Attachment 2 - Specification EIC-INS-SPC-010.pdf

Electron-Ion Collider, Brookhaven National Laboratory Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

Title: ESR Swap-out Injection Stripline Kicker Prototype Revision: 00

TECHNICAL SPECIFICATION

for the

ESR Swap-out Injection Stripline Kicker Prototype Quality Classification: A-3

Prepared By:

_________________________________ Date: __________________ Manfred Wendt, Instrumentation Engineer

BNL, EIC

Reviewed By:

Matthew Paniccia, Technical Representative

Chuyu Liu, Subsystem Manager for Pulsed Devices

EIC

Vincent Schoefer, System Manager for Rapid Cycling Synchrotron EIC

Qiong Wu, Associate Project Manager for Electron Injector EIC

Joseph Zipper, EIC Quality Assurance Representative

Approved By:

Sergei Nagaitsev, Technical Director, EIC

Docusign Envelope ID: 861AC09B-804C-80B6-8124-6ED0C1B95890

8/31/2026

9/7/2026

9/1/2026

9/1/2026

8/31/2026

8/31/2026

9/9/2026

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

REVISION HISTORY

Revision # Effective Date Summary of Change 00 08/31/2026 Initial Release

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

Table of Contents

1 SCOPE

1.1 Background

2 APPLICABLE DOCUMENTS

2.1 Documents

2.2 Engineering Models and Drawings

2.3 Code and Standard Compliance

2.4 Interpretation

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

3.1.1 ESR Injection Operating Requirements

3.1.2 Kicker Timing and Deflection Requirements

3.2 Geometric Requirements

3.3 Mechanical Design and Tolerances

3.4 Materials and Surface Requirements

3.5 HV Coaxial UHV RF Feedthrough

3.6 Thermal Management and Cooling

3.7 RF/Electrical Verification

3.8 Vacuum and Cleanliness

3.9 Fabrication and Assembly

4 INSPECTION, TESTING, AND ACCEPTANCE

4.1 RF Mockup Verification

4.2 Prototype RF Characterization

4.3 Thermal/Cooling Verification

4.4 Vacuum Certification

4.5 Configuration Control and Nonconformance

5 DOCUMENTATION AND SUBMITTALS

5.1 Required Contractor Documentation

5.2 File Formats and Data Delivery

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

LIST OF ACRONYMS

ASR Accelerator Storage Rings

BNL Brookhaven National Laboratory

BSA Brookhaven Science Associates

CAD Computer-Aided Design

CuO Copper Oxide

EIC Electron-Ion Collider

EIA Electronic Industries Alliance interface designation

EIN Electron Injector (EIC)

ESR Electron Storage Ring (EIC)

FWHM Full Width at Half Maximum

HV High Voltage

ID Inner Diameter

OFHC Oxygen-Free High-Conductivity

QA Quality Assurance

RCS Rapid-Cycling Synchrotron

RF Radio Frequency

RTE RCS-to-ESR transport line

SOW Statement of Work

STEP Standard for the Exchange of Product model data

TDR Time Domain Reflectometry

TEM Transverse Electromagnetic

TID Total Integrated Dose

UHV Ultra-High Vacuum

VNA Vector Network Analyzer

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

Technical Specification for the ESR Swap-out Injection Stripline Kicker Prototype

1 SCOPE

This Technical Specification establishes the technical, performance, material, fabrication, verification, documentation, and acceptance requirements for the prototype stripline kicker for the swap-out injection kicker system of the Electron Storage Ring (ESR) of the Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL), managed by Brookhaven Science Associates (BSA). The prototype includes the kicker body, stripline electrodes, cooling features, flex-couplings, coaxial high-voltage ultra-high-vacuum feedthrough interfaces, and associated hardware necessary to demonstrate the design.

This specification is intended to be used together with the applicable Statement of Work (SOW), BSA approved drawings/models, and procurement quality requirements. It defines the technical characteristics that the Contractor shall satisfy in the design, manufacture, assembly, testing, documentation, and delivery of the ESR swap-out injection stripline kicker prototype.

1.1 Background

The Electron Injector (EIN) supplies the ESR with polarized electron bunches at 5 and 9 GeV, with an upgrade path to 18 GeV. To maintain high average electron spin polarization during luminosity operation, depolarized bunches in the ESR are periodically replaced with freshly polarized bunches from the Electron Injector. In this swap-out process, a fresh bunch is injected on axis into a selected RF bucket while the stored bunch occupying that bucket is simultaneously kicked toward a beam dump.

The ESR injection kicker system supports two operating modes: filling the ESR with individual polarized bunches in preparation for luminosity operation and replacing selected individual bunches during luminosity operation without perturbing adjacent bunches. The minimum bunch spacing is 10.15 ns, which drives the fast-pulse performance of the stripline kicker system.

Figure 1: ESR injection operating modes: (a) filling with individual bunches; (b) swap-out replacement of an individual stored bunch.

2 APPLICABLE DOCUMENTS

In the event of a conflict between the applicable documents and this specification, the Contractor shall immediately notify the BSA Contractual Representative. BSA will determine precedence and advise the Contractor in writing.

Failure to identify a conflict does not relieve the Contractor of the responsibility to comply with the requirements of the contract and this specification.

Unless otherwise specified, the issue/revision of each applicable document shall be the version identified in the solicitation, purchase order, or subsequently approved in writing by BSA.

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

2.1 Documents

Document Number Document Title

EIC-INS-SOW-017 Statement of Work for an ESR Swap-out Injection Stripline Kicker Prototype for the EIC

TBD Existing BNL EM design package and performance requirements for the ESR Injection Kicker

TBD Applicable EIC interface document

BNL-QA-101 Brookhaven National Laboratory Supplier Quality Assurance Requirements (when invoked by the procurement documents)

2.2 Engineering Models and Drawings

Reference Description Status/Use

ESR_StriplineKicker_lossy_NormalBGND_L900A90_cool6_graphics.stp Full stripline kicker geometry

Primary mechanical geometry basis

ESR_KickerStriplineMockup_lossy_NormalBGND_L150A90_cool6_graphics.stp Short RF mockup geometry

RF/tolerance verification mockup

BNL-provided CST Studio model Electromagnetic analysis model

File name/revision TBD by BSA

Minor geometry revisions may retain the base file names with revision suffixes such as “_cool6a_”, “_cool6b_”, etc.

The Contractor shall use only the latest BSA-approved geometry/model revision identified in the solicitation/PO or subsequently approved in writing for fabrication or analysis.

2.3 Code and Standard Compliance

• ASME Y14.5-2018, Dimensioning and Tolerancing, shall apply to engineering drawings unless otherwise specified by BSA.

• Applicable BNL/EIC ESR vacuum, cleanliness, quality assurance, environment, safety and health, brazing, and material-control requirements shall apply when invoked by the contract, purchase order, approved drawings, or BSA procedures.

2.4 Interpretation

All dimensions, tolerances, materials, and internal geometric details of the kicker body, stripline electrodes, cooling bars, flex-couplings, and coaxial feedthrough interfaces shall conform to the BSA-approved STEP geometry and construction drawings. No change to geometry, material, or functional interface shall be made without prior written BSA approval.

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

3.1.1 ESR Injection Operating Requirements

Parameter Requirement Notes

Injection beam energy 5 and 9 GeV Upgrade path to 18 GeV Maximum filling repetition rate 1 Hz One bunch at a time

Minimum bunch spacing 10.15 ns ESR stored-bunch spacing Maximum ESR stored beam current 2.5 A Up to 1160 stored bunches

Stored bunch length 7 mm Gaussian bunch length cited in source content

Maximum stored bunch charge 28 nC Per bunch

Swap-out objective Replace a selected stored bunch without perturbing adjacent bunches

Fresh bunch injected on axis while selected stored bunch is kicked out

3.1.2 Kicker Timing and Deflection Requirements

Parameter Requirement Notes

Kicker action window ≤ 20.3 ns Equivalent to 2 × 10.15 ns at 5 and 9 GeV Pulse length (FWHM = 50 %) 8 ns Nominal supply pulse duration Pulse rise time (10-90 %) 2–3 ns leading edge Pulse fall time (10-90 %) 2–3 ns trailing edge Ringing/tail safety margin 3–4 ns Allowance within action window

Kicker constant >80 Nominal ~83.6

Loss factor <60 mV/pC For 7 mm bunch length, 1 nC bunch charge, 50 m integrated wake length

Total system kick angle 1.26 mrad at 5–9 GeV Includes safety overhead; upgradeable for 18 GeV operation

Individual stripline target kick ~315 µrad at 9 GeV At approximately ±24 kV between electrodes

HV supply capability Up to ±30 kV Kicker array / component interface capability

The longitudinal wake potential and loss factor shall be kept reasonably low for Gaussian bunches with length σz = 7 mm and beam current up to 2.5 A and shall be approved by BSA prior to final acceptance.

3.2 Geometric Requirements

Parameter Requirement

Minimum clear beam aperture 30.0 mm ID (approximately 15σ distance to the septa for the circulating beam)

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

Parameter Requirement

Active stripline electrode length 900 mm

Maximum installation length 1200 mm between vacuum flanges

All internal geometric dimensions, including kicker-body pockets and bores, stripline electrode geometry, cooling bars, flex-couplings, and coaxial feedthrough connections, shall follow the dimensions extracted from the BSA approved STEP geometry. The 900 mm active electrode length is selected to maximize interaction with the nominal ~8.5 ns pulse while maintaining the required field-propagation characteristics.

3.3 Mechanical Design and Tolerances

• The Contractor shall establish a complete set of detailed construction drawings for all individual parts and assemblies based on the BSA-provided geometry and viable UHV brazing and assembly procedures.

• Mechanical tolerances shall be established using RF measurement results from the short stripline mockup and, where applicable, from the prototype. Final fabrication tolerances shall be documented on drawings and approved by BSA before production of the prototype hardware.

• The design shall preserve the intended TEM-field geometry and shall not incorporate passive thermal features or geometric modifications that compromise beam/signal velocity matching or characteristic impedance without BSA approval.

• The design shall provide practical assembly, brazing, cooling, and feedthrough interfaces while maintaining the approved RF geometry.

3.4 Materials and Surface Requirements

Item Requirement

Kicker body and stripline electrodes Hardened OFHC copper alloy Stripline electrode thickness 2 mm

Cooling bars Hardened OFHC copper alloy preferred Stainless-steel parts exposed to RF fields Copper coated, nominal thickness 25 µm Electrical/cooling insulating components Al2O3 alumina ceramic

All materials used in the kicker shall withstand the total integrated radiation dose expected in the ESR injection area over a 10-year EIC operating period. The required TID value will be provided by BSA.

Where used to improve radiative heat transfer, copper surfaces shall be blackened with a high-emissivity CuO layer of nominally a few micrometers thickness. The coating process, thickness range, and areas to be treated shall be submitted for BSA approval and shall be compatible with the applicable UHV cleanliness requirements.

3.5 HV Coaxial UHV RF Feedthrough

• The feedthrough shall be a UHV-compatible, industry-manufactured unit, such as a Kyocera water-cooled

EIA 7/8-inch feedthrough or BSA-approved equivalent, with vacuum-side modifications as required by the approved geometry.

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

• The RF interface shall be flange-mounted EIA 7/8-inch coaxial with nominal characteristic impedance of 50 Ω.

• The feedthrough return loss shall be at least 30 dB over the principal operating range from DC to 2 GHz, unless a different BSA-approved acceptance limit is established by prototype testing.

• The feedthrough shall withstand 30 kV for an 8 ns pulse at a repetition rate of 1 Hz. The maximum electric surface field shall not exceed 20 MV/m in the approved design.

• External water cooling of the feedthrough shall be provided if required by thermal analysis or component rating.

3.6 Thermal Management and Cooling

Active cooling is required for the kicker body and stripline electrodes. A liquid-cooling approach shall be the primary cooling method. Reasonable liquid-cooling design options shall be evaluated before alternative cooling approaches are considered.

Estimated Heat Dissipation:

Heat/Power Source Design Load max. kicker body beam-induced power loss ≤ 220 W max. beam-induced power loss per stripline electrode ≤ 150 W max. signal power per coaxial port Up to 1150 W

• The kicker body shall be actively water cooled.

• Each stripline shall be actively liquid cooled using BestSolv Zulu or BSA-approved equivalent. Cooling shall be provided through a cooling bar brazed to the back of the stripline and supplied through a ceramic tube spacer from the center of the kicker, consistent with the approved STEP geometry.

• The Contractor shall perform a thermal analysis using proposed coolant properties, flow rates, heat-transfer coefficients, boundary conditions, and the design loads specified above. The analysis shall demonstrate acceptable component temperatures and thermal deformation without compromising RF geometry or UHV performance.

3.7 RF/Electrical Verification

• A simplified, shortened stripline RF mockup shall be fabricated prior to prototype manufacture to verify the kicker-body/stripline geometry, dimensions, characteristic impedance, and coaxial-port transitions.

• The mockup shall be characterized using a two-port VNA, including S-parameter measurements and TDR.

Results shall be used to validate or refine the mechanical tolerances and, if required, the BSA-provided geometry.

• Any proposed geometry modification resulting from RF testing shall be submitted to BSA for approval before implementation in the prototype design.

• The completed prototype shall undergo an in-depth RF/electrical characterization in collaboration with BSA, including VNA/TDR measurements and stretched-wire measurements as applicable.

3.8 Vacuum and Cleanliness

• The completed stripline kicker shall satisfy EIC ESR UHV and cleanliness requirements.

• All vacuum-facing materials, brazes, coatings, cleaning processes, handling methods, and assembly procedures shall be compatible with the applicable BSA/EIC UHV requirements.

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

• Quantitative vacuum acceptance criteria and the controlling BSA/EIC vacuum/cleanliness document numbers are TBD and shall be incorporated before final release.

3.9 Fabrication and Assembly

• The Contractor shall develop detailed fabrication, brazing, assembly, and inspection procedures suitable for the UHV kicker construction.

• The Contractor shall maintain the BSA-approved geometry during all manufacturing operations, including brazing, coating, cooling-bar attachment, and feedthrough integration.

• Manufacturing drawings shall identify materials, dimensions, tolerances, surface requirements, inspection points, brazing/assembly requirements, and configuration/revision status.

• No substitutions of materials, feedthroughs, coolants, coatings, or geometry shall be made without prior

BSA approval.

4 INSPECTION, TESTING, AND ACCEPTANCE

The Contractor shall prepare test procedures, record test configurations and calibration information, document measured data, and provide test reports. Test procedures and acceptance criteria shall be submitted to BSA for review before formal acceptance testing.

4.1 RF Mockup Verification

• Fabricate the shortened brass half-stripline RF mockup defined by the BSA-provided STEP model. The mockup has no vacuum or cooling requirement.

• Perform 2-port VNA S-parameter and TDR measurements in collaboration with BSA. To meet the odd-mode characteristic impedance boundary conditions, a simple metal plate need to be added as symmetry ground-plane, made of brass or aluminum, covering the mockup structure.

• Demonstrate that the measured impedance behavior and transitions are consistent with the intended nominal 50 Ω system and support the selected construction tolerances. Quantitative acceptance bands not supplied in the source package shall be established and approved by BSA prior to final prototype fabrication.

4.2 Prototype RF Characterization

• Perform VNA/TDR characterization of the completed prototype and compare results with the approved model and mockup measurements.

• Perform differential stretched-wire RF measurements in collaboration with BSA to characterize the beam-coupling/wake behavior.

• Document all RF results, observed resonances/mismatches, and any corrective actions.

4.3 Thermal/Cooling Verification

• Perform cooling tests of the kicker body and stripline circuits using the approved coolant(s), flow conditions, and instrumentation.

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

• Demonstrate consistency with the approved thermal model and stable cooling operation at representative or conservatively equivalent heat loads. Maximum allowable temperatures and flow/pressure acceptance limits are TBD pending the final thermal design and BSA approval.

4.4 Vacuum Certification

• The completed prototype shall undergo vacuum certification consistent with the applicable EIC ESR UHV requirements.

• Vacuum test method, bakeout/cleaning requirements, leak-rate limit, pressure/outgassing criteria, and acceptance documentation are TBD pending release of the controlling BSA/EIC vacuum specification.

4.5 Configuration Control and Nonconformance

• The Contractor shall maintain configuration control of BSA-provided models, Contractor drawings, material selections, procedures, and test configurations.

• Any nonconformance, deviation, repair, or proposed design change that affects fit, function, RF performance, UHV performance, cooling, materials, or interfaces shall be documented and submitted to BSA for disposition before use or incorporation.

5 DOCUMENTATION AND SUBMITTALS

5.1 Required Contractor Documentation

• Thermal analysis report, including assumptions, material properties, heat loads, coolant selection, flow rates, boundary conditions, predicted temperatures, thermal deformation, and design margins.

• Complete detailed construction drawings for all parts and assemblies, including dimensions, tolerances, materials, coatings, cooling features, brazing/assembly requirements, and inspection requirements.

• RF mockup fabrication drawings and VNA/TDR test report.

• Feedthrough quotation/specification and technical data for the proposed water-cooled UHV EIA 7/8-inch feedthrough, including any required vacuum-side modifications.

• Prototype fabrication, brazing, assembly, cleaning, and inspection procedures.

• Prototype RF characterization report, including VNA/TDR and stretched-wire results.

• Cooling test report and comparison to the thermal analysis.

• Vacuum certification report.

• As-built drawings and CAD/CAE models reflecting all approved changes.

• Design Review Documentation Package required by the SOW to support the PDR and FDR of the ESR

Swap-Out Injection Kicker.

• Material certifications, process certifications, inspection records, nonconformance dispositions, and other quality records required by the contract or BNL-QA-101 when invoked.

5.2 File Formats and Data Delivery

All documentation shall be in English and shall be provided electronically using a BSA-identified secure file-transfer location, shared network folder, or other approved data-transfer method. Reports shall include sufficient technical detail for independent review. Equations shall define variables and show values used; diagrams and figures shall use labels consistent with the design drawings.

Doc No. EIC-INS-SPC-010 Author: Manfred Wendt Effective Date: August 31, 2026 Review Frequency: N/A

Manufacturing drawings and CAD/CAE data shall be provided in BSA-acceptable native and/or exchange formats, including as applicable ACIS SAT/SAP, STEP, IGES, STL, or input files for widely used CAD/CAE tools such as CATIA, SolidWorks, Autodesk, Solid Edge, HFSS, CST Studio, AWR, or ADS.