The process of lubricating gears is not as straightforward as simply buying an effective oil and putting it into a system. When inexpertly administered, the danger is that the oil becomes contaminated, potentially in just a few hours, and can be rendered ineffective.

The vicious cycle of fluid replacement becomes very expensive over time and isn't sustainable environmentally or financially. Fortunately, the procedure doesn’t have to be too taxing. By following a three-step process, an http://www.ncheurope.com/en/solutions/lubricants-fuel-additives/greases-oils/gear-oils effective oil maintenance program can be as simple as one, two, three.

Time for a change

While many engineers top up a machine with oil and expect it to last a long time without changing, it is not the longevity but the quality of the oil itself that must be measured.

For example, oxidation is a naturally occurring process that affects oil over time. If left long enough, the acidity of oxidised oil will steadily increase and result in corrosion and pitting. By measuring increases in the system’s total acid number (TAN), maintenance engineers and plant managers can identify acceptable limits of oil acidity and act accordingly.

By using advanced insight into gear oil, engineers can ensure that changes happen at the right time to avoid damaging machinery. However, to extend oil life and maximise performance, engineers must first clear away contaminants.

Flush and clean

One of the most commonly forgotten stages of the oil change process is cleaning the system before refilling with fresh oil. Neglecting this leads to oil that is ineffective and heavy with contaminants mere hours after use. 

These contaminants quickly form deposits on metal surfaces in the system, raising operating temperature and reducing power transmission through the gearbox. To prevent this from occurring, it is imperative that engineers remember to clean their systems before replacing machinery oil. 

An effective system cleaning product, such as NCH Europe's Flush & Clean, works by being allowed to run through the system during a brief period of operation. This separates the deposits from the system surface, leaving them suspended in the old oil so they are removed during the oil change.

The right stuff

Engineers must consider both the traits of the oil and the problems the application faces. Even if one gear oil is theoretically suited to a piece of equipment, it may not necessarily suit the operating environment. 

Several industries are subject to strict regulations that govern the products that can be used to maintain equipment and machinery, so engineers must ensure that products comply with the relevant standards.

In the food sector, maintenance engineers replacing the gear oil in a food conveyor system must use an effective food-grade oil with NSF H1 certification. It is also important to check the NSF rating of the other products used, such as the system cleaning product, to ensure regulatory compliance.

Regardless of whether it is from a practical or a legal perspective, consideration must be paid at every step of the process to determine the best lubrication products for an application. This treatment should then be repeated for every subsequent refill.

It might not need a 300-page explanation, but it is clear that oil changing is not the simple process many consider it to be. However, with the right knowledge and solutions, boosting machine efficiency can be as easy as one plus one. 

Mark Burnett is VP of the Lubricants and Fuel Additives Innovation Platform at NCH Europe