vsi oil sensor overview
TRANSCRIPT
![Page 1: VSI Oil Sensor Overview](https://reader035.vdocuments.net/reader035/viewer/2022062311/58ec94871a28abc9458b456b/html5/thumbnails/1.jpg)
Voelker Sensors, Inc. – VSI
Continuous On-board Oil Condition Monitoring
2016
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Overview
• Who is VSI ?• Key Oil Quality Indicators• Technology• Trending – Continuous Monitoring vs.
Sample and Analyze• Applications and Field Data• Customers• Partners
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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
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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
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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)
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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
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Hydrocarbon Structure
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“The most important chemical reaction of a hydrocarbon, for a lubrication engineer or analyst, is oxidation.”
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“The most important chemical reaction of a hydrocarbon, for a lubrication engineer or analyst, is oxidation.“
• http://www.machinerylubrication.com/Read/14/lubricant-oxidation
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Polarity Measurement
Relative Low Conductivity
Bead Matrix in Clean (nonpolar) Oil
Relative High Conductivity
Bead Matrix in Degraded (polar) Oil
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Oil Conductivity
• Direct DC measurement
• Conductivity decreases as conductive additives are
consumed
• Potential for multi-frequency excitation to extend
functionality
• Conductivity measures conductive metals
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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
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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
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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
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Sample and Test• Benefits
– Lots of information• Drawbacks
– Sample point– Sample time– Delivery, Test, Report delay– Accuracy of results– Sample frequency
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Sampling Two Data Points Create a Straight Line
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Continuous Monitoring
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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
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Mine Installation
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C112 Completely Worn OilPolarity
Additive Depletion
Base-stock Breakdown
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C112 Completely Worn OilConductivity
Additive Depletion
Wear Metals (slight increase)
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C112 Wear Calculation or RULEDetermined from polarity and conductivity measurements
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Coolant DetectionExample from Haul Truck
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Soot Detection
0 10 20 30 40 50 60 70 80 90 100
110
120
130
140
150
160
170
178
150
170
190
210
230
250
Sequence III Test - Soot
Polarity
Time - Hrs
Sign
al
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A Closer Look at Coolant IntrusionA large leak shows up at 468 hours however, the leak began at 117 hours
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Fuel Detection in the Field
• Lab Reports 0.2 % fuel on 3/4/2012
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 AM0
50
100
150
200
250
Fuel Signal Truck 343
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Cummins Engines
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Wear Comparison Identical vehicles, engines and driving conditions, different amounts of wear on
oil as determined by FTIR and VSI sensor
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IR/VSI Comparison
0 5000 10000 15000 20000 25000 30000 35000 40000 450000
5
10
15
20
25
30
35
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
531 IR - OX532 IR Ox531 VSI - Ox532 VSI Ox
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Transmission Fluid
0 6 22 44 66 84 90 105
128
133
139
145
151
163
0
20
40
60
80
100
120
140
160
180
Synthetic Transmission Oil
Polarity
Conductivity
Hours
Cond
uctiv
ity Oil Added
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NC Machine Tools
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NC Machine Oils
20 25 30 35 40 45 500
5
10
15
20
25
30
35
40
45
50
Machine Oils
Clean Oil
Used Oil #5
Used oil # 4
Temperature C
Pola
rity
Sign
al
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Wind Turbine Gear Box
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Wind Turbine Gear Oil
2013/02/03/20:45
2013/02/13/12:45
2013/02/23/2:45
2013/03/03/3:45
2013/03/08/16:45
2013/03/15/13:45
2013/03/26/1:45
2013/04/03/17:45
2013/04/10/9:45
2013/04/15/7:45
2013/04/23/0:45
2013/04/26/19:45
2013/04/30/9:45
2013/05/07/12:45
2013/05/11/2:45
2013/05/15/3:45
2013/05/19/3:45
2013/05/23/3:45
2013/05/27/16:45
2013/05/30/20:45
2013/06/04/10:45
2013/06/06/16:45
2013/06/08/7:45
2013/06/13/1:45
2013/06/14/17:45
2013/06/18/5:45
2013/06/26/11:45
2013/06/28/12:45
2013/06/29/21:45
2013/07/04/20:45
0
50
100
150
200
250
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
TAN (mg KOH/g)Water (PPM)
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Generator Set
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Gen Set Data
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 0:000
50
100
150
200
250
Power Box - PNG
Cond
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VSI Sensor Integrated with Oil Fill System
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Reburn System with Sensor
4/1/2012 0:00 4/5/2012 0:00 4/9/2012 0:00 4/13/2012 0:00 4/17/2012 0:000
20
40
60
80
100
120
140
0
5
10
15
20
25
30
35
40
45
PolarityConductivityCoolantTemperature
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Level System Data
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Oil Sensor Built into Pump
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Hydro Electric
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Sensor Installed at Hydro
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Oil Field Installation
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Natural Gas Installation
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NG Compressor
50
70
90
110
130
150
170
-10
10
30
50
70
90
110
130
150
Compressor Data
Polarity Conductivity Moisture
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NG Engine Data
40
50
60
70
80
90
100
110
120
130
0
1
2
3
4
5
6
7
8
9
10
Engine Data
Polarity Conductivity Water
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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
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Partners• Cincinnati Machine• Reserve Systems• Emtec• Micron Scientific• Serveron Corp• Eaton?
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Conclusion• Production products in the field for 10 years• Detects
– Oil breakdown– Aqueous contamination– Fuel contamination
• Multiple products for multiple applications