Launch News (FAILURE) Proton-M/Block-DM-03 launch with triple GLONASS-M, July 2, 2013

Urwumpe

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1200°C temperature in the engine compartment after a few seconds is more a sign of a turbopump fire (Fuel and oxidizer must mix and burn inside the compartment). From what i can read in Russian about the engines, there are also no such stupid checks. Once you get a lift-off indication, the hardware has only one duty: Deliver as much thrust as you can until shutdown, and only shutdown before that, if you are really in trouble. A slower reaction as usual would be no reason to stop an engine, but it would be noted. Before launch, such a slower reaction would be a reason to abort the launch.

Also, the engine did not shutdown - all engines had been running and emitting hot glowing exhaust, though this tells you little about the actual mass flow.
 

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4. For some reason the initialization of the emergency mode caused the system to command the launch table to release the rocket even when the rocket has not yet reached its nominal thrust level.

Interesting. I would have expected any emergency mode to command an immediate shut down on the pad rather than to release the rocket. It does sound like either an error in the process or the software.
 

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Apparently the rocket hit the ground about 1.4 km ESE from the pad at around 46°03'38''N, 62°59'43'' E, creating a 40 * 25 m hole with depth up to 5 meters, and a burnt out area of 4.9 hectares.

Source

Meanwhile there are various reports that residents within several dozen km of the crash site (Baikonur city and other settlements) are reporting quite a few cases of breathing difficulty and irritations over the past few days following the crash. :shifty:
 

Cosmic Penguin

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1200°C temperature in the engine compartment after a few seconds is more a sign of a turbopump fire (Fuel and oxidizer must mix and burn inside the compartment). From what i can read in Russian about the engines, there are also no such stupid checks. Once you get a lift-off indication, the hardware has only one duty: Deliver as much thrust as you can until shutdown, and only shutdown before that, if you are really in trouble. A slower reaction as usual would be no reason to stop an engine, but it would be noted. Before launch, such a slower reaction would be a reason to abort the launch.

Also, the engine did not shutdown - all engines had been running and emitting hot glowing exhaust, though this tells you little about the actual mass flow.

Roscosmos chief Popovkin has confirmed yesterday that the rocket did launch 0.4 seconds too early, while the rocket has yet to reach full thrust (the pressure in the combustion chamber of one of the 1st stage engines (#5) was only at 90 atm. instead of the usual 150 atm.). He also confirmed that something did went wrong when the engines should throttle up to full thrust, i.e. right when the "contact liftoff command" should have been issued.

Source: http://www.interfax.ru/news.asp?id=316788
 

Urwumpe

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Roscosmos chief Popovkin has confirmed yesterday that the rocket did launch 0.4 seconds too early, while the rocket has yet to reach full thrust (the pressure in the combustion chamber of one of the 1st stage engines (#5) was only at 90 atm. instead of the usual 150 atm.). He also confirmed that something did went wrong when the engines should throttle up to full thrust, i.e. right when the "contact liftoff command" should have been issued.

Source: http://www.interfax.ru/news.asp?id=316788

Yes, that is what we also deduced from the flight videos. There are quite a few possible reasons why this happened.

The question is: Did the early lift off cause the engine failure, or did the engine failure cause the early lift off? Two things going wrong at once is possible, but highly unlikely.

---------- Post added at 07:18 PM ---------- Previous post was at 05:51 PM ----------

Here is a rough translation of the engine start sequence (Russian-language readers should correct me, where ever I am wrong):

RD-253_flow_diagram_3.jpg


Running the engine

Motor starting

On the command "Start" the programmable power distribution unit is activated. After about 0.7 seconds the programmable power distribution unit (PTR) issues the command "Start DU". At this command voltage is distributed to the pyromembrane squibs of fuel valve (16) and oxidizer valve (18).

When triggered the squibs destroy the membranes of the pyromembrane valves (MVP). Under tank ullage pressure and the hydrostatic pressure of the column of fuel components begin filling the oxidizer and fuel main lines. Components of the fuel pump (12) and the second oxidizer pump stage of the oxidizer pump (14) flow into the gas generator (27) and ignite spontaneously. Oxidizer-rich exhaust flows to turbine rotor blades (30), this rotor starts spinning the turbopump unit and the gas flows further into the main combustion chamber (3).

Fuel from the first stage pump (13) is supplied to the collector of the combustion chamber and passes through cooling channels through the nozzle and is then injected into the main combustion chamber (KC) with some delay relative to the oxidizer-rich gas. A certain weight ratio of the components is provided through consumption-regulating orifices: (6) for fuel and (31) for oxidizer.

In the combustion chamber the components are mixed and ignited. Products of combustion at the end of the MCC (34) open a plug installed in the throat section of the MCC.

With increasing speed of the turbopump and growing pressures of the propellant components in the lines and the MCC, the engine is at preliminary stage of the operation. Preliminary stage thrust is controlled by the appropriate setting flow control valve (23) and the oxidizer control valve (35).

When the thrust of the engine is on preliminary stage the burst membrane units (4) and (20) open and begin pressurizing the propellant tank ullage spaces through the pressurant gas generator (5) and the oxidizer pressurization mixer (21). Nominal flows of propellant components entering the gas generator are provided by orifices (32) and (7) through the pyrovalve (33) and the fuel line to the pressurant gas generator. The oxidizer-rich exhaust gas and the oxidizer is fed into the oxidizer presurization mixer through the orifices (24) and (25).

Also, after the engine is operating at preliminary stage, two membranes are burst on the pipelines supplying high-pressure fuel to the TVC hydraulic system (15) and high pressure oxidizer (17) to the oxidizer bypass injector (19), respectively.

After 1.8 ± 0.44 seconds from the command "Start DU" the PTR commands the ГСТ (main stage). At this command, voltage is distributed to the squibs of the pyro-actuator check valve (23) and flow control valve (35). Oxidizer flow cross section and fuel flow control valve position increases, increasing the flow of fuel and oxidizer through the gas generator, which increases the turbine speed, fuel flow and fuel pressure. The engine is now on the main stage of the flight regime.

Source: http://lpre.de/energomash/RD-253/index.htm

Some corrections: COB had been a wrong translation, COB seems to refer to a control system in the drawing (it sets a throttle valve position for example), according to the text, the RKS controls thrust, while the COB controls mixture ratio.

---------- Post added 07-07-13 at 12:58 AM ---------- Previous post was 07-06-13 at 07:18 PM ----------

Found some explanation of what could have happened in the text:

The thrust controller and the mixture ratio controller are activated once the KC lift-off signal is activated, and the start-up logic is assumed completed. Since the signal happened, when the engine was not operating in main stage yet, there are some valves that are still commanded closed, especially the valve (22), that limits the maximum amount of oxidizer entering the gas generator.
 
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Oh, well.

Looks like the problem was that ours wanted to cheer the Americans on their independence day.
But we messed it up - it's 4th of July, not the 2nd, and the rocket is supposed to explode in the air, not on the ground!


:erhm: [ame="http://www.youtube.com/watch?v=COiw-1_Zzpo"]Proton Launch Done Right! - YouTube[/ame]
 

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Next Proton payload put in storage during failure probe (ASTRA 2E)

[FONT=VERDANA, ARIAL, HELVETICA, SANS-SERIF][SIZE=+2]Next Proton payload put in storage during failure probe[/SIZE][/FONT]
[FONT=VERDANA, ARIAL, HELVETICA, SANS-SERIF][SIZE=-2]
BY SPACEFLIGHT NOW

Posted: July 9, 2013

[/SIZE][/FONT]
spacer.gif

A European television satellite that was scheduled to ride a Russian Proton rocket into orbit later this month has been placed into an extended storage mode, its launch date now unknown in the wake of the disastrous liftoff and crash of a similar booster last week.

astra2e.jpg

[FONT=Verdana, Arial, Helvetica, sans-serif][SIZE=-3]Mission poster for ASTRA 2E launch. Credit: ILS[/SIZE][/FONT]

International Launch Services, the U.S.-based commercial marketer of the Proton, announced Monday that the ASTRA 2E spacecraft, which had not yet been fueled, would be stored at Baikonur Cosmodrome and the team of engineers handling the mission already sent home while the investigation plays out.

A government Proton topped with a triplet of navigation satellites blasted off July 2 (local time), immediately went out of control and smashed into ground a short distance from the pad. (See earlier story)

ILS said the launch complex was not damaged in the mishap and there were no reports of injuries in the frightening crash.

"The Russian State Commission has been established and will be investigating the potential causes of the failure. Flight and ground telemetry was transferred to Moscow and is being reviewed by subject matter experts. As this mission failed very early in flight, the investigation is concentrating on the pre-launch sequence and early flight telemetry data," ILS said in its statement Monday.

"There are many rumors and much speculation on the internet and through other sources, and you may have your own thoughts and questions as well. The Russian State Commission will complete their work and release their findings in due time."

Once the State Commission announces its findings, ILS will initiate its own Failure Review Oversight Board, or FROB, to review the report and corrective action plan. The FROB will be comprised of representatives from ILS customers, insurance underwriters and technical experts from the industry.

"Since the Russian State Commission is still in progress, we cannot reliably estimate the timing of the FROB, but based on experience, we estimate that it would not start until late July at the earliest," ILS said.

"The schedule for the return to flight and subsequent missions will be determined once the Russian State Commission and ILS FROB completes their efforts and the required corrective actions have been implemented."

ASTRA 2E had been slated for launch July 21.

Headed for geostationary orbit, the spacecraft will be used by global satellite operator SES of Luxembourg for direct-to-home television and broadband services to Europe, the Middle East and Africa from an orbital slot 28.2 degrees East.

Built for SES by Astrium of France using the Eurostar E3000 platform, the spacecraft carries 60 Ku-band and three wideband Ka-band transponders. It has a 15-year design life.

SES has flown 22 previous times with ILS Proton. The firm has 53 satellites in orbit today in a fleet that covers over 99 percent of the world's population.

"Our number one priority at ILS is safety, and we are pleased to report that all personnel associated with the ASTRA 2E campaign were a safe distance away at the ILS safety area, and are all safe. Additionally, we have been told that there were no injuries or casualties to Russian or Kazakh personnel," Monday's statement said.

"The ASTRA 2E spacecraft is safe and has been configured for short term storage. The spacecraft has not been fueled."

The flight is scheduled to be the fifth ILS Proton of the year, the 82nd since 1996 and the 17th with an Astrium-built payload.
 

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So... According to the info leaks on NK forum, a whole assembly of angular velocity sensors and attitude angle transducers was simply installed upside down on this unhappy rocket, and that is what was clearly seen in the wreck pieces...

How that was possible to do and escaped quality checks, is yet to be seen.

The sensors are really designed in a symmetrical shape and can theoretically be installed a wrong way:
http://www.zavod-zvezda.ru/produkciya.html

Rumors are, the guy who was doing the assembling, only worked for 2 months on the plant.
 
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DaveS

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So... According to the info leaks on NK forum, a whole assembly of angular velocity sensors and attitude angle transducers was simply installed upside down on this unhappy rocket, and that is what was clearly seen in the wreck pieces...

How that was possible to do and escaped quality checks, is yet to be seen.
Has happened before on NASA's Genesis Sample Return Capsule and this was the result:

 

Urwumpe

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If the sensors are installed 60°-90° around, this would already explain the flight behavior.

But usually, you would notice that the sensors are not reporting proper values before launch, when the guidance platform is aligned.
 

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Hi Alex, happy to see you there again, 'was a long time :cheers:
 

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So apparently Khrunichev et al. bumped into the infamous Murphy's Law..... :huh:

The late historical engineer Murphy — whose presence, or at least influence, is sorely missed today — uttered his original observation in connection with one of the gut-wrenching rocket-sled tests in the 1950s. Such tests subjected equipment, and eventually a human volunteer, to peak forces of 50 G's or more. After one run in which the test subject, Dr. John Stapp, nearly had his eyes torn out of their sockets by the shock, Murphy had to break the news that there were no force measurements because the sled’s sensors had been mounted backward. The whole eyeball-popping test would have to be done over again.
 

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Looks like my uncle's opinion turned out right after all.
My uncle, who worked on Baikonur until retirement a few year ago says that these days the people working there are "educationless order-following dumbbell-heads, who have no clue about the big idea".
So the extra fuel on that one launch, so the trash in the plumbing on the other launch, so the whatever on this launch.
 

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Right, so with sensors inverted, the rocket computer attempted to stabilize the vehicle in a perfect nose-down trajectory. And it almost succeeded. :blink:
 

Urwumpe

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Right, so with sensors inverted, the rocket computer attempted to stabilize the vehicle in a perfect nose-down trajectory. And it almost succeeded. :blink:

It more looks like some rate gyros had not been installed orthogonal to the others, since there was a spinning out of control.

But it does still not explain the early launch.
 
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