With substantial operating hours on the RF system, considerable information on reliability of the 5 kW CW klystrons has been obtained. High early failure rates led to examination of the operating conditions and failure modes. Internal ceramic contamination caused premature failure of gun potting material and ultimate tube demise through arcing or ceramic fracture. A planned course of repotting and reconditioning of approximately 300 klystrons, plus careful attention to operating conditions and periodic analysis of operational data, has substantially reduced the failure rate. It is anticipated that implementation of planned supplemental monitoring systems for the klystrons will allow most catastrophic failures to be avoided. By predicting end of life, tubes can be changed out before they fail, thus minimizing unplanned downtime. Initial tests have also been conducted on this same klystron operated at higher voltages with resultant higher output power. The outcome of these tests will provide information to be considered for future upgrades to the accelerator.
