P15671: Expansion Joint Health Monitoring Data Acquisition YOUSIF AL-ALINICK D’ERMILIOJAMES JEWIS JESSE FOLLMANMATTHEW SUTTON

What is an Expansion Joint? An expansion joint is a rubber and fabric component that provides flexible joints between 2 different sections of piping. Expansion joints are subject to high pressure, high temperature, and chemical attacks. Expansion joints are used on pipes ranging in size from 2 to 120 inches in diameter.

Problem Statement Garlock Sealing Technologies is seeking to improve the performance of their expansion joints by developing a robust monitoring system. The purpose of this project is to develop a monitoring system that can withstand extreme temperatures and pressures while directly measuring the conditions encountered by the expansion joint. Understanding the conditions and how they impact product health allows proactive maintenance, versus the far more expensive and dangerous method of reactive maintenance. The updated monitoring system must meet minimum thermal, mechanical and pressure cycles. The system must also be able to connect to a DAQ program and accurately monitor temperature, pressure, position and system strain. The sensor package must be able to be integrated with any EJ larger than 2 inches. Testing will have to be done at both Garlock and RIT.

Stakeholders Garlock Sealing Technologies Wayne Evans and Steve Cramb Maintenance teams Dr. Kolodziej – RIT Expansion Joint Users Oil and gas industry Nuclear Industry Municipal Infrastructure

Previous Project Overview Developed a working list of customer needs and specifications Designed a package with limited sensing capabilities Demonstrated proof of concept Successful sensor mounting modification Collected and stored data using Arduino (Axial Displacement) Provided detailed insight on challenges of the project Purchased some parts that can be reused by this iteration of the project

Customer Needs RequirementImportanceCustomer Requirement CR19Temperature Sensing CR29Radial Position Sensing CR39Pressure Sensing CR49Axial Position Sensing CR59Manual stop/start with visual indication CR69Live data collection and storage CR79Retrievable data format in an easy manner CR89Trigger alert when leak occurs along flange face CR93User defined sampling rate CR103Monitoring of current conditions/alarm conditions CR113Portable power source CR123Portable data acquisition and storage CR133Robust sensing package CR143Integration versatility with various size EJ's CR151Wireless communication capability

Engineering Specs ImportanceSource Engr. Requirement Unit of Measure Marginal Value Ideal Value Accuracy 9CR3/CR8Measure Pressure PSI 4590±0.25% 9CR1Measure Temperature°F400450±0.75% 9CR4Measure Axial Displacement in 24±.025% 9CR2Measure Radial Displacement % 540±.025% 3CR13Temperature Cycles to Fail cycles CR13Pressure Cycles to Fail cycles CR13Mechanical Cycles to Fail cycles CR12Small Size (Width) in84- 3CR12Small Size (Length) in53- 3CR12Small Size (Height) in32- 3CR14Easily Mountable Steps81- 1CR11Battery LifeDays CR6Data StorageDays CR9Sampling RateHz110- 3CR14Various Size Mount-abilityin CR5Buttons for on/off/resetBinary-1- 3CR7Able to output to excelBinary-1- 3CR10Light intensity of LED alarm indicationsLumens510- 3CR10Sound intensity of alarmDecibels7080-

Functional Decomposition

Whole System Pugh Chart Key:

Subsystem Pugh Analysis

Temperature Sensing

Temperature Sensing Winner - Thermocouple Cheap – Can be found for around 30 dollars Already own one from previous group Accurate to +/- 2°C with ranges from -270°C to 1300°C Negatives: Although Thermocouple outputs an analog voltage, the changes in voltage for different temperatures are too small to be distinguished by Arduino analog inputs. A thermocouple amplifier needs to be used ($15). K – Type Threaded Thermocouple Thermocouple Amplifier Breakout Board

Pressure Sensing Notes:  Strain Pressure Transducer is type used by previous group  Capacitance Pressure Sensors: Typically used for low pressure settings  Piezeoelectric Pressure Sensors typically used for dynamic pressure changes and not long term static pressures

Pressure Sensing Winner – Strain Pressure Transducer Very resistant to shock and vibration We already own one (Saves $350) Performs with 0.25% accuracy Can be powered by 9 V supplied to Arduino while outputting 0-5 V analog voltage Negatives: Only compensates for environmental temperatures up to 80°C. May requires mounting further from expansion joint to maintain accuracy Validyne P V Strain Gage Pressure Transducer

Axial Displacement Sensing

Axial Displacement Winner – String Potentiometer Have an accuracy of.025% of full scale (10 in = +/-.0025in) Lightweight and easy to mount Ability for different types of outputs Operation in temperatures -65°C to 125°C We own one that meets the current requirements

Radial Displacement Sensing

Radial Displacement Winner – Spring Loaded Caliper Two main types of spring loaded calipers Forceps model is less expensive than Snap model Both have SPC outputs which can be converted to Arduino Vibration will affect forceps model more than Snap model

Alerting the User

Alerting the User Winner – LED’s and LCD Already own a 20x4 LCD screen which can be used Allows for very specific alerts/monitoring of current conditions LED’s are compact and attention grabbing Additional option for audio alert can be added later with minimal difficulty 20x4 LCD Screen – Easily compatible with Arduino LED’s

Writing Data

Writing Data Winner -.csv “Comma-Separated Values” Very common, relatively simple format that is used for many applications Arduino has functions already in place to write a.csv file with simple commands Can be easily imported into Excel Text file so it’s compact

Remote Data Transmission

Remote Data Transmission Winner – Wi-Fi Implemented on an Arduino with an easy to use Wi-Fi shield Allows for portability inside a factory setting Using to use on the customer end Fairly cheap ($80) Negatives: Wi-Fi shields do tend to use a lot of power while in use so this option may not be feasible while running on a battery for long periods of time. Arduino Wi-Fi Shield

Grouping/Housing of Internal Components

Grouping-Housing Winner – Metallic Box Strong and durable compared to other options Can be cut and shaped Aesthetically clean and robust looking Cheap Can be bolted, strapped or bent to fit many mounting configurations Negatives: Although cutting and shaping can be performed, it is not as easy as other options. Machining will be required or working around the shape of what is purchased.

Physical User Input – Power, Reset, Thresholds

Physical User Input Winner - Buttons Pushbuttons can be easily used on an Arduino platform to allow the user to power on, off, or reset the board Threshold values will be set in software but the possibility to use numbered buttons is also an idea Very durable in industrial environments Extremely cheap

Component List ComponentOwned? Arduino BoardYes Pressure TransducerYes String PotentiometerYes Wi-Fi ShieldNo Spring Loaded CaliperNo ThermocoupleYes* CaseNo LCD ScreenYes BatteryNo

Sketch of Mounting on EJ

Sketch of Monitoring Package Temp Press R-Disp A-Disp Thresholds

Risk List IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimalize RiskOwner 1Team runs out of timeUnfinished ProjectPoor planning/”senioritis” 2510Develop a good plan for finishing project on timeMatthew 2Device draws too much powerCannot run on battery power easily Choosing parts poorly 335Perform thorough calculation on different parts to determine power consumption EE’s 3Data samples take up too much storage room Missing data collection Sample rate too high 134Communicate with and agree on acceptable rate of sampling with customer Jesse 4Components take up too much room to be put into enclosure Less portable/visually appealing Choosing too large of components 224Choose smaller technology along with efficient methods of creating circuitry EE’s 5Device does not stay mounted onto EJ Durability issuesInferior mounting246Create an effective mount out of a strong materialNick 6Alarm indications are not easily noticed Critical issues with EJ go unnoticed Choosing alarm indicators poorly 134Agree on how many alarm indicators are necessary to achieve acknowledgement from operator James 7“Scope Creep”Lack of focus on critical parts Not having a concrete plan 348Communicate with customer and decide as a team which concepts to pursue and which to not focus on Team 8Sensors fail during testing/monitoring Issues involving EJ go unmonitored Choosing less durable sensors 135Choose industrial setting sensors onlyME’s 9Lead time for critical partsProject not done on time Ordering parts too late 248Assess lead time of critical parts and take into account leeway for shipping times Matthew 10Data is not easily interpretedDifficult usability by customer Poor data capture/processing 135Have methods in place to have data easy translate to spreadsheets/graphs Yousif

Questions?