Systems analysis determining critical items, critical assembly processes, primary failure modes and corrective actions on ASST magnets

During the assembly process through the completion of the Accelerator Surface String Test (ASST) phase one test, Magnet Systems Division Reliability Engineering has tracked all the known discrepancies utilizing the Failure Reporting, Analysis and Corrective Action System (FRACAS) and data base. This paper discusses the critical items, critical assembly processes, primary failure modes and corrective actions (lessons learned) based on actual data for the ASST magnets. The ASST magnets include seven Brookhaven Lab Dipoles (DCA-207 through 213), fourteen Fermi Lab Dipoles (DCA-310 through 323) and five Lawrence Berkeley Lab Quadrupoles (QCC-402 through 406). Between all the ASST magnets built there were one hundred eighty six (186) class one discrepancies reported out of approximately eleven hundred total discrepancy reports. The class one or critical discrepancies are defined as form, fit, function, safety or reliability problem. Each and every ASST magnet is considered a success, as they all achieved the quench performance requirements and were capable of being incorporated into the string test. This paper will also discuss some specific magnet discrepancies, including failure cause(s), corrective action and possible open issues