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Expansion Joint Active Monitoring

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Team Members Joe Savino Mechanical Engineer Adam Remick Electrical Engineer Andrew Hintermeier Mechanical Engineer

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Expansion Joints Bolted between pipes Made of Rubber, Fabric and Metals Diameters of 2 to 130 Factors that contribute to failure: Axial Displacement Wear Pressure/Temperature

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Benchmarking No system in the market Difficult to measure composite/rubber degradation Multiple reasons for degradation Current method is regular preventative maintenance Visual Inspection Qualitative data no quantitative data

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Our Goal Deliverables Sensor package for EJs 4in and larger Collect and Store data Measure axial displacement, pressure and temperature Stretch Goals: Mountable on any type of EJ Measure difference in vibration across EJ Integrate with previous software groups package

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Customer Requirements Customer Rqmt. # ImportanceDescription CR11Monitor Temperature, Pressure, Displacement CR21Withstand working environment CR31Easy data access CR42Compatible with existing hardware CR51Alterations must not significantly affect the strength of the EJ CR61Fit on the EJ CR71Capture data for 3-6 months

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Engineering Requirements rqmt. #ImportanceSource Engr. Requirement (metric)Unit of Measure Marginal Value Ideal Value S15CR1Measure Pressure PSI 11 S25CR1Measure Temperature F 400450 S35CR1Measure Axial Displacement in 24 S45CR2/CR5Temperature cycles to Fail cycles500750 S55CR2/CR5Pressure cycles to fail cycles10001500 S65CR2/CR5Mechanical cycles to fail cycles30004500 S72CR6Small Size in24 S84CR4Sensors connect to old system Binary11 S93CR6Easily Mountable number of steps81 S103CR3Analog Votage outputBinary11 S115CR7Battery LifeDays90180 S125CR7Data StorageDays90180

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Functional Decomposition Detect EJ Failure Sense EJs Current state Sense Localized Defect Sense General Wear Process Data Collect Data Determine Dangerous Conditions

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Actively Monitoring of Sensor Data Active monitoring on EJ mount: Real time measurements of pressure, temperature, etc, for warning about exceeding limitations of EJ Could be based off time (ex: temperature over limits for 1 sec may be ok, but 10 sec is not) LED or other signal visible to passersby to show error Difficult to reset In addition to data capture

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Event Triggered Monitoring If the EJ is subjected to a harmful environment, start collecting data Faster sample rate Collect for a smaller period of time Show warning LED Would be used to gather a smaller amount of data then send to Garlock for analysis

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Block Diagram of Electrical System Temperature Sensor 1 MicroProcessorLED DisplayPressure SensorDAQ Device Memory Storage Displacement Sensor MicroProcessor

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Data Storage Requirements Assuming: Rate of 1 sample/second 16 bits/sample Required 3 to 6 months of data 6 months would take 240MB Easily obtainable

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MicroProcessor Temperature Sensor Pressure Sensor Displacement Sensor Reset Button Pre- processing MicroProcessor I/O 1 I/O 2 I/O 3 I/O 4 LED Circuit I/O 5 I/O 6 I/O 7

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Concept Development Measure Pressure Measure Temperature Measure Axial Displacement Mount sensors to EJ Diaphragm (strain) sensor Thermocouple (Grounded) UltrasoundBuilt into EJ Diaphragm (capacitance) sensor Thermocouple (ungrounded) Laser sensorGlued on outside Diaphragm (piezoelectric) sensor Thermocouple (Exposed) Linear Potentiometer Zip Ties LVDTBracket Infrared Metal insert String Potentiometer

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Axial Displacement Linear Potentiometer/LVDT Water/Environment Accelerometer eliminated due to effects from vibration Ultrasound was picked for measuring wear, worried about interference

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Axial Displacement Ultrasonic Laser

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Axial Displacement Infrared String Potentiometer

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Displacement LVDT Linear Potentiometer Accuracy : High Water proof, shock and impact ressistant Price : $495 Accuracy: +/-0.0001 in Vibration/impact Price: $395

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Displacement Laser Utrasonic Accuracy: Diffracts too easily Durability: IP54 not dust resistant, water resistant Price: $377 Accuracy: Heat/wind Durability: Splash/shock/impact Price: $250

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Displacement Infared String Potentiometer Accuracy:+/- 0.04 in Durability: IP67 Dust protected, Water proof Price: $305 Accuracy: +/- 0.025 in Durability: Water Proof Impact/shock resistant Price: $247

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Pugh Chart for Axial Displacement

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Temperature Measurement Thermocouple Exposed Benefits Previously tested successfully Fits between layers within EJ Difficulties Calculating temperature difference between inner layer of EJ and fluid

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Temperature Grounded Faster Response time, Vulnerable to noise Ungrounded Slower Response, Reduced Noise

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Pugh Chart for Temperature

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Pressure Regular sensor with heat dissipation stem $350-$500 Simple non insulated straight pipe High Temperature sensor High Price Custom made

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Mounting Options Spacer addition Potentially one per side Allows access to fluid without altering EJ Use with Pressure Sensor and potentially vibration sensor Outside Mount Used with displacement and thickness sensor Inside Mount Used with Thermocouple Already been tested by previous iteration

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Mounting Black RTV With nut Mounting Plate Threaded inserts

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Engineering Analysis Simulated an EJ under compression and tension in ANSYS Workbench Displacement of 1 inch Used to determine where stress concentrations will be Helps to determine sensor placement

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Compression

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Tension

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Engineering Analysis Avoid areas in the middle of EJ and areas right below or above flanges Embed sensors in between these areas Minimize risk of EJ leaking after sensors are embedded

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Engineering Analysis-Insert

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Temperature Isolation of Pressure sensor May not be able to find a pressure sensor that can withstand the temperature EJ does Can use a tube protruding from EJ to dissipate heat A stainless steel tube would need to extend at least 6 in out for our applications

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Schedule Week 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8Week 9 Week 10 Week 11 Week 12 Week 13 Week 14 Week 15 TRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRS Create Problem Definition Create Customer Needs Create Engineering Specs Create Interview Questions Interview Customer/Garlock Visit Create Functional Decomposition Concept Development Create Pugh Charts Risk Assesment Benchmarking Sensor Research Basic ANSYS Model Engineering Analysis (1st Order) Engineering Analysis (2nd Order) Sensor Selection Test Plans Created Custom Parts Designed Order Sensors Presentations Problem Definition Presentation System Design Review Subsystem Design Review Fourth Presentation DDR Presentation

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Questions?

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Back Up Slide

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Risk Analysis IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize Risk 1 Weaken EJ Doesnt past test cycles Poor design implementation 339 Consult Garlock design Engineers 2Sensors fail early Does not measure failure criteria Sensors not rated for EJ requirements133 Pick sensors with high safety factor 3Scope too large Not able to accomplish all requirements More goals than team is capable of224Discussed with customer 4Parts ordered too late Not enough time to build and testLate deign choices133 Identify and order long lead time parts early in design process 5Poor team work ethic Do not complete work on time Poor communication/motivati on122 Bonding activities/high communication 6Not sensing local failure Failure to measure failure criteriaInsufficient research339 Research rubber failure degradation thoroughly 7Mounting failure Ease of mounting/cycle failure/ doesnt measure failurePoor construction236Consult Garlock Engineers