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Group 14671

Group 14671. Expansion Joint Active Monitoring. Team Members. Joe Savino Mechanical Engineer Adam Remick Electrical Engineer Andrew Hintermeier Mechanical Engineer. Expansion Joints. Bolted between pipes Made of Rubber, Fabric and Metals Diameters of 2’’ to 130’’

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Group 14671

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  1. Group 14671 Expansion Joint Active Monitoring

  2. Team Members • Joe Savino Mechanical Engineer • Adam Remick Electrical Engineer • Andrew Hintermeier Mechanical Engineer

  3. 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

  4. 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

  5. Our Goal Deliverables • Sensor package for EJ’s 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 group’s package • Send data wirelessly

  6. Customer Requirements

  7. Engineering Requirements

  8. Functional Decomposition

  9. 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

  10. 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

  11. Block Diagram of Electrical System

  12. 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

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

  14. Concept Development

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

  16. Axial Displacement Ultrasonic Laser

  17. Displacement Infrared String Potentiometer

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

  19. 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

  20. 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

  21. Pugh Chart for Axial Displacement

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

  23. Temperature • Grounded – Faster Response time, Vulnerable to noise • Ungrounded – Slower Response, Reduced Noise

  24. Pugh Chart for Temperature

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

  26. 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

  27. Mounting Black RTV With nut Threaded inserts Mounting Plate

  28. 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

  29. Compression

  30. Tension

  31. 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

  32. Engineering Analysis-Insert • Pullout force in ABS plastic is 900lbf • Assume fluid pressure of 2000psi (higher than burst pressure of EJ) • For .25 diameter thread, OD is .391

  33. 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

  34. Schedule

  35. Questions?

  36. Back Up Slide

  37. Risk Analysis

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