Attachment C - Technical Specification for the EIC HSR BPM Cryo-Cable Assembly Rev 02.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-ISG-SPC-012 Author: M. Paniccia Effective Date: October 17, 2024 Review Frequency: N/A

Specification Title: EIC HSR BPM Cryo-Cable Assembly Revision: 02

TECHNICAL SPECIFICATION

for the

EIC HSR BPM Cryo-Cable Assembly Quality Classification: A-3

Prepared By:

__________________________________________ Date: __________________ Matthew Paniccia, C-AD Instrumentation Engineer Brookhaven National Laboratory

Reviewed By:

Joseph Tuozzolo, Technical Division Group Leader Electron-Ion Collider

David Gassner, EIC Instrumentation Group Leader

Frederic Micolon, EIC Mechanical Engineer

Charlie Hetzel, EIC Vacuum Group Leader

Docusign Envelope ID: 652869A0-42D9-4E1A-B671-DA23CA64ED72

10/17/2024

10/17/2024

10/17/2024

10/18/2024

Joe Zipper, Quality Assurance

Chuck Schaefer, ESH

Cindy Galdamez, Procurement Liaison Engineer

Approved By:

Vadim Ptitsyn, HSR L2 Manager

10/17/2024

10/19/2024

10/21/2024

REVISION HISTORY

Revision # Effective Date Summary of Change

00 9/29/2023 Initial Release

01 11/15/2023

Minor clarifications in Table 1. Changed VSWR from 1.2:1 to 1.3:1. Changed minimum bend radius from 0.4 inch to

0.5 inch. Separated out Cable-to-cable insertion loss comments from the 3.1.1.1 Voltage Standing Wave Ratio (VSWR) section, and put them into their own new section

3.1.1.2.

02 10/17/2024

Changed connectors to RP-SMA Male. Changed acceptable cable size range to 0.090 ± 0.005 to 0.142 ±

0.005 inches. Updated format and wording for better clarity.

Table of Contents

1 SCOPE

1.1 Background

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

3.1.1 Electrical Requirements

3.1.2 Mechanical Requirements

3.1.3 Vacuum Requirements

3.2 Materials

3.2.1 Hazardous Materials

3.3 Marking and Serialization

3.3.1 Serial Numbers

3.3.2 Part Numbers

3.4 Packaging/Shipping

4 VERIFICATION

4.1 Classification of Inspections

4.1.1 Pre-production Units

4.1.2 Acceptance Tests

LIST OF ACRONYMS

ATP

AMU

Acceptance Test Procedure Atomic Mass Unit

BNL Brookhaven National Laboratory BPM Beam Position Monitor

BSA

C

Brookhaven Science Associates Celsius

EIC Electron-Ion Collider ESH Environment, Safety and Health He Helium HSR Hadron Storage Ring K Kelvin OD Outer Diameter RF Radio Frequency SiO2 Silicon Dioxide RP-SMA Reverse Polarity Sub-Miniature version A connector UHV Ultra-High Vacuum VSWR Voltage Standing Wave Ratio

Technical Specification for the EIC HSR Beam Position Monitor Cryo-Cable Assembly

1 SCOPE

This specification defines the technical requirements for the Hadron Storage Ring (HSR) Beam Position Monitor (BPM) Cryo-Cable Assembly to be used at the Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA).

1.1 Background

The EIC Project will design, build, and install the accelerator hardware for a new electron storage ring, a new electron accelerator synchrotron ring with an electron injector, and modifications to the hadron ring required to produce an electron-ion collider and associated infrastructure. It will include one interaction region with a complete detector. The EIC is being designed to reserve space for a second interaction region with a second detector. The facility is designed to meet requirements to ensure high reliability and availability for the user program.

The HSR BPM Cryo-Cable Assemblies (Cable Assemblies hereafter) will be procured by BSA for installation in the HSR of the EIC. The Cable Assemblies will be used to carry beam position monitor radio frequency (RF) electrical signals through the cryostat insulating vacuum, from the liquid helium cooled cryogenic BPM feedthrough to the room temperature insulating vacuum to air feedthrough.

2 APPLICABLE DOCUMENTS

The following specifications, standards and drawings form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents shall be that in effect on the date of the solicitation or contract. Exceptions must be approved in writing by BSA.

In the event of a conflict between the applicable documents and this specification, the Contractor shall immediately notify the BSA Contractual Representative who shall in each instance determine which document takes precedence and advise the Contractor accordingly. Failure to notify BSA of a document conflict shall not relieve the Contractor’s responsibility to ensure full compliance with all requirements.

Document Number Document Title

2551M0002 Drawing for Hadron Storage Ring, Beam Instrumentation, BPM Coaxial Cables, SiO2

MIL-STD-348B Specifications for Radio Frequency Connector Interfaces

MIL-PRF-39012F Specification for Radio Frequency Coaxial Connectors

MIL-STD-130 Identification Marking of U.S. Military Property

ASTM A269 Standard Specification for Seamless and Welded Austenitic Stainless-Steel Tubing for General Service

ASTM B75 Standard Specification for Seamless Copper Tube

ASTM B170 Standard Specification for Oxygen-Free Electrolytic Copper

29 CFR 1910.1200 Hazard communication & materials

BNL-QA-101 Brookhaven National Laboratory Supplier Quality Assurance Requirements

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

Table 1: Technical Specifications for Cryo-Cable Assemblies Physical Characteristics

Characteristic Specification

Connector 1 and 2 RP-SMA Male1,2,3 (see notes below)

Cable Outer jacket material Non-magnetic stainless steel (304 or equivalent)

Cable Outer conductor material Seamless Copper C10100 Cable Outer conductor coating thickness

Thickness and tolerance must be specified.

A thinner coating is preferred whenever possible.

Cable Inner conductor material Copper C10100

Cable Dielectric material Low density, high purity silicon dioxide (SiO2)

Cable Outside diameter, range 0.090 ± 0.005 to 0.142 ± 0.005 inches

Electrical Characteristics

Characteristic Specification

Characteristic impedance 50 ohm ± 1 ohm

VSWR 1.3:1 from 20 MHz through 3 GHz

Breakdown Voltage >500 Vdc

Contact Resistance ≤4 mΩ

Insertion Loss Read and record from 20 MHz to 3 GHz Insertion Loss Variation, Cable to Cable ± 0.05 dB from 20 MHz to 3 GHz

Electrical Length Read and record Electrical Length Variation, Cable to Cable ± 25 ps

EMI Shielding >110 dB 1 RP-SMA Male connectors do not require sealing gaskets 2 Hex nut shall have locking wire holes 3 Connectors shall be vented

3.1.1 Electrical Requirements

3.1.1.1 Impedance – The characteristic impedance for the Cable Assembly shall be 50 ohms.

The impedance shall remain within ± 1 ohm over the electrical length of the Cable Assembly. The degree of impedance mismatch shall be quantified by the voltage standing wave ratio (VSWR).

The VSWR shall be less than 1.3:1 from 20 MHz to 3 GHz.

3.1.1.2 Insertion Loss – Insertion Loss (IL) of the Cable Assembly is defined in the frequency domain and shall be measured from 20 MHz to 3 GHz. Variations in cable-to-cable insertion loss between different Cable Assemblies shall be less than ± 0.05 dB from 20 MHz to 3 GHz.

3.1.1.3 Phase Matching – The Cable Assembly electrical length shall not vary from cable-to-cable more than ± 25 ps over the 300 MHz - 3 GHz range. The electrical length shall be measured for a finished Cable Assembly; refer to drawing 2551M0002 for details on physical length tolerances.

3.1.1.4 Contact Resistance – The maximum resistance through the SMA center contact shall be less than or equal to 4 milliohms. The contact resistance shall remain less than or equal to 4 milliohms after 150° C bakeout.

3.1.2 Mechanical Requirements

Mechanical configurations and tolerances shall be in accordance with drawing 2551M0002.

3.1.2.1 Environment – The Cable Assembly shall have an operating range of 4 Kelvin to room temperature.

3.1.2.2 Connectors – The Cable Assembly connectors, reference designators P1 and P2 in drawing 2551M0002, shall be RP-SMA Male. The connectors shall be built in accordance with MIL-PRF-39012F, Category A. The inner dimensions and interfaces of the SMA connector shall be in accordance with the MIL-STD-348B and shall be capable of mating with other connectors of the opposite gender for a minimum of 100 mating cycles. The RP-SMA connectors do not require a sealing gasket. Both connectors shall be vented and shall have locking wire holes on the hex nut.

3.1.2.2.1 Connector Material – The RP-SMA Male connector detailed design, material used (beryllium copper C17300 is recommended), and attachment method used for the female contacts that are attached to the end of the Cable Assembly center conductor shall be provided by the Contractor and approved by BSA in writing.

3.1.2.3 Coaxial Cable – The coaxial cable shall be semi-rigid and maintain its shape after bending. Acceptable standard cable outer diameters (ODs) range from 0.090 inches ± 0.005 inches to 0.142 inches ± 0.005 inches; other configurations are subject to BSA approval.

3.1.2.3.1 Coaxial Cable Material – The outer conductor shall be a seamless stainless steel of type 316L or 304, per ASTM A269, lined with a seamless oxygen-free copper, C10100, per ASTM B75. The dielectric material shall be silicon dioxide (SiO2). The inner conductor shall be made from oxygen-free copper per ASTM B170.

3.1.3 Vacuum Requirements

3.1.3.1 Ultra-High Vacuum (UHV) Environment – The Cable Assembly will be used in an insulating vacuum environment. The coaxial cable and SMA connectors will be exposed to the insulating vacuum (10-9 - 10-4 Torr). All design details, fabrication techniques, and materials shall be in accordance with this application. All surfaces of each cable shall be smooth and free of scale, stains and residues of any kind upon receipt by BNL.

3.1.3.2 Bake-out – The Cable Assembly shall be capable of baking to 150° C without developing leaks and without degradation of its electrical performance. All design details and materials shall be consistent with this application.

3.1.3.3 Leak Rate – The Cable Assembly shall have a leak rate of less than 1×10-8 std. cc/sec He when tested with a helium mass spectrometer leak detector over the full operating temperature range (cryogenic temperature to 150° C). All leak checking shall be carried out in an UHV-compatible clean environment using oil-free pumps.

3.1.3.4 Vented connectors – All cavities within a connector and/or a connector body shall be vented. Venting holes design shall not jeopardize the electrical performance of the connector.

3.1.3.5 Cleaning and Handling – During and after fabrication, all components shall be cleaned, free of hydrocarbon contaminants, and handled in accordance with their intended use in UHV systems. The Cable Assemblies as received shall exhibit no traces of halocarbons, oils or other contaminants with atomic mass of 35 or greater than 40 atomic mass unit (AMU) with the exception of 44 when tested using a residual gas analyzer with a minimum detectable partial pressure of 1x10-11 torr N2. The predominant gas component shall be hydrogen and be at least 60% of the total pressure after being pumped for 100 hours. The sum of partial pressures of atomic mass 35 and 40 through 100 excluding atomic mass 44, shall be less than 1% of the total pressure of the system.

3.2 Materials

Written material certification shall be provided for the Cable Assembly including the outer conductor, dielectric insulator, center conductor, and connectors.

3.2.1 Hazardous Materials - Materials which may be defined as hazardous in accordance with 29 CFR 1910.1200, Hazard Communication shall not be used.

3.3 Marking and Serialization

Cable Assemblies shall be laser engraved with marking text in accordance with MIL-STD 130 on the first straight length of cable after each connector as per drawing 2551M0002.

3.3.1 Serial Numbers – Each Cable Assembly shall be assigned a unique serial number by the Contractor.

3.3.2 Part Numbers – Each Cable Assembly shall be assigned BSA’s drawing number, dash number, connector reference designator, clocking position, and serial number, as specified in drawing 2551M0002 note 5, and shall be included in the marking text.

3.4 Packaging/Shipping

Each set of Cable Assemblies shall be wrapped in lint-free paper or vacuum-grade aluminum foil and put into clean transparent polyethylene bags back-filled with clean, dry nitrogen.

Each bagged assembly shall be individually packaged in a way to ensure protection during the shipping process. The Cable Assemblies shall be shipped to BNL in boxes which are durable enough to facilitate subsequent storage at BNL after completion of incoming inspection. Plastic

“peanuts” or other such loose packing material shall not be used by the Contractor in the packaging of the Cable Assemblies.

4 VERIFICATION

Appropriate inspection/tests shall be performed to ensure the Cable Assemblies’ compliance to all requirements in section 3 of this specification.

4.1 Classification of Inspections

Items covered by this specification shall be subjected to the following tests to determine compliance with all applicable requirements:

4.1.1 Pre-production Units

A set of pre-production Cable Assemblies shall be fabricated and tested prior to the start of the fabrication of the production units. The pre-production units shall undergo the same acceptance tests as the production units, described in Section 4.1.2 herein. The Contractor shall not commence fabrication of the production units until receiving authorization in writing from BSA.

4.1.2 Acceptance Tests

4.1.2.1 Acceptance Tests Performed at Contractor - The Contractor shall provide Acceptance Test Procedures (ATPs) for BSA written approval that are in accordance with this specification and all reference documents noted herein. Each Cable Assembly shall be tested at the Contractor’s facility to demonstrate compliance with the requirements specified below. All data shall be documented and delivered to BSA for review prior to acceptance. The following tests shall be conducted on each Cable Assembly at the Contractor’s facility according to the ATPs, prior to delivery to BNL:

• Dimensional Measurement – The overall length and bends of the Cable Assemblies shall be measured for conformance to the drawing requirements. The inspection shall be in accordance with drawing 2551M0002.

• Electrical Measurements – Network analyzer trace data with S11 vector terminated with 50 ohm load from 100 kHz to 3 GHz, and trace data with S21 vector from 100 kHz to 3 GHz shall be provided.

• Cleanliness – The Cable Assemblies shall be inspected for cleanliness and free of hydrocarbon contaminants.

• Leak checking - Shall be performed at room temperature and have a leak rate of less than 1×10-8 std. cc/sec He when tested with a helium mass spectrometer leak detector.

4.1.2.2 Acceptance Tests Performed at BNL - In addition to the acceptance tests performed at the Contractor’s facility, the Cable Assemblies will be acceptance tested at BNL. Any Cable

Assemblies that fail to pass these tests shall be returned to the Contractor for analysis and corrective action. The Contractor is responsible for incorporating any configuration changes if it is determined that the failure is caused by a design or manufacturing flaw. The Contractor’s responsibility includes shipping, labor, and materials.

• Electrical Measurements – Verify conformance to specifications listed in 3.1.1.

Measurements will be made at room temperature and at cryogenic temperature. Network analyzer S11 measurements with vector terminated with 50 ohm load from 100 kHz to 3 GHz, and measurements with S21 vector from 100 kHz to 3 GHz.

• Mechanical tests – The Cable Assembly will be thermal cycled multiple times (~10) from room temperature to cryogenic temperature.

• Dimensional Measurements – Overall length measurement and bends of the Cable Assembly will be performed as required to ensure conformance to drawing 2551M0002.

• SMA Connector Mating Tests - The RP SMA Male connectors will be tested for conformance with the insertion and withdrawal force specifications in MIL-STD-39012F and MIL-STD-348B. The contact resistance will be measured before and after the test to verify conformance with Section 3.1.1.4.

• Leak Checking – Leak checking shall be performed in accordance with this specification as described in section 3.1.3.3 at room temperature.

• UHV Cleanliness – With the Cable Assembly remaining under vacuum in the leak checking apparatus following the helium leak test a 0-100 AMU residual gas analyzer spectrum analysis will be performed to verify UHV cleanliness per paragraph 3.1.3.5 herein.

3.4 Packaging/Shipping