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VSI Oil Sensor Overview

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VSI Oil Sensor Overview

  1. 1. Voelker Sensors, Inc. – VSI Continuous On-board Oil Condition Monitoring 2016
  2. 2. Overview • Who is VSI ? • Key Oil Quality Indicators • Technology • Trending – Continuous Monitoring vs. Sample and Analyze • Applications and Field Data • Customers • Partners
  3. 3. Who is VSI • 1st Generation products (Oil Sentinel, Oil Insyte) measure oil polarity and temperature • 2nd Generation product - Oil Advantage – measures base oil breakdown (polarity) – additive depletion (conductivity, polarity) – fuel contamination – moisture contamination – coolant contamination – over temp condition – excess soot – 6 Patents granted
  4. 4. Key Oil Indicators • Oxidation – first step in oil breakdown • TAN/TBN – second step in oil wear • Viscosity – secondary indication of oxidation • Additive depletion • Contaminants – Fuel – Water, Coolant – Soot – Metals
  5. 5. VSI Technology • VSI Measurements – Polarity (base stock breakdown) - includes multi- frequency excitation (patented) – Conductivity (additive depletion) – Patented differential sensor measurements – Water, Coolant in oil (patented) – Temperature – Excess Soot – Fluid Level – Fuel Contamination (patented)
  6. 6. Polarity • Clean base stock is non-polar • Oil becomes more polar as it breaks down • c=c bond breaks, c-o oxygen attaches forming carbonyl – correlates with FTIR Oxidation • Second bond breaks forming carboxylic acid – Correlates with TBN • Polarity measurement uses patented ion exchange polymeric bead matrix methodology
  7. 7. Hydrocarbon Structure
  8. 8. “The most important chemical reaction of a hydrocarbon, for a lubrication engineer or analyst, is oxidation.”
  9. 9. “The most important chemical reaction of a hydrocarbon, for a lubrication engineer or analyst, is oxidation.“ • http://www.machinerylubrication.com/Read/14/lubricant-oxidation
  10. 10. Polarity Measurement Relative Low Conductivity Bead Matrix in Clean (nonpolar) Oil Relative High Conductivity Bead Matrix in Degraded (polar) Oil
  11. 11. Oil Conductivity • Direct DC measurement • Conductivity decreases as conductive additives are consumed • Potential for multi-frequency excitation to extend functionality • Conductivity measures conductive metals
  12. 12. Water/Coolant Contamination • Water detected using patented technology • Some water is expected – All oil has some moisture – Tolerable amount is application specific – Caused by Condensation or – Coolant leaks
  13. 13. Fuel Contamination • Fuel decreases oil’s ability to lubricate • Fuel is aromatic hydrocarbon • Patented VSI fuel sensor detects presence of aromatic hydrocarbon in oil down to a theoretical limit of 0.02% • Sensor can be manufactured to different limits of fuel contamination
  14. 14. Excess Soot • Soot is byproduct of diesel combustion process • Dispersants in oil to control soot agglomeration (carbon sticking together) • Dispersants exhausted, soot agglomerates, plugs filters • Excess soot creates unique sensor signal
  15. 15. Sample and Test • Benefits – Lots of information • Drawbacks – Sample point – Sample time – Delivery, Test, Report delay – Accuracy of results – Sample frequency
  16. 16. Sampling Two Data Points Create a Straight Line
  17. 17. Continuous Monitoring
  18. 18. VSI Installations • Mine Trucks • On Road Trucks • Transmissions • Locomotives • Oil Filled Transformers • Generator Sets • Gas Compressors • Steel Mills • Paper Plants • Wind Turbine Gear Boxes • Hydro-Electric Generators • Propane engines • On road vehicles • Hydraulics
  19. 19. Mine Installation
  20. 20. C112 Completely Worn Oil Polarity Additive Depletion Base-stock Breakdown
  21. 21. C112 Completely Worn Oil Conductivity Additive Depletion Wear Metals (slight increase)
  22. 22. C112 Wear Calculation or RULE Determined from polarity and conductivity measurements
  23. 23. Coolant Detection Example from Haul Truck
  24. 24. Soot Detection 150 170 190 210 230 250 Signal Time - Hrs Sequence III Test - Soot Polarity
  25. 25. A Closer Look at Coolant Intrusion A large leak shows up at 468 hours however, the leak began at 117 hours
  26. 26. Fuel Detection in the Field • Lab Reports 0.2 % fuel on 3/4/2012 0 50 100 150 200 250 2/02 - 12:00 AM 2/07 - 12:00 AM 2/12 - 12:00 AM 2/17 - 12:00 AM 2/22 - 12:00 AM 2/27 - 12:00 AM 3/03 - 12:00 AM Fuel Signal Truck 343
  27. 27. Cummins Engines
  28. 28. Wear Comparison Identical vehicles, engines and driving conditions, different amounts of wear on oil as determined by FTIR and VSI sensor
  29. 29. IR/VSI Comparison 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0 5 10 15 20 25 30 35 -5000 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 531 IR - OX 532 IR Ox 531 VSI - Ox 532 VSI Ox
  30. 30. Transmission Fluid 0 20 40 60 80 100 120 140 160 180 Conductivity Hours Synthetic Transmission Oil Polarity Conductivity Oil Added
  31. 31. NC Machine Tools
  32. 32. NC Machine Oils 0 5 10 15 20 25 30 35 40 45 50 20 25 30 35 40 45 50 PolaritySignal Temperature C Machine Oils Clean Oil Used Oil #5 Used oil # 4
  33. 33. Wind Turbine Gear Box
  34. 34. Wind Turbine Gear Oil 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 0 50 100 150 200 250 Water (PPM) TAN (mg KOH/g)
  35. 35. Generator Set
  36. 36. Gen Set Data 0 50 100 150 200 250 5/20/2012 0:00 5/25/2012 0:00 5/30/2012 0:00 6/4/2012 0:00 6/9/2012 0:00 6/14/2012 0:00 Power Box - PNG Cond
  37. 37. VSI Sensor Integrated with Oil Fill System
  38. 38. Reburn System with Sensor 0 5 10 15 20 25 30 35 40 45 0 20 40 60 80 100 120 140 4/1/2012 0:00 4/5/2012 0:00 4/9/2012 0:00 4/13/2012 0:00 4/17/2012 0:00 Polarity Conductivity Coolant Temperature
  39. 39. Level System Data
  40. 40. Oil Sensor Built into Pump
  41. 41. Hydro Electric
  42. 42. Sensor Installed at Hydro
  43. 43. Oil Field Installation
  44. 44. Natural Gas Installation
  45. 45. NG Compressor -10 10 30 50 70 90 110 130 150 50 70 90 110 130 150 170 Compressor Data Polarity Conductivity Moisture
  46. 46. NG Engine Data 0 1 2 3 4 5 6 7 8 9 10 40 50 60 70 80 90 100 110 120 130 Engine Data Polarity Conductivity Water
  47. 47. Customers • Freeport McMoran - Mine • Kennecott Utah Copper Company – Mine • Serveron Corporation - Transformer • Reserve Systems Corporation - mine • DCP Midstream – Natural gas transmission • Master Tech – Power Generation • Avatrak – Hydro Power, Wind Power, Mine • GE – Wind Power, Machine Tools • Cincinnati Machine – Machine Tools
  48. 48. Partners • Cincinnati Machine • Reserve Systems • Emtec • Micron Scientific • Serveron Corp • Eaton?
  49. 49. Conclusion • Production products in the field for 10 years • Detects – Oil breakdown – Aqueous contamination – Fuel contamination • Multiple products for multiple applications

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