| Course
Outline
Lubrication Fundamentals
- Lubrication regimes
- Hydrodynamic
- Elasto-hydrodynamic
- Boundary
- Base oils
- Common mineral oil characteristics
- Common synthetic oil characteristics, advantages and disadvantages
- Synthesized hydrocarbons
- Phosphate esters
- Dibasic acid esters
- Polyglycols
- API and other base oil classifications
- Basic lubricant additive functions
- Antioxidants/oxidation inhibitors
- Rust inhibitors
- Corrosion inhibitors
- Demulsifying agents
- Viscosity index (VI) improvers
- Detergents
- Dispersants
- Pour-point depressants
- Foam inhibitors
- Anti-wear (AW) agents
- Extreme pressure (EP) agents
Fundamentals of Machine Wear
- Common machine wear mechanisms
- Abrasive wear
- Two-body abrasive wear
- Three-body abrasive wear
- Adhesive wear
- Surface fatigue
- Corrosive wear
- Fretting wear
- Erosive wear
- Electrical wear
- Cavitation wear
- Gaseous cavitation
- Vaporous cavitation
- Common machine-specific wear modes
- Gearing
- Plain bearings
- Rolling element bearings
- Hydraulics
Wear Debris Analysis
- Analytical ferrography
- Wear debris analysis techniques
- Light effects
- Magnetism effects
- Heat treatment
- Chemical treatment
- Morphology
- Surface detail
- Wear particle types, origins and probable causes
- Cutting wear particles
- Spherical particles
- Chunky particles
- Laminar particles
- Red oxide particles
- Black oxide particles
- Corrosion particles
- Non-ferrous particles
- Friction polymers
- Atomic emission elemental spectroscopy
- Basic determination of wear particle metallurgy from elemental composition
- Evaluating sequential trends
- Evaluating lock-step trends
- Particle size limitations of common atomic emission spectrometers
- Advanced techniques
- Acid/microwave digestion
- Rotrode filter spectroscopy
- X-ray fluorescence (XRF) and other advanced elemental spectroscopy methods
Analyzing Lubricant Degradation
- Oxidative base oil failure
- Causes of oxidative base oil failure
- Recognizing at-risk lubricants and applications
- Strategies for deterring or mitigating base oil oxidation
- Recognizing the effects of base oil oxidation
- Strengths, limitations and applicability of tests used to detect and troubleshoot base oil oxidation
- Acid number
- Viscosity
- Fourier Transform Infrared (FTIR) analysis
- Rotating Pressure Vessel Oxidation Test
- Sensory inspection
- Thermal failure of base oil
- Causes of thermal degradation
- Hot surface degradation
- Adiabatic compression induced degradation
- Strengths, limitations and applicability of tests used to detect and troubleshoot thermal failure of the base oil
- Acid number
- Viscosity
- Fourier Transform Infrared (FTIR) analysis
- Thermal stability test (ASTM D 2070-91)
- Ultracentrifuge detection of carbon insolubles
- Sensory inspection
- Additive depletion/degradation
- Assessing risk for common additive depletion/degradation mechanisms
- Neutralization
- Shear down
- Hydrolysis
- Oxidation
- Thermal degradation
- Water washing
- Particle scrubbing
- Surface adsorption
- Rubbing contact
- Condensation settling
- Filtration
- Aggregate adsorption
- Evaporation
- Centrifugation
- Strengths, limitations and applicability of methods for measuring additive depletion/degradation
- Atomic emission spectroscopy
- Fourier Transform Infrared (FTIR) spectroscopy
- Acid number
- Base number
- Viscosity index (VI)
- Rotating Pressure Vessel Oxidation Test
- Blotter spot test
- Detecting wrong lubricant addition
- Viscosity
- Neutralization number (AN/BN)
- Elemental spectroscopy
- Fourier Transfer Infrared Analysis
- Other tests
Oil Analysis Program Development and Program Management
- Machine-specific test slate selection
- Optimizing frequency of analysis
- Setting alarms and limits
- Setting goal-based limits for contamination
- Statistically derived level limits
- Editing data
- Calculating averages
- Calculating standard deviation
- Setting upper and lower limits using the mean and standard deviation
- How changes in system operation or maintenance influence statistically derived inferences
- Rate of change limits
- Calculating rate of change
- Slope-based alarms
- Statistically derived rate of change limits
- Setting aging limits for fluid properties
- Physical properties
- Chemical properties
- Additive properties
- Managing oil analysis information
- Creating and managing oil analysis procedures
- Scoping oil analysis training for reliability technician, trades people and management
- Performing cost/benefit analysis for oil analysis and contamination control programs
- Calculating program costs
- Estimating program benefits
- Calculating return on investment metrics
- Generating an effective business proposal
- Quality assurance
- Of onsite oil analysis
- Of offsite oil analysis providers
 |
 Excellent
learning forum. Provided substantial
information that will be immediately
useful in improving existing oil analysis
program.
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-- Steve Fox, Maintenance Engineer,
Aera Energy
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