航空锻件常见表观缺陷及其控制研究

目的 揭示服役寿命长、工况苛刻、锻造成本高、质量控制难度大的航空结构件与发动机盘件用钛合金、高温合金等锻件外观缺陷的产生原因及控制措施。方法 按照航空锻件锻造流程(开坯、制坯、模锻和锻后热处理),分别研究裂纹、折叠、错移等锻造缺陷产生的原因。结果 航空锻件产生表观质量缺陷的原因一般由工艺设计不合理、锻造操作不当、工装设备保障不到位等导致,需结合锻件材料、形状、变形过程等采取对应措施进行优化解决。结论 对航空锻件缺陷产生原因进行了研究,给出了行之有效的解决措施,对于航空锻件质量的提高,尤其是新材料、大尺寸、复杂结构的航空锻件研制具有重要的工程指导意义。     

Anomaly detection of aircraft lead-acid battery

The lead-acid battery has been widely used in various fields. In civil aviation aircraft, it plays a vital role in the power system to maintain normal operation during the flight mission. Thus, an effective abnormal detection system for monitoring and diagnosing the status of aircraft lead-acid battery is essential to ensure its safety and reliability. This paper aims to effectively identify aircraft battery faulty using unsupervised anomaly detection techniques. It introduces state-of-the-art anomaly detection algorithms and evaluates their performance on a large real civil aviation battery data. The experimental results show that the latest isolation-based anomaly detectors, iForest and iNNE, have outstanding performance on this task and have promising applicability as efficient methods for guaranteeing the lead-acid battery quality and reliability in civil aviation aircraft.     

Severe accidents in the energy sector: comparative perspective

This paper addresses one of the controversial issues in the current comparative studies of the environmental and health impacts of energy systems, i.e. the treatment of severe accidents. The work covers technical aspects of severe accidents and thus primarily reflects an engineering perspective on the energy-related risk issues, though some social implications are also touched upon. The assessment concerns fossil energy sources (coal, oil and gas), nuclear power and hydro power. The scope is not limited to the power production (conversion) step of these energy chains but, whenever applicable, also includes exploration, extraction, transports, processing, storage and waste disposal. With the exception of the nuclear chain the focus of the work has been on the evaluation of the historical experience of accidents. The basis used for this evaluation is a comprehensive database ENSAD (Energy-related Severe Accident Database), established by the Paul Scherrer Institut (PSI). For hypothetical nuclear accidents the probabilistic technique has also been employed and extended to cover the assessment of economic consequences of such accidents. The broader picture obtained by coverage of full energy chains leads on the world-wide basis to aggregated immediate fatality rates being much higher for the fossil chains than what one would expect if only power plants were considered. Generally, the immediate fatality rates are for all considered energy carriers significantly higher for the non-OECD countries than for OECD countries. In the case of hydro and nuclear the difference is in fact dramatic. The presentation of results is not limited to the aggregated values specific for each energy chain. Also frequency-consequence curves are provided. They reflect implicitly the ranking based on the aggregated values but include also such information as the observed or predicted chain-specific maximum extents of damages. This perspective on severe accidents may lead to different system rankings, depending on the individual risk aversion.     

Age-dependent reliability model considering effects of maintenance and working conditions

Nowadays, there is some doubt about building new nuclear power plants (NPPs). Instead, there is a growing interest in analyzing the possibility to extend current NPP operation, where life management programs play an important role. The evolution of the NPP safety depends on the evolution of the reliability of its safety components, which, in turn, is a function of their age along the NPP operational life. In this paper, a new age-dependent reliability model is presented, which includes parameters related to surveillance and maintenance effectiveness and working conditions of the equipment, both environmental and operational. This model may be used to support NPP life management and life extension programs, by improving or optimizing surveillance and maintenance tasks using risk and cost models based on such an age-dependent reliability model. The results of the sensitivity study in the example application show that the selection of the most appropriate maintenance strategy would directly depend on the previous parameters. Then, very important differences are expected to appear under certain circumstances, particularly, in comparison with other models that do not consider maintenance effectiveness and working conditions simultaneously.     

C形环小试样疲劳裂纹扩展试验方法与应用

航空航天、核反应堆工程等重要工程结构的安全控制对材料断裂性能有重要需求,小尺寸试样断裂韧性测试需求日益凸显。该文提出了一套用于小尺寸构件疲劳裂纹扩展速率测试的C形环小试样试验方法,设计了试样构形和试验夹具,并基于有限元分析和柔度法理论,建立了C形环小试样裂纹长度预测公式和应力强度因子K的表达式。对于低压转子材料26NiCrMoV11-5钢,采用C形环小试样和标准CT试样完成了疲劳裂纹扩展试验,获得了材料的疲劳裂纹扩展特性,并讨论了新方法的有效性。     

Limit load analyses of helical coiled steam generator tubes with a volumetric flaw

Maintaining structural integrity of piping has always been an important effort in the nuclear power industry. To resolve piping issues such as unanticipated failures caused by diverse planar and volumetric flaws, several guidelines were developed and used especially for assessment of steam generator tubes. However, because the major components of new reactors have dissimilar geometric features and loading conditions compared with those of conventional operating reactors, most of existing assessment methods are not expected to be applicable; therefore, new alternative assessment guidelines are required. In this paper, a systematic structural integrity assessment of helical coiled steam generator tubes for a small and medium modular reactor, which is currently being designed, is introduced. Three‐dimensional detailed finite element (FE) limit analyses have been carried out to simulate the behaviours of the tube containing a volumetric flaw such as elliptical wear‐type, rectangular wear‐type and tapered wear‐type defects subjected to external pressure. Failure pressures were calculated from the FE analyses by changing defect depth, defect length and defect angle affecting the load‐carrying capacity of the tube. Thereby, engineering equations were developed as a function of these key parameters to predict structural failures and system reliability to enable more reasonable design and manufacturing decisions.     

Electronics in nuclear power programme of India—An overview

This paper presents an overview of state-of-the art developments in electronics for nuclear power programme of India. Indigenous activities in instrumentation and control (I&C) in the areas of detector development, nuclear instrumentation, monitoring and control electronics and special sensors paved the way to self-reliance in nuclear industry. Notable among the recent I&C systems developed for 540 MWe reactors are Liquid Zone Control System (LZCS), flux mapping system and advance reactor regulating system. In a nuclear plant, apart from ensuring functional requirements, design of electronics needs to meet high level of reliability, safety and security standards. Therefore, a lot of importance is attached to activities such as design review, testing, operation, maintenance and qualifications of I&C systems. Induction of computer based I&C systems mandated a rigorous verification process commensurate with the safety class of the system as specified in Atomic Energy Regulatory Board (AERB) safety guides. Software reliability is assured by following strict development life cycle combined with zero-defect policy and is verified through verification and validation (V&V) process. Development of new techniques in data transmissions with optical fibres as transmission medium and wireless networks in control systems is being pursued. With new I&C systems, efforts were made to utilize the same hardware and software platforms for various plant applications, i.e., for standardization. Thrust was given to use Field Programmable Gate Arrays (FPGA) and Application Specific Integrated Circuits (ASIC) in order to improve the reliability of system by reducing component count. It has become imperative to develop modern contemporary solutions like ASICs, HMCs, System on Chip (SOC) and detector mounted electronics and towards that various ASICs and HMCs have been developed in-house to meet the challenges.     

Vertebral fractures in motor vehicle accidents–a medical and technical analysis of 33,015 injured front-seat occupants

Spinal injuries pose a considerable risk to life and quality of life. In spite of improvements in active and passive safety of motor vehicles, car accidents are regarded as a major cause for vertebral fractures. The purpose of this study was to evaluate the current incidence of vertebral fractures among front-seat occupants in motor vehicle accidents, and to identify specific risk factors for sustaining vertebral fractures in motor vehicle accidents. Data from an accident research unit were accessed to collect collision details, preclinical data, and clinical data. We included all data on front-seat occupants. Hospital records were retrieved, and radiological images were evaluated.     

我国核电站老化与寿命管理数据质量的表征

老化与寿命管理技术研究是进行核电站寿命与安全分析的重要手段。数据是开展具体研究的核心纽带,而数据质量的问题严重制约了相关研究技术的推进与发展。本文从我国核电站老化与寿命管理的起因及相关技术研究的现状出发,系统地梳理了核电站老化数据的来源与特点,利用层次分析的观点,引入数据全生命周期的概念,提出影响数据质量的主要因素以及数据表征的体系结构,为开展核电站老化与寿命管理数据质量问题的研究提供重要参考。     

Improving aircraft safety and reliability by aircraft maintenance technician training

Aircraft maintenance is one of the primary causes or contributing factors in aircraft accidents. It is clear that proper training of Aircraft Maintenance Technicians (AMTs) will avoid failures, reduce maintenance related accidents, improve safety and reliability in aviation and provide recovery of the increasing demand to qualified AMTs for sustainability of the market growth. In this study, European Safety Agency (EASA) based AMT licencing system in EU states (and non-EU states implementing EASA rules) has been analysed and a training model developed in accordance with EASA Part-66 requirements and delivered by e-learning methods has been introduced. The analysis of the licensing process based on EASA regulations showed that this process was based on the candidate's demonstration of knowledge and acquisition of experience. The required experience depends on the training background of the candidate. Field exercise showed that developed e-learning training model, which overcomes the disadvantages of traditional face to face training models, succeeded to improve the attendees' theoretical knowledge level and when combined with the practical trainings given to AMT candidates in maintenance organisations during their experience periods, will be very successful in improving safety and reliability in aviation maintenance operations.     

高强韧锆合金的发展与应用

锆及其合金具有较好的尺寸稳定性、抗辐照和耐腐蚀等性能,因此在航空航天、航海、核反应堆和生物医用等领域具有重要的应用前景.而纯锆及应用较为广泛的锆合金的抗拉强度较低,提升锆及其合金的力学性能成为其能成功应用于结构件的关键环节.本文简要概述了锆及其合金在核工业、化工、医疗及航空航海等领域的发展现状.此外,本文还着重介绍了新型高强韧锆合金的设计与制备,获取了可在空间探测、深海探测以及高速铁路等特殊领域中使用的锆系合金的最佳成分,并详细阐述了新型高强韧锆合金的强化机理及其在核电、化工及航空领域中的应用.     

Effect of droplet size distribution on reaction heat in a liquid-liquid heterogeneous reaction process

Within the United Kingdom the Air Accidents Investigation Branch (AAIB) has been used as a model for the other transport modes accident investigation bodies. Government Ministers considered that the AAIB's approach had established the trust of the public and the aviation industry in its ability to conduct independent and objective investigations. The paper will examine the factors that are involved in establishing this trust. They include: the investigation framework; the actual and perceived independence of the accident investigating body; the aviation industry's safety culture; the qualities of the investigators and the quality of their liaison with bereaved families those directly affected by the accidents they investigate.     

NAROAS: a neural network-based advanced operator support system for the assessment of systems reliability

We have developed and implemented a computerized reliability monitoring system for nuclear power plant applications, based on a neural network. The developed computer program is a new tool related to operator decision support systems, in case of component failures, for the determination of test and maintenance policies during normal operation or to follow an incident sequence in a nuclear power plant. The NAROAS (Neural Network Advanced Reliability Advisory System) computer system has been developed as a modularized integrated system in a C++ Builder environment, using a Hopfield neural network instead of fault trees, to follow and control the different system configurations, for interventions as quickly as possible at the plant. The observed results are comparable and similar to those of other computer system results. As shown, the application of this neural network contributes to the state of the art of risk monitoring systems by turning it easier to perform online reliability calculations in the context of probabilistic safety assessments of nuclear power plants.     

核电厂管道振动原因分析及对策

管道是核电厂主要的组成部份。核电厂管道的振动往往引起管道的振动疲劳,长期积累致使管道开裂,严重时核电厂被迫停堆检修,甚至造成灾难性事故。为了减少此类事件的发生,本文总结了诱发核电厂管道振动的主要原因,有旋转设备的振动、水锤、流体脉动、气蚀、气液两相流、风载荷、地震载荷和人为误差等几种,并列举了相关事件案例,提出了常见的整改方案。本文旨在为核电厂管道的设计、建造、维护与整改等工作提供必要的参考依据。     

The contribution of human factors to accidents in the offshore oil industry

Accidents such as the Piper Alpha disaster illustrate that the performance of a highly complex socio-technical system, is dependent upon the interaction of technical, human, social, organisational, managerial and environmental factors and that these factors can be important co-contributors that could potentially lead to a catastrophic event. The purpose of this article is to give readers an overview of how human factors contribute to accidents in the offshore oil industry. An introduction to human errors and how they relate to human factors in general terms is given. From here the article discusses some of the human factors which were found to influence safety in other industries and describes the human factors codes used in accident reporting forms in the aviation, nuclear and marine industries. Analysis of 25 accident reporting forms from offshore oil companies in the UK sector of the North Sea was undertaken in relation to the human factors. Suggestions on how these accident reporting forms could be improved are given. Finally, this article describes the methods by which accidents can be reduced by focusing on the human factors, such as feedback from accident reporting in the oil industry, auditing of unsafe acts and auditing of latent failures.     

The role of safety analysis in accident prevention

The need for safety analysis has grown in the fields of nuclear industry, civil and military aviation and space technology where the potential for accidents with far-reaching consequences for employees, the public and the environment is most apparent. Later the use of safety analysis has spread widely to other industrial branches. General systems theory, accident theories and scientific management represent domains that have influenced the development of safety analysis. These relations are shortly presented and the common methods employed in safety analysis are described and structured according to the aim of the search and to the search strategy. A framework for the evaluation of the coverage of the search procedures employed in different methods of safety analysis is presented. The framework is then used in an heuristic and in an empiric evaluation of hazard and operability study (HAZOP), work safety analysis (WSA), action error analysis (AEA) and management oversight and risk tree (MORT). Finally, some recommendations on the use of safety analysis for preventing accidents are presented.     

国防工业系统民用产业的标准化

本文综合核、航天、航空、船舶、兵器等国防工业民用产业标准化发展的简要历史和现状,并从服务于型号工程、进入国内外市场、保证安全等方面阐述了它的作用、效果和存在问题,最后提出了坚持军民结合、尽快完善高技术民用产业标准体系、继续与专项重大工程相结合,以及与国防接轨等政策性和重点任务的建议。     

Failures in inspection procedures: case studies

The most frequently used inspection methods, i.e., visual examination, dye penetrant examination, magnetic particle examination, eddy current examination, and ultrasonic examination, are, for the most part, effective and reliable. There have been instances, however, particularly in the aviation field, where the designated methods of inspection were not able to detect cracks, and as a result catastrophic failures occurred. In the aviation field, when major-accidents occur there is usually a thorough investigation to determine the cause. We are fortunate the accident reports concerning such events are made public, so that engineers can learn from the mistakes which led to an accident and take corrective action to prevent a recurrence of such accidents. The present paper discusses a number of cases wherein faulty inspection procedures resulted in accidents. These cases are based upon published reports as well as personal experiences, and will deal with the crashes which involved: a 707 freighter (visual examination), a DC-10 (dye penetrant), a small passenger plane (magnetic particle), a 737 (eddy currents), and a 747 freighter (ultrasonics).     

Safety of nuclear power plants

The safety of operating nuclear power plants of the CANDU type is described in this paper. The need for a systematic study on these types of heavy water reactors similar to the safety studies done on light water reactors is brought out in this paper. Some of the work done on station blackout, operational transients, small and large break loss of coolant accidents is reviewed. Recent nuclear power plant accidents, namely Three-Mile Island-2 and Chernobyl, seem to indicate that an understanding of man-machine interaction and human behaviour under stress is important for the safety aspects and more work needs to be done in these areas.     

Testing digital safety system software with a testability measure based on a software fault tree

Using predeveloped software, a digital safety system is designed that meets the quality standards of a safety system. To demonstrate the quality, the design process and operating history of the product are reviewed along with configuration management practices. The application software of the safety system is developed in accordance with the planned life cycle. Testing, which is a major phase that takes a significant time in the overall life cycle, can be optimized if the testability of the software can be evaluated. The proposed testability measure of the software is based on the entropy of the importance of basic statements and the failure probability from a software fault tree. To calculate testability, a fault tree is used in the analysis of a source code. With a quantitative measure of testability, testing can be optimized. The proposed testability can also be used to demonstrate whether the test cases based on uniform partitions, such as branch coverage criteria, result in homogeneous partitions that is known to be more effective than random testing. In this paper, the testability measure is calculated for the modules of a nuclear power plant's safety software. The module testing with branch coverage criteria required fewer test cases if the module has higher testability. The result shows that the testability measure can be used to evaluate whether partitions have homogeneous characteristics.