Bionetics’ Role in the Trace Contaminant Control System (TCCS) and Ensuring Astronaut Safety
Background: The ISS Incident and the Need for Immediate Action
On November 23, 2024, an alarming incident unfolded aboard the International Space Station (ISS) when Russian cosmonauts reported a toxic smell on the Progress MS-29 cargo spacecraft. Launched from Baikonur Cosmodrome on November 21, the Progress MS-29 delivered routine fuel and food supplies to the team of astronauts aboard the ISS. The source of the toxic smell was identified to trace contaminants that posed a potential health risk to the crew. NASA and Roscosmos immediately activated air-scrubbing systems across the station to purify air. Additionally, NASA initiated the Trace Contaminant Control Subassembly (TCCS)—a critical air purification system, deployed to filter the contaminants, purify the air, and ensure the astronauts’ safety. The NASA controllers confirmed that the ISS atmosphere had returned to normal by November 24, 2024, due to the TCCS.
This case study explores The Bionetics Corporation’s involvement in developing, integration, and testing of the TCCS. It highlights how the company has helped NASA address this urgent situation.
The Challenge: Developing a Critical Air Purification System for Space
Space missions like the ISS utilize flawless life support systems to ensure the safety of astronauts. Any failure of life support systems on the ISS can endanger lives. The development of the TCCS used for purification was challenging. The aim was to create a system capable of air purification while withstanding the demands of a vacuum where temperature fluctuate drastically. The TCCS system designed to purify the air aboard the ISS comprised several complex components, including a Flow Meter (Developed by Bionetics), Electrical Interface Assembly, Charcoal Filter Bed Assembly, Catalytic Oxidizer Assembly, and Blower Assembly. These components had tight tolerances and demanding engineering specifications and required precise integration. Each part had to be perfectly engineered to work in a highly sensitive environment. Additionally, the system had to be assembled and tested under tight tolerances to meet NASA standards.
Learn More about Bionetics’ Role in the Trace Contaminant Control System (TCCS)
Case Study: Dual Probe Air In-Leak Detection for Condensers.
This case study highlights our team’s approach to resolving a complex air in-leakage issue in a condenser system with dual off-takes leading into a vacuum pump. The system’s design presented unique installation challenges, restricting the placement of probes to one RheoVac® probe in the individual vent line and another in the common vent line.
Key Equipment and Methods Used
- Dual RheoVac® Probe System: Used to monitor air in-leakage data and assess the impact of repairs on system performance.
- Helium Leak Detection:Applied to trace lines throughout the condenser and accurately pinpoint leak sources.
Key Insights and Results
By leveraging RheoVac® data, we narrowed the leak search to one side of the condenser, where we identified uncapped pipes as the primary source. After completing the necessary repairs, follow-up RheoVac® readings confirmed substantial improvements in air in-leak rates and system efficiency.
This case study demonstrates the power of combining RheoVac probes with helium leak detection technology to accurately diagnose and quantify air in-leakage issues in complex condenser systems.
Case Study: Single MSP System: Advanced Air In-Leak Detection for Condenser Units
This case study showcases the application of a single MSP (Multi Sensor Probe) system for air in-leak detection within a combined cycle condenser unit, featuring a single vent line and limited access. The unit, connected to a side-exhausting steam turbine, required a precise, strategic approach to detect and address air in-leaks effectively.
Key Equipment and Methods Used
- RheoVac® Single MSP System: Selected for its ability to perform in tight spaces with restricted access, making it ideal for this challenging environment.
- Helium Leak Detection: This method enabled comprehensive testing of the entire unit within a single day, allowing for quick and accurate leak detection.
Key Insights and Results
The data obtained from the RheoVac system identified an air in-leakage rate of 30 out of 50 CFM, located in the hood spray pipe, a high-vibration area prone to cracking across multiple units. Identifying this leak allowed for timely intervention, mitigating efficiency losses and pinpointing areas in need of structural reinforcement.
Case Study: Improved Air In-Leak Detection and Location Identification
This case study demonstrates the application of advanced air in-leak detection at a power plant to tackle issues related to high air in-leakage and low exhauster capacity. By utilizing cutting-edge diagnostic tools, our expert team was able to accurately identify and locate the sources of air in-leaks.
Key Equipment and Methods Used
- RheoVac® Multi Sensor Probes (MSP): These probes are essential for measuring critical metrics, including mass ratio, ACFM (Actual Cubic Feet per Minute), mass flow, and pressure. These measurements are crucial for detecting and quantifying air in-leakage.
- Helium Leak Detection: This technique is used to precisely locate specific leakage points within the system, ensuring accurate identification of issues.
Key Insights and Results
The data collected from the RheoVac MSP probes provided valuable insights into:
- Air in-leakage levels
- Vacuum Quality
- Volumetric and Mass flow rates
- Exhauster Pressure diagnostics
By applying these diagnostic tools, you can successfully pinpoint and address air in-leakage issues, improve plant efficiency and reducing performance losses. This case study highlights the diagnostic power of the RheoVac MSP in resolving air in-leakage problems and enhancing operational performance.
Case Study: Pump Capacity Analysis Using Bionetics RheoVac System
In this case study, a customer suspected that one of the Liquid Ring Vacuum Pumps (LRVP) in a power plant was underperforming, but lacked the data to confirm the issue. To solve this, the Bionetics RheoVac system was installed to gather critical performance data. After a pump swap, data comparison between the two pumps revealed that one pump was indeed degraded.
This case study demonstrates how using the pump capacity curve and data-driven insights can effectively monitor pump performance, prevent equipment failures, and improve overall plant efficiency. Learn how Bionetics RheoVac can help optimize your pump systems.
Case Study: Enhancing Pump Capacity with Bionetics RheoVac System
In this case study, we showcase how Bionetics successfully improved pump efficiency for a client facing performance challenges. Upon request for a helium leak audit, our advanced Bionetics RheoVac system was temporally installed to assess the pump capacity during the audit.
During the evaluation, our RheoVac condenser monitor quantified leaks in the bearing seals that were negatively impacting performance. By conducting thorough leak audits on multiple pumps, we provided targeted recommendations to re-establish optimal flow and enhance overall efficiency.
This case study highlights our commitment to leveraging innovative solutions to optimize pump systems and improve operational outcomes. Discover how Bionetics can help transform your pump efficiency and reliability.
“RheoVac Condenser Monitor Case Study | Identify and Repair Air In-Leakage”
In this video, Bionetics Corporation presents an in-depth case study of the RheoVac Condenser Monitor. We showcase the essential instrumentation used to detect and address air in-leakage sources in power plant condensers. Discover how this advanced technology can swiftly determine whether condenser issues are related to air leakage problems or if they stem from other causes, along with effective solutions to tackle these challenges.
Explore actionable strategies to minimize potential losses caused by high condenser pressure and improve operational efficiency.
🔧 Key Topics Covered:
- Identifying and repairing air in-leakage
- Evaluating condenser performance issues
- Solutions to prevent losses from high pressure
Watch now and enhance your condenser performance today!