Neptunus Power Plant Services Pvt. Ltd.
Contact Us

Real-Time
Oil Condition
Monitoring Systems
& Sensors

Get a Quote

What is Oil Condition Monitoring?

Oil condition monitoring is the process of assessing the quality of oil used in machinery or engines. This involves monitoring the physical properties of the oil, such as viscosity, acidity, and presence of contaminants, in order to determine the oil’s condition and any potential issues that could affect the performance of the machinery.

Challenges Faced In The Inspection Of Oil Quality

  • 1. No Quantifiable Way To Measure Oil Quality:
    Relying on subjective visual checks or lagging offline laboratory analysis is costly, slows down operational response times, and misses early-stage wear anomalies.
  • 2. Lack of Continuous, Real-Time Oil Analysis:
    Most legacy operations struggle to catch rapid, catastrophic failure events due to a lack of highly sensitive, online oil monitoring systems built for severe operating environments.
  • 3. Oil Change Schedules Often Lack Qualitative Evidence:
    Performing oil dumps based purely on operational hours or static calendar milestones leads to premature waste of pristine lubricants or, conversely, running engines on completely unserviceable oil.
  • 4. Complex, Non-Standard Configurations:
    Integrating multiple disparate sensors for moisture, particles, and TAN/TBN metrics can cause significant machine downtime and complex software integration issues.

Send in your Enquiry for a Quote

Get a Quote

Why choose Neptunus?

3 Decades of Service Excellence

Engine & Propulsion
End-to-End Solutions

2500+ Successful Projects
Delivered Worldwide

Trusted by 100+
Satisfied Customers

Dedicated Experts to
Address Emergencies

Neptunus’ Oil Condition Monitoring Solution

The Neptunus real-time oil condition monitoring system is designed to monitor the quality of oil used in engines or machines and detect changes. The system is calibrated for a given type of oil and can detect Oil Quality Change Basis 22 Parameters.

Our oil condition monitoring system leverages proprietary Full Spectrum Holistic (FSH™) technology to analyze the electro-chemical properties of the oil in real-time to an accuracy of 0.001%. Unlike traditional sensors that only look at a single metric like the dielectric constant, FSH™ captures all wear and contamination elements simultaneously. Any change in any of the parameters of the oil – viscosity, particle contamination, dilution, additive depletion, flash point, etc. will change the constant value and alert the user. Long-term trends can be established, giving the operator insight into the health of the equipment itself. We have seen that as the mean time to overhaul decreases, the oil deteriorates faster. The approach is simple and most accurate: If the single sensor indicates that the oil is suitable for the manufacturer’s specified hours of operation, no action is needed. Only when the oil deteriorates before the expected timeframe, should samples be drawn and sent for detailed lab analysis.

Failure modes detected by our Oil Condition Monitoring Sensor

  • TAN changes (Total acid number)
  • TBN changes (Total base number)
  • Additive depletion
  • Fuel dilution
  • Soot ingress
  • Particulate contamination
  • Water ingress
  • Fluids or chemical contamination
  • Viscosity changes
  • Incorrect oil changes

Send in your Enquiry for a Quote

Get a Quote

Benefits of Neptunus’ Oil Condition Monitoring Solution

  • 1. Real-Time Oil Condition Monitoring Sensor:
    Our oil monitoring system uses a sensor that continuously monitors the quality of oil in machinery or engines, providing real-time data on the condition of the oil.
  • 2. Senses Oil Quality Change Basis 22 Parameters:
    The system is able to detect changes in oil quality basis 22 different parameters, providing a comprehensive view of the oil's condition.
  • 3. Detect Time To Change Oil:
    Based on the state of the oil and the operating circumstances of the machines, the system can accurately decide when it's time to change the oil.
  • 4. Prevents Costly Repairs:
    It can identify potential issues before they become significant problems by providing real-time data on the status of the oil. This tactic saves time, money, and resources that might otherwise be spent on costly oil-related repairs.
  • 5. Improves Equipment Reliability And Lifespan:
    By monitoring the condition of the oil and detecting potential problems early on, the Neptunus system can help improve the reliability and lifespan of the equipment. This can reduce downtime and maintenance costs over the long term.

Features of the Neptunus Oil Condition Monitoring System

  • 1. TDN Indicator To Know Your Oil Health:
    Fresh oil drops down from a baseline 1200 scale. The official End of Life TDN marker is typically 750.
    An extreme failure mode or a state where the oil is completely unserviceable drops the scale below 350 TDN (not 300). Specific failure triggers cause spikes or rapid drops: Fuel contamination spikes TDN to +1060, and insufficient oil spikes it to +1140.
  • 2. Detects Changes in TBN, Viscosity, Moisture, TAN Levels, Moisture, And Fuel:
    Our oil condition monitoring system is able to detect changes in a variety of oil properties, including total base number (TBN), viscosity, moisture, and total acid number (TAN). This allows users to monitor the quality and performance of oil over time and detect any changes that could indicate a problem. Changes in the above parameters are reflected in Tan Delta Number.
  • 3. Robust Sensor Available For Atex Environment:
    The Neptunus system includes a robust sensor that is designed for use in hazardous environments, such as those with explosive gases or dust. This allows users to monitor the condition of their oil in a wide range of settings.
  • 4. Local, Bluetooth, And Cloud Data Dashboard:
    Oil condition monitoring provides valuable insights into the health of oil, with the ability to visualize data in various ways. This includes real-time monitoring through a local display, remote monitoring through Bluetooth connectivity, and comprehensive trend analysis on the cloud.

Send in your Enquiry for a Quote

Get a Quote

Real-Time Oil Condition Monitoring By Neptunus

With a real-time oil condition monitoring system, you can access oil health data from anywhere, allowing you to keep an eye on the performance of your machinery even when you’re not on site.

The Neptunus system provides users with multiple remote ways to access and view their oil condition data, including on a local display, through Bluetooth connectivity to a mobile device, and on a cloud-based platform.

With our remote condition monitoring, it is easy for users to monitor their oil condition data in real time and make informed decisions about maintenance and repairs.

Installation & Setup Of Oil Condition Monitoring Solution

Our oil condition monitoring comes with 3 easy steps:
  • Step 1 - CADS Software Installation:
    We deploy the Tan Delta Configuration & Data Software (CADS) on your control interface, setting up secure communication pathways between your machinery panels, local loggers, or cloud servers.
  • Step 2 - Digital Oil Profile Configuration:
    Our sensors do not require messy, physical fluid calibrations on site. Instead, the sensor is linked to a PC via a programming cable, and the exact matching Tan Delta Oil Profile is selected from a comprehensive digital database. This programs the sensor configuration to match the exact brand and formula of your specific mineral or synthetic oil.
  • Step 3 - Display Unit & Alarm Configuration:
    Finally, our engineers set up your local interfaces, telemetry networks, or PLC outputs. We configure your specific alert parameters for Advanced Fault Detection (AFD™), ensuring your operational teams receive automated warnings the moment anomalous wear rates are logged.

From Detection to Prevention: Our OQMS Addresses the Bigger Problem

Oil condition monitoring is a crucial process that helps detect issues in the oil and provides early warnings, allowing for prompt corrective action. However, while this method is effective at identifying problems, it doesn’t address the underlying issue of oil filtration. Changing oil frequently is expensive, and a Kidney Loop Filtration System is essential to maintaining the quality of the oil. That’s where our Oil Quality Management Solution (OQMS) comes in. With OQMS, you can ensure that your oil remains in optimal condition for longer periods, reducing costs and improving machine reliability.

Send in your Enquiry for a Quote

Get a Quote

Case Studies that we have worked on

FAQs

Oil condition monitoring is the process of assessing the quality of oil used in machinery or engines. It involves monitoring the oil’s physical properties, such as viscosity, acidity, and contaminants, to determine its condition and identify any potential issues that could affect machinery performance.
Oil condition monitoring is essential because it helps detect potential issues early, preventing costly repairs, reducing downtime, and ensuring the reliability and longevity of machinery. By maintaining optimal oil quality, you can improve overall equipment performance.
An oil control monitoring system uses sensors to measure the oil’s physical and chemical properties in real-time. It collects data on parameters such as viscosity, TBN, TAN, and moisture levels, which is then analyzed to determine the oil’s condition and predict maintenance needs.
Yes, the Neptunus oil condition monitoring system includes a robust sensor for hazardous environments, such as those with explosive gases or dust. This feature ensures reliable oil monitoring in a wide range of settings.
Oil condition data can be accessed and visualized in multiple ways: through a local display, and a cloud-based platform.
The installation involves three steps: software installation, oil sensor calibration with oil, and display unit configuration. These steps ensure accurate real-time monitoring and data collection for effective maintenance decisions.
By providing real-time data on oil quality, the Neptunus system detects potential issues early, allowing for prompt corrective action. This proactive approach prevents significant problems, saving time, money, and resources that would be spent on repairs.
Oil condition monitoring detects issues and provides early warnings, while oil filtration addresses the underlying problem by maintaining oil quality. Frequent oil changes can be costly, so combining condition monitoring with filtration ensures optimal oil condition, reducing costs and improving machinery reliability.
This page has been technically reviewed by the engineering leadership team at Neptunus Power Plant Services Pvt. Ltd.
Last Updated: August 2026

Fill in Details for a Quote

*The demo link will be shared only if a valid work or company email ID is provided.
*The demo link will be shared only if a valid work or company email ID is provided.