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’’ 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 displacement, wear, pressure and temperature Stretch Goals: Mountable on any type of EJ Measure difference in vibration across EJ Integrate with previous software group’s package

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/sizes

Customer Requirements Customer Rqmt. # ImportanceDescription CR11Monitor losses in integrity CR21Withstand working environment CR31Easy data access CR42Compatible with existing hardware CR51Alterations must not significantly affect the strength of the EJ CR61Fit on the EJ

Engineering Requirements rqmt. #ImportanceSource Engr. Requirement (metric)Unit of Measure Marginal Value Ideal Value S15CR1Measure Pressure PSI 11 S25CR1Measure Temperature °F S35CR1Measure Axial Displacement in 24 S45CR1Measure Wear in 35 S55CR2/CR5Temperature cycles to Fail cycles S65CR2/CR5Pressure cycles to fail cycles S75CR2/CR5Mechanical cycles to fail cycles S82CR6Small Size in24 S94CR4Sensors connect to old system Binary11 S103CR6Easily Mountable number of steps81 S113CR3Analog Votage outputBinary11

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

Concept Development Measure Pressure Measure Temperature Measure Axial DisplacementMeasure WearMount sensors to EJ ManometerThermocoupleIMU/AccelerometerUltrasoundBuilt into EJ Diaphragm (strain) sensorThermometerRuler/caliperHardness testerGlued on outside Diaphragm (capacitance) sensorLittle Black chipUltrasoundForce sensorZip Ties Diaphragm (piezoelectric) sensorThermistorLaser sensor Strapped to outside EM Proximity sensor Spacer part Linear Potentiometer

Pugh Chart for Axial Displacement

Axial Displacement Decision Linear Potentiometer Worried about interference with EJ expansion Accelerometer eliminated due to effects from vibration Ultrasound was picked for measuring wear, worried about interference

Pugh Chart for Wear

Wear Measurement Decision Ultrasonic Thickness Sensor Possible difficulties: Mounting challenges Must be on outside of EJ Engineering challenges Ability to use probe without digital output Benefits No impact on fluid No impact on EJ

Pugh Chart for Pressure

Pressure Measurement Decision Diaphragm (strain ) sensor Possible difficulties Requires contact with fluid Impact integrity Fluid’s impact on sensor

Pugh Chart for Temperature

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

Selected 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

Risk Analysis IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize Risk 1 Weaken EJ Doesn’t 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/ doesn’t measure failurePoor construction236Consult Garlock Engineers

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?