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Oil Lubricated Equipment Design Standard

1.0PurposeThis document outlines the equipment modification standards that enable world class lubrication practices and contamination control.

2.0ScopeThis standard covers production and utility equipment in General Mills facilities with oil lubrication.

3.0 Hardware

3.1 Breathers and Expansion ChambersEquipment with oil sumps exchange air with the surrounding atmosphere during operation due to oil level and temperature changes. OEM breathers are not sufficient in excluding contaminants; therefore equipment should be outfitted with desiccant breathers or expansion chambers according to this standard. The options available are as follows:

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Each application using a breather or expansion chamber needs to be evaluated for correct sizing.

3.2 Level and Sight GaugesGearboxes, hydraulic systems, and other equipment with oil sumps should be outfitted with level and sight gauges to allow for proper inspection of oil level and condition without opening to the atmosphere. Pulling level plugs or using dipsticks for routine oil level checks will induce contamination into the oil and result in forced deterioration failure. The options for level and sight gauges are as follows:

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3.3 Adapter KitsCritical equipment should be outfitted with the appropriate adapter kit in order to maintain a closed system during sump filling, draining, and bypass filtration. The following adapter kits should be utilized according to this specification.

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3.4 Oil Sample PortsEquipment sumps should be outfitted with oil sample ports per this standard. The option for this hardware is as follows:

4.0 Gearboxes

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Oil lubricated gearboxes should be outfitted with appropriate hardware to protect from contaminant ingress and allow for proper inspection to ensure design life is achievable. There are three classes of equipment modification based on the criticality and sump size.

4.1 Low Criticality GearboxesThis class of gearbox typically has a small sump size (~1/2 gallon), low MTTR, and low cost to replace. These gearboxes should be outfitted with an appropriate breather for headspace management and a sight gauge for proper inspection of oil level and condition. The following section of the GMI LMS Source of Contamination Control Methods flowchart should be used for proper selection of breather.

The sight gauge used in these applications should be the Esco Products 3D Bullseye for applications that have a level plug at the appropriate oil level. For applications that do not have a plug at the appropriate oil level, an Esco Products Oil Level Indicator should be used. The sizing of this level indicator should be appropriately sized for the application. The following are examples of different configurations.

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Gearbox Example #1 – Intermittent operation in humid/wet environmentRetrofit includes Des-Case Ventguard breather and Esco 3D Bullseye sight gauge

Gearbox Example #2 – Dry environmentRetrofit includes Trico expansion chamber and Esco 3D Bullseye sight gauge

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4.2 Medium Criticality GearboxesThis class of gearbox typically has a sump size of 2-4 gallons, medium to high MTTR, and medium to high cost to replace. These gearboxes should be outfitted with an appropriate breather for headspace management, sight gauge for proper inspection of oil level and condition, and an oil sample port. The following section of the GMI LMS Source of Contamination Control Methods flowchart should be used for proper selection of breather.

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The sight gauge used in these applications should be the Esco Products 3D Bullseye for applications that have a level plug at the appropriate oil level. For applications that do not have a plug at the appropriate oil level, an Esco Products Oil Level Indicator should be used. The sizing of this level indicator should be appropriately sized for the application. The following are examples of different configurations, specific locations of sight gauge and sample port will vary by application. The following is for illustration purposes only, consult OEM documentation for proper placement.

Gearbox Example #3 – Intermittent operation in humid/wet environment with oil samplingRetrofit includes Des-Case Ventguard breather, Esco 3D Bullseye sight gauge, and Checkfluid sample valve

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Gearbox Example #4 – Continuous operation in humid/wet environment with oil samplingRetrofit includes Des-Case Hydroguard breather, Esco oil level indicator, and Checkfluid sample valve

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4.3 High Criticality GearboxesThis class of gearbox typically has a sump size greater than 5 gallons, medium to high MTTR, medium to high cost to replace, and a long lead time. These gearboxes should be outfitted with a gearbox adapter kit and breather, sight gauge, bottom water and sediment bowl, oil sample port, drain adapter kit, and ISO quick disconnects. These applications should utilize filtration carts for bypass filtration. The following section of the GMI LMS Source of Contamination Control Methods flowchart should be used for proper selection of breather.

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The sight gauge used in these applications should be the Esco Products 3D Bullseye for applications that have a level plug at the appropriate oil level. For applications that do not have a plug at the appropriate oil level, an Esco Products Oil Level Indicator should be used. The sizing of this level indicator should be appropriately sized for the application. The following is an example of this configuration, specific locations of sight gauge and sample port will vary by application. The following is for illustration purposes only, consult OEM documentation for proper placement.

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Gearbox Example #5 – Continuous operation in humid/wet environment with oil samplingRetrofit includes Des-Case Hydroguard breather, gearbox adapter, drain adapter, Esco oil level indicator, bottom water/sediment bowl, and Checkfluid sample valve

5.0 HydraulicsHydraulic systems should be outfitted with appropriate hardware to protect from contaminant ingress and allow for proper inspection to ensure design life is achievable. There are two classes of equipment modification based on the criticality and sump size.

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5.1 Low Criticality HydraulicsThis class of hydraulic system typically has a sump size less than 5 gallons and is on support equipment such as pallet lifts. These hydraulic systems should be outfitted with an appropriate breather for headspace management and a sight gauge for proper inspection of oil level and condition where applicable. The following section of the GMI LMS Source of Contamination Control Methods flowchart should be used for proper selection of breather.

5.2 Medium to High Criticality HydraulicsThis class of hydraulic system typically has a sump size greater than 5 gallons and operates production equipment. These hydraulic systems should be outfitted with a Des-Case hydraulic adapter kit, Des-Case breather, level gauge, oil sample valve, full flow filter, and ISO quick connects for bypass filtration. The following section of the GMI LMS Source of Contamination Control Methods flowchart should be used for proper selection of breather.

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Each hydraulic system will have a customized solution based on the size of the tank and configuration. Oil sampling valves should be placed in the system to ensure a consistent representative sample is obtained. Driven components such as hydraulic cylinders should be evaluated to minimize contaminant ingress. Solutions such as rod boots may be employed to reduce the risk of pulling contaminants into the system during operation. Full flow filtration should be appropriately sized and used in conjunction with bypass filtration. Consult the OEM for proper filter sizing based on oil viscosity and flowrate. The following is an example of a hydraulic system retrofit.

Hydraulic Example #1Retrofit includes Des-Case hydraulic adapter kit, desiccant breather, Esco level gauge, bottom water and sediment bowl, ISO quick connects, and Checkfluid sample valve

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6.0 Equipment Drain PortsAll oil lubricated sumps shall have a drain plug to allow for period oil changes. The oil plug must be accessible and able to drain freely into a drain pan or bucket. If the positioning or orientation of the component does not allow for free flow into a drain pan, modifications must be made to allow oil to be directed to a drain pan without contacting equipment framework or the floor. Large sumps should be outfitted with an ISO quick disconnect in order to connect to a pump for extraction of used oil.

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