Proposal for an Online Water Content Monitoring System for JCW-1 Rolling Mill Lubricating Oil

JCW-1 Online Water Content Monitoring System for Rolling Mill Lubricating Oil

Accurately measures water content in oil (ppm)

Measurement range: 0–15%

Includes calibration software for easy customer calibration

Plug-in design, compact and space-saving, for easy installation

Measures various oil samples, including lubricating oil, hydraulic oil, and insulating oil

Built-in temperature sensor for high-precision temperature compensation

Long-term stable operation in harsh environments

Optional on-site display instruments and LCD control screens

Contact: 18611648453 (WeChat ID same as phone number)

Since high-speed wire rod production lines use large amounts of high-pressure water for cooling, cooling water inevitably enters the rolling mill lubrication system. This necessitates prompt action upon detecting cooling water ingress to minimize the risk of emulsion formation. For oil-film bearing lubricants used in high-speed wire rod mills, a water content exceeding 0.5% significantly increases the likelihood of bearing failure; if the water content exceeds 1%, rolling bearing failure is highly likely to occur within a short period.

Currently, the lubrication system for wire rod mills is a centralized thin-film lubrication system, typically configured with dual oil tanks. Oil is supplied by a lubrication pump station, flows through the oil-film bearings of the rolling mill, and then returns via the mill’s return lines to a common return line leading back to the oil tanks. This requires monitoring the lubrication of each rolling mill and the oil tanks to promptly identify which rolling mill is leaking water and whether the water content in the main oil tank exceeds the limit, so that timely repairs can be made, the standby oil tank can be activated, and the tank dewatering device can be activated.

1.2 Sensor Selection

This solution utilizes the JCW-1624 online oil moisture monitoring sensor, independently developed and manufactured by Beijing Jiecheng IoT Technology Co., Ltd. The JCW-1624 is a new type of online oil moisture content detection sensor based on the dielectric constant method. The sensor features a unique dual-symmetrical electrode structure, utilizes high-precision dielectric constant detection technology, and incorporates temperature compensation technology along with extensive experience in moisture calibration to accurately detect changes in oil moisture content. It is widely applicable for online moisture content monitoring of crude oil and lubricating oil across multiple sectors, including petroleum extraction, smelting, power generation, steel, chemicals, and marine gearboxes.

Sensor Technical Specifications

Mechanical Installation of Sensors

This analyzer is typically installed vertically, with the oil flowing from bottom to top, which prevents the accumulation of bubbles in the measurement zone. An appropriate flow rate must be maintained to prevent water separation in the measurement zone. For crude oil, the minimum flow rate is 4 USGPM; for high-wax-content oils, the flow rate must be at least 20 GPM to prevent wax buildup in the sensor.

For sensor installation, you can choose to connect a large-bore sensor in series with the main pipeline or a small-bore sensor in parallel with the main pipeline. It is essential to ensure that the sample flow accurately reflects the actual conditions of the fluid in the main pipeline.

1.3 Smart Terminal - Protocol Converter

Product Name: Smart Terminal - Protocol Converter

Model: JCS-1000

Function Description: Industrial equipment networking, protocol conversion, data acquisition, etc. Applications: Power distribution automation, factory automation, IoT, smart home, photovoltaic power generation, smart security, energy management, etc. Interface Description: 1x 10M/100M port, 2x RS232/RS485 composite serial ports, 9–36 VDC power input, port serial optical transceiver

1.4 Introduction to the System Cloud Platform and Mobile App

The system cloud platform developed by Beijing Jiecheng IoT Technology Co., Ltd. provides end-users with digital solutions based on cloud architecture, industrial IoT, and big data technology, covering the following functional modules:

— Real-time monitoring of device status and historical data logging

— Device alarm monitoring

— Device maintenance management

The goal is to help end-users improve the operational and maintenance management of their equipment assets, enhance device performance, increase production efficiency, and reduce costs.

1.4.1 Dedicated Website, Data Isolation

•   Provides a dedicated account for each end-user

•   Data isolation ensures security and reliability

•   Comprehensive user role and permission management

1.4.2 Powerful Features, Intuitive Interface

•   Provides real-time and historical data

•   Displays current and historical alarm information

•   Manages equipment maintenance

•   The backend offers complete and reliable user role and permission management capabilities

Remote Monitoring Platform (Customizable)

1.4.3 PC Web Interface

1.4.3.1 Multi-point Map Navigation for an At-a-Glance View of Industrial Control and Alarms

•   Displays the alarm status of each device

•   Digital display of key metrics

1.4.3.2 APP-ALPHA System

• APP-ALPHA is a system that revolutionizes traditional server-based data systems

• ALPHA directly reads data that is valid and accurately reflects on-site conditions

• Features a window for entering equipment operating status information on-site

• An effective pathway for establishing diagnostic models

• Basis for diagnostic experts’ assessments

• A database for inspection personnel, enabling efficient inspection tracking

• With a tablet in hand, equipment health history is traceable

• Can be used to calibrate sensors connected to the system

APP-ALPHA System Interface (Customizable)

II. Case Study: Online Monitoring of Moisture Content in Rolling Mill Lubricating Oil at a Special Steel Group in Shandong

Steel production line