Scalable machine protection technology
Continuous monitoring without compromising engine integrity
The use of the developed sensors minimizes the risk of unplanned downtime and failure of the infrastructure used in the continuous operation regime. In particular, this applies to equipment (gas engines, compressors) used in natural gas and, in the future, hydrogen transmission networks where both the maximum availability and reliability are critical and crucial.
Our sensors are designed in such a way that their installation and use do not affect the weakening of the engine structure. The sensors are mounted directly on the connecting rod shoe, where the sensor probe is inserted through a 2 mm hole. The materials used to manufacture the connecting rod shells are designed for temperatures between 110 and 130°C, while the normal operating conditions for a connecting rod bearing are between 60 and 90°C. The purpose of measuring with our sensors is to detect a rapid rise in temperature above normal as quickly as possible and to record the temperature during operation in order to monitor changes and, if necessary, detect unfavourable or dangerous trends.
Failure to detect a sudden temperature change and not switching off the gas engine will result in seizure of the bearing at best, and can also lead to shaft breakage. Each time, however, it leads to unplanned downtime for engine or compressor overhaul.
The closer the probe is placed to the connecting rod pan, the greater the chance of quickly detecting a sudden temperature rise. The time involved is counted in single seconds.
Scalable engine and compressor protection technology
In addition to transmission network equipment, the developed technological solutions can be successfully applied in the protection of high-power engines operating in power plants, on ships or in biogas plants, and wherever it is crucial to minimize the risk of operation and ensure trouble-free continuous operation of the equipment.
Demanding operating conditions such as the presence of oils, combustion products and explosive atmospheres were taken into account when developing the measurement technology.
Thanks to implementation of standard communication protocols such as MODBUS, TCP/IP, measuring system is adapted to cooperation with industrial control-measurement equipment of the customer.
Integration and collection of data acquired by sensors does not require any additional interfaces. By default, the developed measuring system cooperates with cloud solutions (MODBUS -> TCP/IP -> Cloud IIoT).
The developed technology is the subject of patent applications:
- P.439110 “Sensor for remote object temperature measurement and system and method for remote object temperature measurement”
- P.440420 ,,Wireless passive sensor for remote object temperature measurement and system and method for remote object temperature measurement”
Publications
- Mazur, M; Maciejewski, Ł.; Pilecki-Silva, D.: „Contactless Temperature Sensing Utilizing Resonant Antenna Loaded with Thermistor”
Abstract
In this paper the passive sensor allowing contactless temperature measurements is described. The solution is dedicated for industrial rotating equipment like reciprocating engines or compressors operating in hazardous (eg. explosive) environment. Presence of mineral oil particles and combustion products does not allow to use common optical measurement methods. The defined user case requires easy sensor installation and no wired or battery power supply. As any service requires stopping the entire machinery and processes it drives, the simplicity and robustness of the sensor is an advantage. The proposed solution is based on a microstrip resonant antenna operating in 2.4 GHz ISM band and loaded with thermistor directly or via a coaxial line. First, the application is extensively described and the rationale behind the work is presented. Next, the theoretical considerations and simulation results are presented to confirm the concept feasibility. The hazardous environment and other on-site operation factors are taken into account in the design of the sensor and system. The experiments proving concept of operation were conducted and described in that paper. The representative results are revealed and demonstrate a linear relation between measured resonance depth and the sensor temperature. The achieved performance allowed to formulate final conclusions on the developed solution.
Keywords—temperature measurement, wireless, thermistor, antenna
Paper submitted to the 24th International Microwave and Radar Conference, Gdansk 2022, organized under the auspices of the Polish Academy of Sciences and the Institute of Electrical and Electronics Engineers (IEEE).
- Mazur, M.; Maciejewski, Ł.; Wysocka, M.: “Projektowanie pasywnych czujników temperatury na bazie planarnych struktur rezonansowych”
Abstract
A temperature sensor design was developed at Microsensor Sp. z o.o. HFSS software was used during the design work. The license on preferential terms was obtained within the ANSYS Startup Program.
Two variants of the temperature sensor were created:
• multilayer, built on a microwave substrate with metallization layers on both sides,
• single-layer, made of a conductor plate.
The basic assumption of the conducted research was the variation of the resonant frequency of the analyzed structures due to the changes in the linear dimensions of these structures caused by temperature changes.
MESsenger, Nr 12, jesień 2021, MESCo Sp. z o.o.