Introduction to Risk Assessment in Engineering: With Application to Heat Shield Reliability Modeling...
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![Page 1: Introduction to Risk Assessment in Engineering: With Application to Heat Shield Reliability Modeling Presented by: Austin Howard University of Idaho Mechanical.](https://reader036.fdocuments.us/reader036/viewer/2022062714/56649d595503460f94a389d6/html5/thumbnails/1.jpg)
Introduction to Risk Assessment in Engineering: With Application to Heat Shield Reliability Modeling
Presented by:
Austin HowardUniversity of IdahoMechanical Engineering Dept.Idaho Space Grant Consortium
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2Austin Howard
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3Austin Howard
OutlineOutline
Introduction Failure Mode Effect Analysis Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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Purpose of This TalkPurpose of This Talk
Describe importance of risk assessment
Introduction to key tools, processes, and concepts related to risk analysis
Provide context with case study based on experiences at summer internship at NASA Ames 2006
Note: Risk assessment is its own discipline and therefore it is outside the scope of this talk to show you how to create/evaluate risk models
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Definition: RiskDefinition: Risk
Risk: “The combination of the frequency, or probability, of
occurrence and the consequence of a specified hazardous event” -www.bees.unsw.edu.au/ohs/definitions.html
One of many ways to calculate risk: Risk=(Probability of failure)x(Severity of the Consequence)
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6Austin Howard
RiskRisk
Risk is also a board game:
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Risk vs. UnreliabilityRisk vs. Unreliability
Risk is not the same as Unreliability Reliability: Probability that a device will function without
failure over a specified period of time or amount of usage
Reliability is one of the (but not the only) factors that contributes to system risk
Reliability analysis is often used interchangeably with risk, but they are two different concepts
Engineers often present reliability statistics rather than risk values due to difficulty of measuring and comparing consequence severity
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Risk vs. SafetyRisk vs. Safety
Judging Risk is a quantitative activity grounded by testing, and physical
modeling
Judging Safety is a qualitative, political activity
You must have a safety standard to judge system risk against otherwise risk is a relatively meaningless value in decision making and design assessment
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Deterministic vs Non-DeterministicDeterministic vs Non-Deterministic
Deterministic model-model behaves predictably In other words, for a constant input, you will always get
the same output
Non-deterministic model-model with one or more choice points where different continuations are possible In other words for a constant input, you will not always
get the same output Requires input from one or more: user, global variables,
hardware timer, random numbers, stored data…
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Purpose of Risk AssessmentPurpose of Risk Assessment
Purpose of Risk Assessment: Answering and effectively communicating the following questions/considerations:
Haimes, Yacov Y. Risk Modeling, Assessment, and Management.Hoboken, NJ, USA: John Wiley & Sons, Incorporated, 2005. p 23.http://site.ebrary.com/lib/uidaho/Doc?id=10114200&ppg=47
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Reputation
Customer Satisfaction/Safety
Warranty Costs
Repeat Business
Cost Analysis
Customer Requirements
Competitive Advantage
Importance of Risk AnalysisImportance of Risk Analysis
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Cont…Cont…
Reduce long term cost
http://klabs.org/DEI/References/design_guidelines/analysis_series/1314msfc.pdf
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ProcessProcess
Risk Communication/Safety Check
Component
Sub System
System
Model and/or Test
Sub System Tree(Fault and/or Event)
Risk AssessmentEx. FMEA
System Tree(s)(Fault and/or Event)
Sub System Tree(Fault and/or Event)
Model and/or Test
Model and/or Test
Model and/or Test
Production
PassRisk
Mitigation
Fail
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OutlineOutline
Introduction Failure Mode Effect Analysis (DFMEA) Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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Failure Mode Effect Analysis Failure Mode Effect Analysis (FMEA)(FMEA)
Other wise known as: Failure Mode Effect Criticality Analysis (FMECA) Design Failure Mode Effect Analysis (DFMEA) Process Failure Mode Effect Analysis (PFMEA)
Purpose Define and guide a logical design process Identify, quantify, and reduce design risk Provide a traceable document for design and development Justify design activities Provide a means for continuous product improvement
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Cont…Cont…
Combines Possible Failure: Severity (rate 1-10) Occurrence (rate 1-10) Detect-ability (rate 1-10)
Product of the parameters is called the RPN, this value describes the overall risk of each failure mechanism
High RPN numbers = high risks Focus on these failure mechanisms first in risk mitigation
process
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FMEA ProcessFMEA Process
http://www.qualitytrainingportal.com/resources/fmea/fmea_process.htm
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Example: FMEAExample: FMEA
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OutlineOutline
Introduction Failure Mode Effect Analysis (DFMEA) Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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Fault TreesFault Trees
At the top of a fault tree is a failure
Under the tree are all the possible faults that could lead to the top failure
Fault trees are used for viewing a system and the interactions between faults and possible paths to a failure
Fault trees can be built with software and combined with probabilities to produce reliability estimates
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Cont…Cont…
Paths from bottom to top of tree are termed cutsets, the shortest cutset is the minimum cutset
Symbols used:
Haimes, Yacov Y. Risk Modeling, Assessment, and Management.Hoboken, NJ, USA: John Wiley & Sons, Incorporated, 2005. p 530.http://site.ebrary.com/lib/uidaho/Doc?id=10114200&ppg=554
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Example: Fault TreeExample: Fault Tree
http://safety.transportation.org/htmlguides/implement/ProcAppJ.htm
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OutlineOutline
Introduction Failure Mode Effect Analysis (DFMEA) Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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Event TreesEvent Trees
Goal of event tree to determine the probability of an event based on the
outcomes of each event in the chronological sequence of events leading up to it
By analyzing all possible outcomes using event tree analysis, you can determine the percentage of outcomes which lead to the desired result
Event trees can be built with software to produce reliability estimates
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Example: Event TreesExample: Event Trees
http://www.ece.cmu.edu/~koopman/des_s99/safety_critical/
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OutlineOutline
Introduction Failure Mode Effect Analysis (DFMEA) Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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TestingTesting
AdvantagesCan illuminate overlooked failure mechanismsSome situations cannot be modeled accurately with
current physical understanding Turbulence
LimitationsExpensiveTime consumingNeed lots of data to be meaningful
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How Modeling Produces How Modeling Produces UnreliabilityUnreliability
Load Probability Curve
Design Probability Curve
Area=Probability of failure
Mean LoadMean Design
SpecDesign Margin
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ModelingModeling
AdvantagesCan be relatively inexpensive/fast
LimitationsEasy to make incorrect assumptions/mistakesSome situations are difficult/impossible to model
accurately
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System/Sub-System ReliabilitySystem/Sub-System Reliability
Series Reliability
A B C
Rtot = RA * RB * RC
Full RedundancyA
B
C
Rtot = 1- (1- RA ) * (1 - RB) * (1 - RC)
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OutlineOutline
Introduction Failure Mode Effect Analysis (DFMEA) Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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The Essence of Monte CarloThe Essence of Monte Carlo
Monte Carlo: Method of modeling involving inputs from random or pseudo random numbers
Output produced has the similar characteristics to that of data collected from an experiment*Similar scattering of dataThe more “runs” of the model, the more pronounced
the trends are
*If input is correct - your model output is only as good as the information you put into the model
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What Monte Carlo Looks LikeWhat Monte Carlo Looks Like
Vose, David; Quantitative Risk Analysis:A guide to Monte Carlo simulation modeling; 1996
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OutlineOutline
Introduction Failure Mode Effect Analysis (DFMEA) Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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Heat Shields 101Heat Shields 101
Kinetic Energy: +Potential Energy: Thermal Energy (hot)
Entry velocities between 7km/s(LEO)-11km/s (Lunar return), Altitude ~400 km (+ for lunar return)
Blunt body advantage Shuttle vs Apollo
mgdy2
2
1mV
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Cont…Cont…
Apollo Shuttle
Bef
ore
Aft
er
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Case Study ObjectivesCase Study Objectives
Risk Assessment Objectives For Orion Heat Shield:
Obtain an estimation of the overall system reliability
Identify components/events most likely to cause failure
Identify sub-systems that may be too conservative
Determine sensitivity of design/modeling/testing/environmental parameters on system reliability Determine where resources should be allocated in order to
reduce risk most efficiently
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Failure ModesFailure Modes
TPS Failure Modes
Burnthrough of heat shield material
Crack
Damage
De-bonding
Hot spots
Flowthrough
Bondline overheat
Excessive conduction
Radiation absorption
System interface failure
e.g. electromagnetic interference, landing system interference
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The Software UsedThe Software Used
SAFE – Space Architecture Failure EvaluationCode in development at NASA AmesMonte Carlo Simulation method
Input Assembly architecture Nominal reliabilities of components and events Consequences of failure Mission outline (events and segments)
The software generates hundreds or thousands of semi-random repetitions of the given scenario
The output Histograms and mission summaries that engineers can use to
determine when the system is likely to fail, what will cause failure, and how often system failures are likely to occur…
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Simple ExampleSimple Example
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Risk Interaction ExampleRisk Interaction Example
Micro-Meteoroid and Orbital Debris (MMOD) Risk of significant sized particles hitting heat
shield with significant velocity to cause damage
Risk of the MMOD damage causing/contributing to TPS failure
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Another ExampleAnother Example
Environment modeling Accurately predicting entry environment
Recession modeling based on predicted environment
Material selection/Thickness design based on recession modeling
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Organizing the RisksOrganizing the Risks
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Visualizing Risk InteractionVisualizing Risk Interaction
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Calculating Risk ValuesCalculating Risk Values
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The ModelThe Model
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Predicting ReliabilityPredicting Reliability
Historical records Apollo Shuttle Others
Physics based simulation tools
Testing Ground Tests Flight Tests
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Results of Summer WorkResults of Summer Work
Reliability model: Incorporates over 90 potential TPS risks
Each risk can fail in either a benign or catastrophic manner
Multiple benign failures have the ability to contribute to a catastrophic failure
All pre-entry factors influence risks during entry and landing phases
Risk Analysis Document Outline for detailed sub-system interaction Can be used to track changes and understand model Can be used to help understand risk dependence on material
choice and other design factors
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OutlineOutline
Introduction Failure Mode Effect Analysis (DFMEA) Fault Trees Event Trees Obtaining Component Reliability Monte Carlo Method Case Study: Heat Shield Reliability Modeling Summary
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SummarySummary
Risk analysis is a large topic that describes an entire discipline of engineering
Risk analysis is an iterative process If used correctly, can save money, and lives!Can aid in decision making process, justify actions
There are lots of tools available for engineers
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Cont…Cont…
The output of a risk assessment is only as good as the input The engineer must have plenty of test data or a sound
model before a valid risk model can be produced
Model output is meaningless without bounds on the solution
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Questions?Questions?