Risk assessment method for aeroengine multiple failure risk using Monte Carlo simulation

Purpose - The purpose of this paper is to develop a method to predict the multi-failure risk of aero engine in service and to evaluate the effectiveness of different corrective actions. Design/methodology/approach - The classification of failure risk level, the determination of hazard ratio and the calculation of risk factor and the risk per flight have been proposed. The multi-failure risk assessment process of aero engine has been established to predict the occurrence of failure event and assess the failure risk level. According to the history aero engine failure data, the multi-failure risk, i.e., overheat, blade wounding, pump failure, blade crack, pipe crack and combustor crack, has been predicted considering with and without corrective action. Two corrective actions, i.e., reduce the maintenance interval and redesign the failure components, were adopted to analyze the decreasing of risk level. Findings - The multi-failure risk of aero engine with or without corrective action can be determined using the present method. The risk level of combustor crack decreases from high-risk level of 1.18 x 1e-9 without corrective action to acceptable risk level of 0.954 x 1e-9 by decreasing the maintenance interval from 1,000 to 800 h, or to 0.912 x 1e-9 using the redesign combustor. Research limitations/implications - It should be noted that probability of detection during maintenance actions has not been considered in the present analysis, which would affect the failure risk level of aero engine in service. Social implications - The method in the present analysis can be adapted to other types of failure modes which may cause significant safety or environment hazards, and used to determine the maintenance interval or choose appropriate corrective action to reduce the multi-failure risk level of aero engine. Originality/value - The maintenance interval or appropriate corrective action can be determined using the present method to reduce the multi-failure risk level of aero engine.