Attachment update

update

LETTER submitted by EchoStar

update

2008-02-07

This document pretains to SAT-MOD-20060329-00031 for Modification on a Satellite Space Stations filing.

IBFS_SATMOD2006032900031_621629

February 7,2008

Marlene H. Dortch
Secretary
Federal Communications Commission
445 12th Street S.W.
Washington, D.C. 20554

Re:     EchoStar Satellite Operating L.L.C.
        File Nos. SAT-LOA-20051221-00247, SAT-AMD-20060120-00007, SAT-MOD-
        20060329-00031

Dear Ms. Dortch,

EchoStar Satellite Operating L.L.C.’ (“EchoStar”) updates its orbital debris mitigation plan for the
EchoStar 10 satellite, previously submitted on December 2 1,2005. That satellite uses the
Lockheed Martin A21 00 bus, and EchoStar discovered that this update was appropriate recently
when filing its application to operate the AMC-14 satellite, which uses the same bus. The
characteristics of the EchoStar 10 and AMC-14 satellites are shared by a large number of
Lockheed Martin A2 100 satellites in operation today. We want to ensure that the Commission has
a full and comprehensive record with respect to our EchoStar 10 satellite. That satellite has been a
critical addition to our satellite fleet, allowing us to expand greatly the number of local broadcast
markets served by DISH Network.

In the EchoStar 10 satellite orbital debris mitigation plan, EchoStar stated that “[alt end of life and
once the satellite has been placed into its final disposal orbit, all on-board sources of stored energy
will be depleted, the batteries will be discharged and all fuel line valves will be left open.” See
File No. SAT-LOA-2005 1221-00247, app. A, at 10. This statement remains true with respect to
all fuel tanks relied upon to operate the satellite once it arrives at its destination. Two oxidizer
tanks on the satellite - used only to propel the spacecraft into geostationary orbit - however, will
retain a small amount of oxidizer and helium pressurant (approximately 18.8 kg pressurized with
helium to approximately 250 psi) at the satellite’s end-of-life. Because of the design of the
Lockheed Martin A2 100 bus, this residual oxidizer and pressurant in the two tanks cannot be
vented at end-of-life.

Instead, as affirmed in the attached Declaration from Lockheed Martin (“Lockheed
Memorandum”) (Attachment A), the residual oxidizer and pressurant were securely sealed using
pyrotechnic valves upon completion of the satellite’s transfer to geostationary orbit, and have been
stored under conditions that would make even a leak extremely unlikely, and an accidental, post-
mission explosion more unlikely still. EchoStar has been informed by the Lockheed Martin that


I
           Effective January 1,2008, EchoStar was converted from a Colorado corporation into a Colorado limited
liability company. Under Colorado law, “[tlhe resulting entity is the same entity as the converting entity.” See Colo.
Rev. Stat. 7-90-202(4).


                              1233 Twentieth Street, N.W., Washington D.C. 20036


this is a feature common to all Lockheed A2100 spacecraft buses, on which the EchoStar 10
satellite was built.

As demonstrated in the Lockheed Memorandum, Lockheed has taken a number of measures to
avoid an explosion. First, it has built hardy tanks that are extremely unlikely to leak. The tanks
are all-titanium vessels that have been inspected, tested and qualified to the stringent requirements
of the MIL-STD-1522A (Standard General Requirements for Safe Design and Operation of
Pressurized Missile and Space Systems) and the EWR-127-1 (Eastern and Western Range Safety
Requirements). See Lockheed Memorandum at 1. Given the small amount of oxidizer that
remains in the oxidizer tanks, the tanks would have to be heated above 165” F (or 76” C) in order
for their designed pressure tolerances to be exceeded. Such temperatures are highly unlikely to be
experienced, and Lockheed’s worst-case analysis shows that temperatures will be less than 95” F
(or 35” C) at end-of-life, resulting in a maximum pressure well below the pressure tolerance of the
tanks. See id.at 1. Second, Lockheed has designed and constructed the tanks in accordance with
stringent technical standards to leak rather than burst in the case of a flaw in the materials. The
tanks have accordingly been qualified as leak-before-burst pressure vessels. Id. at 1-2. For these
reasons, post-mission storage of the oxidizer in this manner is no less secure than post-mission
venting.

In these circumstances, EchoStar believes that the Lockheed-designed and built tanks comply with
sections 25.283(c) and 25.114(d)(14)(ii) of the Commission’s orbital debris mitigation rules.
Section 25.283(c) mentions an illustrative list of “appropriate measures” for discharging energy
sources. The measures taken by Lockheed to discharge the energy (including the ultra-secure
storage of a small residual amount) qualifies as such an appropriate measure. This understanding
of the rule is confirmed by Section 25.1 14(d)(14)(ii), which requires applicants to address
“whether [not that] stored energy will be removed at the spacecraft’s end of life, by depleting
residual fuel and leaving all fuel line valves open, venting any pressurized system, leaving all
batteries in a permanent discharge state, and removing any remaining source of stored energy, or
through other equivalent procedures specifcally disclosed in the application.” In other words,
Section 25.1 14(d)(14)(ii) contemplates “other equivalent procedures” than the ones listed for
limiting the probability of accidental explosions and does not restrict these procedures to removal
or depletion of energy. Finally, the Lockheed design is consistent with the purpose of the rules,
which, as is evident from Section 25.114(d)(14)(ii), is to “limit the probability of accidental
explosion . . . after the completion of mission operations,”2 and with FCC p r e ~ e d e n t . ~

2
         Section 25.114(d)(14)(ii) of the Commission’s rules requires space station applicants to “assess[] and limit[]
the probability of accidental explosions” at the end-of-mission by, among other things, “address[ing] whether stored
energy will be removed at the spacecraft’s end of life . . . .” 47 C.F.R. Q 25.1 14(d)(14)(ii).
3
         For example, Hughes Communications, Inc. was granted an authorization for the Spaceway-3 satellite
without a waiver of the orbital debris mitigation rules, even though four tanks on the Boeing 702 spacecraft would
continue to have residual helium and xenon gas in them at the end-of-life. See Hughes Communications, Inc., Stamp
Grant, File Nos. SAT-MOD-20050523-001 06, SAT-AMD-20060306-00025 (granted Jun. 24,2006) (“HNS’). As
Hughes noted in its amended application, “the standard practice of retaining four tanks with a low residual pressure is
both a responsible approach and results in a far lower risk of accidental explosion over time than would any attempt to
completely depressurize the tanks during or after the spacecraft’s mission.” Amendment at Att. A, p.20, File No.
SAT-AMD-20060306-00025. The Commission reached a similar conclusion when it evaluated a request by
PanAmSat for a waiver of the orbital debris mitigation rules with respect to the sealing of oxidizer tanks on its
Horizons 2 and Intelsat 11 spacecraft. See PanAmSut H-2 Licensee Corp, Stamp Grant, File No. SAT-AMD-


                                                           2



              - ---   ---1I 2 1  -            I 1 l‘iI           ,


While we are confident that the EchoStar 10 satellite is compliant with the Commission’s rules,
we provide this more granular information to supplement the record in connection with the above-
captioned file. We also wish to notify you that the two most recent satellites we have contracted
for - EchoStar 11 and EchoStar 14 - do not present similar challenges.

Please contact the undersigned if you have any questions.

Respectfully submitted,

/s/ Linda Kinney
Linda Kinney
Vice President, Law and Regulation

Enclosure (by email)

cc:      Robert Nelson
         Karl Kensinger




20070731-00108 (granted Nov. 30,2007) (“PanAmSut H-2”); PunAmSat Licensee Corp., Stamp Grant, File No. SAT-
AMD-20070716-00102 (granted Oct. 4, 2007) (“Zntelsut 11”). While the Commission granted the request for waiver
in those cases, it stopped short of saying that the rule could never be complied with by alternative measures such as
the ones taken here, if an appropriate showing is made. It found only that “the information submitted in [PanAmSat’s]
application is not sufficient to support a finding that the intent of the rule would be satisfied by the described
procedure for sealing the oxidizer tanks.” PunAmSat H-2 at condition 5; Intelsut 11 at condition 7. In contrast, the
detailed information provided in this case supports a finding that the EchoStar 10 spacecraft design is consistent with
the Commission’s orbital debris policies.


ATTACHMENT A


                                                       Lockheed Martin Space Systems
                                                                                                  LOCKHEED
                                            Engineering Memorandum
                                                                                      Date: 18 December 2007
                                           Pressures                                  EM No.: PSS07-A2100-0040
 Kev Words: End of Life. Oxidizer. Pressures
 Prepared For: B. Noakes                     Prepared by: J.
 LMCSS Chief Engineer                        LM Propulsion                                                           ---_.




       1.0 Summary
   Currently, the A2100 propulsion system has no way to vent off the oxidizer tanks following
   transfer orbit. The pressure and residual oxidizer is sealed via pyrotechnic valves in the two
   oxidizer tanks. We consider it very unlikely that these tanks could catastrophically lose pressure
   either during the mission or after the spacecraft has been placed in a disposal orbit.


   2.0 Background
   The oxidizer tanks are all titanium pressure vessels that have been inspected, tested and
   qualified to the requirements of the MIL-STD-I 522A (Standard General Requirements for Safe
   Design and Operation of Pressurized Missile and Space Systems) and the EWR-127-1 (Eastern
   and Western Range Safety Requirements) as hazardous leak before burst pressure vessels.
    These documents place stringent requirements on the design, manufacturing, test and operation
   of the pressure vessels so that it is extremely unlikely that these tanks will leak external and even
   more unlikely that they would rupture with explosive force. The leak before burst requirement was
   demonstrated on the qualification tank.

       Specifically, the tanks are designed to a Maximum Expected Operating Pressure of 300 psia, and
       are proof tested during manufacturing and after system integration to 375 psia. The tanks are
       designed such that their rupture pressure is not less than 450 psig -the qualification test unit for
       this tank design actually ruptured at 664 psig. At the end of transfer orbit, the tanks have
       between 255 - 265 psia inside them. The maximum expected amount of remaining oxidizer is
       less than 3% of the tank volume. To get the tanks to a pressure above the design rupture
       pressure, the tank temperature would have to increase to above 165 F (76 C). Analysis of the
       spacecraft at end of life indicates a warst case temperature less than 95 F(35 C), with a
       corresponding maximum pressure in the tanks less than 295 psia. Therefore, there is no risk of
       rupture of the tanks after retirement of the spacecraft. The other failure mode for the tank is
       leakage. The tanks are designed such that they will leak before they burst - the tank materials
       have been inspected to such an extent that flaws, if they are present in the material, will not
       propagate catastrophically - they will growth through the wall and the tank will leak, relieving the

___~                      ..... -  ~. NOTICE
                          PROPRIETARY   .                                 __                                     Page 1
This material is the property of Lockheed Martin Corporation and contains material
proprietary to Lockheed Martin Corporation. The contents arc?for confidential use
only, for purposes of recipient’s contractual performance, and are not to be
disclosed to any others in any manner, in whole or in part, except with the express
written approval of Lockheed Martin Corporation.


                                                        Lockheed Martin Space Systems
                                             Engineering Memorandum
               ______- _____                -.__..--                                    ---    -___---       -

  pressure, rather than grow in a manner that the stored energy in the tank will be released in an
  instant. Because of this design, the tanks will not fail in such a manner that debris is generated.


  3.0 Conclusion
   It is extremely unlikely that the oxidizer system in an A2100 will catastrophically lose pressure
   after the system has been isolated following transfer orbit.




_.___     -___._-
                           PROP.RIETARY NOTICE                                     .

This material is the property of Lockheed Martin Corporation and contains                      Page 2 of 2
material proprietary to Lockheed Martin Corporation. The contents are for
confidential use only, for purposes of recipient's contractual performance, and
are not to be disclosed to any others in any manner, in whole or in part, except
with the express written approval of Lockheed Martin Corporation.



Document Created: 2008-02-12 14:57:35
Document Modified: 2008-02-12 14:57:35

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