Intelsat 27 Launch Updates -- Sea Launch
Archived Launch Coverage, Intelsat Blog, Launch Vehicle Information
Sea Launch provides initial Details about Zenit 3SL Mishap
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February 2, 2013
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Photo: Intelsat
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After Friday’s launch failure of a Zenit 3SL launch vehicle carrying the Intelsat 27 payload, Sea Launch has provided initial details about the mishap. The company and Energia Logistics formed a Failure Review Oversight Board and all contractors involved in Zenit 3SL mission operations will provide detailed investigation reports on the systems they are responsible for.
In a release, Sea Launch confirms that all pre-launch operations leading up to the ill-fated Intelsat 27 launch were nominal and all systems of Zenit 3SL, the Block DM Upper Stage and Boeing-built payload unit and satellite were functional and in readiness for the mission, after being thoroughly testing at their manufacturers, Sea Launch home port and during final launch preparations in the Pacific Ocean. Countdown operations leading up to liftoff were nominal and no problems were detected during handover to the vehicle’s computers and RD-171 engine start-up. The engine reached nominal operating conditions and full thrust and the vehicle was committed to liftoff. |
“11.4 seconds into flight, the Zenit flight control system detected an exceedance of a pre-programmed roll limit and responded appropriately with activation of the on-board thrust termination sequence,” Sea Launch said in the statement.
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The flight control system is programmed to wait at least 20 seconds after liftoff before shutting down the engine in an emergency scenario to make sure the vehicle does not impact near the Odyssey launch platform. The launcher made its impact about 4 Kilometers from Odyssey and nobody was injured. No recoverable debris were found by helicopters performing search flights.
“Based on preliminary information received from the launch vehicle designer, the investigation will focus on Zenit-3SL systems associated with thrust-vector control of the first stage engine,” the Sea Launch statement said. According to Russian sources, the root cause of the failure is most likely a hydraulic pump within the first stage propulsion system. The BIM pump provides hydraulic pressure to the gimbal mechanism that controls RD-171 nozzle gimbaling to control the vehicle. Telemetry indicated that the pump performed nominally during engine start and started to slow down early in the flight before completely stopping, resulting in a loss of Thrust Vector Control early in the flight which most likely caused the higher-than-allowed roll on the vehicle leading to the emergency shutdown. RD-171 is the most powerful liquid-fueled rocket engine of the world. It provides 7,550 Kilonewtons of thrust at sea level and a vacuum thrust of 7,887kN. The Main Engine has four combustion chambers, all fed by a single, vertically mounted turbopump, powered by two gas generators feeding hot oxidizer-rich gas to a single turbine. RD-171 provides throttle capabilities ranging from 56% to 105% of rated performance which is used to limit stress on the vehicle during ascent. The Engine weighs 9,500 and has a thrust-to-weight ratio of 82. First stage attitude control is provided by gimbaling each nozzle individually by up to 8 degrees. The BIM pump assembly consists of two turbopumps, one is driven by high-pressure helium and one uses Kerosene provided by the RD-171 fuel subsystem. When being powered with helium, the BIM reaches an intermediate power level which is increased to full hydraulic pressure when BIM switches to the Kerosene pump. Because the Kerosene pump can only function in association with a burning engine, it can not be tested pre-flight. The helium turbine is tested ahead of flight and starts ten seconds before liftoff to start the BIM and reach intermediate power before switching to the Kerosene system at the point of RD-171 ignition. BIM is manufactured in the Ukraine. |
Photo: NPO Energomash
RD-171 Engine
BIM within RD-171 - Source: LPRE - Click Here
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Search for Root Cause of Friday's Zenit 3SL Launch Failure begins
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February 1, 2013
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Photo: Intelsat
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Friday’s failure of a Sea Launch Zenit 3SL rocket was likely caused by a fault in the rocket’s Flight Control System. The launcher took off from the Sea Launch Odyssey launch platform at 154 degrees West in the Pacific Ocean at 6:56 UTC and encountered a major problem immediately after launch, causing it to fall into the Pacific Ocean under one minute after liftoff.
So far, there were a number of reports on the nature of the failure. The most plausible ones point to a malfunction of the Flight Control System of the launch vehicle. As countdown clocks ticked down on Friday, the launcher went through its nominal launch sequence. Control was handed over to the launcher three-and-a-half seconds ahead if liftoff and the RD-171 engine started its ignition sequence at the same time. As the engine soared up to full thrust of 7,550 Kilonewtons at sea level, computers were monitoring engine performance to trigger an emergency shutdown before committing the vehicle to launch if any abnormal parameters were detected. Once the engine has reached its operational thrust, hold down clamps are released by pyrotechnic initiators, and the vehicle can lift off. Once committed to lift off, the Zenit rocket blasted off from Odyssey and began a short vertical ascent. The planned flight path would have taken the rocket East, right along the equator to reach Geostationary Transfer Orbit with zero inclination. In order to reach this orbit, the launcher is required to perform a pitch maneuver to the East shortly after blastoff. Source information indicates that the vehicle pitched over and started flying south, far off the anticipated ground track. The live streaming video provided by Sea Launch showed that the RD-171 engine was shut down between 20 and 25 seconds after liftoff. |
The Zenit is not equipped with a Flight Termination System that could be used to destroy the launcher in the event of a major malfunction. Like other launch vehicles that have their origins in the Soviet Union, the Zenit would shut its engine down in case of an anomaly to terminate the flight.
It is likely that the launcher’s control system detected the off-nominal flight path and triggered the engine shutdown. In case of a problem with the launcher, but with a functioning propulsion system, Zenit will not shut its engine down in the first 20 seconds of the flight to ensure the launcher is not impacting in the vicinity of the Odyssey launch platform. After 20 seconds of mission elapsed time, the flight control system has the authority to trigger an shutdown of the engine. NPO Energomash, the manufacturer of the RD-171 four-chamber engine, informed that the performance of the Propulsion System was nominal during Friday’s mission. In a press release issued on Friday, Roscosmos noted that initial analysis has not revealed any apparent failures of the propulsion or control systems of the launcher. Why the vehicle veered off course has not been officially confirmed.
Other reports that emerged on Friday blamed rough seas on the failure, but seas and winds were calm at the time of liftoff and Odyssey was designed to withstand even rough seas.
After engine shutdown, the Zenit rocket fell back to Earth impacting in the Pacific Ocean at a safe distance to the launch platform. Video of the launch shows a bright flash that is likely caused by the launch vehicle exploding upon impact. According to Sea Launch, the telemetry signal from the Zenit was lost at T+40 seconds.
It is likely that the launcher’s control system detected the off-nominal flight path and triggered the engine shutdown. In case of a problem with the launcher, but with a functioning propulsion system, Zenit will not shut its engine down in the first 20 seconds of the flight to ensure the launcher is not impacting in the vicinity of the Odyssey launch platform. After 20 seconds of mission elapsed time, the flight control system has the authority to trigger an shutdown of the engine. NPO Energomash, the manufacturer of the RD-171 four-chamber engine, informed that the performance of the Propulsion System was nominal during Friday’s mission. In a press release issued on Friday, Roscosmos noted that initial analysis has not revealed any apparent failures of the propulsion or control systems of the launcher. Why the vehicle veered off course has not been officially confirmed.
Other reports that emerged on Friday blamed rough seas on the failure, but seas and winds were calm at the time of liftoff and Odyssey was designed to withstand even rough seas.
After engine shutdown, the Zenit rocket fell back to Earth impacting in the Pacific Ocean at a safe distance to the launch platform. Video of the launch shows a bright flash that is likely caused by the launch vehicle exploding upon impact. According to Sea Launch, the telemetry signal from the Zenit was lost at T+40 seconds.
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After the incident, launch personnel evaluated the safety of the Sea Launch Command Ship with focus on the release of toxic propellants. The Block DM Upper Stage uses a Hydrazine attitude control system and the satellite contained about three tons of Nitrogen Tetroxide and Hydrazine propellants.
Sea Launch will establish a Failure Review Oversight Board to determine the root cause of the incident and recommend corrective measures. Intelsat said in a release that the company’s customers will not experience any service interruptions as the Intelsat 805 spacecraft that was supposed to be replaced by Intelsat 27 is still providing communication services. The Intelsat 27 satellite and launch were insured with $400 million. |
Credit: Sea Launch
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Zenit 3SL Rocket fails shortly after Liftoff, crashes into Pacific Ocean
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February 1, 2013
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A Sea Launch Zenit 3SL Launch Vehicle suffered a major launch failure on Friday, crashing into the Pacific Ocean shortly after lifting off from the Odyssey Launch Platform at 154 degrees West. Liftoff occurred on Friday at 6:56 UTC, but the Zenit 3SL launch vehicle lost control and an emergency shutdown of its engine was commanded just seconds after blastoff, causing the rocket to fall back to Earth.
Launch operations kicked off 72 hours ahead of liftoff when the Zenit launch countdown was initiated. After completing payload communication checks, ground support equipment verifications and the usual test of the launch platform’s fire suppression system, the Zenit launch vehicle was rolled out of its hangar. A transporter erector was used to place the rocket in its vertical launch position to begin final reconfigurations and close outs. Launch Day operations got underway aboard the 133 by 67-meter Odyssey Launch Platform located at 154 degrees West longitude, several hours ahead of the opening of the day’s launch window. Teams performed final launch pad and platform close-outs while the Boeing Satellite Team initiated the countdown sequence of the Intelsat 27 spacecraft. As clocks ticked down, the Zenit launcher was powered up and the launch team started final testing of the launcher’s electrical and communication systems. Once verifications were made, the rocket received its software for flight. Propellant loading started at T-2 hours and 30 minutes with the chilldown of Liquid Oxygen Ground Support Equipment and Transfer Lines Chilldown. 15 minutes later, LOX started flowing in the first and second stage of the launcher. A total of 233,515 Kilograms of LOX were loaded into the first stage while the second stage was filled with 58,908 Kilograms of supercold oxidizer. The next step was loading the vehicle’s first and second stage with rocket-grade Kerosene which started at T-1 hour and 30 minutes. |
*File Image* - Photo: Sea Launch
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A total of 88,768 Kilograms of Kerosene were loaded into the first and 22,832 Kilograms into the second stage. The Upper Stage, Block DM, was loaded with Kerosene earlier in the launch campaign while the vehicle was still in Home Port. Block DM holds a total of 4,560 Kilograms of fuel.
The final part of fueling commenced at T-55 minutes when the Block DM Upper Stage started Liquid Oxygen Loading. A total of 11,290kg of oxidizer were loaded into the Upper Stage. At T-36 minutes, the final Launch Readiness Poll took place and all stations reported GO for launch. Weather conditions in the middle of the ocean were acceptable for flight.
Starting at T-15 minutes, the Transporter Erector retracted from the launcher and was rolled back inside the Platform’s Hanger, a safe position for launch. Launch pad cameras were activated, range officers checked the vicinity of the flight path to make sure no vessel or aircraft were in the blast danger zone, and the doors and roof of Odyssey’s hanger were closed.
Over the final two minutes of the countdown, the launcher transferred to internal power and propellant tank pressurization took place.
The final part of fueling commenced at T-55 minutes when the Block DM Upper Stage started Liquid Oxygen Loading. A total of 11,290kg of oxidizer were loaded into the Upper Stage. At T-36 minutes, the final Launch Readiness Poll took place and all stations reported GO for launch. Weather conditions in the middle of the ocean were acceptable for flight.
Starting at T-15 minutes, the Transporter Erector retracted from the launcher and was rolled back inside the Platform’s Hanger, a safe position for launch. Launch pad cameras were activated, range officers checked the vicinity of the flight path to make sure no vessel or aircraft were in the blast danger zone, and the doors and roof of Odyssey’s hanger were closed.
Over the final two minutes of the countdown, the launcher transferred to internal power and propellant tank pressurization took place.
*File Image* - Photo: Sea Launch
*File Image* - Photo: Sea Launch
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3.5 seconds before lifting off, the Zenit rocket started its massive RD-171 main engine which is the most powerful liquid-fueled engine in the world. Zenit switched to internal control and monitored engine ignition and transition to full thrust. After turbopumps reached flight speed and the engine achieved its liftoff thrust of 7,550 Kilonewtons, the launcher was released and blasted off from Odyssey. Zenit 3SL lifted off at 6:56 UTC and made a thundering blastoff, lighting up the night skies over the Pacific Ocean.
Shortly after lifting off, the launch vehicle turned to the wrong direction – indicating a failure of the Zenit’s guidance system. An emergency shutdown of the RD-171 was commanded shortly after liftoff (at about T+25 seconds) and the launch vehicle crashed into the Ocean, not far from the launch platform. All telemetry from the vehicle was lost at T+40 seconds. The exact nature of the failure is unknown, but indications are that the Guidance System is to blame since the vehicle veered off course instantly. "We are very disappointed with the outcome of the launch and offer our sincere regrets to our customer, Intelsat, and their spacecraft provider, BSSI,” said Kjell Karlsen, president of Sea Launch AG. “The cause of the failure is unknown, but we are evaluating it and working closely with Intelsat, BSSI, Energia Logistics Ltd. and our Zenit-3SL suppliers. We will do everything reasonably possible to recover from this unexpected and unfortunate event.” This marked the 35th Sea Launch Mission since 1999 and the first of 2013. It is the third major failure that occurred since the company’s formation. The loss of the launch vehicle along with its Intelsat 27 payload is a major blow to Sea Launch and its shrinking customer base. After coming back from bankruptcy in 2012, the company did not have many customers to begin with. Intelsat was the largest and most important customer of Sea Launch. In June 2012, Sea Launch delivered the Intelsat 19 Payload to orbit, however, the satellite is only partially functional due to one of its Solar Arrays failing to deploy. Intelsat 21 was successfully delivered to Orbit by a Zenit 3SL in August 2012 and Intelsat 27 was planned to follow on Friday. This failure came at a point at which Sea Launch and Zenit 3SL were considered to potentially get a boost of its customer base by launching payloads that were planned to be launched atop Proton Rockets. Proton is facing an extremely crowded manifest after being grounded twice in 2012 due to failures of its Briz-M Upper Stage. Additionally, the Kazakh government is trying to limit Proton launches to 12 a year in an ongoing fight over the Baikonur Cosmodrome with the Russian Space Agency. Reports indicated that several payloads for Proton flights were being transferred to Sea Launch in case problems with Proton continue. Originally, Sea Launch had planned two more flights in 2013, the next one being planned for August. |
Intelsat 27
Image: Boeing
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The Intelsat 27 satellite was built by Boeing and will be operated by Intelsat of Luxembourg. The spacecraft is based on Boeing's BSS-702MP Satellite Platform that is capable of hosting powerful communication payloads. It is equipped with two large deployable solar arrays featuring four panels of triple-junction Gallium Arsenide Solar Cells, and onboard batteries to provide power to its systems and the payload. Expected End-Of-Life Power is 11.8 kilowatts.
The satellite is three-axis-stabilized and features its own bi-propellant propulsion system that is used once in orbit to boost the satellite into its position in Geostationary Orbit. The system is also used for stationkeeping to stay in its operational position in orbit. Intelsat 27 is equipped with a Liquid Apogee Engine and satellite has a reaction control system consisting of four 22-Newton axial thrusters and eight 4-Newton North/South Jets. In its deployed configuration, IS-27 is 6.9 by 9.25 by 36.85 meters in size with a liftoff mass of 6,203 Kilograms. |
Intelsat and Boeing Space and Intelligence Systems along with the US government have reached an agreement to host a UHF Payload for US government use on the satellite. To mitigate a shortfall in UHF capability, more and more commercial satellites host government payloads. The UHF Payload of Intelsat 27 complements that of existing UFO (UHF Follow On) and new MUOS (Multi-User Objective System) satellites. The IS-27 UHF payload is digitally tunable and operable with existing ground infrastructure and terminals. The UHF Payload consists of a total of 20 transponders.
The commercial payload that is installed on Intelsat 27 consists of Ku-Band and C-Band transponders. Sixteen 36MHz and four 72MHz C-Band transponders are installed on the satellite and the Ku payload features transponders combining channels at 27, 36, 54, 72 and 77MHz. The commercial portion of the satellite will provide communication to media and network customers in North- and South America as well as Europe. Intelsat 27 will be stationed at 304.5 degrees East in Geostationary Transfer Orbit from where it will operate for at least 15 years, replacing the Intelsat 805 satellite.
The commercial payload that is installed on Intelsat 27 consists of Ku-Band and C-Band transponders. Sixteen 36MHz and four 72MHz C-Band transponders are installed on the satellite and the Ku payload features transponders combining channels at 27, 36, 54, 72 and 77MHz. The commercial portion of the satellite will provide communication to media and network customers in North- and South America as well as Europe. Intelsat 27 will be stationed at 304.5 degrees East in Geostationary Transfer Orbit from where it will operate for at least 15 years, replacing the Intelsat 805 satellite.
Flight Trajectory & Timeline
Mission Timeline
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Ascent Profile
Image: Sea Launch
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Launch Site: Sea Launch Odyssey Platform at the equator at 154°West
GEO Transfer Orbit Parameters: 200 by 35,275 Kilometers - 0° Inclination
GEO Transfer Orbit Parameters: 200 by 35,275 Kilometers - 0° Inclination
Ground Track Map
Map: Sea Launch
Next Sea Launch delayed 24 Hours, Set for Friday |
January 28, 2013 |
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The launch of a Sea Launch Zenit 3SL launch vehicle on a mission to deliver the Intelsat 27 satellite to Geostationary Transfer Orbit has been delayed 24 hours and is now set for 6:56 UTC on February 1, 2013 at the opening of a 48-minute launch window.
This delay became necessary when the launch of NASA's TDRS-K satellite atop an Atlas V out of Florida was delayed 24-hours. Both missions, the Sea Launch flight and the Atlas V mission use NASA's Tracking and Data Relay Satellite System to track their respective vehicles. TDRSS requires some time between launches to be reconfigured properly, so that launch conflicts are generally avoided. Preparations for the Zenit Mission are continuing on track, out in the Pacific Ocean. After ten days of transit, the Launch Platform reached the launch position at 154 degrees West, right on the equator. While making is journey to the equator, the Odyssey Platform met with the Assembly & Command Ship carrying the majority of the launch team. Both vessels arrived at the launch site on January 26, local time. |
*File Image* - Photo: Sea Launch/Kirk Pysher
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Final launch preparations are currently underway as the Boeing satellites is completing frequency checks, countdown and flight simulations and battery charging. Countdown Operations were officially started on L-3 days, January 28. Once arriving at the launch site, Odyssey was lowered by more than 20 meters, flooding its ballast tanks to place the launch platform in the proper configuration for countdown operations and launch. This process took seven hours and set the stage for operations aboard Odyssey. Also on L-3, communications systems were put in place and communication links between the ACS vessel and Odyssey were established.
The Launch Vehicle will be moved out of its hangar and placed in its vertical launch position one day prior to liftoff. After being placed in its launch configuration, personnel will complete final tests and close-outs of the vehicle. During the terminal countdown sequence, the platform will be evacuated and all personnel will board the Seal Launch Commander vessel that acts as Launch and Mission Control Center.
Tanking will start about 2 hours 15 minutes ahead of launch. A total of 233,515 Kilograms of Liquid Oxygen and 88,768kg of Rocket-Grade Kerosene will be loaded into the rocket’s first stage. The second stage will be loaded with 58,908kg of Oxidizer and 22,832 of Kerosene. The Blok DM upper stage will hold 11,290kg of LOX and 4,560kg of Kerosene at blastoff.
The Launch Vehicle will be moved out of its hangar and placed in its vertical launch position one day prior to liftoff. After being placed in its launch configuration, personnel will complete final tests and close-outs of the vehicle. During the terminal countdown sequence, the platform will be evacuated and all personnel will board the Seal Launch Commander vessel that acts as Launch and Mission Control Center.
Tanking will start about 2 hours 15 minutes ahead of launch. A total of 233,515 Kilograms of Liquid Oxygen and 88,768kg of Rocket-Grade Kerosene will be loaded into the rocket’s first stage. The second stage will be loaded with 58,908kg of Oxidizer and 22,832 of Kerosene. The Blok DM upper stage will hold 11,290kg of LOX and 4,560kg of Kerosene at blastoff.
Odyssey Platform starts Journey to the Equator for next Sea Launch
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January 18, 2013
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Photo: Intelsat
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Launch preparations for the next Sea Launch mission are continuing on schedule for an on-time launch from the Pacific Ocean on January 31, 2013.
Last weekend, after the payload unit had been installed on the Zenit 3SL launch vehicle and final testing was complete, teams moved the fully assembled rocket from the Assembly and Command Ship to the Odyssey Launch Platform. The next day, the launch vehicle was placed in its launch position atop the platform’s launch pad to complete a full countdown rehearsal and ascent simulation. Additionally, the Intelsat 27 spacecraft was powered up and ran through its launch sequence. All systems were functioning as planned and the rocket was moved back into the hangar of the platform to get ready for its trip to the equator. On January 15, the Launch Platform started the journey to the launch position at 154 degrees West in the Pacific Ocean, right on the equator. The ACS ship travels faster than the platform so that it can stay in port several days longer. It is planned to set sail for the launch site on Saturday to catch up with Odyssey by Wednesday. Once both vessels have reached the launch position, the 72-hour countdown sequence will be started. The Launch Vehicle will be moved out of its hangar and placed in its vertical launch position one day prior to liftoff. After being placed in its launch configuration, personnel will complete final tests and close-outs of the vehicle. During the terminal countdown sequence, the platform will be evacuated and all personnel will board the Sea Launch Commander vessel that acts as Launch and Mission Control Center. Launch remains planned for January 31 at 6:56 UTC, at the opening of a 58-minute launch window. |
Sea Launch prepares to launch Intelsat 27 in late January |
January 13, 2013 |
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Sea Launch has started final preparations for its next mission, set to take place at the end of the month to deliver the Intelsat 27 Communications Satellite to orbit with their Zenit 3SL launch vehicle taking off from the Odyssey Platform in the Pacific Ocean. Currently, final preparations are underway at Sea Launch home port to prepare the Rocket, its Payload and the two vessels, Sea Launch Commander and the Odyssey launch platform.
The two-stage Zenit 3SL Launch Vehicle departed the port at Oktyabrsky, Ukraine on October 28, 2012 to begin the trip from its manufacturer to Sea Launch home port in Long Beach, California. The launcher arrived early in December and the payload fairing provided by Boeing also arrived in December. Earlier in 2012, the Block-DM Upper stage was shipped to the launch site. Final reviews cleared the way and launch preparations started in December. Over the course of the month, the Zenit launcher was assembled and testing got underway inside the Assembly Facility aboard the ACS ship. The Intelsat 27 satellite arrived at the launch site on November 28, after completing a short 30-Kilometer road trip from its manufacturer, Boeing, to Sea Launch. Once arriving at home port, Intelsat 27 was unpacked and placed in a test stand to begin preliminary tests to make sure the spacecraft was in good condition following its transfer to home port. These tests included electrical checks, propulsion system pressure checks and valve cycles, and mechanical tests. Standalone testing was completed in mid-December and teams began the next step, hazardous processing. Intelsat 27 was loaded with 3,400 Kilograms of propellants. Late in the year, final satellite checkouts were completed. To start 2013, the Satellite and Launch Vehicle Teams began combined operations. Intelsat 27 was attached to its Payload Adapter and completed final inspections before being installed in the protective Payload Fairing. On January 10, the Upper Composite was rolled from the Payload Processing Facility to the Assembly & Command Ship where the assembled launch vehicle was waiting for it. Currently, the process of installing the Upper Composite on the launch vehicle is underway. Once the integration process is complete, the Zenit launcher will be moved over the the Odyssey launch platform. Before departing home port, the launch vehicle will go through a countdown test on the launch platform before being moved to the platform's hangar for the trip to the equator that will start two weeks ahead of launch. Once arriving at the launch site, final preparations for the countdown and launch will be performed. |
Photo: Intelsat
Intelsat 27 arrives at Sea Launch Home Port
Photo: Intelsat
Intelsat 27 during final Processing
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Liftoff is planned to occur at 6:56 UTC on January 31, 2013. For payload and mission information, refer to the section below.
Photo: Intelsat
Payload Fairing Installation
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Photo: Intelsat
Payload Unit Installation on Zenit Rocket
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