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How to build a satellite

Preliminary design review and critical design review

One of the first important milestones in a satellite project, is the Preliminary Design Review (PDR) and later Critical Design Review (CDR).

Satellites are still no run-off-the-mill product, and very few satellites are mass produced. Even the most common communication satellites and weather satellites are built one at time or in very few numbers and still they are moderated and adapted during production. Satellite projects are known for their considerable technical and economic risk. Our ASBM satellites are very large and very complex, and this means that even if the base principles are set, everything must be built from scratch.

The first thing to do as a customer is to send a Request for Proposal (RfP) to several satellite suppliers, detailing what kind of payloads will be on board, what kind of functionality is expected and other specific demands. In 2019, Space Norway selected Northrop Grumman as the ASBM supplier, and the design work started immediately.

Our satellites are communication satellites, meaning that the payloads consist of radio equipment for receiving signals from the ground and returning signals down to Earth. Because the satellites’ orbits go far out in space in its highly elliptical path, vast land areas are covered by the payload radios. The unique thing about the ASBM satellites is that one satellite alone delivers radio coverage all over the Arctic, and one satellite will always be visible over this area.

On board, antennas for both receiving and transmitting signals, signal filters that eliminate unwanted noise as well as a number of amplifiers are found. The amplifiers enhance the signals that are picked up from the ground before they are sent back down. Simplified, one could say that they pick up a whisper and shout it in return. The return signals are down converted in frequency to avoid interference to the receiving antennas on board the satellite.

All this activity demands power, and the power is produced by the large solar panels and large battery banks that ensure that the equipment functions when the satellites are not exposed to the sun. Temperature control ensures that everything functions on board under as normal as possible conditions even when the outside temperature varies between very cold and very hot. All these elements are tailor made to cover the specific demands that are made by the programme. Additionally, there is always a margin, and for the life span of a component, this will typically be around 50% performance above the need.

The first design phase ends with a preliminary design review, a PDR, where the supplier presents its suggestion for how the satellite would look and be built. It will display the placement of each component and unit, specify the performance each sub system would have, how to operate the satellites and so on. The PDR for ASBM was carried out in February 2020. After this point, it is still possible to make changes to the design, and the design is continually evaluated. Adjustments are made, mostly together with the suppliers of the payloads and this phase usually takes about one year.

Once all these important decisions are made, there is the critical design review, a CDR. For ASBM, the CDR was in August of 2020. Here, the final design is agreed upon, and further changes are not made. No further functionalities are added, and no more units are added to the satellite. CDR locks the design and construction, and building commences.

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Preliminary and Critical Design Review

How to build a satellite

One of the first important milestones in a satellite project, is the Preliminary Design Review (PDR) and later Critical Design Review (CDR).

Satellites are still no run-off-the-mill product, and very few satellites are mass produced. Even the most common communication satellites and weather satellites are built one at time or in very few numbers and still they are moderated and adapted during production. Satellite projects are known for their considerable technical and economic risk. Our ASBM satellites are very large and very complex, and this means that even if the base principles are set, everything must be built from scratch.

The first thing to do as a customer is to send a Request for Proposal (RfP) to several satellite suppliers, detailing what kind of payloads will be on board, what kind of functionality is expected and other specific demands. In 2019, Space Norway selected Northrop Grumman as the ASBM supplier, and the design work started immediately.

Our satellites are communication satellites, meaning that the payloads consist of radio equipment for receiving signals from the ground and returning signals down to Earth. Because the satellites’ orbits go far out in space in its highly elliptical path, vast land areas are covered by the payload radios. The unique thing about the ASBM satellites is that one satellite alone delivers radio coverage all over the Arctic, and one satellite will always be visible over this area.

On board, antennas for both receiving and transmitting signals, signal filters that eliminate unwanted noise as well as a number of amplifiers are found. The amplifiers enhance the signals that are picked up from the ground before they are sent back down. Simplified, one could say that they pick up a whisper and shout it in return. The return signals are down converted in frequency to avoid interference to the receiving antennas on board the satellite.

All this activity demands power, and the power is produced by the large solar panels and large battery banks that ensure that the equipment functions when the satellites are not exposed to the sun. Temperature control ensures that everything functions on board under as normal as possible conditions even when the outside temperature varies between very cold and very hot. All these elements are tailor made to cover the specific demands that are made by the programme. Additionally, there is always a margin, and for the life span of a component, this will typically be around 50% performance above the need.

The first design phase ends with a preliminary design review, a PDR, where the supplier presents its suggestion for how the satellite would look and be built. It will display the placement of each component and unit, specify the performance each sub system would have, how to operate the satellites and so on. The PDR for ASBM was carried out in February 2020. After this point, it is still possible to make changes to the design, and the design is continually evaluated. Adjustments are made, mostly together with the suppliers of the payloads and this phase usually takes about one year.

Once all these important decisions are made, there is the critical design review, a CDR. For ASBM, the CDR was in August of 2020. Here, the final design is agreed upon, and further changes are not made. No further functionalities are added, and no more units are added to the satellite. CDR locks the design and construction, and building commences.

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ASBM

Landing rights in the US

One of the first things that must be done when you plan for a satellite launch, is to consider the countries the satellite will fly over when in orbit.

It is the satellite’s area of coverage that is important. When Space Norway decided to establish broadband mobile communication to the Arctic using two highly elliptical satellites, applications to the UN’s International Telecommunication Union (ITU) were made. The ITU is an entity for coordination seeking international coexistence, but without sanctioning powers over nations. The filing with the ITU secures, in general terms, the utilization of necessary frequencies for satellites in their specified orbits. The ITU has the complete overview over all spectrum filings, what it may be used for and what it actually is used for. Space Norway’s filings registered with the ITU is the first stop on the way to being able to use the frequencies on the satellites’ payloads.

Each country has its own national organization that coordinates the satellite operators’ filings with the ITU. In Norway, this is administered by the National Communications Authority (Nkom). The Nkom keeps track of all frequency use in Norway and has a national coordination role.

Some countries have organizations with more authority than others, for example the USA and Canada – and both countries are important for Space Norway’s Arctic broadband satellites since permission to use the systems in each country must be obtained. The telecommunications authority for the US is the Federal Communications Commission (FCC). Back in 2017, an application was submitted and later that same year, a conditional permission was granted. The condition was that an agreement be reached with all other satellite operators. This means that the real work begins with this permission. A satellite operator must make sure that their signals do not interfere with other signals and the other way around. See this article about this very demanding process. Space Norway immediately started dialogue with operators in the US (and the rest of the world) to analyze coexistence. For the US, this included for example SpaceX, with a very high number of satellites in low earth orbit, being one of the operators. Now, several years later, agreements have been made with SpaceX, One Web and Amazon, while some operators still remain. The FCC is an enforcing agency, and all operators with landing rights must pay a bond up to USD 5M. Operators that are not operational within six years after receiving permissions, risk loosing this bond. This is done to prevent spectrum harvesting, meaning that the very limited frequency resources are bound by systems not being built or put into operation. The way the US organizes this, is different from most other countries, but then nowhere else in the world is the activity level as high regarding the need for frequencies as in the US.

Landing rights are not needed in the EU, including Norway, but the need to manage frequencies is the same, and the ITU regulated coordination is done in dialogue with each country’s administration or with each operator.

As for some of the other countries in the Arctic, landing rights are needed for ASBM also in Canada, which was achieved when coordination with all relevant Canadian satellite operators were in place.

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Bringing live transmissions out of the most isolated parts of Alaska.

Live transmissions from Alaska

When BBCOB Comms and Timeline-TV approached us about getting connectivity out of some the remotest parts of Alaska for the amazing BBC programme Wild Alaska Live, the Telenor Satellite’s OU team’s motto “No Mission Impossible” kicked in.

Telenor Satellite was faced with the challenge of finding several Ku-band satellites with coverage over Alaska with connectivity to the US and UK.

Multiple paths were required out of four locations, as well as reverse vision feeds to enable the main studio to keep in touch with the remote sites. One of the locations where a small studio & uplink was located, Katmai National Park, only source of power were batteries, charged by solar panels and hydrogen fuel cells. Even with state of the art SSA’s this limited the up-link to 50W. Telenor was faced with the challenge of finding a satellite “hot” enough to get the job done. As well at satellite coverage, fibre was used to provide the transatlantic connectivity to and from the US.

Live broadcasting from Alaska
Our OU team relished the challenge of being involved in something so exciting and unique.

“Telenor definitely had the easier job, coordinating the coverage from the office, compared to the operational team working in challenging conditions in Alaska”, commented Zara Evans, Bookings Manager at Telenor Satellite. Over the two weeks testing and filming, Telenor booked over 140 feeds, all without a single glitch.

Coverage took place in various venues across Alaska, from the world’s largest temperate rainforest, Tongass National Forest, to the Katmai National Park.

“The Alaska project was very complex with three uplinks in Alaska for sending content into the hub and for two live broadcasts each day for UK & US viewers.  We depended on Telenor to find the right satellite capacity to make it all work. The booking team at Telenor Satellite are so efficient and coped really well with loads of changes, three time zones and varying channel bandwidths. There were a lot of things to worry about on Wild Alaska Live but thanks to Telenor, sat space was not one of them” commented Nick Buckley, Head of Operations at Timeline Television.

“At the Main Site we had connectivity requirements far in excess of just pictures and sound! With a live show centred on animals appearing for us, “on cue”, nothing stayed the same for long! We felt totally supported by Telenor Satellite with the many daily changes we requested to them. They also helped the project by installing an interest in our programme with the Satellite owners who then found it easier to accept some of our non-standard workings!” commented Chris Cobb, Vice Chairman of BBC OB-Comms Ltd.

Telenor Satellite's Occasional Use team provided services to BBC and PBS production of “Wild Alaska Live” – three-part series in 2017.
Working in Alaska brings unique challenges to the operational team; with three uplinks and two live broadcasts each day, it was a very complex project which involved more than 140 feeds over the two weeks of testing and filming – and all without a single glitch! Photo: BBC.

Wild Alaska Live was a major three-part series event for BBC One, produced by BBC Studios’ Natural History Unit and co-produced by PBS.