System Health Management

Dr Stephen B. Johnson is a Heath Management Systems Engineer at the NASA Marshall Space Flight Center in the USA, as well as an associate research professor at the University of Colorado at Colorado Springs. He has been active in the field of SHM for over 20 years, and has authored many research papers on the topic. He has also authored or edited 3 books in the aerospace field including The Secret of Apollo: Systems Management in American and European Space Programs. Mr Thomas Gormley has been involved with the NASA Aerospace industry for over 20 years, and was the Integrated Vehicle Health Management Project Leader for Rockwell Space Systems during the early 1990s. He brings expertise in systems implementation to the project.Dr Seth S. Kessler is president and owner of Metis Design Corporation, a design consulting firm specializing in custom sensing solutions. He brings expertise in structural health monitoring and composite materials to the project.Mr Charles Mott is a business analyst with the Tauri group, currently under contract at NASA. He brings expertise in the socio-technical aspects of large-scale technological projects to the project.Dr Ann Patterson-Hine is Group Leader of the Health Management Technologies Group at the Ames Research Center. She brings expertise on the use of engineering models for model-based reasoning in advanced monitoring and diagnostic systems to the project.Dr Karl Reichard is head of the ARL Penn State Monitoring and Automation Department. He brings expertise in the implementation of signal processing, control and embedded diagnostMr Philip A. Scandura, Jr joined Honeywell in 1984 where he currently holds the position of Staff Scientist in their Advanced Technology Organization. He brings expertise in the system definition and implementation of real-time, embedded systems for use in safety-critical and mission-critical applications to the project.

• About the Editors xxiii List of Contributors xxvForeword xxixPreface xxxiiiPart One THE SOCIO-TECHNICAL CONTEXT OF SYSTEM HEALTH MANAGEMENTCharles D. Mott1 The Theory of System Health Management 3Stephen B. JohnsonOverview 31.1 Introduction 31.2 Functions, Off-Nominal States, and Causation 71.3 Complexity and Knowledge Limitations 101.4 SHM Mitigation Strategies 111.5 Operational Fault Management Functions 121.6 Mechanisms 191.7 Summary of Principles 221.8 SHM Implementation 231.9 Some Implications 241.10 Conclusion 26Bibliography 262 Multimodal Communication 29Beverly A. SauerOverview 292.1 Multimodal Communication in SHM 312.2 Communication Channels 342.3 Learning from Disaster 362.4 Current Communication in the Aerospace Industry 372.5 The Problem of Sense-making in SHM Communication 372.6 The Costs of Faulty Communication 382.7 Implications 392.8 Conclusion 41Acknowledgments 43Bibliography 433 Highly Reliable Organizations 49Andrew WiedleaOverview 493.1 The Study of HROs and Design for Dependability 493.2 Lessons from the Field: HRO Patterns of Behavior 523.2.1 Inseparability of Systemic Equipment and Anthropologic Hazards 533.2.2 Dynamic Management of System Risks 543.2.3 Social Perceptions of Benefits and Hazards 563.3 Dependable Design, Organizational Behavior, and Connections to the HRO Project 573.4 Conclusion 60Bibliography 614 Knowledge Management 65Edward W. RogersOverview 654.1 Systems as Embedded Knowledge 664.2 KM and Information Technology 664.3 Reliability and Sustainability of Organizational Systems 674.4 Case Study of Building a Learning Organization: Goddard Space Flight Center 694.5 Conclusion 75Bibliography 755 The Business Case for SHM 77Kirby Keller and James PobleteOverview 775.1 Business Case Processes and Tools 785.2 Metrics to Support the Decision Process 805.3 Factors to Consider in Developing an Enterprise Model 825.4 Evaluation of Alternatives 865.5 Modifications in Selected Baseline Model 865.6 Modeling Risk and Uncertainty 875.7 Model Verification and Validation 885.8 Evaluation Results 885.9 Conclusion 90Bibliography 91Part Two SHM AND THE SYSTEM LIFECYCLESeth S. Kessler6 Health Management Systems Engineering and Integration 95Timothy J. Wilmering and Charles D. MottOverview 956.1 Introduction 956.2 Systems Thinking 966.3 Knowledge Management 976.4 Systems Engineering 986.5 Systems Engineering Lifecycle Stages 996.6 Systems Engineering, Dependability, and Health Management 1006.7 SHM Lifecycle Stages 1036.8 SHM Analysis Models and Tools 1106.9 Conclusion 112Acknowledgments 112Bibliography 1127 Architecture 115Ryan W. Deal and Seth S. KesslerOverview 1157.1 Introduction 1157.2 SHM System Architecture Components 1177.3 Examples of Power and Data Considerations 1197.4 SHM System Architecture Characteristics 1207.5 SHM System Architecture Advanced Concepts 1267.6 Conclusion 126Bibliography 1278 System Design and Analysis Methods 129Irem Y. TumerOverview 1298.1 Introduction 1298.2 Lifecycle Considerations 1308.3 Design Methods and Practices for Effective SHM 1328.4 Conclusion 141Acknowledgments 142Bibliography 1429 Assessing and Maturing Technology Readiness Levels 145Ryan M. MackeyOverview 1459.1 Introduction 1459.2 Motivating Maturity Assessment 1469.3 Review of Technology Readiness Levels 1479.4 Special Needs of SHM 1499.5 Mitigation Approaches 1519.6 TRLs for SHM 1539.7 A Sample Maturation Effort 1549.8 Conclusion 156Bibliography 15710 Verification and Validation 159Lawrence Z. Markosian, Martin S. Feather and David E. BrinzaOverview 15910.1 Introduction 15910.2 Existing Software V&V 16010.3 Feasibility and Sufficiency of Existing Software V&V Practices for SHM 16510.4 Opportunities for Emerging V&V Techniques Suited to SHM 16710.5 V&V Considerations for SHM Sensors and Avionics 17010.6 V&V Planning for a Specific SHM Application 17110.7 A Systems Engineering Perspective on V&V of SHM 18010.8 Conclusion 181Acknowledgments 181Bibliography 18111 Certifying Vehicle Health Monitoring Systems 185Seth S. Kessler, Thomas Brotherton and Grant A. GordonOverview 18511.1 Introduction 18511.2 Durability for VHM Systems 18611.3 Mechanical Design for Structural Health Monitoring Systems 18911.4 Reliability and Longevity of VHM Systems 19011.5 Software and Hardware Certification 19011.6 Airworthiness Certification 19111.7 Health and Usage Monitoring System Certification Example 19111.8 Conclusion 194Acknowledgments 194Bibliography 194Part Three ANALYTICAL METHODSAnn Patterson-Hine12 Physics of Failure 199Kumar V. Jata and Triplicane A. ParthasarathyOverview 19912.1 Introduction 20012.2 Physics of Failure of Metals 20112.3 Physics of Failure of CMCs 21212.4 Conclusion 216Bibliography 21613 Failure Assessment 219Robyn Lutz and Allen NikoraOverview 21913.1 Introduction 21913.2 FMEA 22013.3 SFMEA 22113.4 FTA 22213.5 SFTA 22213.6 BDSA 22313.7 Safety Analysis 22513.8 Software Reliability Engineering 22513.9 Tools and Automation 22813.10 Future Directions 22913.11 Conclusion 229Acknowledgments 230Bibliography 23014 Reliability 233William Q. Meeker and Luis A. EscobarOverview 23314.1 Time-to-Failure Model Concepts and Two Useful Distributions 23314.2 Introduction to System Reliability 23614.3 Analysis of Censored Life Data 23914.4 Accelerated Life Testing 24314.5 Analysis of Degradation Data 24414.6 Analysis of Recurrence Data 24614.7 Software for Statistical Analysis of Reliability Data 249Acknowledgments 250Bibliography 25015 Probabilistic Risk Assessment 253William E. VeselyOverview 25315.1 Introduction 25315.2 The Space Shuttle PRA 25415.3 Assessing Cumulative Risks to Assist Project Risk Management 25415.4 Quantification of Software Reliability 25715.5 Description of the Techniques Used in the Space Shuttle PRA 26015.6 Conclusion 263Bibliography 26316 Diagnosis 265Ann Patterson-Hine, Gordon B. Aaseng, Gautam Biswas, Sriram Narashimhan and Krishna PattipatiOverview 26516.1 Introduction 26616.2 General Diagnosis Problem 26716.3 Failure Effect Propagation and Impact 26716.4 Testability Analysis 26816.5 Diagnosis Techniques 26816.6 Automation Considerations for Diagnostic Systems 27616.7 Conclusion 277Acknowledgments 277Bibliography 27717 Prognostics 281Michael J. Roemer, Carl S. Byington, Gregory J. Kacprzynski, George Vachtsevanos and Kai GoebelOverview 28117.1 Background 28217.2 Prognostic Algorithm Approaches 28217.3 Prognosis RUL Probability Density Function 28717.4 Adaptive Prognosis 28717.5 Performance Metrics 28917.6 Distributed Prognosis System Architecture 29217.7 Conclusion 292Bibliography 293Part Four OPERATIONSKarl M. Reichard18 Quality Assurance 299Brian K. HughittOverview 29918.1 NASA QA Policy Requirements 30018.2 Quality System Criteria 30218.3 Quality Clauses 30318.4 Workmanship Standards 30418.5 Government Contract Quality Assurance 30418.6 Government Mandatory Inspection Points 30518.7 Quality System Audit 30618.8 Conclusion 307Bibliography 30819 Maintainability: Theory and Practice 309Gary O’NeillOverview 30919.1 Definitions of Reliability and Maintainability 31019.2 Reliability and Maintainability Engineering 31119.3 The Practice of Maintainability 31419.4 Improving R&M Measures 31519.5 Conclusion 316Bibliography 31720 Human Factors 319Robert S. McCann and Lilly SpirkovskaOverview 31920.1 Background 32020.2 Fault Management on Next-Generation Spacecraft 32320.3 Integrated Fault Management Automation Today 32520.4 Human–Automation Teaming for Real-Time FM 32820.5 Operations Concepts for Crew–Automation Teaming 33020.6 Empirical Testing and Evaluation 33320.7 Future Steps 33420.8 Conclusion 336Bibliography 33621 Launch Operations 339Robert D. Waterman, Patricia E. Nicoli, Alan J. Zide, Susan J. Waterman, Jose M. Perotti, Robert A. Ferrell and Barbara L. BrownOverview 33921.1 Introduction to Launch Site Operations 33921.2 Human-Centered Health Management 34021.3 SHM 34621.4 LS Abort and Emergency Egress 34721.5 Future Trends Post Space Shuttle 34821.6 Conclusion 349Bibliography 34922 Fault Management Techniques in Human Spaceflight Operations 351Brian O’Hagan and Alan CrockerOverview 35122.1 The Flight Operations Team 35222.2 System Architecture Implications 35322.3 Operations Products, Processes and Techniques 35822.4 Lessons Learned from Space Shuttle and ISS Experience 36422.5 Conclusion 366Bibliography 36723 Military Logistics 369Eddie C. Crow and Karl M. ReichardOverview 36923.1 Focused Logistics 37123.2 USMC AL 37323.3 Benefits and Impact of SHM on Military Operations and Logistics 37823.4 Demonstrating the Value of SHM in Military Operations and Logistics 38123.5 Conclusion 385Bibliography 386Part Five SUBSYSTEM HEALTH MANAGEMENTPhilip A. Scandura, Jr.24 Aircraft Propulsion Health Management 389Al Volponi and Bruce WoodOverview 38924.1 Introduction 38924.2 Basic Principles 39024.3 Engine-Hosted Health Management 39324.4 Operating Conditions 39424.5 Computing Host 39524.6 Software 39624.7 On-Board Models 39824.8 Component Life Usage Estimation 39824.9 Design of an Engine Health Management System 39924.10 Supporting a Layered Approach 40124.11 Conclusion 401Bibliography 40225 Intelligent Sensors for Health Management 405Gary W. Hunter, Lawrence G. Oberle, George Y. Baaklini, Jose M. Perotti and Todd HongOverview 40525.1 Introduction 40625.2 Sensor Technology Approaches 40725.3 Sensor System Development 40925.4 Supporting Technologies: High-Temperature Applications Example 41225.5 Test Instrumentation and Non-destructive Evaluation (NDE) 41325.6 Transition of Sensor Systems to Flight 41425.7 Supporting a Layered Approach 41525.8 Conclusion 416Acknowledgments 417Bibliography 41726 Structural Health Monitoring 419Fu-Kuo Chang, Johannes F.C. Markmiller, Jinkyu Yang and Yujun KimOverview 41926.1 Introduction 41926.2 Proposed Framework 42126.3 Supporting a Layered Approach 42726.4 Conclusion 427Acknowledgments 427Bibliography 42727 Electrical Power Health Management 429Robert M. Button and Amy ChicatelliOverview 42927.1 Introduction 42927.2 Summary of Major EPS Components and their Failure Modes 43127.3 Review of Current Power System HM 43727.4 Future Power SHM 44027.5 Supporting a Layered Approach 44127.6 Conclusion 442Bibliography 44228 Avionics Health Management 445Michael D. Watson, Kosta Varnavas, Clint Patrick, Ron Hodge, Carl S. Byington, Savio Chau and Edmund C. BarothOverview 44528.1 Avionics Description 44528.2 Electrical, Electronic and Electromechanical (EEE) Parts Qualification 44828.3 Environments 45028.4 Failure Sources 45328.5 Current Avionics Health Management Techniques 45328.6 Avionics Health Management Requirements 46028.7 Supporting a Layered Approach 46428.8 Conclusion 464Bibliography 46429 Failure-Tolerant Architectures for Health Management 467Daniel P. Siewiorek and Priya NarasimhanOverview 46729.1 Introduction 46729.2 System Failure Response Stages 46829.3 System-Level Approaches to Reliability 46929.4 Failure-Tolerant Software Architectures for Space Missions 47029.5 Failure-Tolerant Software Architectures for Commercial Aviation Systems 47529.6 Observations and Trends 47729.7 Supporting a Layered Approach 48029.8 Conclusion 480Acknowledgments 481Bibliography 48130 Flight Control Health Management 483Douglas J. ZimpferOverview 48330.1 A FC Perspective on System Health Management 48330.2 Elements of the FC System 48530.3 FC Sensor and Actuator HM 48530.4 FC/Flight Dynamics HM 49030.5 FC HM Benefits 49330.6 Supporting a Layered Approach 49330.7 Conclusion 493Bibliography 49431 Life Support Health Management 497David Kortenkamp, Gautam Biswas and Eric-Jan MandersOverview 49731.1 Introduction 49731.2 Modeling 50131.3 System Architecture 50431.4 Future NASA Life Support Applications 50931.5 Supporting a Layered Approach 51031.6 Conclusion 510Bibliography 51032 Software 513Philip A. Scandura, Jr.Overview 51332.1 Sampling of Accidents Attributed to Software Failures 51332.2 Current Practice 51432.3 Challenges 51732.4 Supporting a Layered Approach 51832.5 Conclusion 518Bibliography 518Part Six SYSTEM APPLICATIONSThomas J. Gormley33 Launch Vehicle Health Management 523Edward N. Brown, Anthony R. Kelley and Thomas J. GormleyOverview 52333.1 Introduction 52333.2 LVSHM Functionality and Scope 52433.3 LV Terminology and Operations 52633.4 LV Reliability Lessons Learned 52733.5 LV Segment Requirements and Architecture 52833.6 LVSHM Analysis and Design 52933.7 LV LVSHM System Descriptions 53433.8 LVSHM Future System Requirements 53733.9 Conclusion 540Bibliography 54134 Robotic Spacecraft Health Management 543Paula S. MorganOverview 54334.1 Introduction 54434.2 Spacecraft Health and Integrity Concerns for Deep-Space Missions 54434.3 Spacecraft SHM Implementation Approaches 54634.4 Standard FP Implementation 54634.5 Robotic Spacecraft SHM Allocations 54734.6 Spacecraft SHM Ground Rules and Requirements 54834.7 SFP and SIFP Architectures 55034.8 Conclusion 554Bibliography 55435 Tactical Missile Health Management 555Abdul J. Kudiya and Stephen A. MarottaOverview 55535.1 Introduction 55535.2 Stockpile Surveillance Findings 55635.3 Probabilistic Prognostics Modeling 55735.4 Conclusion 563Bibliography 56436 Strategic Missile Health Management 565Gregory A. RudermanOverview 56536.1 Introduction 56536.2 Fundamentals of Solid Rocket Motors 56636.3 Motor Components 56736.4 Challenges for Strategic Rocket Health Management 56836.5 State of the Art for Solid Rocket System Health Management (SHM) 57036.6 Current Challenges Facing SRM SHM 57236.7 Conclusion 574Bibliography 57437 Rotorcraft Health Management 577Paula J. Dempsey and James J. ZakrajsekOverview 57737.1 Introduction 57737.2 Rotorcraft System Health Management Standard Practices 57937.3 New Practices 58237.4 Lessons Learned 58337.5 Future Challenges 58437.6 Conclusion 585Bibliography 58538 Commercial Aviation Health Management 589Philip A. Scandura, Jr., Michael Christensen, Daniel Lutz and Gary BirdOverview 58938.1 Commercial Aviation Challenge 59038.2 Layered Approach to SHM 59038.3 Evolution of Commercial Aviation SHM 59138.4 Commercial State of the Art 59338.5 The Next Generation: Intelligent Vehicles/Sense and Respond 60038.6 Conclusion 603Bibliography 603Glossary 605Acronyms 607Index 617