Polar Satellite Launch Vehicle (PSLV), the Indian operational launcher, completed its twenty-fifth flight during the year. It was the twenty-fourth successive successful mission, proving the reliability and versatility of this medium lift vehicle developed by ISRO. PSLV has emerged as a versatile launch vehicle to carry out Sun Synchronous Polar Orbit (SSPO), Geosynchronous Transfer Orbit (GTO) and low inclination Low Earth Orbit (LEO) missions.

Besides, PSLV-C22 in the ‘XL’ configuration successfully launched IRNSS-1A satellite, the first satellite in the Indian Regional Navigation Satellite System (IRNSS), on July 01, 2013 from the First Launch Pad (FLP) at Satish Dhawan Space Centre (SDSC) SHAR, Sriharikota. The spacecraft weighing 1425 Kg was precisely injected into the intended orbit of 282.5 x 20,625 km with an inclination of 17.9 degree.

PSLV-C25, the 25th mission of PSLV and fifth in the XL configuration, successfully launched the Mars Orbiter Spacecraft on November 05, 2013 from the First Launch Pad at Satish Dhawan Space Centre SHAR, Sriharikota. India’s first interplanetary mission, the Mars Orbiter spacecraft weighing 1337 Kg, was precisely injected into the elliptical orbit of 246.9 x 23,566 km. The major technical challenges for the launch vehicle in accomplishing this mission were the longest flight duration of 43 minutes, long coasting duration of 23 minutes between third stage separation and fourth stage ignition and larger argument of perigee in order to minimise the energy required in transferring the satellite from the Earth to the Mars. After six orbit raising manoeuvres spread over several days, the Mars Orbiter Spacecraft was injected into the Mars Transfer Trajectory on December 01, 2013 and will reach Martian orbit on September 24, 2014.

The next PSLV flight, PSLV-C24, in ‘XL’ configuration, will launch IRNSS-1B satellite, the second satellite in the Indian Regional Navigation Satellite System (IRNSS) and is targeted for launch in April 2014.

The subsequent PSLV flight, in core-alone configuration, will carry SPOT-7, a French earth observation satellite from M/s Astrium, France along with 4 satellites, under commercial arrangements by Antrix.

PSLV-C22 on First Launch Pad

GSLV is a three-stage vehicle employing solid, liquid and cryogenic propulsion modules for its stages. GSLV-D5 with Indigenous Cryogenic Upper Stage, the fourth developmental flight of GSLV, successfully launched GSAT-14 communication satellite with Ku and Extended C transponders and a Ka-band beacon.

GSLV-D5 vehicle was made robust through design modification and with necessary re-qualification. Design modifications were implemented in Fuel Booster Turbo Pump along with rigorous ground testing and strict quality control to enhance the reliability. Start sequence of cryogenic engine was modified to reduce the chamber pressure during ignition and was validated in two ignition trials as per the flight sequence simulating vacuum conditions at the High Altitude Test facility. Design modifications with increased margins were also implemented for lower shroud, wire tunnel and connector mounting brackets and these were validated through extensive qualification tests. Aerodynamic characterisation was carried out with the latest configuration of GSLV through extensive wind tunnel tests and Computational Fluid Dynamics (CFD) simulations.

GSLV-D5 with indigenously developed Cryogenic Upper Stage (CUS) liftS-off from the Second Launch Pad

Due to non-availability of imported components, certain critical sub-systems such as Propellant Acquisition System for liquid hydrogen, Level Sensors and Polyimide Pipelines were indigenously designed, developed, qualified and integrated in the Cryogenic flight stage.

A Comprehensive Technical Review of the GSLV-D5 vehicle and indigenous Cryogenic Upper Stage (CUS-05) by a National Panel of Experts was conducted, to assess the preparedness of the launch vehicle with special focus on the indigenous cryogenic stage. After detailed review, the Panel cleared GSLV-D5 mission for launch.

Indigenously developed Cryogenic Engine

GSLV-D5 Launch: The Launch of the GSLV-D5 mission, scheduled on August 19, 2013 was called off during the last lap of the countdown due to a leak observed in the fuel tank of the second stage. A specialist team supervised the safing operations and ensured the safety of the vehicle, launch pad facilities and personnel. The timely detection of leakage and immediate actions taken avoided any risk and minimised the loss.

A high level task team was constituted by Chairman, ISRO to investigate the cause of leak and assess the health of the vehicle systems, identify the systems required to be replaced or reused after refurbishment and evolve a strategy for restoration of the vehicle towards achieving an early launch. The leak of fuel tank of the second stage was attributed to a crack formed on the parent metal portion of the Aluminium-Zinc alloy (AFNOR 7020) due to stress corrosion cracking (SCC).

After the restoration of the vehicle, the launch campaign for GSLV-D5 mission commenced on October 18, 2013. Following a smooth countdown of 29 hours, GSLV-D5 lifted off at 1618 hours IST on January 05, 2014. After a flight of 17 minutes 5 seconds, GSAT-14 satellite was precisely injected into the GTO with a perigee of 175 km, an Apogee of 35,945 km and an orbital inclination of 19.3 degree with respect to the equator. Later, three orbit raising operations were conducted to place GSAT-14 in geostationary orbit. The indigenous Cryogenic Upper stage performance was as per prediction. Through GSLV-D5 mission, the indigenous Cryogenic Upper stage was successfully flight tested.

GSLV-Mk III is the next generation launch vehicle of ISRO capable of delivering 4 ton class spacecraft to Geosynchronous transfer orbit (GTO).

GSLV-Mk III is a three stage launch vehicle with three propulsion stages and has a lift-off weight of 630 tonnes and a height of 42.4 m. The GSLV-Mk III vehicle configuration is two Solid strap-on boosters Stages (S200), One Liquid Stage (L110) and One Cryogenic Stage (C25). The spacecraft is accommodated in a 5 metre diameter composite payload fairing of 110 m³ volume.

GSLV-Mk III is in the advanced stage of development with the completion of static firing of the S200 solid strap-on motor, stage testing of L110 liquid stage, completion of development tests of the engine subsystems of the C25 cryogenic upper stage and development and qualification tests of major sub-systems.

CE 20 Thrust Chamber Hot Test

The major development and qualification tests conducted during the year include structural and separation tests of payload fairing, acoustic test of Strap-on Base Shroud, Strap-on Nose Cone and S200 Flex Nozzle Control (FNC) tank, vibration tests of Proto Equipment Bay and Proto Strap-on Nose Cone, ground resonance test for the full vehicle configuration, system level functional test of satellite separation system and hot test of CE 20 thrust chamber. The Critical Design Reviews of S200 solid strap-on motor, L110 liquid stage and avionics systems have been completed.

L110 Flight Stage for X Mission

An experimental sub-orbital flight (LVM3-X) with passive cryogenic stage is targeted during the third quarter of 2014, to validate the entire vehicle configuration during the complex atmospheric regime of flight including its controllability. Towards this mission, two S200 flight motors, L110 flight stage, avionics packages, flight actuator and control electronics are ready for integration for the experimental flight. The passive cryogenic stage is in the final stages of assembly and integration and the vehicle avionics is undergoing system-level simulations.

The semi-cryogenic Project envisages the design and development of a 2000 kN semi-cryogenic engine for a future heavy-lift Unified Launch Vehicle (ULV) and Reusable Launch Vehicle (RLV). The semi-cryogenic engine uses a combination of Liquid Oxygen (LOX) and ISROSENE (propellant-grade kerosene), which are eco-friendly and cost-effective propellants.

Realisation of semi-cryogenic engine involves the development of performance-critical metallic and non-metallic materials and related processing technologies. 23 metallic materials and 6 non-metallic materials have been developed. Characterisation of injector elements and hypergolic slug igniters with different proportion of Tri-ethyl Aluminium and Tri-ethyl Boron has been completed. Sub-scale models of thrust chamber have been realised and ignition trials have been carried out successfully. Single element thrust chamber hot test in stage combustion cycle mode was also conducted successfully.

Establishment of test facilities like Cold Flow Test Facility and Integrated Engine Test Facility are under various stages of realisation. Fabrication drawings are realised for all sub-systems and fabrication of booster turbo-pump and pre-burner subsystem commenced.

A winged Reusable Launch Vehicle Technology Demonstrator (RLV-TD) has been configured to act as a flying test bed to evaluate various technologies, viz., hypersonic flight, autonomous landing, powered cruise flight and hypersonic flight using air breathing propulsion towards realising a Two Stage to Orbit (TSTO) fully Reusable Launch Vehicle.

Major highlights of RLV-TD during the year include completion of major actions identified by the National Review Committee during the Integrated Technical Review (ITR) of hypersonic experimental flight (RLV-TD HEX-01). Mission analyses on the design of trajectory, autopilot and guidance have been completed.

The Avionics Bay powering for the Avionics packages in the Technology Demonstrator Vehicle (TDV) was carried out through Checkout System and On-Board Checkout Computer (OBCC). The second phase of the full scale Flush Air Data System (FADS) model was successfully tested and validated at the Wind Tunnel Facility, IIT, Kanpur with modified algorithms and recalibrated sensors. Radar Altimeter along with antenna was also validated through a Balloon test at Tata Institute of Fundamental Research (TIFR), Hyderabad and the capability of the system has been demonstrated.

Trial assembly of Thermal Protection System for qualifying the bonding procedure and trial assembly of Booster with Interstage and TDV have been completed. The realisation of the flight hardware and its assembly and integration is in progress. The launch of RLV-TD HEX-01 mission is planned in 2014.

The objective of Human Spaceflight Programme is to undertake a human spaceflight mission to carry a crew of two to Low Earth Orbit (LEO) and return them safely to a predefined destination on earth. The programme is proposed to be implemented in defined phases. The pre project activities are progressing with a focus on the development of critical technologies for subsystems such as Crew Module (CM), Environmental control and Life Support System (ECLSS), Crew Escape System, etc., and performance demonstration of major systems through Crew Module Atmospheric Re-entry Experiment (CARE) and crew escape system through Pad Abort Test (PAT).

Preliminary design reviews for most of the systems pertaining to CARE for LVM3-X mission and PAT have been completed. Configuration, layout, and structural analysis of Crew Module for CARE mission have been completed. Design of re-entry trajectory for CARE mission corresponding to launch vehicle ascent trajectory has been carried out. Crew Module structure is in advance stage of realisation for flight test in GSLV-MkIII Experimental Mission.

Human Space flight Programme Crew Module undergoing a test

Functioning of newly developed Head-end Mounted Safe Arm (HMSA) for solid motors in Crew Escape System was successfully demonstrated. A parachute ejection test with Mortar was carried out at Terminal Ballistics Research Laboratory (TBRL), Chandigarh wherein sequential deployment of pilot parachute and drogue parachute was demonstrated. As part of deceleration system qualification, main and drogue parachutes, in modified and improved pack cover configuration, was drop tested at ADRDE, Agra. Parachute Reefing Line Cutter [RLC] of main parachute was realised and development tests were also carried out.

Gas analysers for environment monitoring of crew cabin, cabin lighting system with intensity control and MEMS based barometric sensor have been developed. Wind tunnel testing of Scale model of Crew escape system was completed in National Aerospace Laboratories, Bengaluru.

A unique state-of-the-art test facility – Environment Simulation Chamber (ESC) has been realised and commissioned at VSSC for stand-alone and integrated testing of Environmental Control & Life Support System (ECLSS) functional modules and Flight suit systems. A Variable length-to-diameter [L/D] Lithium Hydroxide (LiOH) proto-canister has been realised as part of air re-vitalisation system development. An integrated thermal performance test setup was realised for testing of crew cabin thermal and humidity control system and tests are in progress.

Air Breathing (AB) propulsion along with Reusable Launch Vehicle technology is the key for low cost access to Space. Unlike conventional rockets, Air Breathing Propulsion system makes use of atmospheric oxygen for combustion thus resulting in substantial improvement in payload fraction and reduction in overall cost.

ISRO has taken up a systematic R&D programme for demonstrating stable supersonic combustion through a series of ground tests on the Air-Breathing Propulsion Technology. The flight demonstration of this technology is planned with Advanced Technology Vehicle (ATV).

Towards Scramjet flight testing, mission studies have been carried out and feasibility established. Qualification and flight model of the Scramjet Engine Avionics Module with High Frequency Data Acquisition Units and its sub-systems were realised. Test and evaluation of these packages for flight were also successfully carried out.

Functional tests of the ignition system of scramjet with different mixture ratios of Gaseous Hydrogen – Gaseous Oxygen were carried out. High pressure gaseous hydrogen flow control module and a module for operating the start valves of Fuel Feed System for scramjet engine flight testing were realised.

The scramjet engine frame assembly for flight and the flow duct segments made out of super alloy Inconel-718 have been realised. Qualification test to demonstrate sliding capability of scramjet engine and vehicle interface was successfully carried out. The Scramjet Characterisation flight is targeted in 2014.

SRE-2 Project was formed with the main objective of realising a fully recoverable capsule and to provide a platform to conduct microgravity experiments. SRE capsule has four major hardware, namely, Aero Thermo-structure (ATS), Spacecraft platform, Deceleration & Floatation system and Payloads.

ATS base structure has been realised. Six plasma wind tunnel tests were conducted to validate repair scheme of the silica tile. To qualify new elements mounted in the base region of SRE-2, an integrated test of annular deck was successfully completed. Carbon-Carbon cap has been processed as 4D composite through Hot Isostatic Pitch Impregnation and Carbonisation (HIPIC) route. Processing of Carbon-Carbon shell through 2D Pitch Impregnation and Carbonisation route is in progress. Interface design of Carbon-Carbon cap and shell was revisited based on the new thermo-mechanical properties. SiC coated Carbon-Carbon samples have been validated at plasma wind tunnel facility.

Aerothermo-structure of SRE-2

Advanced Technology Vehicle (ATV) has the unique capability to carry a payload of 200-400 kg up to an altitude of 800 km. Ascent of ATV in a direct vertical profile is an excellent platform for studies related to upper atmosphere and short duration transient phenomena in the atmosphere. ATV provides a cost effective platform for the study of micro-gravity providing a dwell time of 10 minutes at levels better than 100 micro-g, which can be used for microgravity experiments in fluid physics, combustion research, material sciences, biology and also to perform precursor experiments for launch vehicles, satellites and human spaceflight mission.

The Scramjet characterisation flight will be carried out using ATV. Towards ATV-D02 flight with active scramjet engine, mission specifications, qualification of Expanding Tube Assembly (XTA) based stage separation system and structures have been completed. The environmental qualification tests and flight measurement plan have been firmed up. Hardware system such as customised Avionics, improved fibre glass igniter case, booster and sustainer after end shrouds and fins for the flight have been realised.

Sounding Rockets
Six RH200 flights with chaff payload were successfully conducted from TERLS Range for collecting meteorological data.

The Golden Jubilee year of India's space transportation system was commemorated with the launch of a RH200 sounding rocket from Thumba at 1830 hrs on November 21, 2013.

Infrastructure

1. Infrastructure at SDSC SHAR, the spaceport of India is augmented to support the increased frequency of launches and also to cater to the advanced launch vehicle programme. Major infrastructure facilities that were realised during the current year are:
• 300 Gallon Vertical Mixer
• Acoustic Suppression system at Second launch pad
• Ku-Band Uplinking System
• PS1/GS1 Preparation facility
• PS3 + PS4 Preparation facility
• Bulk Propellant storage facility
• Ammonium Perchlorate and Aluminium Powder storage facility
• Multilayer Security System


2. Major infrastructure facilities that were realised at IPRC, Mahendragiri during the current year are:
• Augmentation and Commissioning of Main Engine & Stage Test facility (MET) for C25 Stage test
• Augmentation and Commissioning of Thrust Chamber Test (TCT) facility to evaluate the ignition characteristics of the indigenous cryogenic engine in vacuum condition


3. Sodium Chlorate Plant
Sodium Chlorate plant of 5 Tonne capacity per day has been established at M/s.Travancore Cochin Chemicals Ltd (TCC), Ernakulum. The plant is fully commissioned and was inaugurated on November 30, 2013.


4. Energy Systems
A 50 kW Fuel Cell was developed indigenously and installed at NE-SAC, Shillong and TERLS, Thiruvananthapuram for powering the Automatic Weather Stations.