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New Angara production line to open

In 2016, Russia's new-generation Angara rocket came one step closer to becoming an operational vehicle with the completion of major renovations at its future serial production line in Siberia. By the beginning of the 2020s, the state-of-the-art factory in the city of Omsk should take over the entire manufacturing process for the Angara, churning up as many as 100 booster stages a year.

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Angara

Russian officials inspect Angara production line in Omsk in 2015.


Too expensive for rockets?

When the Angara project left the drawing board in mid-2000s, the manufacturing of the rocket's initial hardware was centered at Building No. 128 at GKNPTs Khrunichev in Moscow, with the final assembly conducted at next-door Building No. 22. However for the mass production of the rocket, the company turned to the Siberian city of Omsk, the home of the PO Polyot company, which built the now discontinued Kosmos-3M rockets. Initially, the final assembly of the Angara would still be conducted in Moscow, before a fully integrated production line could be established in Omsk.

One of the reasons prompting GKNPTs Khrunichev to shift its production as far as Siberia was the skyrocketing cost of real estate in Moscow, making the Russian capital one of the most expensive cities in the world at the turn of the 21st century. As a result, Khrunichev's vast campus in the district of Fili, on the shore of the Moscow River, turned out to be one of its most valuable assets. By selling some of its land to commercial developers, GKNPTs Khrunichev hoped to straighten its shaky financial position and raise badly needed cash for modernization of its aging infrastructure. The PO Polyot company in Omsk, with its low-cost workforce and dormant capacity, could be a sensible alternative. Khrunichev's officials hoped that the move to Omsk would eventually help bring down the cost of the Angara's production to as low as the target price for the Proton rocket, which was set in 2016 at 1,381 billion rubles ($21.6 million). However Soviet-era facilities in Omsk themselves required major renovations.

Moscow

Early Angara rockets were assembled and outfitted in Moscow.

Moving to Omsk

Khrunichev formally absorbed PO Polyot during 2007 and in the same year, technical documentation and blueprints for the Angara reportedly began arriving at Omsk. In 2008, Khrunichev officials promised major upgrade of the manufacturing facilities in the city. Also in 2008, a team of specialists from PO Polyot worked at Khrunichev's plant in Moscow on the manufacturing of elements for the South-Korean KSLV rocket, which closely resembled the URM-1 booster of the Angara. During 2009, the production line for the KSLV in Moscow was to be dismantled and re-assembled in Omsk, for the benefit of the Angara program. (322)

Beginning in 2009, PO Polyot was to take responsibility for the production of the Briz-KM upper stage for the Rockot booster, as well as Rockot's adapter rings and payload fairings. Also, the manufacturing of all key elements for the Angara-1.2 version of the rocket would end up in Omsk as well.

Additionally, the Ust-Katav Wagon-building Plant, UKVZ, would produce components for Angara and its KVTK upper stage, along with sections of the Proton rocket and the Briz-M upper stage.

By 2010, it was decided that the Angara-5 would have to be preceded by a test launch of the light-weight Angara-1 rocket. As a result, PO Polyot planned to produce the first Angara-1 rocket and five URM-1 boosters for the heavy Angara-5 by 2012. The company was expected to turn out 60 URM stages annually for 10 Angara-5 rockets and 10 Angara-1.2s by 2015 and as many as 120 boosters per year were to be produced to support 20 missions annually by 2020, the official ITAR-TASS news agency promised, quoting director at PO Polyot Grigory Murakhovsky.

According to Murakhovsky, the Angara production required a massive reconstruction of the obsolete factories at PO Polyot with a planned price tag of 3,349 billion rubles, including 771 million in 2009. Around 300 million were to be spent on purchases of new manufacturing tools and equipment. He said that not all of the 329 million rubles allocated for the project in 2008 had been provided and the resulting deficit was included in the 2009 funding schedule. Murakhovsky said that active modernization of the plant had been underway, 15 high-tech metal-processing machines had been ordered and the installation of new hardware and software was expected to be completed by the end of 2009. (342)

The project ultimately took more than five years to complete. By the end of the renovations in Omsk in 2014, its price tag reportedly reached more than seven billion rubles, or more than twice of the original estimate. According to local officials more than 300 new pieces of manufacturing hardware had been procured and production facilities with a total area of 38,000 square meters had been renovated.

Preparing full-cycle production in Omsk

The second round of upgrades started at Angara's production plant in Omsk during 2015 at a reported price tag of six billion rubles (in addition to the seven billion spent on the first round from 2009 to 2014). By that time, the first launch of the Angara-5 had already taken place and the serial production of the rocket was becoming a reality. Imported state-of-the-art machines for manufacturing of tanks as large as four meters in diameter were installed at Building No. 12, where special foundations had to be built first.

machinist

Head of GKNPTs Khrunichev Andrei Kalinovsky explains the work of machinists welding components of the Angara rocket at PO Polyot to Deputy Prime Minister Dmitry Rogozin (in red jacket) and head of Roskosmos Igor Komarov (to Rogozin's left).

At the end of June 2015, a big delegation of space officials led by Deputy Prime Minister Dmitry Rogozin visited Omsk on their way to Vostochny. At the time, the full cycle of serial production of the Angara rocket was expected to begin in Omsk between 2018 and 2021. Only then, apparently, would it be possible to avoid sending rocket stages to Moscow for final outfitting and checks and to ship them directly to launch sites in Plesetsk or Vostochny.

GKNPTs Khrunichev's Moscow facility was still expected to manufacture upper stages for Angara, such as the next-generation KVTK booster and the MOB-KVTK space tug for prospective human missions into deep space.

2016: Angara serial production line to open

In July 2016, the head of GKNPTs Khrunichev Andrei Kalinovsky confirmed to the Izvestiya daily that 11 URM-1 boosters would be produced per year until 2020, enough to assemble a pair of Angara-5 rockets and one Angara-1.2 a year during that five-year period. Operating in three shifts, the serial production plant for the Angara family in Omsk could turn up 100 URM-1 modules for 20 rockets per year, Kalinovsky said, however he did not specify when such a manufacturing rate would be reached.

Around the same time, the Spetsstroi military construction agency informed the Gazeta.ru web site that it was putting the finishing touches on the new production facility for the Angara rocket at PO Polyot's Hall 66 in Omsk.

The full production complex included two already completed production halls and a power conversion station. The latest facility would include clean-room equipment and an X-ray chamber for inspection of large components, both of which were all in the final stages of installation, making the production line ready for opening by the end of July 2016. According to Kalinovsky, the new facility would be used to begin the work on the third and fourth Angara-5 rockets in the second half of 2016.

Switching to digital

During 2016, GKNPTs Khrunichev also hoped to finally switch from traditional to computer design of the Angara rocket. The company began digitizing blueprints for the rocket in 2015 and by the end of that year completed around 55 percent of the transition process, Kalinvosky told RIA Novosti. The blueprints for the URM-1 booster module were digitized first and, by April 2016, engineers began working on designs for the URM-2 stage and on the payload section.

Flight 1

Angara-A5 rocket with Briz-M upper stage. Copyright © 2014 Anatoly Zak


Summary of renovations at PO Polyot in Omsk for the Angara production:

-
First phase (2009-2014)
Second phase (2015-2020)
Projected cost
3.3 billion rubles
7 billion rubles
Actual cost
7.1 billion rubles
-
Equipment unit procurement
300
100
Renovated facility area
38,000 square meters
48,000 square meters

 

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Next chapter: The second launch of the Angara rocket

 

The article and illustration by Anatoly Zak; Last update: July 14, 2016

Page editor: Alain Chabot; Last edit: July 14, 2016

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URM-2

Installation of cable equipment on the static prototype of the Angara rocket at Hall 66 in Omsk. Credit: PO Polyot


welding

A section of the Angara propellant tank during welding. Credit: PO Polyot


roll

A completed section of the Angara propellant tank is rolled for welding with other components. Credit: PO Polyot


bulkhead

A bulkhead for Angara's propellant tank is being prepared for welding with its cylindrical section. Credit: PO Polyot


tank

Work inside the tank section of the Angara rocket in Omsk. Credit: PO Polyot


o2

kerosene

An oxygen tank (top) and a kerosene tank for the URM-1 booster during production inside renovated facility in Omsk in 2015. Click to enlarge. Credit: PO Polyot


engine

An RD-191 engine is being prepared for integration with an URM-1 booster of the Angara rocket at PO Polyot facility in Omsk. Credit: PO Polyot


top

Click to enlarge. Credit: PO Polyot

porduction

Angara production line in Omsk. Credit: PO Polyot