INTRODUCTION FOR MACHINERY LUBRICATION
The Machinery Lubrication course is most beneficial for maintenance, reliability and operations professionals who are directly responsible for lubrication tasks. Planners, supervisors and managers and others can also gain valuable insights into lubrication program gaps, cost-saving opportunities and data-driven decision-making from this course.
Understanding the overall health and well-being of your equipment can improve your profitability and provide a competitive edge. Lubrication management and oil analysis are focused on getting the most out of their equipment.
KEY OBJECTIVES
- Understanding the classification of lubricants.
- Understanding the suitability for the purpose and conditions under which lubrications are
- Understanding the various lubrication terms used.
- Understanding what Hydrodynamic lubrication is.
- Understanding the properties and function of lubrication and how to choose a lubrication.
- Distinguishing between the various lubricating devices.
- Understanding the working principle of lubricating devices.
- Understanding the reasons why cutting fluids and cutting oils are used in workpieces
WHO SHOULD ATTEND
- Maintenance Managers
- Maintenance Engineers and Supervisors
- Maintenance Line Leaders
- Manufacturing and industrial engineers
- Predictive maintenance technicians
- Reliability engineers
METHODOLOGY
Comprise the following training methods:
- Lectures
- Seminars & Presentations
- Group Discussions
- Assignments
- Case Studies & Functional Exercises
COURSE CONTENT
Module 1
Lubrication Fundamentals
- Important functions of lubricating oils
- How oils and greases are formulated and why it is important
- How friction is generated in lubricated machinery
Module 2
How Lubrication Affects Machine Reliability
- Financial benefits from achieving lubrication excellence
- Five equipment maintenance strategies, and when each applies
- Important implementation steps to lubrication excellence
- Roadblocks to achieving lubrication excellence
Oil Drains, Flushing, and Reservoir Management
- How to optimize and extend oil change intervals
- Interval vs. condition-based oil change
- How to monitor lubricant consumption
- Best practices for oil changes
- How and when to perform a flush
- Selecting appropriate cleaning and flushing procedures
Module 3
Lubrication Fundamentals
- 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
Module 4
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
- 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
Module 5
Lubricant Performance Properties
- Understanding viscosity grades, measurement, and reporting
- Why Viscosity Index is important and how it improves your work
- Lubricant performance tests and reporting – what you need to know
- How water contamination generates other contaminants
- How to control and eliminate aeration problems
Module 6
Lubricating Grease Application Methods
- Advantages and disadvantages of centralized lubrication systems
- Best practices for greasing motor bearings
- How to calculate greasing intervals and quantity
- Best practices for ultrasonic/sonic-based greasing
- Important tips for working with your motor rebuild shop
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
- 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 critical factors affecting rolling-element bearing lubricant selection
- How to convert required operating temperature viscosity
- to ISO viscosity grades
Gear Lubricants
- Key requirements for gear oil
- How to select the best viscosity for a gear lubricant
- Best practice guidelines for storing spare gear boxes –
- lubrication matters!
- Conditions that may require synthetic gear lubricants
- Lubrication best practices for enclosed gears –checklist
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
Module 7
Lubricant Contamination Control
- Building reliability through contamination control
- Common destructive contaminants and how to control them
- Three steps to proactive maintenance
- 10 ways to maximize filter cart usage
- How dirt, metal particles and soot mechanically destroy
- machine surfaces
- The No. 1 cause of machine wear and how to manage it
- How to set realistic cleanliness levels for lubricants
Module 8
Oil Drains, Flushing, and Reservoir Management
- How to optimize and extend oil change intervals
- Interval vs. condition-based oil change
- How to monitor lubricant consumption
- Best practices for oil changes
- How and when to perform a flush
- Selecting appropriate cleaning and flushing procedures
Module 9
Storage, Handling, and Managing Lubricants
- How to set up a world-class lube room
- How to optimize lubricant selection/procurement
- How to implement a lubricant consolidation program and select suppliers
- Best practices for inspecting/testing new lubricants
- Used lubricant storage, handling, and disposal best practices
Module 10
Oil Sampling – The Very Best Practices
- How clean should sample bottles be?
- How to find the best sampling locations
- Sampling valves 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
- How to properly sample circulating systems
Module 11
Essential Field Inspections
- Question your filter will answer about your machine
- Which visual inspections can provide big results?
- Used filter inspections
- Quick tips for using scent, sound, and touch to inspect lubricants
