In water and wastewater treatment facilities, proper lubrication of bearings, gears, and shafts is essential to prolong the service life of pumps, blowers, and mixers. Lubricants degrade over time and lose effectiveness, impacted by factors like temperature, moisture, air entrapment, and contaminants. Daily monitoring of equipment lubricants can prevent failures by checking for issues such as:
- Low levels
- Debris contamination
- Water contamination (cloudy oil)
- Air contamination (cloudy and frothy oil)
- Overextended oil (dark, smudgy appearance)
Equipment Inspections and Testing
Equipment inspections should be conducted to detect potential issues, including:
- Checking oil level in the sight glass (should be halfway when equipment is off)
- Inspecting oil color, foam, and debris in the sight glass
- Measuring bearing or surface temperature
- Inspecting the breather element for signs of foaming or leakage
If issues are observed, perform these low-cost physical tests:
- Blotter Spot Test: Checks for contaminants
- Crackle Test: Detects water in oil
- Cold Oil Turbidity: Indicates dissolved water
- Bottle and Magnet Test: Detects ferromagnetic particles
- Laser Pointer Test: Particles in the oil can be easily observed
Oil Change Steps
Follow these steps for an oil change on a bearing box or gearbox:
- Lock out and tag out equipment for safety.
- Prepare a clean drain pan and filling containers to avoid contamination
- Clean and inspect fill and drain plugs.
- Use only the recommended oil grade stored in clean, sealed containers.
- Drain old oil into a pan and inspect it for color, transparency, and debris.
- Refill to the correct level as per the manufacturer’s recommendations.
Accurate oil levels are critical. Under-filling leads to under-lubrication and potential damage, while overfilling can cause heat and seal failures. Take time with each oil change, and follow manufacturer guidelines. Documenting service intervals, oil type, inspection findings, and tests is important, especially for warranty purposes.
Conclusion
Effective lubrication is crucial for the longevity of equipment like pumps, mixers, and blowers. Proper oil care involves more than just replacing it; it includes monitoring oil conditions and conducting simple tests to catch early issues. U.S. Water recommends quarterly to semi-annual equipment servicing for optimal performance. Contact our maintenance team today for more information.
