1. Expansion Joint Active Monitoring
Group 14671
Expansion Joint Active Monitoring

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

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
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

6. 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

7. 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

8. 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

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

10. 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

11. Pugh Chart for Axial Displacement

12. Sensors Ultrasonic Range Finder Linear Potentiometer
Laser Range Finder

13. Pugh Chart for Wear

14. Sensors
Ultrasound Thickness Gauge
Durometer

15. Pugh Chart for Pressure

16. Pressure Chart for Temperature

17. Sensors
Thermistor
Thermocouple

18. Mounting Options
Spacer
Zip tie

19. 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

20. Questions?