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“ ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicals ” SBIR Phase II Contract: HQ0006-05-C-7254 Status Meeting 1 May, 2006 Air Force Program Manager Brandon Arritt, AFRL/VSSV Odyssian Technology Barton Bennett Paul Ditsler Ben Smith.

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“ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicals ”SBIR Phase II Contract: HQ0006-05-C-7254Status Meeting1 May, 2006Air Force Program ManagerBrandon Arritt, AFRL/VSSVOdyssian TechnologyBarton BennettPaul DitslerBen Smith

DISCLAIMER STATEMENT

The 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.

DISTRIBUTION

SBIR Data Rights. Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

AGENDA

  • 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


Distribution

ODYSSIANTECHNOLOGY

Smart Piping Systems

Integrated Leak Detection Sensors

e-Board

Multifunctional

Thin Film Igniters

Deposition of Conductive Material

Sporting Goods

Multifunctional Structure

Small UAV

Multifunctional Structure


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

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

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

ODYSSIANTECHNOLOGY

CY2005

CY2006

CY2007

Q1

Q2

Q3

Q1

Q2

Q3

Q4

Q4

TASKS

Aug 2 –Nov 1

Nov 2 –Feb 1

Feb 2 –May 1

May 2 –Aug 1

Aug 2 –Nov 1

Nov 2 –Feb 1

Feb 2 –May 1

May 2 –Aug 1

Rqts & Criteria

Definition

Task I

Task II

Sensor & Controls Dev

Design & Modeling

Task III

Process Dev. and Fabr

Task IV

Task V

Testing, Evaluation

Task VI

Program Mgt. &

Reporting

Kick-off Mtg @ MDA

Mtg @ Odyssian

Mtg @ Odyssian

Mtg @ MDA

> <

May 1, 2006


Phase ii team

ODYSSIANTECHNOLOGY

Phase 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.

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

AGENDA

  • 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


Distribution

HQ0006-05-C-7254

Positive Electrical Pin (for shown circuit)

Positive Electrical Pin (for circuit on other side of seal)

Copper foil conductor

Secondary O-ring

Primary O-ring

Chlorine Sensor (Tin Fuse)

Common Ground

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Design and Modeling

Threaded Pipe Design

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Design and Modeling

Flanged Pipe Design

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Designand Modeling

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Designand Modeling

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

Flange Design

Based on ANSI B16.5 Standard

Estimated 50% Weight Savings Over Hastelloy Baseline

Smart Pipe Design Made of Aluminum with PVDF Insert

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Designand Modeling

Baseline

Smart Pipe Design

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

Curved Pipe

Braided or Wound

Mates to other Smart Pipe Fittings

Lighter Weight than Elbow Joints

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Designand Modeling

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Design and Modeling

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

Smart Collar

Usable on pre-existing piping systems

Large array of commercial uses

Developed under 21st Century Fund cost match

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Designand Modeling

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

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

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Design and Modeling

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

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

ODYSSIANTECHNOLOGY

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

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

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task III: Designand Modeling

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

AGENDA

  • 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


Distribution

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

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task II: Sensors and Controls

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

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

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

MEMS Pressure Sensors

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

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

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Sub-Miniature Pressure Transducers

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

Activates at 75 psi

2-3 cycles before failure

Simple design and materials

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Prototype Pressure Transducers

Diaphragm Concept

Spring Contact Concept

  • Activates at 30 psi

  • Unknown failure

  • Simple design and materials

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

Activates at 40 psi

3 cycles before failure

May be susceptible to vibration

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Prototype Pressure Transducers

Developed under non-SBIR Funds

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

Activates at 35 psi

6-8 cycles before failure

Eliminates failure due to vibration

Eliminates fatigue of spring conductor

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Prototype Pressure Transducers

Developed Under non-SBIR Funds

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Pressure Vessel

Used for Testing Pressure Sensors

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

AGENDA

  • 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


Distribution

Table Rolling

Oven Curing

Inexpensive, Re-usable Tooling

High Quality Parts

Compaction Pressure from Heat Shrink

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task IV: Process and Fabrication

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Table Rolling Process

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

Bias plies increase waste and production cost

FEA analysis indicates that bias plies are unnecessary

20% Weight savings

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task IV: Process and Fabrication

No Bias Plies

Bias Plies

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Wash-out Mandrel

For Use in Fabricating Curved Pipe

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Curved Pipe Process

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

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

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Task IV: Process and Fabrication

Proprietary or Confidential Data

Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

AGENDA

  • 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


Distribution

HQ0006-05-C-7254

ODYSSIANTECHNOLOGY

ABL SMART PIPING SYSTEM

Plans for Next Quarter

  • Achieve Better Definition of Current ABL Piping

    • Flange Design

    • Seal Design

    • Cost

  • Complete Design and Analysis (Task III)

    • Pipe, fitting, seals

    • Phase II Demo

  • Continue Sensor Development

    • Determine Feasibility of COTS Sensors

      • MEMS

      • Subminiature Transducers

    • Develop BHP Reactive Sensor Concepts

    • Develop Additional Pressure Sensor Concepts

  • Conduct Chemical Compatibility Testing

  • Complete Process Dev/Eval of Curved Pipe

    • Braided VaRTM Curved Pipe

    • Wound Prepreg Curved Pipe

  • Develop initial sensor circuit design

  • Proprietary or Confidential Data

    Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


    Distribution

    HQ0006-05-C-7254

    ODYSSIANTECHNOLOGY

    AGENDA

    • 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


    Distribution

    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

    ODYSSIANTECHNOLOGY

    Issues / Discussion Topics

    Proprietary or Confidential Data

    Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


    Distribution

    Phase II Test Matrix

    Proprietary or Confidential Data

    Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


    Distribution

    HQ0006-05-C-7254

    ODYSSIANTECHNOLOGY

    AGENDA

    • 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


    Distribution

    HQ0006-05-C-7254

    ODYSSIANTECHNOLOGY


    Distribution

    Backup Slides


    Distribution

    HQ0006-05-C-7254

    Phase 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)

    Proprietary or Confidential Data

    Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


    Distribution

    HQ0006-05-C-7254

    Phase 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

    Proprietary or Confidential Data

    Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.


    Distribution

    Phase II SBIR Program


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