This paper describes an end-to-end Integrated Vehicle Health Management (IVHM) development process with a strong emphasis on the COTS software tools employed for the implementation of this process. A mix of physical simulation and functional failure analysis was chosen as a route for early assessment of degradation in complex systems as capturing system failure modes and their symptoms facilitates the assessment of health management solutions for a complex asset. The method chosen for the IVHM development is closely correlated to the generic engineering cycle. The concepts employed by this method are further demonstrated on a laboratory fuel system test rig, but they can also be applied to both new and legacy hi-tech high-value systems. Another objective of the study is to identify the relations between the different types of knowledge supporting the health management development process when using together physical and functional models. The conclusion of this lead is that functional modeling and physical simulation should not be done in isolation. The functional model requires permanent feedback from a physical system simulator in order to be able to build a functional model that will accurately represent the real system. This paper will therefore also describe the steps required to correctly develop a functional model that will reflect the physical knowledge inherently known about a given system.
Integrated Vehicle Health Management (IVHM) describes a set of capabilities that enable effective and efficient maintenance and operation of the target vehicle. It accounts for the collecting of data, conducting analysis, and supporting the decision-making process for sustainment and operation. The design of IVHM systems endeavours to account for all causes of failure in a disciplined, systems engineering, manner. With industry striving to reduce through-life cost, IVHM is a powerful tool to give forewarning of impending failure and hence control over the outcome. Benefits have been realised from this approach across a number of different sectors but, hindering our ability to realise further benefit from this maturing technology, is the fact that IVHM is still treated as added on to the design of the asset, rather than being a sub-system in its own right, fully integrated with the asset design. The elevation and integration of IVHM in this way will enable architectures to be chosen that accommodate health ready sub-systems from the supply chain and design trade-offs to be made, to name but two major benefits. Barriers to IVHM being integrated with the asset design are examined in this paper. The paper presents progress in overcoming them, and suggests potential solutions for those that remain. It addresses the IVHM system design from a systems engineering perspective and the integration with the asset design will be described within an industrial design process.
Traditionally the life cycle phases of a typical project in the Oil & Gas industry can be broken down into: Feasibility & Concept Design; Front End Engineering Design (FEED); Detail Design; Manufacture and Construction; Installation and Commissioning; Operation. A range of Process Hazard Analysis (PHA) tools are used throughout these phases in hazard identification and analysis, to understand the effects to the system as a result of the hazards and to eliminate/reduce/mitigate the identified hazards. These PHA tools are typically carried out independent from one another albeit from the same base documentation (e.g. P&ID’s) and they are subsequently documented independently e.g. Hazardous & Operability (HAZOP) study, Risk Analysis, Layer of Protection Analysis (LOPA), Failure Mode, Effects and Criticality Analysis (FMECA). Prognostics and Health Management (PHM) is a life cycle concept introducing an integrated approach to the health management of a system through the design and operation cycles. The design cycle can be broken down into: System Design; Identification and Analysis of Risk; Failure Modelling and how it affects the System in terms of Reliability/Availability/Maintainability. The operation cycle can be broken down into: Real-time Monitoring; Diagnostics; Failure Prediction; Determine Maintenance Strategies. Parallels can be drawn between life cycle phases in both the traditional approach and a PHM approach during project development. Therefore, if projects can be developed within a PHM environment, this may lead to greater integration between the stakeholders, with the potential for a technically superior product developed with cost and efficiency savings. The aim of this paper is to review the concepts of Functional Analysis within a PHM environment, to assess its suitability and applicability during the engineering design and operation of an Oil-Injected Rotary Screw Compressor. PHA tools, sensor set design and the organisation interfaces that exist between the stakeholders represented throughout the life cycle of a project shall be reviewed. The outcomes from the Functional Analysis modelling application, Maintenance Aware Design environment (MADe™) in terms of sensor set design and PHA tools shall be compared with the existing processes used in the traditional approach throughout the life cycle of a project. The paper shall also review the organisational interfaces that exist between the stakeholders that are represented throughout the life cycle of the project and how these relationships can deliver a safe, functional system that maximises reliability, availability and maintainability of the asset whilst facilitating fault detection/isolation and potential fault prediction. A functional model of the compressor package was created using the MADe™ functional modelling application. Functional analyses of key components were performed and sensors set options were reviewed for applicability and suitability. Key components were identified for functional failure analysis either from Offshore Reliability Data Handbook (OREDA, 2015), documentation supplied by the Original Equipment Manufacturer (OEM) or from a FMECA report derived from the functional model’s PHA suite of tools. The key roles and responsibilities of each of the stakeholders were analysed to explore shared responsibility, business outcomes and engineering/technical deliverables. The results demonstrate that functional analysis software applications can facilitate sensor set design to detect and isolate faults associated with the system’s components and that those are comparable – with some manual adjustment – with the traditional approaches used in sensor set design. The results also show that a functional analysis approach is a viable tool in the PHA process i.e. it can generate FMECA reports and can be used to complement HAZOP studies. Finally using a PHM functional modelling application can benefit the main stakeholders in terms of demonstrating reliability, availability and maintainability of equipment whilst realising cost savings and improved efficiency.
This paper describes an end-to-end Integrated Vehicle Health Management (IVHM) development process with a strong emphasis on the automation in creating functional models from 3D Computer Aided Design (CAD) system’s representation, throughout the implementation of this process. It has been demonstrated that functional analysis enhances the design and development of IVHM but this approach is not widely adopted by industry and the research community as it carries a significant amount of subjectivism. This paper is meant to be a guideline that supports the correctness through construction of a functional representation for a complex mechatronic system. The knowledge encapsulated in the 3D CATIA™ System Design environment was linked with the Maintenance Aware Design environment (MADe™) with the scope of automatically creating functional models of the geometry of a system. The entire process is documented step by step and it is demonstrated on a laboratory fuel system test rig. The paper is part of a larger effort towards an integrated COTS toolset for IVHM design. Another objective of the study is to identify the relations between the different types of knowledge supporting the health management development process when used together with the spatial and functional dimensions of an asset. The conclusion of this work is that a 3D CAD model containing the topological representation of a complex system can automate the development of the functional model of such a system.
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