| Course
Outline
How Lubrication Affects Machine Reliability
• Financial benefits from achieving lubrication excellence
• Four equipment maintenance strategies, and when each applies
• Important implementation steps to lubrication excellence
Lubrication Fundamentals
• Six important functions of lubricating oils
• How oils and greases are formulated and why it is important
• How friction is generated in lubricated machinery
• The importance of oil film thickness and critical clearances
Understanding Additives, Base Oils and Grease Thickeners
• How lubricant properties irreparably change
• Seven important physical properties of a base oil
• The importance of API's five base oil categories
• What causes grease to dry out and 18 ways to prevent it
• How to detect the root causes of lubricant oxidation
• When to select one of the six most commonly used synthetic base oils
• How to use temperature to determine the right base oil for your machine
• How to select grease thickeners for your application
Lubricant Performance Properties
• Key additives that enhance lubricant performance
• Viscosity grades, measurement, and reporting
• Why Viscosity Index is important
• What causes oil viscosity to change and how to set monitoring limits
• Lubricant performance tests and reporting - what you need to know
• How water contamination generates other contaminants
• How to control and eliminate aeration problems
Food-grade and Environmentally-friendly Lubricants
• Important USDA requirements and government regulations for food-grade lubricants
• What you need to know about food-grade additives, base oils and grease thickeners
• Guidelines for food-grade lubricants
Lubricating Grease Application Methods
• How to protect against incompatible grease mixtures
• Advantages and disadvantages of centralized lubrication systems
• Best practices for greasing motor bearings
• How to control pressure when greasing bearings
• The unique problems caused by over-greasing - specific steps to eliminate
• 3 critical instructions to give your electric motor rebuild shop
• Comparing single- and multi-point lubrication options
• How to calculate greasing intervals and quantity
• Best practices for ultrasonic/sonic-based greasing
Lubricating Oil Application Methods
• Overview of oil lubrication methods and devices
• How to use oil mist and other automatic lubrication methods
• Using pressure spray methods for gearboxes
• Best practices for the maintenance of grease guns and fittings
• How to protect against problems caused by constant-level oilers
• Overview of single-point direct lubrication systems
Journal Bearing Lubricants
• The 8 most common journal bearing lubrication problems
• How to select journal bearing viscosity based on speed
Rolling-element Bearing Lubricants
• The nine critical factors affecting rolling-element bearing lubricant selection
• How to convert required operating temperature viscosity to ISO viscosity grades
Gear Lubricants
• 5 key requirements for gear oil
• How to select the best viscosity for a gear lubricant
• Best practice guidelines for storing spare gearboxes - lubrication matters!
• 10 conditions that may require synthetic gear lubricants
• Lubrication best practices for enclosed gears - a 12 point checklist
• Mastering the challenges of open gear lubrication
Automotive and Mobile Equipment Drive-line Lubricants
• How to read a motor oil label: what really matters
• The 6 critical objectives a motor oil must accomplish
• Understanding API service classifications for engine and gear oils
• The #1 reason automatic transmission fluids fail and how to protect against it
• Service classifications for automotive greases - how to select
• Extending engine life - surprising engine oil filter study results
Compressor Lubricants
• Steps you can take right now to combat compressor lubricant failure
• The most common compressor lubricant stressors
• When to use synthetic compressor lubricants and why
Steam and Gas Turbine Lubricants
• Why turbine/generator lubricants are the #1 contributor to forced outages
• Comparing steam and gas turbine oils - how they differ
• Checklist for best practice steam turbine lubrication
Hydraulic Fluids
• How to select the ideal hydraulic fluid viscosity for gear, vane and piston pumps
• Nine key hydraulic fluid requirements and why they matter
• Specific conditions that may require a synthetic hydraulic fluid
• Fire-resistant hydraulic fluids - what you need to know
• Hydraulic system maintenance best practices - 21 point checklist
Contamination Control
• Strategies for building reliability through contamination control
• The seven most destructive contaminants and how to control them
• Specific steps for managing a proactive lubricant maintenance program
• The ISO Solid Contaminant Code - understand it, track it
• 10 ways to get more mileage out of portable filter carts
• How dirt, metal particles and soot mechanically destroy machine surfaces
• Guidelines for controlling machine surface fatigue and extending machine life
• The #1 cause of machine wear and how to manage it
• How to set realistic cleanliness levels for lubricants
• Effective lubricant contamination control strategies for extending machine life
• 4 ways water contamination attacks lubricant additives
• How to set limits for water-in-oil contamination
• Managing the root causes of foam and aeration
• Best practices for excluding and removing contaminants
• The right way to control contamination in tanks and sumps
• How oil filters are rated
• Calculating the clean-up rate for portable filters
• Best practices for removing water contamination from oil
• The unique problems created by varnish - how to remove and stop it
Oil Drains, Flushing, and Reservoir Management
• How to optimize and extend oil change intervals
• Interval vs. condition-based oil changes - pros and cons
• Metrics for monitoring lubricant consumption
• Best practices for oil changes
• Know how and when to perform a flush
• The best procedures for oil draining and refilling
• How and when to use the bleed-and-feed strategy for extending oil drains
• Selecting the right cleaning and flushing procedures
Storing, Handling, and Managing Lubricants
• How to set up a world-class lube room
• How to know when to reject a new oil delivery
• How to optimize your lubricant selection and procurement process
• How to implement a lubricant consolidation program and select suppliers
• Used lubricant storage, handling, and disposal best practices
• Bulk lubricant storage do's and don'ts
• Guidelines for storing and handling drums
• Lubricant dispensing options and what you must avoid
• Lubricant coding and identification systems - what works and what doesn't
• Portable oil transfer and filter carts selection advice
• How and where to store oil transfer and filter carts
• Understanding and managing lubricant storage life
• Keeping grease fresh - best practices for storage
Design and Inspect for Lube Excellence
• World-class strategies for accessorizing equipment for lubrication excellence
• Seven critical accessories for lubricant inspection and sampling
• The right machine accessories for effective contamination control
Used Oil Sampling and Analysis Fundamentals
• What oil analysis can tell you
• Types and categories of oil analysis
• Applications for oil analysis
• Overview of oil analysis tests
• Elements of a successful oil analysis program
• How clean should oil sample bottles be?
• How to find the best sampling locations
• Oil sampling valve and hardware recommendations
• A quick method for optimizing sampling intervals
• An oil sampling technique that ruins trending
• The importance of primary and secondary sampling points
• Advice for sampling hard-to-reach machines
• How to properly sample circulating systems
• Safe, effective high-pressure sampling from hydraulic systems
Essential Field Inspections
• 12 questions your oil filter will answer about your machine
• Visual inspections you can get big results from right now
• Quick tips for using scent, sound, and touch to inspect lubricants
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 This
course has been the most informative
I have attended. It will help me solidify
our program.
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-- Richard Hunt, Maintenance
Supervisor, Georgia Pacific
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