NASA Technical Reports Server (NTRS) 20000021229: Comprehensive Design Reliability Activities for Aerospace Propulsion Systems

146 Pages·7.3 MB·English

by  NASA Technical Reports Server (NTRS)

NASA/TP--2000-209902
Comprehensive Design Reliability Activities
for Aerospace Propulsion Systems
R.L. Christenson and M.R. Whitley
Marshall Space Flight Center, Marshall Space Flight Center, Alabama
K.C. Knight
Sverdrup Technology, Huntsville, Alabama
January 2000
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NASA / TP--2000-209902
Comprehensive Design Reliability Activities
for Aerospace Propulsion Systems
R.L. Christenson and M.R. Whitley
Marshall Space Flight Center, Marshall Space Flight Center, Alabama
K.C. Knight
Sverdrup Technology, Huntsville, Alabama
National Aeronautics and
Space Administration
Marshall Space Flight Center • MSFC, Alabama 35812
January 2000
Acknowledgments
The authors would like to thank the following who made important contributions directly and indirectly to this effort: Charles
Pierce, Richard Ryan, Brenda Lindley-Anderson, David Seymour, and Tom Byrd. A special thanks to Sid Lishman who
supported the extensive analyses needed to support the special reliability topics and the quality data discussion.
Available from:
NASA Center for AeroSpace Information National Technical Information Service
7121 Standard Drive 5285 Port Royal Road
Hanover, MD 21076- i320 Springfield, VA 22161
[phone] [phone]
TABLE OF CONTENTS
1. INTRODUCTION ................................................................................................................ l
2. BACKGROUND .................................................................................................................. 4
3. ISSUES ................................................................................................................................. 5
4. DESIGN RELIABILITY ASSESSMENT METHODOLOGY ........................................... 8
8
4.1 Approach ........................................................................................................................
14
4.2 Key Topics: Design Criteria, Quality Control, and Verification ....................................
MODEL AND MODELING TOOL DEVELOPMENT ...................................................... 15
,
16
5.1 FEAS-M Design Reliability Tool .................................................................................
BASIC ISSUES IN QUANTIFICATION ............................................................................. 25
.
26
6.1 Quantification Methodology ..........................................................................................
6.2 Sources of Data .............................................................................................................. 27
30
6.3 Applicability of Data .....................................................................................................
32
6.4 Indepth: Unsatisfactory Condition Reports and Failure Rate ........................................
7. APPLICATIONS .................................................................................................................. 47
47
7.1 Qualitative Analysis Example ........................................................................................
56
7.2 Quantitative Analysis Example ......................................................................................
8. CONCLUSIONS .................................................................................................................. 61
63
Appendix A--Selected Topics ..........................................................................................................
63
A.l General Design Criteria ................................................................................................
72
A.2 Relationship Between Quality Control and Design ......................................................
84
A.3 Reliability Verification and Models ..............................................................................
88
Appendix B--Design Reliability Strategy (Conceptual to Detailed Phases) ...................................
88
B.1 Conceptual Design Phase Activities .............................................................................
93
B.2 Preliminary Design Phase Activities .............................................................................
99
B.3 Detail Design Phase Activities ......................................................................................
,,.
111
TABLE CONTENTS (Continued)
Appendix C--MPS Qualitative Analysis Support Data ................................................................... 104
C. l X-34 MPS Pneumatic Purge System Design Fault Tolerance Analysis
Engineering Support ............................................................................................................... 104
C.2 Interpropeilant Seal Purge Supply Analysis ................................................................. 104
Appendix D--MPS Quantitative Analysis Support Data ................................................................. 121
REFERENCES ................................................................................................................................. 127
_.=; z
iv
LIST OF FIGURES
i, Disciplines in design ........................................................................................................ 3
2. Design reliability activities .............................................................................................. 9
3. Propulsion systems reliability modeling approach .......................................................... 10
4. Conceptual design phase activities ................................................................................... 11
5. Preliminary design phase activities .................................................................................. 12
Detail design phase activities ........................................................................................... 13
,
7. Model representation ........................................................................................................ 19
8. Model engine cycle schematic ......................................................................................... 20
9. Model time domain analysis ............................................................................................ 22
10. Model probabilistic design analysis support .................................................................... 23
11. Current quantification capabilities ................................................................................... 24
12. Quantification data and analysis methodology ................................................................ 27
13. Model data collection and analysis .................................................................................. 28
14. SSME UCR history .......................................................................................................... 37
15. Early cutoffs for J-2 engine by cumulative EFD ............................................................. 38
16. J-2 engine UCR's by cumulative cutoffs ......................................................................... 39
17. J-2 engine UCR's by cumulative EFD ............................................................................ 39
18. J-2 engine inspection opportunities ................................................................................. 41
19. Hidden failure modes ....................................................................................................... 42
20. First limiting condition ..................................................................................................... 43
V
LIST OF FIGURES (Continued)
21. Second limiting condition ................................................................................................ 43
22. Third limiting condition ................................................................................................... 45
23. X-34 MPS design fault tolerance analysis structure and interfaces ................................ 48
24. Example initiating faults ................................................................................................. 48
25. Example final system state ............................................................................................. 48
26. Example propagation path .............................................................................................. 49
27. Example logical "OR" gate ............................................................................................ 49
28. Example digraph ............................................................................................................. 5O
29. MPS IPS purge supply line, original design ................................................................... 51
30. Original MPS PS purge supply line design failure scenario ........................................... 52
31. MPS PS purge supply line, revised design ..................................................................... 53
32. Revised MPS IPS purge supply line design failure scenario .......................................... 54
33. X-34 MPS tank pressurization system (segment), original design ................................ 55
34. X-34 MPS tank pressurization system (segment), revised design ................................. 55
35. Derivation of traditional SF ............................................................................................ 67
36. Derivation of Z................................................................................................................ 67
37. SF effects ........................................................................................................................ 68
38. CVoeffects ...................................................................................................................... 69
39. Correlation effects .......................................................................................................... 70
40. QC design margin ........................................................................................................... 76
41. Perfect QC system .......................................................................................................... 76
vi
LIST OF FIGURES (Continued)
77
42. Realistic QC system .......................................................................................................
83
43. Engineering model prediction error ................................................................................
106
44. X-34 MPS failure propagation models, pneumatic purge system .................................
vii
LIST OF TABLES
° Aircraft to launch vehicle comparison ............................................................................... 6
2. Failure rate quantification data example ............................................................................ 29
3. Ablative nozzle/chamber surrogate data analysis .............................................................. 31
4. EMA 4-in. valve failure rate quantification ....................................................................... 59
5. Solenoid valve failure rate quantification .......................................................................... 122
6. Relief valve failure rate quantification .............................................................................. 123
7. Check valve failure rate quantification .............................................................................. 124
8. Feedline failure rate ........................................................................................................... 125
9. Duct failure rate quantification .......................................................................................... 126
VIII