Post on 11-Apr-2017
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Voelker Sensors, Inc. – VSI
Continuous On-board Oil Condition Monitoring
2016
Overview
• Who is VSI ?• Key Oil Quality Indicators• Technology• Trending – Continuous Monitoring vs.
Sample and Analyze• Applications and Field Data• Customers• Partners
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
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
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)
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
Hydrocarbon Structure
“The most important chemical reaction of a hydrocarbon, for a lubrication engineer or analyst, is oxidation.”
“The most important chemical reaction of a hydrocarbon, for a lubrication engineer or analyst, is oxidation.“
• http://www.machinerylubrication.com/Read/14/lubricant-oxidation
Polarity Measurement
Relative Low Conductivity
Bead Matrix in Clean (nonpolar) Oil
Relative High Conductivity
Bead Matrix in Degraded (polar) Oil
Oil Conductivity
• Direct DC measurement
• Conductivity decreases as conductive additives are
consumed
• Potential for multi-frequency excitation to extend
functionality
• Conductivity measures conductive metals
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
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
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
Sample and Test• Benefits
– Lots of information• Drawbacks
– Sample point– Sample time– Delivery, Test, Report delay– Accuracy of results– Sample frequency
Sampling Two Data Points Create a Straight Line
Continuous Monitoring
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
Mine Installation
C112 Completely Worn OilPolarity
Additive Depletion
Base-stock Breakdown
C112 Completely Worn OilConductivity
Additive Depletion
Wear Metals (slight increase)
C112 Wear Calculation or RULEDetermined from polarity and conductivity measurements
Coolant DetectionExample from Haul Truck
Soot Detection
0 10 20 30 40 50 60 70 80 90 100
110
120
130
140
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160
170
178
150
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190
210
230
250
Sequence III Test - Soot
Polarity
Time - Hrs
Sign
al
A Closer Look at Coolant IntrusionA large leak shows up at 468 hours however, the leak began at 117 hours
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
Cummins Engines
Wear Comparison Identical vehicles, engines and driving conditions, different amounts of wear on
oil as determined by FTIR and VSI sensor
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
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
NC Machine Tools
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
Wind Turbine Gear Box
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
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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)
Generator Set
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
VSI Sensor Integrated with Oil Fill System
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
Level System Data
Oil Sensor Built into Pump
Hydro Electric
Sensor Installed at Hydro
Oil Field Installation
Natural Gas Installation
NG Compressor
50
70
90
110
130
150
170
-10
10
30
50
70
90
110
130
150
Compressor Data
Polarity Conductivity Moisture
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
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
Partners• Cincinnati Machine• Reserve Systems• Emtec• Micron Scientific• Serveron Corp• Eaton?
Conclusion• Production products in the field for 10 years• Detects
– Oil breakdown– Aqueous contamination– Fuel contamination
• Multiple products for multiple applications