Do you know how to recognize grease in your oil? We recently had an experience where an overzealous operator began overgreasing a gearbox bearing and forced grease into the oil in the gear case. The symptoms we saw were a rising particle count with no indication of any change in wear metals. There was also drop in the oil's viscosity. We were so concerned that we pulled the gearbox out of service for an overhaul. That is when we found the grease in the oil. We have counseled our operators to avoid similar problems in the future. (Submitted by Bill Jacobyansky, Maintenance Manager, Guardian Industries. Thanks Bill!)

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From "The Lubrication Field Test and Inspection Guide"

It is not always possible to gain easy access to tanks, housings, casings, sumps and other oil compartments. However, if possible, the internal conditions should be inspected by someone with a trained eye.

The headspace of many tanks maintains a continuous moist fog. This can lead to a buildup of water in the oil, especially accumulations at the tank floor. The moisture in the headspace typically condenses on the ceiling then drips or runs to the bottom, forming puddles. Tanks like this are referred to as “rainmakers.” This can be observed by touching the inside ceiling with your fingers. If moisture is picked up (sometimes rust as well), the risk is great.

Heavy varnishing sometimes occurs inside of tanks and reservoirs. The appearance can range from gold-colored tank walls to thick dark deposits. Occasionally the “Fruit Roll-up” effect is observed when a putty knife is used to peel away a tarry adherent film. A varnish gauge can be used to rate the severity.

More information about the book "The Lubrication Field Test and Inspection Guide"