SENSORJC ODMS Oil Quality Monitoring and Diagnostic System

SENSORJC ODMS Oil Quality Monitoring and Diagnostic System

Using high-quality sensors (with the option to add differential pressure sensors and liquid level switches via expandable interfaces), the system can simultaneously monitor the following parameters in real time:

Contamination Level: Oil contamination refers to the content of solid particulate contaminants per unit volume of oil and the concentration of these contaminants. It is a key indicator for assessing the degree of oil contamination. Currently, there are two primary methods for expressing oil contamination: mass contamination and particle contamination. This system uses particle contamination for measurement and offers multiple contamination grade standards to choose from.

Water Content: Water in oil exists in two states: dissolved water, which forms a homogeneous single phase with the oil; and free water, which forms a separate phase within the oil. Water in oil accelerates corrosion and aging of system components, leading to oil degradation, reduced lubrication performance, severe downtime failures, and damage to mechanical equipment. This system primarily detects dissolved water.

Water Activity: Water activity refers to the ratio of the water content in the oil to the total amount of water it can hold, with a range of 0 to 1 aw. If aw < 1, it indicates that the oil is not yet saturated with water; if aw > 1, it indicates that the oil is saturated, and the excess water has become free water. The higher the oil temperature, the higher the aw value.

Viscosity: The ratio of a fluid’s dynamic viscosity (μ) to its density (ρ) at the same temperature is known as kinematic viscosity. It serves as a measure of the fluid’s resistance to flow under the influence of gravity. The system calculates changes in viscosity by analyzing real-time data on new oil viscosity and sensor readings, thereby diagnosing oil degradation, deterioration, and contamination.

Density: The mass of a substance per unit volume; the unit of density is grams per cubic centimeter (g/cm³); In the International System of Units (SI) and China’s legal units of measurement, the unit of density is kilograms per cubic meter.

The system primarily consists of data acquisition, system piping, data acquisition terminals, display terminals (HMI), and a cloud-based system.

Data Acquisition: Oil contamination sensors, oil dielectric constant sensors, viscosity sensors, density sensors, temperature sensors, water content sensors, differential pressure sensors, and liquid level sensors

System Piping: A rational oil circulation system is designed according to requirements, typically using a bypass method.

Data Acquisition Terminal: Collects data and transmits it to remote or local destinations.

Display Terminal: Displays and analyzes collected data, presenting both data and analysis results locally via the HMI and on cloud-based PCs.

System Features

Low Maintenance: All modules within the system are designed to withstand industrial field environments, significantly extending the system’s maintenance intervals.

Full-Line Online Calibration: All sensors undergo relevant calibration tests prior to installation, ensuring maximum measurement accuracy.

Remote Data Transmission: The system can transmit data in real-time to cloud servers via a 4G network using a remote data processing module. The communication module is equipped with a State Grid-certified security chip and has passed testing and certification by the State Electric Power Research Institute. It supports integration with the State Grid key management system, meeting the State Grid’s security and confidentiality requirements for system integration.

Flexible operation: Equipped with a robust data acquisition and processing system, the system features multiple analog and digital input/output interfaces. It supports connection to multiple sensor groups and enables fieldbus connectivity (including communication with third-party host computers), making system operation more convenient and flexible.

Highly Expandable: The system design includes reserved points for connecting to end-user tank level and filter differential pressure signals.

Excellent System Stability: Key system components utilize high-quality sensors, maximizing system stability. The system can operate continuously 24 hours a day without interruption and requires no manual maintenance.

Key Features

Monitoring Parameters: Oil contamination level, water content, dielectric constant, viscosity, density, temperature, (filter life and liquid level detection are optional)

Display Features: Fully Chinese interface; displays real-time monitoring values, real-time data curves, historical data curves, and alarm screens.

Data Transmission: System data can be uploaded to the cloud via 4G networks and subsequently transferred to the user’s end for processing and analysis.

Highly Expandable: Can communicate with third-party host computers according to user requirements; supported communication interface: Modbus TCP protocol.

System Specifications

Sensor Parameters

Fluid Property Sensors

Capable of directly and simultaneously measuring the viscosity, density, dielectric constant, and temperature of fluids.

System Installation

Installation configurations include pipeline installation and wiring installation. Pipeline installation involves the oil supply line, return line, and power connection. A schematic diagram of the system’s basic installation configuration is shown below:

Enclosure Installation

•   The entire system is secured within the enclosure using M10 studs. Users may select M10 screws of an appropriate size based on their specific circumstances. The specific dimensions are shown in the figure below:

Local Control System and HMI

To ensure both control and monitoring capabilities, this monitoring system employs a stable and reliable PLC control system along with a stable and reliable smart terminal-protocol converter to collect sensor parameters such as oil quality, differential pressure, and liquid level.

•   The HMI provides easy access to after-sales contact information and website details

•   Parameter settings and alarm thresholds can be configured in the main menu

•   During operation, the system displays various parameter information or fault alarm notifications

An interface for a filter differential pressure sensor is provided. By selecting an appropriate differential pressure sensor, the system can display the filter element’s remaining service life, current differential pressure values, and output differential pressure alarms. An interface for a tank level sensor is also provided; by connecting a level sensor, the system can display the current tank level and output high/low level alarms.

System Cloud Platform and Mobile App

       The system cloud platform developed by Beijing Jiecheng IoT Technology Co., Ltd. provides end-users with digital solutions based on cloud architecture, industrial IoT, and big data technology, covering the following functional modules:

— Real-time equipment status monitoring and historical data logging

— Equipment alarm monitoring and SMS notifications

— Equipment asset management

— Equipment maintenance management

— Work order management

The goal is to help end-users improve the operational and maintenance management of their equipment assets, enhance equipment performance, increase production efficiency, and reduce costs.