Attachment C - Technical Specification EIC-DET-SPC-021 dated 12-4-24.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-DET-SPC-021 Author: Oleg Eyser Effective Date: December 4, 2024 Review Frequency: N/A

Specification Title: Forward Hadronic Calorimeter Absorber Structure Revision: 00

TECHNICAL SPECIFICATION

for the

Forward Hadronic Calorimeter Absorber Structure Quality Classification: A-3

Prepared By:

_________________________________ Date: __________________ Oleg Eyser, Physicist

Reviewed By:

Maggie Haviland, Procurement Liaison Engineer

Dan Cacace, Mechanical Engineer

Joseph Zipper, Quality Representative

Chuck Schaefer, ESH Manager

Approved By:

Elke Aschenauer, Level 2 Manager – EIC Detector Systems

Docusign Envelope ID: 81A995C4-7C9C-41C2-9FE2-ACAC9E56E9B8

12/5/2024

12/5/2024

12/6/2024

12/5/2024

12/5/2024

12/6/2024

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REVISION HISTORY

Revision # Effective Date Summary of Change

00 12/4/2024 Initial Release

TABLE OF CONTENTS

1 Scope

1.1 Background

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

3.2 Materials

3.3 Code/Standard Compliance

3.4 Environment, Safety and Health

3.5 Packaging/Shipping

3.6 Storage

4 VERIFICATION

4.1 Classification of Inspections

4.1.1. Pre-Production Tests (First Article)

4.1.2. Acceptance Tests

LIST OF ACRONYMS

AISI American Iron and Steel Institute ASTM American Society for Testing and Materials ATP Acceptance Test Procedure BNL Brookhaven National Laboratory BSA Brookhaven Science Associates EIC Electron-Ion Collider Fe/Sc Iron-Scintillator G Gauss IP-6 Experimental Hall of the EIC Detector ksi Kilopound per square inch LFHCal Longitudinally segmented Forward Hadronic Calorimeter ORNL Oak Ridge National Laboratory PCB Printed Circuit Board

Technical Specification for the Forward Hadronic Calorimeter Absorber Structure

1 SCOPE

This specification defines the technical requirements for the Absorber Structure for the longitudinally segmented Forward Hadronic Calorimeter (LFHCal) of 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, an electron injector, and modifications to the hadron ring required to produce an electron-ion collider and its infrastructure. It will include one interaction region, with an allowance for a second, and one detector. The facility is designed to meet requirements to ensure high reliability and availability for the user program.

The detector in IP-6 (Experimental Hall of the EIC Detector) will provide an almost 4π coverage in tracking, particle identification, electromagnetic and hadronic calorimetry. The hadronic calorimeter in the forward (hadron-going) endcap is of particular importance, to measure highly energetic particle jets with a sufficient energy resolution, isolate the jet neutral components (neutrons and KL particles), complement the tracking and electromagnetic calorimetry in particle flow algorithms, and be an integral part of the detector solenoid flux return structure.

The LFHCal is an Iron Scintillator (Fe/Sc) sampling sandwich calorimeter, where 16 mm thick steel plates are alternated with 4 mm thick scintillator plates (for a total of 60 layers each) with a depth of around 1.32 meters. All absorber layers will be made of a magnetic carbon steel because they are part of the EIC detector solenoid magnetic flux return. The full LFHCal is comprised of 1138 modules; 1066 are of the 8M layout and 72 are of the 4M layout. The 8M modules have a transverse size of about 200 mm (width) by 100 mm (height) and the 4M modules are one half of an 8M module in transverse size (100 mm x 100 mm). In addition, there are two insert modules (insert left and insert right), which have a combined transverse size of 600 mm x 600 mm with a conical opening to allow for the beampipe to pass through. The steel pieces are electron-beam welded to one module and the full weldment is nickel plated to prevent corrosion.

Each of the LFHCal modules consists of 55 regular absorber plates, 5 tapped absorber plates, and a case (top, bottom, front, back plates) made from magnetic carbon steel (AISI 1020). In addition, each module will include two Printed Circuit Board (PCB) side covers and tower brackets made of AISI 304 stainless steel and 34 screws of various sizes. The total number of pieces for the two different types of modules are listed in the tables below. Dimensions and tolerances are specified in the engineering drawings EPC-FWD-HCL-DET-ASM-100 and EPC-FWD-HCL-DET-ASM- 200.

The absorber plates are electron-beam welded to the bottom, front, and back plates of an LFHCal module. The assembly module is then nickel-plated to prevent corrosion. The nickel-plated top plate is mounted to the assembly with screws prior to packaging and shipping.

Part ID Description Material Units per module

Total units

EPC-FWD-HCL-DET-ASM-100 LFHCal 8M module 1,066 EPC-FWD-HCL-DET-PRT-101 Front plate AISI 1020 Carbon steel 1 1,066 EPC-FWD-HCL-DET-PRT-102 Back plate AISI 1020 Carbon steel 1 1,066 EPC-FWD-HCL-DET-PRT-103 Top plate AISI 1020 Carbon steel 1 1,066 EPC-FWD-HCL-DET-PRT-104 Bottom plate AISI 1020 Carbon steel 1 1,066 EPC-FWD-HCL-DET-PRT-105 PCB side cover AISI 304 Stainless steel 2 2,132 EPC-FWD-HCL-DET-PRT-106 Absorber plate AISI 1020 Carbon steel 55 58,630 EPC-FWD-HCL-DET-PRT-107 Absorber plate, tapped AISI 1020 Carbon steel 5 5,330 EPC-FWD-HCL-DET-PRT-108 Tower bracket AISI 304 Stainless steel 1 1,066

Part ID Description Material Units per module

Total units

EPC-FWD-HCL-DET-ASM-200 LFHCal 4M module 72 EPC-FWD-HCL-DET-PRT-201 Front plate AISI 1020 Carbon steel 1 72 EPC-FWD-HCL-DET-PRT-202 Back plate AISI 1020 Carbon steel 1 72 EPC-FWD-HCL-DET-PRT-203 Top plate AISI 1020 Carbon steel 1 72 EPC-FWD-HCL-DET-PRT-204 Bottom plate AISI 1020 Carbon steel 1 72 EPC-FWD-HCL-DET-PRT-205 PCB side cover AISI 304 Stainless steel 2 144 EPC-FWD-HCL-DET-PRT-206 Absorber plate AISI 1020 Carbon steel 55 3,960 EPC-FWD-HCL-DET-PRT-207 Absorber plate, tapped AISI 1020 Carbon steel 5 360 EPC-FWD-HCL-DET-PRT-208 Tower bracket AISI 304 Stainless steel 1 72

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 will 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 to all requirements.

Document Number Document Title

EPC-FWD-HCL-DET-ASM-100 A full set of engineering drawings for 8M modules

EPC-FWD-HCL-DET-ASM-200 A full set of engineering drawings for 4M modules

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

Refer to the drawing(s) listed in section 2 for component orientations, dimensions, tolerances, and other required technical/performance characteristics.

3.2 Materials

As specified in the drawing package and the tables above, all raw components except the PCB side covers and tower brackets will be AISI 1020 carbon steel, while the PCB covers and tower brackets will be made from AISI 304 stainless steel. All parts shall have broken edges and be thoroughly cleaned and free of grease and oils.

Material composition and magnetic permeability for each heat of steel production shall be certified. The material composition is listed in the table below. The yield strength of AISI 1020 steel alloy will be a minimum of 32 ksi, with a minimum ultimate tensile strength of 64 ksi. The magnetic permeability shall be measured in compliance with ASTM A773 in a range of ±21,000 G. All dimensions of the components shall be inspected with respect to the specifications and tolerances, including the nickel-plating. The carbon steel components shall be assembled using electron-beam-welding. The fully electron-welded structure and the top plate shall be coated using electroless nickel-plating for corrosion reduction (0.001" minimum thickness / 0.002" maximum thickness).

Material composition for AISI 1020 Carbon Steel Element Content (%) Carbon (C) 0.2 ± 0.03 Iron (Fe) 99.3 ± 0.23 Manganese (Mn) 0.45 ± 0.15 Phosphorus (P) <0.04 Sulfur (S) <0.05

3.3 Code/Standard Compliance

ASTM A6: “General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling” ASTM A370: “Standard Test Methods and Definitions for Mechanical Testing of Steel Products” ASTM A751: “Standard Test Methods and Practices for Chemical Analysis of Steel Products” ASTM A773: “Standard Test Method for Direct Current Magnetic Properties of Low Coercivity Magnetic Materials Using Hysteresigraphs” ASTM B733: “Standard Specification for Autocatalytic (Electroless) Nickel-Phosphorus Coatings on Metal” ASTM A830: “Standard Specification for Plates, Carbon Steel, Structural Quality, Furnished to Chemical Composition Requirements”

All Standards to be followed as listed or equivalent to be approved by BSA.

3.4 Environment, Safety and Health

Identification of hazards, and their mitigation, during all stages of the life of the Equipment including: installation, commissioning, operation, maintenance, and repair. Identification of means to eliminate or manage each hazard shall be provided based on the following hierarchy:

• Substitute with something less hazardous, or

• Engineer – mitigate the severity of the hazard, or

• User Personal Protective Equipment (least desirable).

3.5 Packaging/Shipping

LFHCal modules shall be crated and packaged on pallets, suitable for forklift handling. The corresponding crate structure will be agreed upon prior to shipping to allow easy access to the various sites of the module, without removing the crate. The number of LFHCal modules per pallet is to be defined in a communication with the Contractor. During shipment, LFHCal modules shall be protected from extreme humidity or water.

3.6 Storage

Storage at the manufacturing facility after the production shall be done in a dry area, to avoid any adverse effects mentioned in section 3.5.

4 VERIFICATION

Appropriate inspection/tests shall be performed to ensure Absorber Structures conform 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 Tests (First Article)

Compliance with the specification shall be verified using the Acceptance Test Procedure (ATP) generated by the Contractor and approved by BSA in writing. Testing and inspection of pre-production units shall be conducted at Oak Ridge National Laboratory (ORNL) or a third-party testing facility. The Contractor shall not commence fabrication of the production units until receiving notification of pre-production unit acceptance and authorization in writing from BSA. Five LFHCal modules of each 8M and 4M sizes are required for pre-production tests at ORNL.

4.1.2. Acceptance Tests

4.1.2.1. Acceptance Tests Performed at Contractor - The Contractor shall submit ATPs for BSA written approval that are in accordance with this specification and all reference documents noted herein. Material composition of the AISI 1020 steel components shall be documented for each production run and magnetic permeability shall be measured for conformance to the technical specifications for four samples of each heat of steel. The number of steel pours should be limited and preferable the same pour should be used for all modules. The LFHCal modules shall be tested at the Contractor’s facility, Contractor’s subcontractor facility, or pre-approved BSA collaborator to demonstrate compliance with this specification. This includes tests of parts of the assembly prior to the electron-welding of absorber plates and after the nickel-plating. All data shall be documented and delivered to BNL for review prior to acceptance. In addition, the following tests shall be conducted on Absorber Structures by the Contractor in accordance with the ATP, prior to delivery to

BNL:

• Dimensional Measurement – Dimensions of the individual components, prior to assembly shall be measured for conformance to the technical requirements.

Moreover, the final assembly after electron-welding and nickel-plating shall be classified and tested for conformance to the technical requirements. The list of required dimensions that shall be measured will be indicated in the BSA-approved

ATP.

4.1.2.2. Acceptance Tests Performed at BNL – To be performed at ORNL, BNL, or a potential third-party testing facility. All received LFHCal modules will be tested regarding their dimensions. The acceptance of the shipment will depend upon these results and their compliance with the specifications listed in 3.1.