Industrial gear oil turning red: cause analysis, solution strategy and preventive measures
In the maintenance of industrial equipment, gear oil is a key lubricant, and its state is directly related to the operating efficiency and life of the equipment. However, when it is found that the color of industrial gear oil turns red, this is often a signal that cannot be ignored, indicating that the oil may have undergone some change, and it is necessary to identify the cause in time and take corresponding measures. This paper will start with the reason of gear oil turning red, explore the mechanism behind it, and put forward the corresponding solution and prevention strategy.
First, the cause of gear oil red
1. Oil deterioration
Gear oil in the process of long-term use, due to the influence of high temperature, high pressure, mechanical shear and other complex conditions, chemical and physical changes will gradually occur, resulting in oil performance decline, and eventually deterioration. The color of the gear oil after deterioration usually becomes darker and even red, which is due to the gradual depletion of additives in the oil, the oxidation and polymerization of the
Base Oil, and the generation of dark oxidation products and polymers. In addition, the deteriorated oil may also contain a large number of mechanical impurities, sludge and moisture, which further aggravate the deterioration of the oil.
2. Emulsification
Emulsification is another manifestation of gear oil deterioration. When a large amount of water is mixed into the oil, the water interacts with the additives and base oil in the oil to form an emulsion. The gear oil after emulsification not only turns white (in the case of severe emulsification may also show red), but also the lubrication performance is greatly reduced, which is easy to cause equipment failure. The emulsification phenomenon is usually caused by a poor seal of the equipment, water leakage or improper operation of the cooling system.
3. Oxidation
Gear oil in the process of use will contact with the air, oxidation reaction. The oxidation reaction will change the chemical structure of the oil, generate peroxides, aldehydes, ketones and other harmful substances, resulting in darker color of the oil, increased viscosity, acid value. As the degree of oxidation deepens, the color of the oil may gradually change from the initial light yellow to red or even black. Oxidation not only affects the lubrication performance of the oil, but also accelerates the wear and corrosion of the equipment.
Second, the solution strategy
1. Choose high quality gear oil
Choosing gear oil with good oxidation resistance and emulsification resistance is the primary measure to prevent oil deterioration. High-quality gear oil usually contains advanced additive systems, which can effectively inhibit the oxidation and emulsification reaction of the oil and extend the service life of the oil.
2. Change oil regularly
According to the use of equipment and gear oil service life index, develop a reasonable oil replacement cycle. Regular oil replacement can ensure that the equipment always uses a good performance of the lubricating oil, to avoid long-term use of oil caused by deterioration and performance decline.
3. Strengthen oil product monitoring
The gear oil is regularly sampled and tested to monitor the various performance indicators such as acid value, moisture, mechanical impurities, etc. Through data analysis, the changing trend of oil is found in time, the service life of oil is predicted, and the scientific basis for oil replacement is provided.
4. Keep oil clean
Before using oil for the first time, the pipeline and tank should be thoroughly cleaned to ensure that the oil is operated in a clean environment. In the process of use, the sludge and impurities at the bottom of the tank should be cleaned regularly to prevent the pollution of pollutants to the oil. At the same time, the working environment should be kept clean to avoid moisture and dust in the air into the oil.
5. Dispose of spoiled oil
For the gear oil that has been deteriorated, corresponding treatment measures should be taken according to the actual situation. If the oil performance is acceptable, the oil performance can be improved by adding new oil or adding corresponding additives; If the performance of the oil is seriously reduced, the new oil should be replaced in time to avoid further damage to the equipment.
6. Preventive measures
1. Prevent moisture from entering
Strengthen the inspection and maintenance of the sealing performance of the equipment to ensure that all parts of the equipment are well sealed to prevent water and air from entering the oil. At the same time, the cooling system should be regularly checked for leakage, and the leakage point should be found and repaired in time.
2. Control oil level and temperature
Reasonable control of oil level and working temperature of gear oil is an important measure to prevent oil deterioration. The oil level is too high or too low will affect the oil circulation and heat dissipation effect; The high working temperature will accelerate the oxidation reaction and emulsification of the oil. Therefore, the oil level and working temperature should be reasonably adjusted according to the operating instructions and actual conditions of the equipment.
3. Perform regular maintenance
Regular maintenance and inspection of the gear box is a necessary means to prevent oil deterioration. By checking the seal, oil level, oil temperature, oil quality and other parameters of the gearbox, potential problems are found in time and corresponding measures are taken; At the same time, clean the impurities and sludge in the fuel tank and filter screen to keep the oil circuit unimpeded.
In summary, industrial gear oil turning red is one of the important signals of oil deterioration. By choosing high quality gear oil, replacing oil regularly, strengthening oil monitoring, keeping oil clean and taking a series of preventive measures can effectively prevent and deal with the problem of industrial gear oil turning red to ensure the normal operation of equipment and extend the service life of oil
