1. FCC Cryo-magnet Logistics
Part 1

2. Production, assembly and testing of cryo-units

3. Review Overview Production Strategies for Supply Network and Assignment of Processes
Responsibility
Cern / Supplier
Production Coldmass
Production Cryostat
Assembly Cryo-Unit
Test Coldmass
Test Integration
Alternative 1: „Fully Built Up“ and „Tested at CERN“
CERN
Supplier
Alternative 2: “Fully Built Up“ and „Tested at Supplier plant“
Alternative 3: “Fully Built Up at Supplier plant“ and „Test at CERN“
Alternative 4: “Semi Knocked Down” (with Assembly and Test at CERN)
Alternative 5: “Semi Knocked Down with Partial Tests“ (with Assembly and Integration Test at CERN)

4. Review Overview Production Strategies for Supply Network and Assignment of Processes
Responsibility
Cern / Supplier
Production Coldmass
Production Cryostat
Assembly Cryo-Unit
Test Coldmass
Test Integration
Alternative 1: „Fully Built Up“ and „Tested at CERN“
CERN
Supplier
Alternative 2: “Fully Built Up“ and „Tested at Supplier plant“
Alternative 3: “Fully Built Up at Supplier plant“ and „Test at CERN“
Alternative 4: “Semi Knocked Down” (with Assembly and Test at CERN)
Alternative 5: “Semi Knocked Down with Partial Tests“ (with Assembly and Integration Test at CERN)

5. Review Overview Production Strategies for Supply Network and Assignment of Processes
Production at CERN
Process Safety - full control of all processes
high and equal process and product quality,
security against blackout, strike, etc.
Relatively short transport distances (depending on assembling/testing scenario)
Less logistics cost
Less damages on product due to less handling processes
High structural costs for
Infrastructure: production capacities need to be build up
Employees: labor cost, associated labor cost
Operational costs: Energy, Mainenance, ..
Less robustness regarding production shortfalls due to one production facility
Production at Supplier Side
Less structural costs for infrastructure, operational costs, employees
Distributed production increases robustness of supply chain – shortfalls can be better compensated
Existing production facilities can be used for maintenance and minor reparation
Increase of Logistic costs due to long transport distances
Risks for Damages increases due to additional handling effort and unfavorable means of transport have to be used, e.g. containter ships
Decrease in process safety due to reduction of control by CERN
Several fields of actions when outsourcing production like quality management measures, assessment supplier location, transport security and packaging, etc.

6. Review Overview Production Strategies for Supply Network and Assignment of Processes
Responsibility
Cern / Supplier
Production Coldmass
Production Cryostat
Assembly Cryo-Unit
Test Coldmass
Test Integration
Alternative 1: „Fully Built Up“ and „Tested at CERN“
CERN
Supplier
Alternative 2: “Fully Built Up“ and „Tested at Supplier plant“
Alternative 3: “Fully Built Up at Supplier plant“and„Test at CERN“
Alternative 4: “Semi Knocked Down” (with Assembly and Test at CERN)
Alternative 5: “Semi Knocked Down with Partial Tests“ (with Assembly and Integration Test at CERN)

7. Review Delivery Scenarios
Geneva PS
SPS
LHC
Alternative 1:
Central assembly and testing facilities - Surface transports
Central assembly and testing facilities - Underground transports
Alternative 2: Decentral assembly and testing facilities with several shafts
Alternative 3: Underground assembly and integration Test (Coldmass Testing at Supplier Side or overground at CERN)
Geneva PS
SPS
LHC
Geneva PS
SPS
LHC

8. Rough System Description Construction
FCC Length: 97,75 m
Magnet Ring consist of:
4664 Magnet Dipole (L/W/H 13,4m x 1,5 x 1,64m´)
800 Magnet Quadropole (shorter, lighter MD)
others like kicker, high frequency accelerator modules, warm magnets, collimators, etc.
Section 1 4 3 2
Sector
A-B
B-C
C-D
D-E
E-F
F-G
G-H
H-I
I-J
J-K
K-L
L-A
Length Sector (m)
5000
10000
Length Section (m)
25000

9. Rough System Description Installation, Schedule
Section 1 4 3 2
Sector
A-B
B-C
C-D
D-E
E-F
F-G
G-H
H-I
I-J
J-K
K-L
L-A
Magnet-Dipoles (MD)
233
466
Magnet-Quadropoles (MQ) 40 80 MD
1166
4664 MQ
200
800
2036
2037
2038
2039
Section
Sector Q4 Q1 Q2 Q3 1
A-B
B-C
C-D 4
D-E
E-F
F-G 3
G-H
H-I
I-J 2
J-K
K-L
L-A

10. Rough System Description Magnet Process Sequence according to LHC project from Delivery at CERN to Installation
Part Delivery (Cryo-Stat, Coldmass)
Material Storage
Transport
Assembly (SMA 18)
Transport
Storage (PA 18)
Transport
Cold Test (SM 18)
Transport
Integration Test (SMI 2)
Transport*
Storage*
Transport
Shaft / Installation Point
* probably not existent in LHC process flow

11. Rough System Description Facilities
Bottleneck Process
Current Infrastructure (LHC) and Process Steps:
SMA 18 (Process Assembly Cryo Stat, Coldmass incl. Geometry tests, Warm-test etc.)
6 Assembly Lines Magnet Dipole 2 Assembly Lines Magnet Quadropole
15 Magnets per Week (2-shift System, 5/7d, 50/52w)  750 per year
Are capacities usable also for FCC?
Doubling of amount of assembled magnets per week possible when increase production time - (24/24h, 7/7d, 50/52w) ~1575 magnets per year
PA 18 (Process Storage Assembled magnets)
Capacity unknown
Coordination output SMA 18 with input SM 18 minor storage capacities necessary
SM 18 (Process Cold-test)
12 test benches
13 Magnets per Week (24/24h, 7/7d, 46/52w)  600 per year
Are capacities usable also for FCC?
Increase of test rate only by acceleration of test procedure or increase of amount of test benches
SMI 2 (Process Integration Test)
Capacity, Duration unknown
Coordination with output SM 18 should avoid idle times and cause minor storage capacities

12. Rough System Description SM 18 (Process Cold-test) : Test Duration
Total duration cold Test per Magnet:
4,75 days (2,5 Magnets per Day)
Accoding to A. Siemko:
600 Magnets per year (46/52w)  6,44 days per Magnet
Assumtion for Duration of Cold Test for following investigation:
5 days per Magnet  120h

13. Investigation SM 18
Analysis material requirement per section / sector on basis of current construction schedule
Investigation of central and decentral positioning of SM 18
central scenario means positioning of SM 18 at CERN and using existing facilities (as fas as possible or new) for testing and storing
decentral scenario means close to each shaft one new test area and additional storage
Variation of amount of test facilities to reduce storage area
Balancing of construction schedule to reduce amount of test facilities and storage area
Assumption: Scenario investigations consider a magnet throughput time cold test of 5 days.

14. Investigation SM 18 Daily Magnet Demand
Required Amount of Magnets per Day varies between 3 to 6 magnets
Section 2
Section 1
Section 3
Section 4

15. Investigation SM 18 Daily Magnet Demand
Required Amount of Magnets per Day varies between 3 to 6 magnets

16. Investigation SM 18 Central
2800 Tested Magnets
Assuming:
Single Layer Storage
Storage Area per Magnet 15 x 2 m
Required Storage Area in Total* (tested magnets): m²
Attention: material storage + SMA 18 + PA 18 + SMI 2 not yet included
2300 Tested Magnets
Start of Magnet Testing:
Nov. 2032
Magnet Installation Phase

17. Investigation SM 18 Central

18. Investigation SM 18 Central
Analysis with balanced construction schedule:
Average Demand: ~3,7 Magnets
12 Test Benches
max. inventory of 2300 magnets
start of testing in Nov. 2032
22 Test Benches
no pre-testing and no magnets inventory
Further Analysis Results:
~ 22 test benches
allow finishing of tests of ~3,9 magnets per day
tests in advance installation can be avoided
additional buffer (1.300 tested magnets) is necessary to supply installation over construction in time
~ 36 test benches
allow finishing of tests of ~6,4 magnets per day
production and test in advance installation can be avoided
additional buffer (tested magnets) can be avoided

19. Investigation SM 18 Central
Analysis with balanced construction schedule:
Average Demand: ~3 Magnets / ~ 5 Magnets
12 Test Benches
max. inventory of 2800 magnets
start of testing in Nov. 2032
22 Test Benches
no pre-testing but still inventory of 1100 magnets
30 Test Benches
no pre-testing and no magnets inventory
Further Analysis Results:
~ 22 test benches
allow finishing of tests of ~3,9 magnets per day
tests in advance installation can be avoided
additional buffer (1.300 tested magnets) is necessary to supply installation over construction in time
~ 36 test benches
allow finishing of tests of ~6,4 magnets per day
production and test in advance installation can be avoided
additional buffer (tested magnets) can be avoided

20. Investigation SM 18 Decentral (4 test facilities per section)
Section 1,2: 940 Tested Magnets
Storage Area Section 3,4: m²
Storage Area Section 1,2: m²
Section 3,4: 680 Tested Magnets
Start of Magnet Testing (3,4):
Juni 2033
Start of Magnet Testing (1,2):
Aug. 2034

21. Investigation SM 18 Decentral
Analysis with balanced construction schedule:
Average Demand: ~3,7 Magnets
4 Test Benches (each section)
max. inventory of 840 magnets
start of testing in Aug. 2032
12 Test Benches
no pre-testing and no inventory magnets
Further Analysis Results:
~ 10 test benches (each section)
allow finishing of tests of ~1,76 magnets per day (each test area)
tests in advance installation can be avoided
additional buffer (290 / 420 tested magnets) is necessary to supply installation over construction in time
Section 3,4: 170 * (15*2) = m²
Section 2,1: 420 * (15*2) = m²
~ 18 test benches (each section)
allow finishing of tests of ~3,18 magnets per day (each test area)
additional buffer (tested magnets) can be avoided

22. Investigation SM 18 Decentral
Analysis with balanced construction schedule:
Average Demand: ~3 Magnets / ~ 5 Magnets
4 Test Benches (each section)
max. inventory of 770 / 960 magnets
start of testing in Febr / Aug. 2034
14 Test Benches
no pre-testing and no magnets inventory
Further Analysis Results:
~ 10 test benches (each section)
allow finishing of tests of ~1,76 magnets per day (each test area)
tests in advance installation can be avoided
additional buffer (290 / 420 tested magnets) is necessary to supply installation over construction in time
Section 3,4: 170 * (15*2) = m²
Section 2,1: 420 * (15*2) = m²
~ 18 test benches (each section)
allow finishing of tests of ~3,18 magnets per day (each test area)
additional buffer (tested magnets) can be avoided

23. Overview scenarios Schedule Schedule balanced I Schedule balanced II
Amount test benches
Storage capacity
Test start
central 12
2800
Nov 2032
2300 22
1300 -
1100 36 30
decentral 4
680/
940
Juni33/
Aug 34
840/
840
Aug32/
Aug34
770/
960
Febr32/ 10
170/420 14 18

24. Findings I/III Central Assembly at CERN
Existing facilites can be used* but further investment in modernization is necessary
Separated transport of cold mass and cryo stat reduces logistics effort regarding requirements for transport protection
Longer Transport distances of assembled cryo units to installation point compared to decentral
Decentral Assembly at CERN
Short transport distances of assembled cryo units
Separated transport of cold mass and cryo stat reduces logistics effort regarding requirements for transport protection
High costs due to new facilites
Increased number of employees though distributed assembly facilities
* Positive if existing infrastructure can be used for FCC otherwise additional costs for new facilities need to be considered.

25. Findings II/III Central Cold Test at CERN
Existing facilites can be used* but further investment in modernization or extension of benches is necessary
Equal test settings secure high and equal process quality
Longer Transport distances of assembled and tested cryo units to installation point compared to decentral
If supplier production: less robustness caused by late quality / performance checks
Decentral Cold Test at CERN
Short transport distances of assembled and tested cryo units
Higher robustness due to distributed test facilities (redundancy)
High costs in infrastructure due to new facilites
Decrease in process safety due to distributed test facilities
Increased number of employees through distributed assembly facilities
If supplier production: less robustness caused by late quality / performance checks
* Positive if existing infrastructure can be used for FCC otherwise additional costs for new facilities need to be considered.

26. Not discussed yet Assembly, Cold test and Integration test at Supplier Side
Responsibility
Cern / Supplier
Production Coldmass
Production Cryostat
Assembly Cryo-Unit
Test Coldmass
Test Integration
Alternative 1: „Fully Built Up“ and „Tested at CERN“
CERN
Supplier
Alternative 2: “Fully Built Up“ and „Tested at Supplier plant“
Alternative 3: “Fully Built Up at Supplier plant“ and „Test at CERN“
Alternative 4: “Semi Knocked Down” (with Assembly and Test at CERN)
Alternative 5: “Semi Knocked Down with Partial Tests“ (with Assembly and Integration Test at CERN)

27. Discussion Feasibility of Logistics Scenarios Delivery Scenarios
Geneva PS
SPS
LHC
Alternative 1:
Central assembly and testing facilities - Surface transports to shafts (C,E,I,K)
Central assembly and testing facilities - Underground transports (1 shaft CERN / 2 shafts (C,K))
Alternative 2:
Decentral assembly and testing facilities close to shafts (C,E,I,K)
NEW! Decentral assembly and testing facilities close to shafts (C,K)
Alternative 3: Underground assembly and integration Test (Coldmass Testing at Supplier Side or overground at CERN)
Geneva PS
SPS
LHC
Geneva PS
SPS
LHC

28. Discussion Feasibility Delivery Scenarios
costs (Structure e.g. infrastructure, employees, operating costs and logistics e.g. inventory, process costs)
and expected process quality (e.g. Damages, Process Security, Robustness)
Discussion Feasibility Delivery Scenarios
Cost
Quality
Infrast.
Operations
transport
storage
Damages
safety
Robustness
o/+ +
- - - ++
-/imposs.? o
Alternative 1:
Central assembly and testing facilities - Surface transports to shafts (C,E,I,K)
Central assembly and testing facilities - Underground transports (1 shaft CERN / 2 shafts (C,K))
Alternative 2:
Decentral assembly and testing facilities close to shafts (C,E,I,K)
NEW! Decentral assembly and testing facilities close to shafts (C,K)
Alternative 3: Underground assembly and integration Test (Coldmass Testing at Supplier Side or overground at CERN)

29. Outlook further investigation
Identified Supply Chain Alternatives and Delivery Scenario are analyzed regarading necessity and interdependencies of
Production capacities
Storage and Transport capacities
Assembly and Testing Facilities
Current construction schedules is basis for investigation
Experimental model is developed allowing analysis of different scenarios/alternatives presented (except excluded ones) concerning necessary capacities over time through parameterization of
process allocation
process duration
construction schedule variants
PRODUCTION CAPACITIES
Costs
Robustness
Process Safety
LOGISTICS CAPACITIES
ASSEMBLING AND TESTING FACILITIES

30. Further Investigation Needs verification and additional information regarding Process Sequence
Part Delivery (Cryo-Stat, Coldmass)
Material Storage
Transport
Assembly (SMA 18)
Transport
Storage (PA 18)
Transport
Cold Test (SM 18)
HD-Transport
Integration Test (SMI 2)
Transport
Storage
HD- Transport
Shaft / Installation Point
Assumtions regarding
SMA18, SM 18, SMI 2: Process times, Capacities, Production intervall
Storage Capacities, Locations
Process Sequence verification