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Communications on a global scale


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Информационные спутниковые системы

Кооперация


Информационные спутниковые системы

Dear colleagues, Nowadays the application of the space industry’s achievements to the national economy is a top-priority goal. I dare say satellite communications play a most significant role in the country’s life and activity as well as in everyday life of its citizens. With recent economic and technology advancements, there is a growing demand from satellite operators for additional resources provided via advanced telecommunications satellites. That is why the communications satellite market is one of the most promising and actively developing markets. Today the Reshetnev Company is listed among the world’s top five satellite manufacturers of telecommunications satellites with the largest number of contracts made in 2009. In total, in its fifty-year history the company has created over 200 telecommunications spacecraft. Owing to its unique experimental and manufacturing base, highly qualified personnel and reliable partners ISS-Reshetnev is able to create high-powered, high-capacity, long-lived satellites in the shortest possible time. Today, for the creation of next-generation telecommunications satellites, ISS‑Reshetnev offers its customers two unified satellite platforms, Express-1000H and Express-2000. The first platform provides a base for a number of satellites currently in production at the Reshetnev Company, i.e. Amos-5, Telkom-3 and Yamal-300K. The heavy-class Express-2000 platform has been approved for the Express-AM5 and Express-AM6 projects as well as the Yamal-401 satellite. The creation of advanced telecommunications satellites is not only a priority activity of the Reshetnev Company, but also its substantial contribution to Russia’s economic development.

General Designer and Director General of Academician M.F.Reshetnev Information Satellite Systems

Nikolay Testoedov

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Contents

JSC “Academician M.F. Reshetnev “Information Satellite Systems” 52, Lenin Street, Zheleznogorsk, Krasnoyarsk region, 662972 Russia Tel: 8 (3919) 72-80-08 Fax: 8 (3919) 72-26-35

A parade of the latest achievements in the communications industry

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Russia-France: yesterday, today and tomorrow

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Satellite telecommunications

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AMOS-5: ISS-Reshetnev’s new international contract

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TELKOM-3: a satellite system for the Indonesian communications service provider

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Yamal satellites for Gazprom Space Systems

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New technology for manufacturing onboard cable systems

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Integrated approach to human resource management

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SESAT: a successful project, a well‑deserved victory

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Editor-in-Chief � Svetlana Bashkova Managing Editor � Natalia Vnukova Translator � Svetlana Kulaga Photo � Vlada Mineeva Design � Maxim Mikhalchenkov Published by Information Satellite Systems 2010 For details contact: pressa@iss-reshetnev.ru http://www.iss-reshetnev.com tel: 8 (3919) 76-45-25 No unauthorized photocopying.


ISS-Reshetnev enhances cooperation with Sodern

ISS-Reshetnev participates in the international project “Millimetron” The Reshetnev Company is completing the preliminary design of the orbital telescope intended for the space observatory “Millimetron” ordered by the Russian Federal Space Agency.

The French delegation from the Sodern Company visited ISS-Reshetnev in late May to give a presentation on its next-generation devices for space applications, in particular, earth observation cameras and the HYDRA star tracker intended for low-altitude spacecraft. Didier Vilaire, Director of Space Programs, and Yves Kocher, Head of Space Business Development at Sodern, submitted their proposals to Nikolay Testoedov, General Designer and Director General of the Reshetnev Company for developing cooperation and strengthening product competitiveness. So far, the French company has developed, manufactured and supplied a new functional model of the Hydra star tracker for ISS-Reshetnev’s advanced Express-1000H platform as well as related technical equipment and the first flight unit. The visit of the French delegation resulted in signing a protocol stating all the agreements reached. “I hope that in addition to star trackers our companies will find more fields for co-operation in the nearest future,” said Yves Kocher.

ISS-Reshetnev welcomes EUTELSAT The delegation of the European satellite operator EUTELSAT arrived at ISS-Reshetnev on June 29 for a working visit to summarize the results of the SESAT satellite program. Since its launch, conducted on April 18, 2000, the SESAT telecommunications satellite has been performing its mission successfully for over 10 years, thus, providing communications, digital television broadcasting and Internet services to Europe, the Middle East, Eastern and Central Siberia. Despite some minor comments, the satellite has demonstrated stable performance and reached all the mission targets. One of the advantages of the SESAT satellite is that it allows the operator to widely use an independent control mode together with the traditional one. It is also worth mentioning, that EUTELSAT highly appreciates the satellite’s reliability and operation and is quite satisfied with its mission results.

According to the experts of ISS-Reshetnev’s Industrial Center of Large Foldable Mechanical Systems, the main peculiarities of the orbital telescope are its 12-meter diameter, a high-precision mirror and a capability for operating at cryogenic temperatures (-269°C). The telescope will incorporate ISS-Reshetnev’s new technologies and innovative solutions, for instance, composite structures. The telescope’s unique parameters will allow scientists to more deeply explore and study the solar system, the origins of the universe, the formation of star systems and planets as well as detect emerging galaxies. The telescope has been designed with a service life of 10 years.

A new contract between ISS‑Reshetnev and Saft On June 18, 2010 the Siberian satellite manufacturer “Academician M.F. Reshetnev Information Satellite Systems” and the French company Saft signed a frame contract for the supply of lithium-ion batteries for ISS-Reshetnev’s new spacecraft. At the Saint Petersburg Interna­tional Economic Forum Nikolay Testoedov, General Designer and Director General of the Reshetnev Company, and Philippe Jehanno, Saft General Director, signed a frame contract for the supply of lithium-ion batteries for space applications. By applying the lithiumion battery technology ISS-Reshetnev aims to considerably improve performance specifications of its spacecraft, in particular, the capacity of satellite platforms with no extra weight. At present Saft is fulfilling deliveries of lithium-ion batteries for a number of ISS-Reshetnev’s telecommunications satellites, such as AMOS-5, TELKOM-3, Yamal-300K, Express‑AM5 and Expess-AM6.


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Information Satellite Systems

Events

A parade of the latest achievements in the communications industry The Siberian manufacturer “Academician M.F. Reshetnev “Information Satellite Systems” has taken part in the 22nd International Exhibition for Telecommunications, Control Systems, IT and Communication Services “Sviaz Expocomm- 2010”.

ISS-Reshetnev’s exhibition stand

The exhibition took place at Expocentre Fairgrounds, in Moscow, on May 11-14, 2010. This year the industry’s flagship event brought together 540 companies from 22 countries, and attracted as many as 23 460 professionals and 27 600 visitors from Russia and abroad. The annual exhibition “SVIAZEXPOCOMM” is Russia’s largest and most prestigious industrial forum with a 30-year history. The exhibition has earned a good reputation on the international arena for being a highly effective platform for promotion of new technologies and business opportunities, thus, allowing foreign IT and communications equipment manufacturers to seek and develop cooperation with Russia. According to Dmitry Medvedev, President of the Russian Federation, “In its lifetime “Sviaz Expocomm” has become an authoritative forum and one of the largest exhibitions of achievements in the telecommunications and IT industries”. The Reshetnev Company is a regular participant in Sviaz Expocomm. This year ISS-Reshetnev has demonstrated its latest achievements and advanced projects in satellite telecommunications. The company’s exposition “Complex solutions for satellite control” included a  model of the advanced AMOS-5 satellite being built for the Israeli operator Spacecom, as well as models of ground antenna systems developed by NPO PM – Razvitie, a company recently integrated into ISS-Reshetnev. Among other satellite projects presented at the exposition there were two more models developed by ISS-Reshetnev, in particular, Express-AM44, Russia’s most advanced telecommunications spacecraft, and Express-AM5 being currently built for the Russian national satellite operator RSCC. The Express‑AM5 will accommodate more than 80 transponders in the C-, Ku-, Kaand L-bands and produce no less than 14kW of payload power. ISS-Reshetnev’s program of work at SVIAZ-EXPOCOMM-2010 was very intensive and included numerous business meetings with partners and customers.


Information Satellite Systems

Russia-France:

yesterday, today and tomorrow

The Siberian satellite manufacturer “Academician M.F. Reshetnev Information Satellite Systems” took part in the Russian National Exhibition held in France, on June 11-16 within the 2010 Franco-Russian Year Program. The exhibition was held in the Grand Palais, in Paris, under the motto “Russia-France: yesterday, today and tomorrow”. The event was organized to demonstrate Franco-Russian collaboration in different spheres (economy, finance, industry, trade) as well as develop strategic, economic and commercial partnerships, and promote export of high-tech products. The exhibition also provided opportunities for the participants to present large-

scale Franco-Russian cross-investment projects in such fields as space exploration, telecommunications, aircraft and helicopter industries. The Russian National Exhibition was opened by Prime Minister Vladimir Putin and his French counterpart Francois Fillon. In his welcome address at the opening ceremony Vladimir Putin said, “We are inaugurating an exhibition that was created by Russia’s largest companies, including

the research and technical community. This is one of the main events of the Year of Russia in France and the Year of France in Russia. You will see not only Russia’s past achievements but also our ideas spearheaded into the 21st century”. After the opening ceremony the two prime ministers walked around the exposition stands and got familiar with the displays of the latest achievements in different spheres, including the space industry. ISS-Reshetnev was exhibiting jointly with the Russian Space Agency’s integrated exposition. The company’s delegation was headed by Nikolay Testoedov, General Designer and Director General. At the exhibition the Reshetnev Company demonstrated a model of the SESAT telecommunications satellite, the company’s first spacecraft built for a foreign satellite operator jointly with Alcatel Space (now Thales Alenia Space). The SESAT project laid the foundations of a successful long-standing cooperation between the Russian satellite manufacturer and a number of French companies. At the ISS-Reshetnev stand guests and visitors could also see models of the advanced Express-2000 platform and two navigation satellites, Glonass-M and Glonass-K. Besides, the Reshetnev Company exhibited models of the Loutch-5A data relay spacecraft and the AMOS-5 telecommunications satellite that are currently being built in close cooperation with ISS-Reshetnev’s French partners. At the close of the exhibition the ISS-Reshetnev team was awarded a Participant’s Diploma. The Russian National Exhibition in Paris was not the only event attended by the Reshetnev Company within the scope of the Franco-Russian Cross Year Program. Thus, in late May Nikolay Testoedov, General Designer and Director General of ISS-Reshetnev, took part in a round-table session organized by the Office for Science, Technology and Space of the Embassy of France where he delivered a report to the Franco-Russian scientific community on “Man in space: are there any boundaries?”.

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Satellite

telecommunications Satellite telecommunications have become an integral part of everyday life in the 21st century. Digital television and radio broadcasting, fixed and mobile communication as well as access to the Internet are all provided via satellites. Today Academician M.F. Reshetnev Information Satellite Systems is listed among the world’s top five satellite manufacturers with the largest number of orders received for the supply of telecommunications satellites.

Unique know-how Today ISS-Reshetnev is the leading satellite manufacturer in the Russian space industry. In fifty years the company has built more than 1200 spacecraft, a considerable part of which are telecommunications satellites. The company’s first communications and television broadcasting satellites, Molnia-1, operated in the highly elliptical orbit. Thanks to them, the USSR started the exploitation of its first communications system in the late 1970s. In the sequel, the well-proven Molnia-1 design served as the basis for technically improved spacecraft with new repeaters. Those were satellites of the Molnia-2 and Molnia-3 series. Since the 1970s ISS-Reshetnev has been developing geostationary


Information Satellite Systems

telecommunications satellites. Thus, the company’s Raduga geostationary satellites together with Molnia-3 highly-elliptical spacecraft provided a base for the creation of the Unified Satellite Communications System which enabled voice communications and television broadcasting via the Orbita network stations. Telecommunications satellites of the Ekran series formed the core of the world’s first continuous direct broadcasting system that also included a complex of ground devices. ISS-Reshetnev’s next unique telecommunications project was named Gorizont. Spacecraft of this series relayed television and radio news broadcasts of the 1980 Moscow Olympic Games. All those satellites demonstrated high performance and reliability. What is more, many of

them operated in orbit twice longer than projected. In the 1990s the Reshetnev Company created the Express-A series that for the first time carried repeater equipment developed by the French company Alcatel Space (now Thales Alenia Space).

The first international project In the spring of 2010 ISS-Reshetnev celebrated the 10th anniversary of the launch of the Siberian-European telecommunications satellite SESAT built to serve Europe’s largest satellite operator Eutelsat. For ISS-Reshetnev SESAT is a symbol of the company’s entrance into the international arena,

for it was the first satellite built for a foreign operator. SESAT embodies the best Russian and Western technologies. Thus, it was equipped with a Thales Alenia Space payload module. The project was a success, especially taking into account the fact that it was the first Russian satellite designed to operate for as long as 10 years. Today it is still carrying out its space mission successfully, thus, providing services to Russia, Europe, North America, the Middle East and the Indian Region. According to Eutelsat’s representatives, SESAT is one of the most convenient spacecraft to handle. The implementation of the SESAT project confirmed the high quality and competitive performance of ISS-Reshetnev’s space-technology products and their compliance with the world standards.

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Express-AM satellites The company’s next milestone is associated with the development and manufacture of the Express-AM satellite series for Russia’s national satellite operator RSCC. By the time the program started ISS had developed a reliable satellite base to go ahead with, i.e. a satellite platform derived from the SESAT spacecraft. It was a prerequisite for a quick implementation of Russia’s constellation replenishment program. Payload modules for ExpressAM satellites were supplied by Alcatel Space (France) and NTSpace (Japan). The Reshetnev Company was responsible for the development, qualification and manufacture of the PLM structure made from honeycomb panels with embedded liquid thermal loops. Besides, the company manufactured L-band antenna & feeder devices. In accordance with the terms of the contract, ISS manufactured 7 Express‑AM telecommunications satellites which were launched within 2003-2009. At present these spacecraft are the key assets in Russia’s telecommunications satellite fleet.

300K telecommunications spacecraft ordered by the Russian company Gazprom Space Systems. One of the main advantages of these spacecraft is that they will have high capacity, and relatively low masses, at that. ISS-Reshetnev’s heavy-class Express‑2000 platform has been approved for the Express-AM5 and Express-AM6 satellites being manufactured for the Russian national operator RSCC. Each satellite will carry over 70 transponders in the C-, Ka-, Ku- and L-bands. With the payload power no less than 14kW, Express‑AM5 and Express-AM6 are expected to become the most powerful Russian telecommunications satellites. Express-2000 will be also used for one more telecommunications satellite, Yamal-401, ordered by Gazprom Space Systems.

Telecommunications of tomorrow When developing advanced telecommunications satellites, the Reshetnev Company applies a modular design concept, according to which a modern satellite is made up of two modules - a service module (a satellite platform) and a payload module. The main advantages of the modular design principle are the reduced satellite-building time, lower costs of work, higher quality and reliability of spacecraft. Today, for the creation of nextgeneration telecommunications satellites, ISS-Reshetnev offers its customers two unified satellite platforms, Express-1000H and Express2000. The first platform is designed for medium-class satellites weighing no more than 1700 kg; the second is intended for heavy-class spacecraft whose mass can amount to 3.5 tons. The Express-1000H platform has been approved for the AMOS-5 spacecraft being built for SPACECOMMUNICATION LTD. (Israel) and Telkom-3 ordered by PT Telekomunikasi Indonesia Tbk. (Indonesia). Moreover, the platform is intended for the Yamal-

Express-AM44 in the assembly fixture

ISS-Reshetnev cooperates with a number of leading foreign companies in creating advanced telecommunications spacecraft. In partnership with Thales Alenia Space, Saft, Sodern, Aeroflex, Actel and many other well-established firms ISS-Reshetnev manufactures highly competitive, world-class quality products. Today the Reshetnev Company participates in almost all tender competitions for the supply of telecommunications satellites. Owing to its unique experimental and manufacturing base, highly qualified personnel and reliable partners the company is able to create high-powered, high-capacity, long-lived satellites in the shortest possible time.


Information Satellite Systems

AMOS-5:

ISS-Reshetnev’s new international contract

AMOS-5 is the first spacecraft being built by the Reshetnev Company for the Israeli satellite communications service provider, SPACE‑COMMUNICATION LTD. The satellite is based on ISS-Reshetnev’s advanced Express-1000H unpressurized platform, and besides, embodies many unique technical solutions introduced by the Reshetnev team to ensure high power and a 15‑year lifetime.

How it started When in 2008 the Israeli satellite operator SPACE-COMMUNICATION LTD. announced its decision to enlarge its orbital constellation, the Intersputnik International Organization of Space Communications made the company the best offer for the orbital resource. As well as that, Intersputnik invited ISS‑Reshetnev, Russia’s renowned satellite manufacturer, to take part in the program. In April 2008 the three companies met to discuss Spacecom’s requirements and ISS‑Reshetnev’s capabilities. Negotiations continued in the summer, and in three weeks the contract was prepared. It was signed on July 31, 2008 and a month later, came into force. Activities under the project began in September.

Specifications The AMOS-5 satellite is designed to provide communications, broadcasting and broadband services to Africa and Israel.

„„ Launch Mass: 1880 kg „„ Mission Life: 15 years „„ Station keeping accuracy: ±0.05° „„ Payload: 18 active Ku-band transponders and 18 active C-band transponders „„ Antennas: 1 C-band antenna and 3 Ku-band antennas „„ Payload power: 5600 W „„ Orbital slot: 17°E The AMOS-5 spacecraft is based on the advanced Express-1000H unpressurized platform that has a number of advantages, for instance, a hybrid thermal control subsystem and a redundant liquid loop to provide thermal transfer between the satellite’s structural elements of different temperatures. To reduce the height of the satellite the platform equipment has been placed onto the honeycomb

panel installed inside the load-bearing structure of the satellite body, i.e. in the central tube. The platform also houses highly-effective arrays of three-cascade gallium arsenide solar cells as well as lithium-ion batteries and highly-effective stationary plasma thrusters.

ISS‑Reshetnev’s volume of work In terms of volumes of activities being undertaken in-house, the AMOS-5 project is more challenging than any other commercial programs previously implemented by the company. Thus, apart from the satellite platform the company is also making the payload structure from honeycomb

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panels with embedded heat pipes and external liquid loops. As well as that, ISS‑Reshetnev’s activities include installing antenna equipment into antenna panels; performing antenna pattern measurements, mechanical and thermal analyses of the payload, critical design reviews and budget calculations; and finally, satellite assembly, integration, testing and commissioning. In addition, ISS‑Reshetnev is responsible for the manufacture of the ground control

segment. According to the terms of the contract, the company will also provide a satellite software simulator, training services for Spacecom specialists and satellite in-orbit support through the life of the mission.

Subcontractors Thales Alenia Space (France) is ISS‑Reshetnev’s main subcontractor for the development and manufacture of the payload, antenna equipment

and TCR items. Besides Thales Alenia Space, there are two more French companies participating in the project: a provider of star trackers, Sodern, and a supplier of lithium-ion batteries, Saft. Apart from the French companies, ISS‑Reshetnev is cooperating with a number of Russian companies, in particular, IRZ (Izhevsk), Fakel (Kaliningrad), Kvant (Moscow), TSENKI (Moscow), GeophisikaCosmos (Moscow), Polyus (Tomsk) and R&D Institute of Mechanical Engineering (Nizhny Salda). Some of these enterprises have been recently integrated into the Reshetnev Company.

Current project activities The project activities are on schedule. So far, ISS‑Reshetnev has completed equipment qualification tests. A number of major milestones were reached in April, 2010, when the CDRs of the payload and antenna subsystem were carried through; qualification tests on the mechanical devices of solar arrays and their drivers were completed; complex trials of the onboard control system were conducted. The Reshetnev team has also completed the Amos-5 EQM and started testing the satellite attitude control system and pulse code modulation. Work on the payload structure, as scheduled, is nearing completion and in late May the structure will be delivered to Toulouse (France) for further integration and testing. ISS‑Reshetnev’s Russian partners have conducted the qualification of onboard equipment and instruments and started

AMOS-5 EQM in assembly

AMOS-5 PLM structure in preparation for vacuum tests


Information Satellite Systems

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manufacturing and supplying flight equipment to ISS‑Reshetnev.

Launch date In spite of all the team efforts and synergism, the satellite launch was postponed due to force majeure. In April 2010 a large earthquake took place in L’Aquila, Italy. The city was almost destroyed. The local factory that had been manufacturing components for the AMOS-5 TCR and payload equipment was badly damaged. There was no access to the ruined facilities for more than two months. It took several months to transfer production of component parts to other facilities of Thales Alenia Space in Italy. As a result, the launch was rescheduled for mid June, 2011.

Customer AMOS-5 is the first joint project between ISS‑Reshetnev and the Israeli company SPACE-COMMUNICATION LTD. The customer’s team are not only highly-qualified specialists, but also very interesting people. It is human nature to have interest in other countries, history, people and their way of life. The AMOS-5 project provides a great opportunity for a cultural exchange between the two companies. Spacecom’s business is growing. Today the Israeli satellite operator is nourishing the idea of having AMOS-6. As for ISS‑Reshetnev, it is expecting an official bid invitation. The company is ready for fierce competition and will spare no efforts to make a good offer.

AMOS-5 solar panel

Alexander Dostovalov, AMOS-5 project manager

AMOS-5 solar array panel in testing

AMOS-5 service systems module


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Information Satellite Systems

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TELKOM-3: a satellite system

for the Indonesian communications service provider

Activities under the TELKOM-3 project are in full swing. The Reshetnev Company is busy creating the geostationary telecommunications satellite system for PT TELEKOMUNIKASI INDONESIA Tbk, one of the largest satellite operators of the Asian-Pacific region. The Siberian manufacturer won the TELKOM-3 project in intense competition in December, 2008. It is important to note that it was ISS-Reshetnev’s second victory held in international competition in 2008.

Contract terms According to the terms of the contract, ISS-Reshetnev will develop, manufacture and deliver in orbit the TELKOM-3 spacecraft as well as provide a ground control segment, inorbit support and training services for the customer’s personnel. Besides, the Reshetnev team will also transfer part of satellite traffic from Orbital’s TELKOM-2 satellite. When bidding for the contract, the Siberian satellite manufacturer had to compete against such world-famous companies as Orbital Sciences Corporation, Thales


Information Satellite Systems

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Alenia Space and Space Systems/ Loral. ISS-Reshetnev’s bid was the most interesting in terms of delivery dates as well as technical and economic aspects. The satellite is based on the advanced Express-1000H mediumclass platform. It will accommodate 24 C-band transponders, 8 Extended C-band transponders and 10 Ku-band transponders. The satellite has been designed to produce 5.6 kW of payload power and to have a lifespan of 15 years. Once positioned at 118° E, it will provide communications, broadcasting and broadband services to Indonesia and Indochina. The launch is scheduled for July 2011.

Distribution of work Within the scope of the TELKOM-3 project, the Reshetnev Company is carrying out a lot of activities in-house. Thus, the company is manufacturing a satellite platform, and is responsible for complex integration and testing. It is also responsible for the manufacture of a ground control segment, its assembly and installation in Indonesia. ISS-Reshetnev’s main partners are Thales Alenia Space, a supplier of the payload, and Khrunichev State Research and Production Space Center, a launch service provider. ISS-Reshetnev has subcontracted the ground control segment to the German company Vertex Antennentechnik GmbH. Apart from these companies, Reshetnev is cooperating with a number of Russian enterprises, in particular, IRZ (Izhevsk), Fakel (Kaliningrad), Kvant (Moscow), TSENKI (Moscow), Geophisika-Cosmos (Moscow), Polyus (Tomsk) and R&D Institute of Mechanical Engineering (Nizhny Salda). The same Russian companies are involved in the AMOS-5 program. By the way, the TELKOM-3 project and the AMOS-5 program have much in common as regards work distribution patterns and the use of high technology. Besides, part of the TELKOM-3 equipment will be qualified within the framework of the AMOS-5 project. However, the TELKOM-3 contract has some special provisions, according to which ISSReshetnev has to submit a considerable amount of report documentation to the customer. Thus, for every working meeting with PT TELEKOMUNIKASI

Souvenirs for Indonesian colleagues INDONESIA Tbk. the Reshetnev team has to prepare a package of documents and deliverables. So far, the company has completed the design documentation and proceeded to the manufacturing phase. Work on the payload module structure is at full swing; upon its completion the structure will be shipped to Thales Alenia Space. Tests are scheduled for autumn 2010.

Supervision It is the first time the Reshetnev Company has entered into a contract with PT TELEKOMUNIKASI INDONESIA Tbk. According to the terms of the contract, the work

on the project is to be done under the supervision of the customer’s representatives. The Indonesian delegation living in Zheleznogorsk has a direct access to ISS-Reshetnev’s facilities and can discuss any projectrelated issues with the company’s experts and specialists. Besides, the Indonesian company is being consulted by Telesat, one of the largest fixed satellite services operators in the world. Telesat’s team are all experienced consultants specializing in all aspects of the satellite business and having a detailed knowledge of all technical and organizational issues. Telesat’s representatives are also staying in Zheleznogorsk to assist the Indonesian party with design reviews and negotiations.

Modeling of TELKOM-3 parts and assemblies


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Internship

Ribbon cutting to welcome Indonesian specialists to their new homes

According to the terms of the contract, ISS-Reshetnev is currently training 7 staff members of PT TELEKOMUNIKASI INDONESIA Tbk. The interns are all young technical specialists with a good command of the English language. The training course covers theory and practice formalized in an 18-month tailor-made program. For a year and a half ISS specialists will be sharing experience with their Indonesian colleagues. At present the interns are studying theory that covers a range of issues from basic design principles to particular approaches to the TELKOM-3 spacecraft, its design and main systems and subsystems. The theoretical part of the program consists of 35 individual modules and covers the whole spectrum of tasks to solve in the satellite project. At the practicum stage the interns will take part in the integration and testing of the new satellite. In fact, this internship program is ISS-Reshetnev’s unprecedented experience of training specialists from abroad. The representatives of PT TELEKOMUNIKASI Tbk. arrived in Siberia with their families. Every family was provided with a furnished apartment in a new block of flats. ISSReshetnev has been giving the families a lot of support trying to help with household problems as well as with the organization of leisure activities.

Project importance

Indonesian interns at ISS-Reshetnev

The cooperation with the new customer, PT TELEKOMUNIKASI Tbk., as well as the TELKOM-3 project itself are of great importance for the Reshetnev Company and its development. There is no doubt, that this program will allow ISS-Reshetnev to increase its potential and expand its cooperation geography. Yuri Vilkov, TELKOM-3 manager

Honeycomb panels for TELKOM-3 structures


Information Satellite Systems

Yamal satellites

for Gazprom Space Systems In recent years ISS‑Reshetnev has consolidated its hold on the telecommunications market significantly. The company’s customer base has also expanded to include not only Russian but also foreign companies. The ISS team’s expertise as well as a wealth of accumulated solutions grows from project to project. Among those that present a particular interest is the on-going Yamal program being implemented by ISS‑Reshetnev for Gazprom Space Systems, one of Russia’s largest satellite operators. Gazprom Space Systems is a company that creates industrial information space systems based on the principles of commercial return and attraction of extra-budgetary funds. The history of the Yamal program goes back to 2008, when Gazkom (now Gazprom Space Systems) announced a tender competition for the manufacture of two Yamal-400 spacecraft. ISSReshetnev prepared a tender offer and entered the bidding process. In fierce competition with Russian and foreign companies, the Siberian satellite manufacturer managed to win the Yamal-401 project. Prior to the Yamal-400 program, Gazprom Space Systems had awarded a contract for the Yamal-300 program, i.e. the Yamal-301 and Yamal-302 satellites, to S.P. Korolev Rocket and Space Corporation “Energia”. However, the implementation of the program did not go smoothly, and as a result, Gazprom Space Systems broke the

contract. Under the circumstances, the Reshetnev Company proposed to install two repeaters originally intended for the Yamal-301 and Yamal-302 satellites into one of ISS‑Reshetnev’s platforms, in particular, Express-1000H. Gazprom Space Systems got interested. During the 2008-2009 winter months, all the preliminary procedures, details and agreements were finalized. In May 2009 the two companies signed a contract for the manufacture of the Yamal‑300 space complex to be based on the Yamal‑300K spacecraft. On July 17, 2009 the contract entered into force. In accordance with the terms of the contract ISS-Reshetnev is responsible for the development and manufacture of the Yamal-300K telecommunications satellite and the associated ground control systems. Once placed into the geostationary orbit at 90° E, the Yamal-300K satellite will provide C- and Ku-band services to Russia and the CIS countries. Equipped with 26 transponders it will have enough capabilities to offer endusers a complete spectrum of modern communications services.

The advanced satellite platform Express-1000H will ensure the spacecraft the following technical parameters: „„ A lifespan of 15 years; „„ A platform mass of 450 kg; „„ 5600W of power supply; „„ Rejection of up to 3500 W of waste heat. These platform parameters are sufficient enough to enable ISS‑Reshetnev to accommodate the repeater equipment originally projected for two different satellites aboard one spacecraft. The complete satellite will weigh approximately 1700kg, which will allow the company to launch it in tandem with the TELKOM-3 spacecraft (currently in production at ISS‑Reshetnev) aboard a Proton-M rocket. The main advantage of the Yamal300-K project is its reduced order-todelivery cycle time, which is mainly due to the fact that the equipment for the payload and the ground control segment was manufactured within the initial Yamal-300 program. Today’s competitive environment requires that satellites be developed

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and manufactured within 24-30 months. These are rather tight schedules. With Yamal-300K, the order-to-delivery time has been reduced by another 4 months so as to launch the spacecraft together with the TELKOM-3 satellite whose production started much earlier. As Yamal-300K is based on ISS-Reshetnev’s standardized Express-1000H platform (also used in the AMOS-5 and TELKOM-3 projects) the volume and the time of design work will be reduced. Yet, with a number of other spacecraft simultaneously in various stages of manufacture, ISSReshetnev will definitely have a busy period trying to be on schedule for the spacecraft launch in 2011. The original repeater equipment designed and manufactured for the Yamal-301 and Yamal-302 satellites was made to fit a different satellite platform and therefore, has different interfaces. In addition to the obvious integration and combination problems, there will be also difficulties in adapting the payload to the platform, as the payload, or to be more exact, its elements are complete and are subject to no change. These discrepancies include different (platform vs. payload) voltages, interference spectra in electrical lines, mechanical load levels, levels of radiation tolerance, etc. To meet the challenge and successfully integrate a payload into the platform, the company will have to develop additional means, such as power supply units for the communications payload,

Signing the production schedule for the Yamal-300K spacecraft and conduct additional testing. However, the necessity for additional activities reduces the effect of the standardized platform. The Yamal project is also unusual in terms of work distribution. Thus, Gazprom Space Systems, the customer, will supply a payload, a ground control station and other subsystems intended for the ground control segment. The Reshetnev Company, besides manufacturing a payload module structure, which is a company’s typical “contribution”, will be also engaged in the creation of a number of PLM elements, such as antennas,

Discussing the progress of work under the Yamal-300K project with the customer’s representatives

power supply units, onboard control, waveguides and the low-frequency cable system. This is a new field of activity for ISS-Reshetnev and there is no doubt that the new experience the company is gaining in the Yamal project will definitely contribute to the success of its future programs. The same work distribution pattern is followed in the organization of work on the ground control segment. Thus, besides having some ready-to-use control equipment, the customer is also taking part in the creation of the missioncritical onboard and ground control equipment as well as some systems, which also required making changes in the platform’s original structure and the responsibility pattern. Yamal-300K is the first joint project of ISS-Reshetnev and its new customer, Gazprom Space Systems. The second joint project, Yamal401, is to start quite soon. Yet, the Reshetnev team hopes to go beyond these and make a greater contribution to the customer’s fleet. Thus, Gazprom Space Systems has 5 orbital positions in the geostationary orbit, but only three of them are occupied. Besides, the Yamal-100 satellite is completing its designed orbit lifetime. Finally, the Reshetnev Company is currently involved in the development of the joint multifunctional satellite system Arctica intended to provide communications services in the Arctic Region via HEO satellites. Pyotr Shaklein, head of section


Информационные Information спутниковые Satelliteсистемы Systems

New technology

for manufacturing onboard cable systems

Cables are vital for all satellite subsystems. Nowadays, with the market placing greater demands on satellite capabilities, the low-frequency onboard cable system, as an essential part of a satellite, is subject to change as well.

New requirements The Reshetnev Company started developing and manufacturing lowfrequency onboard cable systems in the 1960s. Quite for a long time Soviet rocket-and-space enterprises manufactured onboard cable systems (OCSs) based on obsolete technologies, materials, components, technological and testing equipment that had been developed and implemented 20-25 years before, for satellites with lifetimes of 3-5 years. Besides, OCSs were often designed as sets of separate cables rather than onboard cable networks. Design documentation was prepared and produced manually.

Nowadays satellite design involves meeting rigorous requirements, which equally refers to low-frequency onboard cable systems. Today they are expected to meet the following criteria: „„ to function faultlessly for 15 years under conditions of vacuum, ionizing radiation and magnetospheric plasma; „„ to provide a rise in the frequency range of commands and telemetry signals up to hundreds of MHz and at that, to lower their levels to a few volts; „„ to cause a 30-50% reduction in the mass of a satellite’s power system;

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Информационные Information Satelliteспутниковые Systems системы

Кооперация Projects

„„ to allow engineering changes and improvements at any stage of manufacture; „„ and finally, to be less labourintensive. Thus, the present-day requirements and targets in spacecraft manufacturing completely disagree with the outdated principles once used in OCS design, manufacture and testing.

New technology To meet the targets ISS-Reshetnev has adopted a principally new method of making onboard cable systems for its advanced spacecraft. Now, at Reshetnev, the onboard cable system is implemented not as a set of separate cables, but as a single threedimensional network of electrical interfaces, having a complex multibranched spatial configuration and up to 12000 connector contacts. The new OCS design and manufacturing technology was developed and implemented within the scope of the Loutch-5A satellite project. It is based on the “flowthrough” method which combines separate operations into a single technological process, thus, covering stages from designing to making a finished product.

Design phase Onboard cables

Today the Reshetnev Company designs onboard cable systems in 3D

Wiring cables into connectors

The laying of electrical circuits on the spacecraft dummy


Информационные Information спутниковые Satelliteсистемы Systems

taking into account the optimization of bond lengths and providing electromagnetic compatibility of electrical circuits and ESD protection. To organize work into a systematic, planned activity, compliant with modern standards and requirements, the Reshetnev Company has created a new computerized workplace and provided it with 3D software. The use of computer-aided technologies enables ISS engineers to draw up OCS designs on 3D spacecraft models, where each point is clearly defined in space, as well as achieve the following goals: „„ to calculate damage effects and provide damage resistance (e.g. to vacuum, temperatures, ionizing radiation, magnetospheric plasma); „„ to calculate and ensure electromagnetic compatibility of different electrical circuits as well as ESD protection; „„ to calculate spacecraft reliability and ensure a service life of 10 or even more years. CAD technology also allows making cable systems directly on spacecraft simulators, which minimizes the use of materials and cables and helps to optimize the length of electrical circuits. The company has already developed and implemented new technology for the design and manufacture of spacecraft cables (in accordance with the MIL-STD-1553B standard) for high-speed data links.

21

OCS manufacturing in the cleanroom

Peculiarities of OCS production When manufacturing onboard cable systems ISS-Reshetnev uses modern materials and components, connectors with removable crimp contacts, new methods of laying electrical circuits and sealing cable shields without manual soldering.

Automated cabletest system ТЕST-9110-VXI-12000

Electrical connections performed with removable crimp contacts and crimp sleeves allow making changes and improvements to the cable system at any stage of manufacture and testing without rejecting cables, connectors and components. A cable system is a complex branched network containing up to 12000 contacts. It requires special

Cables installed into a satellite


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Информационные Information Satelliteспутниковые Systems системы

Кооперация Projects

New opportunities

A quality test on crimp contacts equipment for running electrical tests and checking all its electrical circuits. The Reshetnev Company has recently acquired ТЕST-9110-VXI12000, an automated cabletest system which checks all circuits in a system within minutes and provides a quality assessment. The new testing equipment encouraged Reshetnev’s specialists to develop and implement new technology for running in-house electrical tests. To manufacture onboard cable systems in accordance with the latest technology ISS-Reshetnev has created a “cleanroom” in one of its workshops responsible for the manufacture of large-sized foldable antennas, antennafeeder devices, cables and control channels. The cleanroom is really unique and has no analogues in any other Russian space enterprises. The conditions created inside correspond

Electrical checkout

to the ISO Class 8 standards: the concentration of aerosol particles of size 0.5 microns is no more than 3500 particles/m3, which means that the air inside the room is 10-15 times cleaner than in a hospital. Besides, the air humidity in the cleanroom is maintained at 55% (±10%); the temperature at 22° (±3°) and the pressure difference (inside and outside the cleanroom) – from 5 to 20 Pa. To maintain the required conditions, the cleanroom has state-of-the-art climate control equipment including a smart ultrafine filter system. Working in the clean area imposes certain qualification requirements on the personnel, not to mention great responsibility for the quality of work. Therefore, the ‘cleanroom’ staff are all highly-qualified and expertly trained specialists.

Crimp contacts

The new OCS design and manufacturing technology will be used in a number of ISS-Reshetnev’s satellite projects: Loutch‑5A, Loutch‑5B, Yamal‑300K and some others. Its implementation will allow the company: „„ to increase the reliability of its onboard cable systems; „„ to improve the quality of OCS manufacturing; „„ to reduce the design-to-manufacture cycle time from 12 months to 4-6 months; „„ to reduce labor intensity; „„ to significantly improve OCS mass & dimension characteristics (on average three times as much); „„ to improve electrical characteristics; „„ to provide better electromagnetic compatibility and increase its ESD robustness; „„ to allow changes and improvements at any stage without any rejects. The implementation of the new technology also brings the company opportunities for making cable networks for foreign spacecraft manufacturers, which means that the company is reaching a new level of cooperation with Western firms. In April 2008 the Reshetnev Company and Thales Alenia Space signed a memorandum of cooperation, according to which ISS-Reshetnev got the possibility of designing and manufacturing OCSs for Thales Alenia Space spacecraft. Sergey Suntsov, Head of Design Department for Onboard Avionics Equipment, Onboard and Ground Cable Systems.


Информационные Information спутниковые Satelliteсистемы Systems

Human Resource Management

Integrated approach

to human resource management The question of how to make a space enterprise effective and competitive relates to HRM as well. Today the Reshetnev management team attaches great importance to human resource development, especially in the light of the ongoing changes. According to the results for 2009 the company’s personnel policy was acknowledged as one of the best in the Russian rocket and space industry, and its general designer and general director, Nikolai Testoedov, was awarded a commendation by the Russian Space Agency for his “personal creative contribution to the implementation of space programs and highly effective human resource management”.

Improving efficiency The joint-stock company “Academician M.F. Reshetnev “Information Satellite Systems” designs, develops and manufactures high-tech satellites and advanced satellite systems for both commercial and governmental customers. Today ISS-Reshetnev is the major supplier of spacecraft for various governmental programs, including the Federal Space Program, the Federal Target Program and the State Defense Order. In the last 5 years the company has almost tripled its output as well as the volume of activities done in-house. The implementation of the corporate personnel policy is influenced by the specific nature of the company’s activities and is therefore based on internal normative acts and directives, issued by the company’s management as well as on the industrial norms, regulations and orders established by the Russian Space Agency.

The company’s current HRM priorities are as follows: „„ to satisfy the demand of the enterprise for certain professional categories of employees qualified in space-related fields; „„ to facilitate organizational renewal and qualifications improvement; „„ to help young workers to adapt to work; „„ to develop the company’s scientific potential. An integrated approach to HRM is the keystone of a successful personnel policy. Moreover, it best reflects the company’s aim of creating highly effective systems to help employees unlock their creativity and potential.

From school to university The company places great emphasis on attracting and retaining young specialists. For this purpose, in 2003

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Информационные Information Satelliteспутниковые Systems системы

Human ResourceКооперация Management

Graduate-level thesis defence at ISS-Reshetnev ISS-Reshetnev launched a special complex program aimed at the attraction, retention, development and advancement of young staff members. In accordance with the program education starts straight from the school bench, including preschool and elementary school, continues at university and even after it when graduates are placed at the company. This approach is based on the principles of early child development and early aerospace education. Within the scope of its professionally-orientated educational program the company promotes physico-mathematical learning in local schools and provides assistance in furnishing and equipping classrooms. ISS-Reshetnev also organizes regular meetings with students, their parents and teachers as well as excursions for them to the company’s facilities and exhibition center. At the final stage the program culminates in field immersion workshops which allow eleventh grade students to implement

their first satellite design projects. Upon completion of the competitive selection the most talented school leavers are granted state-funded places at university.

Target intake To provide target training and preparation for the intake students ISS-Reshetnev has entered into an agreement with 11 leading Russian higher education institutions: Moscow State Technical University, N.E. Bauman Moscow State Technical University, D.F. Ustinov Baltic State Technical University, Tomsk State University, Novosibirsk State Technical University, Kazan State Technical University, Siberian State Aerospace University, Siberian Federal University and others. Target academic and training programs offered by different universities allow the Reshetnev Company to combine and integrate their strengths so as to provide the best

Change in the composition of staff workforce by age in 2006-2010 01.12.2006

01.12.2007

01.12.2008

01.12.2009

01.06.2010

Headcount of staff

Index

5680

5909

6335

6847

6972

Average age of employees

45,4

45

44,74

44,35

44

Number of young people under 30 (thirty-year-old staff members included)

1005

1179

1371

1731

1863

learning opportunities for the intake students, and in the future to form highly effective teams of specialists able to achieve the company’s objectives and production targets. In accordance with the federal Industry Student Career Intake Program implementation plan, a contract is signed with every selected candidate. It allows the intake students to get all types of onsite training and do graduation work at the Reshetnev Company as well as attend additional professionally-oriented classes. Besides, the company provides extra scholarships for freshmen starting from their second semester. As for students’ obligations, they are expected to work for the company for no less than 3 years after graduation. In the last 2 years over 200 school leavers have become intake students of the best Russian universities. In 5-6 years they will get guaranteed employment with the Reshetnev Company. In 2009 the enterprise received the first group of industryready graduates. The effective implementation of the Industry Student Career Intake Program at ISS-Reshetnev is achieved by: „„ monitoring students’ progress; „„ participating in the development and correction of state education standards and curriculums; „„ providing onsite training opportunities and designating supervisors, the company’s best professionals, to supervise and guide intake students; „„ graduate level thesis assistance (in formulating an appropriate topic as well as providing recommendations, reviews and assessment of the work completed); „„ designating mentors responsible for co-operation with higher educational establishments; „„ taking part in scientific conferences and meetings hosted by educational institutions. The preparation of future specialists is carried out on the basis of an innovative group project-based approach. Thus, in 2008 a team of Reshetnev’s specialists and SIBSAU’s students (abbrev. for Siberian Aerospace University) designed the Yubileiny small-sized spacecraft. The project had definite educational value and allowed the students not only to get familiar with the enterprise and its new equipment, but also to get good


Информационные Information спутниковые Satelliteсистемы Systems

design practice and valuable teamwork experience. Besides, a number of branch faculties and departments have been opened by Siberian Federal University and Siberian Aerospace University at the Reshetnev Company. They encompass the following disciplines “Spacecraft”, “Automated control spacecraft systems”, “Space engineering”, “Electronic devices and communications systems” and “Spacecraft manufacturing technology”.

Young employee incentive programs The Reshetnev Company has introduced a special system to support young specialists in their first years of employment. Thus, once hired yesterday’s graduates are granted a one-time ‘start-up’ allowance in the amount of two fixed official salaries plus a sum of money equivalent to their last monthly scholarship. The enterprise also has a benefits plan, according to which a 10 % bonus is paid to those who have a diploma with distinction; young families get a ‘family’ bonus equal to a minimum monthly wage and one and a half times the minimum rate if they have children. During their first year at work newcomers undergo onsite training under the supervision of experienced specialists and attend an extension course on “Enterprise management. Interactions between business units”. In accordance with the performance appraisal results received at the end of the training period young employees get a pay rise. Thus, by providing training and development opportunities the company helps young staff members to develop their skills and competences and gain a better understanding of business ethics and communications. The effectiveness of the company’s youth recruitment and retention policies is confirmed by a sustained increase in the number of young specialists employed in recent years. In the last 5 years the average age of the company’s employees has decreased by 1.5 years. Another positive trend is a decrease in the staff turnover. Besides, the number of employees under 30 has increased considerably and today makes up 26% of the staff size.

Young production engineers at the workplace

Scientific activity One of the most important tasks of the company’s personnel strategy is to ensure continuous staff development and create conditions for scientific capacity building. Personnel training and development allows the company to achieve the following goals: „„ to create high-tech science-intensive products of high quality, „„ to develop and implement new technology; „„ to increase product marketability. Thus, 2021 ISS employees got trained and retrained in 2009, including 46 managers of all levels, 595 specialists and 623 workers. Most of them (1133 employees) received inservice training; 207 people received advanced training at universities, higher education institutions and

training centers; 5 staff members completed their internship training abroad. The company encourages young employees to scientific work by means of incentive payments. Thus, candidates and doctors of science are paid academic allowances, i.e. 1.6 times the minimum wage rate for a candidate’s degree by dissertation, and 2.1 times the minimum rate for a doctor’s degree. They are also provided with additional paid annual leave (11  and 20 days) for their research work. If a staff member under 40 defends a PhD thesis he is granted 150 thousand rubles. The measure of effectiveness of the company’s personnel development policy is the annual increase in the number of PhD students and graduates.

Change in the composition of staff workforce by education and academic rank in 2006-2010 № 1

2

Index

01.12.2006 01.12.2007 01.12.2008 01.12.2009 01.06.2010

Postgraduate students

11

32

70

110

110

Senior managers and senior professionals with academic degrees:

41

43

52

54

54

D.Sc. in Engineering

9

9

10

12

12

PhD in Technical Sciences

32

34

42

42

42

Senior managers and senior professionals holding academic ranks:

22

21

25

24

24

professors

9

12

12

12

13

associate professors

13

9

13

12

11

25


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Информационные Information Satelliteспутниковые Systems системы

Human ResourceКооперация Management

Reserve pool

Within the scope of its personnel policy ISS-Reshetnev encourages growth and career development of its staff members. The company also takes steps to prepare a reserve pool of managers well in advance. In

training within the framework of the Presidential Program (The Program on Training Managers and Executives for the Enterprises of National Economy of the Russian Federation), which also provides international internship opportunities.

ISS staff member receiving a Presidential Program Diploma accordance with the recommendations laid down in the orders of the Head of the Russian Space Agency concerning assignments to executive positions and the inner “Regulations on personnel reserve” the company has formed a pool of replacement personnel for mid-level and senior-level positions. Moreover, every candidate for a managerial position is provided with training according to an individual training plan. Apart from qualifications and education requirements, candidates for managerial positions must meet seniority requirements and have security clearance. The pool of candidates is reviewed and renewed annually. Besides, the company organizes different career development courses for managers of all levels within the scope of its career executive program. Thus, those who are selected for senior positions undergo training at the Institute for Advanced Training in Aerospace Engineering in Kirov. Those reserved for mid-level positions receive

steps and measures to improve the employees’ social status, living conditions as well as provide support in difficult life situations. In 2010 the company’s management together with the trade union committee adopted a new collective agreement which

SIBSAU’s students assembling the Yubileiny-2 satellite at ISS-Reshetnev

Having a reserve pool is particularly advantageous to the company especially when there is a need for temporary replacement of absent managers. In 2009 within the scope of the personnel reserve preparation program 56 employees received training within competency development programs; 36 candidates were appointed to higher positions.

Social responsibility ISS-Reshetnev is a socially responsible enterprise. Social guarantees provided by the company for its employees are, apart from everything else, effective means of the company’s recruitment policy (attraction and retention). They also lead to the growth in labour productivity. The company regularly increases salaries, and what is notable, the salary growth rate always exceeds the inflation rate. The system of social protection is specified in the collective labour agreement. It encompasses

provides for an extension of benefits, increased bonus rates and new social programs. The company’s administration cooperates closely with a primary trade union organization and the Young Professionals Council. By paying attention to the staff’s needs and wants and taking care of the young and old, ISS-Reshetnev has established a solid basis for the company’s effective development. It is clearly understood that human resources are the company’s main asset and its management requires a careful, integrated and balanced approach. Nowadays corporate social responsibility (CSR) is an essential factor in business competition in many developed countries. ISS-Reshetnev is no exception: improvement in the social sphere is the company’s longterm interest. Sergey Kukushkin, Deputy Director General for HRM


Information Satellite Systems

History

SESAT: a successful project,

a well-deserved victory

Ten years ago, on April 18th, 2000 the SESAT telecommunications spacecraft was successfully launched into orbit. SESAT was a turning point not only in the Reshetnev Company’s history, but also in the Russian space industry’s development, for it was the first Russian spacecraft built in cooperation with foreign companies for Europe’s leading satellite operator EUTELSAT.

The project background SESAT is a story of remarkable victories and triumphs, commitment and search for extraordinary solutions. It is a story of a number of human breakthroughs achieved simultaneously in various fields of Man’s activity:

technical innovations, economic reforms, management and politics. It is a story of a successful program that allowed people of different countries and cultures to undertake more indepth studies of space as well as

The satellite name: Siberian-European Satellite (SESAT) named after Arthur C. Clarke. The name SESAT comes from the name of its coverage area: from the Atlantic Ocean to Eastern Siberia and Asia. A few days after the launch the satellite got its second name in memory of Arthur C. Clarke, the popular science fiction writer who had had visions of future space travel ahead of his time, long before the launch of the first rocket.

master new technologies, enter new markets, and take advantage of new cooperation opportunities. It was a program implemented in hard times by extraordinary, talented people.

Successful tender In October 1994 the International Telecommunications Organization EUTELSAT announced a tender competition for the supply of new satellites to extend their broadcasting area to the East with a view to ensuring coverage from the Atlantic Ocean to

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Information Satellite Systems

History

Y. A. Ryzhov, Y.N. Koptev, J. Grenier, J.-C. Husson, M.F. Reshetnev, E.N. Korchagin, E.N. Petrovichev after signing the contract for the SESAT satellite. Paris, August 4, 1995

Project participants: European Telecommunications Satellite Organization EUTELSAT, a customer.

Federal Space Agency / RosAviaCosmos Activities: organization of the launch campaign.

JSC “Academician M.F. Reshetnev “Information Satellite Systems” / the former federal unitary enterprise NPO  PM, Russia, Zheleznogorsk. Project activities: design, manufacture, and tests of the satellite platform, PLM temperature control elements; satellite assembly and tests; manufacture of the ground control segment; training of the customer personnel.

Thales Alenia Space / Alcatel Espace, France, Toulouse. Project activities: design, manufacture, tests and delivery of the payload module.

AON Space (France, Paris) Insurance coverage.

Eastern Siberia and Asia. Participants had only two months to prepare their bids. At that time NPO PM (now ISS‑Reshetnev) was trying to enter the international market, so the decision arrived naturally. Moreover, the company had all the necessary developments to go ahead with: since 1993 NPO PM and Alcatel Espace (now Thales Alenia Space) had been jointly developing the design of a hypothetical satellite. The collaborative efforts of the two companies resulted in a rather fruitful cooperation. By installing a more competitive European communications payload into a Russian-made platform NPO PM got the opportunity to manufacture a technically improved satellite. The French company, in its turn, got the possibility to add to the marketability of their products in terms of cost, which gave them an advantage over comparable American spacecraft. All these factors allowed the two companies to beneficially occupy a new niche on the international market. However, the road to success was not easy at all. To prepare design documentation for the SESAT project NPO PM involved all the best specialists from its numerous departments. The documentation was refined on by Russian and French specialists at Alcatel Espace in order to satisfy EUTELSAT’s rigorous requirements. Besides, for NPO PM to get the work order, it was necessary to win the government’s approval and to ensure financial support of the SESAT program as well as resolve a number of customs-related issues and, taking into account the unstable political situation in the country, to obtain a political risk guarantee from the European bank for Reconstruction and Development. Mikhail F. Reshetnev, NPO PM General Designer and Director General, spared no efforts in arranging the matters. His regular meetings with Y.N. Koptev, head of FSA, J.-C. Husson, president of Alcatel Espace, Y. A. Ryzhov, Russia’s Ambassador to France and representatives of the Russian Government were critically important for the program. Ice broke up in 1995 when the contract was signed and the integration of technologies began. Russian and French specialists got down to work on the joint project.


Информационные Information спутниковые Satelliteсистемы Systems

29

Specifications Application

Fixed communication, broadcasting, distributed TV broadcasting

Operational orbit

Geostationary

Orbital slot

36° E

Accuracy of longitude and latitude station keeping

0.1°

Number of transponders

18

Operational frequency range (up-link/ 14/11 GHz down-link) Bandwidth

72 MHz

Transponder output power

84 W

Designed lifetime

10 years

Launch mass

2600 kg

EPS power capacity at EOL

5300 W

Launch vehicle

PROTON \ DM

Creation The manufacturing schedule was tight, allowing only 30 months. The project budget amounted to ECU 119 million, with 60% of work awarded to the Russian satellite manufacturers. As a prime contractor, NPO PM was responsible for the development, assembly, complex testing, launch and in-orbit control of the spacecraft. Besides, the Siberian company developed and manufactured a satellite bus, i.e. a functionally complete service systems module (satellite platform). SESAT was to employ the flight-proven platform of the Gals and Express satellites. NPO PM specialists had to adapt it to a foreign payload and to considerably increase its efficiency by extending its lifetime from 5 to 10 years and the payload consumption from 1.5 kW to 3.2 kW. For this purpose all the service subsystems were updated and a number of Russian-made components were replaced with their foreign analogues. For instance, the Attitude Determination and Control Subsystem was equipped with Sodernmade sensors instead of Russian ones. Alcatel Espace, in its turn, was developing a new repeater subsystem trying to keep within mass and power limits. Thus, the whole satellite was built as two independent and functionally complete modules

compatible with each other in all interfaces. For effective cooperation with the European companies NPO PM had to implement a new project management system. Moreover, to successfully meet the contract requirements the company developed and introduced a number of new methods and solutions. Thus, to eliminate equipment failures onboard the spacecraft and ensure its reliable operation, NPO PM decided in favor of centralized bulk purchases of electronic components and their follow-up screening before supplying them to satellite equipment makers. Besides, the company’s assembly room underwent technical modernization which resulted in the creation of a “clean space” compliant with international quality standards; design and test procedures were made automatic. As a result, activities performed within the scope of the SESAT program provided a powerful impetus for the development and modernization of the company, thus allowing it to take a well-deserved position on the international market.

Alcatel Espace specialists working on the SESAT PLM

IKAR One of the most important project stages concerned the development of the satellite’s computer model: a satellite repeater simulator (IKAR). To create the simulator, the company

SESAT in the assembly jig


30

Information Satellite Systems

History

subsystem, thermal control (two stages) were functioning properly. The onboard software passed all tests as well. The in-orbit test operations were conducted by NPO PM’s Satellite Control Center located in Zheleznogorsk. On August 8, 2000 the SESAT satellite was accepted by the customer and became fully operational. It is already 10 years since the SESAT satellite started its service for EUTELSAT. It has been carrying out its mission in orbit successfully. At present all the satellite subsystems are operating in the nominal mode. Thus, with every new day the SESAT spacecraft continues to prove the high quality of Russia’s space-technology products.

SESAT’s role The enplaning of the spacecraft purchased expensive equipment in 1997 and quite soon proceeded to work. By mid 1998 IKAR had been completed. In terms of characteristics, interfaces and functions IKAR excelled foreign analogues. The simulator was used for testing satellite control. In July 1998 EUTELSAT specialist spent two weeks testing the operation of the simulator and all the onboard subsystem models. Tests were successfully completed. In December 1998 the Reshetnev team installed IKAR in EUTELSAT’s Satellite Control Centre (Paris). The creation of the IKAR simulator offered the Reshetnev Company additional opportunities for mastering new technologies to perform satellite design and ground testing at a high level and in due time.

Integration of the rocket parts

In-orbit operation On March 16, 2000 the SESAT satellite was delivered to the Baikonur launch site. Pre-launch preparations took a month. Finally, on April 18, 2000 the SESAT spacecraft was launched atop a Proton launch vehicle. The satellite’s solar arrays and antennas got deployed 14 minutes after the satellite had separated from the upper stage. It took less than 45 minutes for the satellite to enter the damping mode. All the service subsystems were thoroughly tested within the following 22 days. During the first week of in-orbit operation the satellite demonstrated excellent performance: its onboard control unit, ADCS, propulsion subsystem, electrical power

10 years of faultless in-orbit operation as well as the ease of control confirm SESAT’s design reliability. As a matter of fact, the SESAT design served as the basis for a series of Express-AM telecommunications satellites which today form the core of the Russian orbital fleet. The SESAT program laid the foundations of the fruitful cooperation between ISS and the world’s leading space companies. Based on the combination of strengths inherent in Russian and western technologies that cooperation resulted in a radically new space-technology product that excelled any former spacecraft in terms of performance and operational capabilities. The international partnership that was formed during the program proved to be very effective and lasting, thus, giving impetus to greater collaborative initiatives in satellite building.

Russian and French project team members before the satellite launch


Информационные спутниковые системы

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Информационные спутниковые системы

Кооперация

Reshetnev company information satellite systems no 10 2010  
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