This 2 day course will be classroom style in the morning and early afternoon, followed by a lab visit/specific application discussion both days.
Introduction
- Outline
- Introduction to Lubrication World and Tribology
- Early Pioneers of Lubrication
- Maintenance Strategies
- The Need for Lubrication – Microscopically Rough Surfaces
- The Mechanisms of Lubrication
- Importance of Viscosity for Film Thickness
- Lubricant Design Requirements
- What is a Lubricant
- Basestocks – Mineral & Synthetic
- Additives – What They Are and How They Function
- Comparison of Lubricants and Their Properties
- Common Applications of Synthetic Lubricants
- How to Select a Lubricant
- The Importance of Specifications
- Purchasing Lubricants – Tips and Strategies
- Monitoring Lubricant Condition
- Viscosity – Departure From Nominal Value Causes and Effects
- Oxidation
- Thermal Degradation
- Varnish Formation
- Nitration & Sulfation
- Acid and Base Number – What They Mean
- Oil Quality Bench Tests – Oxidation Tests, Foam, Emulsibility, Rust
Contamination
- Types of Contamination
- Liquid Contamination
- Water Causes & Effects
- Tests for Water
- Storage Considerations
- Coolant Contamination
- Glycol Leaks – Causes and Effects
- Fuel Dilution
- Gas Contamination
- Entrained Air – Causes and Effects
- Cavitation
- Tests for Gas Contamination
- Solid Contamination
- Sources and Effects
- Testing for Solid Contamination
- Contamination Codes
- Filtration Fundamentals
- Filter Efficiency
- Lubricant Recycling and Reclamation
- Fundamentals of Wear Debris Generation
- Particle Sizes
- Monitoring for Wear Debris – Methods
- Spectroscopy – Principles
- Elements Tested for Wear Debris and Their Sources
- Detection Efficiency and Comparison of Techniques
- Rotrode Filter Spectroscopy and Doublecheck Technique
- Types of Wear Debris and Source Mechanisms
- Monitoring Wear Debris – Ferrography
- Direct Read Ferrography
- Analytical Ferrograph
Data Interpretation
- Results – Data Analysis, Interpretation and Trending
- Defining Alarms – Absolute and Statistical
- Rate of Change Methods
- Setting Alarms
- Combination Trends
- Root Cause Diagnostic Strategies
- Synergy of Oil Analysis with Other Reliability Technologies
- Requirements of a Successful Program
- Establishing Criticality – What to Monitor
- Working with a Laboratory
- How to Sample Correctly
- Selecting the Right Tests for the Application
- Taking Action
- Feedback and Proactive Maintenance
- Application Spotlights
- Turbines, Gears, Hydraulics, Engines, Compressors
- Cost Savings – Increasing Profits
- Case Studies