I have several gearboxes that are mounted in a steamy environment. My problem is we keep getting water in our gearboxes. The gearboxes do have a vent. To keep from having gearbox failures, we flush the oil out of the gearboxes once a month. With the price of oil, this is getting very expensive. What is the best way to correct this problem? " Assuming the water is coming through the vent due to the humid environment in which these gearboxes are working rather than through the seal or due to the effects of wash down, there are several options to consider. The first is to pipe out the vent to a less humid environment and use a water removal or exclusion breather such as a standard desiccant breather. If this is not possible, the best option is to use an expansion chamber, combination expansion/desiccating breather or membrane-style water exclusion breather so that water cannot enter the gearbox through the breather/vent. In addition, regular, routine visual inspections should be performed to identify signs of water ingression. If water is observed, it may not always be necessary to change oil. You may be able to remove the water using a water-removing filter element or dialysis-style water removal system. Depending on the size and criticality of these gearboxes, you may elect to use quick-connects to allow a portable unit to be periodically hooked-up, or if they are large enough, a dedicated off-line water removal and particle filter system may be justifiable for each gearbox.

"The equipment in my plant is routinely washed down. To reduce water ingestion we installed desiccant breathers, but they became saturated. Do I have any options?" Yours is a common scenario. Here are some suggestions:

1. Train the washdown crew to avoid direct spray onto the breather.

2. Install passive deflectors to direct water away from the breather.

3. Locate the breather in a dry area and connect it to the tank with a hose or pipe.

4. For systems with a stable fluid level, employ an expansion chamber. Some of these have integral desiccant to dehydrate the sump's headspace.

5. Use nondesiccant moisture-blocking breathers that inhibit the entrance of moisture, particularly free water.