“ABL Smart Piping System for Containment and ... - Odyssianodyssian.com/MDA/MDA/files/Phase...

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DISTRIBUTIONSBIR Data Rights. Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only.

Export is restricted.

DISCLAIMER STATEMENTThe views, opinions, and findings contained in this report are those of the author(s) and should not be construed as an official Department of

Defense position, policy, or decision.

““ABL Smart Piping System for Containment and Control ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicalsof Highly Corrosive and Hazardous Chemicals ””

SBIR Phase II Contract: HQ0006SBIR Phase II Contract: HQ0006--0505--CC--72547254

KickKick--off Meetingoff Meeting4 October, 20054 October, 2005

Barton BennettBarton BennettOdyssian TechnologyOdyssian Technology

(574) 257(574) 257--75557555

2

OOODYSSIANDYSSIANDYSSIAN TTTECHNOLOGYECHNOLOGYECHNOLOGY

AGENDAAGENDA

• Odyssian Technology

• Phase I Accomplishments

• Phase II Plans

• Discussion of Phase II – Requirements & Success Criteria – Problem Definition– Technical Solutions

• Phase II Program Logistics– Level of ABL Team Involvement– Technology Transition (Phase III)

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About Odyssian Technology• Started in February 2003

• Located in Mishawaka Indiana

• Integration of circuitry, sensors, interconnects into structure, components, and devices

- Multifunctional structure- Product integration

• Product offerings and emerging technology,

1 Smart Seal – seals with integrated leak detection sensors.

2 Smart Piping System – lightweight pipe sys. with leak detection sensors

3 Missile System Igniters – Thin film electronic igniters for thermal battery

4 Drones – Small UAV with structurally integrated battery, antenna, electronics

5 Measured Sports – Sporting goods product with integrated sensors, electronics, lighting, etc.

6 e-Board™ – chair rail and other boarding with integrated power and signal wiring systems.


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e-BoardMultifunctional

Sporting GoodsMultifunctional Structure

Thin Film IgnitersDeposition of Conductive Material

Smart Piping Systems

Integrated Leak Detection Sensors

Small UAV Multifunctional

Structure

5

Phase I Phase I SBIR ProgramSBIR Program


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ABL SMART PIPING SYSTEM

PHASE I PROGRAM

• Smart Piping System developed for ABL COIL System- Integrated leak detection sensors- Redundant containment structure- Improve safety, reduced weight

• Program funding: $69,000

• Program duration: 6 months

• Phase I Team,- Odyssian Technology- Boeing Phantom Works- Boeing ABL Program

• Related Work- Smart Seal with integrated leak detection sensors (redundant sealing)

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PHASE I PROGRAM

ACCOMPLISHMENTS

1. Selection of ABL Application (smart pipe).

2. Definition of Phase I requirements/targets

3. Research into various sensing technologies & industrial Cl2 handling practices

4. Development of Multiple Conceptual Designs using 3D solid modeling

5. Design of Phase I Demo

6. Fabricated Phase I Demo Component (Smart Pipe)

7. Registered with Defense Logistics Information Services and Department of State Office of Defense Trade Controls.

8. Cost Share,i. Cost sharing Phase I (smart seal ring development)ii. Applied for Indiana SBIR matching funds

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Applications (Boeing ABL Program input)

(1) Lightweight Smart Plumbing System for ABL COIL LaserToxic and corrosive chemicalsChemical and leak detectionStructural health monitoring - Corrosion Detection- Strain sensing

Replace metallic piping with composite piping.- Current Boeing program looking at composite piping.

Smart system may allow reduction in design margins (weight reduction).

(2) Lightweight Smart Belly SkinThermal shock (rapid -55F to 585F temp swings)Replacement Ti skin with shielded composite skin.- Current Boeing program looking at composite skin.

Structural health monitoring- Temperature monitoring- Strain sensing

OT

Missile Defense Agency (MDA) Phase I SBIR

“Multifunctional Structures with Structurally Integrated Circuitry for Use on the Airborne Laser (ABL)”

Boeing Proprietary Data

Appendix B – Applications Identified

Page 1 of 2

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Applications (Boeing ABL Program input) - continued

(3) Smart Laser Containment StructureBurn through of containment structure (beam tube)Integrated sensors within containment structure rings- Burn-through detection

Would allow simplified designLower priority

(4) Integration of circuitry and electrical interconnects into structure (as proposed)Elimination of vibration source (cables, harnesses)Protection of circuitry and interconnects from corrosive chemicalsRecent modeling has shown that cables/harnesses may not be as much of a source of vibration as previously thought.Lower priority (further modeling may change priority)

OT



Boeing Proprietary Data

Appendix B – Applications Identified

Page 2 of 2

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PHASE I PROGRAM

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PHASE I PROGRAM

Positive Electrical Pin (for shown circuit)

Common GroundChlorine Sensor

Copper foil conductor

Secondary O-ring

Positive Electrical Pin (for circuit on other side of seal)

Primary O-ring

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Relatively large industrial gas sensors. Variety of proprietary sensors. Limited supplier information shows some to be electrochemicalGas leak sensors

Kynar (PVDF), Halar (ECTFE), FEPPipe Liner (corrosion)

Lead washersSeals

Brass, nickel plated brassFittings

Schedule 80 carbon steel pipe, stainless steel pipe, copper transfer tubing, Kynar transfer tubing and pipe liner, Monel flex transfer hose.Pipe

MaterialUse


Industrial Materials Used In Handling Chlorine

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OT



0.6480.3210.0180.0361.5800171731.05--52.9

0.4500.3210.0150.0301.25800171731.05--52.9

0.1620.3210.0090.0180.75800171731.05--52.9

0.0930.0540.0230.0301.53000497431.340%60%480

0.0750.0540.0220.0301.253500497431.340%60%480

0.0460.0540.0230.0300.756000497431.340%60%480

0.0250.0540.0060.0081.5800497431.340%60%480

0.0170.0540.0050.0071.25800497431.340%60%480

0.0060.0540.0030.0040.75800497431.340%60%480

RunningWeight

lbf/ft

MaterialDensitylbf/in3

Thickness Required for Axial Loads (ta)

inches

Thickness Required for Hoop Loads (tt)

inches

Inside Diameter

(D)inches

Gas Pressure

(p)psi

Allowable Axial Stress

(Sa)ksi

Allowable Hoop Stress

(St)ksi

Safety Factor

Material Factor

Fiber in Axial

Direction%

Fiber in Hoop

Direction%

Material Strength

ksi

tt=pD/2St

ta=pd/4Sa

Hasteloy Pipe is 34% Heavier over Dual-walled Composite Pipe (lb/ft)(Does not consider standard pipe wall thickness)

Pipe Weight Comparison

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OT



• Pipe Weight Comparison Does Not Consider Standard Wall Thickness

- Pipe weight savings may be higher

• Smart Pipe Fitting Weight: 0.5165 lbs.

• Estimated Baseline Fitting Weight (Hasteloy): .75 lbs.

• Estimated Weight of 6 ft. pipe;

- Smart Pipe: 1.2425 lbs.

- Baseline Pipe (Hasteloy): 1.7 lbs.

• Boeing’s Baseline Weight Data to Provide More Meaningful Comparison

Weight Comparison

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PHASE I PROGRAM

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Chlorine Sensor Test

Discoloration of solderDid not fuse.1.51.52:00

Dry Cl2, 0 VDC0.002 x 0.97 x 0.56Aluminum8

Discoloration of solderDid not fuse.0.40.45:00

Dry Cl2, 3 VDC0.005 x 0.015 x 0.38Copper7

Discoloration of solderDid not fuse. 0.40.410:00

Dry Cl2, 0 VDC0.002 x 0.09 x 0.54Copper6

Fused. Lost electrical continuity after 41 sec.

Fused. Lost electrical continuity.0.40.5:41

Dry Cl2, 0 VDC0.002 x 0.15 x 0.52Tin4

Fused. Lost electrical continuity.

Fused. Lost electrical continuity.0.60.61:08

Dry Cl2, 3 VDC0.002 x 0.15 x 0.44Tin3

Fused. Lost electrical continuity after 39 sec of exposure to chlorine gas.

Fused. Lost electrical continuity 0.60.6:39

Dry Cl2, 0 VDC0.002 x 0.012 x 0.37Tin2

Large droplets of water placed in glass container. White layer formed on surface of tin.

Did not fuse. Poor clip connection gave temporary discontinuity reading, causing the test to be ended. 0.40.53:32

Moist Cl2, 3 VDC0.002 x 0.020 x 0.5Tin1

Final Initial ObservationsTest Results

Electrical Resistance

(Ohms)Exposure Time

(min:sec)Test

Conditions

Approx. Dimensions of

Conductive Element(T x W x L)

Sensor (fuse)

Element Material

Test Coupon Number

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Pressure variation in cavity, by selective absorption of IRPhoto-acoustic gas sensor

Expensive, ComplexHigh accuracy and fast response time, reliable.IR Gas absorption spectral variationPhotonic gas

sensor

Vapor and liquid detectionChange in mass of deposited chemical changes frequency of oscillator

Piezoelectric quartz crystal microbalance sensors

High sensitivityCompares data of enclosed and exposed cavities with microwaves

Microwave Cavity sensor

Low costUses ultrasonic to measure particle concentration, size and type in channel

Ultrasound sensor

Low CostDetects change in acoustic wave velocity and frequency across chemical selective material.

Surface Acoustic Wave sensor

Moderate costIonized gas, timing velocity to detectorIon Mobility sensor

Expensive, Complex, Readiness Level

Sensitive to multi levels and types of gas uses neural net

An electronic nose is chemical sensing and a pattern recognition system.Nose sensor

Readiness level, AvailabilitySmall, Rugged, Multi-gasCeramic metallic gas sensorCermet sensor

One time useSmall, Simple, low costSensor reacts or corrodes in the presence of chemical, activating or breaking electronic circuit.

Reactive Conductor sensor

DisadvantagesAdvantagesDescriptionSensor Technology

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low cost, small, simpleOptical properties change when polymer coating reactsFiber-Optic

non specific gasLight beam interruptionPhoto-electric sensor

RuggedMeasures change in inductanceInductive sensor

Clean, remoteMeasures change in capacitanceCapacitive sensor

RobustMeasures ultrasonic vibration variationUltrasonic sensor

Sensitive, small, self poweredCantilever beam polymer reacts with gas and bendsCantilever beam sensor

Low cost, simpleVariation in potential or resistanceConductive sensor

Robust, corrosive environmentGas sound measurementAcoustic sensor

Gas Specific sensing, reliableIR gas spectral tuning Photonic band gapOptical sensor

High Temp, Pressure and corrosive environmentsCeramic, change in electrical conductivityCeramic sensors

Robust, compact inexpensiveSensors based on low cost thick film technologyThick film sensors

DisadvantagesAdvantagesDescriptionSensor Technology


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Phase II Phase II SBIR ProgramSBIR Program


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Phase II TeamPhase II Team• Odyssian Technology

Contribution: Overall program responsibility. System design, development, fabrication, and evaluation.

• Boeing ABL and Phantom WorksContribution: Requirements and criteria definition and general program oversight.

• Dr. Lieberman (University of Notre Dame)Contribution: Consultation and research on chemical sensors and chemical exposure testing. Facilities and experience for handling hazardous chemicals.

• Dr. Corona (University of Notre Dame)Contribution: Structural analysis modeling and mechanical testing of smart piping system. Facilities for mechanical testing.

• Dr. Lee (Purdue University)Contribution: Chemical sensor testing. Facilities and experience for handling hazardous chemicals.


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TASK Q1

Task I – Rqts & Criteria Definition

Task II – Sensor & Controls Development

Task III – Design & Modeling

Task IV – Process Dev. and Fabrication

Task VI – Program Mgt. &Reporting

Q2 Q3 Q4 Q1 Q2

Kick-off Mtg at ABL SPO

Mtg @ Boeing

Q3 Q4

YEAR 1 YEAR 2

Task V – Testing, Evaluation

Mtg @ Odyssian

Mtg @ Odyssian

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Phase II SBIR ProgramPhase II SBIR Program

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Phase II SBIR ProgramPhase II SBIR Program

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Functionality and Utility TargetsFunctionality and Utility TargetsPhase I:Phase I:-- Containment of Chlorine gas Containment of Chlorine gas -- Leak detection of chlorine gas. Leak detection of chlorine gas. -- Detection prior to leakage outside containment structure.Detection prior to leakage outside containment structure.-- Multifunctional design with integrated leak sensorsMultifunctional design with integrated leak sensors

Phase II:Phase II:-- Containment of Chlorine, Base Hydrogen Peroxide, and Iodine gasContainment of Chlorine, Base Hydrogen Peroxide, and Iodine gaseses-- Leak detection of Chlorine and Base Hydrogen PeroxideLeak detection of Chlorine and Base Hydrogen Peroxide-- Detection prior to leakage outside containment structure.Detection prior to leakage outside containment structure.-- Multifunctional design with integrated leak sensorsMultifunctional design with integrated leak sensors-- WirelessWireless

Improvement TargetsImprovement Targets-- Weight Reduction, 5% Weight Reduction, 5% -- 15% reduction over baseline Hasteloy system 15% reduction over baseline Hasteloy system

(when considering the weight of separate bulk leak detection sys(when considering the weight of separate bulk leak detection systems)tems)-- Acquisition Cost, No more than 5% Acquisition Cost, No more than 5% -- 10% increase10% increase-- Life Cycle Cost, No less than a 30% Life Cycle Cost, No less than a 30% -- 40% reduction40% reduction


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Phase II Piping RequirementsPhase II Piping Requirements• Geometry,

– inside tube diameter, 1.00 to 1.25 inches (chlorine only)– fitting, bolted flanged joint.– Lengths range from 6 to 110 inches long for 1.0” diameter and 30 to 110

inches for 1.25” diameter.• Temperature,

– operating, 40F to 80F– survival, -65F to 160F

• Dynamic,– acceleration, 9g in all 3 axis, followed by leak test at MEOP– vibration, 3-axis random vibration, 0.04g2/Hz, 6.1grms, duration 90 minutes

each axis, analysis requires an uncertainty factor of four (4).• Operating Force Loads, (chlorine only)

– axial, 982 lbs. (P x A x 2)– torsion, 60 in-lbs. (5 ft-lbs)– pressure, 400 psia (MEOP)

• Design Ultimate Loads (static), (chlorine only)– axial, 2,450lbs. (P x A x 2)– torsion, 90 in-lbs. (7.5 ft-lbs)– pressure, 1000 psia– abuse, 500 lbs over 4 inch footprint

MEOP – Maximum estimated operating pressure

Proprietary or Confidential DataDisseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

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Phase II Piping RequirementsPhase II Piping Requirements(continued)

• Impact damage degradation, 100 ft-lbs using a 1.0 inch diameter tip (must be able to operate under all loading condition after impact)

• Leak detection sensitivity, 3 PPM max• Duty cycles up to MEOP, 2,000 cycles• Design per MIL-STD-1522A

– Includes: design burst pressure of 2.5 times MEOP– Includes: proof test pressure of 1.5 times MEOP

• Pressure/Temperature ranges for other ABL Fluid Systems.Excluding GN2, He and Oil lube.

a. BHP: P=300 psia, T=-15Cb. NH3: P=345 psia, T=20F to 90F (Excludes gaseous NH3 exhaust ducts)c. I2: P=50 to 200 psia, T=230F to 660Fd. H2O2: P=1000 to 1300 psia, T=40F to 80F

• Ground rules:– A stress analysis shall be conducted using A-basis equivalent allowables.– A methodology using composite laminate theory shall be employed. Effects of wind

angle, number of layers, fiber thickness, resin content, and geometrical discontinuities shall be assessed.

– Metal welding, if used, shall be Class A, full penetration butt-type per MIL-STD-2219.

MEOP – Maximum estimated operating pressure

Proprietary or Confidential DataDisseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

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Airborne Laser Smart Pipe System Sensors Considerations

OT Phase II ABL SBIR Program

Odyssian Technology Proprietary and Confidential Information

Odyssian Technology Proprietary and Confidential Information4 October, 2005

Possible Sensor Types

1 MEMS Pressure Transducers- Cantilever Beam

2 Gradient Fiber Optic Transducers- Chemical collects to outer coating of fiber optic changing light reflection characteristics

3 Capacitance Affect Transducer- Inner and outer pipes used as conductive plates of a capacitor- Chemical directly changes dielectric

4 Dielectric Changes in Seal Material- Doped seal material changes in dielectric as seal ages and becomes brittle

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Airborne Laser Smart Pipe System Wireless Solutions

OT Phase II SBIR Program



Network Data Rate Power Req Pwr/Range

Zigbee Mesh [email protected] 60mW 30dBm/10m40kbps@915MHz20kbps@858Mhz

Bluetooth Pt. to Pt 1Mbps 80mW 20dBm/10m

WiFi Star Conf 1,2,5.5,11,32Mbps 1.5W 30dBm/40m

Ultra WB Mesh 480Mbps 20mW 12dbm/10m

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Airborne Laser Smart Pipe System Possible Wired Interface Solutions




Analog Solutions

1 4-to-20 mA Current Loop

Digital Solutions

1 Serial Communications Bus (Ex. RS-485)

2 Fiber Optic Network

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Airborne Laser Smart Pipe System Powering Considerations




Induced Power

1 Induction Power Gateway- Induced power via changing magnetic field

2 Radio Frequency Induced Power (RFID Technology)- Electromagnetic waves induces voltage on antenna conductor

Battery Power

1 Coin battery power- Induced or wired recharge

2LiPon- Surface conforming to skin of pipe or coupling interface- Induced or wired recharge

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(1) ABL SPO and Boeing interest and issues (2) Problem definition

a. Discuss preliminary requirements definition.b. Detect only Chlorine and BHP?c. Do we interface with on-board ABL systemsd. Is there interest in displaying system status in crew station? e. Can this be a stand-alone system or do we integrate with other monitoring system?

(3) Technical solutiona. Containment structure

i. Composite dual walled pipe1. Are composites acceptable? Are there testing specifications available?2. Need for stiffness matching or strain isolation couplings?

ii. Hasteloy1. Could consider dual walled Hasteloy piping in phase II. Discuss.

b. Leak detection sensori. Chemical specific .vs. universal

1. Odyssian would like to continue work on Chlorine sensor while exploring the possibility of developing a very small universal detection sensor (such as a MEMS pressure sensor)

c. Communicationi. Wireless .vs. Hard wire; Is wireless acceptable? We can discuss options for various wireless standards

(blue tooth, Zigbee, Ultra-wide band, 802.11). Wireless will simplify interconnecting tubing.d. Power source

i. Hard wire .vs. stored energy (battery) and/or energy harvesting (chemical battery, piezoelectric)e. Leak warning protocol - discuss

i. Plan to assign identifier/address to each pipe segment, tank, and couplingii. Small surface mount LEDs on each component to assist in identifying location of leakiii. System status console displays identifier of leaking component.iv. Display schematic of system with highlighted leaking component to assist in locating leak.

(4) How to best demonstrate smart pipe technology during phase II?a. Odyssian would like to demonstrate this technology on a ground based laboratory system

(5) Success criteriaa. Are the cost and performance targets in attached file acceptable?b. Additional success criteria?

(6) Phase III technology transitiona. Discuss ABL transition path

(7) Programmatic Issuesa. User oversight and direction – ABL SPO, Boeing ABL. Involve Northrop Grumman (?)b. Phase II cost proposal provides ~ $30K to support Boeing oversight. How best used?

32 Odyssian Technology Proprietary and Confidential Information


OT

Simple Smart Pipe Schematic Diagram

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0.6480.3210.0180.0361.5800171731.05--52.9

0.4500.3210.0150.0301.25800171731.05--52.9

0.1620.3210.0090.0180.75800171731.05--52.9Hasteloy

C-276

0.0930.0540.0230.0301.53000497431.340%60%480

0.0750.0540.0220.0301.253500497431.340%60%480

0.0460.0540.0230.0300.756000497431.340%60%480Carbon Epoxy Composite

TR50/NCT301, 60%vf

(0.030" thick)

0.0250.0540.0060.0081.5800497431.340%60%480

0.0170.0540.0050.0071.25800497431.340%60%480

0.0060.0540.0030.0040.75800497431.340%60%480Carbon Epoxy Composite

TubeTR50/NCT30

1, 60%vf(800 psi)

RunningWeight

lbf/ft

MaterialDensitylbf/in3

Thickness Required for Axial

Loads (ta)inches**

Thickness Required for Hoop Loads (tt)

inches*

Inside Diameter

(D)inches

Gas Pressure

(p)psi

Allowable Axial

Stress (Sa)ksi

Allowable Hoop

Stress (St)ksi

Safety Factor

Material Factor

Fiber in Axial

Direction%

Fiber in Hoop

Direction%

Material Strength

ksiMaterial

“ABL Smart Piping System for Containment and ... - Odyssianodyssian.com/MDA/MDA/files/Phase...

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