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  MISSION: Recovery

 

Sea Launch experienced an unsuccessful launch on its 24th mission, on January 30, 2007. The incident occurred seconds after ignition, resulting in the loss of both the rocket and its payload. While the Odyssey Launch Platform remained intact and suffered no structural damage, some of the launch support equipment was damaged. Both the Odyssey and its sister vessel, the Sea Launch Commander, departed the launch site under their own power on February 3. The Sea Launch Commander returned to Sea Launch Home Port on February 9, and the Odyssey returned on February 16, per standard sailing times.

in transit

This recovery mission comprises two distinct and essential tracks, operating in a parallel timeframe toward returning to flight - Investigation and Repair/Recertification. The seasoned Sea Launch team has temporarily redirected its focus from successfully launching customers' satellites, to recovering from the setback. Quoting Dan Dubbs, deputy vice president of operations, "Extraordinary people arise from extraordinary circumstances."


 MISSION ALBUM

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  • Page 1 - The Odyssey Launch Platform returns to Sea Launch Home Port on February 16...
  • Page 2 - Soon after the Odyssey Launch Platform returned to Sea Launch Home Port in February...
  • Page 3 - Work begins on the Odyssey Launch Platform...
  • Page 4 - A test of the cable mast demonstrates its integrity for mission operations…
  • Page 5 - Recovery activities ramp up, supplies, support equipment and contractors arrive...
  • Page 6 - Removing the vent mast from the Launch Platform...
  • Page 7 - Without delay, repairs to the vent mast begin...
  • Page 8 - Assessment and Repairs of Communications Systems - Inmarsat Antenna...
  • Page 9 - Assessment and Repairs of Communications Systems - SAT COM antenna...
  • Page 10 - Assessment and Repairs of Communications Systems - Sea Launch brings special cranes onto the pier...
  • Page 11 - Assessment and Repairs of Communications Systems - Marine Line-of-Sight...
  • Page 12 - Wires and Cables - Cable-pulling and replacement efforts begin...
  • Page 13 - Activities on the Launch Platform are varied and broad in scope...
  • Page 14 - Repairs to the vent mast are completed...
  • Page 15 - Work on the pontoons is completed...
  • Page 16 - In preparation for the upcoming transition to repair work at a shipyard...
  • Page 17 - The vent mast, which was removed for repairs, is now freshly painted...
  • Page 18 - Reconstructing the gas deflector...
  • Page 19 - Return of the large communications antenna...
  • Page 20 - Preparations on the Odyssey Launch Platform continue for the transition to the shipyard...
  • Page 21 - The Odyssey Launch Platform departs for the Victoria Shipyard...
  • Page 22 - The Odyssey Launch Platform sails into Victoria Shipyard...
  • Page 23 - With the arrival of the scaffolding materials and repair and painting supplies...
  • Page 24 - Each day's work at the shipyard begins with a meeting...
  • Page 25 - The amount of gear staged on the launch deck continues to grow...
  • Page 26 - Work continues at the shipyard with supports and protection in position...
  • Page 27 - Shipyard repairs continue as supplies are loaded aboard...
  • Page 28 - Installing the newly repaired marine line-of-sight (MLOS) antenna...
  • Page 29 - The new gas deflector is loaded onto a cargo vessel, the Thor Amalie...
  • Page 30 - Installing the Hangar Doors...
  • Page 31 - The art of high-tech scaffolding at its best...
  • Page 32 - With final painting projects underway, the TECO painting team...
  • Page 33 - Work completed, the Sea Launch Commander eases out of Victoria Shipyard...
  • Page 34 - The vessels depart Victoria, British Columbia...
  • Page 35 - The Odyssey Launch Platform is spotted entering the Port of Long Beach...
  • Page 36 - With the return of the vessels, work resumes at Sea Launch Home Port...
  • Page 37 - Preparations for the installation of the gas deflector are underway...
  • Page 38 - The new gas deflector arrives from St. Petersberg...
  • Page 39 - The gas deflector is moved off the cargo vessel...
  • Page 40 - With its cargo safely delivered, the Thor Amalie prepares for departure...
  • Page 41 - Preparations for installation of the new gas deflector continue...
  • Page 42 - With the gas deflector now floating beneath the Launch Platform...
  • Page 43 - Lifting the Gas Deflector...
  • Page 44 - As the installation continues, the powerful Strand Jack supports the effort...
  • Page 45 - While the installation of the gas deflector is underway, other activities abound...
  • Page 46 - The Condock arrives with new rocket hardware...
  • Page 47 - Activity prevails on the Sea Launch pier…
  • Page 48 - Mission Recovery winds down...

INVESTIGATION OF THE UNSUCCESSFUL LAUNCH

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CIS Interagency Commission
The national space agencies of Russia and Ukraine formed an interagency commission on February 5 to investigate the cause of the Zenit-3SL's unsuccessful launch. Mr. S. N. Konyukhov, general designer and general director of SDO Yuzhnoye, served as chair. The commission concluded its investigation on March 7 and issued a summary statement to Sea Launch, indicating an anomaly within the first stage engine caused an early termination of thrust, resulting in the loss of the mission.

Failure Review Oversight Board
The Sea Launch Failure Review Oversight Board (FROB) held its first meeting, in April, in Dnepropetrovsk, Ukraine, with representatives of a CIS Interagency Commission and Sea Launch partner companies. Chaired by Kirk Pysher, Sea Launch vice president and chief systems engineer, the FROB was comprised of Sea Launch technical leadership and U.S. aerospace industry experts. Following a review of the commission's findings, conclusions and recommended corrective actions, the FROB met with the commission again at the end of May and concluded its review on June 1. All systems were cleared for operations, pending completion and tests of all repairs on the Launch Platform.

The commission had concluded that the failure initiated in the liquid oxygen (LOx) turbopump section of the RD-171M main engine. After the initial FROB meeting in April, the Sea Launch partners performed internal inspections of already manufactured and tested RD-171M engines, with the objective of confirming the LOx feed system and pumps were free of debris. At the second meeting, the FROB reviewed the results of the engine inspections and further findings. Members of the FROB concurred with the commission findings, conclusions and recommendations. "The FROB resolved that the CIS team, led by Energomash experts, manufacturers of the RD-171M main engine, presented sufficient facts and data to substantiate and justify the Joint Commission’s findings and conclusions," said Pysher. "The FROB concurs that the anomaly initiated within the RD-171M LOx turbopump as the result of a metallic object becoming lodged between the pump’s moving and stationary components. This object ignited and burned as a result of friction-induced heat. The combustion of the object set off a string of events that led to the destruction of the LOx pump, RD-171M engine and ultimately the Zenit 3SL."


 RECOVERY CAMPAIGN

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Damage Assessment
In the process of verifying her seaworthiness at the launch site, the marine crew confirmed that the Odyssey Launch Platform's main structures remained in good condition and marine systems were operational. The Sea Launch team developed necessary plans and procedures to fully assess the damage and implement the necessary repairs required for recertification to ensure a safe, thorough and efficient return to reliable service. In March, the team completed its damage assessment phase of the Launch Platform, including a full inventory of repair and recertification requirements and scheduling of these activities. The team smoothly transitioned to a fully integrated recovery process to restore all damaged systems back to their original operating capability.

Repairs/Recertification
While the vessel itself did not sustain structural damage and was certified as seaworthy on February 2, some support equipment had to be repaired or replaced, including heat-affected cable and wiring, the launch support umbilical interface to the launch vehicle, and painting of the vessel’s external surfaces. The aft doors of the hangar required re-installation on their supports. The hangar houses and protects the transporter-erector support structure during launch operations.

The most significant damage was the loss of the gas deflector, which was located directly beneath the launch pad. This one-of-a-kind, 280-metric ton steel structure, including its truss supports, directs the engine exhaust away from the platform and controls the acoustic environment. A replacement gas deflector was manufactured in a shipyard near St. Petersburg, Russia. In July, the new structure sailed to Sea Launch Home Port for installation on the Launch Platform in August.

In June, the Sea Launch vessels sailed to Victoria Shipyard at the Esquimalt Graving Dock in British Columbia, Canada, where industrial repairs and large-scale painting of the Odyssey was executed in a professional, environmentally safe environment. We also completed routine maintenance of the Sea Launch Commander. In August, our marine crew took the vessels out to sea for marine tests and then returned to Home Port. Outstanding repair-recertification items will be completed in August and September. The team at the Repair Operations Center continues to track all items, schedule and location logistics, and assess status. As always, safety is our number one priority throughout this process.

The Sea Launch team is proceeding on schedule with all repairs and recertification of the Odyssey Launch Platform and associated launch support equipment. In September, we are expecting delivery of the Thuraya 3 communications satellite, which we will prepare for integration with a Zenit-3SL rocket. We plan to resume launch operations in October.


RETURN TO FLIGHT

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The Sea Launch partners – Boeing, RSC Energia, SDO Yuzhnoye/PO Yuzhmash and Aker ASA – remain fully committed to resolving the anomaly and recovering from its consequences for Return to Flight, meeting our customer requirements for a safe and successful mission. We are working to a highly integrated recovery plan and are prepared to succeed in its implementation in a methodical, professional approach.


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