Watering Down Your Profits: The Problems Caused by Water In Your Gear Box

"Just 1% of water in an industrial gear oil can reduce bearing life by up to 90%*, which can have significant cost implications in terms of both component costs and potential unscheduled downtime", explains Joe O'Connor, Product Application Specialist from Shell lubricants companies. "While awareness of the problems that water contamination can cause is strong, operators are often surprised to learn how quickly contamination can escalate and the level of damage that can be caused by just a small amount."

Separation Issues

Since water is an inherent part of many production processes, removing the potential for contamination is simply not practical. However, it is possible to manage the contamination issue to help prevent it from becoming a serious problem. Good maintenance practice and the careful selection of a gear oil that quickly separates from water is by far the most effective way of reducing the risk of serious component failure and unscheduled downtime caused by water contamination.

Joe continues: "Because we work closely with OEMs and our customers across a wide range of industrial sectors, the Shell Lubricants teams understand the need to prolong gear oil life and reduce operational downtime to enable operators to maintain production. Our R&D investment means that we now have a wide range of gear oils specifically designed to meet the needs of industry.

"A gear oil with improved water separation properties not only allows faster and easier water draining, but also lessens the frequency of oil changes. As a result, the operator can benefit both operationally and financially from reduced downtime and lower oil consumption."

Cause & Effect

In the real world, protecting gears from water contamination completely is often a losing battle for operators; exposure to the elements, cleaning practices, leaking heat exchangers, process water and condensation resulting from variable operating temperatures can all be contributory factors to water contamination.

There are process improvements that can be made, but the risk factors need to be identified first and any changes in production process may come at an inevitable cost, from either capital outlay or implementation - or both. Joe comments: "The important thing is to identify potential contamination points as early as possible and take steps both to rectify the risk factors and counteract the effects of the problem. In short, the most effective strategy is to combine measures to prevent water entering the system with measures that limit the water's capacity for damaging components."

Even the most vigilant maintenance team may not be aware that there is a serious water contamination problem until, for example, corrosion and fatigue failure has started to occur. Symptoms are often slow to emerge, and by the time pitting and surface wear begin to appear, components may already need urgent replacement, requiring downtime and potentially a disruption in production. Vibration analysis and oil condition monitoring can help to act as an early warning system, and this should form part of an effective lubrication management programme. These, however, are simply a valuable indicator that problems may be occurring, not a preventative measure.

Joe adds: "One important way to help minimize the potential for water damage within the system is to choose a lubricant designed to maintain its performance even when small amounts of water enter the system."

The Secrets of Specification

Protection from water contamination is just one of many factors that should be considered when specifying the best gear oil for an application, and it should be just one of the performance benefits a high quality lubricant offers. Joe adds: "Choosing a gear oil formulated with a high quality base oil and designed to maintain its high performance in tough operating environments simply makes sound financial sense."

Shell Lubricants have revitalized their range of mineral and synthetic industrial gear oils to meet the demands of modern machinery. Shell Omala, Shell Omala HD and Shell Tivela S gear oils, have been specially formulated to help limit the dangers of water contamination, prolong gear life and reduce unscheduled downtime, which can help industrial companies reduce their overall operating costs. www.webershandwick.co.uk <http://www.webershandwick.co.uk/> www.webershandwick.com <http://www.webershandwick.comprweek/>