Oil Analysis for Gearbox Condition Monitoring

This guide details the routine lubrication and oil analysis conducted by AVT Reliability to monitor the condition of a critical cooker mixer gearbox over a period of two years. The analysis involved collecting oil samples every six weeks to assess lubricant quality and identify any wear particles that could indicate internal damage. The findings revealed increasing levels of iron wear particles, prompting further investigation, which confirmed the presence of chipped and worn gearbox teeth. The root cause was identified as excessive movement due to a damaged footstep bearing. By communicating these findings to site management, AVT facilitated planned corrective action, which involved the replacement of the gearbox before a critical failure occurred. This proactive maintenance approach is estimated to have prevented over £35,000 in costs associated with potential production downtime and equipment failure. The replacement gearbox will continue to be monitored under the existing oil analysis program to ensure normal wear rates.