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Acta Astronautica 52 (2003) 563–573www.elsevier.com/locate/actaastro

Kistler reusable vehicle facility design and operationalapproach�

D. Fagan∗;1 , F. McInerney2, C. Johnston2, B. Tolson2

Kistler Aerospace Corporation, 3760 Carillon Point, Kirkland, WA 98033, USA

Received 12 August 1999

Abstract

Kistler Aerospace Corporation is designing and developing the K-1, the world’s 1rst fully reusable aerospace vehicleto deliver satellites into orbit. The K-1 vehicle test program will be conducted in Woomera, Australia, with commercialoperations scheduled to begin shortly afterwards. Both stages of the K-1 will return to the launch site utilizing parachutesand airbags for a soft landing within 24 h after launch. The turnaround 5ow of the two stages will cycle from landing site toa maintenance/refurbishment facility and through the next launch in only 9 days. Payload processing will occur in a separatefacility in parallel with recovery and refurbishment operations. The vehicle design and on-board checkout capability of theavionics system eliminates the need for an abundance of ground checkout equipment. Payload integration, vehicle assembly,and K-1 transport to the launch pad will be performed horizontally, simplifying processing and reducing infrastructurerequirements. This simple, innovative, and cost-e:ective approach will allow Kistler to o:er its customers 5exible, low-cost,and on-demand launch services.c© 2002 Kistler Aerospace Corporation. Published by Elsevier Science Ltd. All rights reserved.

1. Overview of Kistler Aerospace Corporation

Kistler Aerospace Corporation was formed in1993 by Walter Kistler, the co-founder of Kistler–Morse Corporation, and Bob Citron, the founder ofSPACEHAB, Inc. Since 1995, Kistler has been led by

� Paper IAF-98-V.505 presented at the 49th International As-tronautical Congress, September 28–October 2, 1998, Melbourne,Australia.

∗ Corresponding author.E-mail addresses: dfagan@kistleraero.com, rellegaard@

kistleraero.com (D. Fagan).URL: http://www.kistleraerospace.com

1 Vice President of Launch Operations, Australia.2 Kistler Operations Team.

Chairman Robert Wang and Chief Executive ODcerDr. George E. Mueller, the former head of NASA’sApollo Manned Space Program.Kistler Aerospace’s mission is to develop and oper-

ate the world’s 1rst fully reusable aerospace vehicle,called the K-l, designed for a range of Missions inorbit. The K-l is a two-stage vehicle comprised ofthe 1rst stage, or Launch Assist Platform (LAP), andthe second stage, or Orbital Vehicle (OV), and isdesigned to launch and return (through a soft land-ing with the assistance of parachutes and airbags)at the same location. Kistler is fabricating a 5eet ofK-l vehicles that will provide customers with reli-able and 5exible launch capabilities at a low price.The Kistler K-l design combines existing and testedpropulsion technology and advanced light weight

0094-5765/03/$ - see front matter c© 2002 Kistler Aerospace Corporation. Published by Elsevier Science Ltd. All rights reserved.PII: S0094 -5765(01)00221 -1

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composite structures to create a reliable, cost-e:ectivevehicle.Kistler has assembled a team of eminent aerospace

experts and space program managers to design theK-1 vehicle and manage the K-l program. Colle-ctively, these individuals have guided most ofAmerica’s major space programs, including Red-stone, Mercury, Gemini, Saturn, Apollo, Skylab, theUS Space Shuttle and the International Space Station.The team also has extensive industry experience.Kistler is leading the K-l systems engineering and

integration through an integrated team composedof Kistler and contractor personnel. Each of KistlerAerospace’s contractors is a legend in its respective1eld of the aerospace industry and has signi1cant ex-perience in the construction of its components. Thisteam consists of Locuheed Martin Space Systems—Michoud Operation and Northrop Grumman Corpo-ration, GenCorp Aerojet Paper Laboratory, Honey-well, Irvin Aerospace, Inc. and Oceaneering ThermalSystems.From planned launch facilities in Australia and

Nevada, Kistler will also adopt an innovative ap-proach to payload processing and launch operations.With automation and streamlined operations, tu-raround 5ow from landing to launch is expected totake only 9 days. This paper describes the uniqueoperational design philosophy used in developingthe K-l, allowing Kistler to adopt an innovative andcost-e:ective approach to launch operations. It alsodiscusses the launch facilities in construction to sup-port the K-l and discusses the operations process5ow for vehicle recovery, refurbishment, payloadprocessing, integration, and launch.

2. K-1 operational design philosophy

2.1. Simplicity, safety and maintainability

Simplicity and safety are key objectives in thedesign of the K-l vehicle. These attributes may be ob-served in several important aspects of the design. TheNK-33 and NK-43 engines are very powerful and yetare fueled with kerosene. Using kerosene as fuel hasmany operating advantages compared to liquid hy-drogen. Kerosene may be carried in tanks that are notcryogenic and therefore do not require special insula-

tion to sustain extremely low temperatures. Kerosenetanks also are smaller, facilitating the relatively com-pact size of the K-1 vehicle. As a lique1ed gas, incontrast, liquid hydrogen requires much larger tanksbecause it has lower molecular density and highervolatility. These same physical conditions alsocontribute to diDculty in ground handling of liquidhydrogen because of the risk of leaking and othersafety considerations. Therefore, ground facilitiesand ground-handling procedures for kerosene fuelare considerably simpler, and much less potentiallyhazardous, than for liquid hydrogen.Simplicity in operation, ground support and main-

tenance also is re5ected in the attitude control system(ACS) which includes the thrusters used to maintainproper spatial orientation of the LAP at very highaltitudes and of the OV when it is in space. Manycurrent launch vehicles and satellites use hypergolicfuels, such as hydrazine, to power ACS thrusters.Hypergolic fuels ignite spontaneously on contact.The K-l uses instead a hot gas gaseous oxygen

(GOX)/ethanol system. Compared to hydrazine,GOX/ethanol has many advantages in safety, groundhandling and ease of replenishment. It is not toxic,and reduces risk of any contamination to payload afterdeployment. The same principles also are re5ected inthe Orbital Maneuvering System (OMS) of the OV.The OMS is used to perform all on-orbit maneuvers,including adjustments before payload release, maneu-vers to achieve proper phasing orbit before re-entry,and the 1nal de-orbit maneuver. The OMS propel-lants, ethanol and liquid oxygen, are relatively benign.The OMS is derived from a product developed byAerojet for NASA as a potential upgrade for the USSpace Shuttle.Simplicity in design and operation is intended to

result in high reliability and low cost of maintenance.The physical layout of the K-l vehicle, including theplacement of internal systems and components, hasbeen optimized for easy ground access. Many of thekey systems can be accessed through the ends ofthe vehicle stages, minimizing the number of accesspanels needed in the structure. By easing access tosubsystems for maintenance crews, the K-l design isintended to save time and ultimately reduce main-tenance costs. The K-l vehicle also is designed tominimize the interfaces between the payload andthe vehicle, and among the vehicle subsystems. By

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reducing the number of physical connections betweeneach line replaceable unit (LRU), the K-l design isexpected to reduce the time required for integratingand testing each subsystem. The K-l is assembledhorizontally and its payload is integrated in a hori-zontal position. This approach will reduce the cost ofground and launch support facilities. Kistler intendsto perform launch vehicle servicing at the launch site.

2.2. Designed-in reliability

The health monitoring of the K-l di:ers somewhatfrom conventional practice for launch vehicles. An on-board integrated vehicle health management system(IVHM system) is integrated into the LAP and alsointo the OV. It is used after each 5ight to report on thestatus of the vehicle and its systems. IVHM systems ofsimilar concept are used in late-generation commer-cial aircraft, such as the Boeing 777. After each stagelands, the IVHM is plugged into a ground computer.It then reports to the ground computer on the statusof the on-board systems and identi1es what needs tobe serviced. Because the vehicle is built with an LRUconcept, hardware units can be replaced at the launchsite. The a:ected LRUs will be replaced from inven-tories as warranted. The same IVHM also does thepre5ight checkout.The K-l reliability philosophy follows a premise

that if hardware works during 5ight and if on-boardsystems report compliant conditions at the time oflanding, the hardware should work the next time it is5own. Therefore, automated system health queries areconducted after landing and before the next 5ight.If the post-5ight response is that the vehicle is

“ready to go”, then certain consumables are re-plenished in the vehicle-processing facility. Theparachutes and airbags are replaced, the batteries arerecharged and new engine start cartridges are in-stalled. There is only limited cleaning of the main en-gines between 5ights. The main engines are plannedto refurbish after 10 1rings.While the vehicle is being serviced, the payload

module (PM) has been removed and is being handledseparately for installation of the next payload. ThePM is then joined with the serviced vehicle beforerollout. The mated K-l vehicle is brought from theprocessing facility to the launch pad where it is erectedwith a simple tip-up mechanism. Then both stages

will be fueled and checked out, which is expectedto take about 4 h, signi1cantly less than is typicallyexperienced with expendable launch vehicles (ELVs).The designed-in reliability and maintainability are

intended to produce simplicity and economy in oper-ations. It is also expected that these design principleswill enable Kistler to conduct a high rate of launcheswith its 5eet and to achieve a 9-day turnaround foreach vehicle.

3. Overview of K-1 launch site facilities

Kistler has selected two sites to operate the K-lvehicle: the Woomera Prohibited Area in Woomera,Australia, and the Nevada Test Site in Nevada, USA(both shown in Fig. 1). Kistler is working with regula-tory authorities in both locations to secure the appro-priate approvals for licenses required to operate the K-lvehicle.

3.1. Woomera Australia launch site description

The K-l ground facilities, equipment and operationswill be located at Ashton Hill, 12 miles north westof the Woomera Village in the Woomera ProhibitedArea (WPA). The entire WPA totals 49; 000mile2

(127; 000 km2).The WPA was formed in the 1950s as the pri-

mary testing grounds for what became the EuropeanLauncher Development Organization rocket tests.Since the early 1960s, the WPA has been used ex-tensively as a munitions proving ground and as wellas a sounding rocket range. In the 1980s, Australiaconducted three polar launches and in 1995 theEXPRESS re-entry capsule was certi1ed to use therange.Kistler has leased approximately 30 km2 (shown in

Fig. 2) from the Australian Commonwealth for exclu-sive use as a commercial launch site.The K-l requires three principal functional areas

within the WPA for operations: an area for vehicleand payload processing; an area for propellant loadingand launch; and an area for landing and recovery. K-lpermanent facilities are being built in a phased ap-proach that matches the anticipated increasing 5ightrate over time. The initial launch area is shown indetail in Fig. 3.

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Fig. 1. Kistler launch sites in Australia and Nevada.

Fig. 2. Woomera launch site and vehicle recovery site.

3.2. K-1 vehicle-processing facility (VPF)

The main portions of the K-1 vehicle process-ing facility (VPF) shown in Fig. 4 are dedicatedto vehicle integration and refurbishment of the ve-hicle stages. The LAP and OV stages are broughtin through one end of the facility on railed supportequipment. All necessary ground support equipment(GSE) to support nominal LAP and OV refurbish-ment is located in the VPF. The speci1c payloadoperations are discussed below. The PM is re-moved from the OV and processing is performed

o:-line in the payload processing facility (PPF)which is described below. Once the LAP and OVstages have been fully refurbished, checked out andmated, the K-1 vehicle is transported out on thesame railed support equipment to the K-1 launchstand.

3.3. K-1 payload processing facility (PPF)

In addition to those facilities required for K-l launchvehicle processing, specialized facilities are providedfor checkout and preparation of the spacecraft. TheK-l PPF will consist of class 100,000 facility areasfor receiving, storage, hazardous conditions, payloadcheckout and integration, and controls.

3.4. K-1 launch stand

The VPF and the launch stand are connected viathe same rail transportation system used in the VPF tomove and mate the stages. The mated K-l vehicle willbe rolled out on a strongback erector. Umbilicals areconnected and the assembly rotates into position forlaunch. The K-l vehicle after rotation into a verticalposition with the strongback erector retracted is shownin Fig. 5.All necessary consumables are located adjacent to

the launch stand and strongback erector. Once erected,

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Fig. 3. Initial launch and processing complex site plan.

Fig. 4. K-1 vehicle processing facility.

the vehicle is fueled, the avionics platform is alignedand nitrogen and helium consumables are topped o:.

4. K-1 operations �ow

A summary 5ow of the top level processing of theK-1 vehicle is shown in Fig. 6. The recovery of the

LAP and OV stages occurs approximately 24 h apartand the K-l stages are then processed for relaunch inparallel. Payload processing is also in parallel and cancommence as required to meet the scheduled matingoperation. A Flight Readiness Review is conducted toverify that the vehicle, payload, and ground systemsare all ready for launch.

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Fig. 5. K-1 with strongback retracted.

4.1. Landing and recovery

Fig. 7 shows the OV and LAP post-landing recov-ery sequence. Before approaching the vehicle, the K-lprovides con1rmation that they are in a safe condition.The stage is then approached, grounded and exter-nal power applied. To prevent contamination by sandand dust, protective caps are installed on the main en-gines, the ACS and OMS thrusters and stage vents.

Fig. 6. Top level K-1 processing.

The LAP is then lifted using the straddle lift vehicle(SLV) and the airbags removed. The stage is loweredonto the LAP horizontal pallet on the recovery vehicleand transported to the K-l VPF.Parachutes are collected, rolled up, and trans-

ported by truck to the processing facility for shipmentback to the supplier for refurbishment. The removedairbags are packed in crates and also shipped to theirsupplier.The OV returns to the same landing site approxi-

mately 24 h after launch and also lands with parachutesand airbags. Recovery operations are very similar tothose of the LAP except that the OV horizontal pal-let is installed on the recovery vehicle to transport thestage to the VPF.

4.2. Vehicle 5ow description

Vehicle processing begins upon receipt of the K-lstages at the VPF. Each stage is drained of residualfuel, LOX systems are vented, and vacuum cleaned asshown in Fig. 8. The PM is removed from the OV forseparate processing.The vehicle systems and thermal protection are in-

spected and refurbished as required. Consumables andexpended hardware are removed and replaced, andvarious engine components are cleaned. Discrepantelectrical components or other equipment, or any itemscheduled for replacement, is removed and returnedto the supplier for repair. Finally, parachutes, airbags,pyrotechnics, safety devices and other items requiredfor the next 5ight are installed.

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Fig. 7. Landing and recovery.

4.3. Payload processing 5ow description

After removal from the OV stage, the PM ismounted on its individual pallet, rotated to the verti-cal position and transferred to the PPF as shown inFig. 9. It is cleaned and inspected, the thermal pro-tection is refurbished as required, and the module isthen moved into the cleanroom area.ln parallel to the module processing, the payload is

received at the PPF, removed from its container in thereceiving airlock, inspected, and cleaned as required.Inside the facility, the spacecraft is tested, fueled, in-tegrated with the dispenser and mounted in the PM, asshown in Figs. 10 and 11. The PM/payload assemblyis then moved to the VPF.

4.4. Vehicle integration, propellant loading, andlaunch

Once the stages have been processed, the K-l ve-hicle is mated and the PM assembly attached. Thestages are aligned and mated, the stage separationsystem installed, and interfaces checked. The PMassembly pallet is then aligned, connected, and the

payload module assembly mated to the K-l vehicle asdepicted in Fig. 12.At this point, a Flight Readiness Review is

conducted of critical activities associated with themission. Review participants include Kistler andspacecraft managers as well as appropriate launch siterepresentatives. The vehicle con1guration, hardwaretraceability, anomaly corrections and test results areexamined and accepted. Payload readiness is con-1rmed and prelaunch weather and range conditionsreviewed. Final buy-o: on mission launch readinessis documented and approved by all relevant parties.The mated K-l vehicle is transported on rails from

the VPF to the launch stand where umbilicals for pro-pellants, power, air conditioning and purging are con-nected. Power is applied, purging and air conditioninginitiated, 1nal checkouts and leak tests performed, andthe launch ring base aligned. When ready, the vehicleand umbilical mast are erected to the vertical positionas shown in Fig. 13. The stage handling pallets arethen removed from the launch area.Stage fueling is commenced under the control of the

ground control computer which communicates data tothe mission control computer for review and decision

570 D. Fagan et al. / Acta Astronautica 52 (2003) 563–573

Fig. 8. Vehicle 5ow description.

Fig. 9. Processing of PM.

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Fig. 10. Satellite processing.

Fig. 11. PM and spacecraft integration.

making by the 5ight director. Vehicle on-board sys-tems also transmit health monitoring data to the mis-sion control computer which monitors all measure-ments and stimuli associated with vehicle propellantloading and assures only valid commands are beingsent to the onboard systems.After successful propellant loading, an automated

sequence takes over for the vehicle launch count-

down. The vehicle on-board computer enables thevehicle launch commit criteria and communicatesstatus to the mission control computer. In addi-tion, the ground control computer provides facil-ity status to the mission control computer. Basedon the acceptability of all data, the 5ight direc-tor either initiates the launch or terminates thecountdown.

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Fig. 12. Final stage processing.

Fig. 13. Preparing K-1 for launch.

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5. Key elements of Kistler’s approach

Kistler’s approach to launch operations is intendedto reduce cost, increase reliability, and compress leadtime required for payload processing and launch.Speci1cally, the following innovations are expected togive the K-l an edge over expendable launch vehicles.

5.1. Reusability

With expendable launch systems, a new vehiclemust be manufactured for each launch. Manufacturingbottlenecks can create long customer backlogs. Eachexpendable is also essentially a new vehicle, requir-ing extensive checkout to verify integrity. The K-l isreusable; after each use it will only require a mini-mum of service before the next launch. A 5eet of K-lvehicles will have enormous capacity launch capacity.Reuse of the same hardware components will increasesystem reliability, reduce integration time, and poten-tially lead to decreased insurance premiums. Compo-nents are designed with durability in mind.

5.2. Limited handling of stages

When the OV and LAP are recovered, each stage isplaced on its own horizontal pallet and transported tothe VPF on a straddle lift vehicle. Each stage remainson this pallet until vertical erection for launch. Lim-ited handling of stages reduces processing time andminimizes potential damage.

5.3. Parallel processing of stages and PM

After the OV is recovered and transported to theVPF, the module is removed and payload processingoccurs in a separate facility. Parallel processing fur-ther compresses preparation time. A parallel process-ing approach is expected to allow Kistler to expandits capacity in the future by adding modular process-ing facilities to accommodate multiple K-l missionssimultaneously.

5.4. Horizontal processing and integration

Each stage is serviced horizontally in the VPF.Stage mating and transport to the launch pad occurson the rail system. Horizontal processing is simplerand requires less supporting infrastructure than verti-

cal integration. Horizontal rail transport also can beaccomplished more quickly and easily than verticaltransport. The VPF will be located only 500 feet fromthe launch pad to reduce transport time from VPF tolaunch pad. Once the vehicle rolls out to the pad, it isdesigned to be fueled and ready for launch, in ¡6 h.

5.5. Use of automation

The IVHM installed in each vehicle monitors andtests components, tracking performance and allowingoperation crews to plan preventive maintenance. Vir-tually all controls are built into the K-l; after mis-sion control initiates fueling, the K-l controls its owncountdown, monitoring systems and terminating thesequence if it detects an anomaly. The vehicle wouldbe rolled back to the VPF to handle the problem. Au-tomated systems reduce personnel requirements forsystem checkout and launch.

5.6. Process span time

The K-1 has a planned turnaround time of 9 days,from landing to a subsequent launch of the same ve-hicle. This rapid turnaround time is expected to allowthe K-1 to respond quickly in customer demand forschedule 5exibility and rapid response.

6. Conclusion

Kistler Aerospace Corporation’s K-l reusableaerospace vehicle is designed to provide customerswith reliable, cost-e:ective, 5exible and responsivelaunch services. Kistler’s reusable K-l vehicle em-ploys a unique approach to payload processing andlaunch operations that is expected to signi1cantly in-crease industry launch capacity and shorten lead timerequirements. Kistler has made signi1cant process inassembling the 1rst K-l vehicle and preparing for inWoomera.

Acknowledgements

Special thanks to Debra Facktor Lepore and GaryLai for their contributions to the content of this paper.Also, thanks to the key members of the K-1 LaunchTeam—Curt Johnston, Bill Tolson, Frank McInerny,Kenny Phillips, Bill Buckles and Warren Lackie.