Design and Certification of the Extravehicular Activity Mobility Unit (EMU) Water Processing Jumper

The Extravehicular Mobility Units (EMUs) onboard the International Space Station (ISS) experienced a failure due to cooling water contamination from biomass and corrosion byproducts forming solids around the EMU pump rotor. The coolant had no biocide and a low pH which induced biofilm growth and corrosion precipitates, respectively. NASA JSC was tasked with building hardware to clean the ionic, organic, and particulate load from the EMU coolant loop before and after Extravehicular Activity (EVAs). Based on a return sample of the EMU coolant loop, the chemical load was well understood, but there was not sufficient volume of the returned sample to analyze particulates. Through work with EMU specialists, chemists, (EVA) Mission Operations Directorate (MOD) representation, safety and mission assurance, astronaut crew, and team engineers, requirements were developed for the EMU Water Processing hardware (sometimes referred to as the Airlock Coolant Loop Recovery [A/L CLR] system). Those requirements ranged from the operable level of ionic, organic, and particulate load, interfaces to the EMU, maximum cycle time, operating pressure drop, flow rate, and temperature, leakage rates, and biocide levels for storage. Design work began in February 2005 and certification was completed in April 2005 to support a return to flight launch date of May 12, 2005. This paper will discuss the details of the design and certification of the EMU Water Processing hardware and its components.