Overview and Statistical Failure Analyses of the Electrical Insulation System for the SSC Long Dipole Magnets from an Industrialization Point of View

Abstract

The electrical insulation system of the SSC long dipole magnets is reviewed and potential dielectric failure modes discussed. Electrical insulation fabrication and assembly issues with respect to rate production manufacturability are addressed. The automation required for rate assembly of electrical insulation components will require critical online visual and dielectric screening tests to insure production quality. Storage and assembly areas must be designed to prevent foreign particles from becoming entrapped in the insulation during critical coil winding, molding, and collaring operations. All hand assembly procedures involving dielectrics must be performed with rigorous attention to their impact on insulation integrity. Individual dipole magnets must have a sufficiently low probability of electrical insulation failure under all normal and fault mode voltage conditions such that the series of magnets in the SSC rings have acceptable Mean Time Between Failure (MTBF) with respect to dielectric mode failure events. Statistical models appropriate for large electrical system breakdown failure analysis are applied to the SSC magnet rings. The MTBF of the SSC system is related to failure data base for individual dipole magnet samples.