Upgrading and Diagnostics of Zarya FGB PSS and OBCCS Units - July, 2013

1. FSUE Khrunichev SRPSC «Zarya» FGB PSS and OBCCS Units Up-grading and Diagnostics July, 2013 1

2. FSUE Khrunichev SRPSC Introduction This presentation contains data on the current and performed operations involving the manufacture of up-graded «Zarya» FGB PSS units (БСШ-2, БФ-2) and OBCCSunit (11М156М), the diagnostics of these units and on-board FGB replacement, as well as FGB thermal conditions control during units replacement. 2

3. FSUE Khrunichev SRPSC 1. Up-grading the PSS and OBCCS Units (Phase IIIА) As of today completed in full as under the Contract Schedule are the manufacture of up-graded unit 11M156M and its delivery to the Khrunichev SRPSC. At present standard container-packed, this unit is stored at the SRPSC depot. There is a minor delay in БСШ-2 and БФ-2 units manufacture in consequence of the deferral of delivery of the complementary parts required for instruments manufacture.However, this delay will not tell on the general date of work completion as far as these units. concerned.The anticipated date of units delivery to the SRPSC is Sept.18, 2013, which conforms to the schedule of operations under the Contract signed.. 3

4. FSUE Khrunichev SRPSC Before deciding to deliver the units to the FGB, these will be stored at the SRPSC depot in accordance with the specifications of the respective documentsThus, packed in a standard manufacturer’s container, for instance, the 11M156M instrument must be stored in accordance with Т62.393.079 Specs for not over three years in dry heated premises at ambient air temperature varying from +5 to + 40 °C and relative humidity – from 20 to 85% at 20°C. In accordance with the ЕИГА.4688.002-02 ИЭ and ЕИГА.468359.001-02 ИЭ the БФ-2 and БСШ-2 instruments must be stored for not over three years in their standard manufacturer’s containers at ambient air temperature varying from +5 to + 35 °C and relative humidity up to 75 % at 20°C. The SRPSC depot meets these requirements. At present the БСШ-2, БФ-2 and 11М156М units are incorporated in the FGB «Zarya» ground-based SPTA set. The inclusion in the manifesto of equipment delivery to the FGB on-board SPTA or for replacement purposes is made after release of the engineering solution as regards the necessity of the given units replacement aboard the FGB. The decision on the necessity of units replacement and on the deadlines of this work fulfillment is taken according to the results of units diagnostics aboard the FGB or - the Flight Control Center’s report of faults arising in these units. 4

5. FSUE Khrunichev SRPSC 2. Operations Involving FGB Thermal Conditions Control During PSS and OBCCS Units Replacement The results of assessment of FGB thermal state during PSS and OBCCS units replacement are stated in ReportNo. 233-12/60 ТО. This document contains the thermal mathematical models (TMM) of the construction and gas-liquid thermal regulation system (TRS) of the FGB ISS Russian Module. The TMM were tested to justify the assignment of elements thermal-physical parameters and to confirm the observance of thermal balance in the models.. TheТММ data were used to determine the thermal state of instrumental-and-power equipment in the course of power-supply system (PSS) instruments replacement, for the duration of which the FGB module was de-energized, there was no heat release and TRS was OFF, as well as to numerically model the process of FGB module warm-up after instruments replacement. Included in the report is the advice on instrumentation replacements.The thermal mathematical model of the construction of FGB ISS Russian Module is based on the algorithms of thermal balances method.The FGB construction model numbers 1103 elementsand 6960 surfaces.. Associated with the thermal model of FGB construction is the mathematical thermal model of the gas-liquid system that contains 110 elements simulating heat exchange in TRS units, 744 conductive and 111 non-linear links.The FGB geometrical model is based on the outline of the NASA/Boeing-presented product. 5

6. FSUE Khrunichev SRPSC FGB appearance 6

7. FSUE Khrunichev SRPSC NASA /Boeing) outline for sink temperature modeling . 7

8. FSUE Khrunichev SRPSC ПГО1 and ПГО2 assembled 8

9. FSUE Khrunichev SRPSC ПГО3 and ГА assembled 9

10. FSUE Khrunichev SRPSC • According to the results of operations carried out the following conclusions may be made:: • Developed is the thermal mathematical model of the construction and gas-liquid thermal regulation system of the ISS FGB Russian module. • Carried out are the TMM tests to justify the assignment of elements thermal-physical parameters and to confirm the observance of heat balance in the models. • Made is the thermal FGB module analysis for the «hot» and «cool» versions of sink temperatures assignment according to the «Boeing»-provided initial data in the standard mode of operation, during PSS units replacement and during warm-up. • It is ascertained that, for all variants of considered sink temperatures in “hot” and in “cool” conditions the gas-liquid TRSmay be employed after PSS units replacement.. With FGB de-energized and TRS turned off, the engines temperatures at ПГО2 and ГА do not fall for 10 hours below minus 3.7 °С, which is above the freezing point of «Triol» heat carrier pumped through these engines. «Triol» freezing temperature is minus 7 °С; • In the course of PSS units replacement work the air temperature in the ПГО3 section may rise up to ~33°С; 10

11. FSUE Khrunichev SRPSC • The analysis of the increase of the duration of PSS instrumentation replacement up to 32 hoursfor the “coolest mode” brought out the probability of critical elements (engines) temperature decrease below the limit value of minus 7 ° С, in which case extra measures would be necessary to warm-up the article.. Therefore one is advised to reduce the work time at minimum temperatures to 25… 27 hours.Another possible alternative is planning the PSS instrumentation replacement work during «warm modes of operation» • The use of flow-through ventilation makes it possible to provide within the shortest possible time the comfortable conditions for performance of work and to maintain them throughout the entire period of work fulfillment.A proposal is made to install 3 fan heaters in the specific FGB zones, and the respective calculations are currently available.These calculations make it clearthat the given method of thermal conditions maintenance can ensure the duration of repair work for as long as required. Currently under way are the operations to put the mentioned fan heaters into service (mounting, cables laying, power balance estimate). 11

12. FSUE Khrunichev SRPSC • 3. Operations to Prepare Equipment Replacement Procedures and to Arrange the Work Place During Units Replacement • At present the following procedures are ready: • Procedure of preparation for performance of operations and for operations performed after equipment replacement. • Electric power cut-off procedure. • БСШ-2 and БФ-2 replacement procedure • 11М156М.instrument replacement procedure. • The prepared procedures also cast light on the issues relating to work place arrangement during units replacement: • Lighting system. • Ventilation. • Air duct configuration. • Work place clean-up during performance of operations. 12

13. FSUE Khrunichev SRPSC Replacement of 11М156М, БШ-2, БСШ-2 Units

14. 77КМ.2120 - 4200 77КМ.2120 - 4210 ЦВ1-Х1 ССД307-Х1 ≠2100 - Х800 ≠100-А64-Х1 ВК1-Х1 ХТ1 МИМ1 ГА ГАПГО ВК2-Х1 FSUE Khrunichev SRPSC DIAGRAM OF VENTILATION AND LIGHTING FACILITIES CONNECTION IN THE WORK ZONE

15. FSUE Khrunichev SRPSC AIR DUCTS STANDARD LAY-OUT 15

16. Fsue Khrunichev SRPSC AIR DUCTS LAY-OUT DURING PERFORMANCE OF MAINTENANCE-AND-REPAIR WORK Air ducts laid from ЦВ1 to MRW zone 16

17. FSUE Khrunichev SRPSC 4. On-Board Diagnostics of PSS and OBCCS Units Measuring Block Diagram ИН-50 input cables БСШ-2 ИН-50 loads simulator «Х166/100» Instrument cable *MSO-19 oscilloscope «Х167/100» Laptop * Note– power is supplied to МSO-19 oscilloscope via USB-cable

18. FSUE Khrunichev SRPSC Testing Procedure Optimization on Systems Stand Instruments for БСШ-transient process take-off on systems stand «Molybdenum-M»

19. FSUE Khrunichev SRPSC Processing the Results • Oscilloscope records study is made with the use of the MS Excel program. It includes the following: • Signal mathematical processing — noise filtering and dimensional scaling; • Determining the signal data: oscillation period, measuring the first and second half-waves amplitude, finding the signal drop rate and transient process duration. Critical Parameters Estimate In accordance with the results of stored and statistically processed data consideration is given to the trend of in-time critical parameters change.Eventually one will be able to predict the critical parameter behaviour, for instance, it will be possible to estimate capacitors degradation rate and the time, when filter capacity value becomes critical. Space Crews Training, Diagnostic Equipment Delivery to FGB In the CTC (Cosmonauts’ Training Center) the ISS-36 crews (Yurchikhin F, Turin M) were trained to install diagnostic equipment and OBCS (on-board cable system). The diagnostic equipment is included in the plan of components delivery to the“ProgressM-21” transport spaceship (TSS) (24.11.2013).