13 April – 30 years of Zenith LV first launch

Built by Yuzhnoye Design Office team in creative collaboration with cooperating enterprises, the Zenith two-stage launch vehicle, being capable to inject three to fourteen ton spacecrafts into near-Earth orbits, has successfully stood the test of time. The level of excellence of unique general-purpose environmentally friendly Zenith Space Launch System by many criteria is unrivalled in the world until present time.

Zenith Space Launch System was created in accordance with resolution of the CPSU Central Committee and the Council of Ministers of USSR dated 16.03.76 №183-70, the flight tests of which were planned in 1979.

Zenith SLS became the first and the only universal system with middle-class launch vehicle, the demand in which was the most pressing at that time. An idea of its construction is connected with a problem for building a number of advanced light, heavy and super heavy launch vehicles with unification of engines, control systems, upper stages, ground support equipment, etc., being discussed at the beginning of 70-s.

The essence of new approaches is as follows. Zenith SLS was initially under design of Yuzhnoye DO and DOEM (Design Office of Engineering Mechanics) as fully automatic, not requiring the presence of operational personnel at the time when LV is on the launcher. During its design for the first time in practice of rocket engineering the principle of comprehensive approach was implemented to solving the problems of «LV – ground equipment» system, considering the mutual requirements both for launch vehicle and ground support equipment.

Construction of this system was a breakthrough in the area of domestic rocket engineering. The central role of the basic rocket was assigned for Zenith middle-class launch vehicle in USSR, including objectives of both light and heavy-class systems. In particular, for manned flights, as well as for Energiya-Buran heavy-class LV – as wrap-round boosters.

Development and commissioning of Zenith Space Launch System can be fully considered to be as step-by-step work for Yuzhnoye DO team. YSDO and YMZ specialists did not have an experience before in development, manufacture and operation of the vehicles using the cryogenic propellants. The launch vehicle overall dimensions significantly increased. For the first time, development of integrated launch vehicle began from scratch. The launch vehicles which were earlier under development at YSDO were combat ballistic missiles updated for injection of SC (spacecraft) into orbit.

All these things required to regroup the forces in organization and perform the works, engage new departments for this program, radically update the database for development test of the vehicle units and commissioning of new production capacities and technology at Yuzhmash.

As a result of many years hard and painstaking work, numerous cooperative efforts of the ministries and agencies, after a number of failures and misfortunes during development test the system was prepared for the beginning of flight tests in 1985.

A large number of specialists sent to Baikonur from various organizations and industrial enterprises, LV developers and manufacturers and SLS ground equipment was involved in preparing and testing the LV both on technical area and launch-site complex.

The helpful in work was the fact that Chairman of the State commission was Herman Stepanovich Titov, cosmonaut №2, Deputy Head of CDSC (Chief Directorate for Spacecrafts). Thanks to his position and weight all issues were solved immediately. Sometimes, in complex situations, he took responsibility very often for making bold decisions. His catch phrase is still alive in memory, he would pronounce with a joke: “Hell with them… I am the Hero of the entire Soviet Union and honored citizen of Magadan !” in response to comments that “higher-ups” are not quite agreed with acceptance of this or that decision and may hold accountable.

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Among distinguishing features of Zenith SLS development test one may highlight:

– redirecting the focus of development test on ground tests and significant increase of its scope as compared to development test of the previous propellants samples, up to including a new phase – preflight phase of the site test;

– wide application during ground and flight test of the special full-scale mockups, which simulate characteristics  of the standard hardware (LV mockups for fitcheck-test operations at TA and LC, electrical/fueling mockup and LV electrical/fueling mockup, SC dynamic mockups and other payload simulators);

– construction of unique benches and equipment for testing the engines and control system, LV hold-down mechanisms on launch pad, testing the connection of ground-air communications and others., which allowed to perform  thorough and comprehensive development test and system testing under conditions which are maximum close to operational ones.

According to V.G. Komanov, my manager and chief designer of the subject:

Plesetsk launch-site in Arkhangelsk region could become the location of SLS 11К77. A final decision was made after a friendly meeting of Mr. Utkin, the member of CPSU Central Committee, General Designer of Yuzhnoye SDO with Mr. Shestopalov, Deputy Minister of Defense of USSR for construction. Nicolai Fedorovich said: «Vladimir Fedorovich, I will not be able to help you in construction of launch and processing complexes in Plesetsk, as all my construction teams will be sent to Baikonur for fulfillment of the priority task – build Energiya-Buran SLS. While at Baikonur I will have an opportunity of maneuver, and I promise to give you every support». It became a decisive argument in identification of SLS location.

A decision was made for Zenith SLS processing complex at Baikonur to equip additionally Assembly, Integration and Test Building of Р-36 combat missile. The launch complex was being rebuilt, its facilities were built nearby at a distance of 3-4 km from technical area (platform 42), and was named as a platform 45.

The construction activities began in 1978.

To perform the state joint flight tests the program provided for launches of 12 Zenith launch vehicles.

The first rocket for flight tests was manufactured and accepted by the Customer on the eve of the New Year (29.12.84) and was immediately shipped to Baikonur. Transportation by railway transport was carried out within the shortest possible time – 3 days.

Processing and testing of the launch vehicle №1Л at TA continued until 9 of April 1985. All failures and deficiencies found during testing were eliminated, and on April 10 1985 the Zenith on transporter erector was delivered to launch complex. All checkouts of the LV at LC specified in the program had passed with success and the State Commission scheduled the launch of LV №1Л by 13.00 on 12 April 1985.

For coordination and control over progress of operations Mr. Baklanov, the then Minister from the Ministry of General Engineering of USSR sent Mr. Schastlivy, the Chief Engineer of the first Central Administrative Board and Mr. Semenov, Deputy Head of the fifth Central Administrative Board, responsible for construction of entire SLS and LV, as well as for LV CS and ground system.

It was clear that cosmonaut Titov, chairman of the State Commission wanted to carry out the launch particularly on April 12 …

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It would be symbolical – a launch on Cosmonautics Day of the new launch vehicle, opening a number of advanced integrated launch vehicles, including the manned Zenith version. One must say that on April 12 it was Good Friday, and on Sunday – it was Easter, while from the standpoint of Christianity it was a deep sin to carry out the launch in those days.

In the morning during breakfast the chair suddenly breaks apart in the canteen of YSDO hotel on 43rd platform under Mr. Utkin, the General Designer – a bad luck. Mr. Lipka, the mission commander, who was ashen-faced at that time, quickly replaced the chair. Vladimir Fedorovich pretended as if nothing had happened, and did not say a single word.

A strong wind blew on that day, the gusts of wind reached 15 m/s, and the wind velocity restriction during the first launch was up to 12 m/s. Vladimir Fedorovich went himself to check the wind velocity readings. Fortunately, before liftoff the wind fell, and a permit for launch was obtained.

…However, on April 12 1985 the launch did not take place. The first attempt ended with all-clear signal in the ground check and launch complex due to voltage slump in the power network.

The launch was rescheduled to two hours. But the repeated attempt ended with failure. Already in final operations of the launch cyclogram after filling the LV with propellants the transporter erector fails. Hydraulic cylinder locking device of the right erector arm grapple fixture got jammed under the influence of real loads. Operation for removal of the grapple fixture was not performed, and LV prelaunch processing was not stopped.

After cancellation of launch on April 12 it was unanimously proposed on April 13 (!) not to let it go, clear up the cause, eliminate deficiency and provide some rest for launch team and perform launch on April 14. But Mr. Utkin suddenly responded to that proposal with sharp criticism and chose the lesser evil from his point of view – he set the time for launch on April 13 at 13.00. “Well, there you are, five years were not enough for you to let it go on Sunday (to read during Easter)”, – said Vladimir Fedorovich.

And the next day, on April 13, 1985, at 13.00 The Zenith LV launch №1Л was performed successfully!

…It is difficult to convey happiness and exultation of the test participants. There was a meeting on 45th platform, congratulations, reports to the Government on the first successful launch of Zenith LV and the beginning of the first flight test phase of Energiya-Buran complex.

And in the evening there was the first and the only banquet for launch participants over all flight tests of Zenith SLS in “Meridian” canteen of the platform 43 … Perestroika (reconstruction) began in the country and it began with the phase of “struggle for teetotalism”.

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The flight test results and the following operational phase of Zenith complex confirm a high prestige of Zenith launch vehicle as the most perfect vehicle in the launch services world market.

High operational qualities, lucky engineering and schematic solutions, implemented in Zenith launch vehicle, have stipulated its selection as a basic product for development of three-stage launch vehicle under one of the most grand projects of the ХХ century – Sea Launch international project.

By the way, the LV became Zenith much later, when the issue arose on its commercial use. Mr. Fedorov, the Head of the sector from department 102 proposed the name Zenith, and earlier the rocket was named as LV 11К77.

The birth of the 13 number left its mark – the Zenith has a difficult fate, many hardships fell to it. The hardest accident during liftoff due to first-stage engine problem completely damaged the launch pad in the second launching «leg». It happened in October 1990. Its recovery in conditions of breakdown of USSR was not already successful. The accidents happened twice because of the first-stage main engine, and then happened twice due to second-stage main engine. Troubleshooting had to be carried out in conditions when funding was not provided. At the same period the number of launch orders sharply reduced, and the first attempt to use Zenith commercially proved to be a loud accident when 12 Global star SCs were destroyed. But each time Zenith raised itself owing to purposefulness and professionalism of the designer teams headed by YSDO – SPA “Energomash”, NPTs AP, DOEM, PA YMZ, Baikonur test engineers and many other enterprises and organizations.

Over the time of operation of Zenith complex an ideology of its use changed in any ways. In its due time the Zenith SLS was being built as highly efficient, quick-firing complex with large margin of autonomy for maintaining the combat duty and «star wars». With breakdown of the Soviet Union and a change in the foreign political situation the preconditions for using the complex for such purpose were gone. And instead an idea came up and became stronger on its commercial use in international space programs.

Now Zenith can be used in various configurations: two-stage, three-stage configurations, Sea and Land Launch versions, with ДМ-SL and Frigate upper stages, that significantly expands possibilities of its application. The potential of Zenith is unexhausted and it gives firm confidence in its future.

The second birth of Zenit in Baikonur took place under the Land Launch project on April 28 2008 and was marked by successful launch of Israeli Spacecraft AMOS-3 into orbit in the form of Zenith-3SLБ” three-stage launch vehicle based on modernized Zenith-М complex.

May you live long and have successful flights, our Zenith!

Anatoly AGARKOV,

Deputy General

Designer for flight tests