Preventing Water Intrusion in the Gearbox and Oil Tanks

在一家工厂，一条线填充每小时最多50,000罐，然后接缝填充罐头。填充机器中的“自动清洁”程序中的程序可以通过用大量的水和化学品冲洗来清洁它们。

水侵入问题和解决方案

Allied Reliability Group uses oil analysis to monitor the main oil reservoirs. Over a period of five months, the main drive encountered recurring problems with water intruding into the gearbox and oil tanks. The oil was frequently changed and the seals were examined and replaced, but these actions did not solve the issue.

Allied Reliability Group suggested supplying dry air to the oil reservoirs. The overpressure was limited to a small level to prevent blowing out the seals. This method eliminated the water intrusion problems.

In the same factory, a bottle washing machine is used to rinse bottles before they are filled. The translation chain is driven by gearboxes to move bottles through the machine. Vibration measurements have been successfully employed for condition monitoring of the ingoing shaft that operates at 55 rpm.

然而，输出轴仅以1 rpm运行，对于准确的振动测量，太慢了。因此，每三个月在轴润滑水库上进行油分析。

Figure 1.石油分析检测缓慢移动轴中的问题

A sudden increase of wear particles in the oil was observed using the5200 minilab。这first step was to change the oil and re-running the oil analysis, but the new analysis also showed a high level of wear particles. The number and size of wear particles continued to increase, showing particles larger than 40 µm. The machine was shut down and inspected at the first planned stop. The inspection showed a severely damaged bearing on the outgoing shaft.

该问题是通过改进减速传动箱来解决的问题。如果尚未通过油分析识别出这个问题，齿轮箱会破碎并导致其他组件失败。生产将丢失，因为该线路无法运行冲洗机，直到维修完成。

同一家工厂使用一个标签机，每小时可以以60,000瓶装运行。该设备的高复杂性和结构局限性意味着油分析只能监控机器的某些部件。2020欧洲杯下注官网齿轮箱储存器的油分析显示介电常数，粘度增加和水侵入的大幅增加。

An inspection of the gearbox revealed a large amount of glue intruded into the oil reservoir due to a seal failure. If the problem had not been detected by oil analysis, the gearbox would eventually have stopped, causing high repair costs and production losses. Accurate oil analysis delivered relatively inexpensive corrections that addressed the issue during the next scheduled production stop.

钢厂采用冷轧工艺，其中金属股通过一对或多对辊，以减小其厚度和厚度变化。皮肤通过是最终的冷轧通，涉及厚度最小的厚度，通常为0.5％至1％。

皮肤通道也在轧制钢板上产生光滑的均匀表面。驱动皮肤通行证的许多减速器是从持有6,000升（1585加仑）的壳体220油的共用油藏润滑。

最近的油样揭示了含铁指数升高的粘度下降，从220CST至82CST的粘度下降，以及增加数量的颗粒。欧洲杯猜球平台盟军可靠性集团建议钢厂迫切地检查油藏。检查显示，几种加热元件失败，导致颗粒计数和黑色剂指数增加。检查还表现出循环泵的故障，导致油过热并达到高局部温度。

这steel plant replaced the broken heating elements, repaired the circulation pumps, and replaced the oil during a previously planned outage. A new oil sample taken from the same point revealed that the issue was solved. If the plant had continued to run the machine with bad oil, the gearboxes would have been damaged, ultimately leading to increased repair expenses and production loss due to an unplanned outage.

在相同的钢铁厂中，使用振动测量监测更快移动的轴的振动。然而，在9 rpm下驱动齿轮箱的轴移动得太慢以使有效的振动测量值。因此，每三个月分析油样。

这most recent oil sample revealed an increase in particle count and ferrous particles. Vibration analysis of other shafts driven by the same gearbox did not reveal any anomalies. The gearbox was opened up and examined at the next planned stop. The rolling elements of the slow moving axle revealed clear signs of grinding.

由于磨削产生的极端热量，轴承的外圈是黑色的。如果没有被替换，轴承显然会缩短。在这个应用程序中，油分析通过尽量减少维修费用，避免生产中断，保存了相当数量的资金。

在钢铁生产设备中，通过使用以1000rpm的3米直径的风扇去除来自钢转换器的气体。这些气体非常热，风扇叶片必须用水冷却。结果，钢灰尘粘附在风扇叶片上，导致它们超出平衡。

为了补偿这种不平衡，将四个油室集成到风扇中，在围绕风扇的直径彼此排列在90°处。油在腔室之间泵送以平衡风扇。在该平衡系统中，石油分析定期进行。

图2。Oil analysis detects problem in fan balancing system

在某种程度上，在油中鉴定出水平的水平和​​污染物水平的大幅增加。该问题立即向维护团队报告，该团队计划在第一个预定的停止处进行检查。分析进行了几天，在检查前进行，由于水位高，油泵坠毁。检查揭示了一个密封件的问题，允许来自风扇叶片的冷却水进入平衡系统。

从活塞式压缩机中检索的油样揭示了高水位和亚铁颗粒的存在。欧洲杯猜球平台压缩机基于这些结果进行大修。在此检查期间，凸轮轴显示出高水位。磨损可能引起由于水侵入引起的油的润滑性能的降低引起。水分离器的失效使这种水侵入。在这里，石油分析最小化了维修费用并消除了生产中断。

图3。油分析确定了活塞式压缩机的问题

这se applications are typical of the savings in repair costs and lost production that can be provided by oil analysis.资产健康监测早期发现缺陷，以防止意外失败，帮助组织计划和安排维护。这5200 minilab.provides clear indications of metal wear, lubricant chemistry and contamination. The instrument also generates machinery health trend analysis to support data driven predictive and preventive maintenance decisions. Lubricant condition monitoring also conserves oil and reduces oil disposal costs by driving maintenance on an as needed basis.

Niels Maes, Asset Health Analysis, Allied Reliability Group

This information has been sourced, reviewed and adapted from materials provided by AMETEK Spectro Scientific.

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