Application Case Study: Online Oil Condition Monitoring System for EH Oil Station at Fangda Special Steel, Nanchang
1. Project Background
In the steel and metallurgical industry, electro-hydraulic (EH) oil systems play a critical role in ensuring the precise and reliable operation of key equipment. EH oil stations typically operate under high pressure, high temperature, and continuous load conditions. As a result, the condition of fire-resistant hydraulic oil directly affects system stability, control accuracy, and operational safety.
At Fangda Special Steel in Nanchang, maintaining the performance of EH fire-resistant oil became increasingly challenging due to complex operating conditions and higher reliability requirements. Traditional periodic oil sampling and laboratory analysis could no longer provide timely insights into oil degradation, contamination, or abnormal wear. To address these challenges, an advanced online oil condition monitoring solution was required.
2. Monitoring Solution Overview
To enhance the reliability and safety of the EH oil station, INZOC deployed the new-generation IOL-H2 Intelligent Online Oil Condition Monitoring System.
Unlike conventional single-parameter oil monitoring devices, the IOL-H2 system adopts a fully digital control architecture and integrates oil condition monitoring with equipment operating status analysis. By combining multiple sensing technologies, the system enables comprehensive, real-time monitoring and supports predictive maintenance strategies for critical industrial assets.
3. System Configuration and Installation
Application Equipment
Site: EH Oil Station, Fangda Special Steel (Nanchang)
Monitoring System: IOL-H2 Intelligent Online Oil Condition Monitoring System
Oil Type
Hydraulic Fluid: AKZO EHC-C Fire-Resistant Oil
Installation Method
Sampling Point: A T-connector installed at the pressure gauge port
Return Line Modification: G1/4 adapter added to the oil return port
This installation approach required minimal modification to the existing piping system and ensured continuous monitoring without interrupting normal plant operation.
4. Monitoring Parameters
The IOL-H2 system provides multi-dimensional monitoring by simultaneously collecting oil condition data and equipment operating parameters, including:
Oil Condition Parameters
Viscosity
Oil Saturation
Water Content (PPM)
Oil Cleanliness / Contamination Level
Total Ferrous Particle Count
Total Non-Ferrous Particle Count
Operating Condition Parameters
Pressure
Vibration
Flow Rate
High-precision sensors enable the system to detect early-stage oil degradation, abnormal wear, and contamination with high sensitivity.
5. Data Transmission and Intelligent Analysis
All monitoring data are transmitted via wired communication to the cloud-based monitoring platform, enabling centralized management and remote access.
With built-in oil aging models and edge computing capability, the IOL-H2 system can analyze data locally and identify abnormal trends in real time, including:
Viscosity degradation
Sudden increases in wear particles
Rising contamination or water content
Abnormal pressure, vibration, or flow fluctuations
This integrated analysis significantly improves fault prediction accuracy and provides actionable insights for maintenance teams.
6. Application Results and Benefits
Since the deployment of the IOL-H2 online oil condition monitoring system, Fangda Special Steel has achieved the following benefits:
Predictive Maintenance Enablement
Continuous monitoring allows early detection of potential failures, reducing unplanned downtime.Improved Fire-Resistant Oil Safety
Real-time monitoring of water content, cleanliness, and wear particles helps prevent EH system failures.Reduced Maintenance Costs
Less reliance on manual sampling and laboratory testing, improving maintenance efficiency.Enhanced Digital Asset Management
Supports the transition toward intelligent operation and maintenance in steel manufacturing.
7. Conclusion
This application case demonstrates that the IOL-H2 Intelligent Online Oil Condition Monitoring System provides a reliable and effective solution for EH oil stations in the steel industry. By integrating oil condition monitoring with equipment operating data, the system delivers real-time visibility into oil health and system performance.
The successful implementation at Fangda Special Steel, Nanchang, offers a scalable reference for fire-resistant hydraulic oil monitoring and predictive maintenance in metallurgical and heavy industrial applications worldwide.
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