structural:reformatting
Repairs

Orbital Replacement Units (ORUs) are spare parts that can be readily replaced when a unit either passes its design life or fails. Examples of ORUs are pumps, storage tanks, controller boxes, antennas, and battery units. Some units can be replaced using robotic arms. Most are stored outside the station, either on small pallets called ExPRESS Logistics Carriers (ELCs) or share larger platforms called External Stowage Platforms (ESPs) which also hold science experiments. Both kinds of pallets provide electricity for many parts that could be damaged by the cold of space and require heating. The larger logistics carriers also have local area network (LAN) connections for telemetry to connect experiments. A heavy emphasis on stocking the USOS with ORU's occurred around 2011, before the end of the NASA shuttle programme, as its commercial replacements, Cygnus and Dragon, carry one tenth to one quarter the payload.

Unexpected problems and failures have impacted the station's assembly time-line and work schedules leading to periods of reduced capabilities and, in some cases, could have forced abandonment of the station for safety reasons. Serious problems include an air leak from the USOS in 2004, the venting of fumes from an Elektron oxygen generator in 2006, and the failure of the computers in the ROS in 2007 during STS-117 that left the station without thruster, Elektron, Vozdukh and other environmental control system operations. In the latter case, the root cause was found to be condensation inside electrical connectors leading to a short circuit.

During STS-120 in 2007 and following the relocation of the P6 truss and solar arrays, it was noted during unfurling that the solar array had torn and was not deploying properly. An EVA was carried out by Scott Parazynski, assisted by Douglas Wheelock. Extra precautions were taken to reduce the risk of electric shock, as the repairs were carried out with the solar array exposed to sunlight. The issues with the array were followed in the same year by problems with the starboard Solar Alpha Rotary Joint (SARJ), which rotates the arrays on the starboard side of the station. Excessive vibration and high-current spikes in the array drive motor were noted, resulting in a decision to substantially curtail motion of the starboard SARJ until the cause was understood. Inspections during EVAs on STS-120 and STS-123 showed extensive contamination from metallic shavings and debris in the large drive gear and confirmed damage to the large metallic bearing surfaces, so the joint was locked to prevent further damage. Repairs to the joints were carried out during STS-126 with lubrication and the replacement of 11 out of 12 trundle bearings on the joint.

In September 2008, damage to the S1 radiator was first noticed in Soyuz imagery. The problem was initially not thought to be serious. The imagery showed that the surface of one sub-panel had peeled back from the underlying central structure, possibly because of micro-meteoroid or debris impact. On 15 May 2009, the damaged radiator panel's ammonia tubing was mechanically shut off from the rest of the cooling system by the computer-controlled closure of a valve. The same valve was then used to vent the ammonia from the damaged panel, eliminating the possibility of an ammonia leak. It is also known that a Service Module thruster cover struck the S1 radiator after being jettisoned during an EVA in 2008, but its effect, if any, has not been determined.

In the early hours of 1 August 2010, a failure in cooling Loop A (starboard side), one of two external cooling loops, left the station with only half of its normal cooling capacity and zero redundancy in some systems. The problem appeared to be in the ammonia pump module that circulates the ammonia cooling fluid. Several subsystems, including two of the four CMGs, were shut down.

Planned operations on the ISS were interrupted through a series of EVAs to address the cooling system issue. A first EVA on 7 August 2010, to replace the failed pump module, was not fully completed because of an ammonia leak in one of four quick-disconnects. A second EVA on 11 August removed the failed pump module. A third EVA was required to restore Loop A to normal functionality.

The USOS's cooling system is largely built by the US company Boeing, which is also the manufacturer of the failed pump.

The four Main Bus Switching Units (MBSUs, located in the S0 truss), control the routing of power from the four solar array wings to the rest of the ISS. Each MBSU has two power channels that feed 160V DC from the arrays to two DC-to-DC power converters (DDCUs) that supply the 124V power used in the station. In late 2011, MBSU-1 ceased responding to commands or sending data confirming its health. While still routing power correctly, it was scheduled to be swapped out at the next available EVA. A spare MBSU was already on board, but a 30 August 2012 EVA failed to be completed when a bolt being tightened to finish installation of the spare unit jammed before the electrical connection was secured. The loss of MBSU-1 limited the station to 75% of its normal power capacity, requiring minor limitations in normal operations until the problem could be addressed.

On 5 September 2012, in a second six-hour EVA, astronauts Sunita Williams and Akihiko Hoshide successfully replaced MBSU-1 and restored the ISS to 100% power.

On 24 December 2013, astronauts installed a new ammonia pump for the station's cooling system. The faulty cooling system had failed earlier in the month, halting many of the station's science experiments. Astronauts had to brave a "mini blizzard" of ammonia while installing the new pump. It was only the second Christmas Eve spacewalk in NASA history.