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=
0
) (
) (
The failure rate data for the different components have been obtained from the
FARADIP.THREE data bank [RD 12].
4.4 REPAIRABLE AND NON-REPAIRABLE SYSTEMS
Systems can be generally classified into non-repairable and repairable systems. Non-repairable
systems are those that do not get repaired when they fail. On the other hand, repairable systems are
those that get repaired when fail. This is done by repairing or replacing the failed components in
the system.
Considering a system as a non-repairable one, analytical methods can be applied, obtaining
parameters such as the followings:
- system failure probability density function (pdf)
- warranty periods
- system failure rate
- mean time to failure (MTTF)
If the systems are treated as repairable ones and a maintenance policy is established, similar results
can be determined by means of simulation, obtaining the following parameters:
- system availability
- mean time between failure (MTBF)
Depending on the preliminary results of the reliability analysis, actions on the most critical
component of each system in order to improve system reliability can be considered. This action is
focused following two approaches,
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- fault avoidance, e.g. increase components reliability
- fault tolerance, e.g. consider component redundancy or k-out-of-n parallel configurations
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5 UPPER SHUTTER SYSTEM
5.1 INTRODUCTION
The aim of this chapter 5 is to make a comparison between the current status and the new status of
the dome upper shutter system. For this purpose, taking into account the failure rates of the
different components that compose the upper shutter, the MTBF, the MTTR and the availability
will be obtained.
In the new status analysis, the optional counterweight system has not been considered. If this
system is finally installed, it will increase the reliability associated to the upgraded upper shutter.
The following figures show some of the different components and subsystems that have been taken
into account for the reliability analysis:
Fig 5-1 Upper shutter current status guiding system and drive mechanism
Fig 5-2 Upper shutter new status guiding system and drive mechanism
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5.2 CURRENT STATUS
The following figure represents the RBD of the current status of the upper shutter system:
Fig 5-3 Upper shutter system current status reliability block diagram
5.2.1 System representation
For the correct operation of the upper shutter mechanism, the control system, the drive system and
the guiding system must work correctly. Therefore the RBD for the dome upper shutter
mechanism is as follows:
Fig 5-4 Upper shutter mechanism representation
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The control system controls the upper shutter drive system and is composed of a PLC (which
includes communication cards, power supplies, etc.) and a rectifier.
Fig 5-5 Upper shutter control system representation
As shown in Fig 5-1, the drive system is composed of four drives that two of them are in the
upper motor stations (upper part of the dome) and the other two are in the lower motor stations (at
the lower part of the dome). These drives are composed by some subsystems such as the frequency
converter (VSD), the motor, the brake, the encoder, the gearbox and the chain (see Fig 5-6). As it
can be seen in Table 5-1, some drives components have two MTTR (Mean Time To Repair) values
depending if the component belongs to an upper or a lower drive.
Fig 5-6 Upper shutter drive system representation
The guiding system, shown in Fig 5-1, is composed of twenty six bogies, which need to be
working for the correct movement of the dome upper shutter. In the same way, every wheel of the
bogie together with its corresponding bearing has to be working for its correct operation.
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Fig 5-7 Upper shutter guiding system representation
As it has been explained before, the system has been studied as a repairable system. The failure data
for each component, used as input for the system analysis, has been obtained from the
FARADIP.THREE data bank [RD 12], and are shown as follows:
Table 5-1. Component failure rate and MTTR used in the Upper Shutter System Current Status analysis
5.2.2 Results
The whole GTC Dome Shutters lifetime (50 years) has been considered. Up to 10000 different
failure scenarios have been simulated (with different combination of components failure along the
time). For each component, a MTTR (mean time to repair) value has been considered.
The MTBF for each subsystem has been obtained, as well as the MTBF of the whole system.
Applying the formula explained in chapter 4.1, with the selected MTTR, the availability and MTTR
of every subsystem and the whole system have been obtained. These results are shown in the
following table:
Failure Rate
(per million hours)
(1/hours)
Component MTTF
(hours)
Component MTTF
(years)
Component MTTR
(hours)
Wheels 2 0.000002 5.00E+05 119.05 168
Bearings 2 0.000002 5.00E+05 119.05 168
VSD 5 0.000005 2.00E+05 47.62 4
Motor a.c. 5 0.000005 2.00E+05 47.62 Upper: 36 / Lower: 24
Brake 10 0.00001 1.00E+05 23.81 Upper: 12 / Lower: 8
Encoder 7 0.000007 1.43E+05 34.01 Upper: 36 / Lower: 24
Gearbox 20 0.00002 5.00E+04 11.90 Upper: 72 / Lower: 48
Chain 0.5 0.0000005 2.00E+06 476.19 24
PLC 40 0.00004 2.50E+04 5.95 4
Rectifier 4 0.000004 2.50E+05 59.52 24
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Table 5-2. Upper Shutter System Current Status Reliability, Availability & MTTR analysis results.
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2.49031E+05 59.29 167.99 99.93
Guiding System 9.59461E+03 2.28 167.93 98.28
Upper Drive 2.09829E+04 5.00 42.72 99.80
Lower Drive 2.09847E+04 5.00 28.73 99.86
Drive System 5.26684E+03 1.25 35.63 99.33
Control System 2.26503E+04 5.39 5.82 99.97
System 2.95969E+03 0.70 72.40 97.61
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5.3 NEW STATUS
The following figure represents the RBD of the new status of the upper shutter system:
Fig 5-8 Upper shutter system new status reliability block diagram
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5.3.1 System representation
For the correct operation of the upper shutter mechanism, the control system, the drive system and
the guiding system must work correctly. Therefore the RBD for the dome upper shutter
mechanism is as follows:
Fig 5-9 Upper shutter mechanism representation
The control system controls the upper shutter drive system and is composed of a PLC (which
includes communication cards, power supplies, etc.) and a rectifier.
Fig 5-10 Upper shutter control system representation
As shown in Fig 5-2, the drive system is composed of four drives that two of them are at the top
of the shutter and the other two are at the lower part of the shutter. These drives are composed by
some subsystems such as the frequency converter (VSD), the motor, the brake, the encoder, the
gearbox and the chain (see Fig 5-11). As it can be seen in Table 5-3, some drives components have
two MTTR (Mean Time To Repair) values depending if the component belongs to an upper or a
lower drive. Considering the actions taken for the drive system upgrade (higher resistance chains,
improved control strategy) together with the lateral guidance correction, the new design enables the
operation with 3 out of 4 drives
Fig 5-11 Upper shutter drive system representation
DRIVE 1
DRIVE 2
DRIVE 3
DRIVE 4
3/4
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The updated guiding system, shown in Fig 5-2, is composed of four hydraulic groups (5 bogies
per group). All hydraulic groups need to be properly working for the correct support of the dome
upper shutter. It has been assumed that inside each hydraulic group, a failure of one of the new
supporting bogies can be admitted. The new bogie system is composed of a hydraulic actuator and
a new bogie. Each bogie has two radial wheels with each corresponding bearing. None of them can
be damaged for a proper working of this bogie.
NEW BOGIE
SYSTEM 1
NEW BOGIE
SYSTEM 2
NEW BOGIE
SYSTEM 3
NEW BOGIE
SYSTEM 4
4/5
NEW BOGIE
SYSTEM 5
HYDRAULIC BOGIE GROUPS COMPOSITION
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Fig 5-12 Upper shutter guiding system representation
As it has been explained before, the system has been studied as a repairable system. The failure data
for each component, used as input for the system analysis, has been obtained from the
FARADIP.THREE data bank [RD 12], and are shown as follows:
Table 5-3. Component failure rate and MTTR used in the Upper Shutter System New Status analysis
5.3.2 Results
The whole GTC Dome Shutters lifetime (50 years) has been considered. Up to 10000 different
failure scenarios have been simulated (with different combination of components failure along the
time). For each component, a MTTR (mean time to repair) value has been considered.
The MTBF for each subsystem has been obtained, as well as the MTBF of the whole system.
Applying the formula explained in chapter 4.1, with the selected MTTR, the availability and MTTR
of every subsystem and the whole system have been obtained. These results are shown in the
following table:
Table 5-4. Upper Shutter System New Status Reliability, Availability & MTTR analysis results.
Failure Rate
(per million hours)
(1/hours)
Component MTTF
(hours)
Component MTTF
(years)
Component MTTR
(hours)
Wheels 1 0.000001 1.00E+06 238.10 168
Bearings 1 0.000001 1.00E+06 238.10 168
Hydraulic Actuator 15 0.000015 6.67E+04 15.87 48
Hydraulic System 10 0.00001 1.00E+05 23.81 168
VSD 5 0.000005 2.00E+05 47.62 4
Motor a.c. 5 0.000005 2.00E+05 47.62 Upper: 36 / Lower: 24
Brake 10 0.00001 1.00E+05 23.81 Upper: 12 / Lower: 8
Encoder 7 0.000007 1.43E+05 34.01 Upper: 36 / Lower: 24
Gearbox 20 0.00002 5.00E+04 11.90 Upper: 72 / Lower: 48
Chain 0.5 0.0000005 2.00E+06 476.19 24
PLC 40 0.00004 2.50E+04 5.95 4
Rectifier 4 0.000004 2.50E+05 59.52 24
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2.48382E+05 59.14 167.88 99.93
Bogie System 5.26788E+04 12.54 73.09 99.86
Hydraulic Bogie Group 1.98860E+06 473.48 35.81 100.00
Guiding System 8.27506E+04 19.70 145.20 99.82
Upper Drive 2.09829E+04 5.00 42.72 99.80
Lower Drive 2.09847E+04 5.00 28.73 99.86
Drive System 1.05209E+06 250.50 17.37 100.00
Control System 2.26503E+04 5.39 5.82 99.97
System 1.74524E+04 4.16 35.32 99.80
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5.4 RELIABILITY AND AVAILABILITY DIAGRAMS
The next figures show the comparison of the reliability functions for current status and new status
of the upper shutter. Fig 5-13 time scale refers to the lifetime of 50 years. Fig 5-14 shows the first
part of the plots (ten initial years) for discernment of the difference in the curve shape.
Fig 5-13 Upper shutter current and new status reliability diagrams (50 years)
Fig 5-14 Upper shutter current and new status reliability diagrams (10 years)
Next figure shows the system up/down periods along time for the upper shutter current status and
new status. The system availability is increased from 97.61% to 99.80%.
Control System
Drive System
Guiding System
System
Control System
Drive System
Guiding System
System
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Fig 5-15 Upper shutter current and new status availability diagrams
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6 LOWER SHUTTER SYSTEM
6.1 INTRODUCTION
The aim of this chapter 6 is to make a comparison between the current status and the new status of
the dome lower shutter system. For this purpose, taking into account the failure rates of the
different components that compose the upper shutter, the MTBF, the MTTR and the availability
will be obtained.
For the lower shutter system reliability analysis, the windscreen potential failures have not been
considered for the analysis.
The following figures show some of the different components and subsystems that have been taken
into account for the reliability analysis:
Fig 6-1 Lower shutter current status guiding system and drive mechanism
Fig 6-2 Lower shutter new status guiding system and drive mechanism
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6.2 CURRENT STATUS
The following figure represents the RBD of the current status of the lower shutter system:
Fig 6-3 Lower shutter system current status reliability block diagram
6.2.1 System representation
For the correct operation of the lower shutter mechanism, the control system, the drive system and
the guiding system must work correctly. Therefore the RBD for the dome lower shutter mechanism
is as follows:
Fig 6-4 Lower shutter mechanism representation
The control system controls the lower shutter drive system and is composed of a PLC (which
includes communication cards, power supplies, etc.) and a rectifier.
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Fig 6-5 Lower shutter control system representation
As shown in Fig 6-1, the drive system is composed of two drives that both of them are in the
upper motor stations (upper part of the dome). These drives are composed by some subsystems
such as the frequency converter (VSD), the motor, the brake, the encoder, the gearbox and two
chains (as a single motor moves the two chains, see Fig 6-6).
Fig 6-6 Lower shutter drive system representation
The guiding system, shown in Fig 6-1, is composed of ten bogies (5 at each side), which need to
be working for the correct support of the dome lower shutter. In the same way, every wheel of the
bogie together with its corresponding bearing has to be working for its correct operation.
Fig 6-7 Lower shutter guiding system representation
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As it has been explained before, the system has been studied as a repairable system. The failure data
for each component, used as input for the system analysis, has been obtained from the
FARADIP.THREE data bank [RD 12], and are shown as follows:
Table 6-1. Component failure rate and MTTR used in the Lower Shutter System Current Status analysis
6.2.2 Results
The whole GTC Dome Shutters lifetime (50 years) has been considered. Up to 10000 different
failure scenarios have been simulated (with different combination of components failure along the
time). For each component, a MTTR (mean time to repair) value has been considered.
The MTBF for each subsystem has been obtained, as well as the MTBF of the whole system.
Applying the formula explained in chapter 4.1, with the selected MTTR, the availability and MTTR
of every subsystem and the whole system have been obtained. These results are shown in the
following table:
Table 6-2. Lower Shutter System Current Status Reliability, Availability & MTTR analysis results.
Failure Rate
(per million hours)
(1/hours)
Component MTTF
(hours)
Component MTTF
(years)
Component MTTR
(hours)
Wheels 2 0.000002 5.00E+05 119.05 168
Bearings 2 0.000002 5.00E+05 119.05 168
VSD 5 0.000005 2.00E+05 47.62 4
Motor a.c. 5 0.000005 2.00E+05 47.62 36
Brake 10 0.00001 1.00E+05 23.81 12
Encoder 7 0.000007 1.43E+05 34.01 36
Gearbox 20 0.00002 5.00E+04 11.90 72
Chain 1 0.5 0.0000005 2.00E+06 476.19 24
Chain 2 0.5 0.0000005 2.00E+06 476.19 24
PLC 40 0.00004 2.50E+04 5.95 4
Rectifier 4 0.000004 2.50E+05 59.52 24
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2.49031E+05 59.29 167.99 99.93
Guiding System 2.50204E+04 5.96 167.94 99.33
Drive 2.08276E+04 4.96 42.54 99.80
Drive System 1.03862E+04 2.47 42.42 99.59
Control System 2.26503E+04 5.39 5.82 99.97
System 5.54270E+03 1.32 61.34 98.91
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6.3 NEW STATUS
The following figure represents the RBD of the new status of the lower shutter system:
Fig 6-8 Lower shutter system new status reliability block diagram
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6.3.1 System representation
For the correct operation of the lower shutter mechanism, the control system, the drive system and
the guiding system must work correctly. Therefore the RBD for the dome lower shutter mechanism
is as follows:
Fig 6-9 Lower shutter mechanism representation
The control system controls the lower shutter drive system and is composed of a PLC (which
includes communication cards, power supplies, etc.) and a rectifier.
Fig 6-10 Lower shutter control system representation
As shown in Fig 6-2, the drive system is composed of two drives located at the upper station.
Each drive moves two chains and includes a redundant auxiliary motor apart from the main motor
(see Fig 6-11)
Fig 6-11 Lower shutter drive system representation
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The guiding system, shown in Fig 6-2, is composed of eight bogies in four hydraulic groups (2
bogies per group). It has been assumed that one bogie out of the eight can fail without affecting to
the guiding system operation. The new bogie system is composed of a hydraulic actuator and a new
bogie. Each bogie has two radial wheels with each corresponding bearing
Fig 6-12 Lower shutter guiding system representation
HYDRAULIC
SYSTEM
NEW BOGIE
SYSTEM 1
NEW BOGIE
SYSTEM 2
HYDRAULIC BOGIE GROUP 1
NEW BOGIE
SYSTEM 3
NEW BOGIE
SYSTEM 4
HYDRAULIC BOGIE GROUP 2
NEW BOGIE
SYSTEM 5
NEW BOGIE
SYSTEM 6
HYDRAULIC BOGIE GROUP 3
NEW BOGIE
SYSTEM 7
NEW BOGIE
SYSTEM 8
HYDRAULIC BOGIE GROUP 4
7/8
NEW BOGIE
SYSTEM 1
NEW BOGIE
SYSTEM 2
HYDRAULIC BOGIE GROUPS COMPOSITION
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As it has been explained before, the system has been studied as a repairable system. The failure data
for each component, used as input for the system analysis, has been obtained from the
FARADIP.THREE data bank [RD 12], and are shown as follows:
Table 6-3. Component failure rate and MTTR used in the Lower Shutter System New Status analysis
6.3.2 Results
The whole GTC Dome Shutters lifetime (50 years) has been considered. Up to 10000 different
failure scenarios have been simulated (with different combination of components failure along the
time). For each component, a MTTR (mean time to repair) value has been considered.
The MTBF for each subsystem has been obtained, as well as the MTBF of the whole system.
Applying the formula explained in chapter 4.1, with the selected MTTR, the availability and MTTR
of every subsystem and the whole system have been obtained. These results are shown in the
following table:
Table 6-4. Lower Shutter System New Status Reliability, Availability & MTTR analysis results.
Failure Rate
(per million hours)
(1/hours)
Component MTTF
(hours)
Component MTTF
(years)
Component MTTR
(hours)
Wheels 1 0.000001 1.00E+06 238.10 168
Bearings 1 0.000001 1.00E+06 238.10 168
Hydraulic Actuator 15 0.000015 6.67E+04 15.87 48
Hydraulic System 10 0.00001 1.00E+05 23.81 168
VSD 5 0.000005 2.00E+05 47.62 4
Motor a.c. 5 0.000005 2.00E+05 47.62 36
Brake 10 0.00001 1.00E+05 23.81 12
Encoder 7 0.000007 1.43E+05 34.01 36
Gearbox (main) 20 0.00002 5.00E+04 11.90 72
Gearbox (auxiliary) 20 0.00002 5.00E+04 11.90 72
Chain 1 0.5 0.0000005 2.00E+06 476.19 24
Chain 2 0.5 0.0000005 2.00E+06 476.19 24
PLC 40 0.00004 2.50E+04 5.95 4
Rectifier 4 0.000004 2.50E+05 59.52 24
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2.48382E+05 59.14 167.88 99.93
Bogie System 5.26788E+04 12.54 73.09 99.86
Hydraulic Bogie Group 2.07920E+07 4950.48 36.96 100.00
Guiding System 8.71346E+04 20.75 150.80 99.83
Drive 4.75259E+04 11.32 69.44 99.85
Drive System 2.37007E+04 5.64 69.48 99.71
Control System 2.26503E+04 5.39 5.82 99.97
System 1.02011E+04 2.43 50.34 99.51
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6.4 RELIABILITY AND AVAILABILITY DIAGRAMS
The next figures show the comparison of the reliability functions for current status and new status
of the upper shutter. Fig 6-13time scale refers to the lifetime of 50 years. Fig 6-14shows the first
part of the plots (ten initial years) for discernment of the difference in the curve shape.
Fig 6-13 Lower shutter current and new status reliability diagrams (50 years)
Fig 6-14 Lower shutter current and new status reliability diagrams (10 years)
Next figure shows the system up/down periods along time for the upper shutter current status and
new status. The system availability is increased from 98.91% to 99.51%.
Control System
Drive System
Guiding System
System
Control System
Drive System
Guiding System
System
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Fig 6-15 Lower shutter current and new status availability diagrams
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7 CONCLUSI ONS
The next tables summarize the final results obtained from the reliability assessment:
Table 7-1. Upper Shutter System comparison between current and new status
Table 7-2. Lower Shutter System comparison between current and new status
In both Upper and Lower Shutter systems, the improvement in the MTBF value is considerable
when comparing the results obtained for the proposed redesign (new status) with the current
installed system (current status).
For the upper shutter, the MTBF of the overall system is increased by a factor of 6, from a current
value of less than 1 year to a new value of more than 4 years. Especially relevant is the increase in
the availability of the drive system, mainly achieved by the possibility of operating with 3 out of the
4 drives. Also, a significant improvement in the MTBF is achieved for the guiding system.
In the case of the lower shutter, the current MTBF is higher than in the upper shutter (1.32 years
instead of 0.7 years), basically because the drive system is currently capable of operating with a
higher safety factor. However, this applies only to the lower shutter individual operation as
currently the lower shutter drives (motors and chains) have not enough capacity to deploy the
windscreen. The proposed actions for the drive system include higher capacity motors and chains
in order to enable windscreen deployment. There would be also an emergency system to guarantee
shutter operation in case of failure of one motor (auxiliary redundant motor in each drive), what
contributes to increase the drive system reliability. Apart from that, and similarly to the upper
shutter, the improved guiding system increases considerably the MTBF with respect to the current
bogies. The combination of these factors increases the MTBF for the lower shutter overall system
from 1.32 years to 2.43 years.
Current Status
MTBF (years)
New Status
MTBF (years)
Upper Shutter System 0.70 4.16
Guiding System 2.28 19.70
Drive System 1.25 250.50
Control System 5.39 5.39
Current Status
MTBF (years)
New Status
MTBF (years)
Lower Shutter System 1.32 2.43
Guiding System 5.96 20.75
Drive System 2.47 5.64
Control System 5.39 5.39
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8 ADDI TI ONAL ANALYSES
During the meeting with GRANTECAN on 6
th
March, 2014, the following actions were agreed:
1. The necessity of referring the reliability study in terms of failures that avoid closing the
shutter system. In this sense, some malfunctions previously considered as failures (as in
the case of the bogies hydraulic system) have been reviewed as they will not affect to the
emergency closing of the shutter system.
2. The review of the drive system modelling: it was pointed out the necessity of representing
a gearbox and chain failure as critical failures which could entail to a stop of the system.
The probability of occurrence of this kind of failures is lower than a simple failure of the
gearbox which can or not bring to a stop of the system (example: the gearbox may not be
able to transmit torque however it is capable to rotate, allowing to be dragged by the rest of
the driving system). Therefore, the failure rate of the gearbox has been reduced down to 5
failures per million working hours.
3. Clarify if the MTBF refer to the operational time or real time. This issue is answered in the
next section. It refers to operational time, which for main components is around 1
hour/day. However, a few subsystems such as the power source of the control system has
a longer operational period, so during this study the operational time has been maintained
in 12 hours/day.
4. Indication of potential improvements in the control system aimed to increase its reliability.
The possibility of including some redundant components is outlined in next section.
This chapter includes the response to the previous actions and corresponding update of the results
of the reliability analysis.
8.1 UPPER SHUTTER UPDATED NEW STATUS
In order to account for the scenario stated in Action 2 of previous section, the Drive System has
been changed from the study shown in chapter 5.3. An additional block called Transmission,
which accounts for the chain and gearbox failure rates (set in series), has been added in series.
Following the request by GRANTECAN, an increase in the reliability of the Control System
(Action 4 of previous section) is proposed by duplicating the power source and the communication
card obtaining an increase in the reliability of the PLC. The new failure rate has been defined as 20
failures per million working hours.
The failure data for each component, used as input for the system analysis are shown as follows:
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Table 8-1. Component failure rate and MTTR used in the Upper Shutter System Updated New Status analysis
The whole GTC Dome Shutters lifetime (50 years) has been considered. Up to 10000 different
failure scenarios have been simulated (with different combination of components failure along the
time). For each component, a MTTR (mean time to repair) value has been considered.
The MTBF for each subsystem has been obtained, as well as the MTBF of the whole system.
Applying the formula explained in chapter 4.1, with the selected MTTR, the availability and MTTR
of every subsystem and the whole system have been obtained. These results are shown in the
following table:
Table 8-2. Upper Shutter System Updated New Status Reliability, Availability & MTTR analysis results.
Even though the operational time of most of the components of the guiding system, transmission
and driving system is around 1 hour/day, during this study the operational time per day has been
maintain in 12 hours/day as it should keep in mind that few subsystems such as the power source
of the control system has that operational period (Action 3 of previous section).
Thus, in case of reading the MTBF of the guiding, transmission and driving system, it is most
convenient to use the hours values and from them generate the corresponding number is years.
Failure Rate
(per million
hours)
(1/hours)
Component
MTTF (hours)
Component
MTTF (years)
Component MTTR
(hours)
Wheels 1 0,000001 1,00E+06 238,10 168
Bearings 1 0,000001 1,00E+06 238,10 168
Hydraulic Actuator 15 0,000015 6,67E+04 15,87 48
Hydraulic System 10 0,00001 1,00E+05 23,81 168
VSD 5 0,000005 2,00E+05 47,62 4
Motor a.c. 5 0,000005 2,00E+05 47,62 Upper: 36 / Lower: 24
Brake 10 0,00001 1,00E+05 23,81 Upper: 12 / Lower: 8
Encoder 7 0,000007 1,43E+05 34,01 Upper: 36 / Lower: 24
Gearbox 5 0,000005 2,00E+05 47,62 Upper: 72 / Lower: 48
Chain 0,5 0,0000005 2,00E+06 476,19 24
PLC 20 0,00002 5,00E+04 11,90 4
Rectifier 4 0,000004 2,50E+05 59,52 24
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2,48382E+05 59,14 167,88 99,93
Bogie System 5,26788E+04 12,54 73,09 99,86
Hydraulic Bogie Group1,98860E+06 473,48 35,81 100,00
Guiding System 8,27506E+04 19,70 145,20 99,82
Transmission 4,53367E+04 10,79 56,89 99,87
Upper Drive 3,68824E+04 8,78 21,21 99,94
Lower Drive 3,68601E+04 8,78 14,39 99,96
Drive System 4,50226E+04 10,72 56,28 99,88
Control System 4,13818E+04 9,85 7,32 99,98
System 1,71494E+04 4,08 54,71 99,68
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Finally, in order to obtain the system reliability in terms of unfeasibility to close the upper shutter
system (Action 1), the simulation has been repeated by assuming that the failures of the hydraulic
actuators and the hydraulic group (hydraulic system) do not cause system failure, i.e., by removing
these components from the guiding system reliability blocks.
The update results, including also the previous modifications, are included in the next table.
Table 8-3. Upper Shutter System Updated New Status, in terms of failures that avoid closing the shutter. Reliability,
Availability & MTTR analysis results.
The reliability of the guiding system in this case increases significantly, as a result of considering
that it will be still operative in case of failure of the hydraulic system. It is important to remark that
under these circumstances the guiding system performance will not be optimal and it should be
avoided to operate it regularly in these conditions. However, an emergency closing of the dome
shutters would be possible.
8.2 LOWER SHUTTER UPDATED NEW STATUS
Following the same criteria explained in the previous section (resulting from Actions 2 and 4), an
updated study of the Lower shutter system has been carried out.
The failure data for each component, used as input for the system analysis are shown as follows:
Table 8-4. Component failure rate and MTTR used in the Lower Shutter System Updated New Status analysis
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2.48382E+05 59.14 167.88 99.93
Bogie System = Bogie 2.48382E+05 59.14 167.88 99.93
(Hydraulic)Bogie Group 1.84210E+07 4385.95 78.83 100.00
Guiding System 4.59510E+06 1094.07 85.80 100.00
Transmission 4.53367E+04 10.79 56.89 99.87
Upper Drive 3.68824E+04 8.78 21.21 99.94
Lower Drive 3.68601E+04 8.78 14.39 99.96
Drive System 4.50226E+04 10.72 56.28 99.88
Control System 4.13818E+04 9.85 7.32 99.98
System 2.15494E+04 5.13 31.11 99.86
Failure Rate
(per million
hours)
(1/hours)
Component
MTTF (hours)
Component
MTTF (years)
Component MTTR
(hours)
Wheels 1 0,000001 1,00E+06 238,10 168
Bearings 1 0,000001 1,00E+06 238,10 168
Hydraulic Actuator 15 0,000015 6,67E+04 15,87 48
Hydraulic System 10 0,00001 1,00E+05 23,81 168
VSD 5 0,000005 2,00E+05 47,62 4
Motor a.c. 5 0,000005 2,00E+05 47,62 36
Brake 10 0,00001 1,00E+05 23,81 12
Encoder 7 0,000007 1,43E+05 34,01 36
Gearbox (main) 5 0,000005 2,00E+05 47,62 72
Gearbox (auxiliary) 5 0,000005 2,00E+05 47,62 72
Chain 1 0,5 0,0000005 2,00E+06 476,19 24
Chain 2 0,5 0,0000005 2,00E+06 476,19 24
PLC 20 0,00002 5,00E+04 11,90 4
Rectifier 4 0,000004 2,50E+05 59,52 24
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The whole GTC Dome Shutters lifetime (50 years) has been considered. Up to 10000 different
failure scenarios have been simulated (with different combination of components failure along the
time). For each component, a MTTR (mean time to repair) value has been considered.
The MTBF for each subsystem has been obtained, as well as the MTBF of the whole system.
Applying the formula explained in chapter 4.1, with the selected MTTR, the availability and MTTR
of every subsystem and the whole system have been obtained. These results are shown in the
following table:
Table 8-5. Lower Shutter System Updated New Status Reliability, Availability & MTTR analysis results.
Even though the operational time of most of the components of the guiding system, transmission
and driving system is around 1 hour/day, during this study the operational time per day has been
maintain in 12 hours/day as it should keep in mind that few subsystems such as the power source
of the control system has that operational period (Action 3).
Thus, in case of reading the MTBF of the guiding, transmission and driving system, it is most
convenient to use the hours values and from them generate the corresponding number is years.
Analogously, the system reliability in terms of unfeasibility to close the lower shutter system (Action
1) has been obtained. The results are collected in the next table.
Table 8-6. Lower Shutter System Updated New Status, in terms of failures that avoid closing the shutter. Reliability,
Availability & MTTR analysis results.
Similarly to the upper shutter, the reliability of the guiding system increases significantly, as a result
of considering that it will be still operative in case of failure of the hydraulic system. In this case the
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2,48382E+05 59,14 167,88 99,93
Bogie System 5,26788E+04 12,54 73,09 99,86
Hydraulic Bogie Group2,07920E+07 4950,48 36,96 100,00
Guiding System 8,71346E+04 20,75 150,80 99,83
Drive 1,66339E+05 39,60 63,66 99,96
Drive System 8,37553E+04 19,94 63,66 99,92
Control System 4,13818E+04 9,85 7,32 99,98
System 2,09424E+04 4,99 56,29 99,73
MTBF
(hours)
MTBF
(years)
MTTR
(hours)
Availability
(%)
Bogie 2.48382E+05 59.14 167.88 99.93
Bogie System = Bogie 2.48382E+05 59.14 167.88 99.93
(Hydraulic)Bogie Group 3.00000E+08 71428.57 68.20 100.00
Guiding System 6.30622E+06 1501.48 84.64 100.00
Drive 1.66339E+05 39.60 63.66 99.96
Drive System 8.37553E+04 19.94 63.66 99.92
Control System 4.13818E+04 9.85 7.32 99.98
System 2.76513E+04 6.58 26.53 99.90
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guiding system performance will not be optimal and it should be avoided to operate it regularly in
these conditions. However, an emergency closing of the lower shutter would be possible.