Limitations of Particle Counting for Oil Analysis Online

Particle counting is widely used in machine oil systems as a measurement of oil degradation. It is relatively inexpensive and it works reliably to detect particles, after damage has been done. However this is not sufficient for large, expensive assets such as large gearboxes, especially if they are in remote locations such as offshore wind farms.  

Customers wish to identify problems before damage is done. Rigid inspection intervals and responsive action to damage is neither time nor cost effective.

Proactive response to changes in the oil system can lead to huge savings and achieve theoretical lifetimes for components. Service and replacement of parts can be accurately predicted. It was this thinking that led cmc Instruments GmbH to work with academia to develop the WearSens® system to solve problems like this.

WearSens® can control the proper operating conditions in oil lubrication systems and detect changes in the system before damage occurs. It is a condition monitoring system for oil quality, more sensitive and with lower detection limits than previously seen. It is more sensitive than laboratory analysis and earlier than vibration or particle counting technologies. The work of oil additives does not mask the problem until it is too late either.

The WearSens® sensor measures oil aging via elements of the complex impedance of oils, in particular conductivity and permittivity, together with temperature. Oil aging results from degradation of the oil and products of contamination in the oil. A unique, patented, self-learning, adaptive temperature compensation algorithm allows values to be compared with accuracy. Together these two temperature compensated measurements give a clear picture of the health of the ‘oil-machine’ system.

Three good reasons for using the unique WearSens®  system above all others,

Sustainability - Optimized cooling lubricant composition minimizes energy consumption, reduces costs and preserves the environment.

Optimization - Continuous analysis of the lubricant performance with WearSens® provides essential information about the current machine condition, such as additive consumption and critical operating states. The realtime data from WearSens® enables optimization of the cooling lubricant composition (oil and additives).

Extended Lifetime - Continuous condition monitoring of lubricant quality with WearSens® allows a long-term stable and reliable machine operation with minimum maintenance, only when it is needed. No need for expensive lab analysis of the oil at short intervals.

Applications for this new technology include all large oil lubricated and oil insulated systems. For instance, high performance grinding processes, turbines including offshore wind turbines, compressor systems, cogen electricity plants as well as high voltage transformers.

WearSens® is easy to install and inexpensive to retro-fit. The decentralised, web based monitoring system makes results available anywhere in the world. It can be employed as a stand-alone unit or as part of a more comprehensive condition monitoring system.