Energia s. P. Korolev Rocket and Space Corporation Energia

Advanced Crew Transportation System (ACTS)

The new-generation Advanced Crew Transportation System is a Manned Space Complex for carrying out missions to low-Earth orbit and beyond, including missions to the Moon, and has as one of its constituent parts a Manned Transportation Spacecraft with a base element – a Re-entry (Descent) Vehicle, which provides safe return of the crew to Earth.

In accordance with the government contract for the project “Development of the New-Generation Crew Transportation Complex” (so far as it relates to work of 2013 – 2015) with designation: ACTS R&D (Phase 1) work has been conducted on:

• 
  development of the working documentation, manufacturing of mockups and prototypes of the crew transportation spacecraft system.
  
• 
  constructing a layout mockup of the crew transportation spacecraft;
  
• 
  manufacturing structural elements and shells of the crew transportation spacecraft;
  
• 
  Manufacturing elements of the crew transportation spacecraft.
  

In November 2014, the work was delivered for the milestone Manufacturing a Layout Mockup of the First Phase Crew Transportation Spacecraft. Within the framework of this milestone a layout mockup of the First-Phase Crew Transportation Spacecraft.

The layout mockup of the re-entry vehicle of the crew transportation spacecraft was used to conduct tests in order to experimentally evaluate acoustic properties of the volume and the interior of the command compartment, to evaluate crew control panels from the standpoint of human engineering, to try out the procedure for abandoning the spacecraft in case of an emergency landing. A number of experiments have been conducted at subcontractor organizations to develop components of the crew transportation spacecraft, as well as studies of the aerodynamic properties.

It should be noted that within the framework of the government contract, a transition to the Russian-made electronic components and materials is under way.
Overall view of the manned transportation spacecraft

Launch vehicles

Major areas of activities are:

• 
  support for prelaunch processing and launch of Block DM-type upper stages
  
• 
  support for preparing launch services contracts;
  
• 
  author’s supervision of manufacturing and tests of systems, assemblies and upper stages at the subcontractors’ and at ZAO ZEM of RSC Energia;
  
• 
  analytical integration and adaptation of upper stage systems for launching spacecraft for various purposes;
  
• 
  improving mass properties and performance of the upper stage;
  
• 
  upgrading and standardizing the upper stages design;
  
• 
  conducting R&D on advanced launch vehicles.
  

Developed and published over the period under review are more than 110 project design documents, including:

• 
  Technical proposal “Super-Heavy Space Rocket System at Vostochny Launch Site” (Fig.1).
  
• 
  Engineering note “Oxygen/Kerosene Upper Stage ML for Medium Launch Vehicle Soyuz-2 (Fig.2);
  
• 
  Scientific and technical report “Upper Stage of the SOAR System”;
  
• 
  Engineering designs for upper stages 14С48 and 14С49 (Figures 3 and 4);
  

Proposals on the LV development phases

• 
  Development of the stack of the LV stages and the upper stage
  
• 
  Manned circumlunar mission
  
• 
  launches in 2025-2028
  

• 
  Delivery of a lander to the Moon surface in 2029.
  
• 
  Manned expedition to lunar surface in 2030.
  

Fig. 1

• 
  Flight developmental testing of a rocket stage
  
• 
  Beginning of flight tests with a mockup of the crew transportation vehicle
  
• 
  Development of the crew transportation vehicle for low-Earth orbit missions
  

LV Energia -5KI

LV Energia -5KV

Launch mass, metric tons

LV Energia-1K

Payload capacity (Нcirc=200 km, i=51.7)

Upper stages developed by RSC Energia

Layout and engineering data for upper stage ML

Fig. 2

Loading pattern

Load-bearing monoblock

Truss


Main engine

O tank


Low-thrust thruster unit

Intertank bay


Propellant components for main engine and thrusters

• 
  oxidizer
  
• 
  fuel
  

11D58MF

11D58MF


Liquid oxygen

RG-1/ synthene

Up to 6200

F tank


Propellant load, kg

Support bay


Minimal propellant supply for the last burn of the main engine

Thrus-ters



Final mass of the upper stage, kg
including

• 
  residual propellant and gases, kg
  

ME 11D58MF


Upper stages developed by RSC Energia

Layout and engineering data for upper stage 14S48


Instrumentation truss

• 
  Propellant components:
  
  • 
    oxidizer Liquid oxygen
    
  • 
    fuel Naphthyl (Synthene)
    
• 
  Main engine 11D68M
  
  • 
    thrust in vacuum, kgf 8100
    
  • 
    specific impulse kgf s/kg
    

• 
  Lox + Naphthyl 363
  
• 
  Lox + Synthene 361
  

• 
  Propellant load, kg up to 18900
  
• 
  Dry mass of the upper stage, kg 3240
  

Including:

• 
  middle adapter mass 700
  
• 
  removable compartment mass 260
  
• 
  lower adapter mass 290
  

СМ

Fig. 3

O tank


Middle

Removable


compartment

adapter

F tank

Lower

adapter

ME 11D58M



Upper stages developed by RSC Energia

Layout and engineering data for upper stage 14S49


Instrumentation


truss

• 
  Main engine 11D58MF
  
  • 
    thrust in vacuum, kgf 5000
    
  • 
    specific impulse, kgf s/kg
    

• 
  Lox + Naphthyl 372
  

• 
  Propellant components for the main engine and Onboard Propulsion Unit (OPU):
  
  • 
    oxidizer Liquid oxygen
    
  • 
    fuel Naphthyl
    
• 
  Propellant load, kg up to 18900
  
• 
  Dry mass of the upper stage, kg 3140
  

Including:

• 
  middle adapter mass 700
  
• 
  removable compartment mass 260
  
• 
  lower adapter mass 290
  

Fig. 4

O tank

Removable

compartment


Middle

adapter

F tank

Lower

adapter

OPU

ME 11D58MF

Spacecraft have been launched using Upper Stages (US) of the Block DM type.

A contract has been singed between a Swiss company Swiss Space Systems Holding S.A. and RSC Energia to validate key technical characteristics and determine the technical feasibility of the upper stage of the SOAR system. Based on the results of the study a scientific and technical report “Upper Stage of the SOAR System” was published.


In 2014, work on the projects "Persei-KV” and “Dvina-DM” continued.

On the project “Persei-KV”, technical design for the complex 14K45 has been updated.

On the “Dvina-DM” R&D effort, development of design documentation for the upper stage has begun. A list of experimental models has been defined, requirements were issued for an upgraded control system for the upper stage.

Sea Launch space launching system

March 28, 2014, was the 15^th anniversary of the first launch from the space rocket complex Sea Launch. Over these 15 years, the launch platform launched from the equator more than 36 spacecraft.

Preservation and evolutionary development of LV and upper stage DM-SL technologies, including those of propulsion, navigation and control systems, made it possible to achieve unique precision of spacecraft insertion into their target orbits.

After restructuring of the Sea Launch company in 2011, RSC Energia is responsible for system management of the Sea Launch complex, integrated operations planning, is the prime company for the Rocket Segment, supports manufacturing and operation of upper stages DM-SL as the third stage of Zenit-3SL ILV, as well as supervises work done by other partners and subcontractors.

In response to an accident which occurred during launch in 2013, corrective measures were initiated at the Sea Launch complex to restore its launching activities, which were completed by February 2014.

In accordance with the Eutelsat 3B mission preparation plan, 2014 saw continuation and successful completion of analytical integration to adapt the upper stage DM-SL No.36L and launch vehicle Zenit-2S to the requirements for the insertion of SC Eutelsat 3B into its target orbit, the publication of the final Interface Control Document (ICD) between the payload unit and the ILV Zenit-3SL. After conceptual designs for the upper stage, integrated launch vehicle and payload module were developed, the final Mission Design Document (MDD) was developed and published. ILV flight simulation has been conducted, the flight task has been approved. Annual maintenance-2014 of the Rocket Segment ground equipment was completed. The results were analyzed and presented in the technical report on the results of the Annual Maintenance-2014. The completed work resulted in assuring and verifying the operational status of the rocket segment.

ILV Zenit-3SL carrying Eutelsat ЗB spacecraft was launched on May 26, 2014 at 21:09:59 GMT (May 27 2014 at 01:09:59 Moscow Time). Spacecraft Eutelsat ЗB was put into its final geotransfer orbit with high accuracy.

In 2014, regardless of successful launch of Eutelsat 3B on May 26, 2014, there arose some constraints on the use of the Sea Launch system for its intended purpose, which had to do with the lack of orders for launch services in connection with the complex geopolitical situation in the Ukraine.

Based on the above, in accordance with the adopted decision, the Sea Launch system has been deactivated since July 2014. At present, the Home Port equipment and facilities are kept under controlled storage, and conditions are maintained that are needed for an eventual return of the Sea Launch system to launch operations.

Land Launch space launching system

There were no orders for launch services in the year under review. Under contract with FGUP TsENKI, the Corporation performed work to support manufacturing of components and the upper stage 452GK as a whole. At present its assembly is under way at ZAO ZEM of RSC Energia.

Flight operation and tests of rocket and space systems

In the field of rocket and space systems flight operation and testing, the following work was performed in 2014:

• 
  ISS RS flight operations support during Expeditions ISS-38,
  ISS-39, ISS-40, ISS-41, ISS-42.
  
• 
  Controlling missions of the six upgraded manned transportation spacecraft Soyuz TMA-M and six cargo spacecraft Progress M-M.
  
• 
  Support for work with the European cargo spacecraft ATV-5.
  
• 
  ISS RS mission control during operations with US spacecraft Dragon (Space X-4, Space X-5) and Cygnus (Orb-2), as well as with the Japanese logistics spacecraft HTV-4.
  
• 
  Support for crew operations during four extravehicular activities performed from ISS RS and three EVAs performed from USOS.
  
• 
  Support for the ISS RS systems upgrade operations and maintaining the station in good working order.
  
• 
  Conducting Radar-Progress experiments onboard cargo spacecraft Progress M-M and Izgib experiment onboard Progress M-20M.
  
• 
  Supporting development of equipment and methods for providing life support, maintaining the ISS crew health and fitness to work.
  
• 
  Support for the tests of the new rendezvous equipment Kurs-NA during the flight of cargo spacecraft Progress M-21M, and conducting its docking on the ISS RS using this equipment.
  
• 
  Supporting the operation and upgrading of the ground automatic control system, including the operation of optical communication channels, to expand its functionality and extend its life.
  
• 
  Support for theoretical and practical training of the ISS crews and the personnel of the Lead Operations Control Team.
  
• 
  Support for creating, upgrading and maintaining training facilities for the crew and control personnel;
  
• 
  Coordination of work done by rocket-and-space industry organizations in order to ensure that the ISS RS flight tests are conducted to a high standard of quality.
  
• 
  Performing work to correct anomalies occurring in flight operation of the orbital constellation of Yamal-200 communication satellites, and organizing real-time engineering support for the flight operation of the constellation.
  
• 
  Preparing and controlling the flight of an upper stage.
  

This work produced the following results:

• 
  The ISS mission plan goals were achieved and the Federal Space Agency obligations to its international partners were met.
  
• 
  Reliability of the ISS RS onboard systems was improved, functionality of Ground Automated Control System was expanded, its life was extended and reliability, stability and flexibility of the mission control system in 24-hour operational mode were achieved.
  
• 
  Engineering support for the mission of communication satellites belonging to the Yamal-200 orbital constellation was provided.
  

Unmanned space complexes and systems

The activities in this area include:

• 
  development of space systems for communications and Earth Remote Sensing;
  
• 
  research spacecraft;
  
• 
  development of aerospace vehicles;
  
• 
  spacecraft mission control;
  
• 
  design and delivery of spacecraft assembly and testing centers;
  
• 
  payload data processing.
  

2014 saw the completion of the cycle of ground developmental testing on a high-resolution optical-electronic observation spacecraft. The spacecraft was launched on April 16, 2014. During the period from April to December 2014, flight and demo tests of the spacecraft were conducted together with the ground segment facilities. On January 6, 2015 the space system was accepted into service.


The launch of the spacecraft The spacecraft
In 2014, in this area of activities, work was performed on the ground developmental testing of a communications spacecraft for a high elliptical orbit, which is to be launched in October 2015. A battery of electrical and radio engineering tests were run, along with thermal vacuum tests and transportability tests.

In the year under review work continued to develop the working documentation on an experimental system for personal satellite communications.

In the course of work on the communications spacecraft RSC Energia initiated work under the program of replacement of electronic components made abroad with similar components made in Russia.

In the second quarter of 2014 preliminary design studies were completed on a communications and broadcasting space system developed in the interest of a foreign customer. RSC Energia and its subcontractors proceeded with the development of the working documentation. Contracts have been concluded for the deliveries of the onboard transponder and antenna and feeder devices.

A program for additional training of RSC Energia specialists is being implemented together with FGUP Kosmicheskaya Svyaz and Airbus DS.

2014 saw resumption of precontract work with the JSC Gazprom Space Systems on the development of the new-generation Yamal-series communications spacecraft, as well as optical-electronic spacecraft of the Smotr series.

In the year under review, work continued on the design of unmanned monitoring spacecraft for high-elliptical and geostationary orbits, spacecraft for observation of asteroids and comets.

Tentative design studies have been initiated in the field of aerospace vehicles.

The use of space technologies in terrestrial applications

Prosthetics aids

In 2014, the most important line of work in the field of prosthetics aids remained the work which was defined in the government contract dated May 22, 2013 for an R&D effort “Development of Technologies for and Setting up Production of Electromechanical Hand with Three Types of Active Movements”, concluded with the Ministry of Industry and Trade of Russia within the framework of the federal special program “Development of the Pharmaceutical and Medical Industries of the Russian Federation for the Period of up to 2020 and Beyond”.

Developed in 2014 were:

• 
  a technical design defining key engineering specifications of the electromechanical hand; description of the structure was provided; manufacturability assessment was conducted, as well as a kinematic and force analyses of the mechanisms, and analyses verifying performance ability, reliability and strength;
  
• 
  design documentation for manufacturing mockups and prototypes of the electromechanical hand. Taken into account during development of the design documentation for the prototypes were concerns raised in the course of work on manufacture and testing of breadboard models of the hand;
  
• 
  Program and procedure for testing the hand prototype.
  

5 breadboard models have been built and tests were run to check their functional performance, acoustic noise, electromagnetic compatibility, strength.

Technical documentation was developed for manufacturing parts for final assembly and for assembly of prototypes of the hand; 10 prototypes of the hand were built.

Funded with the Corporation’s investments, work was conducted to develop design documentation and build a pilot prototype of the system for controlling an artificial forearm, and also work was initiated to prepare and outfit the testing and serial production facilities for the electromechanical hand.

The work to develop the electromechanical hand with three types of active movements will also continue in 2015.

Since July 2014, the pilot batch of the upper limb prosthesis modules hardware manufactured earlier within the framework of the Corporation investment program has been on sale. The upper limb prosthesis modules sales over the period of 2014 amount to 262 thousand roubles.

Work continued on providing prosthetic and orthopedic companies with operational and manufacturing documentation.

In 2014 the sales of prosthetic and orthopedic products amounted to 45.98 million rubles, among which the products developed and manufactured by RSC Energia amounted to 30.8 million rubles.

Hydrogen technologies

In 2014 the Corporation performed the following work ordered by the Keldysh Research Center:

• 
  Operating algorithms for a solid-polymer electrolyte unit were developed.
  
• 
  The algorithms were verified in experiments.
  
• 
  A regenerative battery operating in both “fuel” and “electrolyte” modes was built and tested.
  
• 
  Developed and verified in experiments were 3 procedures for drying the gas diffusion layers of the battery prior to starting operation in the “fuel” mode.
  

The following work has been accomplished in 2014 under the Energetika-Energia R&D project:

• 
  A review of scientific and technical information on the development of closed electrochemical systems with hydrogen cycle was conducted;
  
• 
  The feasibility of crating an accumulator for space applications was proven through analysis and experiments;
  
• 
  Procedure was developed for calculating specific energy of the accumulator though the specific characteristics of the constituent units;
  
• 
  Engineering solutions were identified to support creation of closed electrochemical systems with hydrogen cycle;
  
• 
  Patent research was conducted on the subject of creation of closed electrochemical systems with hydrogen cycle for space applications.
  

The work to prepare the space experiment “Separatsia”.

The objective of the Space Experiment (SE) is to set up a facility for studying in microgravity the processes of gas and liquid separation from fine gas-liquid medium in hydraulic loops of power units with electrochemical generators.

The following work has been accomplished in 2014:

• 
  A technical resolution was published on the subject of conducting the “Separatsia” SE onboard the ISS RS.
  
• 
  A general schedule on preparation for and conduct of the “Separatsia” SE;
  
• 
  The outline drawing of the Electrolysis Installation (EI) was developed.
  
• 
  Protocols of electrical interfaces between the EI and the separation device was published.
  
• 
  Separation device was built.
  

International activities of the Corporation

Space launches	Qty.
ISS
Soyuz-type spacecraft	4
Progress-type spacecraft	4
ATV	1
Sea Launch	1
ERS SC	1
Total	11

11 space launches were successfully carried out in 2014 within the framework of international programs.

Working onboard the ISS as members of the crew were nine foreign citizens, including six citizens of USA and one citizen from Japan, Italy and Germany each. Four expedition crews were delivered to the ISS and brought back to Earth onboard Soyuz spacecraft.

Before the launch of ISS 42/43 International crew


Soyuz and Progress spacecraft delivered to orbit and returned to Earth both Russian and foreign cargoes. Cargoes with the total mass of about 200 kg were returned to Earth onboard Soyuz spacecraft, the waste was disposed of on Progress spacecraft.
International crews that worked onboard the ISS in 2014

Space craft #	Crew #	Spacecraft launch/landing date	The spacecraft crew	Picture
Soyuz TMA-10M	ISS-37/38	09.26.2013/ 03.11.2014	Kotov, Oleg Valerievich
			Ryazansky, Sergei Nikolaevich
			Michael Hopkins (USA)
Soyuz TMA-11M	ISS-37/38/39	11.07.2013/ 05.14.2014	Tyurin, Mikhail Vladislavovich
			Mastracchio, Richard (USA)
			Wakata, Koichi (Japan)
Soyuz TMA-12M	ISS-39/40	03.26.2014/ 09.11.2014	Skvortsov, Alexander Alexandrovich
			Artemiev, Oleg Germanovich
			Steven Swanson (USA)
Soyuz TMA-13M	ISS-40/41	05.28.2014/ 11.10.2014	Suraev, Maxim Viktorovich
			Wiseman, Gregory (USA)
			Gerst, Alexander (Germany)
Soyuz TMA-14M	ISS-41/42	09.26.2014/ 0312.2015	Samokutiyaev, Alexander Mikhailovich
			Serova, Yelena Olegovna
			Wilmore, Barry (USA)
Soyuz TMA-15M	ISS-42/43	11.24.2014	Shkaplerov, Anton Nikolaevich
			Virts, Terry (USA)
			Cristoforetti, Samantha (Italy)

Within the framework of activities to integrate the ISS RS with the US segment and with the assets developed by other participants in the ISS program, joint studies and development efforts were continued to configure the station, to support safe crew activities onboard, to coordinate and support the cargo traffic, to coordinate, distribute and keep track of the ISS RS resources between the partners, etc.

Under contracts with Roscosmos, European Space Agency and other customers, the Corporation carried out:

• 
  manufacturing and packaged delivery of three Russian onboard systems for the ATV spacecraft (docking system, refueling system and the Russian equipment control system);
  
• 
  activities providing operational support of the ATV missions, engineering support of Russian systems during assembly and prelaunch processing of the spacecraft;
  
• 
  delivery of Russian propellant components to be brought to the ISS using the ATV, as well as a number of other activities and services.
  

The launch of the spacecraft ATV-5 Georges Lemaitre from Kourou launch site using launch vehicleAriane-5ES took place on 07.29.2014. Its docking with the Russian Service Module Zvezda took place on August 12. The spacecraft mission lasted till February 14, 2015.

ATV-5 is docking to Russian Module Zvezda

Under the project Sea Launch, May 27, 2014 saw the successful launch of spacecraft (SC) Eutelsat 3B.

Within the framework of the Corporation program to develop satellites for communications and Earth remote sensing, 2014 saw a continuation of the joint work with the European company EADS Astrium (now Airbus Defense&Space), including joint work with the company OOO Energia Satellite Technologies (Energia-SAT), established by the Corporation and EADS Astrium.

The Corporation specialists took part in the work of an International (NASA, Roscosmos, ESA, JAXA, CSA) Expert Working Group (IEWG) on advanced programs in order to come up with proposals and recommendations on the following subjects:

• 
  continuation of the ISS program till 2020 and beyond;
  
• 
  assuring readiness for the scheduled and emergency termination of the ISS flight;
  
• 
  development of the architecture and key principles of forming the international program of deep space research and exploration;
  
• 
  improving the ISS utilization efficiency, including work in support of development of technologies for deep space exploration.
  

Based on the results of the work of the group, specific recommendations were prepared.

In 2014 a working group IESCT was established in order to determine the ISS capabilities to support deep space exploration. The main task of the group is to evaluate the feasibility of using the ISS program partnership as a basis for implementing an international program to establish a man-tended platform in near-lunar space, as well as to develop groundrules and scenarios for such a program.

Participation continued in the activities of the international industrial working group ICM for deep space studies , which includes seven big companies of the space industry: RSC Energia, Boeing, Lockheed Martin, ADS, Thales Alenia Space, Mitsubishi Heavy Industries, MDA. The main task of the group is to develop possible scenarios for establishing an international man-tended platform to support the plans of national agencies and a potential international program.

There was a continued cooperation with the Boeing company on advanced projects, including:

• 
  development of man-tended infrastructure in near-lunar space;
  
• 
  development of an inter-orbital solar-powered tug.
  

Also continued was cooperation with the Lockheed Martin company on the subjects of:

• 
  interfaces between a habitable module (Russia) and Orion spacecraft (USA);
  
• 
  feasibility study of joint launch vehicle development.
  

There was cooperation with the DLR agency (Germany) with respect to studies on the development of a “solar tug" on the basis of the Center for parallel design (Bremen).

On January 27, 2014, optical telescopes were installed onboard the ISS RS. The Optical Telescope System (OTS) makes it possible to obtain high-quality still and video images of the Earth surface.

In 2014 cooperation continued between RSC Energia and the Japanese Aerospace Exploration Agency JAXA in conducting experiments onboard the ISS. Prepared and successfully carried out in the KIBO module were two joint experiments in protein crystallization, experiment Aquarium AQH to study fish behavior in spaceflight environment, two sessions of experiments Matryoshka-R2, as well as the feasibility study of the Japanese proposal to conduct an experiment in mice behavior in zero gravity.

In 2014, the following work was conducted on joint experiments with ESA:

• 
  A joint Russian-European experiment EXPOSE-R2 was started to study the effects of open space on biological objects. The compete scope of check tests was performed on the equipment which was then delivered to the ISS and installed on the outer surface of the Service Module;
  
• 
  work was performed in support of ESA experiments within the framework of the direct contract with RSC Energia;
  
• 
  Russian-European experiment Plasma Crystal 4 was started, the equipment was delivered to the ISS onboard spacecraft Progress M-25M.
  

It should be noted that international activities of the Corporation are affected by political aspects related to the introduction of sanctions against Russia.

RSC Energia specialists organized trips and participation in joint activities at the Baikonur launch site of 15 foreign delegations consisting in total of 250 persons.

RSC Energia’s achievements and technologies were repeatedly showcased at high-profile international thematic exhibitions, shows, congresses and conferences. At such forums, leading specialists of the Corporation met with representatives of agencies and companies, thus promoting an expansion of business connections with partners from abroad and conclusion of new commercial contracts.

RSC Energia participation in international exhibitions (shows) and conferences in 2014:

• 
  Exhibition dedicated to the Cosmonautics Day, Theater of the Russian Army, April 12, 2014, Moscow, Russia;
  
• 
  The international aerospace exhibition China Airshow 2014, November 11-16, 2014, Zhuhai, China;
  
• 
  Exhibition held within the framework of the 40^th Scientific Assembly of the International Committee for Space Research COSPAR-2014, August 4-10, 2014, Lomonosov Moscow State University, Moscow, Russia;
  
• 
  65^th International Astronautical Congress IAC-2014, September 30 – October 3, 2014, Toronto, Canada;
  
• 
  Farnborough International Airshow 2014, July 14-20, 2014, Farnborough, Great Britain.