PROTON (8K82 and variants) - Vehicle use: Satellite, Russian Element Delivery on Proton K, Salyut, Mir Modules
Russian orbital launch vehicle. The Proton design is one of the few heavy-lift vehicles to make use of hypergolic propellants. Initially designed as a two-stage heavy-lift intercontinental ballistic missile in the 1960s, the design evolved into the Proton K variant with the addition of a third stage. The Proton K had a liftoff mass of approximately 700 metric tons. Many Proton K flights used a fourth stage (Block DM variants). The Proton K launched all of the Russian space station elements, including Salyut, Mir, and the Russian elements of the International Space Station. The Proton K was initially developed for the Soviet crewed lunar program, but never carried any crew. Several flights were conducted using uncrewed spacecraft. The design then changed to focus on uncrewed flights. The Proton K was retired after the 310th launch. The Proton design was upgraded to the Proton M variant with lighter structures and a computerized navigation system. It can be flown with two to four stages. The four-stage variant uses either the Briz M or Block DM booster with a liftoff mass of approximately 702 metric tons.
Source: www.khrunichev.ru
Variant
All variants
Proton
K (no 4th stage)
K, Blok variants
M, all variants
Launches
424
4
30
280
110
Failures
29
1
3
17
8
Realized
0.93
0.75
0.90
0.94
0.93
Predicted
0.93
0.67
0.88
0.94
0.92
50
51
53
52
55
56
54
57
58
59
60
61
62
64
63
65
67
66
69
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81
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91
92
93
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98
01
00
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09
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11
10
13
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17
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24
Not publicly available
9/27/1967 - Proton K/D
1st STAGE ENGINE FAILURE
Launch of Zond-4
One first stage engine did not start at liftoff due to a rubber plug accidentally left inside during assembly, causing control to gradually fail during ascent. The cutoff command was issued at T+97 seconds, and the booster crashed downrange. The launch escape system performed nominally, and the capsule was safely recovered.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
11/22/1967 - Proton K/D
2nd STAGE ENGINE FAILED TO IGNITE
Launch of Zond-4
One second stage engine failed to ignite at staging. The remaining three engines shut down automatically, and the booster crashed downrange. The launch escape system performed nominally, and the capsule was safely recovered. The cause was determined to be premature release of fuel into the second stage, resulting in overheating and engine failure.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
4/22/1968 - Proton K/D
EARLY 2nd STAGE SHUTDOWN DUE TO SHORT CIRCUIT
Launch of Zond-5
A short circuit in the Zond control system resulted in a false vehicle failure signal. The abort system terminated the flight and initiated payload separation. The payload was successfully recovered.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
1/20/1969 - Proton K/D
2nd ENGINE FAILURE
Launch of Zond-7
The second stage RD-0210 engine failed. The resulting flight path deviation resulted in activation of the flight termination plan.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
2/19/1969 - Proton K/D
PAYLOAD FAIRING FAILURE
Launch of Luna-15
A payload fairing collapsed at T+51 seconds. Flying debris ruptured the first stage and caused leaking propellant to ignite on contact with the engine exhaust, resulting in the explosion of the launch vehicle.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
3/27/1969 - Proton K/D
3rd STAGE TURBOPUMP FAILURE
Launch of Mars-2
A third stage turbopump failed at T+438 seconds. The upper stages and payload crashed in the Altai Mountains.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
4/22/1969 - Proton K/D
1st STAGE ENGINE FAILURE
Launch of Mars-2
Shortly after liftoff, a first stage engine failed, resulting in the launch vehicle flight path becoming horizontal. The Proton crashed within the launch complex, severely contaminating the facility and delaying further operations.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
11/28/1969 - Proton K/D
1st STAGE FAILURE
Launch of Cosmos-313
Failure of first stage.
SOURCES:
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
2/6/1970 - Proton K/D
FALSE PRESSURE READING LEADS TO FLIGHT TERMINATION
Launch of Luna-16
After 128.3 seconds of flight, the first stage engine cut off due to a false alarm from the launch vehicle safety system, activated by the engine pressure gage. This was a manufacturing defect. An additional check of gages was introduced at the point of installation. [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
7/29/1972 - Proton K
SHORT CIRCUIT IN FLIGHT STABILIZATION SYSTEM
Launch of Salyut-2
After 181.9 seconds of flight, a second stage automated stabilization system failure occurred due to a relay short circuit in the "pitch" and "yawing" channels. This was caused by elastic deformation of the device housing (which operates in vacuum), and was a design defect. In response, the design of instruments was upgraded and additional testing was undertaken. [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
8/4/1977 - Proton K
MANUFACTURING DEFECT CAUSES LOSS OF CONTROL
Launch attempt of Cosmos
After 40.13 seconds of flight, there was a spontaneous deflection of the first stage engine, loss of stability, and engine cutoff at 53.68 seconds into the flight safety system command. A steering failure due to a spool-and sleeve pair manufacturing defect (faulty liner) caused penetration of hard particles under the liner rim and resulted in spool-and-sleeve seizure.
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
8/4/1977 - Proton K
MANUFACTURING DEFECT CAUSED LOSS OF CONTROL
Launch attempt of Cosmos
After 40.13 seconds of flight, there was a spontaneous deflection of the first stage engine, loss of stability, and engine cutoff at 53.68 seconds into the flight safety system command. A steering failure due to a spool-and sleeve pair manufacturing defect (faulty liner) caused penetration of hard particles under the liner rim and resulted in spool-and-sleeve seizure. [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
5/27/1978 - Proton K/DM
HYPERGOLIC FUEL LEAK CAUSED CONTROL FAILURE
Launch attempt of Ekran
The vehicle lost stability after 87 seconds of flight, due to an error of the first stage second combustion chamber steering gear. A high temperature impact on the cables occurred due to a heptyl leak into the second block engine compartment. The leak likely developed at the heptyl feed coupling to the gas generator. As a result of the failure, the coupling was upgraded. [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
8/17/1978 - Proton K/DM
HOT GAS LEAK IN 2nd STAGE ENGINE
Launch attempt of Ekran
After 259.1 seconds the flight was terminated due to the loss of launch vehicle stability. An automatic stabilization system electric circuit failure in the rear compartment of the second stage was caused by hot gases leaking from the second engine gas inlet due to faulty sealing of the pressure gauge. As a result of this failure, the gauge attaching point was upgraded. [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
10/17/1978 - Proton K/DM
2nd STAGE TURBINE FAILURE
Launch attempt of Ekran
The second stage engine shut down and experienced loss of stability after 235.62 seconds into flight. This was caused by a turbine part igniting in the turbo pump gas tract, and followed by gas inlet destruction and hot air ejection into the second rear section. As a result of this failure, the engine design was upgraded. [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
7/22/1982 - Proton K/DM
FLIGHT CONTROL SYSTEM RESONANCE FAILURE
Launch attempt of Ekran
A major malfunction of the first stage engine, fifth chamber, occurred at 45.15 seconds into the flight. The flight was terminated by the launch vehicle safety system command. The failure was caused by a steering motor malfunctioning. The first stage of the hydraulic booster got out of balance and was coupled with booster dynamic excitation at resonance frequencies. In response, the hydraulic booster design was redefined. [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
12/24/1982 - Proton K/DM
2nd STAGE FAILURE DUE TO VIBRATIONS
Launch attempt of Raduga
"Second stage engine failure caused by high-frequency vibrations. Engine design upgraded." [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
11/29/1986 - Proton K
VIBRATION-INDUCED ELECTRICAL FAULT IN CONTROL SYSTEM
Launch attempt of Cosmos
"Control system failure due to brief relay contact separation caused by engine vibration. Upgrading included introduction of self-latching action capability for program power distributor shaft." [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
1/18/1988 - Proton K/DM-2
FUEL-LINE FAILURE IN 3rd STAGE
Launch attempt of Gorizont
"Third stage engine failure caused by destruction of fuel line leading to mixer." [source 1] This was classified as a unique manufacturing defect. The inventory was checked to prevent a recurrence.
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
8/8/1990 - Proton K/DM-2
2nd STAGE SHUTDOWN DUE TO CONTAMINATION
Launch attempt of Ekram-M
Engine shutdown during second stage flight due to a cleaning rag left in the oxidizer supply line. Work process changes were implemented to prevent recurrence.
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
5/27/1993 - Proton K/DM-2
PROPELLANT CONTAMINATION CAUSED CATOSTROPHIC BURN-THROUGHS
Launch attempt of Gorizont
Propellant contamination resulted in catastrophic burn-throughs of the engine combustion chambers and loss of vehicle during second stage flight. "Remedial program introduced to modify propellant specifications and testing procedures. All launch site propellant storage, transfer, and handling equipment purged and cleaned." [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
7/5/1999 - Proton K/Briz-M
2nd STAGE EXPLOSION
Launch attempt of Raduga
Contaminants from a weld repair of a defect in the turbopump resulted in the failure of second stage engine number 3 and the loss of vehicle. Improvements were made in filter design and work process.
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
10/27/1999 - Proton K/DM-2
FAILURE DURING 2nd STAGE BURN
Launch attempt of Ekspress K-1
Failed early in second stage burn. Particulate contamination caused the turbine exhaust duct of second stage engine number 1 to catch fire. This resulted in second stage shutdown and was attributed to poor workmanship. Additional filters were installed and the turbopump was redesigned to increase combustion resistance.
SOURCES:
Proton Launch System Mission Planner’s Guide
Steven Isakowitz, Joshua Hopkins, Joseph Hopkins, Jr. International Reference Guide to Space Launch Systems, AIAA, 2004, Fourth Edition, pp. 314
9/5/2007 - Proton M/Briz-M P1
FAILURE TO SEPARATE 1st AND 2nd STAGE
Launch attempt of JSCat 11
This was a failure of the launch vehicle (LV) first and second stage separation. "Burnthrough of the LV stage 1/stage 2 separation pyrobolt actuation cable. Corrective action is to over-wrap the pyrobolt wiring harness by two layers of asbestos tape with 50% overlap. This increases the heat resistance to well over 400°C, the harness melting point. Additionally the ring and harness are jointly over-wrapped with two layers of tape with 50% overlap impregnated with glue, and the harness was re-routed away from the exhaust gas." [source 1]
SOURCES:
Proton Launch System Mission Planner’s Guide
12/5/2010 - Proton-M/DM-3
HUMAN ERROR RESULTED IN PROPELLANT OVERLOADING
Launch attempt of GLONASS satellite
The launch was the first flight with the new Block DM-03. The Block DM-03 had larger propellant tanks than the previous version. The fueling team used fueling procedures for the previous Block DM, which resulted in loading an extra 1.5 tons of oxygen. While the launch vehicle performed nominally, the extra mass due to the loading error exceeded performance capabilities, resulting in the failure of the payload to reach orbit.
SOURCES:
Spaceflight Now Article
7/2/2013 - Proton M/Briz-M P3
INCORRECTLY INSTALLED ANGULAR VELOCITY SENSORS
Launch attempt of Uragan Satellites
The first stage guidance failed due to angular velocity sensors installed upside down. The rocket crashed near the launch pad. The booster began pitching left and right along the vertical axis within a few seconds of launch. Attempts by the onboard guidance computer to correct the flight trajectory failed and ended up putting it into an unrecoverable pitch-over. The upper stages and payload were stripped off 24 seconds after launch due to the forces experienced, followed by the first stage breaking apart and erupting in flames. Impact with the ground occurred 30 seconds after liftoff.
SOURCES:
article from www.russianspaceweb.com
Proton Launch System Mission Planner’s Guide
VIDEO:
Proton-M Launch Failure - July 2, 2013
10/21/2014 - Proton M/Briz-M P3
STRUCTURAL FAILURE
Launch attempt of Express AM4R
The Russian failure investigation team determined the probable cause of the failure to be a “loss of structural integrity of a bolted interface that attaches the Stage III steering engine turbopump to the main engine structural frame.” The failure of the structure resulted in vibrations sufficient to damage the fuel inlet line to the oxidizer gas generator. The loss of fuel led to the shutdown of the turbopump and catastrophic loss of control at approximately L+545 seconds.
SOURCES:
article from www.ilslaunch.com
Proton Launch System Mission Planner’s Guide
5/16/2015 - Proton M/Briz-M P3
3rd STAGE VERNIER ENGINE FAILURE
Launch attempt of MEXSAT 1
Malfunction of the third stage Vernier engine eight minutes into flight led to a premature shutdown and impact of stage 3, Briz-M and payload in the Chita region in Russia, between Lake Baikal and the Chinese border. The Russian commission concluded that a turbopump imbalance led to excessive vibration loads, which resulted in the failure of the engine. Materials failure and inadequate balancing contributed to the failure. Corrective actions included new material for the turbopump rotor shaft, upgraded balancing procedures, and redesigned structure for attachment of the steering engine turbopump to the framework of the main engine.
SOURCES:
article from www.russianspaceweb.com
Proton Launch System Mission Planner’s Guide
article from www.astronautix.com
0.92
0.92
0.79
0.79
0.75
0.74
0.69
0.67
0.63
0.60
0.75
0.67
1.00
0.75
0.93
0.93
0.88
0.87
0.92
0.92
0.83
0.83
0.82
0.81
0.70
0.69
0.90
0.89
0.92
0.92
0.82
0.81
0.80
0.79
0.66
0.65
0.93
0.93
0.89
0.88
0.93
0.92
0.87
0.86
0.90
0.90
0.91
0.91
0.91
0.91
0.81
0.80
0.78
0.77
0.61
0.60
0.93
0.92
0.89
0.88
0.92
0.92
0.85
0.84
0.90
0.90
0.91
0.90
0.92
0.92
0.84
0.83
0.82
0.81
0.71
0.70
0.90
0.89
0.93
0.93
0.88
0.87
0.90
0.90
0.91
0.91
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.92
0.91
Realized Rate
Predicted Rate