Boeing Fusion Energy Plan
Defining an ARIES
Process
PresentedRAMI
to US ITER
xx December 2008
Tom Weaver
Boeing Research and Technology
Boeing
Phantom
Works
ARIES 2011
Quarter #1 Review
4-5 April, 2011; Bethesda, Maryland
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 1 of 21
Background and Need
• 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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 2 of 21
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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 3 of 21
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.
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 4 of 21
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 Terminology
Reliability
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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 5 of 21
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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 6 of 21
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.
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 7 of 21
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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 8 of 21
Boeing Distillation
Three categories of Boeing RM&SH documents
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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 9 of 21
NUREG
Documents
Risk Aversion
Economics Dominance
Documents Map
BCA
Documents
Fusion
Need
BDS
Documents
Prescriptiveness
Documentation
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 10 of 21
RAMI Process Interfaces
(from RM&SH Process)
Technical
Publications
Retrofit and
Modification
Training
Systems
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Systems
and Safety
Engineering
RAMI Process
Site
Activation
Design
Engineering
Plant/Fleet
Support
Engineering
Contractor
RAMI
Support
Page 11 of 21
Where Most of RAMI Starts
Where most of
RAMI is done
Systems
and Safety
Engineering
Design
Engineering
Supplies/Interprets
Requirements
RAMI Process
Plant/Fleet
Support
Engineering
Supplies/Interprets
Requirements
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 12 of 21
RAMI Ramp-Up
Systems
and Safety
Engineering
RAMI Process
Site
Activation
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Design
Engineering
Plant/Fleet
Support
Engineering
Contractor
RAMI
Support
Page 13 of 21
Mature Project
Technical
Publications
Retrofit and
Modification
Training
Systems
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Systems
and Safety
Engineering
RAMI Process
Design
Engineering
Plant/Fleet
Support
Engineering
Contractor
RAMI
Support
Page 14 of 21
ARIES Immediate Task
Technical
Publications
Retrofit and
Modification
Training
Systems
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Systems
and Safety
Engineering
RAMI Process
Site
Activation
Design
Engineering
Plant/Fleet
Support
Engineering
Contractor
RAMI
Support
Page 15 of 21
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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 16 of 21
RAMI Process Flow
Responsible
Entity
Input
Provided
Customer and
Regulator
SoW and
Spec Rqmts
Program
Manager
SoW and
Spec Rqmts
Prime
Contractor
Standards
“Command
Media”
RAMI
Engineering
Data, Methods, Tools,
Expertise, Processes
CAE/CAD/CAM
Systems
Requirements
Logistics
Candidate Logistics
Support Analyses
Design
Engineering
HW & SW Rqmts
Systems and
Safety
Engineering
Requirements
Suppliers
RAMI Data
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Design Data
RAMI Process
Define
RAMI
Program
Collect &
Provide
Experience
Data
Output
Provide
RAMI
in the
Product
Assess
RAMI
In
Design
And
Production
Requirements
and Data
RAMI
“Design”
Incorporation
of RAMI in
Design
Page 17 of 21
Next Step
• 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.
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 18 of 21
Supporting Pages
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 19 of 21
Reliability Focused Resources
(Highlights)
Reliability, Availability, Maintainability, and System Health
(Inspectability) all addressed in top-level documents
•
•
Boeing
Boeing
D950-10446-1
D950-10088-3
• IEC
• IEC
• IEC
•
•
•
•
•
•
•
IEEE
NRC
NASA
DoD
DoD
SAE
SAE
– Boeing
• FAA
– Boeing
1014
1078
1164
Programs for Reliability Growth
Analysis Techniques for Dependability
Reliability Growth – Statistical Test and
Estimation
Std 1332
Reliability Program for Electronic Systems
NUREG-0492
Fault Tree Handbook
Fault Tree Handbook with Aerospace Applications
MIL-STD-756B
Reliability Modeling and Prediction
MIL-STD-498
Software Development and Documentation
JA 1000
Reliability Program Standard
JA 1002
Software Reliability Program Standard
D6-25382-80
AC, Part 25
D950-10386-3
• Boeing D6-56674
•
Boeing
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
System Engineering Process
Reliability, Maintainability and
Systems Health (RM&SH) Process
D950-10088-4
Reliability Engineering Design Guide
Airworthiness Standards
FMEA/FMECA – Process Guide
FMEA Guidelines
System Support Analysis Process
Page 20 of 21
Maintainability Focused
Resources (Highlights)
•
Boeing
–
Boeing
•
IEC
BPI-1092
Maintainability Engineering Process
Overview
D6-25382-20
Maintainability Design Guide
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
ARIES Quarterly Review
Bethesda, MD – 4, 5 April 2011
Page 21 of 21