Course Outline

Maintenance Strategy

• The impact of lubrication on machine reliability
• The impact of lubrication on lubricant life and consumption
• Maintenance program strategies for achieving lubrication excellence
  

Lubrication Theory

• Friction & tribology
• Types of friction and wear
• Wear modes and influencing factors
• Machine frictional surfaces most at risk for specific wear modes (e.g., abrasion)
• Mechanisms of lubrication regimes
• Boundary
• Mixed film
• Hydrodynamic
• Elastohydrodynamic
• Lubricant categories
• Gaseous
• Liquid
• Cohesive
• Solid
  

Lubricant Formulation

• Base-oil refining methods and API categories
• Solvent-refined
• Hydro-treated
• Severely Hydro-treated
• Hydrocracked
• Mineral base oils
• Naphthenic
• Paraffinic
• Aromatic
• Vegetable base oils & biolubes
• Synthetic lubricant characteristics/applications/compatibility
• Synthesized hydrocarbons (e.g., Polyalphaolifins)
• Dibasic acid esters
• Polyol esters
• Phosphate esters
• Polyalkylene glygol
• Silicones
• Fluorocarbons
• Polyphenil esters
• Food grade lubricant classification
• Types and func0tions of additives
• Types and functions of solid additives
• Modes of additive depletion
  

Grease Application and Performance

• Grease applications requiring high consistency
• Grease applications requiring low consistency
• Causes of grease separation
• Multipurpose greases
• Performance and application of specific grease thickeners
• High temperature greases
• Coupling greases
  

Lubricant Selection

• Viscosity selection/adjustments according to machinery condition/environmental conditions
• When to use synthetic lubricants
• When to use biodegradable lubricants
• Lubricant consolidation
• Select lubricating oils for:
• Fire-resistant applications
• Hydraulics - Mobile/industrial
• Turbines
• Compressors
• Bearings
• Chains/conveyors
• Mist applications
• Gears - Automotive/industrial
• Engines - Diesel/Gas/Gasoline
• Pneumatic tools
• Spindles
• Ways/slides
• Selecting greases for:
• Chassis
• Couplings
• Anti friction bearings
• Journal bearings
• Automotive bearings
• Automatic Lubrication Systems
• Lubricant selection standards development
• Procedures for testing and quality assurance of incoming lubricants
• Procedures for approval of candidate lubricants
  

Lubricant Testing and Performance Analysis

• Viscosity
• Flash/Fire point
• Pour ASTM D97/Cloud point ASTM D2500
• Foam ASTM D892
• Air release properties ASTM D3247-99
• Neutralization number
• Acid Number ASTM D 664/D974
• Base Number ASTM D 974/D2896
• Filterability ISO 13357
• Oxidation stability
• Turbine Oil Oxidation Test ASTM D943
• Rotary Pressure Vessel Oxidation Test ASTM D2272
• Rust and Corrosion tests
• Turbine Oil Rust Test ASTM D665
• Copper strip corrosion ASTM D130
• Anti-wear tests
• Four ball wear test ASTM D2266
• Vickers wear pump test ASTM D2882
• SRV Test
• Extreme Pressure
• Four ball EP test ASTM D2596
• Timken Extreme Pressure Test ASTM D2509
• Falex EP/Wear Test ASTM D2670
• FZG Four Square Gear Test Rig ASTM D5182.97
• Demulsibility ASTM D 1404
• Grease consistency ASTM D217
• Dropping point of grease ASTM D2265
• Mechanical stability of greases ASTM D217A
• Rolling stability if greases ASTM D1831
• Water washout test for greases ASTM D1264
• Water spray test for greases ASTM D4049
• Rolling bearing rust test ASTM D1743
• Koppers Centrifugal Stability Test
• Oil separation in grease storage ASTM D1742
• Oxidation stability - greases ASTM D942
  

Lubricant Application

• Procedures for:
• Oil drain
• Reservoir/system flushing
• Disassembling/cleaning reservoirs and sumps
• Filling
• Top-up
• Grease packing
• Re-greasing
• Grease changeout
• Determine/calculate correct amount for re-greasing
• Determine/calculate correct frequency interval for re-greasing
• Select and manage optimum equipment/systems for lubricant application according to machinery requirements
• Safety/health requirements for lubricant application
• Manage proper maintenance of lubrication equipment
• Manage proper maintenance of automatic lubrication systems
• Create/update lube survey
• Record execution of lube program
• Proactive management and detection of leaks
• Waste oil/filters management/disposal
• Writing a lubrication PM
  

Preventive and Predictive Maintenance

• Creating and managing lube PMs and routes
• Creating and manage lubrication inspection check list
• Used oil analysis to determine optimum condition based oil changes
• Used oil analysis to troubleshoot abnormal lubricant degradation conditions
• Used oil analysis to troubleshoot abnormal wear related to lubricant degradation/contamination
• Procedures and methods for identifying root cause of lubricant failure
• Use of technology aids to determine optimum re-grease frequency/quantity (ultrasonic, temperature monitoring, shock impulse, etc.)
  

Lubricant Condition Control

• Proper sampling procedures
• Proper sampling locations
• Proper selection of breathers/vents
• Proper selection of filters according to cleanliness objectives
• Filter rating - Beta Ratio
• Sump/Tank management to reduce:
• Air entrainment/foam
• Particles
• Water
• Sediments
• Heat
• Silt/sediments
• Unnecessary lubricant volume
• Proper selection of reconditioning systems for:
• Water
• Air/gas
• Particles
• Oxidation products
• Additive depletion
• Lube reclamation
• Requirements
• Feasibility
• Procedures for reclaiming/reconditioning
• Use of oil analysis to approve reclaimed/reconditioned lubricants
  

Lube Storage and Management

• Design optimum storage room
• Defining maximum storage time according to environmental conditions/lubricant type
• Safety/health requirements
• Proper sampling procedures/locations for sampling stored lubricants
• Procedures for reconditioning/filtering stored lubricants

Packed with powerful information that can be applied with measureable results. The right training to influence a cultural change in maintenance and operation organizations. -- Brian Baldwin, Reliability Engineering Manager, Dynergy Midwest Generation