System Safety in the Military Jet Utilization Stage
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1 System Safety in the Military Jet Utilization Stage Marco Geering Department Manager Military Jet&Missiles Engineering / CSEP RUAG Aviation Military Aircraft Division ETH ZH,
2 CH Jet System Safety - Agenda 1. Introduction 2. Military System Safety 3. System Safety Requirements 4. Examples 6.1 Planing Link Failure 6.2 Operational Impact on Design 5. Summary 2 06/10/2014
3 CH Jet System Safety Introduction MIL-STD-882E 3
4 CH Jet System Safety Introduction SSPP describes in details how RA as an contractor fulfils Swiss Government system safety requirements throughout all phases of the system life cycle. SSPP does not cover operational issues which shall be managed by ORM from the operator 4 06/10/2014
5 CH Jet System Safety MIL System Safety The system safety applied for military weapon systems is different from the civilian approach due to: The level of safety = f (situation) Urgent Ops needs: - SAR - Intercept - AAR etc MIL Ops - Recce - Dog Fight - Weapons etc Unusual designs to meet higher performance requirements The residual (mishap) risk acceptance by the appropriate authority is unique to military. The As Low As Reasonably Practicable ALARP philosophy is applied in Switzerland. 5 06/10/2014
6 CH Jet System Safety Requirements Process Risk tracking and monitoring Hazard identification Risk avoidance Risk control Risk transfer Risk acceptance Hazard/risk assessment 6 06/10/2014
7 CH Jet System Safety Requirements Process - Identify FMS I-Level Ops Laws Regulations etc OEM Example F/A technical ASR OEM/USN/FMS Messages defect reports (O-/I-/D-Level) OSTR 7 06/10/2014
8 CH Jet System Safety Requirements Process Analyse - Hazard Risk Index 8 06/10/2014
9 CH Jet System Safety Requirements Process - Analyse 1. Review item failure mode 2. Assess the severity 3. Identify failure rates or probabilities of occurence 4. Identify the critical operational environment and associated ops factors 5. Identify mitigating or exacerbing factors 6. Select the worst credible risk 9 06/10/2014
10 CH Jet System Safety Requirements Process - Treat Risk mitigation mesures are 1. Design changes 2. Incorporate safety devices 3. Provide warning devices 4. Develop procedures and training Example: TEF Connecting Link Modification 10 06/10/2014
11 CH Jet System Safety Requirements Process - Monitor System Monitoring SSWG 11 06/10/2014
12 CH Jet System Safety Example Planing Link Failure 12
13 CH Jet System Safety Example Planing Link Failure MLG PLF: If connecting or planing link fails due to buckling than the wheel axis is not blocked anymore => instable roll out Probability Level is set to probable (Swiss has a PLF rate of 10 / 100k FH) Severity is set to critical (Status 2008) HRI 5 (serious risk) World wide issue 13
14 CH Jet System Safety Example Planing Link Failure Switzerland has done shock absorber flight tests to gave inputs to the correct modelling of the MLG behaviour (static, dynamic). The following mitigation actions have been taken: Re-design of planing link machanism New rigging procedures New shock absorber servicing tolerances 14
15 CH Jet System Safety Example Operational Impact on Design 15
16 CH Jet System Safety Example Operational Impact on Design Hornet F/A-18C/D procurement Requirements Improved Air-To-Air Load Factor Capability Swiss G-Load > USN G-Load Service Life Criteria Swiss hours > USN Hours Swiss usage spectrum about three times more severe than USN usage (CH F/A-18 A/A ops, shorter times to mil training area) Design Change Center Fuselage Titanium parts (Ti-6AI-4V) instead of Aluminium (7075-T7351) 16
17 CH Jet System Safety Example Operational Impact on Design Swiss Full Scale Fatigue Test Fracture and maintenance critical parts meet 2 Swiss lifetimes of durability life Fracture critical parts (safety of flight parts) meet 2 Swiss lifetimes of damage tolerance life for the mutual agreed initial flaw sizes Results Updated Swiss Fatigue Inspection Schedule based on FSFT results Structural Refurbishment Program: re-design of critical areas such as Crease Longeron, Fuel Cell Floor, Fuel Barrier Web, Upper Outboard Longeron etc. 17
18 CH Jet System Safety - Summary Residual risk acceptance is the main difference between civil and military safety The system safety program is based on established processes MIL-STD-882 Good collaboration between different stakeholder are a key factor (ORM by Operator, system /usage monitoring by industry, acceptance (technical) by Military Airworthiness Authority) 18
19 CH Jet System Safety - Summary It takes a minute to write a safety rule It takes a hour to hold a safety meeting It takes a week to plan a safety program It takes month to put it into operation It takes a year to win a safety award It takes a lifetime to make a safe worker IT TAKES ONE SECOND TO DESTROY IT ALL WITH ONE ACCIDENT 19
20 Questions Thank you for your attention! 20 RUAG Aviation
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