Expansion Joint Active Monitoring Group 14671 Expansion Joint Active Monitoring

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

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

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

Our Goal Deliverables Sensor package for EJ’s 4in and larger Be able to predict impending EJ failure Measure axial temperature, wear, pressure and temperature Stretch Goals: Mountable on any type of EJ Measure difference in vibration across EJ

Approach Use one model of EJ for development and testing 206 EZ-FLO 8” Diameter If a proven method is demonstrated we will move on to testing on other types

Customer Requirements Customer Rqmt. # Importance Description CR1 1 Monitor losses in integrity CR2 withstand working environment CR3 Easy data access CR4 2 compatible with existing hardware CR5 Alterations must not significantly affect the strength of the EJ CR6 Fit on the EJ

Engineering Requirements rqmt. # Importance Source Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value S1 5 CR1 Measure Pressure PSI 1 S2 Measure Temperature °F 400 450 S3 Measure Axial Displacement in 2 4 S4 Measure Wear 3 S5 CR2/CR5 Temperature cycles to Fail cycles 500 750 S6 Pressure cycles to fail 1000 1500 S7 mechanical cycles to fail 3000 4500 S8 CR6 Small Size S9 CR4 Sensors connect to old system Binary S10 Easily Mountable number of steps 8 S11 CR3 Analog Votage output

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

Measure Axial Displacement Concept Development Measure Pressure Measure Temperature Measure Axial Displacement Measure Wear Mount sensors to EJ Manometer Thermocouple IMU/Accelerometer Ultrasound Built into EJ Diaphragm (strain) sensor Thermometer Ruler/caliper Hardness tester Glued on outside Diaphragm (capacitance) sensor Little Black chip Force sensor Zip Ties Diaphragm (piezoelectric) sensor Thermistor Laser sensor   Strapped to outside EM Proximity sensor Spacer part Linear Potentiometer

Pugh Chart for Axial Displacement

Sensors Ultrasonic Range Finder Linear Potentiometer Laser Range Finder

Pugh Chart for Wear

Sensors Ultrasound Thickness Gauge Durometer

Pugh Chart for Pressure

Pressure Chart for Temperature

Sensors Thermistor Thermocouple

Mounting Options Spacer Zip tie

Project Schedule (near future) System Design Review – Today Subsystem – 10/24/13 Sensors selected and Quoted – 10/31/13 Detailed Design - 12/5/13 Custom parts designed w/ Engineering Drawings Test Plans Final Review – 12/12/13

Questions?