page 1 of 21 aries quarterly review bethesda, md – 4, 5 april 2011 boeing fusion energy plan...
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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
Page 2 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
• 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
Page 3 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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
Page 4 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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.
Page 5 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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
Page 6 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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
Page 7 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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.
Page 8 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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
Page 9 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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
Page 10 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Documents Map
Prescriptiveness
Ris
k A
ve
rsio
n
BDSDocuments
BCADocuments
NUREGDocuments
FusionNeed
Documentation
Ec
on
om
ics
Do
min
anc
e
Page 11 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
RAMI Process Interfaces (from RM&SH Process)
RAMI Process
TechnicalPublications
SiteActivation
Plant/FleetSupport
Engineering
TrainingSystems
ContractorRAMI
Support
Retrofit andModification
Systemsand Safety
EngineeringDesign
Engineering
Page 12 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Where Most of RAMI Starts
RAMI Process Plant/FleetSupport
Engineering
Systemsand Safety
EngineeringDesign
EngineeringSupplies/Interprets
Requirements
Supplies/InterpretsRequirements
Where most ofRAMI is done
Page 13 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
RAMI Ramp-Up
RAMI Process
SiteActivation
Plant/FleetSupport
Engineering
ContractorRAMI
Support
Systemsand Safety
EngineeringDesign
Engineering
Page 14 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Mature Project
RAMI Process
TechnicalPublications
Plant/FleetSupport
Engineering
TrainingSystems
ContractorRAMI
Support
Retrofit andModification
Systemsand Safety
EngineeringDesign
Engineering
Page 15 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
ARIES Immediate Task
RAMI Process
TechnicalPublications
SiteActivation
Plant/FleetSupport
Engineering
TrainingSystems
ContractorRAMI
Support
Retrofit andModification
Systemsand Safety
EngineeringDesign
Engineering
Page 16 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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
Page 17 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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
Page 18 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
• 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
Page 19 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Supporting Pages
Page 20 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
• 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
Page 21 of 21ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
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