Online Monitoring System

WOS is an industrial online oil analysis system that continuously monitors lubricant and transformer oil health — delivering lab-grade metrics in real time so maintenance teams can act before failures occur. Designed for thermal power plants and heavy industries, WOS eliminates frequent lab sampling, provides remote diagnostics, and preserves historical data for trend analysis and audit compliance.

Key Features

Simultaneous measurement of up to 10 oil parameters: oil density, dynamic & kinetic viscosity, temperature, dielectric constant (oil quality), moisture (ppm), water activity, free water (ppm), particle counts (NAS/ISO, configurable), + wear debris classification for Fe and Non-Fe.
7” touch screen local UI for configuration & viewing trends.
Local storage (memory card) with up to 5 years of historical oil data retention.
Data output via RS485 and cloud visualization for remote access & trending.
Customizable parameter sets for gear oil, hydraulic oil, transformer oil and other fluids.

Technical Specifications

Parameter	Value / Capability
Parameters measured	10 (density, dynamic/kinetic viscosity, temperature, dielectric constant, moisture ppm, water activity, free water ppm, particle count NAS/ISO, wear debris categories).
Particle size channels	1, 2, 5, 10, 15, 25, 50, 100 μm.
Wear debris sizing	Fe: 40–99 μm, 100–199 μm, 200–299 μm, 300–399 μm, ≥400 μm; Non-Fe: >150–199 μm, 200–299 μm, 300–399 μm, 400–499 μm, ≥500 μm.
UI	7″ Touchscreen.
Data output	RS485, Cloud visualization.
Data retention	Up to 5 years (local memory).

Industry Applications — use cases & recommended deployments

Power Plants (Transformer oil): Continuous dielectric & moisture monitoring flags insulation degradation early — preventing transformer failures and catastrophic outages.
Steel & Heavy Engineering: Gearboxes and hydraulic systems in mills are protected through particle counts & wear debris analysis (predicts bearing/gear wear).
Cement & Mining: Monitor lubricants in crushers, mills and conveyors where contamination and water ingress are common; early detection avoids line stoppages.
Transformer OEM / Utilities: Use WOS for condition-based transformer maintenance and to extend overhaul intervals when oil health is good.

Benefits & Typical ROI

Reduce oil testing costs and lab turnaround time (no frequent sampling).
Prevent catastrophic equipment damage and associated production loss.
Typical payback: often within 6–18 months depending on asset criticality and cost of downtime (site pilot → scale-up). (Tailor with case numbers during discovery.)

Integration & Installation Notes

Plug into existing lube/oil filtration lines or sample points; requires mounting, power & RS485 network.
Can be configured for transformer/hydraulic/gear oil parameter sets.

Maintenance & Calibration

Routine cleaning and periodic sensor validation recommended (frequency depends on site operating conditions). For precise calibration intervals, WRT India provides calibration services and SOPs on deployment.

WOS — FAQs

What parameters does WOS measure?

WOS measures oil density, dynamic & kinetic viscosity, temperature, dielectric constant, moisture (ppm), water activity, free water, particle counts (NAS/ISO), and wear debris classification.

Does WOS remove the need for lab testing?

WOS is designed to reduce dependence on frequent lab tests by providing continuous, lab-grade insights, but periodic lab validation is recommended during initial commissioning.

What particle sizes are reported?

Particle size channels include 1,2,5,10,15,25,50,100 μm and NAS/ISO reporting is supported.

How is data accessed remotely?

Data can be accessed via RS485 output and cloud visualization tools provided as part of the platform.

How much data is stored locally?

Memory card stores up to 5 years of oil data.

Can parameters be customized?

Yes — parameter selection is configurable for different oil types and monitoring goals.

What environmental conditions can WOS handle?

WOS is engineered for industrial use and harsh environments; exact IP rating and ambient specs available on request.

What’s the power requirement?

Power requirements and installation checklist are provided in the hardware datasheet upon inquiry.

Is training provided?

Yes — deployment packages include operator training, dashboard walkthroughs and initial analytics setup.

Can WOS integrate with plant DCS/SCADA?

Yes — via RS485 and standard integration methods (integration mapping performed during implementation).