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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

International Space Station Passive Thermal Control System Top Ten Lessons-Learned

Final document not an Abstract attached. The International Space Station (ISS) has been on-orbit for nearly 20 years, and there have been numerous technical challenges along the way from design to assembly to on-orbit anomalies and repairs. The Passive Thermal Control System (PTCS) management team has been a key player in successfully dealing with these challenges. The PTCS team performs thermal analysis in support of design and verification, launch and assembly constraints, integration, sustaining engineering, failure response, and model validation. This analysis is a significant body of work and provides a unique opportunity to compile a wealth of real world engineering and analysis knowledge and the corresponding lessons-learned. The PTCS lessons encompass the full life cycle of flight hardware from design to on-orbit performance and sustaining engineering. These lessons can provide significant insight for new projects and programs. Key areas to be presented include thermal model fidelity, verification methods, analysis uncertainty, and operations support.

Iovine, John V.↗
NASA NTRS2007

Living Together in Space: The International Space Station Internal Active Thermal Control System Issues and Solutions-Sustaining Engineering Activities at the Marshall Space Flight Center From 1998 to 2005

On board the International Space Station, heat generated by the crew and equipment is removed by the internal active thermal control system to maintain a comfortable working environment and prevent equipment overheating. Test facilities simulating the internal active thermal control system (IATCS) were constructed at the Marshall Space Flight Center as part of the sustaining engineering activities to address concerns related to operational issues, equipment capability, and reliability. A full-scale functional simulator of the Destiny lab module IATCS was constructed and activated prior to launch of Destiny in 2001. This facility simulates the flow and thermal characteristics of the flight system and has a similar control interface. A subscale simulator was built, and activated in 2000, with special attention to materials and proportions of wetted surfaces to address issues related to changes in fluid chemistry, material corrosion, and microbial activity. The flight issues that have arisen and the tests performed using the simulator facilities are discussed in detail. In addition, other test facilities at the MSFC have been used to perform specific tests related to IATCS issues. Future testing is discussed as well as potential modifications to the simulators to enhance their utility.

Wieland, P. O.↗
NASA NTRS2003

Development of the Next Generation Gas Trap for the Space Station Internal Thermal Control System

The current dual-membrane gas trap is designed to remove non-condensed gases (NCG) from the Internal Thermal Control System (ITCS) coolant on board the International Space Station (ISS). To date it has successfully served its purpose of preventing depriming, overspeed, and shutdown of the ITCS pump. However, contamination in the ITCS coolant has adversely affected the gas venting rate and lifetime of the gas trap, warranting a development effort for a next-generation gas trap. Design goals are to meet or exceed the current requirements to (1) include greater operating ranges and conditions, (2) eliminate reliance on the current hydrophilic tube fabrication process, and (3) increase operational life and tolerance to particulate and microbial growth fouling. In addition, the next generation gas trap will essentially be a 'dropin" design such that no modifications to the ITCS pump package assembly (PPA) will be required, and the implementation of the new design will not affect changes to the ITCS operational conditions, interfaces, or software. This paper will present the initial membrane module design and development work which has included (1) a trade study among several conceptual designs, (2) performance modeling of a hydrophobic-only design, and (3) small-scale development test data for the hydrophobic-only design. Testing has shown that the hydrophobic-only design is capable of performing even better than the current dual-membrane design for both steady-state gas removal and gas slug removal.

Leimkuehler, Thomas O.↗
NASA NTRS1992

Modeling and analysis of the Space Station Freedom Active Thermal Control System radiators using SINDA/FLUINT

Detailed SINDA/FLUINT models have been developed to assess the adequacy of the Space Station Freedom External Thermal Control System's radiator design, as well as to simulate the effects of various operational scenarios. Design margins can be deduced by quantifying such real-world effects as flow maldistribution due to line-pressure drop and uneven heat loads. The factor which most reduced the heat-rejection capacity is an uneven heat load split between the two low temperature loops.

Andish, Kambiz K.↗
NASA NTRS1993

Prototype test article verification of the Space Station Freedom active thermal control system microgravity performance

To verify the on-orbit operation of the Space Station Freedom (SSF) two-phase external Active Thermal Control System (ATCS), a test and verification program will be performed prior to flight. The first system level test of the ATCS is the Prototype Test Article (PTA) test that will be performed in early 1994. All ATCS loops will be represented by prototypical components and the line sizes and lengths will be representative of the flight system. In this paper, the SSF ATCS and a portion of its verification process are described. The PTA design and the analytical methods that were used to quantify the gravity effects on PTA operation are detailed. Finally, the gravity effects are listed, and the applicability of the 1-g PTA test results to the validation of on-orbit ATCS operation is discussed.

Chen, I. Y.↗
NASA NTRS1985

In-flight testing of the space shuttle orbiter thermal control system

In-flight thermal control system testing of a complex manned spacecraft such as the space shuttle orbiter and the considerations attendant to the definition of the tests are described. Design concerns, design mission requirements, flight test objectives, crew vehicle and mission risk considerations, instrumentation, data requirements, and real-time mission monitoring are discussed. An overview of the tests results is presented.

Taylor, J. T.↗
NASA NTRS1999

Analytical Assessment of a Gross Leakage Event Within the International Space Station (ISS) Node 2 Internal Active Thermal Control System (IATCS)

Results of the International Space Station (ISS) Node 2 Internal Active Thermal Control System (IATCS) gross leakage analysis are presented for evaluating total leakage flowrates and volume discharge caused by a gross leakage event (i.e. open boundary condition). A Systems Improved Numerical Differencing Analyzer and Fluid Integrator (SINDA/FLUINT) thermal hydraulic mathematical model (THMM) representing the Node 2 IATCS was developed to simulate system performance under steady-state nominal conditions as well as the transient flow effects resulting from an open line exposed to ambient. The objective of the analysis was to determine the adequacy of the leak detection software in limiting the quantity of fluid lost during a gross leakage event to within an acceptable level.

Holt, James M.↗
NASA NTRS2001

Analytical Assessment of a Gross Leakage Event Within the International Space Station (ISS) Node 2 Internal Active Thermal Control System (IATCS)

Results of the International Space Station (ISS) Node 2 Internal Active Thermal Control System (IATCS) gross leakage analysis are presented for evaluating total leakage flow rates and volume discharge caused by a gross leakage event (i.e. open boundary condition). A Systems Improved Numerical Differencing Analyzer and Fluid Integrator (SINDA85/FLUINT) thermal hydraulic mathematical model (THMM) representing the Node 2 IATCS was developed to simulate system performance under steady-state nominal conditions as well as the transient flow effect resulting from an open line exposed to ambient. The objective of the analysis was to determine the adequacy of the leak detection software in limiting the quantity of fluid lost during a gross leakage event to within an acceptable level.

Holt, James M.↗
NASA NTRS1992

Space Station external thermal control system design and operational overview

The driving design requirements and resulting design characteristics for a two-phase ammonia system of the Space Shuttle are reviewed with particular attention given to operational and station assembly issues related to system activation and steady-state operation. Design is described at an overall system level and an orbit replaceable unit level. It is concluded that a system flow network must be designed and ammonia pressures must be controlled to acquire waste heat efficiently from all contributing heat sources at a controlled temperature.

Raetz, John↗
NASA NTRS2001

Design of the Thermal Control System for the Space Technology 5 Microsatellite

The New Millennium Program's (NMP) Space Technology 5 (ST-5) Project, currently in Phase B of the design process, is slated to launch three 20-kg class spin stabilized microsatellites in late 2003. The proposed orbit is highly elliptical and could result in an earth shadow eclipse of almost 2 hours. Although ST-5's maximum eclipse is only 2 hours, future missions could involve eclipses as long as 8 hours. As spacecraft size, mass, and available resources decrease and eclipse duration increases, thermal engineers will be challenged to design simple but robust thermal control systems that meet temperature requirements for all phases of the mission. This paper presents the results of a study of three design concepts and preliminary analysis of the design selected for ST-5.

Douglas, Donya↗
NASA NTRS1973

Space shuttle heat pipe thermal control systems

Heat pipe (HP) thermal control systems designed for possible space shuttle applications were built and tested under this program. They are: (1) a HP augmented cold rail, (2) a HP/phase change material (PCM) modular heat sink and (3) a HP radiating panel for compartment temperature control. The HP augmented cold rail is similar to a standard two-passage fluid cold rail except that it contains an integral, centrally located HP throughout its length. The central HP core helps to increase the local power density capability by spreading concentrated heat inputs over the entire rail. The HP/PCM modular heat sink system consists of a diode HP connected in series to a standard HP that has a PCM canister attached to its mid-section. It is designed to connect a heat source to a structural heat sink during normal operation, and to automatically decouple from it and sink to the PCM whenever structural temperatures are too high. The HP radiating panel is designed to conductively couple the panel feeder HPs directly to a fluid line that serves as a source of waste heat. It is a simple strap-on type of system that requires no internal or external line modifications to distribute the heat to a large radiating area.

Alario, J.↗
NASA NTRS2014

International Space Station (ISS) External Thermal Control System (ETCS) Loop A Pump Module (PM) Jettison Options Assessment

On December 11, 2013, the International Space Station (ISS) experienced a failure of the External Thermal Control System (ETCS) Loop A Pump Module (PM). To minimize the number of extravehicular activities (EVA) required to replace the PM, jettisoning the faulty pump was evaluated. The objective of this study was to independently evaluate the jettison options considered by the ISS Trajectory Operations Officer (TOPO) and to provide recommendations for safe jettison of the ETCS Loop A PM. The simulation selected to evaluate the TOPO options was the NASA Engineering and Safety Center's (NESC) version of Program to Optimize Simulated Trajectories II (POST2) developed to support another NESC assessment. The objective of the jettison analysis was twofold: (1) to independently verify TOPO posigrade and retrograde jettison results, and (2) to determine jettison guidelines based on additional sensitivity, trade study, and Monte Carlo (MC) analysis that would prevent PM recontact. Recontact in this study designates a propagated PM trajectory that comes within 500 m of the ISS propagated trajectory. An additional simulation using Systems Tool Kit (STK) was run for independent verification of the POST2 simulation results. Ultimately, the ISS Program removed the PM jettison option from consideration. However, prior to the Program decision, the retrograde jettison option remained part of the EVA contingency plan. The jettison analysis presented showed that, in addition to separation velocity/direction and the atmosphere conditions, the key variables in determining the time to recontact the ISS is highly dependent on the ballistic number (BN) difference between the object being jettisoned and the ISS.

Murri, Daniel G.↗
NASA NTRS2003

International Space Station Internal Thermal Control System Cold Plate/Fluid-Stability Test: Two Year Update

Operation of the Internal Thermal Control System (ITCS) Cold Plate/Fluid-Stability Test Facility commenced on September 5, 2000. The facility was intended to provide advance indication of potential problems on board the International Space Station (ISS) and was designed: - To be materially similar to the flight ITCS. - To allow for monitoring during operation. - To run continuously for three years. During the first two years of operation the conditions of the coolant and components were remarkably stable. During this same period of time, the conditions of the ISS ITCS significantly diverged from the desired state. Due to this divergence, the test facility has not been providing information useful for predicting the flight ITCS condition. Results of the first two years are compared with flight conditions over the same time period, showing the similarities and divergences. To address the divergences, the test facility was modified slightly to more closely match the flight conditions, and to gain insight into the reasons for the divergence. Results of the modifications are discussed and provide insight into the development of the conditions on orbit.

Paul Wieland↗
NASA NTRS2008

KSC Electrostatic Discharge (ESD) Issues

Discussion of key electrostatic issues that have arisen during the past few years at KSC that the Electrostatics Laboratory has studied. The lab has studied in depth the Space Shuttle's Thermal Control System Blankets, the International Space Station Thermal Blanket, the Pan/Tilt Camera Blankets, the Kapton Purge Barrier Curtain, the Aclar Purge Barrier Curtain, the Thrust Vector Controller Blankets, the Tyvek Reaction Control System covers, the AID-PAK and FLU-9 pyro inflatable devices, the Velostat Solid Rocket Booster mats, and the SCAPE suits. In many cases these materials are insulating meaning that they might be a source of unsafe levels of electrostatic discharge (ESD). For each, the lab provided in-depth testing of each material within its current configuration to ensure that it does not cause an ESD concern that may violate the safety of the astronauts, the workers and equipment for NASA. For example the lab provides unique solutions and testing such as Spark Incendivity Testing that checks whether a material is capable of generating a spark strong enough to ignite a flammable gas. The lab makes recommendations to changes in specifications, procedures, and material if necessary. The lab also consults with a variety of non-safety related ESD issues for the agency.

Buhler, Charles↗
NASA NTRS2018

Developing a Foundation for Space-Based Two-Phase Thermal Control Systems: Future of 2-Phase Thermal Control

Two-phase thermal control systems in microgravity, with significant density differences between phases, pose challenges for many current and proposed spacecraft systems. Because of the lack of understanding of these effects and the inability to scale multiphase systems in low gravity, NASA generally opts to avoid using two-phase systems for spacecraft despite the significant performance increases and lower mass. The goal of this panel discussion will be to identify key technology gaps and challenges that thermal engineers face today when considering a two-phase thermal management system. The panel discussion will begin with a brief overview of recent and on-going NASA projects designed to elicit a fundamental understanding of gas-liquid two phase behavior as it applies to thermal control systems in the Space environment. The projects/experiments discussed will range from boiling/condensation fundamentals, heat pipes, and cryogenic storage systems. We will identify what fundamental question or questions are being addressed in each case. An overview will be also be presented to address future mission needs and the specific advantages multi-phase systems offer, in particular for low cost planetary science missions and enabling missions in extreme environments. The need for efficient heat transfer with concurrent spatial and temporal temperature stability to reduce thermally-induced noise drives a serious look at multi-phase systems as a solution. Furthermore, missions to environments such as the Venus surface or penetration of ice layers in ocean worlds will likely require them. Time will be allocated at the end of this session to allow comments and questions from attendees. The intent is to use this session as a starting point to advocate for a coordinated technology development effort in this area.

Thermal Control Systems↗
NASA NTRS2014

The International Space Station 2B Photovoltaic Thermal Control System (PVTCS) Leak: An Operational History

As early as 2004, the Photovoltaic Thermal Control System (PVTCS) for the International Space Station's 2B electrical power channel began slowly leaking ammonia overboard. Initially, the operations strategy was "feed the leak," a strategy successfully put into action via Extra Vehicular Activity (EVA) during the STS-134 Space Shuttle mission. This recharge was to have allowed for continued power channel operation into 2014 or 2015, at which point another EVA would have been required. In mid-2012, the leak rate increased from 1.5lbm/year to approximately 5lbm/year. As a result, an EVA was planned and executed within a 5 week timeframe to drastically alter the architecture of the PVTCS via connection to an adjacent dormant thermal control system. This EVA, US EVA 20, was successfully executed on November 1, 2012 and left the 2B PVTCS in a configuration where the system was now being adequately cooled via a different radiator than what the system was designed to utilize. Data monitoring over the next several months showed that the isolated radiator had not been leaking, and the system itself continued to leak steadily until May 9th, 2013. It was on this day that the ISS crew noticed the visible presence of ammonia crystals escaping from the 2B channel's truss segment, signifying a rapid acceleration of the leak from 5lbm/year to 5lbm/day. Within 48 hours of the crew noticing the leak, US EVA 21 was in progress to replace the coolant pump - the only remaining replaceable leak source. This was successful, and telemetry monitoring has shown that indeed the coolant pump was the leak source and was thus isolated from the running 2B PVTCS. This paper will explore the management of the 2B PVTCS leak from the operations perspective.

Vareha, Anthony N.↗
NASA NTRS2005

Assessment of Microbiologically Influenced Corrosion Potential in the International Space Station Internal Active Thermal Control System Heat Exchanger Materials: A 6-Momths Study

The fluid in the Internal Active Thermal Control System (IATCS) of the International Space Station (ISS) is water based. The fluid in the ISS Laboratory Module and Node 1 initially contained a mix of water, phosphate (corrosion control), borate (pH buffer), and silver sulfate (Ag2SO4) (microbial control) at a pH of 9.5+/-0.5. Over time, the chemistry of the fluid changed. Fluid changes included a pH drop from 9.5 to 8.3 due to diffusion of carbon dioxide (CO2) through Teflon(reistered Trademark) (DuPont) hoses, increases in dissolved nickel (Ni) levels, deposition of silver (Ag) to metal surfaces, and precipitation of the phosphate (PO4) as nickel phosphate (NiPO4). The drop in pH and unavailability of a antimicrobial has provided an environment conducive to microbial growth. Microbial levels in the fluid have increased from >10 colony-forming units (CFUs)/100 ml to 10(exp 6) CFUs/100 ml. The heat exchangers in the IATCS loops are considered the weakest point in the loop because of the material thickness (=7 mil). It is made of a Ni-based braze filler/CRES 347. Results of a preliminary test performed at Hamilton Sundstrand indicated the possibility of pitting on this material at locations where Ag deposits were found. Later, tests have confirmed that chemical corrosion of the materials is a concern for this system. Accumulation of micro-organisms on surfaces (biofilm) can also result in material degradation and can amplify the damage caused by the chemical corrosion, known as microbiologically influenced corrosion (MIC). This paper will discuss the results of a 6-mo test performed to characterize and quantify the damage from microbial accumulation on the surface of the ISS/ATCS heat exchanger materials. The test was designed to quantify the damage to the materials under worst-case conditions with and without micro-organisms present at pH 8.3 and 9.5.

Roman, Monsi C.↗
NASA NTRS2001

Comparison of Analytical and Numerical Performance Predictions for a Regenerative Heat Exchanger in the International Space Station Node 3 Internal Active Thermal Control System

The complexity of International Space Station (ISS) systems modeling often necessitates the concurrence of various dissimilar, parallel analysis techniques to validate modeling. This was the case with a feasibility and performance study of the ISS Node 3 Regenerative Heat Exchanger (RHX). A thermo-hydraulic network model was created and analyzed in SINDA/FLUINT. A less complex, closed form solution of the system dynamics was created using Excel. The purpose of this paper is to provide a brief description of the modeling processes utilized, the results and benefits of each to the ISS Node 3 RHX study.

Wise, Stephen A.↗