The Next Steps for Environmental Control and Life Support Systems Development for Deep Space Exploration
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48th International Conference on Environmental Systems ICES-2018-276 8-12 July 2018, Albuquerque, New Mexico The Next Steps for Environmental Control and Life Support Systems Development for Deep Space Exploration Mark Jernigan1 NASA Johnson Space Center, Houston, TX 77058 Robyn Gatens2 and Jitendra Joshi3 NASA Headquarters, Washington, D.C. 20546 and Jay Perry4 NASA Marshall Space Flight Center, Huntsville, AL 35812 Throughout the life of the International Space Station (ISS), NASA has developed, deliv- ered and operated a suite of progressively more capable environmental control and life support system (ECLSS) components and assemblies. These efforts have resulted in substan- tially reducing the supply chain necessary to sustain crews in flight and garnering invaluable lessons for sustained long term operations of the equipment. Currently, the ISS provides a unique platform for understanding the effects of the environment on the hardware. NASA’s strategy, already underway, is to evolve the ISS ECLSS into the Exploration ECLSS and perform a long-duration demonstration on ISS in preparation for deep space missions. This includes demonstrations of upgrades and/or new capabilities for waste management, atmos- phere revitalization, water recovery, and environmental monitoring. Within the Advanced Exploration Systems Program under the Next Space Technologies for Exploration Partner- ships (NextSTEP) model, NASA intends to revise the architecture developed for ISS to make the systems completely independent of the Earth supply chain for the duration of a deep space crewed mission by increasing robustness, including prospective system monitoring to anticipate failures, designing for maintenance, repair and refurbishment, reducing spare part count through use of common components, and grouping subsystems into modular pal- lets to minimize interfaces and reduce complexity. The NextSTEP ECLSS will be a partnership between NASA and a competitively selected team of industry partners to pro- duce a closed loop long duration test capability to establish confidence that the systems will be able to work properly in the deep space environment for extremely long missions. Nomenclature AR = atmosphere revitalization BAA = Broad Agency Announcement BPA = brine processing assembly DRA5 = Design Reference Architecture 5.0 DSG = Deep Space Gateway DST = Deep Space Transport ECLSS = environmental control and life support system EVA = extravehicular activity ISS = International Space Station 1 NextSTEP GFE ECLSS Lead, Human Health and Performance Directorate, Mail Stop SA311. 2 Deputy Director, International Space Station Division, Mail Stop CJ000. 3 Lead for Technology Integration, Advanced Exploration Systems, Mail Stop CQ000. 4 Lead Engineer-Environmental Control Systems, Space Systems Dept., Mail Stop ES62. LSS = life support system NASA = National Aeronautics and Space Administration NextSTEP = Next Space Technologies for Exploration Partnerships PPE = personal protective equipment UWMS = universal waste management system WRM = water recovery and management MPa = mega-pascal psia = pounds per square inch absolute I. Introduction HE environmental control and life support system (ECLSS) deployed aboard the International Space Station T (ISS) has provided the National Aeronautics and Space Administration (NASA) with valuable experience on functional deployment and long-term systems operations that will serve as a reference basis for future crewed space exploration beyond low-Earth orbit. In addition to this experience, the ISS affords a unique environment in which to demonstrate improved process technologies and logistics management concepts in preparation for these future mis- sions. Realizing future crewed exploration objectives1 builds on the foundation of nearly two decades of in-flight ECLSS operations experience gained aboard the ISS. Yet, to reach the next crewed exploration destinations requires advancing core ECLSS technologies to address obsolescence, improve logistics management and in-flight maintain- ability, and develop methods to increase oxygen and water recovery percentages. The initial life support systems delivered to ISS in the U.S. Laboratory Module, Destiny, included an open-loop four-bed molecular sieve carbon dioxide (CO2) removal assembly, trace contaminant control assembly, temperature and humidity control systems, and stored oxygen and water replenished via Space Shuttle-based logistics support. This system was adequate to support the initial crew of three; however, in order to increase the crew size to six without making resupply prohibitive, additional regenerative life support functions were required. To address this need, regenerative ECLSS hardware was delivered to the ISS in 2007 and 2009. This equipment included urine and potable water processing that recovers approximately 90% of crew urine and humidity condensate, and a water- electrolysis-based oxygen generation system. A functional scar was included in the oxygen generation system rack to accommodate a future CO2 reduction assembly. Initially installed in Destiny, this regenerative ECLSS hardware was moved permanently to Node 3 (Tranquility). In 2010, a Sabatier-based CO2 reduction system was installed in the oxygen generation subsystem rack. This addition allowed CO2 that was initially being vented overboard to be processed with H2 from the oxygen generation unit to produce water which is recycled. With this process in place, nearly 50% of the oxygen could be reclaimed from CO2. Although these systems had been in development since the early 1990s, they were still considered somewhat ex- perimental when deployed aboard the ISS. Over the past decade of operation, many lessons have been learned regarding the performance and reliability of these systems in the ISS microgravity environment. Though the current system is adequate to support long duration missions, its basic design and operations take advantage of the proximi- ty of the ISS to Earth and the ability to frequently resupply spare parts and consumable items. Therefore, improvements must be made to evolve the ISS ECLSS functionally into the system needed for deep space explora- tion. Given the resources needed to mature developmental systems into reliable operational systems, wholesale changes from the ECLSS state-of-the-art may be prohibitive as a strategy to achieve exploration goals. Instead, a strategy consisting of a combination of state-of-the-art component upgrades, new technologies, and targeted sup- plemental capabilities may yield results more rapidly and economically. The capability gaps by function that the current exploration ECLSS development and test campaign is addressing via using the ISS as a testbed have been defined. The following is an overview of each ongoing and planned activity. II. ISS ECLSS Maturation The evolution of the ISS ECLSS into the Deep Space Exploration ECLSS is in progress and will continue through the early 2020s. Figure 1 provides an overview of developmental activities and flight demonstrations planned to be executed aboard the ISS by NASA and ISS international partners. Vertical arrows indicate when a flight demonstration or upgrade of a current system is planned aboard the ISS, while diamonds represent decision points or down-selection between alternate technologies. By 2021, the majority of down-selections and individual flight demonstrations will have been conducted, allowing NASA to begin a long- duration integrated test of the resulting Exploration ECLSS system. At the same time, these Exploration ECLSS technologies will become the baseline for the Deep Space Transport (DST) design work beginning in the early 2020s. 2 International Conference on Environmental Systems Figure 1. ECLSS development roadmap to enable deep space exploration. While the testing aboard the ISS will be conducted in parallel with the initial DST design and development, there will be an opportunity to incorporate lessons learned prior to completion and launch of the DST to cis-lunar space in the late 2020s. Thus, the development and testing of the Exploration ECLSS aboard the ISS is a critical risk reduction step. Although the systems will not be packaged as they will in the DST module or integrated with the DST power, data, and thermal systems, the long-duration systems testing aboard the ISS allows performance and reliability to be evaluated in the unique cabin and microgravity environments that cannot be duplicated in ground-based testing facili- ties. NASA’s plan includes flight demonstration of at least three CO2 removal technologies. The best of these three CO2 removal approaches will be included in an integrated atmosphere revitalization system along with upgraded oxygen generation and trace contaminant control assemblies as well as a new CO2 reduction assembly capable of recovering >75% of the oxygen from CO2. A high pressure, high purity oxygen (O2) capability will also be developed to refill the 20.7 MPa (3000 psi) oxygen tanks used for extravehicular activity (EVA) and to provide contingency medical-grade oxygen. The current ISS urine and water processor assemblies will be upgraded to improve reliability and reduce consumables, and a new brine processor assembly (BPA) will be added to recover water from the urine processor brine. These improvements will result in >98% water recovery for the Exploration ECLSS water system. For solid waste management, a new universal waste management system (UWMS), or toilet, will be demonstrated aboard the ISS as well as deployed on board