1. Page 1 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 Boeing Fusion Energy Plan Presented to US ITER xx December 2008 Boeing Phantom Works Defining an ARIES RAMI Process Tom Weaver Boeing Research and Technology ARIES 2011 Quarter #1 Review 4-5 April, 2011; Bethesda, Maryland

2. Page 2 of 21 ARIES 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, 1 st -of-Kind, and 10 th -of-Kind planning require industry-style coverage and formality Aerospace a convenient, mature, starting point Background and Need

3. Page 3 of 21 ARIES 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

4. Page 4 of 21 ARIES 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.

5. Page 5 of 21 ARIES 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 TerminologyARIES Terminology ReliabilityReliability, reliability-related aspects of Availability, and most instrumentation and control MaintainabilityMaintainability; 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

6. Page 6 of 21 ARIES 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

7. Page 7 of 21 ARIES 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.

8. Page 8 of 21 ARIES 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

9. Page 9 of 21 ARIES 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

10. Page 10 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 Documents Map Prescriptiveness Risk Aversion BDS Documents BCA Documents NUREG Documents Fusion Need Documentation Economics Dominance

11. Page 11 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 RAMI Process Interfaces (from RM&SH Process) RAMI Process Technical Publications Site Activation Plant/Fleet Support Engineering Training Systems Contractor RAMI Support Retrofit and Modification Systems and Safety Engineering Design Engineering

12. Page 12 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 Where Most of RAMI Starts RAMI Process Plant/Fleet Support Engineering Systems and Safety Engineering Design Engineering Supplies/Interprets Requirements Supplies/Interprets Requirements Where most of RAMI is done

13. Page 13 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 RAMI Ramp-Up RAMI Process Site Activation Plant/Fleet Support Engineering Contractor RAMI Support Systems and Safety Engineering Design Engineering

14. Page 14 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 Mature Project RAMI Process Technical Publications Plant/Fleet Support Engineering Training Systems Contractor RAMI Support Retrofit and Modification Systems and Safety Engineering Design Engineering

15. Page 15 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 ARIES Immediate Task RAMI Process Technical Publications Site Activation Plant/Fleet Support Engineering Training Systems Contractor RAMI Support Retrofit and Modification Systems and Safety Engineering Design Engineering

16. Page 16 of 21 ARIES 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

17. Page 17 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 RAMI Process Flow RAMI Process Define RAMI Program Collect & Provide Experience Data Provide RAMI in the Product Assess RAMI In Design And Production Responsible Entity Customer and Regulator Program Manager Prime Contractor Standards RAMI Engineering Logistics Design Engineering Systems and Safety Engineering Suppliers Candidate Logistics Support Analyses Input Provided 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

18. Page 18 of 21 ARIES 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

19. Page 19 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 Supporting Pages

20. Page 20 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 BoeingD950-10446-1System Engineering Process BoeingD950-10088-3Reliability, Maintainability and Systems Health (RM&SH) Process IEC1014Programs for Reliability Growth IEC1078Analysis Techniques for Dependability IEC1164Reliability Growth – Statistical Test and Estimation IEEEStd 1332Reliability Program for Electronic Systems NRCNUREG-0492Fault Tree Handbook NASAFault Tree Handbook with Aerospace Applications DoDMIL-STD-756BReliability Modeling and Prediction DoDMIL-STD-498Software Development and Documentation SAEJA 1000Reliability Program Standard SAEJA 1002Software Reliability Program Standard –BoeingD6-25382-80Reliability Engineering Design Guide FAAAC, Part 25 Airworthiness Standards –BoeingD950-10386-3FMEA/FMECA – Process Guide BoeingD6-56674FMEA Guidelines BoeingD950-10088-4System Support Analysis Process Reliability Focused Resources (Highlights) Reliability, Availability, Maintainability, and System Health (Inspectability) all addressed in top-level documents

21. Page 21 of 21 ARIES Quarterly Review Bethesda, MD – 4, 5 April 2011 Maintainability Focused Resources (Highlights) BoeingBPI-1092Maintainability Engineering Process Overview –BoeingD6-25382-20Maintainability Design Guide IEC706-6Guide on Maintainability of Equipment –BoeingD6-36667Maintainability Engineering Handbook –BoeingBPI-375Digital Maintainability Analysis Process for V4/V5 Programs (CAD Assembleability/Maintainability Analysis) –BoeingD194-30091-1BCA Experience Analysis Center User’s Guide –BoeingD906-10061-1Design for System Health Guidelines –DoDMIL-HDBK-741Maintainability Program Plan –DoDMIL-HDBK-470ADesigning and Developing Maintainable Products and Systems –DoDMIL-HDBK-472Maintainability Prediction –SAEJA 1010Maintainability Program Standard –SAEJA 2389Fatigue and Limited Life