UNIVERSITY OF THE HIGHLANDS AND ISLANDS PERTH COLLEGE

ENGINEERING RELIABILITY

SUBMITTED BY PALASH BHUYAN 11002401

Contents
1.0 INTRODUCTION ........................................................................................................................... 5 1.1 ENGINEERING RELIABILITY ................................................................................................. 5 GRAPHICAL NOTIFICATION .................................................................................................... 5 Relationship between failure rate and time .............................................................................. 6 RCM ( RELIABILITY CENTERED MAINTENANCE )................................................................. 6 ADVANTAGES OF RCM ............................................................................................................ 7 1.2 AIM AND OBJECTIVE .............................................................................................................. 7 1.3 system description of A340 hydraulic system ....................................................................... 7 OPERATION OF GREEN SYSTEM.......................................................................................... 7 BLUE SYSTEM................................................................................................................................. 8 YELLOW SYSTEM .......................................................................................................................... 8 COMPONENTS FUNCTION .......................................................................................................... 8 PRIORITY VALVES ..................................................................................................................... 8 FIRE SHUTOFF VALVES ........................................................................................................... 8 FILTERS ........................................................................................................................................ 8 HYDRAULIC SYSTEM MONITORING UNIT ( HSMU ) ............................................................. 9 RAT ( RAM AIR TURBINE ) ........................................................................................................... 9 LOGICAL DIAGRAM OF RAT ........................................................................................................ 9 ACCUMULATORS ......................................................................................................................... 10 HYDRAULIC GENERATION ........................................................................................................ 10 PRESSURIZATION OF THE RESERVOIR ............................................................................... 11 LEAK MEASUREMENT VALVES................................................................................................ 12 DISTRIBUTION .............................................................................................................................. 12 1.0 ENGINEERING RELIABILITY THEORY AND TOOLS ......................................................... 13 1.1 WEIBULLS RELIABILITY DISTRIBUTION ......................................................................... 13 1.2 RELIABILITY BLOCK DIAGRAM .......................................................................................... 14 SERIES MODEL......................................................................................................................... 14 PARALLEL OR FULL REDUNDANCY SYSTEM .................................................................. 15 PARTIAL REDUNDANCY SYSTEM ....................................................................................... 15 2.3 FAULT TREE ANALYSIS ....................................................................................................... 16 AND GATE .................................................................................................................................. 16 OR GATE..................................................................................................................................... 16 VOTED GATE ............................................................................................................................. 16

2.3 ANALYSIS ................................................................................. Error! Bookmark not defined. 3.0 Reliability analysis and evaluation ............................................................................................ 18 3.1 RELIABILITY DATA SELECTION......................................................................................... 18 3.2 COMPONENT WRD PARAMETER CLACULATIONS USING COMPUTATIONAL TECHNIQUE ................................................................................................................................... 18

1.0 INTRODUCTION
1.1 ENGINEERING RELIABILITY Reliability of a system / item is the probability that the specific system / item performs specific function under specific operational and environmental conditions at and through a specific time period. (The University of Tennesse Knoxville, 2012) The opposite of reliability is unreliability and the relationship between the two parameters is :R(t)=1Q(t) Where, R ( t ) = reliability, Q ( t ) = unreliability R ( t ) and Q ( t ) are both functions of time ( t ). Engineering Reliability is basically a group of planned or organised activities which are formed through formal or informal management systems and working all together efficiently to prevent any malfunction or loss of the system. (The University of Tennesse Knoxville, 2012) GRAPHICAL NOTIFICATION

The above graph denotes the relationship between both the parameters i.e. R ( t ) and Q ( t ). The slope of the reliability curve is denoted as reliability density ; f(t)=( )

Failure is denoted as; =

Whereas, T is the time elapsed before the failure event and it is also known as MEAN time as it is constant. The relationship between failure rate, reliability density and reliability function is ; ( ) ( ) ( )

RELATIONSHIP BETWEEN FAILURE RATE AND TIME

It is known as Bathtub Curve. Some Aspects of Engineering Reliability Its main objective is to reduce or eliminate maintenance work. It uses technology and management techniques to achieve reliability and efficient maintenance of the system.

RCM ( RELIABILITY CENTERED MAINTENANCE ) RCM is an engineering framework which defines a complete maintenance regime by the reliability of the system. RCM main objective is to focus identify and establish operational, maintenance and capital improvement standards that will reduce failure of systems and equipments. (Sandham, 2012)RCM is recognised by a technical standard which is SAE JA1011.

ADVANTAGES OF RCM Creates a cost effective maintenance program to tackle equipment or system failure. Total knowledge of causes of equipment and system failure along with preventative measures to be taken. Emphasises mostly on Predictive maintenance ( PdM ) over preventive measures. Provides reliability and availability at a very lower cost.

1.2 AIM AND OBJECTIVE

AIM :- Reliability Analysis and evaluation of HYDRAULICALLY ACTUATED RUDDER CONTROL SYSTEM OF A340 OBJECTIVES : Analysis and evaluation of various components of A340 hydraulic system using Weibullss 2-parameter computational method. Verification of components by Graphical method System reliability modelling using RBD and FTA RCM strategy of the system.

1.3 SYSTEM DESCRIPTION OF A340 HYDRAULIC SYSTEM Airbus A340 has three continuously operating hydraulic systems i.e. blue, green, and yellow system where each of the system has its own reservoirs. The normal operating pressure is 3000 PSI and hydraulic fluid can be transferred from one system to another. The system is monitored by a Hydraulic System Monitoring Unit ( HSMU ) . (Airbus, 2012) OPERATION OF GREEN SYSTEM Green system is pressurize by engines 1 and 4. An electric pump can also pressurize the green system which can be manually or automatically controlled. The electric pump runs automatically in flight for 25 seconds in the event of failure of engine 1 or 4, when landing gear is selected up and on the ground when engines 1 and 4 are stopped and engines 2 and 3 are running

A pump driven by a Ram Air turbine ( RAT ) pressurize the green system in an emergency. When the RAT pressurize the green system, the aileron, elevator and spoiler servo control operating speeds are reduced. (Airbus, 2012) BLUE SYSTEM Blue system is pressurize by engine 2 and a manually controlled electric pump can also pressurize the system. YELLOW SYSTEM Yellow system is pressurize by engine 3. An electric pump can also pressurize the yellow system which can be operated manually or automatically controlled which enables ground operations when the engines are stopped. The electric pump runs in flight in the event of engines 3 failure, if flaps lever is not at 0 and aircraft speed is above 100 knots.

COMPONENTS FUNCTION
PRIORITY VALVES It cuts off hydraulic power to heavy load users if green system hydraulic pressure gets low. FIRE SHUTOFF VALVES Each of the green, blue and yellow systems has a FSV in its line upstream of its engine driven pump. The flight crew can close it b pushing the FIRE pushbutton. The ENG 1 and ENG 4 FSV are automatically closed by the HSMU in the event of green reservoir low level. This enables isolation of a possible leak in the engine pylon allowing restoration of the green system using RAT, in the event of a further blue reservoir low level. The flight crew cannot re-open the FSV in flight once they have been automatically closed. FILTERS Filters clean the hydraulic fluid as follows HP filters on each system and on the reservoir filling system and the normal braking system. Return line filters on each line Case drain filters on engine pumps

HYDRAULIC SYSTEM MONITORING UNIT ( HSMU )

The HSMU monitors the hydraulic system. It processes : Control and monitors the hydraulic system. RAT extension. ENG 1 and ENG 4 FSV closure in case of green reservoir low level. Hydraulic quantity indication correction for fluid temperature. Reservoir overheat warning FAULT light illumination logic. Leak measurement valve control

RAT ( RAM AIR TURBINE ) A drop out RAT coupled to a hydraulic pump allows the green system to function. The RAT may be extended at any time by the pilot. The RAT deploys automatically in the event of four engine failure or electrical power loss when engines 1 and 4 are stopped or a low level in the green and blue reservoirs. LOGICAL DIAGRAM OF RAT

Source :- (Airbus, 2012)

ACCUMULATORS Each of the hydraulic system has an accumulator which helps to maintain a constant pressure by covering transient demands during normal operation. HYDRAULIC GENERATION

Source :- (Airbus, 2012)

PRESSURIZATION OF THE RESERVOIR Bleed air from ENG 2 pressurize the hydraulic reservoirs automatically. When the bleed air pressure becomes too low, the system takes bleed air pressure from the crossbleed duct. Thus all the three systems maintain a high pressure to prevent their pumps from cavitating.

Source :- (Airbus, 2012)

LEAK MEASUREMENT VALVES They are used only when the aircraft is on the ground and are positioned upstream of the primary controls. They are used for the leak measurement of each system and may only be closed on ground by using the LEAK MEASUREMENT VALVES pushbutton the maintenance panel. DISTRIBUTION

source :- (Airbus, 2012)

1.0 ENGINEERING RELIABILITY THEORY AND TOOLS

WRD is one of the best statistical tool for predicting reliability which is a probability measure. WRD function can be stated as :-

WRD 1- Parameter, In this case = 0, = 1

Where ,

Hence,

The simplified expression can be expressed as,

WRD 2- Parameter, Where, = 0

And thus it can be stated as In most of the cases 2-parameter is sufficient to describe a set of reliability data.

1.2 RELIABILITY BLOCK DIAGRAM A Reliability Block Diagram (RBD) performs the system reliability and availability analyses on large and complex systems using block diagrams to show network relationships. The structure of the reliability block diagram defines the logical interaction of failures within a system that are required to sustain system operation. The rational course of a RBD stems from an input node located at the left side of the diagram. The input node flows to arrangements of series or parallel blocks that conclude to the output node at the right side of the diagram. A diagram should only contain one input and one output node. The RBD system is connected by a parallel or series configuration. A parallel connection is used to show redundancy and is joined by multiple links or paths from the Start Node to the End Node. (ITEM Software, Inc, 2007) There are two RBD models Series reliability model Parallel or Redundancy Model

SERIES MODEL

The reliability of the system can be expressed as Rs = R1 x R2 In general, Rs = R1 x R2 .....x Rn

PARALLEL OR FULL REDUNDANCY SYSTEM

The reliability of the system can be expressed as :Rs = 1 ( 1 R1 ) ( 1 R2 ) In general Rs = 1 ( 1 R1 ) ( 1 R2 ).... ( 1 Rn ) PARTIAL REDUNDANCY SYSTEM The system is said to be partial redundancy when any two of the three components of the system to be functional.

The reliability of the system can be expressed as

Whereas a general expression can be formed as

2.3 FAULT TREE ANALYSIS Fault tree diagrams (or negative analytical trees) are logic block diagrams that display the state of a system (top event) in terms of the states of its components (basic events). Like reliability block diagrams (RBDs), fault tree diagrams are also a graphical design technique, and as such provide an alternative to methodology to RBDs. An FTD is built top-down and in term of events rather than blocks. It uses a graphic "model" of the pathways within a system that can lead to a foreseeable, undesirable loss event (or a failure). The pathways interconnect contributory events and conditions, using standard logic symbols (AND, OR etc). The basic constructs in a fault tree diagram are gates and events, where the events have an identical meaning as a block in an RBD and the gates are the conditions. (reliasoft, 2012) There are three main gates used in FTA :-

AND GATE

In an AND gate, the output event occurs if all input events occur. OR GATE

In an OR gate, the output event occurs if at least one of the input occurs. VOTED GATE

In a Voting OR gate, the output event occurs if some quantity (k) or more of the (n) input events occur. The voting gate is visually distinguished from the OR gate by the k/n value displayed on it. (reliasoft, 2012)

The figure below is an illustration of a FTA diagram

Source :- (Olufisan, 2012)

3.0 RELIABILITY ANALYSIS AND EVALUATION

The various data selection for failure rates of components has been taken from appendix 4 and the data which are not available has been taken from the table. COMPONENT Filter Non Return valve Pressure Relieve valve Electric Pump Accumulator Electric driven pump Fire shut valve Turbine Source :- (Smith, 2011) Failure 0.5 1 2 200 20 10 8 30 Rate in Failures per 1 Million Hours 10 20 8 500 100

200 50 20 40

3.2 COMPONENT WRD PARAMETER CLACULATIONS USING COMPUTATIONAL TECHNIQUE

ACCUMULATOR Using WRD 2- parameter, Where, t ( hour ) from the the data above = 5000, 6666.66, 8333.33, 12500, 20000, 50000 r = 1,2,3,4,5,6 median rank Q ( t ) = x = ln ( t ), y = ln ( - ln (1-Q ( t ) ), , N = no. Of intervals

 = m,

The extracted table from MS Excel shows the following parameters of accumulator using the above WRD 2-parameter :R ( t ) = 99.93 % = 1.170626 = 18871 = 0.65535

EDP ( Engine Driven Pump ) Using WRD 2- parameter the extracted table from MS Excel shows the following parameters of EDP : = 1.4269 = 6869.405 R ( t ) = 99.97 % = 0.948452866

RAT ( Ram Air Turbine ) Using WRD 2- parameter the extracted table from MS Excel shows the following parameters of RAT : R ( t ) = 100 % = 0.988232 = 9.677184 = 30526.86

ELECTRIC PUMP Using WRD 2- parameter the extracted table from MS Excel shows the following parameters of electric pump: = 0.822819 = 240494.7 = 0.863629 R ( t) = 99.99%

ACTUATOR Using WRD 2- parameter the extracted table from MS Excel shows the following parameters of actuator : = 1.170626 = 18871.71 = 0.929252 R ( t ) = 99.97 %

FIRE SHUTOFF VALVE

Using WRD 2- parameter the extracted table from MS Excel shows the following parameters of fire shutoff valve : = 1.69934 = 118082.9 R ( t ) = 99.999 = 0.8548

RESERVOIR Using WRD 2- parameter the extracted table from MS Excel shows the following parameters of reservoir : = 1.08 = 340.1564 = 0.90090 R ( t ) = 99.399 %

VERIFICATION OF COMPONENT WRD PARAMETERS ( GRAPHICAL TECHNIQUE )

3.5 RELIABILITY DISTRIBUTION FOR EACH COMPONENT OVER THE RANGE 0 < R < 100 %
ACCUMULATOR

Source :- ReliaSoft Weibull ++

EDP

RAT

Source :- ReliaSoft Weibull ++ ELECTRIC PUMP

Source :- ReliaSoft Weibull ++

ACTUATOR

Source :- ReliaSoft Weibull ++ FSV

Source :- ReliaSoft Weibull ++

RESERVOIR

Source :- ReliaSoft Weibull ++

3.6 SYSTEM RELIABILITY MODELLING

Source :- Reliasoft BlockSim

The above diagram is the RBD of A340 hydraulic system of the rudder actuation.

The overall reliability of the system is 99.38 % which is found using MS Excel as below :- ( taking average flight time of A340 as 18.25 )

By using Reliasoft BlockSim software the reliability of the overall system is 95.833% which is quiet closer to the results of MS Excel. ( taking average flight time of A340 as 18.25 )

RCM SYSTEM STRATEGY

The content of the maintenance program itself consists of two groups of tasks: a) A group of scheduled tasks to be accomplished at specified intervals. The objective of these tasks is to prevent deterioration of the inherent safety and reliability levels of the equipment. The tasks in a scheduled maintenance program may include: (1) Lubrication/Servicing (LU/SV) (2) Operational/Visual Check (OP/VC) (3) Inspection/Functional Check (IN/FC) (4) Restoration (RS) (5) Discard (DS)

b) A group of non-scheduled tasks which result from: (1) The scheduled tasks accomplished at specified intervals. (2) Reports of malfunctions (usually originated by the operatingcrew). (3) Data analysis.

FAULT TREE ANALYSIS

Source :- ReliaSoft BlockSim software The above FTA depicts that the whole system will fail if any of the five subsystem fails i.e pneumatic system, green system, blue system, yellow system and rudder system.

CONCLUSION
The overall reliability of the hydraulic system of A340 of the actuation of rudder control system is considerable which is 99.38 % which is very good whereas in software its around 95% so there is some error. The various components in the system has a very high percentage of reliability.