Reverse Engineering Overview - Amazon S3...engineering analysis • Value Engineering –is...

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Reverse

Engineering

Overview

EPRI Procurement Form

3 August 2016


Elevator Pitch

Old Car with a broken radio

Look and function identically

Dashboard cut-out, connector, fuse rating

No software

Must be Qualified to meet reliability, environmental, seismic, EMC conditions

Design, Qualify &

Manufacture

Form, Fit, & Functional

replacement

Nuclear QA requirements


Why Reverse Engineering?

Majority of components used in the

safety systems are no longer

commercial available

Component Obsolescence

Average component life cycles (5-7 years)

Replaced with newer technology

Corporate mergers and acquisitions

System Design Evolution

Limited development & availability of the types

of components needed

Software free

Nuclear Qualified

Required

Available

Cost of a Modification is usually greater than the cost of a Reverse Engineered Solution

By replacing with like technology, no new failure modes are introduced


Reverse Engineering

• Reverse Engineering– the process of developing technical information sufficient to

duplicate an item by physically examining, measuring or testing existing items; reviewing technical data; and/or performing engineering analysis

• Value Engineering– is considered a subset of reverse engineering. The processes are

identical except that the defined purpose of value engineering is to improve the item’s original design. This can take the form of improved reliability, functionality, capability, materials, or other significant changes.

• Both process are the same in that they require a set of requirements and a means of verifying compliance

• Reference: EPRI TR-107372


Our Experience

• Understanding where and why RE project fall short enables us to properly manage them to achieve a positive result

• Based on our experience with RE projects the majority of projects fail due to

– Inadequate technical specifications

– Not understanding and managing the design requirement delta


Technical Specifications

• legacy design specifications and product literature

– Legacy specifications not updated to an as built status after installation and commissioning

– Legacy OEM product specifications contain errors, are incomplete or not available

– Legacy component modified and not documented

• Properly define the safety function

• Determine critical characteristics based on safety function & FMEA

– Acceptance criteria

• Obtain functioning sample and test to validate requirements

• Walk down

• Kick-off Meeting & Walk Down– Understanding of system and

interactions with adjacent components

• Test samples to benchmark unknown parameters

MitigationCause• Technical Specifications

– written at the system level

– Do not adequately address the safely function of the component

– Not all critical characteristics defined

• unspecified characteristics– Parameters such as response time, inrush

current, power consumption not addressed in legacy requirements as they were not considered critical characteristics


Design Delta

• Electromagnetic Compatibility

(EMC) requirements)

• Additional functional requirements Front panel accessible tests jacks for maintenance and troubleshooting

ExampleDelta• Seismic requirements

– Legacy technology not seismic qualifiable

• Changes in temperature and humidity specifications

The Design Requirement Delta can be defined as any changes to the

component requirements since the original component was installed.

Additional components added to cabinet

increased ambient temperature

• Mercury wetted relays

• Optical sensors for trip setpoints on

analog indicating alarm meters

Additional components required to meet

DRD may effect unspecified parameters

(i.e. response time)

• Changes to product safety standards (UL/CSA)

Fusing, dielectric strength, insulation

leakage


The Kinectrics Approach to RE

Proposal

Planning

DesignQualification

Production

Alpha

BetaFinal

Invest the time at the proposal stage Obtain surplus sample

Detailed technical design proposal

Realistic schedule and financial budget

Planning Walk down

Engage the customer

(engineering, maintenance,

operators)

OPEX research

Comprehensive design plan

Design Requirements

Design 3 Phase planned

approach

Alpha Circuit breadboard

3D prototype of housing

Validated to test procedures based

on FMEA of safety function

Preliminary MTBF calculations

Beta Circuit on PCB installed

in prototype housings

EMC and Temperature /

Humidly pre-scan

Tested to updated

procedure

FMEA and MTBF

analysis updated

Final Production quality samples

All components procured from

approved vendors to approved

drawings and specifications

Assembly performed to approved

drawings and procedures

All results fully documented in test

reports to a full documented design

to facilitate future production and

component support

Qualification ITP

Procedures

Calibrated MTE

Reports

Production ITP

Drawings &

procedures

used to

fabricate

qualification

samples


Capturing the RequirementsStation Documentation

Purchase order

Technical Specifications

System Design Manual

System Wiring Diagram

OPEX

Legacy OEM Documentation

Kinectrics Design Requirements Define Safety Function

Human Interface

Electrical & Mechanical Boundaries

Table of design requirements, referenced to source

Comprehensive list of all requirement that must be

met in order for the replacement unit to meet its

safety function.

Surplus Sample Test to validate assumptions

Missing specifications

Kick-off Meeting / Walk-down Plant Design & Procurement Engineers

Operators & Maintenance

Validate assumptions

Field wiring

Mechanical installation

Evaluate Safety Function

FMEA analysis

Critical Characteristic for Design


Design Process

Design Requirements

Design

Prototype

Test / Evaluate

Review Results

Design Review Meeting

Design Requirements Critical Characteristics for Design

Safety Function

FMEA

Validated assumptions

Design Output Docs Drawings

Schematics & PCB Layout

Component Specifications

Test Procedures

Design Requirement

Traceability Matrix All DR addressed

referenced to

result or

evaluation

Deficiency List

Open Items List

All Stakeholders Present prototype

Review all results

Leave prototype with

customer for

independent testing

Maintainability of the

design

Spare parts

Prototype vs. Design Requirements Test prototype against DR with test procedure

Evaluate all non-tested requirements

Document all results

MTBF analysis

Component FMEA

Human Factors Analysis

Fabrication Build Prototype

Update Design

Requirements and

Repeat


Managing RiskMurphy’s Law

• Anything that can go wrong, will go wrong.

Projects are managed to minimize Risk

• 3 Stage Design Process with realistic goals– Alpha – Functional, Beta – Performance, Qualification

– Design Review at each stage (All stakeholders)

• Technology – Unless required (OPEX, DRD) do not change technology

– Linear Power Supply

– RC circuit for time delay relay

• Reliability– Meet the design requirements with a few components as possible

– No additional features


Managing DesignTimeless design

• Use standard components that will be around forever– Resistors, Capacitors, Transistors, Op-amps, etc.

• Avoid single source priority components– Multiplexers, microprocessors, etc.

• When components become obsolete, design can be easily updated for new package and requalified

Design Control

• Design must be completely documented– COTs parts – data sheet

– Custom parts – drawings

– Procedures– assembly, conformal coating, testing

• Provides a design base for item equivalency evaluations to mitigate obsolescence

• Allows future production lots to be qualified against the original qualification reports

• Provides an auditable trail from the installed product back to the technical specifications


Rod Logic Unit Legacy

– Custom designed analog comparator

– Provide bias for position sensing potentiometer

– Two adjustable alarm setpoints

Requirement Delta– EMC

– Front panel test jacks

– Modified adjustment ranges (resolution)

KIN Solution– Custom designed linear power supply

– MIL standard op-amps

– Double sided PCB

– EMC filters

Obsolescence Mitigation– Custom power supply

– No electrolytic capacitors

– Industry standard op-amp packages


Analog Indicating Meter Legacy

– Bach Simpson Model 3623

– 3-1/2” analog indicating meter

– DC current and voltage inputs


KIN Solution– Injection molded cases

– Commercial available analog meter

– Identical scale design to allow use of existing scale plates


Programmable Controller Microprocessor based

programmable controller

Specifically design to replace conventional electromagnetic relays for process and logic control

6 Cards per controller Power Supply, CPU, Input, Output

2 Controllers housed in a 19” rack mounted cage

RS232 to a Communication Module Multiple controllers to talk together,

Isolation via fiber optic cable


Motherboard Legacy

– Custom designed backplane


KIN Solution– Custom plated gold connectors

– Daughter board for I/O connectors

– Updated input power connector


Power Supply Legacy

– Custom designed switching power supply

– 48VDC input, 48VDC/1A and 5VDC/4A output

Requirement Delta– Single point vulnerability, Dual Redundant

– EMC

KIN Solution– DC-DC converters

– External shutdown monitoring and shutdown for voltage / current

– Response of shut down vs. internal DC-DC converter

– Overcurrent 90/10 sharing

– LEDS PS1/PS2

Obsolescence Mitigation– Industry standard packages for DC-DC

converters

– No electrolytic capacitors


CPU and EPROM Legacy

– Intel 8085 microprocessor

– Execute legacy EPROM

– Fault detection circuitry

Requirement Delta

– EMC

KIN Solution

– Remanufactured microprocessor using the original die

– UART purchased from surplus market and validated by destructive testing

Obsolescence Mitigation

– Lifetime supply of UART


Input / Output Board s

Legacy

– 24 Input channels

– Multiplex on 8 bit data bus

– Addressed by CPU

Requirement Delta

– EMC

KIN Solution

– SMT components

– Solid State Relays (output)

Obsolescence Mitigation

– Industry standard

packages for components

– No all in one multiplexers


F&P Analog Controller• Same analog display to reduce human factors impact.

• Minimal impact on station documentation (CMP’s, Drawings,

Manual).

• No degradation in scale resolution vs. a digital bar-graph.

• 100% analog design, therefore no software maintenance

plans will be required.

• No electrolytic capacitors for reduced maintenance.

• New design is based on the legacy F&P design with no new

failure modes introduced.

• Power up performance will be identical to the legacy unit.

• No software quality assurance issues as the unit is 100%

analog.

• Complete FMEA and MTBF calculation reports.

• Full replacement of the 3000 and 4000 series


In-Core Flux Detector Amplifier

SDS2

Ion-Chamber Amplifier SDS2

Neutron over Power Amplifier

SDS1

• EMC Compliance

• Human Factors

• Custom design test jigs (10pA-

150uA Ion chamber) log ramp

• MTBF, FMEA analysis

• Z299.2 / Z299.1

Neutron Bases Amplifiers


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