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Oil & Asset Health Digitization - Poseidon Systems

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Overview of how the Poseidon Systems' sensor suite digitizes oil and machine health though an innovative and holistic approach. This next generation digitalization technology will revolutionize rail, mining, energy, wind, marine, etc., bringing asset operational cost down significantly.

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Oil & Asset Health Digitization - Poseidon Systems

  1. 1. Oil and Machine Health Digitization © 2018 Poseidon Systems, LLC Stephen Steen Vice President, Industrial IoT stephen.steen@poseidonsys.com Phone: +1 (419) 509-9857
  2. 2. ©2018 Poseidon Systems, LLC – Proprietary Information 2 Why Online Oil Monitoring? It’s already happening! • Market leaders are implementing online programs to capture real time oil quality to reduce the reliance on periodic sampling • Example: Poseidon is monitoring wear debris on over 2,500 wind turbines, doubling in 2019 • Better detection capability than offline capabilities alone • Detect failure events when they happen; like coolant contamination, dirty fuel, lubricated metallic components faults, etc. • Capture faults regardless of location • Capture faults regardless of asset location • Assets tracked and measured while in service, instead of once a month Poseidon IIoT Oil Sensors
  3. 3. ©2018 Poseidon Systems, LLC – Proprietary Information 3 Real-time, Cloud-based Oil Monitoring Program Current Lab Services Real-time, Cloud-based monitoringFleet Poseidon Live Sample(s) scheduled & sent to lab Alert sent w/ recommended actions Monitoring services IIoT Oil Sensors Poseidon
  4. 4. ©2018 Poseidon Systems, LLC – Proprietary Information 4 Online Oil Health Monitoring Benefits IIoT Oil Sensors • Increased Uptime -> earlier detection of fault condition/failure • Lubrication health tracked real-time, capturing events for immediate corrective action -> no longer waiting for transit or processing time to take first action • Machine health tracked real-time, wear debris focused on machine health -> adding to actionable recommendations • Lower Maintenance Cost -> preventative maintenance • Oil samples based on events, lower sampling cost -> based on expert real time trending, event detection, and analytics • Field access for better decision making -> connected directly to field O&M decision makers, real-time Fleet Poseidon One place for ALL lubricated equipment health
  5. 5. ©2018 Poseidon Systems, LLC – Proprietary Information 5 One place for ALL lubricated equipment health Monitoring services Poseidon Live Current Lab Services • Connect Lab to Real-Time Data -> complete oil picture • Correlate detailed lab sampling to real-time events, cause & effect • Centralized Data -> real-time + lab + historical • One place for all lubrication data • Capture all events, analytics, alarms, health, etc. • New Maintenance Models -> cost saving opportunities • New indicators for preventative planning and cost reduction • Connect Poseidon Live to current monitoring systems, adding lubrication to key indicators Online Oil Health Monitoring Benefits
  6. 6. ©2018 Poseidon Systems, LLC – Proprietary Information 6 Oil Quality Monitoring
  7. 7. ©2018 Poseidon Systems, LLC – Proprietary Information 7 Trident QW3100 Impedance Spectrum Analysis Provides more information on fluid quality than competing technologies Integrated Water-in-Oil Sensor Accurate tracking of water contamination levels Real-time Continuous Monitoring Observe and respond to oil problems before they become equipment problems Easy to Install and Use Simple thread-in sensor backed by Poseidon’s online data analysis services Enables Condition Based Maintenance Reduce the need for offline oil sampling and analysis Optimize oil drain intervals
  8. 8. ©2018 Poseidon Systems, LLC – Proprietary Information 8 What is Impedance Spectroscopy? Permittivity, conductivity, dielectric, etc. • Only measure one point on this curve – capturing only a small amount of the total information Impedance Spectroscopy • Sensing method based on analyzing a fluid’s electrical properties across a range of frequencies • Provides more information about an oil’s properties than single frequency analysis • Zero consumables as compared to in-situ test kits
  9. 9. ©2018 Poseidon Systems, LLC – Proprietary Information 9 • At low to medium frequencies the sensor measures the bulk impedance of the oil • Polar additives • Oxidation products • Contaminants • Typically shows a rise in value as new oil mixes with old, additives agglomerate, additives surround contaminants • Downward trend indicative of decreasing additive health • Accelerating downward slope indicative of contamination Typical Trend New Oil Depleted Oil Example OilChange OilChange Bulk Resistance Measurement
  10. 10. ©2018 Poseidon Systems, LLC – Proprietary Information 10 Oxidation Testing – Offline results vs Online
  11. 11. ©2018 Poseidon Systems, LLC – Proprietary Information 11
  12. 12. ©2018 Poseidon Systems, LLC – Proprietary Information 12 12 OilChange OilChange Coolant Leak Event Oxidation / Additive Depletion Online impedance spectroscopy measurements from mining truck Mining Example Problem: High % of coolant leaks not detected early enough causing secondary damage. Solution: Using Poseidon’s oil quality sensor, customer able to detect these events and immediately take action, reducing costly secondary damage.
  13. 13. ©2018 Poseidon Systems, LLC – Proprietary Information 13 Case Study: Oil Change Optimization Problem: Oil change cost high, non-optimized, oil sampling cost too high Solution: Using Poseidon’s oil quality sensor, customer able to measure oil quality real time until condemning limits met, extending useful life by up to 500 hours.
  14. 14. ©2018 Poseidon Systems, LLC – Proprietary Information 14 Oxidation Testing – Offline results vs Online
  15. 15. ©2018 Poseidon Systems, LLC – Proprietary Information 15
  16. 16. ©2018 Poseidon Systems, LLC – Proprietary Information 16 Expected Measured Properties Property How Monitored Capability Overall Health Relative changes in feature Strong correlation Soot High frequency impedance Strong correlation Contamination Contaminant specific Good water, soot, wrong oil Oxidation/Nitration Bulk resistance Good correlation TAN Bulk resistance Application Dependent TBN Bulk resistance Strong Correlation Viscosity In development TBD Temperature Thermistor +/-1 C Water Content % of Saturation +/- 3%
  17. 17. ©2018 Poseidon Systems, LLC – Proprietary Information 17 Wear Debris Monitoring
  18. 18. ©2018 Poseidon Systems, LLC – Proprietary Information 18 Trident DM Inductive Coil Metallic Debris Monitor Monitor wear levels to determine asset health in an intuitive manner Best-in-Class Sensitivity Detects ferrous particles as small as 40μm and non-ferrous as small as 150 μm Real-time Continuous Monitoring Detect and characterize wear events that my otherwise be missed Easy to Install and Use Easily installed in line with filtration loops or in a bypass loop Enables Condition Based Maintenance Reduce downtime and fix issues before they become unmanageable
  19. 19. ©2018 Poseidon Systems, LLC – Proprietary Information 19 Metallic wear debris monitoring enables: • Earliest detection of mechanical degradation • Particle size distribution can be used to isolate type of fault (i.e., geartooth crack vs bearing spall) • Estimate of remaining useful life and whether safe operation can continue for a period of time, or if immediate shutdown must occur • Reduced number of inspections Trident DM4500/4600 Trident DM4500 (installed in bypass loop) Trident DM4600 (direct integration w pump and filter)
  20. 20. ©2018 Poseidon Systems, LLC – Proprietary Information 20 Technology Overview • One or more coil windings around a non-conductive fluid passage (sensing bore) • Coil is excited with a high frequency oscillating voltage • Resulting magnetic field couples with metallic particle present within the field • Particle passage result in a measurable impedance change in sensing coils • Detected as amplitude and phase shifts • Magnitude indicates size of the particle • Relative phase angle indicates particle type (ferrous or nonferrous) • Width of disturbance represents the speed of the particle Inductive Coil Sensing 0 0.01 0.02 0.03 0.04 0.05 0.06 -0.15 -0.1 -0.05 0 0.05 0.1 100um Iron Particle Signature Time (s) Output(Volts) Real Imaginary
  21. 21. ©2018 Poseidon Systems, LLC – Proprietary Information 21 Life Gauge Overview • Wear debris is a direct measurement of gearbox damage • Poseidon’s sensor can detect flow rates & therefore concentrations • Poseidon has several life gauge indicators, 2 key measurements are: 1. Rate of material loss 2. Fault Severity Fault Severity Total Ferrous Metal Lost (mg) Rate of Material Loss Concentration (ug/L)
  22. 22. ©2018 Poseidon Systems, LLC – Proprietary Information 22 Planet Carrier Bearing • Identified accelerating wear on NGC gearbox • No faults detected by vibration monitoring system • Notified customer of serial defect resulting in spinning planet carrier bearing • Fault confirmed via borescope • Up-tower repair (pinned) • >$200k cost savings by avoiding gearbox replacement Concentration(µg/L) Wear(mg) Planet Carrier Bearing Damage Repaired
  23. 23. ©2018 Poseidon Systems, LLC – Proprietary Information 23 Gear Regrind Fault repair utilizing wear debris feedback to take advantage of optimized gearbox replacement timing. 11 months * $2,000 = $46,000 additional savings Feedback from Wear Scheduled Regrinding Concentration(µg/L) Wear(mg) 11 Months of Additional Life = $46k Damaged Gear Tip *Reference image only, Clipper
  24. 24. Wear Rates – Why Online? • Wear metal generation is not a continuous, predictable process • It is typically observed in bursts • Samples drawn minutes can vary by orders of magnitude • Impractical to analyze frequently enough to characterize gearbox health • Online, inductive coil sensors are not skewed by: • Presence of nonmetallic particles • Oil changes • Filter media changes Wear metal concentrations vary dramatically based on operating conditions. Accurate conclusions cannot be drawn from periodic sampling.
  25. 25. Lab Samples & ISO Codes Don’t Predict Health Viewing particle count data by ISO code or iron concentrations from lab samples is unclear • Case Study Across 140 Assets: • 70ppm Alarm • 0.8% false alarms (1/119) • 100% missed detection (0/18) • 100% nuisance (1/1) • 50ppm Warning • 13% false alarms (16/119) • 72% missed detections (13/18) • 77% nuisance (17/22) • Lab recommended limits of 25/14/11 • Exceeded on every gearbox for >6 and >14µm Little to no value for taking actionable insights or measuring health
  26. 26. ©2018 Poseidon Systems, LLC – Proprietary Information 26 Online Does Predict Health After estimating particle mass and calculating the sum across bin sizes, we see that T9 and T10 are actually generating more wear material. Both assets had faulted gearboxes.
  27. 27. Replaced DeratedFault identified via online monitoring Offline Sampling Online vs. Offline Example Offline sampling unreliable for capturing fault events Case Study – Oil samples did not indicate signs of fault, online sensor alerted years earlier Normal iron and ISO values ISO codes decrease ISO increase, but still within “norms”
  28. 28. ©2018 Poseidon Systems, LLC – Proprietary Information 28 Products & Capabilities
  29. 29. ©2018 Poseidon Systems, LLC – Proprietary Information 29 Trident FQMS Wear Debris Monitoring Oil Quality and Water Monitoring Oil Viscosity Monitoring Protective NEMA 4 Enclosure Easy Installation and Data Flow
  30. 30. ©2018 Poseidon Systems, LLC – Proprietary Information 30 Installation Overview RJ45 - CANbus RJ45 – Modbus RTU 8-28 VDC 500mA max Not Shown: 2x Non-directional -8 Male JIC Bulkhead Oil Connections Ethernet (Modbus TCP) Cell Connection JSON CSV
  31. 31. ©2018 Poseidon Systems, LLC – Proprietary Information 31 • All-in-One Monitoring Portal • Poseidon Sensors • Turbine SCADA • CAN + Modbus RTU Sensors • Other Available Data Poseidon Demonstration available upon request • Built-in Analytics for Easy Use • Set Automated Alarms • Create Custom Plots • Mobile Access
  32. 32. ©2018 Poseidon Systems, LLC – Proprietary Information 32 Poseidon Live Navigation Personalized graphing & plots Export Data Alarming
  33. 33. ©2018 Poseidon Systems, LLC – Proprietary Information 33 Poseidon Live Sortable Overviews Asset Tables Map (if GPS available)
  34. 34. ©2018 Poseidon Systems, LLC – Proprietary Information 34 Poseidon Live Fleet/group customizable pareto charts
  35. 35. ©2018 Poseidon Systems, LLC – Proprietary Information 35 Poseidon Live Customizable, sharable charts Customizable, configurable alarms
  36. 36. ©2018 Poseidon Systems, LLC – Proprietary Information 36 Poseidon Live Asset level customizable graphs
  37. 37. ©2018 Poseidon Systems, LLC – Proprietary Information 37 Poseidon Live Display multiple customizable graphs
  38. 38. ©2018 Poseidon Systems, LLC – Proprietary Information 38 Testimonials
  39. 39. Debris monitoring is the cat’s meow of condition monitoring! Steve Abe Operations Manager – AES
  40. 40. ©2018 Poseidon Systems, LLC – Proprietary Information 40 It is our belief that metallic debris monitoring provides the earliest, most reliable, most cost effective gearbox condition monitoring solution. We install Poseidon’s products on all Revolution gearboxes and recommend their products to all of our customers. Bruce Neumiller CEO – Gearbox Express
  41. 41. ©2018 Poseidon Systems, LLC – Proprietary Information 41 We have been using the Poseidon oil debris sensors since 2011 and have managed many gearbox failures successfully, even over periods greater than two seasons giving ample time for budgeting and planning. Art Miller CBM Specialist - EDF
  42. 42. This technology provided me with nearly a million dollars in warranty claims in the first 3 months of operation. John McKay Operations Team Leader – AES
  43. 43. ©2018 Poseidon Systems, LLC – Proprietary Information 43 Poseidon provided fault detection, six months of severity assessments, and derating recommendations… Eddie Legg Lead Technician – Allete Clean Energy
  44. 44. ©2018 Poseidon Systems, LLC – Proprietary Information 44 About Our Company Poseidon Systems is a spinoff from Impact Technologies, a company founded in 1999, acquired by Sikorsky Aircraft in 2011. Impact Technologies specialized in developing innovative technologies for enabling Condition Based Maintenance (CBM) for critical military assets including drivetrains for air vehicles, Army ground vehicles, and Navy ships. For the past 7 years, Poseidon Systems has been a leading innovator in developing and manufacturing real-time condition monitoring solutions, specifically fluid diagnostics. We provide end-to-end solutions for enabling online oil condition and metallic wear debris monitoring allowing customers to optimize maintenance practices. 2017 Small Vendor of the Year Wind Energy Update
  45. 45. ©2018 Poseidon Systems, LLC – Proprietary Information 45 Company Timeline Impact Sensors formed to focused on fluid sensing products Impact Technologies acquired by Sikorsky, Impact Sensors carved out 2011 2010 DM product line released (R&D till 2012), first full wind farm w/ Poseidon Live 2012 DM4500/4600 standardized 2014 Gen7 QM/QW3100 released (R&D till 2016) 2016 Largest wind operator worldwide selects DM4500 gearbox monitoring standard 2018 Impact Sensors renamed Poseidon Systems 2013 Several major wind trials begin 2015 First fleet-wide deployments for DM4500, Qx selected for two IIoT fluid platforms 2017 Impact Technologies begins development of EIS sensor 2002 Impact Technologies US Army contract for combined wear debris / oil quality sensor 2009
  46. 46. ©2018 Poseidon Systems, LLC – Proprietary Information 46 Poseidon Around the World This Photo by UnknownAuthor is licensed under CC BY-SA Headquarters & Manufacturing Rochester, NY European Distributor Est. 2018 Chinese Distributor Est. 2017 African Distributor Est. 2018 Indian Distributor Est. 2016 Australian Distributor Est. 2016 Manor Technologies Cardiff, Wales
  47. 47. ©2018 Poseidon Systems, LLC – Proprietary Information 47 Poseidon Capability Design •Custom Sensors •Custom Electronics •Installation Kits Manufacturing •Final Assembly •Prototype & Final Testing •ISO 9001:2015 Software •Cloud Based Apps •Embedded •Edge Device •Controls Systems Integration •Sensor Integration •End-to-End Solutions IoT •Wireless Solutions •Data Acquisition •Custom Integrations Customer Service •Monitoring •Troubleshooting •Consulting
  48. 48. ©2018 Poseidon Systems, LLC – Proprietary Information 48 USS FORT WORTH (LCS-3) / MRMS Komatsu Haul Trucks Komatsu Rock Crushers Marine Mining IndustrialWind Energy Current Markets

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