Fault Tree Analysis in Reliability and Safety Evaluation of A Production System

Ilkka Virtanen

Summary

This paper outlines the basic concepts for a systematic approach to the reliability and safety analysis of a complex system. The principal method for identifying system failures - with their causes and consequences - and for evaluating probabilities of failure occurences is the fault tree analysis.

The fault tree analysis has rapidly gained favor with reliability analysts of complex systems. The main feature of the fault tree technique is the versatility in the degree of detail in which the analysis can be carried out. Also the analyst has options for qualitative and quantitative analysis. And further, the simple logic of the fault tree approach makes it a visibility tool for both engineering and management. These general properties of the fault tree technique are discussed in Section 1.

The first step in reliability analysis is the identification of all system failure modes. This step is called the Failure Mode and Effect Analysis (FMEA). During FMEA all component failures are hypothesized and the possible adverse effects on the system are determined by investigating how the system responds to each failure and failure combination. Section 2 contains a brief discussion about this preceding step for the actual fault tree analysis.

In Section 3 the general procedure for constructing a fault tree is dealt with. Fault tree is a tool by which failures that can contribute to an undesired event in the system (e.g. fire, explosion) are organized deductively and represented pictorially. Fault tree is so one way to diagram and relate the information developed in the preceding FMEA. The resulting arrangement is a treelike logical structure with information flows from the branches (component failures) to the top of the tree (the undesired event, system failure). The general construction principle of the fault tree and the commonly used fault tree symbols - logic gates and fault events - as well as the main steps involving in the tree construction are included in the discussion of Section 3.

Section 4 deals with the analysis of a fault tree. Two different approaches are possible: qualitative or quantitative analysis. In the qualitative analysis the fault tree is inspected in order to determine all the combinations of component failures that can lead to the undersired event (minimal cut set evaluation). In the quantitative analysis such quantitative reliability measures as

- the probability of occurrence of the undesired event
- the failure rate for the undesired event
- the expected number of occurences of the undesired event during the time interval from 0 to t
- the expected number of undesired event occurences per unit time

can be obtained. Similar information can also be determined for the minimal cut sets and primary events (component failures). There is a great number of methods available for carrying out the fault tree evaluation, both analytical and simulation methods. These methods are also touched upon in Section 4.

The construction and evaluation of a fault tree is illustrated in Section 5 by means of a simplifield system. The system is a lawn mower internal combustion engine. The engine can be started by batter power or by a pull cord. The undesired event is "Engine does not start". One possible fault tree for the undesired event of this system is presented. For the fault tree of the example both qualitative and quantitative analysis are carried out.

(Tutkielmia ja tutkimusraportteja 1976, Publications of The Turku School of Economics and Business Administration, Series A1-2:1976, 243-269.)