Efficient problem-solving with lubrication review

To maintain maximum operating reliability in the ISD Dunaferr Cold Rolling Mill unit, the lubricants in equipment with large filling volumes are continuously monitored using MOL LubCheck oil and machine diagnostics. Based on feedback from oil diagnostics reports, it is possible to plan maintenance and repairs and to reduce the downtime caused by breakdowns. Going beyond analysis, MOL-LUB experts also help reveal the root causes of defects, which eventually led to a successful solution for the Georg sheet slitting hydraulic unit at ISD Dunaferr. For this particular machine, oil diagnostics and lubrication technology review allowed the extension of the earlier 2-3 year oil change period not justified by operating conditions and finally, the inherent technical problem was identified, too.

“With the help of MOL-LUB experts, we have managed to eliminate the slitting machine’s recurrent technical issue. Thus we have achieved increased operating reliability and more efficient operation. In the future, I will not hesitate to contact MOL experts with confidence regarding issues with relevance to lubrication, as they provide comprehensive background support.”

Csaba Hekele, mechanical engineer, plant manager,
Cold Rolling Mill,
ISD Dunaferr Zrt.

ISD Dunaferr corporate group is the largest company in the Hungarian domestic steel industry, manufacturing almost 2 million tons of finished products annually. In the CRM, different types of steel strip bands are cut to size on the plant’s Georg slitting line. However, the hydraulic unit of the equipment has not achieved the desired oil change period of 8-10 years, typical for similar feed units, since its commissioning. In view of reducing maintenance costs, samples were sent to the LubCheck oil diagnostics laboratory each year on a regular basis. After a short operating period, the tests readily concluded that the cleanness of the oil was inadequate. Due to the dark brown sediments present in the oil, the laboratory recommended the replacement of the oil filling, and the cleaning and monitoring of the equipment. Given that, initially, no operating issues were observed, the symptoms were treated by relatively frequent oil changes every 2-3 years and the addition of an extra filer unit. However, over the course of that time, operating problems occurred too, as the hydraulic valve parts started to get stuck. The oil sample taken at the time showed high brown sediment content, which in turn suggested local overheating.

ISD Dunaferr experts and MOL-LUB lubrication engineers set out to find the causes together. Although thermovision tests did not pick up local hot spots in the system, the review of the hydraulic system showed that there was a problem with oil heating. The manufacturer originally set up the hydraulic feed system by placing electric heating cartridges in the tank. Even though heating was controlled, the thermostat was able to be switched on for non-moving pumps too, with no fluid flow. Therefore oil could be overheated locally near the heating filaments.

This design defect is remedied with the incorporation of a heating and circulation unit. The reconstruction of the system is also expected to reduce the thermal load of hydraulic oil and sediment generation. It will be possible to maintain the required oil purity, extending the lifetime of the oil filling and increasing equipment availability.

Data sheet

Company:

ISD Dunaferr, Cold Rolling Mill

Industry:

Steel industry

Application:

Georg slitting hydraulic system

Product:

MOL Hydro HME 46

Ask our experts!
Róbertné Nagy

Lubricants Expert
Specialization: industrial lubricants, lubricating greases

rnenagy@mol.hu
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