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NASA NTRS2010

International Space Station Common Cabin Air Assembly Condensing Heat Exchanger Hydrophilic Coating Failures and Lessons Learned

The ability to control the temperature and humidity of an environment or habitat is critical for human survival. These factors are important to maintaining human health and comfort, as well as maintaining mechanical and electrical equipment in good working order to support the human and to accomplish mission objectives. The temperature and humidity of the International Space Station (ISS) United States On-orbit Segment (USOS) cabin air is controlled by the Common Cabin Air Assembly (CCAA). The CCAA consists of a fan, a condensing heat exchanger (CHX), an air/water separator, temperature and liquid sensors, and electrical controlling hardware and software. The CHX is the primary component responsible for control of temperature and humidity. The CCAA CHX contains a chemical coating that was developed to be hydrophilic and thus attract water from the humid influent air. This attraction forms the basis for water removal and therefore cabin humidity control. However, there have been several instances of CHX coatings becoming hydrophobic and repelling water. When this behavior is observed in an operational CHX, the unit s ability to remove moisture from the air is compromised and the result is liquid water carryover into downstream ducting and systems. This water carryover can have detrimental effects on the cabin atmosphere quality and on the health of downstream hardware. If the water carryover is severe and widespread, this behavior can result in an inability to maintain humidity levels in the USOS. This paper will describe the operation of the five CCAAs within in the USOS, the potential causes of the hydrophobic condition, and the impacts of the resulting water carryover to downstream systems. It will describe the history of this behavior and the actual observed impacts to the ISS USOS. Information on mitigation steps to protect the health of future CHX hydrophilic coatings and potential remediation techniques will also be discussed.

Balistreri, Steven F.↗
NASA NTRS2013

International Space Station Common Cabin Air Assembly Condensing Heat Exchanger Hydrophilic Coating Operation, Recovery, and Lessons Learned

The ability to control the temperature and humidity of an environment or habitat is critical for human survival. These factors are important to maintaining human health and comfort, as well as maintaining mechanical and electrical equipment in good working order to support the human and to accomplish mission objectives. The temperature and humidity of the International Space Station (ISS) United States On-orbit Segment (USOS) cabin air is controlled by the Common Cabin Air Assembly (CCAA). The CCAA consists of a fan, a condensing heat exchanger (CHX), an air/water separator, temperature and liquid sensors, and electrical controlling hardware and software. The CHX is the primary component responsible for control of temperature and humidity. The CCAA CHX contains a chemical coating that was developed to be hydrophilic and thus attract water from the humid influent air. This attraction forms the basis for water removal and therefore cabin humidity control. However, there have been several instances of CHX coatings becoming hydrophobic and repelling water. When this behavior is observed in an operational CHX in the ISS segments, the unit s ability to remove moisture from the air is compromised and the result is liquid water carryover into downstream ducting and systems. This water carryover can have detrimental effects on the ISS cabin atmosphere quality and on the health of downstream hardware. If the water carryover is severe and widespread, this behavior can result in an inability to maintain humidity levels in the USOS. This paper will describe the operation of the five CCAAs within the USOS, the potential causes of the hydrophobic condition, and the impacts of the resulting water carryover to downstream systems. It will describe the history of this behavior and the actual observed impacts to the ISS USOS. Information on mitigation steps to protect the health of future CHX hydrophilic coatings as well as remediation and recovery of the full heat exchanger will be discussed.

Balistreri, Steven F.↗
NASA NTRS1988

Uniformity of environmental conditions and plant growth in a hydroponic culture system for use in a growth room with aerial CO2 control

A portable system of hydroponic culture was developed that maintained temperature, pH, and nutrient concentrations of circulating nutrient solutions. The hydroponic system is used within a controlled-environment room (CER) for control of aerial environment. The CER was equipped with an auto-calibrating system for atmospheric CO2 control. The control systems for the hydroponic chambers were able to maintain acidity within +/- 0.2 pH units and the temperature with +/- 0.5 degree C. Mixing time for the 200-liter volume of solution within a hydroponic chamber was less than 12 min. The CO2 control system was able to maintain aerial concentrations within +/- 10 ppm CO2 during the light period. The only gradient found to occur within the hydroponic chambers or CER was a slight gradient in aerial temperature along the length of hydroponic chambers. Growth of soybeans [Glycine max (L.) Merr.] was characterized during a 3-week period of vegetative development by leaf number and area, plant dry weight, total N content of plants, and N depletion from the nutrient solution. The growth characteristics among populations for three hydroponic chambers within the CER were not significantly different, and the percent standard errors of means of the measurements within populations from each chamber were nearly all less than 10%. Thus, the uniformity of plant growth reflected the uniformity of environmental conditions.

NASA Discipline Life Support Systems↗
NASA NTRS2018

An Initial Validation of Landsat 5 and 7 Derived Surface Water Temperature for U.S. Lakes, Reservoirs, and Estuaries

The United States Harmful Algal Bloom and Hypoxia Research Control Act of 2014 identified the need for forecasting and monitoring harmful algal blooms (HAB) in lakes, reservoirs, and estuaries across the nation. Temperature is a driver in HAB forecasting models that affects both HAB growth rates and toxin production. Therefore, temperature data derived from the U.S. Geological Survey Landsat 5 Thematic Mapper and Landsat 7 Enhanced Thematic Mapper Plus thermal band products were validated across 35 lakes and reservoirs, and 24 estuaries. In situ data from the Water Quality Portal (WQP) were used for validation. The WQP serves data collected by state, federal, and tribal groups. Discrete in situ temperature data included measurements at 11,910 U.S. lakes and reservoirs from 1980 through 2015. Landsat temperature measurements could include 170,240 lakes and reservoirs once an operational product is achieved. The Landsat-derived temperature mean absolute error was 1.34 C in lake pixels (is) greater than180 m from land, 4.89 C at the land-water boundary, and 1.11 C in estuaries based on comparison against discrete surface in situ measurements. This is the first study to quantify Landsat resolvable U.S. lakes and reservoirs, and large-scale validation of an operational satellite provisional temperature climate data record algorithm. Due to the high performance of open water pixels, Landsat satellite data may supplement traditional in situ sampling by providing data for most U.S. lakes, reservoirs, and estuaries over consistent seasonal intervals (even with cloud cover) for an extended period of record of more than 35 years.

Schaeffer, Blake A.↗
NASA NTRS2003

Wireless Temperature-Monitoring System

A relatively inexpensive instrumentation system that includes units that are connected to thermocouples and that are parts of a radio-communication network has been developed to enable monitoring of temperatures at multiple locations. Because there is no need to string wires or cables for communication, the system is well suited for monitoring temperatures at remote locations and for applications in which frequent changes of monitored or monitoring locations are needed. The system can also be adapted to monitoring of slowly varying physical quantities, other than temperature, that can be transduced by solid-state electronic sensors. The system comprises any number of transmitting units and a single receiving unit (see figure). Each transmitting unit includes connections for as many as four external thermocouples, a signal-conditioning module, a control module, and a radio-communication module. The signal- conditioning module acts as an interface between the thermocouples and the rest of the transmitting unit and includes a built-in solid ambient-temperature sensor that is in addition to the external thermocouples. The control module is a "system-on-chip" embedded processor that includes analog-to-digital converters, serial and parallel data ports, and an interface for local connection to an analog meter that is used during installation to verify correct operation. The radio-communication module contains a commercial spread-spectrum transceiver that operates in the 900-MHz industrial, scientific, and medical (ISM) frequency band. This transceiver transmits data to the receiving unit at a rate of 19,200 baud. The receiving unit includes a transceiver like that of a transmitting unit, plus a control module that contains a system-on-chip processor that includes serial data port for output to a computer that runs monitoring and/or control software, a parallel data port for output to a printer, and a seven-segment light-emitting-diode display.

Solano, Wanda↗
NASA NTRS1988

Experimental results on atomic oxygen corrosion of silver

The results of an experimental study of the reaction kinetics of silver with atomic oxygen in 10 degree increments over the temperature range of 0 to 70 C is reported. The silver specimens, of the order of 10,000 A in thickness, were prepared by thermal evaporation onto 3 inch diameter polished silicon wafers. There were later sliced into pieces having surface areas of the order of 1/4 to 1/2 square inch. Atomic oxygen was generated by a gas discharge in a commercial plasmod asher operating in the megahertz frequency range. The sample temperature within the chamber was controlled by means of a thermoelectric unit. Exposure of the silver specimens to atomic oxygen was incremental, with oxide film thickness measurements being carried out between exposures by means of an automated ellipsometer. For the early growth phase, the data can be described satisfactorily by a logarithmic growth law: the oxide film thickness increases as the logarithm of the exposure time. Furthermore, the oxidation process is thermally activated, the rate increasing with increasing temperature. However, the empirical activation energy parameter deduced from Arrhenius plots is quite low, being of the order of 0.1 eV.

Fromhold, Albert T.↗
NASA NTRS1977

A portable personal cooling system for mine rescue operations

Design of a portable personal cooling system to reduce physiological stress in high-temperature, high-humidity conditions is discussed. The system, based on technology used in the thermal controls of space suits, employs a combination of head and thoracic insulation and cooling through a heat sink unit. Average metabolic rates, heart rates, rectal temperature increase and sweat loss were monitored for test subjects wearing various configurations of the cooling system, as well as for a control group. The various arrangements of the cooling garment were found to provide significant physiological benefits; however, increases in heat transfer rate of the cooling unit and more effective insulation are suggested to improve the system's function.

Webbon, B.↗
NASA NTRS2010

International Space Station Common Cabin Air Assembly Water Separator On-Orbit Operation, Failure, and Redesign

The ability to control the temperature and humidity of an environment or habitat is critical for human survival. These factors are important to maintaining human health and comfort, as well as maintaining mechanical and electrical equipment in good working order to support the human and to accomplish mission objectives. The temperature and humidity of the International Space Station (ISS) United States On-orbit Segment (USOS) cabin air is controlled by the Common Cabin Air Assembly (CCAA). The CCAA consists of a fan, a condensing heat exchanger (CHX), an air/water separator, temperature and liquid sensors, and electrical controlling hardware and software. The Water Separator (WS) pulls in air and water from the CHX, and centrifugally separates the mixture, sending the water to the condensate bus and the air back into the CHX outlet airstream. Two distinct early failures of the CCAA Water Separator in the Quest Airlock forced operational changes and brought about the re-design of the Water Separator to improve the useful life via modification kits. The on-orbit operational environment of the Airlock presented challenges that were not foreseen with the original design of the Water Separator. Operational changes were instituted to prolong the life of the third installed WS, while waiting for newly designed Water Separators to be delivered on-orbit. The modification kit design involved several different components of the Water Separator, including the innovative use of a fabrication technique to build the impellers used in Water Separators out of titanium instead of aluminum. The technique allowed for the cost effective production of the low quantity build. This paper will describe the failures of the Water Separators in the Quest Airlock, the operational constraints that were implemented to prolong the life of the installed Water Separators throughout the USOS, and the innovative re-design of the CCAA Water Separator.

Balistreri, Steven F., Jr.↗
NASA NTRS2010

Environmental Stress Testing of the Single Sample Cylinder: A Proven Consensus Standard for Internal Gas Analysis (IGA) or Residual Gas Analysis (RGA)

In August 2008, Schuessler Consulting was contracted by NASA GSFC in support of the NASA Electronic Parts and Packaging (NEPP) program to perform two separate studies on moisture laden air in a stainless steel cylinder that had been designed to become a consensus standard for Test Method 1018. This Test Method was originally released for hybrids under Mil. Std. 883 but was quickly utilized on other microelectronic devices under the auspice of Mil. Std. 750. The cylinder had subsequently been fabricated for the 750 community. It was back-filled with moist air and subsequently analyzed over a period of time under a previous NASA contract. It had been shown that moisture in the 4000 - 5000 ppm range could be analyzed rather precisely with a mass spectrometer, commonly referred to as a Residual Gas Analyzer (RGA). The scope of this study was to ascertain if the composition and precision varied as a function of thermal shock at sub-zero temperatures and whether there was consensus when the standard was submitted to other RGA units. It was demonstrated and published that the consensus standard would yield precise RGA data for moisture within +/- 1% when optimized for a given RGA unit. It has been subsequently shown in this study at Oneida Research Services, that sub-zero storage did not affect that precision when a well-defined protocol for the analysis was followed. The consensus standard was taken to a second facility for analysis where it was found that moisture adsorption on the transfer lines caused precision to drop to +/- 12%. The Single Sample Cylinder (SSC) is a one liter stainless steel cylinder with associated sampling valves and has considerable weight and volume. But this considerable size allows for approximately 300 gas samples of the same composition to be delivered to any RGA unit. Lastly, a smaller cylinder, approximately 75 cc, of a second consensus standard was fabricated and tested with a different mix of fixed gases where moisture was kept in the 100 ppm range. This second standard has the potential of providing 30 gaseous samples and can be readily shipped to any analytical facility that desires to generate comparison RGA data. A series of comparison residual gas analyses was performed at the Honeywell Federal Manufacturing & Technologies facility in the National Nuclear Facility Administration s plant in Kansas City to complete this project. It was shown that improvements in the precision of a given RGA unit can be done by controlling the cycle time for each analysis and increasing analysis temperatures to minimize moisture adsorption. It was also found that a "one time event" in the subzero storage of the large SSC did not effect the units ability to continuously supply precise samples of the same chemistry, however the "event" caused a permanent +8% shift in the reported value of the moisture content. Lastly, a set of SSC RGA results was plotted on a common graph with DSCC "correlation study" RGA data. The result demonstrates the ability of the SSC to remove many of the individual variances that single, individual samples introduce. The consensus standards are now in storage at Oneida Research Services, one of the DSCC certified houses that does RGA to Military Standards, where they await future studies. The analytical data and the operational parameters of the instruments used are provided in the following discussion. Limitations and suggested means for improvement of both precision and accuracy are provided.

Schuessler, Philipp WH↗
NASA NTRS1974

Design of H2-O2 space shuttle APU. Volume 1: APU design

The H2-O2 space shuttle auxiliary power unit (APU) program is a NASA-Lewis effort aimed at hardware demonstration of the technology required for potential use on the space shuttle. It has been shown that a hydrogen-oxygen power unit (APU) system is an attractive alternate to the space shuttle baseline hydrazine APU system for minimum weight. It has the capability for meeting many of the heat sink requirements for the space shuttle vehicle, thereby reducing the amount of expendable evaporants required for cooling in the baseline APU. Volume 1 of this report covers preliminary design and analysis of the current reference system and detail design of the test version of this reference system. Combustor test results are also included. Volume 2 contains the results of the analysis of an initial version of the reference system and the computer printouts of system performance. The APU consists of subsystems for propellant feed and conditioning, turbopower, and control. Propellant feed and conditioning contains all heat exchangers, valves, and the combustor. The turbopower subsystem contains a two-stage partial-admission pressure-modulated, 400-hp, 63,000-rpm turbine, a 0-to 4-g lubrication system, and a gearbox with output pads for two hydraulic pumps and an alternator (alternator not included on test unit). The electronic control functions include regulation of speed and system temperatures; and start-and-stop sequences, overspeed (rpm) and temperature limits, failsafe provisions, and automatic shutdown provisions.

Harris, E.↗
NASA NTRS1981

Evaluation of the Doraiswamy-Thompson winter wheat crop calendar model incorporating a modified spring restart sequence

The Robertson phenology was used to provide growth stage information to a wheat stress indicator mode. A stress indicator model demands two acurate predictions from a crop calendar: date of spring growth initiation; and crop calendar stage at growth initiation. Several approaches for restarting the Robertson phenology model at spring growth initiation were studied. Although best results were obtained with a solar thermal unit method, an alternate approach which indicates soil temperature as the controlling parameter for spring growth initiation was selected and tested. The modified model (Doraiswamy-Thompson) is compared to LACIE-Robertson model predictions.

Taylor, T. W.↗
NASA NTRS1977

Development of a prototype regeneration carbon dioxide absorber

A prototype regenerable carbon dioxide absorber was developed to maintain the environmental quality of the portable life support system. The absorber works on the alkali metal carbonate-bicarbonate solid-gas reaction to remove carbon dioxide from the atmosphere. The prototype sorber module was designed, fabricated, and tested at simulated extravehicular activity conditions to arrive at optimum design. The unit maintains sorber outlet concentration below 5 mm Hg. An optimization study was made with respect to heat transfer, temperature control, sorbent utilization, sorber life and regenerability, and final size of the module. Important parameters influencing the capacity of the final absorber unit were identified and recommendations for improvement were made.

Patel, P. S.↗
NASA NTRS2006

Valve Health Monitoring System Utilizing Smart Instrumentation

The valve monitoring system is a stand alone unit with network capabilities for integration into a higher level health management system. The system is designed for aiding in failure predictions of high-geared ball valves and linearly actuated valves. It performs data tracking and archiving for identifying degraded performance. The data collection types are cryogenic cycles, total cycles, inlet temperature, body temperature torsional strain, linear bonnet strain, preload position, total travel and total directional changes. Events are recorded and time stamped in accordance with the IRIG B True Time. The monitoring system is designed for use in a Class 1 Division II explosive environment. The basic configuration consists of several instrumentation sensor units and a base station. The sensor units are self contained microprocessor controlled and remotely mountable in three by three by two inches. Each unit is potted in a fire retardant substance without any cavities and limited to low operating power for maintaining safe operation in a hydrogen environment. The units are temperature monitored to safeguard against operation outside temperature limitations. Each contains 902-928 MHz band digital transmitters which meet Federal Communication Commission's requirements and are limited to a 35 foot transmission radius for preserving data security. The base-station controller correlates data from the sensor units and generates data event logs on a compact flash memory module for database uploading. The entries are also broadcast over an Ethernet network. Nitrogen purged National Electrical Manufactures Association (NEMA) Class 4 enclosures are used to house the base-station

Jensen, Scott L.↗
NASA NTRS2004

Summary of Resources for the International Space Station Environmental Control and Life Support System For Core Complete Modules

The Core Complete Environmental Control and Life Support (ECLS) System for the International Space Station (ISS) will consist of components and subsystems in both the United States (U.S.) and International Partner elements which together will perform the functions of Temperature and Humidity Control (THC), Atmosphere Control and Supply (ACS), Atmosphere Revitalization (AR), Water Recovery and Management (WRM), Fire Detection and Suppression (FDS), and Vacuum System (VS) for the station. Due to limited resources available on ISS, detailed attention is given to minimizing and tracking all resources associated with all systems, beginning with estimates during the hardware development phase through measured actuals when flight hardware is built and delivered. A summary of resources consumed by the addition of future U.S. ECLS system hardware to get to Core Complete is presented, including launch weight, average continuous and peak power loads, on-orbit volume and resupply logistics.

Williams, David E.↗
NASA NTRS1974

Augmented RIGS

The results of the Phase 2 Resonant Infrasonic Gauging System (RIGS) development program are presented. The program consisted of design, fabrication, and testing of an "augmented" RIGS concept. The RIGS is a gauging system capable of measuring propellant quantities in zero-g as well as under accelerated conditions. Except for hydrogen, it can be used to gauge virtually any propellant in liquid form, including cryogenics. The gage consists of a sensor unit which is attached to the propellant tank and an electronic control unit which may be positioned separately from the sensor. The control unit receives signals from the sensor as well as the propellant temperature measurement and the ullage gas pressure, and computes the propellant quantity in the tank.

Kaminskas, R. A.↗
NASA NTRS1999

Lightweight Battery Charge Regulator Used to Track Solar Array Peak Power

A battery charge regulator based on the series-connected boost regulator (SCBR) technology has been developed for high-voltage spacecraft applications. The SCBR regulates the solar array power during insolation to prevent battery overcharge or undercharge conditions. It can also be used to provide regulated battery output voltage to spacecraft loads if necessary. This technology uses industry-standard dc-dc converters and a unique interconnection to provide size, weight, efficiency, fault tolerance, and modularity benefits over existing systems. The high-voltage SCBR shown in the photograph has demonstrated power densities of over 1000 watts per kilogram (W/kg). Using four 150-W dc-dc converter modules, it can process 2500 W of power at 120 Vdc with a minimum input voltage of 90 Vdc. Efficiency of the SCBR was 94 to 98 percent over the entire operational range. Internally, the unit is made of two separate SCBR s, each with its own analog control circuitry, to demonstrate the modularity of the technology. The analog controllers regulate the output current and incorporate the output voltage limit with active current sharing between the two units. They also include voltage and current telemetry, on/off control, and baseplate temperature sensors. For peak power tracking, the SCBR was connected to a LabView-based data acquisition system for telemetry and control. A digital control algorithm for tracking the peak power point of a solar array was developed using the principle of matching the source impedance with the load impedance for maximum energy transfer. The algorithm was successfully demonstrated in a simulated spacecraft electrical system at the Boeing PhantomWorks High Voltage Test Facility in Seattle, Washington. The system consists of a 42-string, high-voltage solar array simulator, a 77-cell, 80-ampere-hour (A-hr) nickel-hydrogen battery, and a constant power-load module. The SCBR and the LabView control algorithm successfully tracked the solar array peak power point through various load transients, including sunlight discharge transients when the total load exceeded the maximum solar array output power.

Soeder, James F.↗
NASA NTRS2015

Effects of Oxygen Partial Pressure on the Surface Tension of Liquid Nickel

The NASA Marshall Space Flight Center's electrostatic levitation (ESL) laboratory has been recently upgraded with an oxygen partial pressure controller. This system allows the oxygen partial pressure within the vacuum chamber to be measured and controlled, theoretically in the range from 10‐36 to 100 bar. The oxygen control system installed in the ESL laboratory's main chamber consists of an oxygen sensor, oxygen pump, and a control unit. The sensor is a potentiometric device that determines the difference in oxygen activity in two gas compartments (inside the chamber and the air outside of the chamber) separated by an electrolyte, which is yttria‐stabilized zirconia. The pump utilizes coulometric titration to either add or remove oxygen. The system is controlled by a desktop control unit, which can also be accessed via a computer. The controller performs temperature control for the sensor and pump, PID-based current loop, and a control algorithm. Oxygen partial pressure has been shown to play a significant role in the surface tension of liquid metals. Oxide films or dissolved oxygen may lead to significant changes in surface tension. The effects of oxygen partial pressure on the surface tension of undercooled liquid nickel will be analyzed, and the results will be presented. The surface tension will be measured at several different oxygen partial pressures while the sample is undercooled. Surface tension will be measured using the oscillating drop method. While undercooled, each sample will be oscillated several times consecutively to investigate how the surface tension behaves with time while at a particular oxygen partial pressure.

SanSoucie, Michael P.↗