PROJECT 331
Even as the Fanhui Shi Weixing (FSW) recoverable satellite program was under way, Chinese engineers moved on to a new, ambitious goal: putting satellites into geosynchronous orbit 36,000 km over the Earth. This program involved the building of a new launcher, the Long March 3, and a new launch site, Xi Chang. The single event that contributed most to this development was the visit of President Richard Nixon in 1972, which began the process of international recognition of communist China after years of isolation. At a practical level, the Chinese were amazed by the satellite television crews who followed the president’s every movement and beamed pictures back live to admiring American homes through their now well-established network of satellites in geostationary orbit. Shipping their pooled satellite van back home proved to be expensive, so it was left behind in China, like the calling card of visitors passing through.
There were several reasons why China should develop satellite-based communications. Communications satellites offered the possibility of providing advanced telecommunications for a large country quite quickly. Quality telecommunication links were increasingly considered an essential feature of a modernizing economy. Communications satellites offered both direct television transmission (saving the establishment of elaborate systems of relays) and telephone lines (saving the setting – в. Harvey, China in Space: The Great Leap Forward, Springer Praxis Books,
DOI 10.1007/978-l-4614-5043-6_5, © Springer Science+Business Media New York 2013
up of land lines) or a combination of the two. In the 1970s, the Chinese leased a number of Western satellite lines to test the potential of a space-based communications system and needed no further convincing.
SatelUtes circling at an altitude of 36,000 km over the Earth’s equator orbit every 24 hr thus appear to hover over the same point all the time. The value of such an orbital position was first appreciated by science writer Arthur C. Clarke, who, in Wireless World (1945, Iliffe and Sons), outlined how three such satellites could cover the entire planet. The Americans pioneered the use of the 24-hr orbit in 1965 with Early Bird. The 24-hr orbit is now quite crowded and elaborate arrangements exist both for the allocation of slots there and to ensure that dead satellites are taken out of that orbit and sent to less densely populated regions of the sky (graveyard orbits).
However, the 24-hr orbit presents its own problems. First, to reach an altitude of 36,000 km and enter a circular orbit, a powerful launcher and upper stage able to reach the final destination is required. Second, the 36,000-km orbit is over the equator, which means that the rocket must not only reach a great height, but also carry out a dogleg maneuver southwards to get there. While it is possible to reach 24-hr orbit on a conventional three-stage rocket, placing a sizable payload there requires more powerful fuels and/or a restartable upper stage.
The idea of a communications satellite for China was discussed and approved by the Central Committee in 1965. The China Academy of Launcher Technology (CALT) allocated staff for preliminary design studies of launchers and rockets in 1970. The Chinese considered the development of a low-Earth-orbiting system first, Uke the American Telstar, and also considered the idiosyncratic but highly effective Soviet Molniya system of satellites which orbit the Earth every 12 hr with an apogee slowly transiting the northern hemisphere. However, they opted to go straight for a 24-hr system, despite the difficulties. Progress was impeded by the cultural revolution and the project progressed little until the Nixon visit and when Zhou Enlai convened design conferences in 1974. What finally tilted the argument was the danger that slots in 24-hr orbit allocated by the International Telecommunications Union to China (87.5°E, 98°E, 103°E, 110°E, and 125°E) would be lost unless taken up – a prospect to which Zhou had been alerted in a handwritten letter by four technicians in the Ministry of Posts & Telegraphs. In February 1975, the State Planning Commission approved the Report Concerning the Question of Development of This Country’s Satellite Communications. Pressed by Deng Xiaoping, Mao Zedong gave the project the go-ahead in April 1975, along with the code of project 331, and it was probably his last decision on the space program. Conceptual design took place over 1975-77 and the first engineering model of the new satellite was built in 1979. Italy was invited to install a 3-m dish to receive signals from its Sirio satellite and thereby test the reception of signals. Deng Xiaoping, a vocal proponent of the project because of its practical benefits to China, was in such a hurry that he separately initiated two years of negotiations to buy a communications satellite from the United States in the meantime, but they came to nothing.
The need for a powerful launcher prompted the Chinese to consider the use of a hydrogen-fuelled rocket. Hydrogen, while having considerable advantages in terms of thrust (50% more than conventional rockets) and environmental friendliness, is a difficult substance to handle. It must be cooled to a temperature of -253°C and its oxidizer to -183°C. This in turn requires very strong metals, for conventional alloys will turn as brittle as glass under such temperatures. The fuels and oxidizer evaporate quickly on the pad and have to be continuously topped up right to the moment of ignition. Liquid hydrogen has a rate of seepage 50 times higher than water. This area of work is sometimes referred to as cryogenics technology.
The Americans experienced great difficulty with introducing a hydrogen-powered upper stage in the 1960s (the Centaur) and the Russians did not operationalize such technology until 1987 (Energiya). Not only that, but restarting any rocket stage for a second burn has always proved a persistent problem in rocketry, for the engine must be restarted in zero gravity, without the normal forces that push propellants into the combustion chamber. The Russians had lengthy problems with their Molniya and Proton upper stages failing to restart, expensive Moon, Venus, and Mars probes becoming stranded in low Earth orbit as a result.
During a feasibihty study in 1974, the Chinese weighed the options of using a conventional launcher and a hydrogen-powered third stage. COSTIND director Ren Xinmin, educated in Michigan until he returned to China after the revolution, fought a hard battle to convince his colleagues of the long-term benefit of mastering this difficult technology. Despite the challenges, the Chinese decided in August 1976 to go for the most ambitious system – a hydrogen-powered restartable upper stage. The Chinese began their first work on liquid hydrogen in the Liquid Fuel Rocket Engine Research Institute in 1965 but the first tests were not run until 1974.
The Long March 3, introduced for the new comsats. Courtesy: Cindy Liu. |
The new rocket, called the Long March 3, was the biggest so far constructed in China – 43.25 m tall, 3.35 m in diameter, 202 tonnes in weight, with a take-off thrust of 280 tonnes. The first two stages were adapted from the Long March 2, but the real test was the hydrogen-powered third stage, the H-8, and its new engine, the YF-73, whose principal designer was Wang Zhiren, one of China’s few prominent women rocket scientists. Developing the YF-73 was troublesome and timeconsuming, taking over seven years, including an explosion in January 1978 which led to injuries and some fatalities.
The transfer to geosynchronous orbit required a complex set of maneuvers. First, the upper stage is placed in a low Earth orbit, typically at around 215 km. On its first southbound pass over the equator, generally about an hour later and over 160°E longitude, the hydrogen-powered upper stage is fired to raise the high point of the orbit, the apogee, to 36,000 km, the altitude of geosynchronous orbit. This burn requires the highest level of energy and achieves what is called the Geostationary Transfer Orbit (GTO). Then the low point must be raised and the inclination changed from 28° to 0°. Several of the key operations take place when the rocket is well outside the line of sight of Chinese ground control. Chinese computers lagged far behind Western and Soviet ones in the late 1970s – China could not obtain the latest computer technology – so modernizing them was a huge challenge. The final maneuver was carried out by an apogee kick motor – a small, solid-fuel rocket that would be used to adjust the satellite’s elliptical GTO into a circular geostationary orbit.
The apogee motor: although small in size, its role was crucial in the final stage of the journey to geosynchronous orbit. |
A related problem to that of the launcher was how to reach equatorial orbit from a launch site with a high latitude (Jiuquan was 41.1°N). Other countries solved this problem by setting up launch sites on the equator, as France did in its colony of Guyana, while, more exotically, a Russian-Ukranian-American consortium converted a Norwegian oil rig into a launching platform and towed it to the midPacific (Sea Launch). The Chinese landmass lies some distance north of the equator. By establishing a new site much closer to the equator in southern China, some of the burden of reaching equatorial orbit could be reduced – 18.5% compared to Jiuquan, to be precise. Accordingly, a new site was found, at Xi Chang, at 28.25°N, coincidentally at a similar latitude to Cape Canaveral.
Xi Chang, though much closer to the equator, had its drawbacks. The launch site is in hilly country, which must have imposed additional construction costs. Climatically, temperatures are more clement than Jiuquan, ranging from -10°C to + 33°C. The site has excellent dry weather from October to April but May to September may see downpours and thunderstorms. It is also far from deserted, being surrounded by villages. Virtually all the other launch sites in the world are either on the coast or located in inland desert, thereby reducing the risk of civilian casualties to a minimum – but this was not the case with Xi Chang.
Construction at Xi Chang, showing gantries and the slimmer lightning towers. |
The first communications satellite, set atop the CZ-3. Courtesy: Cindy Liu. |
The satellite itself was a drum, 3.1 m tall and 2.1 m in diameter, with an apogee motor underneath and two receiving and broadcasting antennae on top. The satellite was called Shiyang Weixing (“experimental satellite”), identified subsequently as the Dong Fang Hong 2 (“2” presumably in deference to the first Earth satellite, which was “1”). Launch mass was 916 kg but, by the time the apogee kick motor had fired, the weight of the satellite on station would be 420 kg. Its essential function was to receive transmissions from the ground with a high-gain antenna, to amplify them, and, using two transponders, to retransmit them on a spot beam focused on China itself. Solar cells generating 315 W were fitted on the outside of the drum. The most difficult part was the design of the de-spin system: whereas the satellite itself was spun at 50 revolutions per minute (to maintain its stability and ensure that it was evenly exposed to solar rays), the antenna system had to point in a fixed direction. Chief designer was Hangzhou-born mechanical engineer Hu Haicheng (1928-2011).