WHY IT'S IMPORTANT?

This course is designed for Industrial professionals to have a thorough understanding of Lubrication and Bearings in Industrial Plant environment. It covers the requirements of Level II and Level III Machinery Lubrication and Oil Analysis programs.

An overview of the thermal properties of lubricants, lubricant viscosity theory, Viscosity Index Improvers (VI), low and high shear rate properties of lubricants, and how these properties are measured. Detailed discussion on lubricant additives’ chemistry and mechanism action, Additives including antioxidants, anti-wear, and extreme pressure agents, friction modifiers, corrosion inhibitors, and metal deactivators.

Tribology understanding with various kinds of wear, wear mechanisms, and equipment failure modes. The condition monitoring, Failure analysis, and techniques will be covered in detail and help understand the effectiveness of the Maintenance program. Modern tools for failure analysis, predictions will be delivered.

The overall course objective is to provide pertinent information to improve the performance of rotating equipment and bearings through effective lubrication programs, focusing on reliability improvement of these important elements as integrated with the Lubrication systems in plant equipment.

It will help you learn proper oil analysis procedures and how to interpret oil analysis data properly. This course goes beyond the basics and shows you the necessary strategies to improve your maintenance through the integration of oil analysis.

KNOW ABOUT YOUR TRAINER

Over 30+ years of experience in Mechanical Power Engineering , Consulting , Training & Development includes. A highly experienced Professional Engineer with Six Sigma qualification & demonstrated ability to lead diverse teams of professionals to new levels of success in a variety of highly competitive industries, cutting-edge markets, and fast-paced environments. Over 30 years of experience in the Engineering industry in the field of Maintenance and reliability engineering, Risk-based analysis and studies, performance evaluation of Power Plants, Plant maintenance repair & overhaul of Turbo Machinery in Oil & Gas, Petrochemical, Power Generation, and Aviation Industry. Strong technical qualifications with an impressive track record comprising of Plant and Equipment Maintenance Strategies. Proven ability to successfully analyze an organization's critical engineering requirements, identify deficiencies and potential opportunities, and develop innovative and cost-effective solutions for enhancing efficiency, increasing reliability Maintenance cost reduction, and improving engineering processes. Highly sought after Technical Trainer in Process, Power Generation and Aviation in RCM Based Maintenance & Reliability Program Development / Implementation Strategies, Turbo Machinery, Risk-Based Maintenance Study, Plant Asset Management & Reliability Analysis.

Companies that has been benefited from Our Consultant


• Abu Dhabi Company for Onshore Oil Operations (ADCO)

• Abu Dhabi Marine Operating Company

• ADMA-OPCO

• Abu Dhabi National Oil Company (ADNOC)


• GASCO

• SCECO Kingdom of Saudi Arabia

• DUBAAL Dubai Aluminum ALBA Aluminum

• Bahrain Abhasin


• Petro Vietnam

• Mongolian Airlines

• Riyadh Cement KSA

• Gulf Drilling Company


• Fiber Glass Bahrain

• Malakoff LUMUT Power Plant

• Malakoff Tanjung Bin Power Plant Air Niugini PNG

• Singapore Technologies Aerospace


• Mynamar Airlines

• Brunei Airlines

• Iraqi Petroleum

• KESC Karachi Electric Supply Corporation


• YTL Power Corp Sdn Bhd

• Terranganu Malaysian Civil Aviation

• Energy Commission Malaysia Hunts Town Power Plants Ireland

• TUN Singapore Fleming Gulf India IIRME Middle East


• GENCO I , II , III Pakistan WAPDA

• DHA 220MW Combined Cycle Pakistan

• ARAMCO KSA

• SABIC KSA


• Corporate Frontier Malaysia IQPC Singapore

• Strategic Biznet Singapore INBI Singapore

• Shell Philippines

COURSE OUTLINE

  • DAY ONE


  • Understanding Plant Environment

  • • Types of Plants / Equipment
    • Classifications , Categories , Rotating Equipment
    • Design requirements for Performance & Reliability
    • Plant Reliability Standards & Programs


  • Fundamentals of Machine Wear and Failures

  • • Common machine wear mechanisms
    • Abrasive wear
    • Two-body abrasive wear
    • Three-body abrasive wear
    • Adhesive wear , Surface fatigue
    • Corrosive , fretting wear
    • Erosive wear
    • Electrical wear
    • Cavitation wear
    • Gaseous cavitation
    • Vaporous cavitation
    • Common machine-specific wear modes
    • Gearing
    • Plain bearings
    • Rolling element bearings
    • Hydraulics
    • Plant Life Cycle Analysis , Design Materials Used
    • Types of Failures , Design Failures
    • Bath Tub Curve , understanding
    • Operational / Functional Failures
    • Root Cause Failure Analysis
    • Weibull Analysis in Machinery failure
    • Advanced Analysis tools and techniques


  • Maintenance Strategy

  • • The impact of lubrication on machine reliability
    • 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) o Mechanisms of lubrication regimes
    • Boundary , Mixed film ,Hydrodynamic ,Elasto-hydrodynamic


  • Lubricant Categories & Formulation

  • • Gaseous , Liquid , Cohesive , Solid
    • 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


  • Types and functions of additives

  • • Modes of additive depletion Grease Application and Performance
    • Grease applications requiring high and 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
    • Machinery condition/environmental conditions
    • When to use synthetic lubricants , biodegradable lubricants
    • Lubricating Oils
    • 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
    • Chassis , Couplings , Anti friction bearings
    • Journal bearings , Automotive bearings


  • Lubricant selection standards development

  • • Procedures for testing , quality assurance , Approval.
    • 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
    • Calculating correct amount for re-greasing
    • Calculating correct frequency interval for re-greasing
    • Optimum equipment/systems for lubricant application
    • SMS for lubricant application
    • Maintenance of lubrication equipment / System
    • Lube survey , Record of lube program
    • Proactive management and detection of leaks
    • Waste oil / filters management / Disposal


  • Preventive and Predictive Maintenance

  • • Lube PMs and routes
    • 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
    • Determining optimum re-grease frequency / quantity
    • Tools (ultrasonic, temperature monitoring, shock impulse, etc.)



  • Lubricant Condition Control

  • • Proper sampling procedures , locations
    • Proper selection of breathers/vents, filters.
    • Filter rating - Beta Ratio
    • Sump/Tank management to reduce:
    • Air entrainment/foam
    • Particles , Water , Sediments
    • Heat , Silt/sediments
    • Over 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



  • DAY TWO


  • Lube Storage and Management

  • • Design optimum storage room
    • Defining maximum storage time
    • Safety/health requirements
    • Proper sampling procedures / locations for sampling stored lubricants
    • Procedures for reconditioning / filtering stored lubricants



  • 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 elemental composition
    • Evaluating sequential trends , 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 o 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
    • 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



Share With Your Colleagues

WEB ICON 10 X 10-03
WEB ICON 10 X 10-04
WEB ICON 10 X 10-05
WEB ICON 10 X 10-01
WEB ICON 10 X 10-02