This issue of over-filling oil reservoirs in large motors, gearboxes, and other equipment at our 300mW coal fired plant is a common human reliability problem that needs to be addressed. Despite correct PM levels, individuals tend to mistakenly add excessive oil, leading to leaks and contamination. While training and proper oil administration are crucial solutions, are there any effective processes or tools available to prevent this over-filling in the meantime? Any successful strategies to share? Thank you, Gordon Littleton.
Years ago, I experienced issues with operators who were not diligent. Despite training and procedure updates, the problem persisted for short periods. To address this, we created a bleed-out point to eliminate excess oil that operators previously had to clean up from the bed-plates. Initially, the operators complained about the bleed points, but they soon realized the importance of controlling over-lubrication. This simple solution proved effective in maintaining equipment efficiency and reducing maintenance costs. V.Narayan.
Thank you for the prompt response. Your proposed solution sounds promising, especially if we are able to effectively screen or filter the drain hole. Dealing with coal dust could potentially be more problematic than dealing with excess oil. Gordon
Hello, in our design, we incorporated a vent hole that functions as a release for excess oil. We installed a pipe connected to the existing drain, with a small (1/16") weep hole drilled near the top of the pipe, positioned 2" higher than the required oil level. To prevent dust buildup, you could cover the top 3-4" with fine gauze. Additionally, we implemented a similar method to automatically drain water from steam condensing in the bearings of our small (200HP) steam turbines. Thank you, V.Narayan.
Hey Malpais, just wanted to elaborate on what "Vee" mentioned. Beswick Engineering offers small sintered Brass or Stainless conical filter elements that are perfect for this type of application. I received an email from them regarding this today. You can reach them at (603)433-1188 and ask for their sales contact, Mike Donati. These filter elements are specifically designed to meet your needs.
I'm having trouble visualizing your explanation. Could you provide a picture or sketch to convey your message more clearly on the forum? I am keen on comprehending each detail you mention.
Hey Gordon, one strategy you might consider is implementing an electronic oil monitoring system if you haven't done so already. These systems can provide real-time oil level readings, which can drastically reduce the risk of over-filling. Additionally, by integrating this system with maintenance management software, all the plant individuals can access the live data ensuring they adhere to proper PM levels. In essence, this will not just mitigate the risk of errors but also serve as a continuous training tool, fostering a culture of doing things right the first time.
Hi Gordon, faced with a similar issue, we introduced a layered prevention system at our plant. This included using color-coded fill lines and labels directly on the equipment to clearly indicate the correct oil level, which helped to reduce confusion. Additionally, investing in automated oil monitoring systems can provide real time data and alert operators if oil levels exceed the recommended amount. These can be pricy but can significantly decrease the chances of over-filling and potential damage. Always keep in mind that a preventative solution will involve a combination of improved training, consistent communication and the right tools.
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Answer: Answer: Common causes of overfilling oil reservoirs include human error, lack of proper training, incorrect PM practices, and individuals mistakenly adding excessive oil.
Answer: Answer: Overfilling oil reservoirs can lead to leaks, contamination, reduced equipment efficiency, and potential damage to the machinery in the long run.
Answer: Answer: Effective solutions include providing proper training to personnel, implementing strict oil administration processes, utilizing tools or indicators to measure oil levels accurately, and sharing successful strategies among team members.
Answer: Answer: Tools such as oil level indicators, automatic shutoff systems, and clear guidelines for oil addition can help prevent overfilling in motors and equipment. Processes like regular monitoring and auditing of oil levels can also be effective.
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