THE SOVIET HEAVY-LIFT LAUNCH VEHICLE

• Document Type: CREST
• Collection: NGA Records (Formerly NIMA)
• Document Number (FOIA) /ESDN (CREST): CIA-RDP91T01115R000100170003-4
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 14
• Document Creation Date: December 28, 2016
• Document Release Date: July 2, 2012
• Sequence Number: 3
• Publication Date: May 1, 1984
• Content Type: REPORT

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Directorate of Secret
Intelligence
The Soviet Heavy-Lift
Launch Vehicle (s)
Secret
IA 84-10032
May 1984
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Warning Notice Intelligence Sources
or Methods Involved
(WNINTEL)
National Security Unauthorized Disclosure
Information Subject to Criminal Sanctions
Dissemination Control NOFORN (NF) Not releasable to foreign nationals
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ORCON (OC) Dissemination and extraction of information
controlled by originator
REL...
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All material on this page
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This information has been authorized for release to...
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Secret
lA 84-10032
May 1984
Directorate of ret
Intelligence
The Soviet Heavy-Lift
Launch Vehicle (s)
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The Soviet Heavy-Lift
Launch Vehicle (S)
Summary A new Soviet heavy-lift space launch vehicle, under development by the
Information available V.P. Glushko space systems design bureau since the mid-1970s, is near-
through / February
1984 was used in this ing first flight at Tyuratam Missile and Space Test Center. A fully
report. (U) assembled prototype of this launch vehicle was seen for the first time
at Tyuratam, where it was undergoing compatibil-
ity checkout with launch pad facilities. The Intelligence Community es-
timates that the heavy-lift vehicle is capable of orbiting payloads weigh-
ing up to 100 metric tons, such as the Soviet space shuttle orbiter and
large space station modules. Future variants of the booster may be able
to orbit up to 150 metric tons. The first launch of the heavy-lift vehicle
(probably without the shuttle orbiter) may occur in mid-1985. Initial
launch operations with a shuttle orbiter are not expected before late
1985.
The basic heavy-lift vehicle consists of a large core booster and
strap-on, thrust-augmentation boosters. The 59-meter-long,
core booster has at least two and possibly three main propul-
sion engines and will use liquid oxygen and liquid hydrogen, a high-
energy propellant combination. The 41-meter-long
strap-on boosters, which are mounted offset to one side of the core
booster, will use liquid oxygen and probably a hydrocarbon-based fuel
such as kerosene. Large payloads, such as the shuttle orbiter, and possi-
bly payloads with attached upper stages, will be mounted to the side of
the core booster. Future variants of the heavy-lift vehicle may have
differing numbers of strap-on boosters, use high-energy-propellant up-
per stages, and be capable of accommodating either side- or top-
mounted payloads.
This information is Secret
Secret
IA 84-10032
May 1984
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HLLV Components
Strap-On Booster
HLLV Configuration
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The Soviet Heavy-Lift
Launch Vehicle (S)
A new Soviet two-stage, heavy-lift launch vehicle
(HLLV) is under development which is the successor
to the large SL-X-15 (formerly the TT-5) booster.
The SL-X-15 was to have been used in the Soviet
manned lunar landing program, but after three suc-
cessive launch failures from Tyuratam Missile and
Space Test Center between 1969 and 1972, the SL-X-
15 program was cancelled in early 1974. According
to since at least
1976 a new three-stage space launch vehicle has been
under development by the V.P. Glushko space sys-
tems design bureau.' This booster, which we believe
is the new HLLV, was described as being smaller
than the SL-X-15 and employing liquid oxygen
(LOX) and liquid hydrogen (LH), a high-energy
nronellant combination. (S
A fully assembled prototype HLLV was first seen in
October 1983 at Space Launch Site W, one of three
HLLV launch sites under construction or modifica-
tion at Tyuratam. Based on movements of ground
support equipment, the HLLV (temporarily designat-
ed the SL-W by the Intelligence Community) was
transported from its as-
sembly and checkout building to the launch site.
There it was erected for the initial series of launch
pad compatibility checkout tests.
a probable LOX-loading umbilical
was observed in the extended position from a pad
service structure to the vehicle. No propellant load-
ing activity was identified, however. The HLLV was
returned to the assembly and checkout building on
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The Intelligence Community estimates that the pay-
load-lift capability to low earth orbit for the HLLV
and potential variants of the HLLV will probably
range from 100 to 150 metric tons. The version of
the HLLV observed in October 1983 will be used for
launching large orbital payloads weighing up to 100
metric tons, such as the Soviet shuttle orbiter and
space station modules. Potential upgrades to the
HLLV, such as the use of additional stages or strap-
on boosters, may enable the orbiting of payloads
weighing up to 150 metric tons. The first launch of
the HLLV (probably without the shuttle orbiter) is
expected no earlier than mid-1985. Initial launch op-
erations with a shuttle orbiter are expected to begin
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no earlier than late 1985.2 (S 25X1
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The basic HLLV consists of a core booster and four
strap-on, thrust-augmentation boosters (figure 1). We
believe that the core booster will use LOX and LH
and that the strap-on boosters will use LOX and
probably a hydrocarbon-based fuel such as kerosene.
(S 25X1
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'For additional information on HLLV facilities at Tyuratam and the So-
viet shuttle orbiter, see IA 84-10017. Soviet heat} -Lilt Launch Iehiclt,
and Space Shuttle Orbiter Pacilities. I vuratam ,Afissile and Spare 7i'ti
Center, March 1984 (Secre and IA 83- 25X1 1
10077, Analtcis of the Savet Space Shuttle Orbiter, August 1983 (Secret 25X1
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The ogival nosecone is used for the
core booster LOX tankage. Although the exact size
and configuration of the LOX tank is not known,_
cylindrical tank section was
and had an approximate
Core Booster
The HLLV core booster, about 59 meters long and
has at least two and possibly
three LOX/LH propulsion engines. The core booster
serves as the structural backbone of the HLLV con-
figuration, in that the strap-on boosters and pay-
loads are mounted to it for launch. The core consists
of two major components which are manufactured at
Kuybyshev Aerospace Plant 1.
two com onents
onsists of the core nose-
cone/LOX tank and the intertank structure. The
larger of the two components, the LH tank, is about
volume of at least 500,000 liters.' (s
volume of 292,000 liters (figure 3). Based on the
LOX-to-LH propellant mixture and volume ratios
used on US boosters, and on the known size of the
core's LH tank, the complete LOX tank will have a
The bottom of the LOX tank is attached to the in-
tertank section, which is the structural connection
used to join the LOX and LH tanks of the core
booster together.
strap-on boosters. (S
eral of which are used as attachment points for the
ar points are o
cate around the circumference of the intertank, sev-
skoye Flight Test Center (figure 3). (S
The LH tank is cylindrical with domed endcaps and
has an approximate volume of 1.5 million liters. An
LH tank without its aerodynamic transport cover
was imaged in late 1980 and early 1981 at Ramen-
At some point during core processing, the LOX/LH
engines, which comprise the core booster's propul-
sion system, are attached to the base of the LH tank.
Each engine assembly
(figure 4). The presence of engine pod structures sug-
gests that the engines may be reusable and that each
pod may be detachable and house a recovery system
for the return of its engine after completion of the
boost phase. (s
The first fully assembled core booster
outside its assembly and c eck-
tached to the intertank section of the smaller component for transport,
increasing the overall length of the componen~ An I (-
meter-long ogival aerodynamic cover also is attached to one end of the
LH tank for transport, increasine the overall length of this component to
out building at Tyuratam. The core was then trans-
ferred to one of two high-bay areas in the buildin
for integration with its strap-on boosters. (S
^LOX-to-LH propellant mixture and volume ratios commonly employed
on US space booster systems are 5: or 61 and 1:3, respectively. (U)
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about 41 meters long
is derived from the P
Strap-On Booster
The HLLV strap-on, thrust-augmentation boosters
are assembled at Dnepropetrovsk Missile Develop-
ment Production Center. Each strap-on booster is
first stage of the SL-Y, a medium-lift space
launch vehicle also under development at Tyuratam
(figure 5). The additional length of the strap-on
booster is for an asymmetric nosecone which is at-
tached to the intertank of the core booster. The
nosecone could house a recovery parachute system if
the strap-on is to be reused. Because the strap-on
booster is derived from the SL-Y first stage, it will
probably use the same propellants and quantity of
propellants as the SL-Y's first stage. Analysis of on-
pad propellant tanking tests indicates that the SL-Y
first stage has a LOX tank and probably a kerosene
tank. The LOX tank, located beneath the strap-on's
nosecone,
(positioned
beneath the LOX tank.' Based on these dimensions,
the quantities of LOX and kerosene required for
tanking each HLLV strap-on booster (before losses
due to venting, overflow, etc.) are approximately
The size and location of the propellant tankage is based on the identifi-
cation of icing on specific sections of the SL-Y airframe during tanking
tests at Tyuratam in September and November 1983. The sections with
ice probably are used for housing LOX tankage. Those sections without
ice (except for the payload shroud) probably are used for housing kero-
206,000 liters and 106,000 liters, respectively. The
propellant volume ratio (volume oxidizer to volume
fuel) of the strap-on is about 1.9 : I. (sF--]
Analysis of the SL-Y first-stage engine section, which
located beneath the kerosene tankage, suggests that
the propulsion system will use a single exhaust noz-
zle. A ring appears to encircle the
end of this nozzle and apparently is connected to
four possible actuators on the booster. If so, the ring
may be gimballed or pivoted by these actuators into
the exhaust flow from the nozzle in order to provide
thrust vector control for the booster during launch.
HLLV Configuration
The prototype HLLV observed at Launch Site W in
October 1983 had an overall length of about 60 me-
ters The
vehicle consisted of the core booster and four at-
tached strap-on boosters, two per side. While no
payload was present on the prototype, the basic
HLLV is intended to carry payloads which will be
mounted to the side of the core booster. (s F--]
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The four strap-on boosters are mounted to the core
booster in an arrangement in which the strap-on po-
sitioning is offset toward one side of the core. The
angular displacement of the two opposing pairs of
strap-on boosters is abou respectively
(figure 6).6 The offset positioning of the HLLV
strap-ons is designed to accommodate the attach-
ment of large payloads, such as the shuttle orbiter,
on the opposite side of the core and to counter the
center-of-gravity shift caused by the weight of such
payloads. (S
'Angular displacement is defined geometrically as the angle between the
intersection of a reference plane with another plane. As seen in the top
view of the HLLV, the reference plane is located equidistant between the
opposing pairs of strap-on boosters and passes through the center of the
core booster. The other plane bisects the strap-on booster and terminates
Each strap-on booster is attached to the core booster
at a minimum of two points. The top of each strap-
on's nosecone is attached near the center of the in-
tertank section, and the lower portion of each strap-
on is attached to the LH tank's base. At least two
probable circumferential stiffener rings are present
near the base of each strap-on booster and may in-
clude the lower core booster mounting points. Fur-
thermore, the HLLV core booster apparently is
physically supported by the strap-ons while on pad
since no structures for core booster support have
been identified. (s
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Propellant loading of the strap-on boosters may, in
part, be conducted through the core booster. Only
one propellant-loading umbilical has been identified
at site W for supplying LOX to the HLLV. This um-
bilical mates with a probable receptacle or fixture on
the exterior of the core's intertank section and is
probably used for tanking LOX onto the core
booster. Hypothetically, because no umbilicals are
evident for loading LOX onto the strap-ons, LOX
from the single umbilical also may be distributed to
the strap-ons by means of a possible intertank piping
system. Conceivably, LOX lines could run from the
intertank into each strap-on booster through its at-
tachment point at the intertank. The kerosene-type
fuel for the strap-ons probably will be loaded
through individual fixtures on the launch pad's
HLLV support pedestal into each booster's kerosene
tank. (s
Payloads which will be launched by the basic HLLV
will be attached to the side of the core booster.
These payloads will be side-mounted in a manner
similar to that of the US shuttle orbiter on its launch
system (figure 7). The positioning of the strap-on
boosters toward one side of the core booster has
made a large, relatively unrestricted area available on
the opposite side of the core for payload attachment.
The attachment of large payloads on the side of the
core booster probably will require special fittings or
structural provisions on the core for mounting such
payloads. Two structural features on the core have
been identified which may serve such a purpose (fig-
ure 1). The possible attachment structures are lo-
cated on the side and base of the core booster's LH
tank and appear similar to the orbiter mounting
structures on the US shuttle system's external
tank. (s
Figure 7
Soviet and US Launch Vehicles with Side-Mounted Orbiter Payload
Note: Orbiter configuration
details are provisional.
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HLLV Transport
The major components of the HLLV's core booster
and the strap-on boosters are shipped assembled
from their manufacturing plants to Tyuratam to
maximize factory control over component quality
and reduce processing time after delivery. The two
major components comprising the core booster are
outfitted with aerodynamic covers and are individu-
ally air-transported atop modified Bison aircraft
from Kuybyshev to Tyuratam (figure 8). Upon arriv-
al at Tyuratam, the components are transported by
dolly from the airfield to the HLLV assembly and
checkout building for aerodynamic cover removal
and receipt and inspection activities. The compo-
nents are then mated to form the propellant tankage
of the core booster. Each HLLV strap-on booster is
shipped by flatbed rail train from Dnepropetrovsk to
Tyuratam (figure 8). The strap-ons are offloaded in
the HLLV asembly and checkout building in prepa-
ration for core booster attachment. Once assembled
and checked out, the core and strap-on boosters are
integrated in the horizontal position to form the
HLLV. (s
After HLLV integration has been completed, the
HLLV is mounted on a transporter/erector (TE) for
horizontal transport from the assembly and checkout
building to another building for payload mating. Fi-
nally, the HLLV arrives at the launch pad where it
and the attached payload are erected into place.?
Transportation and erection is accomplished by one
of two TEs formerly used for the SL-X-15 booster
and later reconfigured for the HLLV. The TEs, each
of which consists of a rectangular, steel-framework
chassis with two hydraulic erecting arms, are nor-
mally parked outside the HLLV assembly and check-
out building. Each TE is about 55 meters long, 24
meters wide, 19 meters high and travels on a 20-
meter-gauge rail network (figure 9). A total of four
locomotives, two per TE side, are used for moving
the TE between locations on the rail network.
'The October 1983 series of compatibility checkout tests between the pro-
totype HLLV and the launch pad did not involve a payload; therefore,
The HLLV is supported on the TE by a curved sup-
port cradle and two bracketlike, rectangular support
structures. The cradle is a permanent structure lo-
cated near the front of the TE that mates with the
intertank for support of the forward portion of the
HLLV. The rectangular structures are positioned
around the lower portion of the HLLV and are sup-
ported by the rear of the TE during transport and
erection. These structures apparently provide HLLV
support both during transport and after erection on
pad, since they remain attached to the strap-on
boosters once the HLLV is mounted on the pad's
launch vehicle support pedestal (figure 9). (s F_
Variants of the basic HLLV may be developed which
will use differing numbers of strap-on boosters, high-
energy-propellant upper stages, and be capable of
launching either side- or top-mounted payloads. Al-
though up to eight strap-on boosters could be ac-
commodated around the core, it is unlikely such an
HLLV variant will be developed because of limita-
tions at the launch facilities. Based on launch pad
configurations, the HLLVs launched from site W
apparently will be limited to four strap-on boosters.
Those launched from the other two HLLV launch
sites, JI and J2, will have at least four and possibly
six strap-ons, depending on the final pad configura-
tion, the capabilities of the TE, and the mounting
position for the payload. (s
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