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All sources NASA NTRS DOE OSTI

NASA NTRS2006

Importance Of Quality Control in Reducing System Risk, a Lesson Learned From The Shuttle and a Recommendation for Future Launch Vehicles

This paper presents lessons learned from the Space Shuttle return to flight experience and the importance of these lessons learned in the development of new the NASA Crew Launch Vehicle (CLV). Specifically, the paper discusses the relationship between process control and system risk, and the importance of process control in improving space vehicle flight safety. It uses the External Tank (ET) Thermal Protection System (TPS) experience and lessons learned from the redesign and process enhancement activities performed in preparation for Return to Flight after the Columbia accident. The paper also, discusses in some details, the Probabilistic engineering physics based risk assessment performed by the Shuttle program to evaluate the impact of TPS failure on system risk and the application of the methodology to the CLV.

Safie, Fayssal M.↗

NASA NTRS2014

Application of Fault Management Theory to the Quantitative Selection of a Launch Vehicle Abort Trigger Suite

The theory of System Health Management (SHM) and of its operational subset Fault Management (FM) states that FM is implemented as a "meta" control loop, known as an FM Control Loop (FMCL). The FMCL detects that all or part of a system is now failed, or in the future will fail (that is, cannot be controlled within acceptable limits to achieve its objectives), and takes a control action (a response) to return the system to a controllable state. In terms of control theory, the effectiveness of each FMCL is estimated based on its ability to correctly estimate the system state, and on the speed of its response to the current or impending failure effects. This paper describes how this theory has been successfully applied on the National Aeronautics and Space Administration's (NASA) Space Launch System (SLS) Program to quantitatively estimate the effectiveness of proposed abort triggers so as to select the most effective suite to protect the astronauts from catastrophic failure of the SLS. The premise behind this process is to be able to quantitatively provide the value versus risk trade‐off for any given abort trigger, allowing decision makers to make more informed decisions. All current and planned crewed launch vehicles have some form of vehicle health management system integrated with an emergency launch abort system to ensure crew safety. While the design can vary, the underlying principle is the same: detect imminent catastrophic vehicle failure, initiate launch abort, and extract the crew to safety. Abort triggers are the detection mechanisms that identify that a catastrophic launch vehicle failure is occurring or is imminent and cause the initiation of a notification to the crew vehicle that the escape system must be activated. While ensuring that the abort triggers provide this function, designers must also ensure that the abort triggers do not signal that a catastrophic failure is imminent when in fact the launch vehicle can successfully achieve orbit. That is, the abort triggers must have low false negative rates to be sure that real crew‐threatening failures are detected, and also low false positive rates to ensure that the crew does not abort from non‐crew‐threatening launch vehicle behaviors. The analysis process described in this paper is a compilation of over six years of lessons learned and refinements from experiences developing abort triggers for NASA's Constellation Program (Ares I Project) and the SLS Program, as well as the simultaneous development of SHM/FM theory. The paper will describe the abort analysis concepts and process, developed in conjunction with SLS Safety and Mission Assurance (S&MA) to define a common set of mission phase, failure scenario, and Loss of Mission Environment (LOME) combinations upon which the SLS Loss of Mission (LOM) Probabilistic Risk Assessment (PRA) models are built. This abort analysis also requires strong coordination with the Multi‐Purpose Crew Vehicle (MPCV) and SLS Structures and Environments (STE) to formulate a series of abortability tables that encapsulate explosion dynamics over the ascent mission phase. The design and assessment of abort conditions and triggers to estimate their Loss of Crew (LOC) Benefits also requires in‐depth integration with other groups, including Avionics, Guidance, Navigation and Control(GN&C), the Crew Office, Mission Operations, and Ground Systems. The outputs of this analysis are a critical input to SLS S&MA's LOC PRA models. The process described here may well be the first full quantitative application of SHM/FM theory to the selection of a sensor suite for any aerospace system.

Lo, Yunnhon↗

NASA NTRS1997

Award-Winning CARES/Life Ceramics Durability Evaluation Software Is Making Advanced Technology Accessible

Products made from advanced ceramics show great promise for revolutionizing aerospace and terrestrial propulsion and power generation. However, ceramic components are difficult to design because brittle materials in general have widely varying strength values. The CARES/Life software developed at the NASA Lewis Research Center eases this by providing a tool that uses probabilistic reliability analysis techniques to optimize the design and manufacture of brittle material components. CARES/Life is an integrated package that predicts the probability of a monolithic ceramic component's failure as a function of its time in service. It couples commercial finite element programs--which resolve a component's temperature and stress distribution - with reliability evaluation and fracture mechanics routines for modeling strength - limiting defects. These routines are based on calculations of the probabilistic nature of the brittle material's strength.

Source record↗

DOE OSTI2023

Simulation-Based Recovery Action Analysis Using the EMRALD Dynamic Risk Assessment Tool

A recovery action is defined as the action that prevents deviant conditions from producing unwanted effects. It generally indicates a kind of countermeasure performed in response to a failure of human action. The recovery actions especially play an important role in complex systems like nuclear power plants (NPPs), which consist of highly sophisticated controllers to ensure that desired performance and safety must be achieved and maintained. This is because a combination of human error and its recovery failure may be able to cause a catastrophic effect on a system. Analyzing recovery actions has been a critical part of HRA, which is a technique to evaluate human errors and provide human error probabilities (HEPs) for application in probabilistic safety assessment (PSA). If recovery actions are not adequately analyzed and applied to PSA models, the PSA results may be under-estimated or be not able to reasonably account for the failure of human actions in the context of PSA. For this reason, some regulatory documents such as ASME/ANS RA-Sb-2013 by the American Society for Mechanical Engineers and the American Nuclear Society and NUREG-1792 by U.S. Nuclear Regulatory Commission have emphasized the importance of recovery analysis within the HRA. A couple of existing HRA methods, such as the Technique for Human Error-Rate Prediction (THERP), the Cause-Based Decision Tree (CBDT), and the Korean Standard HRA (K-HRA), have respectively suggested their own approaches to the HRA recovery analysis. However, there are a couple of limitations to treating recovery actions using only the current HRA methods available. The biggest limitation is that the existing recovery analysis does not explicitly consider a variety of recovery action types and recovery sequences as they occur in actual NPPs. To handle the limitations of existing recovery analysis, this study proposes a simulation-based recovery analysis method using the Event Modeling Risk Assessment Using Linked Diagram (EMRALD) software. The EMRALD software is a dynamic simulation tool for PSA. It supports realistic and dynamic modeling of human actions as they would be performed at NPPs. It is also favorable to simultaneously model the specific moment at which an action is performed, the time it takes to perform the action, and the failure probability of that action. In this paper, a detailed methodology for modeling recovery actions in the simulation platform is proposed with a couple of examples. Then, outputs from the simulation are discussed as reviewing if this novel approach can complement the challenges of existing recovery analyses.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS2005

Reliability-Based Control Design for Uncertain Systems

This paper presents a robust control design methodology for systems with probabilistic parametric uncertainty. Control design is carried out by solving a reliability-based multi-objective optimization problem where the probability of violating design requirements is minimized. Simultaneously, failure domains are optimally enlarged to enable global improvements in the closed-loop performance. To enable an efficient numerical implementation, a hybrid approach for estimating reliability metrics is developed. This approach, which integrates deterministic sampling and asymptotic approximations, greatly reduces the numerical burden associated with complex probabilistic computations without compromising the accuracy of the results. Examples using output-feedback and full-state feedback with state estimation are used to demonstrate the ideas proposed.

Crespo, Luis G.↗

DOE OSTI2022

Game-Theoretic Strategies for Cyber-Physical Infrastructures Under Component Disruptions

In this work, networked infrastructures of recursively defined systems composed of discrete cyber and physical components are considered. The components of basic systems at the finest levels can be disrupted by cyber or physical means, and can be reinforced to survive at certain costs. A problem of ensuring the infrastructure performance is formulated as a game between a provider and an attacker, who probabilistically choose components to reinforce and attack, respectively. The disruptions of this infrastructure are characterized using the aggregate failure correlation function that specifies the conditional failure probability of the infrastructure given the failure of an individual system at that level. The survival probabilities of basic systems satisfy simple product-form, first-order differential equations expressed in terms of the multiplier functions. The utility functions of the provider and attacker are composed of the reward and cost terms, both expressed in terms of the component reinforcement and attack probabilities. The Nash equilibrium of this game is characterized, along with the sensitivity functions of the survival probabilities of basic systems that highlight their dependence individually on the cost-benefit terms, the correlation functions, and the multiplier functions. These results are illustrated using simplified models of a distributed cloud servers infrastructure, a 5G data network infrastructure, a high performance computing federation, and a smart energy grid infrastructure.

42 ENGINEERING↗

NASA NTRS2001

Slow Crack Growth and Fatigue Life Prediction of Ceramic Components Subjected to Variable Load History

Present capabilities of the NASA CARES/Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code include probabilistic life prediction of ceramic components subjected to fast fracture, slow crack growth (stress corrosion), and cyclic fatigue failure modes. Currently, this code has the capability to compute the time-dependent reliability of ceramic structures subjected to simple time-dependent loading. For example, in slow crack growth (SCG) type failure conditions CARES/Life can handle the cases of sustained and linearly increasing time-dependent loads, while for cyclic fatigue applications various types of repetitive constant amplitude loads can be accounted for. In real applications applied loads are rarely that simple, but rather vary with time in more complex ways such as, for example, engine start up, shut down, and dynamic and vibrational loads. In addition, when a given component is subjected to transient environmental and or thermal conditions, the material properties also vary with time. The objective of this paper is to demonstrate a methodology capable of predicting the time-dependent reliability of components subjected to transient thermomechanical loads that takes into account the change in material response with time. In this paper, the dominant delayed failure mechanism is assumed to be SCG. This capability has been added to the NASA CARES/Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code, which has also been modified to have the ability of interfacing with commercially available FEA codes executed for transient load histories. An example involving a ceramic exhaust valve subjected to combustion cycle loads is presented to demonstrate the viability of this methodology and the CARES/Life program.

Jadaan, Osama↗

NASA NTRS2002

Reliability Analysis of Brittle Material Structures - Including MEMS(?) - With the CARES/Life Program

Brittle materials are being used, or considered, for a wide variety of high tech applications that operate in harsh environments, including static and rotating turbine parts. thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and MEMS. Designing components to sustain repeated load without fracturing while using the minimum amount of material requires the use of a probabilistic design methodology. The CARES/Life code provides a general-purpose analysis tool that predicts the probability of failure of a ceramic component as a function of its time in service. For this presentation an interview of the CARES/Life program will be provided. Emphasis will be placed on describing the latest enhancements to the code for reliability analysis with time varying loads and temperatures (fully transient reliability analysis). Also, early efforts in investigating the validity of using Weibull statistics, the basis of the CARES/Life program, to characterize the strength of MEMS structures will be described as as well as the version of CARES/Life for MEMS (CARES/MEMS) being prepared which incorporates single crystal and edge flaw reliability analysis capability. It is hoped this talk will open a dialog for potential collaboration in the area of MEMS testing and life prediction.

Nemeth, Noel N.↗

NASA NTRS1991

Probabilistic composite analysis

Formal procedures are described which are used to computationally simulate the probabilistic behavior of composite structures. The computational simulation starts with the uncertainties associated with all aspects of a composite structure (constituents, fabrication, assembling, etc.) and encompasses all aspects of composite behavior (micromechanics, macromechanics, combined stress failure, laminate theory, structural response, and tailoring) optimization. Typical cases are included to illustrate the formal procedure for computational simulation. The collective results of the sample cases demonstrate that uncertainties in composite behavior and structural response can be probabilistically quantified.

Chamis, C. C.↗

NASA NTRS1995

Probabilistic simulation of long term behavior in polymer matrix composites

A methodology to compute cumulative probability distribution functions (CDF) of fatigue life for different ratios, r of applied stress to the laminate strength based on first ply failure criteria has been developed and demonstrated. Degradation effects due to long term environmental exposure and mechanical cyclic loads are considered in the simulation process. A unified time-stress dependent multi-factor interaction equation model developed at NASA Lewis Research Center has been used to account for the degradation/aging of material properties due to cyclic loads. Fast probability integration method is used to perform probabilistic simulation of uncertainties. Sensitivity of fatigue life reliability to uncertainties in the primitive random variables are computed and their significance in the reliability based design for maximum life is discussed. The results show that the graphite/epoxy (0/+45/90) deg laminate with ply thickness 0.125 in. has 500,000 cycles life for applied stress to laminate strength ratio of 0.6 and a reliability of 0.999. Also, the fatigue life reliability has been found to be most sensitive to the ply thickness and matrix tensile strength. Tighter quality controls must therefore be enforced on ply thickness and matrix strength in order to achieve high reliability of the structure.

Shah, A. R.↗

DOE OSTI2020

An Approach to Dependence Assessment in Human Reliability Analysis: Application of Lag and Linger Effects

Dependence assessment refers to an approach used in human reliability analysis (HRA) to adjust a human error probability (HEP) for the following action by considering the impact of the preceding action. It has been known to significantly affect the overall results of probabilistic safety assessment (PSA). If the dependence assessment is not adequate, the result could be unconvincing for explaining the operator failures in the context of PSA. To date, several methods and some recent research have identified suggestions for treating dependence issues in HRA; however, these are still exclusively based on the intrinsic approach of the Technique for Human Error Rate Prediction (THERP), an HRA method. THERP inevitably has a challenge with the subjectivity of expert evaluation as well as the requirement for PSA and HRA expertise with resource-intensive and time-consuming processes. This paper suggests an approach to dependence assessment that could not only minimize the influence of expert judgment, but also saves time to perform the analysis with reasonable manpower. It modifies existing HRA methods with considering lag and linger effects to apply dependence effects for them. Based on a representative HRA method, i.e., Standardized Plant Analysis Risk - HRA (SPAR-H), guidance for how to apply lag and linger effects for the HRA method is suggested. Then, an investigation is carried out to compare quantification results of the revised HRA method with that of the original approach based on experimental data.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2021

An extended polynomial chaos expansion for PDF characterization and variation with aleatory and epistemic uncertainties

This paper presents an extended polynomial chaos formalism for epistemic uncertainties and a new framework for evaluating sensitivities and variations of output probability density functions (PDF) to uncertainty in probabilistic models of input variables. An ”extended” polynomial chaos expansion (PCE) approach is developed that accounts for both aleatory and epistemic uncertainties, modeled as random variables, thus allowing a unified treatment of both types of uncertainty. We explore in particular epistemic uncertainty associated with the choice of prior probabilistic models for input parameters. A PCE-based Kernel Density (KDE) construction provides a composite map from the PCE coefficients and germ to the PDF of quantities of interest (QoI). Here, the sensitivities of these PDF with respect to the input parameters are then evaluated. Input parameters of the probabilistic models are considered. By sampling over the epistemic random variable, a family of PDFs is generated and the failure probability is itself estimated as a random variable with its own PCE. Integrating epistemic uncertainties within the PCE framework results in a computationally efficient paradigm for propagation and sensitivity evaluation. Two typical illustrative examples are used to demonstrate the proposed approach.

Aleatory uncertainty↗

DOE OSTI2022

Mechanistic modeling of lifetime distribution of SiC/SiC composite claddings

Silicon carbide (SiC) fiber-reinforced SiC matrix (SiC/SiC) composites have emerged as a new material candidate for fuel claddings in light water reactors. Recent studies showed that the load capacity of SiC/SiC materials exhibits a considerable statistical variation. Therefore, reliability analysis plays a critical role in design of SiC/SiC composite claddings. Here, this paper presents a probabilistic model for the lifetime distribution of SiC/SiC composites. The model is anchored by a multiaxial stress-based failure criterion and subcritical damage accumulation mechanism. Based on the kinetics of subcritical damage growth, the lifetime distribution of a laboratory test specimen for any given loading history can be calculated. A finite weakest-link model is used to extrapolate the lifetime distribution of test specimens to full-length claddings. It is shown that the damage accumulation mechanism has a strong influence on the lifetime distribution of the cladding. This finding highlights the importance of understanding the static fatigue behavior of SiC/SiC composites. The present analysis also demonstrates an intricate length effect on the failure probability of the cladding, which is expected to play a crucial role in design extrapolation.

36 MATERIALS SCIENCE↗

NASA NTRS1982

A unified method for evaluating real-time computer controllers: A case study

A real time control system consists of a synergistic pair, that is, a controlled process and a controller computer. Performance measures for real time controller computers are defined on the basis of the nature of this synergistic pair. A case study of a typical critical controlled process is presented in the context of new performance measures that express the performance of both controlled processes and real time controllers (taken as a unit) on the basis of a single variable: controller response time. Controller response time is a function of current system state, system failure rate, electrical and/or magnetic interference, etc., and is therefore a random variable. Control overhead is expressed as a monotonically nondecreasing function of the response time and the system suffers catastrophic failure, or dynamic failure, if the response time for a control task exceeds the corresponding system hard deadline, if any. A rigorous probabilistic approach is used to estimate the performance measures. The controlled process chosen for study is an aircraft in the final stages of descent, just prior to landing. First, the performance measures for the controller are presented. Secondly, control algorithms for solving the landing problem are discussed and finally the impact of the performance measures on the problem is analyzed.

Shin, K. G.↗

NASA NTRS1985

A unified method for evaluating real-time computer controllers and its application

Shin, K. G.↗

NASA NTRS1999

Design of Composite Structures for Reliability and Damage Tolerance

A summary of research conducted during the first year is presented. The research objectives were sought by conducting two tasks: (1) investigation of probabilistic design techniques for reliability-based design of composite sandwich panels, and (2) examination of strain energy density failure criterion in conjunction with response surface methodology for global-local design of damage tolerant helicopter fuselage structures. This report primarily discusses the efforts surrounding the first task and provides a discussion of some preliminary work involving the second task.

Rais-Rohani, Masoud↗

NASA NTRS2006

Hard and Soft Constraints in Reliability-Based Design Optimization

This paper proposes a framework for the analysis and design optimization of models subject to parametric uncertainty where design requirements in the form of inequality constraints are present. Emphasis is given to uncertainty models prescribed by norm bounded perturbations from a nominal parameter value and by sets of componentwise bounded uncertain variables. These models, which often arise in engineering problems, allow for a sharp mathematical manipulation. Constraints can be implemented in the hard sense, i.e., constraints must be satisfied for all parameter realizations in the uncertainty model, and in the soft sense, i.e., constraints can be violated by some realizations of the uncertain parameter. In regard to hard constraints, this methodology allows (i) to determine if a hard constraint can be satisfied for a given uncertainty model and constraint structure, (ii) to generate conclusive, formally verifiable reliability assessments that allow for unprejudiced comparisons of competing design alternatives and (iii) to identify the critical combination of uncertain parameters leading to constraint violations. In regard to soft constraints, the methodology allows the designer (i) to use probabilistic uncertainty models, (ii) to calculate upper bounds to the probability of constraint violation, and (iii) to efficiently estimate failure probabilities via a hybrid method. This method integrates the upper bounds, for which closed form expressions are derived, along with conditional sampling. In addition, an l(sub infinity) formulation for the efficient manipulation of hyper-rectangular sets is also proposed.

Crespo, L.uis G.↗

DOE OSTI2020

Limitations of traditional tools for beyond design basis external hazard PRA

Probabilistic risk assessment (PRA) is being used increasingly by the nuclear industry for safety during normal operations as well as for the protection against external hazards. Computation of total risk in an external hazard PRA is dependent on hazard assessment, fragility assessment, and systems analysis. A systems analysis for propagation of component fragilities is conducted using event and fault trees. The event and fault trees for an actual power plant can be fairly large in size, which imposes computational challenges. Hence, certain assumptions are employed for computational efficiency. These assumptions typically represent the conditions imposed during the design basis (DB) scenario. The traditional PRA tools based on these assumptions are also widely applied to perform risk assessment in the context of beyond design basis (BDB) scenarios. However, some of these assumptions may not be valid for certain BDB scenarios. In addition, the probability of dependent failures also increases in BDB scenarios due to common cause failures (CCF) which usually results from design modifications, human errors, etc. In this manuscript, a simple and a relatively more complex illustrative examples are used to show the limitation of these assumptions in the numerical quantification of risk for the case of BDB conditions. Case studies with CCF events across multiple fault trees are also presented to illustrate the effect of these assumptions when traditional approach is used in BDB risk assessment. It is shown that the assumptions are valid for the case of DB conditions but may lead to excessively conservative risk estimates in the case of BDB conditions. Finally, a Bayesian network based top-down algorithm is proposed as an alternative tool for accurate numerical quantification of total risk in systems analysis.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗