Maintenance, reliability and policies for orbital space station life support systems

The performance of productive work on space missions is critical to sustaining a human presence on orbital space stations (OSS), the Moon, or Mars. Available time for productive work has potentially been impacted on past OSS missions by underestimating the crew time needed to maintain systems, such as the Environmental Control and Life Support System (ECLSS). To determine the cause of this apparent disconnect between the design and operation of an OSS, documented crew time for maintenance was collected from the three Skylab missions and Increments 4–8 on the International Space Station (ISS), and the data was contrasted to terrestrial facility maintenance norms. The results of the ISS analysis showed that for four operational and seven functional categories, the largest deviation of 60.4% over the design time was caused by three of the four operational categories not being quantitatively included in the design documents. In a cross category analysis, 35.3% of the crew time was found to have been used to repair air and waste handling systems. The air system required additional crew time for maintenance due to a greater than expected failure rate and resultant increased time needed for repairs. Therefore, it appears that the disconnect between the design time and actual operations for ECLSS maintenance on ISS was caused by excluding non-repair activities from the estimates and experiencing greater than expected technology maintenance requirements. Based on these ISS and Skylab analyses, future OSS designs (and possibly lunar and Martian missions as well) should consider 3.0–3.3h/day for crews of 2 to 3 as a baseline of crew time needed for ECLSS maintenance.