Fall 2014 Co-op Rotation Summary

Co-op Rotation Summary

GE HealthcareFlorence, SC

Fall 2014Rotation 2

Mentors: Edwin Legall & Ben GronemeyerAsh Abel

2 GE Title or job number

04/15/2023

About Me

• Junior Mechanical Engineering Major at Clemson University

• Member of the Calhoun Honors College at Clemson

• #1 Clemson Club Tennis Player

• Clemson ASME LeMons Team Member

3 GE Title or job number

04/15/2023

Goals & Objectives Overview

1. Test Performance of AH2-1 Gradient Coil• Thermal• Acoustic• Vibration

2. Post-Process Testing Data and Analyze Results

3. Identify Leak Testing Equipment/Procedure for LCM

4. Research Opportunities for LCM VV Leak Testing

Chamber

4 GE Title or job number

04/15/2023

Test Performance of AH2 Gradient Coil Thermal

• Evaluate the accuracy of the ANSYS software simulation of the AH2 coil

• Collect thermal data for varying boundary conditions in ANSYS

• Characterize the cooling loops of the hollow gradient coils

What I Learned:• How to perform thermal

measurements• How to evaluate gradient

coil thermal performance• How to capture flow rate

data• The geometry of the AH2

coil

5 GE Title or job number

04/15/2023

Test Performance of AH2 Gradient Coil

• Used thermal camera, thermal couples, and thermistors to measure the average and peak temperatures of the AH2-1 coil while running various protocols

• Captured thermal images of coil to determine hot spot magnitudes and locations

Thermal cont.

• Assisted in building flow rate/pressure testing rig

• Gathered flow rates with data logger

• Gathered temperatures and pressures at the inlets and outlets of the system for force balance and cooling efficiency calculations

6 GE Title or job number

04/15/2023

Test Performance of AH2 Gradient Coil

• Characterize AH2-1 Gradient Coil’s acoustic signature

• Compare AH2-1’s performance to previous coil designs

• Compare different vibration-dampening materials’ affect on acoustic data

Acoustic

What I Learned:• How to set up and run acoustic

tests• The variables present in acoustic

testing• How to document test procedures

7 GE Title or job number

04/15/2023

Test Performance of Gradient Coil Characterize AH2-1 Gradient Coil’s physical

reactions to standard protocols as it is Florence’s first hollow-conductor coil

o Magnet-Gradient Relative Displacement

o Inner and Outer Gradient Rel. Displ. o Floor transmission loadings

• Measure the difference in vibration caused by using a coaxial cable on XRMw as this cable it may replace the current one and be used on Rio

o Coaxial Cable and Connector Rel. Displ.

Vibration

Vibromat 1 Vibromat 2 Orange Pads Green PadTRICKS 0.58 0.17 0.14 0.20 0.08

FSPGR CINE 0.47 0.13 0.20 0.07 0.07FMRI 0.16 0.1 0.09 0.02 0.02

FIESTA CINESFOV 0.41 0.14 0.14 0.09 0.08DTI 3.76 0.22 0.18 0.03 0.02

AXIAL LAVA 0.55 0.25 0.15 0.10 0.10AXIAL 2D FSPGR 0.44 0.16 0.12 0.20 0.20

AXDWI 3.71 0.14 0.12 0.01 0.012D GRE EPI 1.21 0.21 0.13 0.06 0.05

2D FIESTA AXIAL 0.18 0.11 0.15 0.10 0.20

XRMw AH2Specification [m/s^2]

Left Floor

What I Learned:• How to gather acceleration data• How to run ETA system software

for vibration and acoustic protocols

8 GE Title or job number

04/15/2023

Post-Process Testing Data and Analyze Results

• Double integrated vibration data using LMS software to find magnet-gradient relative displacement

• Analyzed locations of peak g-loadings to find critical frequencies of each coil

What I Learned:• How to find relative displacement• How to use LMS software to post-

process data• Why learning how software

processes data so that the results can be analyzed properly

XFFT [mic] Freq [Hz]

1,4,7 Hz g 0.38 7.151 575.36 0.012 996.95 0.043 1286.28 0.024 1691.35 0.035 2385.74 0.066 2997.47 0.05

2,5,8 Hz g 0.4 7.221 996.95 0.022 1501.21 0.023 2501.47 0.054 3088.4 0.05

3,6,9 Hz g 0.36 7.461 583.62 0.012 996.95 0.073 2203.87 0.054 2732.94 0.115 3147.27 0.07

Sine Sweep 180

Sine Sweep 180 X+X 1,4,7

6400.000.00 Hz

0.06

0.00

Am

plitu

de

g

1.00

0.00

Am

plitu

de

2997.472385.741691.351286.28

996.95

575.36

0.01

0.02

0.03

0.04

0.05

0.06

F Spectrum Pos 1,4,7 X:+X

9 GE Title or job number

04/15/2023

Identify Leak Testing Equipment/Procedure

for LCM LCM Leak Test Flow Charttime

75 min45 min25 min30 min75 min75 min

Full Helium Loop Chamber Test

Leak Detected?Leak Test Joint F1450-F15480

Leak Test Joint F1490-F1520

Leak Test Joint F1530-F1560

Leak Test Joint F1570-F1590, B410

Leak Test Joint F1260-F1280

Leak Detected? Leak Detected? Leak Detected? Leak Detected? Leak Detected?

Repair Leaking Joint(s)

Repair Leaking Joint(s)

Repair Leaking Joint(s)

Repair Leaking Joint(s)

Repair Leaking Joint(s)

Leak Test Repaired Joint(s)

Full Helium Loop Chamber Test

Leak Test Repaired Joint(s)

Full Helium Loop Chamber Test

Full Helium Loop Chamber Test

Leak Detected? Leak Detected? Leak Detected? Leak Detected? Leak Detected?

Helium and Nitrogen Loop Chamber Test

Leak Detected?Leak Test Joint B360,

B440, M3450Leak Test Joint M3390, M3460

Leak Detected? Leak Detected?

Repair Leaking Joint(s)

Repair Leaking Joint(s)

Leak Test Repaired Joint(s)

Full Helium Loop Chamber Test

Leak Detected? Leak Detected?

Vacuum Vessel Chamber Leak

Test

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yes

yes yes

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yes

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yes

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yesno

yes

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yes

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no

Spec Inficon UL 200 VS MD30 PHOENIXL 300Lowest Detectable He Leak Rate (Vacuum) [mbar*ltrs/s] < 5 x 10^ -11 < 5 x 10^ -12 < 5 x 10^ -12Lowest Detectable He Leak Rate (Sniffer) [mbar*ltrs/s] < 1 x 10^ -7 < 1 x 10^ -7Max Detectable He Leak Rate (Vacuum) [mbar*ltrs/s] 0.1 0.1

Max Permissible Inlet Pressure [mbar] 3 13 15Pumping speed for He at Test Connection [ltrs/s] 1 1.8 2.5

Display Range for Leak Rates [mbar*ltrs/s] 11 decades 1 x 10^ -11 to 1 x 10^ -4 12 decadesTime until ready for Operation [min] < 3 min < 2 min

Power input [V] 380V 120V 420VWeight [lbs] 74 250 (incl. 620 pump) 88

Price [$] 12000 32000 (incl. 620 pump) 22000

Spec PTS 300 TPS Mobile PTS 600 Oerlikon Leybold RUTAUltimate Pressure [Torr] 1 x 10^ -2 1 x 10^ -2 7 x 10^ -3 6 x 10^ -4

Peak Pumping Speed @ 50Hz [lpm] 210 13200 (He) & 15000 (N2) 420 3418Peak Pumping Speed @ 60Hz [lpm] 250 NA 500 NA

Model Number PTS03001UNIV 9698429 PTS06001UNIV WAU 251/D65B/GWhere Currently Used CH and He chamber LCM He chamber LCM

Price [$] 6,300 26,000 (incl. pump monitor) 9,800 20,200

Agilent Varian Triscroll PTS 300/600 Oil-Free Dry Scroll 1-Phase Vacuum Pump (220V)

Leak Detector Comparison Chart

10 GE Title or job number

04/15/2023

Research Options for LCM VV Leak Testing Chamber

GNB Valves

What I Learned:• The physics behind vacuum

pumps/chambers• Professional communication

skills • How to write an ERS

• Researched and Recorded desired vacuum chamber specs

• Coordinated with 5 vacuum leak chamber manufacturers

• Setup meetings and presentations to update engineers of progress made

• Helped write ERS to send to manufacturers

11 GE Title or job number

04/15/2023

The 4 Big Ideas I Learned from GEHC

1. Clear communication is vital for efficiency

2. Documentation allows for repeatability

3. Manufacturability should refine design

4. Efficiency and Time Management are crucialTask # FW Priority

Assigned by

Assigned Due Completed Description of Task Comments on Progress Time

1 35 10 GEHC 8/25/2014 9/5/2014 8/29/2014 Complete GE G's and O's List and Submit complete2 35 10 Clemson 8/25/2014 9/1/2014 8/29/2014 Complete Clemson G's and O's List and Submit complete3 35 10 Edwin 8/26/2014 8/26/2014 8/26/2014 Create Hosed T-brackets for Flow Rate Rig (x12) complete4 35 10 Edwin 8/26/2014 8/26/2014 8/26/2014 Install Hosed T-brackets for Flow Rate Rig (x12) complete5 35 10 Edwin 8/25/2014 8/26/2014 8/26/2014 Create 48 bridges for circuit in Electronic Flow Rate Rig complete6 36 10 GEHC 8/25/2014 9/2/2014 9/2/2014 Gain access to Kronos and GE Learning complete7 35 10 Edwin 8/26/2014 8/29/2014 8/29/2014 Test Flow rate and pressure drops for gradient complete8 35 10 Edwin 8/28/2014 8/28/2014 8/28/2014 Setup Thermal Test Rig hoses etc. complete 6hrs9 35 10 Edwin 8/28/2014 8/28/2014 8/28/2014 Find initial pressure drop and leak check thermal test rig complete10 36 10 Ben 8/28/2014 9/4/2014 9/4/2014 Compile data on types of leak testers and equip. complete 2 hrs11 36 10 Ben 8/28/2014 9/4/2014 9/3/2014 Schedule Meeting with Ben and Dogan complete12 36 10 Edwin 8/29/2014 9/5/2014 9/5/2014 Thermal test AH2 gradient complete 30hrs13 36 10 GEHC 8/25/2014 9/5/2014 9/3/2014 Update Emergency Info and Adress complete14 36 10 GEHC 8/25/2014 9/5/2014 9/4/2014 Update Internal Resume complete15 39 10 GEHC 8/25/2014 9/26/2014 9/25/2014 Complete GE Learning complete16 38 10 Edwin 9/4/2014 9/19/2014 9/17/2014 Write "cheat sheet" on how to change protocalls in ETA B CPU complete 1.5 hrs17 36 10 Chuck 9/5/2014 9/5/2014 9/5/2014 Make list of inlet and outlets on AH2 complete18 37 10 Edwin 9/8/2014 9/8/2014 9/8/2014 Take down testing equipment from AH2 complete 5 hrs19 38 10 Ben 9/5/2014 9/15/2014 9/15/2014 Collect leak test parameters for magnet series complete 3 hrs20 37 10 Edwin 9/8/2014 9/8/2014 9/8/2014 Extract data from loggers and thermal camera complete 2hrs21 37 10 Edwin 9/10/2014 9/12/2014 9/11/2014 Put raw data from loggers into chopped excel sheet complete 5 hrs22 37 10 Edwin 9/11/2014 9/12/2014 9/11/2014 Find logger data from pressure testing and send complete23 37 10 Edwin 9/8/2014 9/11/2014 9/10/2014 make master steady state file and send complete 11 hrs24 38 10 Edwin 9/9/2014 9/19/2014 9/17/2014 make thermal images with data from files complete 14 hrs25 39 10 Ben 9/15/2014 9/26/2014 9/24/2013 Collect more leak test info and tools with PN's complete 3.5 hrs26 38 10 Edwin 9/15/2014 9/19/2014 9/17/2014 Connect thermal times and data logger times to ID protocals complete 3 hrs27 38 10 Edwin 9/16/2014 9/16/2014 9/16/2014 Make Powerpoint of Full Y Hi and Lo Thermal Images complete 2 hrs28 40 10 Ben 9/17/2014 10/7/2014 10/7/2014 Redline He Vessel Leak Test Chamber Instr. complete 5.5 hrs29 38 10 Edwin 9/16/2014 9/19/2014 9/19/2014 Assist and Check WI for acoustic testing complete 6 hrs30 38 10 Edwin 9/17/2014 9/18/2014 9/17/2014 Write "EI" on how to operate acoustic test PC setup complete 3 hrs31 38 10 Edwin 9/17/2014 9/18/2014 9/18/2014 Support and Learn Vibration Testing and data manipulation complete 7 hrs32 39 10 Edwin 9/19/2014 9/26/2014 9/22/2014 Convert acoustic data from cpu into graphs and maxs in Excel complete 2.5 hrs33 40 10 Ben 9/17/2014 10/7/2014 10/7/2014 Redline CH Leak Test Joint Instr. complete 3hrs34 39 10 Edwin 9/19/2014 9/26/2014 9/25/2014 Convert vibration data from cpu into Excel file complete 9 hrs35 39 10 John 9/26/2014 9/26/2014 9/26/2014 Revise and Replace Nitrogen line pics in Weld Map Room complete 1.5 hrs36 40 10 Edwin 9/29/2014 9/23/2014 9/30/2014 Record data during acoustic testing complete 5 hrs37 40 10 Edwin 9/29/2014 9/30/2014 9/30/2014 Observe Force Balance, Relative Displ. Testing, and Back EMF complete 4 hrs38 40 10 GEHC 9/30/2014 10/1/2014 10/1/2014 Re-do GE Learning Module labelled as overdue complete39 41 10 Edwin 10/1/2014 10/3/2014 10/6/2014 Reduce new acoustic data and compare to FW 38 data complete 1.5 hrs40 41 10 Edwin 10/1/2014 10/10/2014 10/6/2014 Transfer Sine Sweep Vibration data using FFT and find maxs complete 10.5 hrs41 40 10 Ben 9/24/2014 10/3/2014 10/3/2014 Get overall leak test plan from Lance complete 1hrs42 40 10 Edwin 10/3/2014 10/3/2014 10/3/2014 Complete Thermal images using SEQ file and summarize complete 2 hrs43 41 10 Ben 9/24/2014 10/7/2014 10/6/2014 Find specs and info on vacuum pumps complete 1.5 hrs44 41 10 Ben 9/24/2014 10/7/2014 10/6/2014 find leak tester manuals and specs and compare complete 2 hrs45 41 10 Edwin 10/6/2014 10/7/2014 10/7/2014 Install Workstation and setup all needed programs complete 2 hrs46 41 10 Edwin 10/7/2014 10/8/2014 10/7/2014 Alter geometry and refresh ANSYS model in workstation complete 2 hrs47 41 10 Edwin 10/8/2014 10/9/2014 10/8/2014 Apply thermistors to all 8 locations on gradient layers complete 6 hrs48 41 10 Ben 10/9/2014 10/9/2014 10/9/2014 Attend Cryostat Meetings and make plans for work complete 1.5 hrs49 41 10 Edwin 10/9/2014 10/9/2014 10/9/2014 Refresh and Run updated model since RF boundaries change complete 2 hrs50 42 10 Edwin 10/10/2014 10/17/2014 10/17/2014 Update Data and Run Z_lo, Z_hi, Z80_2, and XYZ in ANSYS complete 21 hrs51 42 10 Ben 10/10/2014 10/17/2014 10/14/2014 Find missing Leybold Leak Tester and unbox complete 3 hrs52 42 10 Ben 10/10/2014 10/17/2014 10/17/2014 Work on filling in gaps and updating flow chart complete 2.5 hrs53 42 10 Edwin 10/10/2014 10/17/2014 10/14/2014 Remesh AH2 Ansys model and debug model complete 7 hrs54 43 10 Other 10/6/2014 10/24/2014 10/20/2014 Ask Edwin/Ben to write a letter or recommendation for intern abroad complete55 42 10 GEHC 10/14/2014 10/31/2014 10/15/2014 Complete New GE Learning Module complete 2 hrs56 42 10 GEHC 9/8/2014 11/28/2014 10/16/2014 Complete GE Safety Learning complete .5 hrs57 44 10 Edwin 10/10/2014 10/31/2014 10/28/2014 Fill in results tables from ANSYS data complete 2 hrs58 43 10 Edwin 10/17/2014 10/24/2014 10/22/2014 Fix ANSYS protocals on all 8 protocals complete 19 hrs59 45 10 Ben 10/21/2014 10/31/2014 10/31/2014 Make initial sketches of CB safety shroud and get safety regul. complete 4.5 hrs60 43 10 Ben 10/21/2014 10/24/2014 10/24/2014 Prepare for Friday Leak testing meeting and attend complete 2 hrs61 9 Ben 10/23/2014 Attend Cryo and Leak Test meetings 10 complete. Next is FW 50.2 11.5 hrs62 44 10 Lance 10/27/2014 10/31/2014 10/30/2014 Make VCR fitting ordering list and add to xcel sheet complete 3.5 hrs63 44 10 Lance 10/27/2014 10/31/2014 10/30/2014 Research Vacuum Chamber vendors and find current one complete 2 hrs64 44 10 Edwin 10/28/2014 11/5/2014 10/30/2014 Manipulate summary data and populate all z-related charts complete 7.5 hrs65 44 10 Lance 10/29/2014 10/31/2014 10/30/2014 Sketch LCM helium vacuum chamber with dimensions complete 1.5 hrs66 47 10 Lance 10/31/2014 12/12/2014 11/25/2014 Write EI for LCM Leak Testing Localization and Rework complete 6 hrs67 45 10 Lance 10/28/2014 11/7/2014 11/6/2014 Gather info on vacuum chamber aux/valves needed for LCM complete 1 hr68 45 10 GEHC 11/3/2014 11/4/2014 11/3/2014 New GE Learning Module assigned complete .5 hrs69 45 10 Edwin 11/3/2014 11/4/2014 11/3/2014 Plot Simulated, Test Data, and Predicted AH2 Temps. complete 1.5 hrs70 45 10 Edwin 11/4/2014 11/4/2014 11/4/2014 Check X and Y protocol formulas and references complete 1.5 hrs71 46 10 Lance 11/4/2014 11/14/2014 11/13/2014 Get quote from Lad (Swage) for VCR fittings list complete 2 hr72 45 10 Lance 11/4/2014 11/7/2014 11/5/2014 Get in contact with Pfeiffer for helium chamber estimate complete 2.5 hrs73 45 10 Edwin 11/4/2014 11/7/2014 11/5/2014 Check formulas and measured values against 45W est. complete 1 hrs74 46 10 Ben 11/6/2014 11/14/2013 11/13/2014 Find info about Vacuum Chambers and get quote/timelines complete 6 hrs75 45 10 Edwin 11/7/2014 11/7/2014 11/7/2014 Take Screenshots of X80 protocal and start running D1 complete 1.5 hrs76 45 10 GEHC 11/7/2014 2/5/2015 11/7/2014 Complete new learning module complete .5 hrs77 47 10 Ben 11/10/2014 11/20/2014 11/20/2014 Get price and timing estimate from Muzzillo and Scatturo complete 5 hrs78 46 10 Edwin 11/7/2014 11/14/2014 11/12/2014 Make ppt for Z coil that resembles x&y presentation complete 5.5 hrs79 47 10 Ashraf 11/12/2014 11/18/2014 11/18/2014 Data Acquisition for XRMw (Setup, Assist, Teardown) complete 5.5 hrs80 47 10 Edwin 11/13/2014 11/21/2014 11/20/2014 Consolodate Vibration/Displ. Data and check formulas complete 9.5 hrs81 47 10 Ben 11/11/2014 11/18/2014 11/17/2014 Measure ID's of omega tubes on TD4 and pop. Excel sheet complete 1.5 hrs82 47 10 Clemson 11/17/2014 11/24/2014 11/23/2014 Complete End of Assignment Report complete 1.5 hrs83 1 Mark 11/14/2014 12/11/2014 Complete End of Rotation Presentation started. List of items. ERS. EI's. look through file 7.5 hr84 47 10 Edwin 11/14/2014 11/18/2014 11/16/2014 Redraw Thermal Couple Locations complete 2 hrs85 47 10 Lance 11/18/2014 11/18/2014 11/18/2014 Measure ID's of omega tubes on TD3" and pop. Excel sheet complete 1.5 hrs86 47 10 Ashraf 11/18/2014 11/19/2014 11/19/2014 Document Vibration XRMw testing setup/procedure (up until analysis) complete 3.5 hrs87 47 10 Ben 11/20/2014 11/20/2014 11/21/2014 Get ASTM Standards for Al3003 and SS316L complete 2.5 hr88 48 10 Edwin 11/21/2014 12/3/2014 11/26/2014 Scale displacement data to 900A using freq and vibration results complete 14 hrs89 48 10 Ben 11/17/2014 11/26/2014 11/25/2014 Meet with GNB Valves rep and discuss chamber deliverables complete 3 hrs90 50 10 Edwin 12/1/2014 12/8/2014 12/8/2014 Get DRF for Relative Displ. from Richard to compare data (1Hz & 7Hz) complete 6.5 hrs91 49 10 Edwin 12/1/2014 12/3/2014 12/2/2014 Process Sine Sweep displ. Data from ETA cpu and plot in excel complete 5 hrs92 49 10 Lance 12/1/2014 12/5/2014 12/5/2014 Write ERS from Lance for vacuum chamber (draft Wed, final Fri) complete 9 hrs93 49 10 Lance 12/1/2014 12/3/2014 12/2/2014 Get dimensions of wide-bore for vacuum chamber size complete .5 hrs94 8 GEHC 12/1/2014 12/16/2014 Complete End of Rotation Paperwork and Action Items complete #2-4 2 hr95 49 10 Edwin 12/3/2014 12/5/2014 12/4/2014 Add w/ and w/out green pad to vibration/acoustic ppt complete 2.5 hrs96 49 10 Edwin 12/3/2014 12/5/2014 12/4/2014 Add a 1m away slide of acoustic data to ppt complete 2.5 hr97 7 Lance Prepare for Tuesday Vacuum Chamber Meeting meet FW50.2 at 8am .5 hrs

12 GE Title or job number

04/15/2023

Thank you for listening

Any Questions?