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Boeing Fusion Energy Plan Presented to US ITER xx December 2008

Boeing Fusion Energy Plan Presented to US ITER xx December 2008. Defining an ARIES RAMI Process. Tom Weaver Boeing Research and Technology. Boeing Phantom Works. ARIES 2011 Quarter #1 Review 4-5 April, 2011; Bethesda, Maryland. Background and Need.

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Boeing Fusion Energy Plan Presented to US ITER xx December 2008

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  1. Boeing Fusion Energy PlanPresented to US ITERxx December 2008 Defining an ARIES RAMI Process Tom Weaver Boeing Research and Technology Boeing Phantom Works ARIES 2011 Quarter #1 Review 4-5 April, 2011; Bethesda, Maryland

  2. 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

  3. 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

  4. 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.

  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

  6. 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

  7. 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.

  8. Activities of an RM&SH Process • Define RM&SH Program • Collect/Provide Experience Data • Provide RM&SH in the Product • Assess RM&SH in Design and Production Feature 1 must assure that Features 2 – 4 are part of an iterative process

  9. Boeing Distillation Three categories of Boeing RM&SH documents • Corporate “Authorizing” documents • Corporate “Procedure Description” documents • Boeing Defense Systems-focused plan descriptions and handbooks • Boeing Commercial Aircraft-focused plan descriptions and handbooks Boeing documents, and their references, appear to bracket fusion needs in multiple parameters

  10. Economics Dominance Risk Aversion Prescriptiveness Number of Customers Documentation Documents Map NUREG Documents Fusion Need BCA Documents BDS Documents

  11. Systems and Safety Engineering Technical Publications Design Engineering RAMI Process Plant/Fleet Support Engineering Retrofit and Modification Training Systems Contractor RAMI Support Site Activation RAMI Process Interfaces (from RM&SH Process)

  12. Where most of RAMI is done Systems and Safety Engineering Design Engineering Supplies/Interprets Requirements RAMI Process Plant/Fleet Support Engineering Supplies/Interprets Requirements Where Most of RAMI Starts

  13. Systems and Safety Engineering Design Engineering RAMI Process Plant/Fleet Support Engineering Contractor RAMI Support Site Activation RAMI Ramp-Up

  14. Systems and Safety Engineering Technical Publications Design Engineering RAMI Process Plant/Fleet Support Engineering Retrofit and Modification Training Systems Contractor RAMI Support Mature Project

  15. Systems and Safety Engineering Technical Publications Design Engineering RAMI Process Plant/Fleet Support Engineering Retrofit and Modification Training Systems Contractor RAMI Support Site Activation ARIES Immediate Task

  16. 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

  17. Responsible Entity Input Provided RAMI Process Output SoW and Spec Rqmts Customer and Regulator SoW and Spec Rqmts Program Manager Define RAMI Program Prime Contractor Standards “Command Media” Provide RAMI in the Product Collect & Provide Experience Data Data, Methods, Tools, Expertise, Processes RAMI Engineering CAE/CAD/CAM Systems Assess RAMI In Design And Production Requirements Requirements and Data Logistics Candidate Logistics Support Analyses RAMI “Design” Design Engineering HW & SW Rqmts Requirements Incorporation of RAMI in Design Systems and Safety Engineering Design Data Suppliers RAMI Data RAMI Process Flow

  18. 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.

  19. Supporting Pages

  20. Reliability Focused Resources (Highlights) Reliability, Availability, Maintainability, and System Health (Inspectability) all addressed in top-level documents • 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

  21. 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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