Gasket Connection Reliability Evaluation for Piping Failure Prediction
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Solution Overview
Problem
Existing methods lack a reliable and proactive approach to evaluate the connection reliability of gasket connections in piping systems, often leading to unnoticed failures and potential accidents.
Innovation Solution
A gasket connection reliability evaluation system that includes a measurement value acquisition unit, a simulation unit, a loading analysis unit, a fatigue analysis unit, and a reliability evaluation unit, which collectively assess the connection reliability by analyzing measurement values, simulating fluid behavior, and calculating state quantities, connection indices, and deterioration indices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaskets are monitored and evaluated proactively, then reliability and safety are improved, but device complexity and measurement requirements increase
Solution Approach 1:
The evaluation system is divided into five functional modules: measurement value acquisition unit, simulation unit, loading analysis unit, fatigue analysis unit, and reliability evaluation unit. Each module performs a specific function in the evaluation process, making the complex system manageable and maintainable while achieving comprehensive gasket reliability assessment
Solution Approach 2:
The system integrates multiple evaluation functions into a single unified platform that can assess gasket reliability under various operating conditions (temperature, pressure, vibration, chemical exposure). The system serves multiple purposes: monitoring current state, predicting future reliability, and providing maintenance recommendations
2Measurement precision
If comprehensive measurement and simulation are performed, then measurement precision and evaluation accuracy are improved, but loss of time and computational resources increase
Solution Approach 1:
The simulation unit pre-calculates fluid behavior and loading conditions based on measured parameters. By performing simulations in advance and storing results, the system avoids time-consuming real-time calculations while maintaining high measurement precision for reliability evaluation
Solution Approach 2:
The system continuously acquires measurement values from sensors and feeds them back into the simulation and analysis units. This closed-loop feedback mechanism allows the system to update reliability assessments in real-time without requiring complete re-simulation, reducing computational time while maintaining accuracy
3Reliability
If gasket fatigue and deterioration are analyzed in detail, then reliability evaluation accuracy is improved, but device complexity and analysis requirements increase
Solution Approach 1:
The analysis process is segmented into distinct functional units: loading analysis unit that evaluates applied loads, fatigue analysis unit that assesses cumulative damage, and reliability evaluation unit that synthesizes results. This segmentation allows each unit to focus on specific aspects of gasket deterioration without overwhelming complexity
Solution Approach 2:
The system introduces intermediate evaluation metrics (connection index, fatigue index, deterioration index) that bridge raw measurement data and final reliability assessment. These intermediate indices simplify the complex analysis process by providing standardized metrics that capture essential gasket conditions
Data Source
AI summary
A system which evaluates a reliability of piping connections with gaskets is provided. A gasket connection reliability evaluation system includes: a measurement value acquisition unit configured to acquire a measurement value obtained through measurement by a sensor provided in a system including piping connections with gaskets; a simulation unit configured to simulate a behavior of a fluid flowing through the system on the basis of the measurement value and calculate a state quantity relating to the fluid; a loading analysis unit configured to analyze a loading applied to each of the gaskets on the basis of the measurement value and the state quantity and calculate a connection index of the gasket; a fatigue analysis unit configured to analyze a fatigue state of the gasket on the basis of the measurement value, the state quantity, the loading applied to the gasket, and a specifications and condition of the gasket connection and calculate a deterioration index of the gasket; and a reliability evaluation unit configured to calculate a reliability of the gasket on the basis of the measurement value, the state quantity, the connection index, the deterioration index, and a predetermined reliability evaluation model.