Roscosmos comes to sea launch rescue:

http://ria.ru/science/20130226/924699372.html
« Last Edit: 02/26/2013 11:53 am by owais.usmani »

Offline Targeteer

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Update via Facebook

Sea Launch
On February 22, 2013, ELUS received a status report from the Ukrainian failure investigation commission, comprised of senior representatives of Yuzhnoye SDO, designer of the two-stage Zenit-2S launch vehicle, Yuzhmash, the Zenit-2S manufacturer, and the National Space Agency of Ukraine (NKAU). The report demonstrates that the Commission is making progress in the ongoing effort to identify the root cause of the SL-48 failure. The investigation continues to focus on anomalous performance of the hydraulic power supply (BIM) for the 1st stage main engine thrust vector control system. A limited set of possible causes has been established by the Commission along with identified tests and analysis to support or refute each of the candidate causes, and thereby isolate and substantiate the most probable root cause. The commission is working to a defined schedule for completion of all the required tests and analysis and issuance of a final report in early April
Best quote heard during an inspection, "I was unaware that I was the only one who was aware."

Offline anik

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Addition from http://www.sea-launch.com/missions-q11349-Failure_Review_Oversight_Board.aspx

ELUS has identified technical consultants to support the FROB review, who encompass broad knowledge and extensive experience with launch vehicle technical and program matters (including prior Sea Launch experience), as well as subject matter expertise. 

The SL-48 failure investigation Technical Assistance Agreement (TAA) has been approved by the US Government and is currently in the signature cycle with the TAA parties.

Based on the Ukrainian commission’s schedule of events, and assuming timely completion of the necessary export compliance efforts, a FROB meeting with the Zenit-2S investigators is tentatively planned for the second half of April.  In addition, per standard Sea Launch investigation procedure, the FROB will also review all other segments of the Sea Launch system during the SL-48 mission to verify nominal performance and ensure that there were no other contributors to the failure.

Offline Danderman

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Although the main engine gimbaling system failed early in this flight, does the RD-171 engine also use turbopump exhaust for steering or roll control?

Offline yinzer

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What turbopump exhaust?
California 2008 - taking rights from people and giving rights to chickens.

Offline Jim

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Although the main engine gimbaling system failed early in this flight, does the RD-171 engine also use turbopump exhaust for steering or roll control?


It is a closed cycle engine and there are four nozzles which negate the need for auxiliary roll control. 

Offline Danderman

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Sorry, forgot it was closed cycle!

Offline Galactic Penguin SST

Well it seems that the current leading theory (as told at NK) is that the hydraulic turbopump was blocked by something in the order of 2 cm diameter (probably a loose bolt), which was crushed at start up and either destroying the turbopump blades or damaging the turbine bearing / drive shaft.  :P

Sounds like the similar story of the Ariane 4 with a left cloth in one of the first stage engines......
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Online jcm

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Addition from http://www.sea-launch.com/missions-q11349-Failure_Review_Oversight_Board.aspx

ELUS has identified technical consultants to support the FROB review, who encompass broad knowledge and extensive experience with launch vehicle technical and program matters (including prior Sea Launch experience), as well as subject matter expertise. 

The SL-48 failure investigation Technical Assistance Agreement (TAA) has been approved by the US Government and is currently in the signature cycle with the TAA parties.

Based on the Ukrainian commission’s schedule of events, and assuming timely completion of the necessary export compliance efforts, a FROB meeting with the Zenit-2S investigators is tentatively planned for the second half of April.  In addition, per standard Sea Launch investigation procedure, the FROB will also review all other segments of the Sea Launch system during the SL-48 mission to verify nominal performance and ensure that there were no other contributors to the failure.

If SL-48 is the Zenit-2S serial, that's quite a jump out of sequence
(was expecting SL-36)
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Offline anik

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If SL-48 is the Zenit-2S serial, that's quite a jump out of sequence (was expecting SL-36)

http://forum.nasaspaceflight.com/index.php?topic=30213.msg1008275#msg1008275

SL-48 is probably a name of Sea Launch mission.
« Last Edit: 03/18/2013 07:16 am by anik »

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