ANALEXrs range of wear sensors are robust on-line machinery condition sensors. They can be used where ever real-time monitoring of metallic content of a fluid is required. The factory calibrated sensors posses high reliability with long term stability which eliminates the need for re-calibration.
The sensors reduce the overall operating cost of machinery as part of a proactive maintenance programme, with associated reductions of routine checks, lab testing and failure related downtime.
The sensors can operate independently, but have been designed with several interface options for integrating into existing control systems, condition monitoring networks and software.
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The ANALEXrs suite of instruments has been designed to accomplish the three primary objectives of oil analysis
• Ensure lubricant condition
• Control contamination
• Detect and analyse wear debris
Replicating this on a single sensor is impossible for the foreseeable future and as such the sensor suite has been developed to offer real-time monitoring on critical plant such as a wind turbine gearbox. Using its own piston pump the sensor suite makes frequent inspections of remote oil and machine health a feasible option. The risk of sampling error is eliminated and data from the sensors can be streamed via any network system, allowing remote monitoring and more effective maintenance planning. It goes beyond the normal protection systems; it addresses the root cause of lubricant and machine failure.
Designed for mounting into the lubrication system of a machine, the suite reports metallic ferrous wear debris, the condition of the oil, including contamination and the Moisture content of the oil. Housed in a robust box it includes the following three sensors;
Total Ferrous Sensor (Piston Version)
Moisture Sensor
Oil Condition Sensor
Options Include
FG-K16521-KW – Standard Sensor Suite
FG-K16567-KW – Heated Sensor Suite
Features:
Benefits:
Financial benefits example: Wind Turbine gearbox
As wind turbines become larger and more complex, the power produced from them increases but so can the maintenance costs. There have been many well publicised failure events which have been very costly to the owners, manufacturers and to the general perception of wind as a renewable energy source. One such event was the failure of all 30 2MW turbines installed at Scroby sands in the UK. All failures occurred within one year of installation. Using data provided from a gearbox manufacturer, the total cost of removing, overhauling and reinstalling a gear box can be up to €450,000*. This can be due to the turbines inaccessibility, crane rental, man hours used and loss of earnings on the turbine. If sensor equipment detects a potentially serious problem before it becomes too advanced and the repair could happen without the need for a crane then the repair bill could cost less then half that. If a sensor detected oil contamination such as water in the oil or oxidation which could lead to a serious failure then the turbine could be saved by just replacing the oil this could be a €450,000 saving.
* Data taken from “the industrial gearbox life cycle and the total cost of ownership” by Gary Bills – Hansen Transmissions – BGA Gears 2006 Seminar
All ANALEXrs Sensors have been thoroughly tested for vibration and shock condtions. Click here to download certificates
Ambient operating temperature: | 0 to 70°C ( 32 - 158°F) |
Ambient operating temperature Heated version: | -20°C to 70°C |
Analogue Communication Interfaces: | 4-20mA |
Detection: | 0-2000 parts per million [ppm] Un-combined ferrous debris by weight, Oil Quality Units – Index Scale, 0-100% Relative Humidity, -20 – 120°C Temperature |
Digital Communication Interfaces: | RS232, RS485, CAN Bus, Wireless LAN 802.11b |
Fluid Compatibility: | Petroleum, synthetic oils – not ester based. |
IP rating: | IP65 |
Max system fluid pressure: | 10 Bar |
Maximum fluid viscosity: | 350 cst @40°C |
Permitted Fluid temperatures : | 10 to 70°C (50 – 158°F) |
Power consumption : | 0.8 A |
Power Input: | 18 – 30V DC |
Weight: | 15kg |
Want to know more?
Contact Kittiwake here
For other related products see also:
ANALEXrs Moisture Sensor
ANALEXrs Oil Condition Sensor
ANALEXrs Online Sensor Suite
ANALEXrs Particle Content Sensor
ANALEXrs Total Ferrous Debris Sensor
Download PDF of ANALEXrs Sensors Brochure 