Page 1 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 Boeing Fusion Energy Plan...

Page 1 of 21ARIES Quarterly Review

Bethesda, MD – 4, 5 April 2011

Boeing Fusion Energy Plan

Presented to US ITERxx December 2008

Boeing Phantom Works

Defining an ARIES RAMI Process

Tom WeaverBoeing Research and Technology

ARIES 2011 Quarter #1 Review4-5 April, 2011; Bethesda, Maryland



• Reliability, Availability, Maintainability, and Inspectability

(RAMI) have always been part of ARIES

– Sometimes implicitly: e.g. redesign of a divertor to reduce

predicted stresses

– Sometimes explicitly: e.g. “ARIES-CS Maintenance System

Definition and Analysis”

• Formal procedures and processes acknowledged, but

not yet examined for applicability

• DEMO, 1st-of-Kind, and 10th-of-Kind planning require

industry-style coverage and formality

• Aerospace a convenient, mature, starting point

Background and Need



RAMI Timing in ARIES

• Natural Follow-on to Fusion TRL Adoption

– Applicable at all TRLs

– Importance grows with rising TRL

– Critical element of other readiness measures

• Apply at higher TRLs, include:

– Integration Readiness Level (IRL)

– Manufacturing Readiness Level (MRL)

• RAMI Process a foundation of ITER-to-Power

Plant maturation



RAMI Resources for ARIES

• Hard part already done by industry• RAMI program structures exist• Why?

– Improve Sales– Prevent Massive Losses

Example: the Boeing view of Failure Mode and Effects Analyses

“The principles of FMEA are straightforward and easy to grasp. The practice of FMEA is tedious, time consuming, and very profitable.”

Boeing Document D6-25382-80; Reliability Engineering Design Guide, Appendix A, Page 5.



Aero Terminology

• Reliability, Availability, Maintainability, and Inspectability definitions can be precise

• Methods to achieve R, A, M, and I blend into each other.

• Aerospace and Military speak of Reliability, Maintainability, and System Health to cover more than RAMI

Mil-Aero Terminology ARIES TerminologyReliability Reliability, reliability-related aspects of

Availability, and most instrumentation and control

Maintainability Maintainability; maintainability-related aspects of Availability; and some instrumentation and control, including Inspectability related to plant maintenance

System Health (Plant and fleet operational statistics collection and analysis. Fleet logistics and support.)

Inspectability related to reactor fleet support



Aero RM&SH Responsibilities

• RM&SH is the responsibility of the Program

Managers and Design Engineers/Scientists

• Managers and Engineers must be assisted

by RM&SH Specialists with:

– General RM&SH Guidance, as necessary to

plan program

– Specialized RM&SH Analyses, as necessary

to implement program



RM&SH Assistance

• Available support must include, but not be limited to:

– Requirements Generation– Metrics Generation– Safety– Reliability– Availability– Inspectability/Testability– Fault Coverage– Fault Mitigation– Risk Analyses– Risk Mitigation

– Configuration Control– Dependability Cost– Test Planning– Testing– Reporting– Support– Logistics– Reliability Growth

• Operational Data Collection• Operational Data Analysis• Data Base Maintenance

• Conceptual design teams (e.g. ARIES) not

expected to have deep expertise in these areas.• Deep expertise comes from RM&SH specialists.



Activities of an RM&SH Process

1. Define RM&SH Program

2. Collect/Provide Experience Data

3. Provide RM&SH in the Product

4. Assess RM&SH in Design and Production

Feature 1 must assure that Features 2 – 4

are part of an iterative process



Three categories of Boeing RM&SH documents

Boeing Distillation

1. Corporate “Authorizing” documents

2. Corporate “Procedure Description” documents

3. Boeing Defense Systems-focused plan descriptions

and handbooks

4. Boeing Commercial Aircraft-focused plan descriptions

and handbooks

Boeing documents, and their references, appear to bracket fusion needs in multiple parameters



Documents Map

Prescriptiveness

Ris

k A

ve

rsio

n

BDSDocuments

BCADocuments

NUREGDocuments

FusionNeed

Documentation

Ec

on

om

ics

Do

min

anc

e



RAMI Process Interfaces (from RM&SH Process)

RAMI Process

TechnicalPublications

SiteActivation

Plant/FleetSupport

Engineering

TrainingSystems

ContractorRAMI

Support

Retrofit andModification

Systemsand Safety

EngineeringDesign

Engineering



Where Most of RAMI Starts

RAMI Process Plant/FleetSupport

Engineering

Systemsand Safety

EngineeringDesign

EngineeringSupplies/Interprets

Requirements

Supplies/InterpretsRequirements

Where most ofRAMI is done



RAMI Ramp-Up

RAMI Process

SiteActivation

Plant/FleetSupport

Engineering

ContractorRAMI

Support

Systemsand Safety

EngineeringDesign

Engineering



Mature Project

RAMI Process


Plant/FleetSupport

Engineering

TrainingSystems

ContractorRAMI

Support


Systemsand Safety

EngineeringDesign

Engineering



ARIES Immediate Task

RAMI Process


SiteActivation

Plant/FleetSupport

Engineering

TrainingSystems

ContractorRAMI

Support


Systemsand Safety

EngineeringDesign

Engineering



Elements of a RAMI Process

• Define RAMI Program– Develop Strategy– Develop Plan

• Collect/Provide Experience Data– Early Procedure – Survey the Past: Data from disparate experiments & studies– Developmental Procedure – Mine Present Activities: Data from DEMO-Path

experiments (e.g. ITER, FNSF)– Final Procedure – Carry into the Future: Data from DEMO, Plant 1 through Plant n

• Provide RAMI in the Product– Manage Program (Administration of the Plan)– Assure RAMI in Design (RAMI processes in Design processes)– Qualify RAMI in Design (V&V of RAMI in Design)– Feed Qualification lessons back into Design

• Assess RAMI in Design and Production– Manage Program– Assure RAMI in Fabrication, Assembly, and Construction– Qualify RAMI in Fabrication, Assembly, and Construction– Feed Qualification lessons back into Fabrication, Assembly, and Construction



RAMI Process Flow

RAMI Process

DefineRAMI

Program Collect &Provide

ExperienceData

ProvideRAMIin the

Product

AssessRAMI

InDesign

AndProduction

ResponsibleEntity

Customer and Regulator

Program Manager

Prime Contractor Standards

RAMIEngineering

Logistics

Design Engineering

Systems and Safety

Engineering

Suppliers

Candidate Logistics Support Analyses

InputProvided

RAMI Data

Requirements

Design Data

HW & SW Rqmts

CAE/CAD/CAM Systems

Data, Methods, Tools, Expertise, Processes

“Command Media”

SoW and Spec Rqmts

Requirements

SoW and Spec Rqmts

Output

Requirements and Data

RAMI “Design”

Incorporation of RAMI in

Design



• Begin RAMI Process Document

– Intend to identify all elements and include as placeholders

– Concentrate early on content for:

• Define RAMI Process

• Define RAMI Program

• Collect/Provide Experience Data

– Some placeholders may remain for extended time

– Note: Existing Boeing RM&SH Process Document is the

result of decades of work by multiple people.

It is 210 pages long. Fusion RAMI will start much

smaller.

Next Step



Supporting Pages



• Boeing D950-10446-1 System Engineering Process• Boeing D950-10088-3 Reliability, Maintainability and

Systems Health (RM&SH) Process• IEC 1014 Programs for Reliability Growth• IEC 1078 Analysis Techniques for

Dependability• IEC 1164 Reliability Growth – Statistical Test

and Estimation• IEEE Std 1332 Reliability Program for Electronic

Systems• NRC NUREG-0492 Fault Tree Handbook• NASA Fault Tree Handbook with Aerospace Applications• DoD MIL-STD-756B Reliability Modeling and Prediction• DoD MIL-STD-498 Software Development and

Documentation• SAE JA 1000 Reliability Program Standard• SAE JA 1002 Software Reliability Program Standard

– Boeing D6-25382-80 Reliability Engineering Design Guide• FAA AC, Part 25 Airworthiness Standards

– Boeing D950-10386-3 FMEA/FMECA – Process Guide• Boeing D6-56674 FMEA Guidelines

• Boeing D950-10088-4 System Support Analysis Process

Reliability Focused Resources (Highlights)

Reliability, Availability, Maintainability, and System Health (Inspectability) all addressed in top-level documents



Maintainability Focused Resources (Highlights)

• Boeing BPI-1092 Maintainability Engineering Process Overview

– Boeing D6-25382-20 Maintainability Design Guide

• IEC 706-6 Guide on Maintainability of Equipment

– Boeing D6-36667 Maintainability Engineering Handbook

– Boeing BPI-375 Digital Maintainability Analysis Process for V4/V5 Programs (CAD

Assembleability/Maintainability Analysis)

– Boeing D194-30091-1 BCA Experience Analysis Center User’s Guide

– Boeing D906-10061-1 Design for System Health Guidelines

– DoD MIL-HDBK-741 Maintainability Program Plan

– DoD MIL-HDBK-470A Designing and Developing Maintainable Products and Systems

– DoD MIL-HDBK-472 Maintainability Prediction

– SAE JA 1010 Maintainability Program Standard

– SAE JA 2389 Fatigue and Limited Life

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