Fluids and Combustion Facility (FCF) 1 GRC Project Manager: MSI/Robert Corban Chief Engineer: Dennis Rohn Safety Mission Assurance Lead: Bipin Patel NASA Customer: SLPSRA Key Contractor(s): ZIN Technologies Inc. Project Mission Statement: Operate and Sustain the Combustion Integrated Rack (CIR) and the Fluids Integrated Rack (FIR) on the International Space Station (ISS) thru GRC’s Telescience Support Center. GRC Scope: Planning, Operation and Coordination of FCF and associated payloads Mission Integration and Planning Telescience Support Center operations and maintenance Sustaining engineering on FCF Flight racks, spares, and GIU Project Life Cycle Schedule (Operations) MilestonesCIR LaunchCIR OpsFIR LaunchFIR OpsFIR CVBCIR FLEXFIR ARISFIR PACEFIR ACE-1CIR FLEX2Final Report Actual/ Baseline11/20082/20098/20091/20107/201011/20119/201110/20108/ N/A FIR Flight Rack on ISS CIR Flight Rack on ISS

2 Fluids and Combustion Facility Sustaining Eng. Project Manager: Robert Corban WBS  Status  Variances TECHNICAL: CIR failed to provide telemetry and boot the rack; FIT held with JSC; HD to be replaced; CIR/MDCA fuel dispensing #2 blockage needs to be tested; potential issue with the CIR ICM (did not have time to asses health prior to rack failure). Key Issue/ConcernPotential ImpactAction Plan Resolution Date FLEX - motor position error associated with the fuel reservoir dispenser #2 Operational Impact Science Delay 1.Perform on-orbit Trouble-shoot (encoder or blockage)√ 2.Replace Fuel Reservoir #1 to continue current Ops (6/19) √ 3.Hold ERB to determine best plan forward √ 4.Install new needle set and/or fuel reservoir√ 8/2012 Need to Verify blockage resolved Data Management operational time will be excessive for future planned payloads (i.e, ACME) Limited Science Return 1.Perform options Assessment for future planning√ 2.Develop proposal for additional funding to support upgrades to enhance science return. √ 3.Implement some of the “low hanging fruit” options in FY12 – put in new SOW for CY12. 8/2012 New IPSU-G Option to by-pass IOP CIR Illumination Control Module Communications Loss of primary FLEX2 science instrument 1.Additional testing is planned on resolution of CIR loss of MRDL/LRDL, maybe thermal issue 2.Accelerate spare for earliest manifest opportunity TBD (ATV4) – No On-orbit Spare 3.Manifest spare ICM even if issue resolved TBD New CostScheduleTechnicalMgmt. Current MonthGGRG Prior MonthYGGG  Key Issues

3 Combustion Integrated Rack (CIR) Loss of Health & Status Data  Loss of Telemetry (8/9) CIR was performing routine file management of previous day video from IPSU to IOP CIR lost all MDL and LRDL Telemetry (intermittent drop outs occurred several times starting about 5 minutes prior, with issues also with Read/Writes on sd0 Hard Drive) Controllers attempted a soft reset and then attempted a complete rack power cycle with no joy.  Failure Investigation Team (8/10) Attendance: CIR Payload Developer (PD), PIRATe console (MER payload integration console), POIC (POM and PSE), OB8, OZ, OC, EA and ISS Safety. Three probable causes: power failure in the Electrical Power Control Unit (EPCU), Hard Drive (HD) failure within the Input/Output Processor (IOP), and IOP failure EPCU ruled out because seeing similar power draws of a typical start up and smoke detector signals IOP HD (sd0) failure was determined to be the most likely cause (note: IOP boots up on sd0 HD) Recommendation: IOP HD R&R and Swap (sd1 drive to sd0 location); also attempt another startup; If HD R&R not successful, will look at IOP R&R (one unit spare on-orbit)  Status (8/15) CIR rack reboot was attempted 8/14. Health & Status was consistent with previous attempt. Hard drive swap 8/16. Rack power up and check out on Mon/Tues. First need to do s/w updates on both hard drives.

4 Fluids and Combustion Facility Sustaining Eng. Project Manager: Robert Corban WBS  Accomplishments CIR Operations: 24 successful test points over last two months. Replaced needle for fuel dispensing #2. Successfully removed and replaced the MDCA igniter tips FIR Operations: Crew inspection successful of the ACE-1 samples shortly after delivery by HTV-3. Completed 1st ACE particle sample over 9 day test period. R&R of 2 nd ACE Sample. Completed safety and engineering verifications for the FCF and MDCA SpaceX-1 flight manifest. Successful SpaceX-1 ERB/SAR and shipment of h/w to JSC. Performed crew increment training at JSC Supported the POIWG meeting at Huntsville, AL. Developed IPSU-G upgrade concept and cost ROM ($2.4M over 3 years) Completed the off-gas testing of the GCIP at MSFC  Planned Work Environmental testing of ATCU Fan Spare, ATCU Electronics Enclosure Unit, and the Smoke Detector spare CIR & FIR Filter Characterization testing GCIP Interface Functional Test CIR Droplet Deployment Viscosity Test Complete the MDCA Control Box spare unit Life Extension study for CIR and FIR TSC upgrade of the ISS video distribution

Fluids and Combustion Facility Sustaining Eng. Milestone Summary Next Milestone Risk SpaceX-1 Manifest SAR ERB (July 2012) Milestones (CY12)BaselineProjectedActualSchedule Variance HTV-3 Manifest SARMar 12 Apr 12HW shipped ATCU Fan/EEU SparesApr 12Jun 12 Assembly complete (March); Vibe (June); Thermal (June) MDCA Avionics Package spareMay 12Sept 12Assembly complete (April); Vibe complete (May); EMI complete (June); Thermal complete (June) TSC Video UpgradeJun 12Aug 12Equipment on Order; TV Install & Operating CIR’s Gas Chromatograph (GCIP)Jun 12Sept 12Assembly complete (March); Vibe complete (June); EMI complete (May); Thermal complete (June); Off Gas Complete ( Aug) LMM GIU upgradesAug 12 Technicians working to resolve issues Common IAM sparesNov 12 Assemble complete MDCA Color Camera replacementNov 12 Assemble in work DCM (2) & ICM sparesDec 12 ICM made higher priority LMM Control Box SpareDec 12 Most Parts Delivered Project is less than 1 month behind planProject is less than 2 months behind planProject is greater than 2 months behind plan Schedule Color Key 5 Project Milestone Schedule CY 2012 JFMAMJJASOND ATCU Fan/ EEU Spares DCMs & ICM GCIPTSC Video Upgrade LMM GIU Upgrade HTV-3 SAR IAM Spar e MDCA Avionics Pckg Spare LMM Control Box MDCA Color Camera

FCF Operations (over last two months) 6 Increment WeekCIRFIR 31/328 (6-21)No Ops 31/329 (6-28)Fuel Reservoir R&R; Fiber Arm R&R No Ops 31/3210 (7-5)FLEX-2 Data Points (16)No Ops 31/3211 (7-12)FLEX-2 Data Points (4)No Ops 31/3212 (7-19)No Ops 31/3213 (7-26)No Ops 31/3214 (8-2)No OpsACE Sample Pics & Installed; Ops began 31/3215 (8-9)Needle #2 R&R; Igniter R&R; FLEX-2 Data Points (4) ACE 1 st Sample Ops

ISS OCCUPANCY -- CIR RACK 1 July 2012 (Data through 30 June 2012) [POC: Robert Corban/GRC] MLPIMLPI Rack Moves, Maintenance, Annual Cert Trouble-shooting or Crew- time/ sched conflict Rack not Occupied Avg. Historical Usage Greater than 1-sigma below the mean occupancy 9% 2% CIR As-Run Data CIR Utilization Plan CIR Occupancy & Powered Ops (Powered Operational Time/Monthly Available Time) % Occupancy (Powered and Unpowered) FLEX FLEX FLEX-2 FLEX FLEX-2 ICE FLEX NASA Payload Powered Ops IP Payload Powered Ops NASA Payload Dwell Time IP Payload Dwell Time

ISS OCCUPANCY -- FIR RACK 1 July 2012 (Data through 30 June 2012) [POC: Robert Corban/GRC] MLPIMLPI Rack Moves, Maintenance, Annual Cert Trouble-shooting or Crew- time/ sched conflict Rack not Occupied Avg. Historical Usage Greater than 1- sigma below the mean occupancy 7% 0% FIR As-Run Data FIR Utilization Plan FIR Occupancy & Powered Ops (Powered Operational Time/Monthly Available Time) NASA Payload Powered Ops IP Payload Powered Ops % Occupancy (Powered and Unpowered) ARIS PACE BIO ACE-1A CVB-2 PACE BIO ACE-1A ARIS NASA Payload Dwell Time IP Payload Dwell Time

FCF Project Review Action Items Action Number Date Initiated Date Due Person(s) Responsible ProjectActions - Notes/Status Date Completed MSI-Rev-1808/26/1102/27/12CorbanFCF Evaluate the cost/schedule impact of replacing/upgrading the IPSUs. 08/15/12 MS-Rev-2501/19/1202/29/12CorbanFCFAdd State of Health Chart for FCF (Jalopy) 02/29/12

National Aeronautics and Space Administration CIR State of Health – Sustaining Engineering MDCA Subsystems Radiometer Avionics Box Color Camera Flex Consumables Flex 2 Consumables HiBMSSpare Focus Prism Spare ATCUSpare EPCUSpare IOPSpare DiagnosticsEnvironmentalAvionicsFacility Ground Systems (Nominal status only) Diagnostics Data Subsystems Environmental PRCU Avionics MDCA CIA GIU Facility Grey Shadow – Resolution in Work Red Shadow – Resolution Not in Work LLL-UV CIA FOMA Cal WFCAIPSU FDSS IPSU-A FOMA Control PaRIS SAMS TSH-ES Windows Seals Spare RECIR Pumps Spare GCIP Spare Fuel Stowed: 6 mo. Bottles Stowed: 9 mo.Spare OperationsSpares YELLOW – Spare On Ground RED – No Spare GREEN – Spare On Orbit YELLOW – Off-Nominal RED – Not Operational GREEN – Nominal Illumination Spare

National Aeronautics and Space Administration YELLOW – Spare On Ground RED – No Spare FIR State of Health – Sustaining Engineering GREEN – Spare On Orbit White LightSpare ATCUSpare EPCUSpare IOPSpare DiagnosticsEnvironmentalAvionicsFacility Ground Systems (Nominal status only) Diagnostics Data Subsystems Environmental PRCU Avionics Facility YELLOW – Off-Nominal RED – Not Operational GREEN – Nominal OperationsSpares Grey Shadow – Resolution in Work Red Shadow – Resolution Not in Work PACE ACE WFCAIPSU FSAP ARIS SAMS TSH-ES Seals Spare Microscope LMM Subsystems Control Box Camera X-Y Stage Objectives Samples Stowed: 0 m FDSS Spare

12 Project Manager’s Top Concerns o Increasing CIR (and FIR) data management efficiency (ACME needed for sure) o Maintaining trained and certified CIR and FIR Operations Team o Keep TSC operational and properly maintained with minimal staffing (CoNNeCT operations may impact need for more staffing) o Delays and gaps in FIR operations o Completing the Long-Term Life study (2028) for CIR and FIR o MDCA and LMM lack of sparing for long-term operations (FCF Sustaining Engineering inheriting the risk) o Failures of DCM and similar designed, ICM. No Spare ICM on-orbit. o Determination and funding of long-term upgrades to the CIR and FIR (Cameras, IPSUs, LMM, Software, etc)

Facility Risks Top 10 Risks LIKELIHOODLIKELIHOOD 5 4 F1 3 F2, F3 2 F4, F CONSEQUENCES Risk IDRisk TitleRisk StatementLCApproach F1 Technical Corban 10/04/2011 FCFSE: DCM LCTF failure Given the DCM LCTF fails on the CIR flight rack; then there is an inability to accomplish full FLEX2 science. 43Mitigate: Manifest DCM LCTF S/N2001 on the next DO period of performance. Add procurement and assembly of a second spare LCTF DCM to the DO period of performance. Status: Plans to add procurement and assembly of a second spare to the DO Close Date: 07/31/2012 F2 Technical Corban 10/18/2010 FCFSE: Unknown cause DCM failure Given that the LCTF DCM had a communication failure on the CIR aboard ISS without a known cause; there is a risk of subsequent DCM failures on remaining DCMs will occur. 33Mitigate: The flight spare on the ground is in the process of being certified for flight. This unit will need to be manifested as a flight spare to mitigate this risk. Status: There is currently additional troubleshooting going on as additional issues have arisen and need to be better understood to resolve.. Close Date : 02/29/2012 F3 Technical Corban 10/04/2011 FCFSE: LMM GIU does not fully emulate the flight unit Given that the LMM GIU does not fully emulate the flight unit;; the possibility exists that future LMM flight experiments will not operate correctly. 33 Mitigate: Plan is to review LMM GIU non-flight design issues and add task to update LMM GIU to the next DO period of performance. Status: Task has been added t the DO to upgrade to LMM GIU. Close Date: 07/02/2012 F4 Technical Corban 02/10/2010 FCFSE: Lack of critical spares aboard ISS Given that there is a lack of critical spares aboard the ISS; then there is the possibility that a lack of meeting all science requirements will occur. 23 Mitigate: A priority list for flight critical spares has been established. ZIN has shipped and manifested flight White Light EPCU IOP FSAP. Additional flight h/w for ULF5 include: IPSU-A FCU Q-Imaging camera and IPSU (Remora). ZIN is in the process of verifying additional spare hardware(FIR &CIR velocity probe White Light lamps IPSU-A FCU and an IAM. Status: Working to add next set of spares to DO; will include spare fiber-optic cable to backfill for suspect cable on-orbit Close Date: 04/06/2012 F5 Technical Corban 02/10/2010 FCFSE: IOP removable hard drive shelf life Given that the IOP removable hard drives have a limited shelf life; then there is the possibility that these hard drives won't work over time and the FIR and CIR racks will not be able to provide support for their payloads to perform science operations will occur. 23 Watch: Awaiting to see if funding issues will be resolved. Status: Funding for new design functional model IOP hard drives in the current DO. Close Date: 12/31/2012 CriticalityL x C Trend High  Decreasing (Improving)  Increasing (Worsening)  Unchanged * New since last month Med Low Approaches: Mitigate, Watch, Accept, Research