New Glenn Payload Users Guide Rev C
New Glenn Payload Users Guide Rev C
New Glenn Payload Users Guide Rev C
CONTACT INFORMATION
As Blue Origin works step by step toward the goal of New Glenn’s first launch, we
are eager to engage with you, our customer. For technical inquiries or for more
information on New Glenn plans, pricing, and availability, customers should
contact the Sales, Marketing & Customer Experience team via email at
NewGlenn@blueorigin.com.
Blue Origin
Attention: New Glenn Payloads
21218 76th Ave S.
Kent, WA 98032
USA
Since our founding by Jeff Bezos, Amazon Founder and CEO, Blue Origin has
been working on reusable propulsion technologies and space transportation
systems necessary to make commercial spaceflight safe, affordable, and
routine. We believe low-cost space access will dramatically reduce barriers to
entry for new commercial and governmental activities in space.
The New Glenn launch system is designed to launch spacecraft into low Earth
orbit (LEO), geostationary transfer orbit (GTO), and beyond. New Glenn is
designed from the ground up to deliver reliable and affordable services:
With New Glenn, we seek to help our customers achieve their spaceflight
objectives, as your success is our primary focus. Your feedback will make New
Glenn more capable and customer-friendly, and together we will make the
benefits of space accessible for everyone.
Gradatim Ferociter!
List of Tables
Table 1-1: Two-stage New Glenn system characteristics ............................................................... 18
Table 1-2: Standard launch services .............................................................................................. 20
Table 1-3: Optional launch services ................................................................................................ 21
Table 2-1: Notional mission profile timelines for LEO, GTO.............................................................27
Table 2-2: Separated mass to GTO in dual manifest ...................................................................... 30
Table 2-3: Orbital injection accuracy .............................................................................................. 31
Table 2-4: Attitude control pointing accuracy ............................................................................... 31
Table 2-5: Attitude control rotation capability .............................................................................. 32
Table 3-1: Payload fundamental frequencies ..................................................................................36
Table 3-2: Allowable launch vehicle shock induced by the payload ................................................ 37
Table 3-3: Payload allowable radiated emissions / New Glenn RF susceptibility ............................38
Table 4-1: Maximum ground processing load factors .................................................................... 42
Table 4-2: Standard thermal and air quality environments for spacecraft .................................... 43
Table 4-3: Typical launch range emissions at LC-36 ..................................................................... 44
Table 4-4: PLF broadband electrostatic field limits ...................................................................... 46
Table 4-5: Particulate cleanliness near the payload ...................................................................... 48
Table 4-6: New Glenn allowable radiated emissions / payload RF susceptibility ........................... 50
Table 4-7: PLF sound pressure level.............................................................................................. 52
Table 4-8: Lateral and axial sinusoidal vibration ............................................................................53
Table 4-9: Payload shock induced by the launch vehicle ............................................................... 54
Table 5-1: Standard payload adapter system options .....................................................................68
Table 5-2: Electrical ground support equipment power specifications .........................................72
Table 5-3: Twin-axial cable characteristics ................................................................................... 73
Table 5-4: Electrical interface availability summary ......................................................................74
Table 5-5: EED circuit firing characteristics .................................................................................. 75
Table 6-1: Mission integration milestone reviews ........................................................................... 79
Table 6-2: Blue Origin mission integration engineering documents .............................................. 84
Table 6-3: Blue Origin mission integration analysis services ..........................................................85
Table 6-4: Blue Origin launch campaign support services ..............................................................86
Table 6-5: Customer mission integration milestones and deliverables ......................................... 88
Table 7-1: Launch day timeline of operations ................................................................................. 97
For New Glenn’s first stage, Blue Origin will use the BE-4, a 2,400 kN (550,000 lbf)
sea level thrust booster engine, pictured in Figure 1-2. The BE-4 uses LOX and
liquefied natural gas (LNG), a commercial form of methane, as an affordable,
clean, and operable propellant combination. Industrial-grade LNG is plentiful and
inexpensive, and its use allows for autogenously pressurized tanks and
elimination of helium as a pressurant.
Development testing of both the BE-4 and BE-3U is currently underway at Blue
Origin’s engine test site in West Texas.
New Glenn will operate from a new commercial orbital launch site at Cape
Canaveral Air Force Station (CCAFS), Florida. Florida operations will also include
a complex for launch and mission control, as well as manufacturing and assembly
of the launch vehicle’s (LV) first and second stages, fixed adapter, and PLF. The
facility is situated in Exploration Park, located adjacent to the NASA Kennedy
Space Center (KSC) main entrance.
A future New Glenn launch site for high inclination LEO missions is planned at
Vandenberg Air Force Base.
In addition to launch vehicle manufacturing, Blue Origin and partner facilities will
span pre-launch payload processing and integration, engine testing and
acceptance stands, and first stage recovery and reuse. For more information on
facilities, see Section 8.0: Facilities.
The New Glenn primary booster is an operationally reusable first stage with a
length of 57.5 m (188.5 ft) and a tank diameter of 7 m (23 ft). The stage consists of
three (3) sections: aft, mid, and forward, as shown in Figure 1-3.
The aft module of the booster contains seven (7) BE-4 LOX/LNG engines with 1.71
x 104 kN (3,850,000 lbf) total thrust at sea level. The restartable BE-4 engines
provide precision thrust vector control and continuous deep throttle capability
to support propulsive deceleration and landing maneuvers, while featuring long
design life. The 8.5 m (28 ft) diameter engine skirt protects the engines from
atmospheric reentry conditions and contains six (6) stowed landing gear.
The mid module of the booster houses the fuel (LNG) and oxidizer (LOX) tanks.
The tanks are made of orthogrid aluminum and are designed to withstand the
high g-loads realized during reentry. Large aerodynamic strakes on the aft end
of the tanks give the returning first stage enhanced cross-range during descent
and reentry.
The forward module of the booster features four (4) actuated aerodynamic
control fins for attitude control during descent. This section of the booster also
provides ground umbilical connections for New Glenn and interstage housing of
New Glenn Payload User’s Guide - OCTOBER 2018 16 of 124
The second stage is an expendable LOX/LH2 stage with dual gimballing BE-3U
engines with 1,060 kN (240,000 lbf) total thrust in vacuum. The stage also has a
tank diameter of 7 m (23 ft) and uses common tooling with the first stage to
reduce recurring cost. The length of the second stage tank is 16.1 m (52.9 ft) and
the overall length including the two high expansion ratio nozzle BE-3Us is 23.4 m
(76.9 ft). Similar to the first stage, the second stage has aft, mid, and
forward sections.
The aft section consists primarily of the two BE-3U engines, associated load
bearing cross-bar thrust structure, and tankage/equipment for long duration
operations. The reaction control system (RCS)/settling system uses tri-axial
thrusters distributed in four places along the thrust structure. The second stage
aft section integrates with the first stage forward section and provides one of
two (2) second stage umbilical interfaces.
The mid-section contains all propellant tankage including a forward LH2 tank
and an aft LOX tank, separated by a common insulated bulkhead. The tank
barrels are orthogrid aluminum construction, and the domes are constructed
from welded aluminum. A single external insulated LH2 supply line passes
around the LOX tank.
See Table 1-1 for an overview of the two-stage New Glenn’s key physical system
characteristics.
Reserved.
1.2.4 Reusability
The reusable component of the New Glenn launch system is its first stage,
including its seven (7) BE-4 engines. After second stage separation, the first
stage booster reorients itself to reenter the atmosphere aft end first. Through a
combination of aerodynamics and propulsive maneuvers, the stage performs a
precision landing on the ocean-going platform in the Atlantic Ocean, as shown in
Figure 1-4.
After recovery at sea, the booster returns to the launch site via Port Canaveral
for inspection and reuse.
New Glenn uses the same all liquid propellant system configuration to perform a
wide range of highly energetic missions without the need for solid rocket motors
or multiple cores that can impact system reliability. New Glenn is a single core
design and has only three (3) unique separation events for a dedicated mission
(second stage, PLF, and payload) compared with up to ten (10) with other launch
systems. By using a single configuration for all missions and an operationally
reusable first stage, New Glenn will rapidly accumulate flight heritage and
operational economies of scale.
The New Glenn operating concept is designed to support 12 missions per year
with a single dedicated launch site. To account for seasonal weather variations,
the New Glenn launch system is capable of surging to eight (8) missions within a
four (4) month period and three (3) missions within a single month. This launch
cadence requires only a single launch pad, landing platform, and integrated
transporter erector (TE) with umbilical mast. See Section 7.0: Operations for
more information on New Glenn operations.
The CID is responsible for coordination of all elements and deliverables within
the LSC statement of work. The CID works with the Blue Origin team to support
the mission, including launch operations, mission integration, safety and
mission assurance, contracts and legal, and administration.
The safest and most reliable vehicles are robust, well understood machines
developed in a culture of accountability, discipline, and attention to detail.
System safety requirements drive the design of Blue Origin’s systems. The most
recognizable types of system safety requirements are reliability and fault
tolerance. System safety requirements also include safety factors,
independence and separation requirements, as well as requirements for
monitoring, procedures, and development software/firmware rigor.
At the most basic level, the New Glenn system is designed for stable and
controlled flight, limiting the flight environments to those acceptable for
spacecraft, while satisfying all launch and recovery regulatory requirements.
Payloads also benefit from key mission critical reliability requirements, such as:
Note that until the initial New Glenn flight, all predicted vehicle performance and
payload environment data within the Payload User’s Guide (PUG) are design
targets to be validated through the vehicle and engine development program,
and thus are subject to change.
LC-36 offers:
For more detailed information on the orbital launch site, see Section 8.1.3:
Launch Complex.
Figure 2-1: Available azimuths and inclinations from LC-36, Cape Canaveral, FL
Following liftoff, the typical New Glenn mission profile is illustrated in Figure 2-2.
For a nominal 250 km perigee altitude GTO mission, the first stage booster
initiates an engine shutdown sequence at a mission elapsed time (MET) of 199
seconds. The command induces the BE-4 main engine cut-off (MECO), and
thrust tails off until second stage separation occurs at MET 202 seconds. The
first stage then reorients for atmospheric reentry, landing, and recovery.
The first burn for the second stage BE-3U engines starts once adequate
distance between the stages is achieved, at approximately MET 206 seconds.
Once passing the desired limit for aerodynamic heat flux to the payload at
approximately MET 216 seconds, the payload fairing (PLF) is jettisoned and the
stage continues to sustain powered flight with the un-encapsulated payload. The
engines burn for 618 seconds before second stage engine cut-off (SECO-1) at
MET 824 seconds. Near perigee, the BE-3U engines relight at approximately MET
Depending on the desired orbital insertion, the duration and quantity of vehicle
coasts and BE-3U re-ignitions vary. The second stage has long duration (11+
hours) coast capability and can start the engines up to four (4) times. During
coast phases, the second stage performs attitude and spin rate adjustment
maneuvers as required to address thermal heating and solar angle criteria,
before releasing the payload for orbit insertion. In elliptical transfer orbit
trajectories, on-board spacecraft propulsion completes orbit-raising and/or
circularization of the spacecraft into the final orbit. In a circular trajectory, the
second stage engines typically start three (3) times, including a circularization
burn at apogee of the transfer orbit prior to payload separation. A fourth burn
may be needed to ensure proper stage disposal, depending on the
orbital parameters.
Once the second stage has delivered the payload and executed any necessary
contamination and collision avoidance maneuvers (CCAM), it waits to maneuver
for disposal by reentry. Typically, a retrograde maneuver, such as tank venting or
other propulsive event, is performed a half orbit before the reentry point, which
is selected where altitude is low enough that breakup is over a predictable area
with no safety impacts. Depending on mission parameters, the retrograde
Please contact Blue Origin for initial mass to orbit capabilities and to discuss
specific, desired orbital parameters.
The New Glenn two-stage launch vehicle is specified to deliver a payload mass
of up to 13,600 kg (30,000 lbm) to GTO with an apogee altitude of 35,786 km, a
perigee altitude of at least 185 km, and with an inclination of 27°. An example
standard GTO mission ground trace through payload separation is shown in
Figure 2-4 below.
Accounting for the mass of the dual manifest structure, payload pairing
combinations to a standard GTO with a perigee of 250 km and inclination of 27°
exist on a spectrum of acceptable masses, as per Section 3.1.1: Mass Ranges and
as shown in Table 2-2 below. The target mass is up to 6,200 kg (13,680 lbm) per
payload to enable the greatest flexibility in pairing with other small, medium, or
large-sized payloads. A large 9,000 kg (19,800 lbm) spacecraft can still be
launched in dual manifest, however it requires pairing with a smaller co-
passenger to ensure compatibility with overall vehicle performance.
Exact New Glenn performance will depend on the desired orbital parameters,
particularly if pairing payloads in very different orbits (e.g., LEO and GTO, or GTO
and TLI). Blue Origin expects to begin offering dual manifest capability shortly
after the initial missions of New Glenn. Please contact Blue Origin for more
information on availability of dual manifest, or for performance in dual manifest
to other orbital destinations.
The upper stage coasts between maneuvers for a nominal duration between 18
minutes and 5.25 hours using the standard configuration of batteries and
thermal protection. Depending on the mission profile, mission kits can augment
power, reaction control, thermal, and radiation protection systems to extend
coast durations to 11 hours or longer, with associated impacts to payload mass.
Shorter coasts can also be designed on a mission-unique basis. To
accommodate payload illumination and thermal requirements during coast
periods, New Glenn is capable of accurately orienting the launch vehicle roll axis
(X-axis) in any selected direction and rotating about it at a selected spin rate up
to 3.0°/s in either direction, as described in Table 2-4 and
Table 2-5 below.
The upper stage can separate payloads in any selected attitude to within 1° per
axis. Separation occurs either while 3-axis stabilized or with a selected spin rate
up to 2.5°/s about the launch vehicle spin axis. Rotation accuracies for spin-
stabilized or 3-axis stabilized separations are described in Table 2-5. The
separation spin rate may be aligned with any selected direction in the launch
vehicle body frame and any selected direction in the payload’s desired attitude
reference frame.
New Glenn has two (2) baseline launch vehicle fixed adapter configurations, each
of which results in a different amount of mass to orbit: a 1,575 mm (62 in)
standard capacity bolt pattern, which is compatible with the most popular
commercial-off-the-shelf (COTS) separation systems, and a larger 3,169.9 mm
(124.8 in) high capacity bolt pattern with increased mass and moment capability.
The standard capacity configuration uses and includes a standard COTS clamp
band payload adapter system (PAS) that is capable of handling payloads up to
10,000 kg (22,000 lbm). The high capacity configuration is used for payloads up
to 37,200 kg (82,000 lbm), and provides only a launch vehicle structural interface
for purposes of handling large customer-provided and/or mission-unique
separation systems or dispensers. The high capacity configuration does not
include a PAS or other separation system as part of standard launch services. A
newly-developed COTS clamp band PAS designed for the high capacity
configuration is expected to be available and flight-qualified in time for the first
flight of New Glenn.
With either fixed adapter configuration, the minimum single manifest payload
mass is 2,300 kg (5,000 lbm). The maximum single manifest payload mass
(beyond the high capacity configuration) is determined by the maximum
performance of the launch vehicle and the final desired orbital parameters, as
per Section 2.4: Full Operational Capability.
Both fixed adapter configurations are shown in Figure 3-1 below, and more fully
described in Section 5.3: Mechanical Adapters and Separation Systems. For
other mission requirements not met by these two configurations, such as ultra-
high capacity, multi-payload dispensing systems, or rideshare/auxiliary payload
adapters, please contact Blue Origin for more information.
New Glenn’s fixed adapters can support a combined payload and PAS that has a
center of gravity (CG) above the adapter interface plane (AIP), (also known as the
standard interface plane (SIP)), up to the axial distances in Figure 3-2 below. The
fixed adapter also supports statically unbalanced payloads in single and dual
manifest with a CG located up to 203.2 mm (8 in) laterally from the launch vehicle
centerline. In the case of a dual manifest mission, the standard capacity curve
applies to each AIP.
Note that the AIP forms the launch vehicle to PAS aft interface, which differs
from the customer-selected PAS forward to spacecraft interface, called
spacecraft interface plane (SCIP). Specifications for Blue Origin-provided PAS
are described in Section 5.3.2: Payload Adapter System.
The payload’s first and second structural bending modes must not be below the
values listed in Table 3-1 to avoid adverse load coupling during standard flight
assessments. Lower structural bending modes may be possible under certain
circumstances, requiring more detailed analysis; please contact Blue Origin for
more information.
A coupled loads analysis (CLA) of the payload stack conducted during the mission
integration phase will provide more accurate characterization of the actual
primary and secondary payload structural bending modes. A CLA will also
produce specific predictions for structural load factors, bending moments and
accelerations as inputs to customer design processes (See Section 6.4: Mission
Integration Process for more information).
As part of standard launch services for the customer, Blue Origin provides an RF
and electromagnetic compatibility assessment, as well as a pre-arrival PAS
mechanical fit check analysis, including electrical connector compatibility. Upon
payload arrival, Blue Origin also supports a brief PAS mechanical/electrical fit-
check test. As part of optional launch services, the customer may request a
physical hardware fit check at the customer’s site.
During the formal reviews described in Section 6.4: Mission Integration Process,
the proposed V&V approach and results must be approved. Blue Origin reserves
the right to request more insight into testing and analysis processes, or to
require more rigorous validation to ensure alignment with expected
environments and interfaces.
Details and requirements may vary based on the level of acceptable risk to the
payload. Please contact Blue Origin for more information on possible
V&V approaches.
The payload fairing (PLF) has several environmental control systems to protect
payloads prior to launch and during ascent. These environmental subsystems
include thermal protection, pressure venting, acoustic damping, and pre-launch
environmental conditioning.
The maximum transportation and assembly loads on the payload will be limited
to less than or equal to the levels in Table 4-1 below from payload encapsulation
until liftoff, and will be further enveloped by flight environments.
The Blue Origin operations team controls the pre-launch thermal and air quality
environments during all pre-launch operations and payload processing,
beginning with the spacecraft arrival at the PPF. The PPF is maintained at
consistent temperature, humidity and cleanliness standards as described in
Table 4-2 below. Enhanced, mission-unique control of temperature, humidity
and ECS cleanliness environments, such as those necessary for sensitive
pyrotechnic operations, are possible for certain phases of payload processing
operations as part of optional launch services. Please contact Blue Origin for
more detailed PPF capability information.
Within the controlled environments at the PPF, the payload's air temperature
environment is maintained between 18 – 24 °C (65 – 75 °F) with supply air held to
within 3 °C (5 °F) of a selected set-point. After encapsulation, the payload volume
is maintained at less than 50% relative humidity, assuming the payload
generates less than 2.95 kW (2.8 BTU/s) of heat.
While in transport between the PPF and the IF, local outdoor temperatures
permit maintenance of the payload's air temperature environment between 10 –
29 °C (50 – 85 °F) with supply air held to within 3 °C (5 °F) of a selected set-point.
The payload volume maintains less than 50% relative humidity, assuming the
payload generates less than 2.95 kW (2.8 BTU/s) of heat. For special humidity-
sensitive operations (e.g., pyrotechnic tasks) between encapsulation and mating
to the launch vehicle, the relative humidity and temperature of the encapsulated
volume can be maintained between 25% – 50% and between 10 – 21 °C (50 – 70
°F) respectively, as part of optional launch services.
Following mate of the encapsulated payload to the launch vehicle until liftoff,
including during rollout to the pad, the payload's air temperature environment is
maintained between 7 – 29 °C (45 – 85 °F) with supply air held to within 3 °C (5 °F)
of a selected set-point. The payload volume maintains less than 50% relative
humidity, assuming the payload generates less than 2.95 kW (2.8 BTU/s) of heat.
For special humidity-sensitive operations (e.g., pyrotechnic tasks) between
mating to the launch vehicle and liftoff, the relative humidity and temperature of
the encapsulated volume can be maintained between 25% – 50% and between 7
– 21 °C (45 – 70 °F) respectively, as part of optional launch services.
Pre-launch thermal and air quality environments are summarized in Table 4-2.
Table 4-2: Standard thermal and air quality environments for spacecraft
Relative ECS
Condition Temperature Assumptions
Humidity Cleanliness
Un-encapsulated 18 – 24 °C 100,000
50% ± 10% n/a
processing in PPF 65 – 75 °F ISO 8
Encapsulated processing 18 – 24 °C 5,000 Payload adds
≤ 50%
in PPF 65 – 75 °F ISO 6.7 < 2.8 BTU/s
Encapsulated transport 10 – 29 °C 5,000 Payload adds
≤ 50%
from PPF to IF 50 – 85 °F ISO 6.7 < 2.8 BTU/s
Encapsulated mating and 10 – 29 °C 5,000 Payload adds
≤ 50%
integration in IF 50 – 85 °F ISO 6.7 < 2.8 BTU/s
4.1.3.2 Lightning
Blue Origin’s PPF, manufacturing facilities, and the launch pad at LC-36 feature
lightning protection systems. The PPF and manufacturing facilities incorporate
rooftop lightning rods and grounded lightning protection cables. The LC-36
lightning protection system includes multiple fixed towers supporting catenary
wires arranged to intercept cloud-to-ground lightning and prevent direct strikes
to the launch vehicle or payload. The Cape Aural Warning System further
provides warning of lightning strike risk with enough lead time to safe all
necessary equipment in each location.
The New Glenn PLF is designed to prevent electrostatic discharge to any part of
a payload’s surface, provided the payload remains within the PLF dynamic
envelope, defined in Section 5.2: Fairing. The maximum broadband electric
fields 1 cm (0.394 in) from the PLF inner surface are limited to the levels in Table
4-4 and Figure 4-2 below.
During the pre-launch period, the customer has access to the Blue Origin
partner’s PPF facilities as part of standard launch services. These facilities
provide Class 100,000 (ISO Class 8) processing bays and encapsulation bays,
using high efficiency particulate air (HEPA) filters with 4-6 air changes per hour.
As part of optional launch services, Class 10,000 (ISO Class 7) cleanliness is
available on as-needed basis through stricter filtration, customer operations,
and garment protocols. The PPF also limits organic contamination exceeding 0.5
mg/m2/week (0.046 mg/ft2/week) prior to encapsulation. For more information
on PPF capabilities, see Section 8.1.2: Payload Processing Facility.
During a nominal flight profile, payloads experience axial and lateral acceleration
resulting from winds, liftoff, ascent max aerodynamic flight events, maximum
axial G forces, second stage ignition, steady burn, and shutdown. Conservative
limits to loads are shown in Figure 4-3 below for use in initial design of payload
structural elements. Positive axial acceleration values indicate compression,
whereas negative axial acceleration values indicate tension. BE-4 and BE-3U
engine throttling capability enables New Glenn to maintain accelerations within
these limits:
The PLF thermal protection system is insulation designed to minimize the heat
load imparted to the fairing structure and the payload. The PLF inner wall peak
radiated (encapsulated) heat flux density is predicted to be less than 1,000 W/m2
(317 BTU/ft2 hr). Heat flux density as low as 600 W/m2 (190 BTU/ft2 hr) may be
possible as part of optional launch services; please contact Blue Origin for
more information.
The launch system generates a variety of EM fields both before and during flight,
which may cause potential interference with sensitive payload elements or
materials. Blue Origin performs a launch vehicle electromagnetic compatibility
assessment based on the payload’s radiated emissions and New Glenn
susceptibility as part of standard launch services. The customer is encouraged
to perform their own compatibility testing to ensure operability within the
following radiated environments.
The New Glenn launch system limits its spurious and intentional EM emissions at
the AIP (free space radiating conditions), as per Section 5.2.1: Payload Volume,
to the levels shown in Table 4-6 and Figure 4-5 below.
In a dual manifest mission, it will also be necessary for each payload to establish
RF compatibility with one another. One method to minimize risk is to permit
payload RF susceptibility greater or equal to 160 dBμV/m at frequencies greater
than 1,000 MHz, apart from the payload receiver frequencies bands.
Similarly, the payload itself is limited to the same targets for TML and CVCM (see
Section 3.5: Material Selection for Contamination Control). Contamination levels
are verified by analysis according to ASTM E595-15 Standard Test Method for Total
Mass Loss and Collected Volatile Condensable Materials from Outgassing in a
Vacuum Environment.
Between encapsulation at the PPF and payload separation for most missions,
the New Glenn system limits particulate contamination of the payload such that
it obscures less than 1% of payload surfaces and minimizes molecular
contamination of the payload to deposition of less than 150 angstroms.
The PLF uses several acoustic protection systems to reduce internal noise to an
acceptable level during launch, and may be configurable depending on specific
payload requirements. The acoustic pressure space-averaged over the volume
inside the fairing has been baselined to envelope the acoustic requirements of
most spacecraft manufacturers. Acoustic pressure is not to exceed the levels
given in Table 4-7 and Figure 4-6 with 95% probability with 50% confidence
(P95/50) for a 60% payload fill factor from liftoff through payload separation. For
more information on lower frequency sound pressure levels, please contact
Blue Origin.
4.2.6 Vibration
Shock loads are mainly caused by three (3) significant events: second stage
separation, PLF jettison, and payload separation. The shock from payload
separation, which is largely determined by the mission-unique payload adapter
system (PAS) chosen for separation, envelopes all shock from PLF jettison and
stage separation.
Given the range of PAS that are available as a standard launch service, described
in Section 5.3.2: Payload Adapter System, the launch vehicle-induced payload
shock at the AIP interface with the PAS is limited to the P95/50 accelerations
shown in Table 4-9 and Figure 4-8 and measured within 51 mm (2 in) of the AIP.
The PLF incorporates a series of vents to help control the pressure decay during
ascent. These covered vents help maintain cleanliness within the payload
volume during ground operations and boost, while providing a peak
depressurization rate of less than 4,100 Pa/s (0.60 psi/s). Except for short
periods including immediately following separation of the vent covers and the
transonic flight regime, steady-state depressurization rates are limited to 2,400
Pa/s (0.35 psi/s). The encapsulated payload volume maintains a differential
pressure of less than 400 Pa (0.06 psi) above ambient external at the time of
fairing jettison. Please contact Blue Origin for more information on
venting analysis.
5.2 FAIRING
New Glenn’s standard offering PLF measures 7 m (23 ft) in diameter and 21.9 m
(72 ft) tall. The bi-sector assembly consists of two (2) monolithic half shell
composite sandwich panels manufactured in-house. The PLF halves are joined
laterally by a thrusting rail assembly, and at the aft end by a circumferential
frangible joint, which together provide rapid, debris-free separation of the halves
from each other, the fixed adapter, and the second stage. The PLF halves
jettison shortly after second engine ignition on the second stage, and they are
designed to thrust away to preclude contact with both the second stage and the
payload by more than the required 25.4 mm (1 in) clearance.
The payload usable volume and mass capacity differ depending on which of the
fixed adapter configurations is chosen: standard capacity, intended for most
single spacecraft missions, and high capacity, intended for larger single
payloads and/or multi-spacecraft dispenser missions.
Blue Origin defines the payload usable volume as the dynamic envelope within
which the spacecraft may move and internally deflect without impingement by
the PLF. The dynamic envelope takes into account PLF deflection, fixed adapter
deflection, manufacturing tolerances, and a 25.4 mm (1 in) dynamic clearance.
The standard capacity standard volume shares an axis of symmetry through the
center of the AIP, and is a maximum of 17,835.9 mm (702.2 in) tall. The associated
optional volume, as described next in Section 5.2.1.2: Standard Capacity,
Optional Volume, is located directly beneath the standard volume.
In standard capacity configuration, the payload may use the volume around and
below the AIP both inside and outside of the fixed adapter and PAS on a mission-
unique basis, pending a dynamic clearance and coupled loads analysis. The
optional volume, detailed in Figure 5-3 permits antennas, nozzles, or other
spacecraft components to hang below the AIP while avoiding the PLF vents at
the base of the fixed adapter. Inside the fixed adapter, a curved composite
barrier closes out and separates the volume below the AIP from the forward tank
dome of the upper stage. Please contact Blue Origin to determine if use of the
optional volume will meet the payload’s requirements.
The standard capacity optional volume shares an axis of symmetry through the
center of the AIP, and extends a maximum of 706.1 mm (27.8 in) below the AIP.
The high capacity standard volume shares an axis of symmetry through the
center of the AIP, and is a maximum of 18,542 mm (730 in) tall.
This design assumes that most high capacity payloads will either use a raising
cylinder or adapter, such as the COTS PAS designed for use on the high capacity
interface (see Section 5.3: Mechanical Adapters and Separation Systems), or
require their own mission-unique separation system or dispenser post that
already accommodates their specific geometries.
The payload usable volume and mass capacity of the dual manifest upper and
lower berths are identical and are designed to be completely interchangeable as
a standard launch service. This approach facilitates pairing spacecraft of nearly
any size and mass without constraint beyond the overall performance of New
Glenn. Each berth uses the same standard capacity fixed adapter configuration
and is compatible with the same range of COTS PAS.
Blue Origin defines the payload usable volume as the dynamic envelope within
which the spacecraft may move and internally deflect without impingement by
either the PLF or the dual manifest structure. The dynamic envelope takes into
account PLF and dual manifest structure deflection, fixed adapter deflection,
manufacturing tolerances, and a 25.4 mm (1 in) dynamic clearance.
The dual manifest configuration accommodates a payload and PAS that remain
within the dynamic envelope described in Figure 5-5, and with a standard
capacity mass as per Section 3.1: Mass Properties. The dual manifest standard
dynamic envelope combines the following volumes about the longitudinal (X) axis
of the launch vehicle:
The dual manifest standard volume shares an axis of symmetry through the
center of the AIP, and is a maximum of 7,391.4 mm (291 in) tall. The associated
optional volume, as described next in Section 5.2.2.2: Dual Manifest, Optional
Volume, is located directly beneath the standard volume.
In dual manifest configuration, the payload may use the volume around and
below the AIP both inside and outside of the fixed adapter and PAS on a mission-
unique basis, pending a dynamic clearance and coupled loads analysis. The
optional volume, detailed in Figure 5-6 permits antennas, nozzles, or other
spacecraft components to hang below the AIP while avoiding the PLF vents at
the base of the dual manifest structure. Inside the lower berth fixed adapter, a
curved composite barrier closes out and separates the volume below the AIP
from the forward tank dome of the upper stage. Please contact Blue Origin to
determine if use of the optional volume will meet the payload’s requirements.
The dual manifest optional volume shares an axis of symmetry through the
center of the AIP, and extends a maximum of 706.1 mm (27.8 in) below the AIP.
In the upper berth only, additional volume exists below the AIP and in the ogive
section of the PLF. These maximum volumes are available as part of optional
launch services and are detailed in Appendix C: Dual Manifest, Maximum Volume.
5.2.4 Accessibility
The area acceptable for access doors and RF windows is defined by a 120 degree
arc centered about the Z axis, with 30 degree gaps/keep out zones on each side
of the PLF split plane (Y axis). The placement zone is up to 10,160 mm (400 in) in
length starting 1,828.8 mm (72 in) above the base of the PLF and up to 7,340.6 mm
(289 in) wide in arc length and 6,070.6 mm (239 in) wide in plan view per PLF half,
as shown by the shaded area in Figure 5-7.
On the bottom (-Z) PLF half, an additional keep out zone exists due to the
attachment point of the environmental control system (ECS) umbilical.
Access doors and RF windows may be up to 609.6 x 914.4 mm (24 x 36 in) as part
of standard launch services. Both access doors and RF windows are
manufactured of fiberglass sandwich panel, and RF shielding can be applied to
access doors as required. A typical access door or RF window is shown in Figure
5-8, and consists of the door/window panel, high-temperature seals, structural
support frame, and various attachment hardware. The approach allows flexible
placement and easy repeated access to the payload, while maintaining the PLF
structural integrity and internal environments.
The payload may be accessed via any PLF access door as late as two (2) days
before the scheduled launch as part of standard launch services, following the
horizontal integration and mating of the encapsulated payload. Door placement
and orientation on the PLF may affect accessibility while on the TE.
RF communication with the encapsulated payload on the launch pad via custom
re-radiation system is possible as part of optional launch services. Note that
between 90 minutes before launch through 20 seconds after payload separation,
all payload RF communication must be within flight configuration levels, as per
Section 3.4: Payload Radiated Emissions.
The artwork placement area is defined by a 120 degree arc centered about the Z
axis, with 30 degree gaps/keep out zones on each side of the PLF split plane (Y
axis). The placement zone is up to 10,363.2 mm (408 in) in length starting 1,524
mm (60 in) above the base of the PLF and up to 7,340.6 mm (289 in) wide in arc
length and 6,070.6 mm (239 in) wide in plan view per PLF half.
Blue Origin works with the customer to ensure the best presentation of their logo
on New Glenn. To ensure nominal schedule, artwork must be delivered
electronically in high-resolution vector-based (such as encapsulated postscript,
.EPS) file format no later than 3 months before the scheduled launch date.
In both standard and high capacity configurations, the fixed adapter consists of
a single monolithic conical composite sandwich panel made in-house. The fixed
adapter is designed to support the structural requirements of the mission as well
as various mounted instruments, wire harnesses, access panels, frames,
secondary structures and mounting brackets. The top of the fixed adapter is a
machined aluminum ring that constitutes the AIP between the composite fixed
adapter cone and the PAS or other separation system. The fixed adapter
provides an electrical bonding path to the payload across the PAS with a
resistance of 2.5 mΩ or less. The fixed adapter and PAS are shown
in Figure 5-10.
Figure 5-10: Standard capacity fixed adapter and payload adapter system
Figure 5-11: Standard capacity 1,575 mm (62 in) bolt circle interface
In the high capacity configuration, the fixed adapter provides a large diameter
3,169.9 mm (124.8 in) bolt circle designed to provide enhanced structural support
for heavy spacecraft, payloads with high center of gravity, or multi-spacecraft
dispenser structures. This design is compatible with a new COTS PAS currently
under development by RUAG Sweden, the PAS 3100SX, which has a 3,075 mm
(121.1 in) forward clamp band interface. As with the standard capacity
configuration, the high capacity configuration offers full spacecraft or dispenser
clocking capability. The symmetrical circular 120 bolt pattern, as shown in Figure
5-12, permits straightforward payload orientation adjustment in three (3) degree
increments to customer-specific mission requirements. In the high capacity
configuration, Blue Origin does not include the PAS 3100SX or any other
separation system, but rather installs a customer-provided PAS or other
separation system as part of the standard launch services. For more information
about the high capacity configuration, please contact Blue Origin.
For the standard capacity configuration, Blue Origin provides a COTS PAS for
payload integration or otherwise assists in integration of the customer’s
mission-unique separation system as part of standard launch services. Blue
Origin will supply common PAS options from either RUAG or Airbus, such as those
listed in Table 5-1 below.
The typical PAS includes a clamp band, clamp band opening device (CBOD) with
pin puller or a low-shock payload separation system (LPSS), brackets, clamp
band retention system, electrical harness with in-flight disconnect (IFD)
umbilicals, and separation actuator set, shown in Figure 5-13.
Figure 5-13: Example payload adapter system and clamp band elements
The number of separation springs varies between four (4) and 12, and is
determined based on the payload separation velocity requirement, typically
between 0.5-1.0 m/s (1.6-3.3 ft/s). Typical separation springs impart no more than
1500 N (337 lbf) per spring to the payload, and generate tip-off rates within the
separation accuracy limits described in Section 2.7: Attitude Control. For more
Figure 5-14: Concept design of the New Glenn dual manifest structure
The current barrel inner diameter is 6,324.6 mm (249 in) and the current height
from aft launch vehicle interface to forward AIP interface is 10,600 mm (417.3 in)
– sufficient to allow two tall, wide spacecraft to be encapsulated in the PLF at
Following upper berth payload separation, the upper stage reorients to jettison
the dual manifest structure directly forward to reveal the lower berth payload,
before reorienting again to separate the lower berth payload. Separation of the
dual manifest structure is facilitated by a pyrotechnic frangible joint and
distancing is achieved by a set of in-line separation spring modules. Jettison is
subject to the same one (1) inch dynamic clearance requirement as the PLF to
ensure there is no contact with the lower berth payload. For information on dual
manifest performance and availability, see Section 2.5: Dual Manifest Capability.
5.5 ELECTRICAL
Pre-launch electrical connections are designed to meet commercial spacecraft
manufacturer requirements. Depending on whether a payload uses 37-pin or 61-
pin connectors, each payload can establish up to 122 data or electrical
connections with the customer’s supplied electrical ground support equipment
(EGSE) via New Glenn’s IFD umbilical system at the spacecraft interface plane
(SCIP). The same IFD umbilical system is used to communicate separation and
other signals between the launch vehicle avionics and the payload during flight.
A representative diagram for data and electrical connections is shown in Figure
5-15 below. As part of optional launch services, additional cabling can be added
per customer requirements.
Figure 5-15: New Glenn electrical interfaces and wiring harness connections
The customer has access to two (2) separate, identical EGSE rooms in the
integration facility (IF) and launch pad for communication racks with direct
umbilical connection to the payload during horizontal integration and after
rollout to the pad. For dual manifest missions, each payload customer has their
own EGSE room in both locations.
The EGSE rooms are approximately 9.3 m2 (100 ft2) with 1.82 m (72 in) width by
2.43 m (96 in) tall door-clear dimensions. They are outfitted with the following 60
Hz power capabilities and additional services:
Element Parameters
Voltage 120/208 V ± 5%
Frequency 60 ± 1 Hz
Total harmonic distortion Not to exceed 5%
Not to exceed 200% nominal root mean square voltage for
Voltage transients
more than 20 microseconds
Maximum load 20 kVA
New Glenn provides at least 16 shielded twisted pairs of wires per payload for
purposes of external power, full-power battery charging power, trickle battery
charging power, or other power services as required by the payload. All primary
and secondary power leads are routed with an accompanying return lead, and
each twisted pair constitutes part of a complete circuit, with a power source in
the EGSE room and a load in the payload. Additional ground power lines are
available as part of optional launch services.
Each twisted pair provides a maximum source voltage of 126 VDC and a maximum
source current of 11 A at the SVIP interface. The maximum round-trip resistance
between the SEIP and SVIP for any single pair is 1.0 Ω or less when shorted at the
opposite end.
The switch from ground power to payload internal power may occur as late as
four (4) minutes before launch, and liftoff / T-0 current may not exceed 100 mA.
Blue Origin provides up to 60 shielded twisted pairs per payload at the SVIP
capable of differential monitoring of payload status. Each twisted pair
constitutes part of a complete circuit between the payload and its EGSE.
Each twisted pair provides a maximum source voltage of 126 VDC and a maximum
source current of five (5) A at the SEIP and SVIP interfaces. The maximum round-
trip resistance attributed to this cabling between the SEIP and SVIP for any
single pair is 5.0 Ω or less when shorted at the opposite end.
Blue Origin also provides 8 twin-axial twisted shielded cables per payload at the
SVIP for data connections between EGSE and the payload. Each cable has
characteristics as shown in Table 5-3.
Element Parameters
Wire-to-wire distributed capacitance ≤ 98.4 picofarads/m (30.0 picofarads/ft)
Cable twists ≥ 13 twists/m (4 twists/ft)
Cable shield ≥ 75.0% coverage
Characteristic impedance 70.0 – 85.0 Ω at a sinusoidal frequency of 1 MHz
Cable attenuation at 1 MHz ≤ 4.9 dB / 100 m (1.5 dB / 100 ft)
During most pre-launch phases of a launch campaign, the customer has access
to connect with their payload, with the main exceptions being during
transportation and mating activities.
Table 5-4 below includes a summary of all electrical interface locations available
during the pre-launch period. The customer is responsible for all payload cables
at the payload processing facility (PPF), as well as between local EGSE and the
SVIP within the EGSE rooms in the IF and at the pad. Validation of these electrical
interfaces occurs after each configuration change prior to launch to ensure
continuity isolation, polarity, and signal integrity.
In the coast phase of flight prior to separation, the launch vehicle is capable of
sending pre-determined electrical signals for separation, separation
verification, or other purposes to the payload via its IFD umbilical links. Pre-
programmed spacecraft operations and RF communication must wait until after
payload separation and payload separation +20 seconds, respectively.
Element Parameters
> 0.9 Ω
Total EED circuit resistance
<2Ω
> 5 A per circuit
Firing signal current
< 18 A per circuit
Pulse minimum duration 40 ± 10 milliseconds
Blue Origin works with the customer to develop a pre-determined sequence for
switching camera feeds between them, as only a single feed will transmit to the
ground at a time. The system can provide video of liftoff, ascent, stage
separation, PLF jettison, and payload separation.
6.1 OVERVIEW
Mission integration activities include mission planning, mission interface control
document (ICD) coordination, coupled loads analysis (CLA), and coordination with
various governmental authorities. The nominal mission planning timeline begins
after the LSC effective date of contract (EDC), approximately 24 months or less
before the desired launch, and culminates in launch of the payload into the
desired orbit. High level planning milestones are shown in Figure 6-1 below.
Please contact Blue Origin for more detailed integration schedules or for
information about possible accelerated timelines as part of optional
launch services.
Figure 6-1: High level schedule for a 24 month payload integration process
The overall approach for New Glenn mission integration is early coordination and
regular communications to ensure a successful partnership and mission. As
necessary, Blue Origin will facilitate a joint Technical Assistance Agreement
(TAA) to ensure compliance with the International Traffic in Arms Regulations
(ITAR) and Export Administration Regulations (EAR) during the mission
integration and launch period.
The CID is the customer’s single Blue Origin point of contact for:
The pre-shipment phase centers around two mission analysis cycles and the
preparation of various engineering documentation to ensure the safety of
operations and compatibility of the payload and launch vehicle system before
and during flight. Blue Origin is responsible for developing documentation, data,
models, and analyses with inputs and requirements from the customer to
support the mission schedule. Key customer inputs are summarized in Section
6.5: Customer Deliverables.
The post-shipment phase is also known as the launch campaign and covers
standalone payload integration and combined operations for the mission. Blue
Origin is responsible for providing various services, equipment, facilities, and
operations personnel to support the mission schedule.
The EDC nominally occurs 24 months prior to launch. If the customer has
different schedule needs, the adjusted schedule can be incorporated into
the LSC.
An initial kickoff meeting, typically held within a month after EDC, summarizes
expectations from both sides and sets the stage for future technical reviews
with design and operational interface requirements. The customer is asked to
provide either an IRD or complete a payload questionnaire (see Appendix B:
Payload Questionnaire), and provide the preliminary payload design with mass
properties by the kickoff meeting.
In advance of the first mission analysis review, the customer provides a payload
data package, including a full update of all technical parameters then known. Bi-
directional data exchange begins as early as 18 months prior to launch via a
Technical Interface Meeting (TIM), which is held to review initial mission analysis
results and ensure the integration teams’ efforts are aligned and coordinated.
The CID establishes interfaces though a Blue Origin-controlled preliminary ICD,
and the customer presents an initial payload safety package and a V&V plan that
guides the flight qualification process.
Detailed analysis work continues following GOWG, leading to the second formal
review, the Mission Design Review (MDR), approximately six (6) months prior to
launch. The MDR is held to review the results of the final mission analysis and
verify that the as-analyzed system meets the requirements of the payload. The
MDR marks the nominal end of the mission design analysis cycle, although
additional or delta analyses may be performed as part of optional launch
services. In this timeframe, the customer submits a final payload safety
package, showing analysis of hazards for payload/ground operations and
mitigation strategies.
A third formal review, the Mission Readiness Review (MRR), is typically held three
(3) months prior to launch. The MRR ensures that all parties are ready to begin
the launch campaign. The Range’s approval of a Missile System Pre-launch
Safety Package (MSPSP) should be complete by the MRR and is the final
milestone before shipping the payload to Cape Canaveral for physical
integration. The customer supplies daily launch windows for the proposed
launch slot, and provides a completed set of V&V processes and results,
consistent with the materials presented in the TIM.
The CID may hold additional periodic program management reviews to provide
additional opportunities for status updates throughout the mission
integration process.
Table 6-2 below summarizes Blue Origin’s key engineering documents and
services in the mission integration process. All dates are estimated based on 24
month integration schedule and may be adjusted by mutual agreement between
Blue Origin and the customer. Note that documentation may require multiple
iterations to meet all customer and/or regulatory requirements.
Blue Origin also conducts and reports the technical analyses listed in Table 6-3
below for the customer in accordance with the overall mission integration
schedule. All dates may be adjusted by mutual agreement between Blue Origin
and the customer. The analyses are provided in mutually agreed formats as
determined at the integration kickoff.
During the launch campaign, major payload-related tasks include PAS “touch and
go” fit-check, payload propellant load, and encapsulated payload transport.
These major requirements and all other minor tasks are monitored via a
scheduling meeting, held daily by the PI beginning upon payload arrival. The
typical payload processing flow and operational timeline is described in Section
7.2: Pre-Launch Operations.
The only formal review during this phase is the Launch Readiness Review (LRR),
which occurs approximately two (2) days prior to launch, and is held to ensure all
parties are prepared to proceed with launch operations and to confirm the final
launch window.
Table 6-4 below is a representative (but not all-inclusive) list of the support
services provided by Blue Origin as part of standard launch services during the
launch campaign.
Service Description
Pickup of containerized payload and support equipment from airports listed in Section
8.1.5: Customer Logistics and transport to PPF
Transport of electrical GSE (EGSE) from PPF to integration facility EGSE rooms and
Transportation logistics launch pad EGSE rooms, as necessary
Recovery of EGSE from integration facility and/or launch pad EGSE rooms
Return of payload container and support equipment to airport listed in Section 8.1.5:
Customer Logistics
Handling and Use and operation of Blue Origin GSE, including forklifts, mobile cranes, specialty
Transportation GSE transporters, flatbed trucks, air-ride trailers, aerial lifts, aircraft loaders
ISO Class 8 (Class 100,000) processing and encapsulation bays
ISO Class 6.7 (Class 5,000) supply air to encapsulated volume
Clean rooms, supply air
environmental control Continuous monitoring of relative humidity, temperature and cleanliness in the PPF using
particle counters for compliance with environments listed in Section 4.1.2: Thermal and
Air Quality
ESD coveralls, as well as shoe, beard, and head covers for customer use. Nomex suits
Clean room garments
with hoods and boots for post fueling operations can be provided if required
6.6 SAFETY
Blue Origin strives to deeply understand all systems as designed. Launch vehicle
systems and their payloads are inherently complex, which creates challenges in
verifying their safety for overflight of the general public. Failure mode analyses
and test programs are typically insufficient to discover all of the failure modes
and achieve complete confidence in a design.
All parties must understand payload compatibility with the launch vehicle, as well
as all potentially unsafe designs, materials, systems, or operations that may
impact mission safety or reliability.
The payload safety package includes detailed bill of materials and interface
schematics, data specified by Blue Origin, and data required by the United States
Air Force, such as AFSPCMAN 91-710 Range Safety User Requirements, and FAA
requirements, such as Title 14 CFR Parts 400-460. This data includes hazard
analysis and mitigation plans, vehicle break-up models, and detailed design/test
information on major elements and subsystems, such as structures, pressure
systems, ordnance, telemetry, batteries, propellants, and electrical systems.
The launch site integration package includes launch site operational plans,
timelines, and special service requests, as well as appropriate operating
procedures for all hazards identified in the payload safety package. This data is
incorporated into the ground operations plan, which becomes part of Blue
Origin’s safety submittals.
As part of Blue Origin’s work with the FAA to secure an operator’s license for
launch, payload customers may be asked to provide supporting information. This
information would demonstrate that the launch does not jeopardize public health
and safety, safety of property, or other national interests (Title 14 CFR Part 415
Subpart D).
To ensure the safety of ground crews and the public, the customer is required to
manage all hazards in the payload, its GSE, and any planned operations.
At the TIM review, the customer is asked to identify such hazards, including:
o Ordnance
o Other stored energy, including pressurized systems
o Lasers
o High-power RF systems
o Lifting operations
o Hazardous or toxic materials, including propellants and ground
chemicals
At the MDR, Blue Origin will review mitigation plans for each significant hazard.
Such mitigations may include, in order of preference:
6.8 POLICIES
Reserved.
The payload nominally arrives via air or ground transport to the PPF no earlier
than 30 days before the scheduled launch date, or as specified in the Launch
Services Contract (LSC). This delivery date allows sufficient time for processing
Nominal payload processing lasts two (2) to three (3) weeks, with propellant
loading beginning on L-11 days and completed within four (4) days. After that, the
payload to payload adapter system (PAS) mate, payload to fixed adapter mate,
and payload encapsulation finish between L-8 and L-5 days from planned launch
date. Encapsulation is completed within one (1) day to be ready for transport to
the IF by L-4 days. As necessary for late access, the payload remains vertical
until at least five (5) days before launch, after which the payload is mated to the
launch vehicle in the integration facility (IF). Later physical access via the payload
fairing (PLF) access doors is possible until L-2 days.
Once ready, crews move the PAS into the payload’s designated processing bay,
after which they lift the payload onto the PAS for mating using a crane. The fixed
adapter, which is mounted on the payload transportation frame, is then moved
into the payload’s designated processing bay. Next, the assembled payload and
PAS are hoisted onto the fixed adapter and mated. The completed assembly then
moves on air bearings into the encapsulation bay, where the PLF halves are
staged for encapsulation.
In the case of dual manifest with a very tall upper berth payload, the crews first
transfer the lower berth payload into the encapsulation bay. They then move the
dual manifest structure into the encapsulation bay, where they lift it with a crane,
place it over the lower berth payload, and mate it to the fixed adapter. Finally, the
upper berth payload (already mated to its PAS) moves on air bearings into the
encapsulation bay, and is hoisted atop the dual manifest structure just
prior to encapsulation.
The encapsulation operation involves the installation of the PLF halves around
the payload(s) onto the fixed adapter. The PLF halves are pre-mounted within
ground support equipment (GSE) called strongbacks that elevate and precisely
align and position them during installation over the payload transportation frame
Cleanliness levels are maintained in the PPF high bay when accessing the
encapsulated payload, as well as the cleanliness of the air supply for the
environmental control system (ECS) (see Section 4.1.2: Thermal and Air Quality
for environmental requirements).
Once encapsulated, the customer may use up to two (2) radio frequency (RF)
transparent windows that can be located on the PLF to allow for RF radiation and
interrogation of the encapsulated payload in the PPF to verify spacecraft
communication prior to transport to the IF.
Upon arrival at the IF, Blue Origin positions the encapsulated payload into an
open service bay for horizontal integration and mate with the launch vehicle
based on industry best-practices, as shown in Figure 7-3 below. A breakover GSE
module is attached to the aft of the fixed adapter, and the PLF is rotated 90° into
a horizontal orientation. Once the breakover is complete, the breakover module
is positioned by the horizontal mate GSE module. The horizontal mate module
aligns and connects the encapsulated payload to the launch vehicle, utilizing fine
control and limited six degrees of freedom (6DOF) to account for lateral offsets
and axial misalignment between the fixed adapter and launch vehicle. During the
mating process, all loads on the encapsulated payload are recorded to verify they
remain within the envelope described in Section 4.1.1: Acceleration Loads,
Ground Processing. ECS remains active throughout the entire mate operation
Once mated in the ILV configuration, the last standard access to the payload via
fairing doors occurs no later than two (2) days before launch, although later
access may be possible as part of optional launch services. Please contact Blue
Origin with specific requirements.
The New Glenn concept of operations baselines a five (5) to six (6) hour timeline
between beginning of rollout to the pad and launch of the vehicle, depending on
the duration of preplanned holds, as shown in Figure 7-4. As part of optional
launch services, Blue Origin can extend the countdown prior to propellant
loading in a vertical orientation at the pad for additional time to accommodate
payload verification and checkout timelines. Please contact Blue Origin for more
information about non-standard countdown operations.
Once the ILV arrives at the launch pad on launch day, a series of events and final
systems checks take place in the final hours before launch:
The timeline of operations for a typical low Earth orbit (LEO) or geostationary
transfer orbit (GTO) launch is listed in Table 7-1 below.
Launch vehicle and ground conditions are monitored from the launch control
center (LCC), while the payloads are monitored from both the PPF and the
mission control center (MCC). On-board hydraulic, power, and telemetry are
enabled with final telemetry checks to verify communication between the
vehicle, engine processors, and navigation systems.
Auto sequence starts at T-2 minutes with initiation of tank pressurization, switch
over to on-board auxiliary power units and pneumatic supply, and command of
navigation to flight mode.
By agreement of Blue Origin and the customer, the launch date is refined under
the LSC per the process shown in Table 7-2.
New Glenn launch infrastructure is designed for agile operations with sufficient
consumables storage capability to allow for a launch attempt, scrub, and
reattempt within 48 hours without resupply. New Glenn can remain at the launch
pad as long as 10 consecutive days before needing to return to horizontal
orientation and roll back to the IF.
7.4 LAUNCH
The flight of New Glenn is controlled autonomously on-board the launch vehicle
with no flight control inputs from the ground. During the initial seconds of flight,
the control system steers the vehicle away from the launch pad structures and
the vehicle rolls to orient antennas to an optimal position for communications.
As the vehicle ascends and accelerates, it monitors various loading conditions
(e.g., dynamic pressure, angle of attack, peak payload acceleration) and steers
and throttles as necessary to maintain acceptable environments.
Launch site assets track the vehicle through loss of signal, with downrange
telemetry being relayed back to the MCC via ground stations and satellite links.
The staging point maximizes performance while also permitting the safe and
successful recovery of the first stage. The sequence of events immediately after
stage separation are designed to preclude re-contact between the stages,
mitigate the exposure of the reusable first stage to the plume of the igniting BE-
After the second stage ignites and burns through orbital insertion conditions, the
engine shuts down and the payload separates. See Table 2-1 in Section 2.2:
Mission Profile for notional timelines from liftoff through payload separation.
Blue Origin’s main operational facilities and launch site are located in Florida,
with a system of systems that supports manufacturing, pre-launch operations,
propellant loading, long duration static fires, and full launch operations. Pre-
launch facilities include the payload processing facility (PPF) and Blue Origin’s
manufacturing complex, which incorporates the New Glenn launch control
center (LCC) and mission control center (MCC). Additional operating locations are
spread across the United States, including Washington, Texas, and Virginia.
The facility is the site for manufacturing of all major vehicle assemblies for the
New Glenn launch system. These assemblies include all vehicle tanks, the first
and second stages, the payload fairing (PLF), and the fixed adapter. Production
capabilities on-site are designed to support 12 missions per year.
Beginning with the Launch Readiness Review (LRR) at L-2 to L-3 days, the
customer enjoys 24/7 access to the MCC within the manufacturing complex for
monitoring of final launch vehicle integration, rollout, and pad operations.
ASO is a well-known and respected service provider in the space launch industry
with extensive experience, facilities, and capabilities for hazardous and non-
hazardous payload processing operations, payload and hardware storage, and
customer office accommodations. With nine (9) buildings, ASO provides more
than 10,000 m2 (107,000 ft2) of customer-accessible areas, described below. The
ASO buildings have interlinked voice, data, and video circuits, as well as internet
and gigabit-class fiber connectivity to LC-36 and the MCC. Circuits from ASO to
other off-site customer facilities are also possible.
Figure 8-4: PPF at Astrotech Space Operations – Building 9 Photo Courtesy of Astrotech Space Operations
The PPF can also store and load payload pyrotechnics and hazardous fluids for
payload processing and encapsulation. Propellants are loaded in an isolated
service bay, a “fueling island” that has the capability to collect and dispose of
propellant in the event of a leakage or escape of hazardous material from the
payload. The facility meets all relevant environmental and occupational health
requirements and is designed per Department of Defense standards. ASO's
hazardous processing accommodations include an explosion-proof design, bi-
propellant fueling capability, all standard commodity fluids and gases, and spin
stabilized balancing capacity of 8,400 kg (18,500 lbm). Most importantly, ASO
provides high-quality, climate-controlled, ISO-8 and ISO-7 clean, and secure
working facilities for use in preparation of payloads for flight.
The PPF is available 24/7 beginning upon arrival up to 30 days prior to launch, and
up to five (5) days afterward. Earlier and/or longer access is possible for unique
requirements. Please contact Blue Origin with specific facilities needs or for
more information on the PPF capabilities.
Blue Origin provides a variety of clean and secure work spaces for the customer
before, during, and after the launch campaign as part of standard launch
services. The customer has access to a dedicated office room (minimum area of
91.5 m2 (985 ft2)), control room (minimum area of 112.5 m2 (1,211 ft2)), and high bay
facility and garment room (minimum area of 218.4 m2 (2,351 ft2)) within ASO
Building 1 (see Figure 8-5), as well as shared access to the conference room,
kitchenette facilities, and the main airlock for equipment staging and handling.
This facility features 60 Hz and 50 Hz conditioned and non-conditioned power.
Two (2) dedicated offices with minimum area of 10.4 m2 (108 ft2) each in
ASO Building 5 (see Figure 8-6 below) are included as part of standard launch
services. Shared access to conference rooms, teleconference area, and
reception areas is also included for the duration of the launch campaign.
Additional separate office spaces can be made available as part of optional
launch services for multiple payload teams in ASO Building 5, such as for
operators and manufacturers. This facility features 60 Hz conditioned and non-
conditioned power.
ASO Buildings 4 and 6 provide shared use of warehouse facilities for storage of
flight hardware and GSE totaling more than 859 m2 (9250 ft2) and of bonded
storage area of 18.5 m2 (200 ft2) for the duration of the Launch Campaign. For
more information, please contact Blue Origin or see the ASO Facilities
Accommodation Manual.
New Glenn operates from property on CCAFS encompassing both LC-36 A & B
pads. Prior to Blue Origin’s tenancy, LC-36 hosted 145 Atlas launches spanning
over four decades, including a variety of communication, defense, and
exploration missions. The new launch pad at LC-36 has an integrated launch
vehicle (ILV) vertical axis location at 28°28’18.61” N, 80°32’17.23” W, and is situated
at the eastern end of Cape Canaveral to minimize overflight risk. Inclinations
between 28.5° and 57° are possible with direct launch azimuths out of the site.
Trajectories to equatorial orbits are also possible, subject to vehicle
performance constraints (See Section 2.1: Launch Site for more information).
The 306.4 acre complex will contain numerous launch infrastructure elements to
enable operations, as listed in Table 8-1 and shown in Figure 8-8. The LC-36 site
includes the launch pad, ramp, and all required fluid commodities. The LC-36 site
also has the integration capacity to support multiple concurrent horizontal
operations in support of an annual launch rate of 12 missions per year.
Blue Origin supplies all customary handling and transportation ground support
equipment (HTGSE) necessary for movement of the payload(s) between arrival
and launch, whether transporting by barge, road, rail, or air. The HTGSE includes
equipment such as forklifts, mobile cranes, specialty transporters, flatbed
trucks, air-ride trailers, aerial lifts, and aircraft loaders. The customer provides
any highly specialized, mission-specific HTGSE.
After unloading of the payload(s) at the PPF, the payload(s) and associated GSE
are moved to the appropriate areas of the facility for inspection and checkout,
hazardous and non-hazardous testing, fueling, adapter mating, and PLF
encapsulation. Upon completion of these PPF activities, the encapsulated
payload is transported to the IF for horizontal integration with the launch vehicle,
Separate EGSE rooms designed to meet the Evolved Expendable Launch Vehicle
(EELV) Standard Interface Specifications (SIS) are available for each payload
within the IF and below the launch pad for storage of payload
monitoring/checkout racks and other equipment, as per Section 5.5.1: Ground
Support Equipment Electrical Interfaces.
A combination of HTGSE is used in the IF for the handling of individual stages for
launch vehicle mate, encapsulated payload integration, and ILV installation onto
the transporter erector (TE).
Post-launch, Blue Origin will also provide return transportation of any GSE and
associated containers from the launch pad to facilitate packing and shipment
activities, as well as return transportation to the airport if required.
The Blue Origin team coordinates arrangements to welcome the customer and
their payload(s) to Florida. If arriving by air, most payloads and GSE typically fly to
the area via charter flight to one of the airports in the region listed in Table 8-2.
As necessary, the Customer Integration Director (CID) helps the customer
facilitate landing permissions at KSC with the appropriate aviation authorities.
FAA Latitude /
Airport Runway Dimensions
Identifier Longitude
Space Coast Regional Airport, 28.5148° N
KTIX 2,231 x 46 m (7319 x 150 ft)
Titusville, FL 80.7992° W
NASA Shuttle Landing Facility, 28.6149° N
KTTS 4,572 x 91 m (15,001 x 300 ft)
KSC 80.6944° W
Orlando International Airport, 28.4294° N
KMCO 3,659 x 61 m (12,005 x 200 ft)
Orlando, FL 81.3090° W
Figure 8-10: Developmental rocket launch and test site – Van Horn, TX
o Spacecraft Name
o Spacecraft Owner
o Spacecraft Manufacturer
o Spacecraft Model Number
o Name of Principal Contact
o Telephone Number of Principal Contact
o Date of Submittal
o Date of Launches
o Number of Launches
The upper berth maximum volume, detailed in Figure C-1, permits antennas,
nozzles, or other spacecraft components to hang further below the AIP than in
the lower berth due to the absence of PLF vents, which exist only at the base of
the PLF and dual manifest structure. Additionally, the available dynamic
envelope coincides more closely with the single manifest configuration, being
slightly wider in diameter and reaching the maximum ogive height without the
constraint of the dual manifest structure. Please contact Blue Origin to
determine if use of the maximum volume will meets the payload’s requirements.
The dual manifest maximum volume shares an axis of symmetry about the
longitudinal (X) axis of the launch vehicle through the center of the AIP, and
extends a maximum of 1524 mm (60 in) below the AIP. The ogive portion of the
maximum volume extends 2,362.2 mm (93 in) above the dual manifest
standard volume.