sensors case studies

8/3/2019 Sensors Case Studies

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On-Line Sensors for Condition Monitoring

Michel MurphyCondition Monitoring International LLCRoswell, GA, USA

Thomas S Kent BEng, AMIMechE Development EngineerKittiwake Developments, Littlehampton U.K.

61st STLEAnnual MeetingCondition Monitoring

Technical SessionCalgary, AB

Canada


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Measuring, Monitoring & Managing...

Oil Sampling and Field Testing

Water Sampling and Field Testing

Lab and Field Wear Debris Analysis

Online Oil & Wear Debris Analysis

Laboratory Logistics

Research & Development

Introducing Kittiwake


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Trainingand EducationOil Samples

to CheckMachineHealth

LaboratoryOil TestingInstruments

On-boardOil and Vibration

Machine MonitoringSensors

Diagnoses by Prescientsm

Machine ConditionReports

Machine ConditionReports

Global Solutions for Condition Monitoring Services and Support

Condition Monitoring International


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Online Oil & Wear Debris Analysis

Online Sensor Technologies - The

ultimate in Condition Monitoring

Real Time measurements

In Remote Locations

Multiple outputs for data collection

Online Analysis of:

Ferrous & Non Ferrous Wear Debris

Particle Count

Oil Condition

Moisture


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What we will be talking about?

Range of ANALEXrs wear debrissensors

Technology behind the sensors

Sensor development

Features

Sensor history

Real life testing

Summary and questions


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What we will be talking about?

Range of ANALEXrs wear debrissensors

ANALEXrs Oil Condition sensor

ANALEXrs Moisture sensor

Technology behind the sensors

Sensors Development

Real life testing

Realising cost benefits from sensortechnologies

Interfacing sensors

Summary and questions


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ANALEXrs Wear Debris Sensors

Two base sensors

which share similar

Sensing

technologies Parts

Inputs and outputs

Connection Wiring

Potential

customers

But with different

Detection methods

Data output

Potentialapplications


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ANALEXrs Total Ferrous Debris Sensor

Philosophy

Measurement of total ferrous debris byMagnetometry reporting output in ppm

On-line technology

Automatic operation

No chemicals

Technology

Measures >5 micron (unlike ICP)

No radioactive source (unlike XRF)

Linear response

Independent of oil flow speed

Outputs

CAN interface

4-20 mA, RS232, RS485

Radio link with built-in web server

Base models

Two base models

Targeted at steel works, large marineengines, wind turbines, gear boxes


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History

Kittiwake asked by ExxonMobil toproduce an on-line iron sensor for

trending scrapedown oil. Generation 1 designed,made and tested

successfully on a land based test engine

Laboratory tests successfully completedat steel works

5 generation 1 sensors fitted to a slowspeed marine diesel

2 generation 1 units fitted to a nuclear

submarine gearbox

Generation 1 re-designed, improved, andproduced to become generation 2

5 generation 2 fitted to the same slow

speed marine diesel and all 10 sensorsconnected to a specialist data collectionsoftware on a CAN network


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History Continued

Piston version of sensor designed forinstallations where an using an air blast to

zero is not available or appropriate Piston version successfully trailed by

QinetiQ (Formally UK Defense,Evaluation and Research Agency). On anindustry standard gear failure test rig.

Short term Future / Testing

Continued support and receive data fromthe 10 sensors fitted to the slow speed

marine diesel trials

Trial with steel works to continue

Trial of a piston sensor on a wind turbinegearbox with GE Wind to begin in

approximately 1 month

Sensor to be built into an automated oilsampling test rig to show correlation with

the laboratory results


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Features

Applications

Marine & Industrial Engines

Gearboxes and Bearings

Steel Production

Power generation


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Total Ferrous Piston Set-up

Potential fitting arrangement

Piston sensor is suitable for almost allapplications where customers already

use PQ instruments

Suitable for systems where no air isavailable or an air blast isinappropriate

Trains

Wind turbines (on and offshore) Construction vehicles

Mining

Main Oil Flow

Piston

sensor


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Total Ferrous Piston Test set-up

Installation on FZG geartest Rig FZG = Forschungsstelle fr

Zahnrder und Getriebebau -Technical Institute for the studyof Gears and Drive Mechanisms).

Industry standard gear testing rig

12 load stages

15 minutes a stage

Inspection at each stage to checkon tooth wear


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ANALEXrs Total Ferrous Test Results


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ANALEXrs Particle Content Sensor

Philosophy

Measurement of individual wear debrisparticles to indicate the onset of machinerydamage

Technology

As particles enter a highly sensitive magneticfield they are detected due to their magneticand conductive properties

The magnitude and direction of spikes inmagnetic flux indicate partial size and type

Ferrous and non-ferrous wear particlescounted separately and sized Individually

Non optical Unaffected by Oil, ContaminantType or Flow rate

Detects: >60m (Fe) and >100m (Non-Fe)

Temperature stable operation

Future possibilities to classify the materialof the particle

Outputs

CAN interface

4-20 mA, RS232, RS485

Radio link with built-in web server


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Features

Applications

Gearboxes and Bearings

Turbines

Steel Production

Power generation


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History

First prototype designed and successfullytrailed at QinetiQ (Formally UK Defense,

Evaluation and Research Agency). Tests carried out on the gearbox of the

EuroFighter (Typhoon).

Particles detected down to 60 micron

(ferrous)

Kittiwake acquires licence for thepatented technology

Kittiwake mechanically redesigns thesensor to have commonality of parts withthe total ferrous sensor.

Digital side of the PCB designed toinclude high speed data processing

capabilities

Particle detection software currently inprogress


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ANALEXrs Particle Counter Test Results

Volume of ball vs Pk-Pk Voltage- Carbide (Ferrous Channel)

0

2

4

6

8

10

12

14

0.065 0.13 0.195 0.26 0.325

Volume (mm^3)

Voltage(V) 1m/s

2.5m/s

4.5m/s


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ANALEXrs Particle Counter Test Results

Speed vs Pk-Pk Voltage- Ferrous

0

2

4

6

8

10

12

0.8 1 1.5 2 2.5 3 3.5 4 4.5

Speed (m/s)

Voltage(V

)

Chrome 0.5mm

Brass 0.5mm

Carbide 0.5mm

CCR Steel 0.2mm

RMB 0.3mm

RMB 0.25mm


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Oil Condition

Tan Delta [30-200mhz]

Measures dielectric properties of oil at a fixed frequency Dielectric constant

Real [Energy storage]

Imaginary [Energy loss]

Advantages

Ease of construction, robust and small

Insensitive to contamination: large measurement path

Contaminants have similar scale effects

Disadvantages

Individual contaminants cannot be identified discretely

Sensor technology protected under US Patent 6,459,995 B1 [1st October 1992] and UK Patent 2,306,660 A [7th May 1997]


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Tan Delta


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Oil condition monitoring

Your needs

Reduce operating costs

Reduce failure nightmare

Measure, Monitor & Managecritical systems

Critical performance parameters Measurable

Consistent

Repeatable

On-line technologies

Key indicators trending

Real time

Work where man cannot

0.05% - 1%Water

0.05% - 0.5%Glycol

0% - 2%Insolubles (Soot)50% IncreaseAcid Number (AN)

50% DepletionBase Number (BN)

Quantified as:Parameter

Oil Condition


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Wind turbine gear oil tests

3TAN mg KOH 1.44

2TAN mg KOH 0.39

1TAN mg KOH 0.28

Oxidised samples tested

Water contaminated samples tested 0.5% conc.


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Wind turbine gearbox: oxidised oil

0.5% Water sample was lab simulated - turbomixed (high shear mixing) for 15 seconds shortly before measurement. Gear oil tested is a polyalphaolefin (PAO) synthetic.

Measurements taken successively without turning sensor off sensor head purged of previous test sample with dried and filtered (0.2m) compressed air.


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Automotive: Coolant and new oil


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Gearbox: water in Oil


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Moisture sensor

Relative humidity means before saturation

Dissolved water: some only detect free and emulsified water

No reagents

Internal processing power interface options

Glass to metal hermetic seal IP68

High pressure rating

Performance -40C to 100C

Temp sensing +/-1%

Saturation +/-2%


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Sensor performance

Total Multagri Super 10W 30, Turbomixed Samples

Relative Humidity Probe

0

10

20

30

40

50

60

70

80

90

100

0 500 1000 1500 2000 2500

Water Added ppm

Meterreading

%Sat

Kittiwake

Vaisala


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Interfacing sensors

Universal standard Analogue 4-20mA

Digital CAN and RS232

Wireless Communications

Remote Sensing

Link the sensors into control systems

Third Party software Machine control systems

OEMs

Data loggers


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ANALEXrs


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ANALEXrs


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Summary

Sensors can be used to predict failure,reducing unexpected equipment downtime and labour costs

Robust solutions for monitoring oilcondition and moisture content

Provide real time indicators of oilcondition

Robust solutions for monitoring debrisin a myriad of applications

Provide real time indicators ofmachinery condition

Advanced connectivity to other sensorsin the ANALEXrs Range

These sensors are the solution to manycurrent problems, and hopefully thesolution for some new ones

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