Designing magnetic systems for reliability

Designing magnetic system is an iterative process in which the requirements are set, a design is developed, materials and manufacturing processes are defined, interrelationships with the various elements of the system are established, engineering analyses are performed, and fault modes and effects are studied. Reliability requires that all elements of the design process, from the seemingly most straightforward such as utilities connection design and implementation, to the most sophisticated such as advanced finite element analyses, receives a balanced and appropriate level of attention. D.B. Montgomery's study of magnet failures has shown that the predominance of magnet failures tend not to be in the most intensively engineered areas, but are associated with insulation, leads, ad unanticipated conditions. TFTR, JET, JT-60, and PBX are all major tokamaks which have suffered loss of reliability due to water leaks. Similarly the majority of causes of loss of magnet reliability at PPPL has not been in the sophisticated areas of the design but are due to difficulties associated with coolant connections, bus connections, and external structural connections. Looking towards the future, the major next-devices such as BPX and ITER are most costly and complex than any of their predecessors and are pressing the bounds of operating levels, materials, and fabrication. Emphasis on reliability is a must as the fusion program enters a phase where there are fewer, but very costly devices with the goal of reaching a reactor prototype stage in the next two or three decades. This paper reviews some of the magnet reliability issues which PPPL has faced over the years the lessons learned from them, and magnet design and fabrication practices which have been found to contribute to magnet reliability