Steel mill hydraulic and gearbox oil monitoring
We monitor water, particles and viscosity in rolling-mill hydraulics and gearboxes. You see the oil's condition under heavy load before a stop.
- 1Vibration · Pump bearing
- 2Temperature · Pump bearing
- 3Oil sensor · Return line
- 4Particle sensor · Return line
Monitored equipment
Rolling-mill gearbox, rolling hydraulic unit, continuous-casting hydraulics, cooling-water pump, fan, crane gearbox.
| Topic | In this industry |
|---|---|
| Main oil risk | Heat, water, particles |
| Monitoring goal | Oil condition under heavy load |
| Benefit | Fewer costly downtime hours. |
The right product and monitoring level are defined at the quote stage.
What we measure
In the oil, viscosity, water and moisture, oil ageing, particle contamination (ISO 4406 code) and the wear-metal trend are measured. On the machine, vibration level and temperature are monitored. When a reading moves away from the machine's normal range, the screen changes from green to amber or red. Warning signs and what they mean
What we do not measure: metal identification (which metal a particle is), acid and base number (TAN/TBN) and vibration spectrum analysis (FFT). These tests need a laboratory and a specialist. DataMonitor does not replace them. It works alongside them. The system watches for warning signs and gives early warning. It does not diagnose faults.
Steel & metals FAQ
How is oil cleanliness monitored in rolling-mill hydraulics?
An online particle counter sits on the return or bypass line of the hydraulic unit. It shows oil cleanliness continuously as an ISO 4406 code. The oil sensor is rated to a maximum of 15 bar, so we do not fit it to the high-pressure line. When the code rises, an alarm prompts you to check the filter and the points where dirt gets in.
How can I tell if oil is ageing under high heat?
High heat can speed up oil ageing (oxidation). This shows up in the viscosity and dielectric trend. The oil sensor tracks both values and the oil temperature continuously. It warns you when they drift from normal. With that trend you can plan the oil change instead of waiting for a failure.
Why is unplanned downtime so expensive in a steel plant?
When rolling-mill hydraulics, continuous casting or a cooling-water pump stops, the whole line often stops too. Among large global companies, an hour of unplanned downtime in heavy industry was reported at an average of $187,500 (Siemens, 2024). Your own figure may differ. Spotting warning signs in oil and vibration early helps you move the repair into a planned stop.
A quote for your machine
The machine, the oil in use and the problem are discussed by phone. The right product and monitoring level are defined. The price is sent as a written quote.
- Product recommendation for your machine
- Written quote
- Installation and alarm set-up included