DEVELOPMENT OF SENSORS FOR MONITORING WEAR FAILURE

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Optimum Instruments (the client) is an internationally recognized leader in the field of data acquisition (their clients: Suncor and Verizon). Optimum Instruments is developing sensor modules capable of detecting microscopic metallic particulates in any fluid, in real time. The presence of the particulates is both a signature and a promoter of wear within mechanical systems and machines (e.g., engines, pipes, drills). Ultimately, wear leads to a reduction in the performance of the machines, resulting in increased operational and maintenance costs. In this project, we study the wear failure of engines used in drilling operations. This is motivated by feasibility studies by the client with Precision Drilling, an Alberta-based drilling company. We will study wear from the view point of the particulate, as this is what we will measure with the sensors. Fundamentally, our objective is to understand how particulates are formed and evolve as consequence of various wear processes in the engines. We want to link particulate evolution to wear rates, with ultimate goal of controlling particulate size, shape and number of particulates through the design coatings or operating processes that promote particle failure. The reduction of wear will lead to improved economic benefits for our client and, most importantly, provide real-time monitoring of machine failure that will reduce our overall impact on the environment.