Return-to-Flight Communication
Return-to-Flight Communication
TO: ILS Customers
SUBJECT: Final Return-to-Flight Status Update
Sept. 05, 2008 -- With the successful launch on 19 August of the Inmarsat-4 F3 satellite, I would like to provide a status of commercial Proton’s return to flight and the Khrunichev Quality Initiative. These are very important steps in the process to restore commercial Proton to successfully launching time after time, every time we launch.
Over the last five months we presented you with significant detail about the investigation into the AMC-14 Breeze M failure. We have briefed you on the failure analysis, and on the corrective actions taken. We responded to your concerns about quality control with a Khrunichev-led top-to-bottom quality assessment and overhaul. We instituted changes already, which enabled us to successfully return to flight last month. These are long-term improvements, and we are committed to success and committed to quality for the long haul.
Let me bring you up to date on further steps ILS and Khrunichev have taken:
- Just as Khrunichev has appointed a deputy general director for quality assurance, ILS has also established a position focused on quality assurance.
- Independent and internal audits were conducted on the quality management systems at Khrunichev, Khimmash (the Breeze M engine provider that is now part of the Khrunichev organization) and the Baikonur launch site. These audits looked at the overall processes, as well as the quality control processes for the Inmarsat launch vehicle in particular. This scrutiny validated that the way Khrunichev manages its quality system is sound and complies with world-class standards.
- Khrunichev is implementing such improvements as regular involvement of the design office with production and testing; establishment of a single data bank; tracking of additional key parameters; and upgrades to quality control and measurement tools.
We will continue to keep you informed of our progress toward full implementation through periodic reviews and increased visibility in our program reporting.
We are about halfway through our next campaign, the launch of Nimiq 4 for Telesat scheduled for 19 September. This will be followed by the ASTRA 1M launch in late October. We are eager to get our manifest on track, and with our customer’s support we are making great progress doing just that.
While commercial Proton is back in service, we know that your confidence is earned one mission at a time, so rest assured that we won’t relax our focus on performance and commitment to making every launch a success.
Sincerely, 
Frank McKenna
President
Inmarsat-4 F3 on Target
Aug. 22, 2008 -- On August 19, at 04:43 a.m. local time (Aug. 18: 18:43 EDT, 22:43 GMT), liftoff of the Proton M Breeze M rocket carrying the Inmarsat-4 F3 satellite occurred in Baikonur. The satellite was placed into a geosynchronous transfer orbit at 13:46 local time (Aug. 19: 03:36 EDT, 07:46 GMT).
EADS Astrium acquired control of the satellite during the mission and is in the process of placing the spacecraft into its final orbit.
ILS Proton Successfully Launches Inmarsat-4 F3 Satellite
Aug.19, 2008 -- A Proton Breeze M launch vehicle successfully lifted the Inmarsat-4 F3 satellite into orbit today, marking the third mission of the year for International Launch Services (ILS).
The Proton Breeze M vehicle, built by Khrunichev Space Center of Moscow, lifted off from Pad 39 at the cosmodrome at 04:43 today local time (18:43 EDT Monday, 22:43 GMT Monday). After a 9-hour-3-minute mission, the launcher released the satellite into a geosynchronous transfer orbit.
For more information please see the full press release or mission control.
Launch Rescheduled for Aug. 19
Aug. 13, 2008 -- The ILS Proton Breeze M launch of the Inmarsat-4 F3 satellite has been rescheduled for Aug. 19 at the Baikonur Cosmodrome. The liftoff time at launch pad 39 is 04:43 Baikonur Standard Time (22:43 Aug. 18 GMT and 18:43 Aug. 18 EDT).
For more details, please see the mission overview or media advisory.
Proton Launch with Inmarsat Satellite Delayed
Aug. 4, 2008 – The launch of a Proton M Breeze M vehicle with the Inmarsat-4 F3 satellite has been delayed to allow time to replace and retest a launcher electrical component.
During prelaunch testing in Baikonur, a problem was discovered with the flight computer on the Breeze M upper stage. The vendor-supplied flight computer was replaced over the weekend.
To ensure mission success, Khrunichev specialists will thoroughly check out the new component. The launch will be delayed by a matter of days and a new target launch date will be announced later this week after testing is complete.
Underwriter briefings conclude, customer briefings continue
July 24, 2008 – American underwriters were briefed last week at ILS headquarters about the Proton Breeze M's return to flight progress and about the Quality Initiative under way at Khrunichev Space Center. ILS representatives also began briefing customers at various locations, a process that will continue over the coming weeks.
The latest round of briefings recapped a more extensive presentation that took place over 2 1/2 days in Moscow the previous week. Approximately 30 representatives from the underwriting community attended that session, which was hosted by ILS President Frank McKenna and Khrunichev General Director Vladimir Nesterov. The primary messages from the senior leadership included:
• a commitment to a reliable Proton system;
• a substantive Quality Initiative across the board; and
• increased transparency in information flow to customers and the insurance
community.
Among the speakers were Jim Bonner, ILS Vice President and Chief Technical Officer; Yuri Bakhvalov, First Deputy General Designer and Chief of Salyut Design Bureau; and Alexander Kobzar, Khrunichev Deputy General Director for Quality Assurance. The review of the Russian State Commission findings was led by Bakhvalov, who also provided insight into quality management within the design bureau. Bakhvalov was followed by Bonner detailing the process and findings of the AMC-14 FROB. Kobzar discussed the phased implementation of the quality initiative within Khrunichev, including explaining the structure of quality organization.
On the final day the underwriters were escorted on a tour of Khrunichev’s manufacturing facilities, featuring both the Proton and Breeze M final assembly areas. With many vehicles on the factory floor, the visitors were allowed to see some of the hardware being readied for upcoming missions. Underwriters were also allowed to view the Breeze M engines being integrated for the upcoming Proton missions.
ILS to brief underwriters, customers
July 2, 2008 -- ILS and Khrunichev will begin a series of briefings next week on the investigation into the March 15 Proton Breeze M launch failure. Insurance underwriters have been invited to Moscow from July 9 to 11 to hear presentations on the the results of the failure investigation and the corrective actions. In addition, Khrunichev representatives will address the quality initiative that is under way regarding Proton system production.
Briefings will continue the following week in France for European customers, and at ILS's new headquarters in Reston, Va., for U.S. underwriters. Other briefings will follow at various customer locations.
Inmarsat and ILS set RTF launch date
July 1, 2008 – International Launch Services (ILS) has scheduled its next Proton Breeze M commercial mission for August 14 (August 13 GMT) from the Baikonur Cosmodrome in Kazakhstan, with the launch of the Inmarsat-4 F3 satellite. The satellite is scheduled to be shipped to Baikonur in early July for a six-week launch program.
FROB concludes first phase of review
May 13, 2008 -- The members of the ILS Failure Review Oversight Board (FROB) have concluded two weeks of meetings in Moscow, and concurred with the Russian investigative commission on the cause of the recent Proton Breeze M failure. Both boards determined that the failure was caused by a ruptured exhaust gas duct, which led to a shutdown of the turbo pump feeding the Breeze M engine.
The next phase is for the FROB to evaluate the corrective actions to be taken before the vehicle is cleared for return to flight for ILS missions. Khrunichev will be performing additional analysis and engine tests that are scheduled for completion in mid-June, after which the FROB will reconvene in Moscow.
Russian Commission Determines Cause of Failure
April 21, 2008 - The Russian State Commission investigating the failure of the Proton Breeze M launch with AMC-14 has traced the cause to the rupture of the gas duct between the gas generator and the propellant pump turbine in the Breeze M main engine.
The Russian investigative commission said that the most probable cause of the gas duct rupture was due to the combined effects of duct wall erosion, high temperatures and prolonged low frequency pressure fluctuation in the duct. The Commission recommended corrective actions to comprehensively address each of the contributing factors. ILS, meanwhile, has assembled a group of aerospace experts as well as customer and insurance representatives into a Failure Review Oversight Board (FROB). After an exhaustive review process, the FROB will determine if the corrective actions meet ILS standards for commercial return to flight.
Investigation progress; FROB membership complete
April 2, 2008 – The Russian State Commission investigating the recent Breeze M failure reports that it is close to determining a root cause for the incident. The commission has been meeting regularly since March 18.
Meanwhile, all the members have been selected for the ILS Failure Review Oversight Board (FROB). Members include rocket and propulsion experts as well as representatives of the insurance industry, the affected customer and upcoming launch customers. ILS is in the process of submitting requests to the U.S. State Department for the various licenses required for the FROB meetings in Russia and for subsequent briefings to customers and insurers.
State Commission Led by Vladimir Rachouk
March 18, 2008 - Vladimir Rachouk will lead the Russian State Investigation Committee as Chairman. He is currently the General Director of KBKChA (Design Bureau of Chemical Automatics), Voronezh. The design bureau located together with Voronezh Mechanical Plant, manufactures the Proton second and third stage main engines. This committee will serve as the primary evaluation team to determine the cause of the anomaly. The first formal meeting was conducted early today.
Failure Review Oversight Board Formed
March 18, 2008 - ILS is finalizing the selection of members for the Failure Oversight Review Board (FROB). In accordance with standard industry practices, the FROB will review the findings of the Russian State Commission’s investigation and its corrective action plan.
The board will be chaired by Jim Bonner, ILS Vice President of Operations and CTO. Kevin Sloan, ILS launch operations director, will serve as the executive secretary. The remaining members will be comprised of industry specialists, participants from the affected mission and the return to flight mission campaigns, as well as an insurance industry representative.
Return-to-Flight Progress:
Russian Commission Determines Cause of Failure
