Post on 10-Dec-2015
1
DISTRIBUTIONSBIR Data Rights. Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.
DISCLAIMER STATEMENTThe views, opinions, and findings contained in this report are those of the author(s) and should not be construed as an official Department of Defense position, policy, or decision.
““ABL Smart Piping System for Containment and Control ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicalsof Highly Corrosive and Hazardous Chemicals ” ”
SBIR Phase II Contract: HQ0006-05-C-7254SBIR Phase II Contract: HQ0006-05-C-7254
Status MeetingStatus Meeting1 May, 20061 May, 2006
Air Force Program ManagerAir Force Program ManagerBrandon Arritt, AFRL/VSSVBrandon Arritt, AFRL/VSSV
Odyssian TechnologyOdyssian TechnologyBarton BennettBarton Bennett
Paul DitslerPaul DitslerBen SmithBen Smith
2
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
AGENDAAGENDA Overview
Recent Program Accomplishments– Design and Analysis– Sensor Development and Evaluation– Process Development
Plans for Next Quarter
Open Technical Discussion
AF/MDA Related Work
Closing Session– Financial Overview– Related Federal Appropriation Request
Lab Tour – Overview of Other Technology
HQ0006-05-C-7254
3
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
e-BoardMultifunctional
Sporting GoodsMultifunctional Structure
Thin Film IgnitersDeposition of Conductive Material
Small UAV Multifunctional
Structure
Smart Piping Systems
Integrated Leak Detection Sensors
4
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
Program Status Overview
Recent Accomplishments
• Smart Pipe Designs– Flanged Fitting– Compression Fitting– Integrated Sensor Circuitry
• Sensor Research and Development (non-SBIR funded)– Pressure Sensor
• Process Development– Straight and Curved Composite Dual Wall Pipe– Electrical Tracings
HQ0006-05-C-7254
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5
TASKS
Aug 2 –Nov 1
Task I – Rqts & Criteria Definition
Task II –
Task III – Design & Modeling
Task IV – Process Dev. and Fabr
Task VI –
Program Mgt. & Reporting
Q4 Q1 Q2
Kick-off Mtg @ MDA Mtg @ MDA
Q3 Q4
CY2005 CY2006
Task V – Testing, Evaluation
Mtg @ Odyssian Mtg @ Odyssian
Q1 Q2
Nov 2 –Feb 1
Q3
Feb 2 –May 1 May 2 –Aug 1 Aug 2 –Nov 1 Nov 2 –Feb 1 Feb 2 –May 1 May 2 –Aug 1
CY2007
> <May 1, 2006
Sensor & Controls Dev
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
6
Phase II TeamPhase II Team• Odyssian Technology
Contribution: Overall program responsibility. System design, development, fabrication, and evaluation.
• Boeing ABL and Phantom Works
Contribution: Requirements and criteria definition and general program oversight.
• Dr. Lieberman (University of Notre Dame)
Contribution: Consultation and research on chemical sensors and chemical exposure testing. Facilities and experience for handling hazardous chemicals.
• Dr. Corona (University of Notre Dame)
Contribution: Structural analysis modeling and mechanical testing of smart piping system. Facilities for mechanical testing.
• Dr. Lee (Purdue University)
Contribution: Chemical sensor testing. Facilities and experience for handling hazardous chemicals.
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
Proprietary or Confidential DataDisseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.
7
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
AGENDAAGENDA
HQ0006-05-C-7254
Overview
Recent Program Accomplishments– Design and Analysis– Sensor Development and Evaluation– Process Development
Plans for Next Quarter
Open Technical Discussion
AF/MDA Related Work
Closing Session– Financial Overview– Related Federal Appropriation Request
Lab Tour – Overview of Other Technology
8
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
Positive Electrical Pin (for shown circuit)
Common GroundChlorine Sensor (Tin Fuse)
Copper foil conductor Secondary
O-ring
Positive Electrical Pin (for circuit on other side of seal)
Primary O-ring
Threaded Pipe Design
HQ0006-05-C-7254
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9
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
Flanged Pipe Design
HQ0006-05-C-7254
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10
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
HQ0006-05-C-7254
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11
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
HQ0006-05-C-7254
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12
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
• Flange Design – Based on ANSI B16.5 Standard– Estimated 50% Weight Savings Over Hastelloy Baseline– Smart Pipe Design Made of Aluminum with PVDF Insert
Baseline Smart Pipe Design
HQ0006-05-C-7254
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13
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
• Curved Pipe– Braided or Wound– Mates to other Smart Pipe
Fittings– Lighter Weight than Elbow
Joints
HQ0006-05-C-7254
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14
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
HQ0006-05-C-7254
Proprietary or Confidential DataDisseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.
15
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
• Smart Collar– Usable on pre-existing
piping systems– Large array of commercial
uses– Developed under 21st
Century Fund cost match
HQ0006-05-C-7254
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16
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
Tubing Materials
Composite Material System,• Toray T700G 12K / #2510
– Unidirectional Carbon/Epoxy Prepreg– Toughened Matrix / Intermediate Modulus Fiber– Boeing Certified– 250F Degree Oven Cure
• Toray T800HB / Cytec CYCOM 823– VaRTM Material System– 12K Intermediate Modulus Fiber– 250 Degree Cure VaRTM Resin – Room Temperature Injection
Chemical Resistant Liners (to be explored),• PVDF Sleeve – Straight Pipe• FEP or PVDF Heat Shrink – Curved Pipe
HQ0006-05-C-7254
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17
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
Flanged Fitting Materials • Aluminum 6061 T6
– Bolted Region• PVDF Insert
– Bonded Region• Bolts
– Carbon Steel, ANSI Standard
Flared Fitting Materials • Hasteloy C276 (Chlorine)• Inconel 625 or Stainless Steel 316L (BHP)
Seal Materials
• PVDF body with Viton O-rings (Threaded and Flanged)• SAE AS1098 teflon ring seal (flared)
– To be explored
• Copper Tracing / Gold Plated Electrical Contacts
HQ0006-05-C-7254
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18
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task III: Design and Modeling
FEA Analysis• NEi/Nastran
• Complex Models Created
• Multiple Loading/Boundary Conditions Considered
• Verified Correlation between FEA Models and Classical Hand Analysis
HQ0006-05-C-7254
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19
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
AGENDAAGENDA
HQ0006-05-C-7254
Overview
Recent Program Accomplishments– Design and Analysis– Sensor Development and Evaluation– Process Development
Plans for Next Quarter
Open Technical Discussion
AF/MDA Related Work
Closing Session– Financial Overview– Related Federal Appropriation Request
Lab Tour – Overview of Other Technology
20
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task II: Sensors and Controls
• Ultra Wide Band (UWB)– Newer Technology
– Low Power Consumption Rate
• Zigbee– Mature Technology
• On-Off Keyed (OOK)– Very low power
– Sensor networking
– Simple Signals
• Development Kits and Chipsets Identified
HQ0006-05-C-7254
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21
• Features– Small size– 300 psi operating range– 1500 psi burst– Must be mounted and encapsulated
• Suppliers / Cost– Silicon Microstructures, Memstech– $5 each (bare die)– 500 piece minimum purchase
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
MEMS Pressure Sensors
HQ0006-05-C-7254
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22
• Features– Small size– 500 psi operating range– 1000 psi burst– -40o F to 250o F operating temp– Mounting and packaging options
• Supplier / Cost– Measurement Specialties (Entran)– $475 each– Custom features at additional cost
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Sub-Miniature Pressure Transducers
HQ0006-05-C-7254
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23
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Prototype Pressure Transducers
• Activates at 75 psi• 2-3 cycles before failure• Simple design and
materials
•Activates at 30 psi•Unknown failure•Simple design and materials
Spring Contact Concept
Diaphragm Concept
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24
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
• Activates at 40 psi• 3 cycles before failure• May be susceptible to vibration
ABL SMART PIPING SYSTEM
Prototype Pressure Transducers
HQ0006-05-C-7254
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Developed under non-SBIR Funds
25
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
• Activates at 35 psi• 6-8 cycles before failure• Eliminates failure due to vibration• Eliminates fatigue of spring conductor
ABL SMART PIPING SYSTEM
Prototype Pressure Transducers
HQ0006-05-C-7254
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Developed Under non-SBIR Funds
26
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Pressure Vessel
Used for Testing Pressure Sensors
HQ0006-05-C-7254
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27
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
AGENDAAGENDA
HQ0006-05-C-7254
Overview
Recent Program Accomplishments– Design and Analysis– Sensor Development and Evaluation– Process Development
Plans for Next Quarter
Open Technical Discussion
AF/MDA Related Work
Closing Session– Financial Overview– Related Federal Appropriation Request
Lab Tour – Overview of Other Technology
28
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task IV: Process and Fabrication
• Table Rolling– Oven Curing
– Inexpensive, Re-usable Tooling
– High Quality Parts
– Compaction Pressure from Heat Shrink
HQ0006-05-C-7254
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29
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Table Rolling Process
HQ0006-05-C-7254
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30
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task IV: Process and Fabrication
• Bias plies increase waste and production cost
• FEA analysis indicates that bias plies are unnecessary
• 20% Weight savings
No Bias Plies
Bias Plies
HQ0006-05-C-7254
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31
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Wash-out Mandrel
For Use in Fabricating Curved Pipe
HQ0006-05-C-7254
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32
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Curved Pipe Process
HQ0006-05-C-7254
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33
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Task IV: Process and Fabrication
• Flat Flexible Cable– Expensive– Crimped Terminations– Easily installed
• Conductive Polymer– Silver Filled– Expensive– Can be Printed– Flexible Pattern– Could be Copper Electroplated– Must be Insulated from Pipe
• Copper Foil– Solderable– Must be Insulated from Pipe– High conductivity
HQ0006-05-C-7254
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34
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
AGENDAAGENDA
HQ0006-05-C-7254
Overview
Recent Program Accomplishments– Design and Analysis– Sensor Development and Evaluation– Process Development
Plans for Next Quarter
Open Technical Discussion
AF/MDA Related Work
Closing Session– Financial Overview– Related Federal Appropriation Request
Lab Tour – Overview of Other Technology
35
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
ABL SMART PIPING SYSTEM
Plans for Next Quarter
HQ0006-05-C-7254
1. Achieve Better Definition of Current ABL Piping • Flange Design• Seal Design• Cost
2. Complete Design and Analysis (Task III)• Pipe, fitting, seals• Phase II Demo
3. Continue Sensor Development• Determine Feasibility of COTS Sensors
– MEMS– Subminiature Transducers
• Develop BHP Reactive Sensor Concepts• Develop Additional Pressure Sensor Concepts
4. Conduct Chemical Compatibility Testing
5. Complete Process Dev/Eval of Curved Pipe• Braided VaRTM Curved Pipe• Wound Prepreg Curved Pipe
6. Develop initial sensor circuit design
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36
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
AGENDAAGENDA
HQ0006-05-C-7254
Overview
Recent Program Accomplishments– Design and Analysis– Sensor Development and Evaluation– Process Development
Plans for Next Quarter
Open Technical Discussion
AF/MDA Related Work
Closing Session– Financial Overview– Related Federal Appropriation Request
Lab Tour – Overview of Other Technology
37
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
Issues / Discussion Topics• Input from Shery Welsh 3-17-2006 (Current ABL Pipe, Flange and Seal Design Details)
– Clarification on requirements (geometry); ¼” to 1” flared, 1.25”-12” flanged – AF SPO Approval for ABL Specifications
• Lightweight NASA Flange Designs• SAE Seal Ring AS1098• Female Boss Fitting Design
• Requirements Definition– Purchase of Test Equipment in Lieu of Boeing Subcontract
• Testing– Purchase of Test Equipment in Lieu of ND Testing– Add Braided and Wound Pipe– Vibration – Pressure Burst
• Increased Strain Requirement– 0.41% vs 0.15%– Composite allowable strain 2%
• Curve Shape Definition– Use of Pre-shaped Pipe Segments?– On-site Bending?– Flexible Tooling Needed?
• Phase II Demonstration– More Straight Piping– Circulation/pressurized– Meeting Setup with U of I
HQ0006-05-C-7254
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38
Phase II Test MatrixPhase II Test Matrix
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39
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
AGENDAAGENDA
Overview
Recent Program Accomplishments– Design and Analysis– Sensor Development and Evaluation– Process Development
Open Technical Discussion
AF/MDA Related Work
Closing Session– Financial Overview– Related Federal Appropriation Request
Lab Tour – Overview of Other Technology
HQ0006-05-C-7254
40
OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY
HQ0006-05-C-7254
Category Budget
Cummulative Actual
Expense
Cummulativ
e Paid
Previous Period Unpaid
Period Expense
Adjustments Applied this
Period
Current Period Payment RequestAmount Rate
Salary/Wages (direct) $ 318,085 $ 29,485 $ -
$ - $12,122
$ - $ 12,122
Fringe $ 103,378 $ 6,262 $ -
$ - $ 3,056 25.2%
$ - $ 3,056
Labor Overhead $ 63,641 $ 510 $ -
$ -
$ -
$ -
$ -
Materials/Supplies $ 41,392 $ 2,857 $ -
$ - $ 2,721
$ - $ 2,721
Equipment $ -
$ -
$ -
$ -
$ -
$ -
$ -
Travel $ 8,625 $ 1,123 $ -
$ -
$ -
$ -
$ -
Consultants/Subcontractiors $ 64,230
$ -
$ -
$ -
$ -
$ -
G&A Expense $ 95,080 $ 18,153 $ -
$ - $ 4,846 31.9%
$ - $ 4,846
Fee $ 55,554 $ 4,181 $ 2,361 $ 1,820 8.0% $ - $ 1,820
Total $ 749,985 $ 62,571 $ 31,879 $ - $24,564
$ - $ 24,564
42
Phase II Piping RequirementsPhase II Piping Requirements
• Geometry,– Type A Pipe
• inside tube diameter, 1.00 to 1.25 inches (chlorine only)• fitting, bolted flange joint.• Lengths range from 6 to 110 inches long for 1.0” diameter and 30 to 110 inches for 1.25”
diameter.
– Type B Pipe • inside tube diameter, .75 inches• fitting, Threaded compression fitting• Lengths range from 6 to 110 inches long for 1.0” diameter and 30 to 110 inches for 1.25”
diameter.
• Temperature,– operating, 40F to 80F– survival, -65F to 160F
• Dynamic,– acceleration, 9g in all 3 axis, followed by leak test at MEOP– vibration, 3-axis random vibration, 0.04g2/Hz, 6.1grms, duration 90 minutes each axis, analysis
requires an uncertainty factor of four (4).
• Operating Force Loads, (chlorine only)– Type A
• axial, 628-982 lbs. (P x A x 2)• torsion, 60 in-lbs. (5 ft-lbs)• pressure, 400 psia (MEOP)
– Type B• axial, 353 lbs. (P x A x 2)• torsion, 60 in-lbs. (5 ft-lbs)• pressure, 400 psia (MEOP)
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HQ0006-05-C-7254
43
Phase II Piping RequirementsPhase II Piping Requirements(continued)
• Design Ultimate Loads (static), (chlorine only)– Type A
• axial, 1570 - 2,450lbs. (P x A x 2)• torsion, 90 in-lbs. (7.5 ft-lbs)• pressure, 1000 psia• abuse, 500 lbs over 4 inch footprint
– Type B• axial, 663 lbs. (P x A x 2)• torsion, 90 in-lbs. (7.5 ft-lbs)• pressure, 1000 psia• abuse, 500 lbs over 4 inch footprint
• Impact damage degradation, 100 ft-lbs using a 1.0 inch diameter tip (must be able to operate under burst pressure after impact)
• Leak detection sensitivity, 3 PPM max
• Duty cycles up to MEOP, 2,000 cycles
• Strain of 0.41%
• Design per MIL-STD-1522A
– Includes: design burst pressure of 2.5 times MEOP
– Includes: proof test pressure of 1.5 times MEOP
• Pressure/Temperature ranges for other ABL Fluid Systems.Excluding GN2, He and Oil lube.
a. BHP: P=300 psia, T=-15Cb. NH3: P=345 psia, T=20F to 90F (Excludes gaseous NH3 exhaust ducts)c. I2: P=50 to 200 psia, T=230F to 660Fd. H2O2: P=1000 to 1300 psia, T=40F to 80F
MEOP – Maximum estimated operating pressure
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HQ0006-05-C-7254