Long-term operation of "Orlan" space suits in the "Mir" orbiting station: experience obtained and its application

The started assembly of the International Space Station (ISS) and its further operation will call for a great number of extravehicular activity sorties (EVA) to be performed by ISS crews. Therefore, of great importance is to make use of the EVA experience gained by cosmonauts in the process of 15-year operation of the Mir orbiting station (OS). Over the 15-year period, Mir crewmembers wearing Orlan type semi-rigid space suits have accumulated 158 man/sorties from the orbiting station. Crewmembers used 15 suits in orbit and some of the suits were in operation for more than 3 years. The paper presents principal design features, which provide effective and safe operation of orbit-based suits, and briefly describes procedures for preparation and maintenance of suit systems, which ensure long-term operation of space suit in orbit. The paper gives results of the space suit modifications, presents suit performance characteristics and lists novel or upgraded components of the space suit and its systems. The paper also summarizes improvements in the Orlan type suits described in some earlier publications. They refer, in the first run, to the improvement of space suit operations characteristics and reliability, and the utilization of the Orlan type space suit in the ISS program. The paper analyses the experience gained and drawbacks detected and observations made, and gives statistical data on long-term space suit operations aboard the Mir station. The paper reviews certain problems in the process of EVAs performed from the station, and describes the ways of their solution as applied to the further utilization of the suit within the ISS program.     

EVA 2000: a European/Russian space suit concept

For the European manned space activities an EVA space suit system was being developed in the frame of the Hermes Space Vehicle Programme of the European Space Agency (ESA). The space suit was to serve the needs for all relevant extravehicular activities for the Hermes Columbus operations planned to begin in 2004. For the present Russian manned space programme the relevant EVAs are performed by the Orlan-DMA semi-rigid space suit. The origin of its development reaches back to the 1970s and has since been adapted to cover the needs for extravehicular activities on Salyut and MIR until today. The latest modification of the space suit, which guaranteed its completely self-contained operation, was made in 1988. However, Russian specialists considered it necessary to start developing an EVA space suit of a new generation, which would have improved performance and would cover the needs by the turn of the century and into the beginning of the next century. Potentially these two suit developments could have a lot in common based on similarities in present concepts. As future manned space activities become more and more an international effort, a safe and reliable interoperability of the different space suit systems is required. Based on the results of the Munich Minister Conference in 1991, the European Space Agency and the Russian Space Agency agreed to initiate a requirements analysis and conceptual design study to determine the feasibility of a joint space suit development, EVA 2000. The design philosophy for the EVA 2000 study was oriented on a space suit system design of: space suit commonality and interoperability; increased crew productivity and safety; increase in useful life and reduced maintainability; reduced development and production cost. The EVA 2000 feasibility study was performed in 1992, and with the positive conclusions for EVA 2000, this approach became the new joint European Russian EVA Suit 2000 Development Programme. This paper gives an overview of the results of the feasibility study and presents the joint requirements and the proposed design concept of a jointly developed European Russian space suit.     

Main problems of the Russian Orlan-M space suit utilization for EVAs on the ISS

In the recent years the Russian Orlan-M space suits have been improved as applied to their operational requirements for the ISS. A special attention is paid to enhancement of EVA crew efficiency and safety. The paper considers the main problems regarding specific features of the Russian space suit operation in the ISS, and analyses measures on their solution. In particular, the problems associated with the following are considered: enhancement of the anthropometric range for the EVA crewmembers; use of some US EMU elements and unified NASA equipment elements; Orlan-M operation support in the wide range of the ISS thermal conditions; use of Simplified Aid For Extravehicular activity Rescue (SAFER) designed as a self-rescue device, which will be used for an EVA crewmember return in the event that he (she) breaks away inadvertently from the ISS surface. The paper states the main space suit differences with reference to solution of the above problems. The paper presents briefly the design of space suit arms developed for crewmembers with small anthropometric parameters, as well as peculiarities and test results for the gloves with enhanced thermal protection. Measures on further space suit development with the purpose to improve its performances are considered.     

Evaluation of safety of hypobaric decompressions and EVA from positions of probabilistic theory

Formation and subsequent evolution of gas bubbles in blood and tissues of subjects exposed to decompression are casual processes in their nature. Such character of bubbling processes in a body predetermines probabilistic character of decompression sickness (DCS) incidence in divers, aviators and astronauts. Our original probabilistic theory of decompression safety is based on stochastic models of these processes and on the concept of critical volume of a free gas phase in body tissues. From positions of this theory, the probability of DCS incidence during single-stage decompressions and during hypobaric decompressions under EVA in particular, is defined by the distribution of possible values of nucleation efficiency in "pain" tissues and by its critical significance depended on the parameters of a concrete decompression. In the present study the following is shown: 1) the dimensionless index of critical nucleation efficiency for "pain" body tissues is a more adequate index of decompression stress in comparison with Tissue Ratio, TR; 2) a priory the decompression under EVA performed according to the Russian protocol is more safe than decompression under EVA performed in accordance with the U.S. protocol; 3) the Russian space suit operated at a higher pressure and having a higher "rigidity" induces a stronger inhibition of mechanisms of cavitation and gas bubbles formation in tissues of a subject located in it, and by that provides a more considerable reduction of the DCS risk during real EVA performance.     

EVA Suit 2000: a joint European/Russian space suit design

A feasibility study in 1992 showed the benefits of a common European Russian space suit development, EVA Suit 2000, replacing the Russian space suit Orlan-DMA and the planned European Hermes EVA space suit at the turn of the century. This EVA Suit 2000 is a joint development initiated by the European Space Agency (ESA) and the Russian Space Agency (RKA). The main objectives of this development program are: first utilization aboard the Russian Space Station MIR-2; performance improvement with respect to current operational suits; development cost reduction. Russian experience gained with the present extravehicular activity (EVA) suit on the MIR Space Station and extensive application of European Technologies will be needed to achieve these ambitious goals. This paper presents the current status of the development activities, the space suit system design and concentrates in more detail on life support aspects. Specific subjects addressed will include the overall life support conceptual architecture, design features, crew comfort and operational considerations.     

Ensuring of long operation life of the orbiting station EVA space suit

Russia has gained a lot of experience in operating the space suits (SS) during the extravehicular activities (EVA) by the crews of SALYUT-6, SALYUT-7 and MIR orbiting stations. A total of 21 Orlan-type space suits of various models were operated onboard the orbiting stations (OS) during almost 20 years period. Some of these space suits served up to 3 years in orbit. The paper reviews special features of long SS operation (without return to the Earth) onboard an orbiting station as well as the problems associated with SS repeated use by several crews. An analysis of measures to support solving of the problems of SS long stay and reliable operation onboard the orbiting station is made: selection of a corresponding SS type and separate elements design; selection of the materials; routine and preventive maintenance; development tests. The advantages of the space suit of a semi-rigid type for solving the above problems are shown. The paper includes a short analysis of space suits' operation onboard the Russian orbiting station MIR, and some restuts of inspection of the Orlan-DMA space suit returned to the Earth from orbit by STS-79 alter long operation in orbit. Recommendations on further improvement of the space suits for EVA operations in the International Space Station (ISS) are given.     

The dynamics of blood biochemical parameters in cosmonauts during long-term space flights

Most of the previously obtained data on cosmonauts' metabolic state concerned certain stages of the postflight period. In this connection, all conclusions, as to metabolism peculiarities during the space flight, were to a large extent probabilistic. The purpose of this work was study of metabolism characteristics in cosmonauts directly during long-term space flights. In the capillary blood samples taken from a finger, by "Reflotron IV" biochemical analyzer, "Boehringer Mannheim" GmbH, Germany, adapted to weightlessness environments, the activity of GOT, GPT, CK, gamma-GT, total and pancreatic amylase, as well as concentration of hemoglobin, glucose, total bilirubin, uric acid, urea, creatinine, total, HDL- and LDL cholesterol, triglycerides had been determined. HDL/LDL-cholesterol ratio also was computed. The crewmembers of 6 main missions to the "Mir" orbital station, a total of 17 cosmonauts, were examined. Biochemical tests were carried out 30-60 days before launch, and in the flights different stages between the 25-th and the 423-rd days of flights. In cosmonauts during space flight had been found tendency to increase, in compare with basal level, GOT, GPT, total amylase activity, glucose and total cholesterol concentration, and tendency to decrease of CK activity, hemoglobin, HDL-cholesterol concentration, and HDL/LDL - cholesterol ratio. Some definite trends in variations of other determined biochemical parameters had not been found. The same trends of mentioned biochemical parameters alterations observed in majority of tested cosmonauts, allows to suppose existence of connection between noted metabolic alterations with influence of space flight conditions upon cosmonaut's body. Variations of other studied blood biochemical parameters depends on, probably, pure individual causes.     

The feasibility of Doppler monitoring during EVA

During extravehicular activities (EVA) outside the spacecraft, astronauts have to work under reduced pressure in a space suit. This pressure reduction induces the risk of decompression sickness (DCS) by the formation of gas bubbles from excess nitrogen dissolved in the organism by breathing air at normal pressure. Under laboratory conditions the gas bubbles moving in the blood stream can be detected by the non-invasive ultrasonic Doppler method. By early detection of excessive bubble formation the development of DCS symptoms may be prevented by early application of preventative measures. The method could also be useful when applied in the space suit in order to compare the results of laboratory tests with operational results, because there is a discrepancy according to the DCS risk of laboratory experiments and actual EVA missions, where no symptoms have been reported yet. A prototype Doppler sensor has been developed and implemented in the Russian Orlan suit. To investigate the feasibility of this method under simulated space conditions, the equipment has been used in a series of 12 thermovacuum chamber tests with suited subjects, where intravenous bubble formation was compared to unsuited control experiments. In more than 50% of the suited tests good Doppler recordings could be achieved. In some cases with unsatisfying results the signal could be improved by breathholding. Although the results do not yet allow any conclusion about a possible difference between suited and unsuited subjects due to the small number of tests performed, the method proved its feasibility for use in EVA suits and should be further developed to enhance the safety of EVA procedures.     

Diuretic as a means for rapid adaptation to weightlessness

In a number of flights, cosmonauts and astronauts have experienced aggravation of their health status and general condition in the initial hours and days in a weightless environment. One of the trigger mechanisms for the onset of these unfavourable conditions at the start of space flight is a redistribution of body fluids and a blood shift towards the head. To ensure controlled hypohydration as a countermeasure to the deleterious effects of 0-g and to investigate the feasibility to control adaptation, six cosmonauts were administered lasix once a day during the first 3 days of a mission. All data of the experiment (correction test, questionnaire, hematocrit) were recorded on a special form in the logbook and transmitted to the control centre for processing. Results showed that the diuretic weakened the sensation of discomfort and improved the cosmonauts' general condition. Objective indices of the correction test indicate an increased work ability of cosmonauts. After hypohydration, circulating plasma volumes in the group were reduced by 6.8 + 1.0% on average.     

EVA: European plans

The current status of European EVA (extravehicular activity) plans is reviewed. The major difference to already existing EVA scenarios in U.S.A. and Soviet Union consists in the adoption of a higher suit pressure, namely 500 hPa. The results of a study concerned with the physiological consequences of this adoption are presented, including recommendations for protective procedures and their necessary experimental validation. A certain discrepancy between laboratory experimental decompression data and EVA operational results is discussed, leading to the identification of several items which may influence space decompression. Microgravity and the influence of the space suit itself are most likely factors in the explanation of this discrepancy, and both experimental procedures and technological developments are proposed to clarify their role for the future design of EVA procedures.     

The EVA space suit development in Europe

The progress of the European EVA space suit predevelopment activities has resulted in an improved technical reference concept, which will form the basis for a start of the Phase C/D development work in 1992. Technology development work over the last 2 years has resulted in a considerable amount of test data and a better understanding of the characteristics and behaviour of individual parts of the space suit system, in particular in the areas of suits' mobility and life support functions. This information has enabled a consolidation of certain design features on the one hand, but also led to the challenging of some of the design solutions on the other hand. While working towards an improved situation with respect to the main design drivers mass and cost, the technical concept has been improved with respect to functional safety and ease of handling, taking the evolving Hermes spaceplane requirements into consideration. Necessary hardware and functional redundancies have been implemented taking the operational scenario with Hermes and Columbus servicing into consideration. This paper presents the latest design status of the European EVA space suit concept, with particular emphasis on crew safety, comfort and productivity, in the frame of the predevelopment work for the European Space Agency.     

Improvement of the extravehicular activity suit for the MIR orbiting station program

Since 1977, EVA suits of the semi-rigid type have been used to support sorties from Russian orbiting stations. Currently, within the MIR station program, the Orlan-DMA, the latest modification of the Orlan semi-rigid EVA suit is used by crewmembers. Quite some experience has been gained by Russia in operations of the Orlan type suits. It has proved the advantages of the EVA suit of a semi-rigid configuration, featuring donning/doffing through a hinged backpack door with a built-in life support system. Meanwhile there were some wishes and comments from the crewmembers addressed to the enclosure design and some LSS components. Currently a number of ways and methods are being developed to improve operational characteristics of the suit as well as to enhance its reliability and lifetime. The forthcoming EVAs to be performed by the STS-MIR crewmembers and future EVAs from the common airlock of the International Space Station Alpha make implementation of the planned improvements even more consistent. The paper analyzes the experience gained in the Orlan-DMA operation and discusses planned improvements in light of the forthcoming activities. In particular the Orlan enhancement program is aimed to make the donning/doffing easier, enhance enclosure mobility, improve the condensate removal unit, increase the CCC (Contamination Control Cartridge) operation time and simplify the onboard subsystem design concept.     

舱外活动系统述评

舱外活动（EVA）系统可分为3部分：1）航天员装备系统,包括舱外航天服（EVA航天服）、安全系绳和机动装置;2）空间支持系统,包括气闸、约束装置、EVA工具、在轨训练设施、遥控自动操作装置,以及表面运输工具;3）地面试验、训练与保障系统,包括减重／失重设施、热／真空试验舱、虚拟现实模拟系统、星体表面模拟场地,以及任务保障设施。文章阐述EVA系统的组成与功能,评述EVA技术现状及发展趋势。     

Design to safety: experience and plans of the Russian space suit programme

The paper presents the analysis of the Russian experience gained in the operations of Salyut-6, 7 and Mir orbital stations. The main factors determining their effectiveness and safety are considered and the main requirements to the EVA suit, as the most important tool for the EVA, are formulated.     

The Soviet/Russian spacesuit history: Part III—The European connection

The European spacesuit system (ESSS) initiated by the European Space Agency (ESA) in the late 1980s had many similarities with the Soviet/Russian ORLAN spacesuit system, due to the Hermes system requirements. First, direct contacts in 1989 permitted closer comparison of the two suit systems, and soon the ORLAN manufacturer Zvezda could be contracted as support to the European spacesuit team. In particular, the suit enclosure design and predevelopment testing and operational analysis were performed in close cooperation between Zvezda and the European team under Dornier.

With the changing system requirements and a closer cooperation between ESA and the new Russian Space Agency (RKA) a new joint spaceplane/stations mission scenario came about. This scenario could be served by one spacesuit system, EVA SUIT 2000, which was to be jointly developed by a team headed by Zvezda and Dornier for ESA and RKA. ORLAN-DMA and ESSS experience and hardware were the initial platforms for these activities to create a new generation spacesuits for the Mir 2 and later the ISSs.

A suit demonstrator was manufactured and tested by the end of 1994 when ESA stopped its spacesuit development activities and the joint EVA SUIT 2000 project was terminated. However, many of the features designed, manufactured and tested for the EVA SUIT 2000 were then implemented by Zvezda in the new Russian spacesuit system ORLAN-M, now in full operation onboard the ISS.     

The Soviet-Russian space suits a historical overview of the 1960's

The development of protective suits for space use started with the Vostok-suit SK-1, first used by Yu. Gagarin on April 12, 1961, and then used on all subsequent Vostok-flights. The technical background for the design of these suits was the work on full pressure protective suits for military pilots and stratospheric flights in the 1930's through 50's. The Soviet-Russian space programme contains a large number of 'firsts', and one of the most well known is the first EVA by Leonov in 1965. This event is also the starting point for a long series of space suit development for Extravehicular Activities over the last 35 years. The next step to come was the transfer in void space of crew members between the two spacecraft Soyuz 4 and 5 in 1969. As has later become known this was an essential element in the planned Soviet lunar exploration programme, which in itself required a new space suit. After the termination of the lunar programme in 1972, the space suit development concentrated on suits applicable to zero-gravity work around the manned space stations Salyut 6, Salyut 7 and MIR. These suits have become known as the ORLAN-family of suits, and an advanced version of this suit (ORLAN-M) will be used on the International Space Station together with the American EMU. This paper covers the space suit development in the Soviet Union in the 1960's and the experience used from the pre-space era.     

舱外航天服冷热电一体化系统性能分析

文章提出了一种舱外航天服冷热电一体化(Combined Cooling-Heating-Power,CCHP)系统,该系统的主要组件有质子交换膜燃料电池、热驱制冷装置、金属氢化物储氢装置和辐射器等.在冷热电一体化系统的冷电匹配方法上提出了“以电定冷”方案,按照该方案计算了一组典型工况下系统的工作状态,分析了燃料电池的工作温度、工作电流密度和工作压力对系统质量和消耗性工质损失的影响.结果表明,该舱外航天服冷热电一体化系统在质量大小方面可以接受,在消耗性工质损失方面比水升华器冷源/蓄电池电源方案小得多;且降低燃料电池工作温度和压力、增大燃料电池工作电流密度,均能够减小系统质量、降低系统消耗性工质损失.     

A glimpse from the inside of a space suit: What is it really like to train for an EVA?

The beauty of the view from the office of a spacewalking astronaut gives the impression of simplicity, but few beyond the astronauts, and those who train them, know what it really takes to get there. Extravehicular Activity (EVA) training is an intense process that utilizes NASA’s Neutral Buoyancy Laboratory (NBL) to develop a very specific skill set needed to safely construct and maintain the orbiting International Space Station. To qualify for flight assignments, astronauts must demonstrate the ability to work safely and efficiently in the physically demanding environment of the space suit, possess an acute ability to resolve unforeseen problems, and implement proper tool protocols to ensure no tools will be lost in space. Through the insights and the lessons learned by actual EVA astronauts and EVA instructors, this paper will take you on a journey through an astronaut’s earliest experiences working in the space suit, termed the Extravehicular Mobility Unit (EMU), in the underwater training environment of the NBL. This work details an actual Suit Qualification NBL training event, outlines the numerous challenges the astronauts face throughout their initial training, and the various ways they adapt their own abilities to overcome them. The goal of this paper is to give everyone a small glimpse into what it is really like to work in a space suit.     

Suited crewmember productivity

Analysis of the extravehicular activity (EVA) sortie experience gained in the former Soviet Union and physiologic hygienic aspect of space suit design and development shows that crewmember productivity is related to the following main factors: -space suit microclimate (gas composition, pressure and temperature); -limitation of motion activity and perception, imposed by the space suit; -good crewmember training in the ground training program; -level of crewmember general physical performance capabilities in connection with mission duration and intervals between sorties; -individual EVA experience (with accumulation) at which workmanship improves, while metabolism, physical and emotional stress decreases; -concrete EVA duration and work rate; -EVA bioengineering, including selection of tools, work station, EVA technology and mechanization.