For a better maintenance program, you can install see-through distribution blocks for your centralized lubrication systems. This makes it easier to track down blockages or leaks that could degrade the life of the equipment and save your maintenance budget! (Ryan Schlumbaum, Maintenance Supervisor, Busch Mfg.)

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From the book "Plant and Machinery Failure Prevention":

In case of ball bearing failures, one of the first things to check is the quality of the grease used. If the bearing has seized, the quality of grease in similar bearings may need to be checked. Bearings with a service due for grease replacement should be checked. The feel or consistency of the grease removed from the bearings should be compared with that of new grease.

If the grease feels harder, drier or less slippery, or if oil droplets are seen in bearing overflow vents, it is an indication that some of the suspended oil has been churned out and the grease is unsuitable for the application. If the grease is of the approved brands the whole issue of approval of the brand should be reopened and the manufacturer of the grease should be notified.

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"I have several gearboxes that are mounted in a steamy environment. My problem is we keep getting water in our gearboxes. The gearboxes do have a vent. To keep from having gearbox failures, we flush the oil out of the gearboxes once a month. With the price of oil, this is getting very expensive. What is the best way to correct this problem? "

Assuming the water is coming through the vent due to the humid environment in which these gearboxes are working rather than through the seal or due to the effects of wash down, there are several options to consider. The first is to pipe out the vent to a less humid environment and use a water removal or exclusion breather such as a standard desiccant breather.

If this is not possible, the best option is to use an expansion chamber, combination expansion/desiccating breather or membrane-style water exclusion breather so that water cannot enter the gearbox through the breather/vent. In addition, regular, routine visual inspections should be performed to identify signs of water ingression.

If water is observed, it may not always be necessary to change oil. You may be able to remove the water using a water-removing filter element or dialysis-style water removal system. Depending on the size and criticality of these gearboxes, you may elect to use quick-connects to allow a portable unit to be periodically hooked-up, or if they are large enough, a dedicated off-line water removal and particle filter system may be justifiable for each gearbox.

Bob Scott, Noria Corporation

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