CARIBBEAN ANALYTICAL SERVICES

CARIBBEAN ANALYTICAL SERVICES LIMITED

PHOENIX PARK ROAD WEST
PACIFIC AVENUE POINT LISAS, TRINIDAD WEST INDIES

Mission

To be the number 1 in Lubrication, Filtration & Onsite Nitrogen in the Caribbean

From lubrication, filtration & separation technologies, reverse osmosis plants, nitrogen plants,
hydraulics, pneumatics, fluid connectors, pump & pumping systems.

Land Based Reverse Osmosis Plants

PORTABLE USED OIL ANALYSIS PRODUCTS BY SPECTRO INC.

Infrared Lubricant Check Particle Counting & Image Analysis Viscometer

 Nitrogen Generators

Rental and Sale of Nitrogen Generators Units.

For more information contact us.

CASL Lubrication Services were developed to meet customers' needs. Used oil analysis is
provided through CASL’s state of the art laboratory located in the world renowned
Petrochemical Industrial Estate of Trinidad. Tests are done in accordance to ASTM (American
Society for Testing and Materials) and ISO standards. Lubrication services are complimented
with used oil testing. Rental of lubrication equipment is also available.

Services
Used Oil Testing
CASL’s has a modern state of the art laboratory located in the Point Lisas Industrial Estate of the
island of Trinidad. Analysis focuses on lubricant condition, equipment condition and type of
contamination within used oils than unequivocally provides specific information professionals
expect.

CASL is the only state of the art used oil testing facility in the Caribbean that test lubricants and
transformer oils to ASTM (American Society for Testing and Materials) and ISO standards.
Analytical testing is used to provide detailed information of additive packages including
oxidation inhibitor as well as large wear debris particles associated with fatigue wear that
cannot be detected with conventional testing. Professionals understand the power of this
information that when used appropriately can significantly impact on equipment's uptime and
availability thereby increasing productivity, reliability and financial performance. Some common
tests conducted are:

 Particle counting

 Elemental analysis

 Fourier Transform Infrared Spectroscopy

  Moisture Analysis

 Fuel dilution

 Total Acid Number

 Total Base Number

 Viscosity @ 40oC and 100oC

 Viscosity Index

 Oxidation Inhibitor

 Varnish Potential

 Ferrography

Results are provided via email, fax, mail, but more commonly, registered uses have the
opportunity to log on to CASL’s web reporting through the its website. Reports and historical
data can be viewed through trending capabilities providing the opportunity to capture any
abnormalities.

Oil System Flushing – Lubrication and Hydraulic Systems

Oil Reclamation – Transformers, Lube and Hydraulic Oils

Our filtration and separation business area focuses on the removal or separation of unwanted products. Many solutions are readily available
with emphasis on the following fluids:

 Diesel
 Gasoline
 Bunker C
 Compressed Air
 Compressed Air dryers
 Natural Gas
 Water
  Amine Solution
 Lube Oils
 Transformer Oils –Moisture, Acid Scrubbing, Particulates
 Water/Moisture removal
 Lube Oil Varnish Removal
 Subsea Fluids
 Drilling Fluids
 Petrochemical, Oil & Gas Chemicals

If the fluid to be filtered is not stated above, contact us for a more elaborate list of fluids that CASL can process.

CASL can provide filtration rigs, vacuum dehydrators, varnish removal equipment, centrifuges, decanters, carbon towers, dryers, scrubbers
and many other types of separation equipment to meet the demands of the industry.

Hydrostatic Testing

CASL offers on-site hydrostatic testing services up to 15,000 psi for your mission critical equipment. Pressure testing
services are specific to system applications.
Waste Oil Recovery and Disposal
CASL provides an array of oil recovery and disposal services within the Caribbean market. Oils are consolidated at
strategic locations and then disposed of through environmentally friendly ways.

Reservoir Cleaning
CASL has the capabilities to clean reservoir to ISO standards. These services are provided with the highest safety
driven procedures and includes reservoir monitoring, the used of breathing air and enhanced cleaning systems to
certify reservoirs fit for use.

Lubrication Equipment Rental

CASL offers rental of the following equipment:

 Explosion proof vacuum dehydrators

 Explosion proof varnish removal
 Diaphragm Pumps
 High Flow
 High Pressure
 Filtration Rigs

Equipment training and 24-hour support is offered with these packages. Have lubrication problem! Call CASL, we can
help!

Flushing Services

CASL provides flushing services for new installations and existing systems, primarily to remove contaminants within
systems. We use patented pulsating design techniques to achieve high cleanliness levels. Large flowrates and high
efficiency filtration are available for multiple applications. Deminerilize water units support these services. Need
assistance, ask one of our team members. We can help!

Nitrogen Purging

CASL provides turn-key non-cryogenic nitrogen generation systems for petrochemical, mining oil & gas applications
worldwide. These systems utilize membrane or PSA (pressure swing adsorption) technologies to provide nitrogen on-
demand 24 hours day. Large flow rates at high purities are achievable. CASL provides nitrogen services and
engineered turnkey packages.

CASL rents and leases portable nitrogen systems. These units are packaged 20 ft containerized skids and can be
easily mobilized worldwide. Packages are available with DNV and BS approvals for offshore applications. Intrinsically
safe systems are also available.

CASL provides compressors for its nitrogen systems. Complete packages are available for manned or unmanned
operations. CASL's turnkey solutions have the lowest impact to the environment (energy consumption is the lowest in
its class) compared to other conventional nitrogen production methods. For purchase options, CASL solutions have
the lowest cost of ownership.
Nitrogen Generator Pipeline Purging

Equipment Rental
Rental of large portable compressors (2500 scfm)
Rental of Nitrogen Generators

Hydraulic Services

CASL’s hydraulic services include the services of hydraulic components such as pumps, motor, accumulators,
valves, cylinders and actuators. Our Caribbean location is complimented by our Parker Store giving CASL the
capability of providing turnkey services with supply of hoses, fittings, hydraulic components, filtration, flushing,
hydrostatic testing, and commissioning of systems. These services are provided to mobile, industrial and oil & gas
offshore industries.

Hydraulics – Subsea Applications

Hydraulic – Mobile Applications

Ultrasound Inspections
Partnered with SDT Northamerica, CASL provides ultrasound inspection for lubrication, transformer, hydraulic and
many other related applications. Proactive maintenance solutions are readily available to find your problems.

Heat Exchanger

Cooler or Heat Exchange Flushing

CASL provides cooler and heat exchanger flushing services. High running temperatures eliminated either on-line on
during plant turnarounds/shutdowns. Partnered with Anion Corporation, CASL offers a full range of services using
environmentally fluids that are non-toxic, non-corrosive and biodegradable. CASL’s objective of getting your
equipment up and running efficiently with zero impact to the environment is easily achieved.

Plate, Shell & Tube Exchanges cleaned in situ and off-line.

Ultrasound by SDT

The new SDT 270 is now available.

Pump & Pumping Systems

Now Representing PSG pump group in Trinidad & Tobago. Pumps exclusive to CASL are Blackmer (Industrial
Market only), Almatec, Griswold, Neptune and Mouvex. Have an application, give us a call and we are sure to offer a
competitive solution. Pump rentals and full workshop support also available.

Lubrication
Lube Store

Lubrication Products

 Oil analysis equipment

 Oil Storage containers - Oil Safe® Containers

 Magnetic filters

 Oil sampling equipment and accessories

 Single point lubricators

 Engineered lubrication systems

 Lubrication equipment and accessories

 Pumps, computerized dispensing systems

] Lubrication
Used Oil Testing

CASL’s laboratory is located at Phoenix Park Road West, Point Lisas, and the
Petrochemical Industrial Center of Trinidad and Tobago. This laboratory was
commissioned in January 2003 and utilizes state of the art instrumentation for extensive
and sophisticated lubrication analysis. Our procedures are in accordance to ASTM
methods and together with our automated equipment and skilled technicians we can
guarantee the highest quality data. This information will be available via fax, mail or via
the latest technology in e-commerce.

Our Proactive Maintenance techniques include “Root Cause Analysis” that will help
save our customers costly and untimely-unforeseen breakdowns. This will include
attentive sample collection, detailed laboratory analysis, accurate data compilation,
comprehensive evaluation and easy to understand reports. Whether oil is analyzed from
a lube oil circuit in a turbine, diesel engine, gearbox, hydraulic system, etc., life
extension of systems and its components can be guaranteed by taking the necessary
precautions indicated from the lube analysis report.

Our data is compiled, trended, and comprehensively reported utilizing our Laboratory
Information Management Software; Oracle platform based lubrication software, COAST,
customized specifically for Condition Monitoring via Lubrication Analysis.

Our pledge to the industry is to provide sample processing within 24 to 36 hours

(exclusive of weekends and public holidays) upon receipt of the sample at our
laboratory. CASL has the capability and flexibility in performing test to provide results
within shorter time periods when urgency is required.

CASL’s tribological services include extensive wear particle analysis (sliding, cutting,
fatigue and additional wear mode classification) inclusive of ferrography services.
Detailed images and photos would be presented via our COAST software.

Our ancillary services include lubrication program development, lube oil

conditioning through filtration and dehydration, lube oil disposal, transformer oil
degassing, cleaning and related services. Prices of these services will be made
available upon your request.

CASL is also a partner for world renowned Noria Corporation and offers Oil
Analysis training (public seminars or in-house), lube oil audits and lots more.
Certification of your personnel is also available locally through the International
Council for Machine Lubrication (ICML) and CASL.

Schedule of Oil Analysis Services Offered:

Item Quantity Description ASTM Method

1 1 FTIR
2 1 Elemental 6595
Total Acid Number/Total Base
3 1 664/4739
Number
4 1 Viscosity 445
5 1 Karl Fischer 6304
6 1 Particle Count ISO 4406
7 1 Wear Particle Classification ISO modified
8 1 Ferrography Analysis Analytical
9 1 Fuel Dilution Fuel Sniffer
Water concentration in diesel
10 1 6304
fuel
11 1 Crackle N/A
12 1 Transformer Oil Analysis Complete Analysis
Our basic screen package consist of the following tests:- Elemental, Viscosity, TAN, FTIR
and Crackle. It is recommended that these tests be performed first and base on the
results further test can be recommended.

Equipments, sampling bottles, technicians to take samples can all be provided.

Turn around time for reports- 3 working days.

Brief Description of Tests Quoted

Test
Elemental Analysis (ASTM #6595)
FTIR
Viscosity (ASTM #445)
Titration:
Total Acid Number (ASTM #664)
Total Base Number (ASTM#4739 or
ASTM#2896)
Karl Fischer (ASTM#6304
“Procedure C”)
Particle Count (ISO 4406)
Description
A precise measurement of wear metals, additives and
contaminants. This method is approved for used oil
analysis and measures the concentration (ppm) of 21
elements. This test can tell you if there is incipient wear
on metal components, confirm the additive package of
the lubricant and detect contaminants such as dust/dirt
(important tool to check oil quality as well as abnormal
machine wear). This result prompts you to change/purify
oil as well as indicate possible component damage of the
machine.
Measurement of contaminants/oil degradation products.
This measures the concentration of soot, glycol, water,
fuel, oxidation, nitration and sulphation.
Viscosity at 40, 100 and Viscosity Index. Critical test for
all lubricants, help you identify if the correct oil grade is
being used, incorrect oil (used in top ups). This is an
important tool to check oil quality or oil degradation.
This result prompts you to change oil.
Measures the level acidity or acid contamination also acts
as an indicator of oil oxidation level. If the oil is too
acidic corrosive wear can take place. This is an important
tool to check oil quality. This result prompts you to
change/purify oil.
Measures the concentration of basic additives present in
the oil
Accurate method of determining the concentration of
water contamination in lubricating oil or fuel. This
method eliminates false positive results that can arise if
analysis is performed on lubricants containing interfering
additives.
New Standard for determining particle contamination.
This test can be used to determine the efficiency of
system oil filters. Measures the level of particle
contamination. Checks the level of oil cleanliness with
 respect to particle contamination, a high particle
contamination level can cause damage to bearings and
gears. Therefore this is an important tool to check oil
quality. This result prompts you to change/purify oil.
Basic screen test for water contamination. This is an
Crackle Test important tool to check oil quality. This result prompts
you to change/purify oil.
Allows you to measure wear particles of any size and
classify them into:

 Cutting wear
 Sever Sliding Wear
 Fatigue Wear
 Oxide Particles
Wear Particle Classification  As well as the maximum size of each of the above
wear particles.

Allows you to measure wear particles of any size and

classify them. Monitors dominant wear modes and enable
you to identify equipment damage and possible root
causes. This test is very useful for identifying possible
component damage of the machine.
Ferrography is a technique for separating metal
particles, contamination and other particulates from
liquid. It is a powerful technique for non-intrusive
examination of the oil-wetted parts of a machine. The
particles contained in the lubricating oil carry
detailed and important information about the
Ferrography condition of the machine. This information may be
deduced from particle shape, composition, size
distribution, and concentration. The particle
characteristics are sufficiently specific so that the
operating wear modes within the machine may be
determined, allowing prediction of the imminent
behavior of the machine.
Accurate quantitative check for large severe wear
ARFS
particles similar to spectrometric analysis.
Measures the Remaining Useful Life of the lubricant by
RULER quantifying the amount of anti-oxidant oil additive
present in the oil.
Varnish Potential Test (QSA) Checks the potential of the oil to deposit varnish.

We have recently added new “Ruler” and ARFS technologies to determine the remaining useful life of lubricants and
identification of large severe wear elements respectively.
Filtration
Filtration

Parker Filter Carts

 Filtering new fluid before putting into service

 Transferring fluid from drums or storage tanks to system reservoirs
 Conditioning fluid that is already in use
 Complimenting existing system filtration
 Removing free water from a system
 For use with fluids such as hydraulic, gear and lube oils

Parker filter carts are the ideal way to prefilter and transfer fluids into reservoirs or to
clean up existing systems.

Fluid should always be filtered before being put into use. New fluid is not necessarily
clean fluid. Most new fluids (right out of the drum) are unfit for use due to high initial
contamination levels. Contamination, both particulate and water, may be added to a
new fluid during processing, mixing, handling and storage.

The Parker filter cart uses two high capacity ModuFlow filters for long element life and
better system protection. The first stage (inlet) filter captures larger particles, while the
second stage (outlet) filter controls finer particles or removes water. A rugged industrial
quality gear pump gets the job done fast.

Using a Parker portable filter cart is the most economical way to protect your system from the harm that
can be caused by contamination.

Features Advantages Benefits

Two filters instead of one
Wide variety of particulate
elements available
Par-Gel water removal
elements available.
Lightweight and portable.
Two flow rates available (5
gpm or 10 gpm).
Eleven-foot hose and wand
assemblies included.
Pump protection and long
element life
Capable of getting a fluid to a
desired cleanliness level.
Removes “free water” from a
system
Easy to move from place-to-
place.
Enables use in low or high
viscosity applications.
Additional hardware not
necessary.
Element cost savings and
trouble-free service
Avoids excess costs due filter
to over or under filtration
Gets dirt and water out of
system with one process.
One person operation.
Matched to your needs.
Ready to use as received.

Fuel

CASL is a leader in fuel filtration with many complimentary services. Need a tank,
pump, filter, hoses or flow meter? We can provide fuel management support to ensure
you receive clean fuel for your asset.
CASL is a proud supplier of Racor fuel filtration products and have stock to meet your
needs. From bulk fuel filtration to standard turbine or spin on filters, CASL can supply,
install and even test your fuel quality after filtration.
CASL offers rental services for pumps, filtration systems and can certify you fuel fit for
use upon completion of our services.

Filtration
Portable Purification Systems
Principles of Operation

Contaminated oil is drawn into the Parker Portable Purification System by a vacuum of
25In/Hg. The oil passes through the in-line low watt density heater where the oil is
heated to an optimum temperature of 150° F (66°C).

The oil then enters the distillation column where it is exposed to the vacuum through the
use of special dispersal elements. This increases the exposed surface area of the oil
and converts the water to vapor form which is then drawn through the condenser by the
vacuum pump.

The water-free oil falls to the bottom of the column and is removed by a heavy duty lube
oil pump. This pump forces the dry oil through a final particulate removal filter. Clean oil
passes out of the unit, back to the reservoir – and into the system.

Effects of Water Contamination

Water is one of the most common contaminants in a fluid system and one of the most
damaging. When water contaminates a system, it can cause serious problems such as:

 Corrosion by etching metal

 Fluid breakdown, reduction of lubricating properties, additive precipitation, and oil
oxidation
 Reduced dielectric strength
 Abrasive wear in hydraulic components

Free water occurs when oil becomes saturated and cannot hold any more water. This
water is usually seen as cloudy oil or puddles of water at the bottom of an oil reservoir.
Water which is absorbed into the oil is called dissolved water. At higher temperatures,
oil has the ability to hold more water in the dissolved stage due to the expansion of oil
molecules. As the oil cools, this ability reverses and free water will appear where not
visible before. In addition to temperature, fluid type also determines the saturation point
for your system.

Features Advantages Benefits

Variable flow circuit
Moisture sensor
Automatic operation
Stainless steel used for all
wetted surfaces
Compact size
Clear plexiglass covers on the
condensate tank and vacuum
chamber
Desiccant breather
Reverse phase switch
Condensate holding tank with Large volume for infrequent
optional auto drain
Programmable thermostat
Forklift guides and lifting eyes
Coalescing or packed tower oil Flexibility with various fluid
dispersal elements
Starts to remove water more
Allows oil to heat more quickly
quickly
Real-time water content
At a glance visual confirmation
indication in % saturation
Unattended use Designed for Reduces labor costs Increases
24/7 operation operation time
No corrosion Product reliability
Smallest envelope in the Fits in tight areas Encourages
industry Ease of portability use
See the vacuum dehydration Visual verification of water
process work removal
Insures dry, clean intake air More efficient operation
Enables easy changing of motor Ease of maintenance Prevents
rotation if out-of-phase incorrect rotation
Reduces maintenance costs
servicing intervals
Maintains oil within 1°F
Unattended operation
Prevents overheating the oil
Provides safe and secure
Employee safety
method of lifting the unit
Greater efficiency in removing
viscosities moisture

Filtration
Transformer Oil Dehydrating

CASL vacuum dehydrators are used to dehydrate and degas oil in transformers.
Dehydration is normally required when filling new transformers and in the case of “in
service” transformers, the oil and paper insulation frequently become wet due to
headspace leaks to the atmosphere. Cooling and heating cycles allow moisture to enter
the transformer headspace through these leaks. The oil absorbs the moisture from the
headspace.

CASL’s dehydration equipment removes moisture down to below 15 ppm but lower can
be achieved if required. Combustible gases formed in transformers from overheating,
arcing at loose connections and corona discharge are also removed from the vacuum
dehydration process. The service is provided with on-site testing to ASTM standards.
Clients are provided with a complete package to remove moisture and gases that
accumulate in transformers. It is a very proactive solution that leads to improved
reliability and efficiency allowing for increased life time value and lower operational
costs and in particular insurance costs.

Nitrogen
Membrane Technology

A reliable, high performance membrane module is the heart of a nitrogen gas generator.
Customers around the world trust Parker Hannifin to provide reliable nitrogen gas generators that
meet the specific needs of our customer applications.

Pressurized air is fed to one end of the hollow fiber membranes. The permeation rates of water
vapor, CO2 and oxygen contained in the air stream are faster than nitrogen and argon and will
rapidly diffuse through the fiber walls. The slower diffused nitrogen molecules remain in the fiber
bore and are collected as the nitrogen product gas. The air flow rate will determine how much
undiffused oxygen remains with the nitrogen gas. The nitrogen product gas is extremely dry, with
atmospheric dew points typically below – 40° F. The membranes act like a filter with no moving
parts and continuously generate nitrogen at selected flow and purity.

Why are Parker HiFluxx Membranes Unique from other Membrane Filters?

Simply stated, Parker HiFluxx membranes are the most permeable membranes in the world! High
permeability means more nitrogen is produced in each fiber.

 Fewer membranes are required, resulting in lower membrane investment and smaller
membrane footprints vs competitive systems
 Excellent nitrogen production, even at low pressures, allows Parker membranes to operate
directly from instrument or utility air systems or low pressure industrial compressors and still
be compact and lightweight.
 Low pressure compressors operate with less energy, less noise, and less maintenance.
 Parker fibers are robust and are less sensitive to particle than competitors.
 No additional heating is required to improve membrane nitrogen production rates.
 N2 production is extremely stable over time with little or no performance degradation.
Nitrogen
PSA Technology

PSA Technology (Pressure Swing Adsorption)

Why are Parker PSA Systems Superior to Competing Suppliers?

Parker’s nitrogen gas generators separate nitrogen from air, utilizing pressure swing adsorption
technology. Air entering the generator consists of 21% oxygen and 78% nitrogen. The gas
separation process preferentially adsorbs oxygen over nitrogen using carbon molecular sieve
(CMS) thus enabling the N2 to pass through as a product gas at pressure.

High performance and long bed life all start with good bed design, gas distribution and careful
attention to air velocities and mechanical stresses on the carbon molecular sieves.

Both one and two bed units are specially charged with carbon molecular sieve (CMS). A solid
state programmable controller simply operates the process valves on a cyclic basis, with built-in
logic for automatic stop/start. Parker production and purity remain constant, regardless of the
customer peak usage demands, by utilizing an automatic flow control valve. A continuous
monitoring oxygen (O2) analyzer, with alarms and shutdown, is standard equipment.

©
Copyright
2009
CASL. All
rights
reserved.
Nitrogen
Standard Products

Standard high quality nitrogen generators are available ex-stock or with quick delivery. Interested in a demo, send us
an email and we would call to make all necessary arrangements.

Standard Product Lines

Tyre Saver

NitroSource

NitroFlow

NitroFlow Basic

CASL also has a complete range of Analytical Gas Generators inclusive of Zero Air and Hydrogen Generators made
by world renown Balston Division of Parker Hanifinn Corporation.

Need service! No problem CASL's team of engineers and technicians can support your inquiries. Call your account
manager or send us an email.

Oil Analysis 1 and 2 Course Outline

OIL ANALYSIS 1

INTRODUCTION TO MACHINERY LUBRICATION

 Oil formulation and its importance in effective machinery lubrication

 Six key functions of lubricating oils
 Three primary lubrication regimes
 Introduction to base oils and additives
 Choosing the correct base-stock
 Conditions that dictate use of synthetic oils
 Antioxidant additives and their role in oil life
 Dispersants and Detergents - the key to controlling soot
 Controlling wear with additive chemistry
Oil Sampling - The Very Best Practices

 Six steps to reliable and easy oil sampling

 How to find the best sampling location
 Sampling splash, collar and ring lubricated systems
 How to sample circulating systems
 Safe, effective high pressure sampling from hydraulic systems
 Using primary and secondary sampling points
 A quick method for optimizing sampling intervals
 How clean should sample bottles be?
 Sampling valves and hardware recommendations

Fundamentals of Friction and Machine Wear

 Four primary sources of friction in lubricated machinery

 The 10 wear mechanisms that reduce machine life
 The most common wear modes in plain, rolling element and thrust bearings
 Understanding gear wear
 Understanding wear in hydraulic systems

Machine Fault Detection and Debris Analysis

 How wear metals are measured using RDE and ICP spectrometers
 Measuring larger particles with Rotrode Filter spectroscopy
 Using ferrous density to determine the severity of a wear problem
 Using analytical ferrography for advanced fault detection
 Using ferrography for root cause analysis

Fluid Properties Analysis

 Four common root causes of oil degradation

 Recognizing and controlling oil oxidation
 Monitoring lubricant degradation using acid number
 Monitoring lubricant health using FTIR
 Determining oil life using RPVOT
 Recognizing and controlling thermal failure
 How to recognize additive depletion or degradation
 Using paper chromatography (blotter spot test) to detect additive and base oil degradation
 Four ways to detect the addition of wrong oil

Contamination Control and Proactive Maintenance

 Seven common contaminants

 Oil cleanliness and oil life extension benefits
 Using the ISO Solid Contamination Code
 Proactive maintenance in 3 easy steps
 Case studies for proactive maintenance
 Oil filter and breather recommendations
 Portable filtration carts - 3 ways to use them
 Setting targets for oil cleanliness
 Detecting and controlling moisture contamination
 Selecting moisture removal/filtration methods
 The effects of heat on lubricant
 Controlling air entrainment and foam
 Glycol contamination
 Dealing with soot
  Understanding fuel contamination

Instrument Free Onsite Tests

 How to inspect vents and breathers

 Tips for effective site glass inspection
 Getting valuable information from used filters
 Inspecting reservoirs for clues about lube trouble
 Scenting lubricants to find problems
 Getting visual clues from the oil sample before mailing it out
 Getting into particle analysis for under $100
 Turn your kitchen blender into a test for demulsibility and foam tendency
 Screening for water with a simple hot plate
 How an unwanted business card can reveal oil degradation

Interactive Workshop

 Individual and group participation in problem-solving exercises

 Exercises in how to read oil analysis reports
 ICML MLA Level I flashcard review session

OIL ANALYSIS 2
Lubrication Fundamentals

 Understanding full film, elastohydrodynamic and boundary lubrication

 Comparing solvent-refined, hydro-treated and hydro-cracked mineral base oils
 Advantages and disadvantages of the four most common synthetic base oil types
 Understanding API's five base oil categories
 Other base oil classification systems
 Overview of the 14 key additives that enhance lubricant performance
 Antioxidant additives and their role in oil life
 Controlling wear with additive chemistry

Detecting and Troubleshooting Machine Wear

 Four primary sources of friction in lubricated machinery

 The 10 wear mechanisms that reduce machine life
 Beyond elemental spectroscopy - detecting “large” wear particles
 Using analytical ferrography for advanced root cause failure analysis
 Using magnetism, light and heat treatment with ferrograms
 Tips for chemical microscopy - oil analysis forensics
 The advantages and disadvantages of XRF spectrometers for large particle detection
 Using SEM-EDX for route cause failure analysi
 LaserNetTM; automating ferrographic analysis

Fluid Properties Analysis

 Differentiating between oxidation and other base oil degradation pathways

 Troubleshooting additive depletion with some common and not so common oil analysis tools
 Using FTIR for advanced lubricant chemical analysis
 Determining oil life using RPVOT and RUL tests
 Troubleshooting air release and foaming problems
 Identifying the addition of wrong oil using oil analysis

Using Oil Analysis to Define Lubricant Standards

  Setting up a basic QA program for incoming lubricants
 Defining minimum performance standards for new lubricants using oil analysis
 Conducting lubricant cross compatibility testing
 Using oil analysis viscometric properties to guide and troubleshoot lubricant selection

Grease Analysis

 Obtaining samples for in-service grease analysis

 Identifying possible grease compatibility issues using grease analysis
 Determining oxidation and the RUL of a grease
 Troubleshooting wear problems in grease lubricated bearings

Oil Analysis Program Design

 Using RCM and FMECA analysis to guide analysis program design

 Designing an oil analysis program to ensure proactive and predictive maintenance success
 Integrating oil analysis with other condition-monitoring technologies
 Ensuring oil analysis quality on-site and off-site
 Selecting machine-specific oil analysis test slates
 Creating effective oil analysis procedures
 How to scope training for the rest of the oil analysis and lubrication team
 Tips to setting up an effective on-site lab

Managing an Oil Analysis Program

 Selling oil analysis to management - how to write an effective oil analysis proposal
 Using financial data to justify lubrication and oil analysis program costs
 Using statistics to set level limits
 Modifying limits to account for operational changes
 Calculating and using rate-of-change limits
 How to set condition-based oil change limits
 Learning multi-parameter diagnostic techniques
 How to effectively manage oil analysis data
 Using oil analysis to develop lubrication Key Performance Indicators (KPI’s)

Data Interpretation Workshop

 Individual and group participation in advanced problem-solving exercises, including designing and
implementing an oil analysis program, analyzing data and making decision on continuous improvements
 ICML MLA Level I flashcard review session

Machinery Lubrication 1 and 2 Course Outline

MACHINERY LUBRICATION 1

How Lubrication Affects Machine Reliability

 Financial benefits from achieving lubrication excellence

 Don’t attempt Reliability-Centered Maintenance (RCM) without
the 5–I lubrication method
 Five equipment maintenance strategies, and when each applies
  Important implementation steps to lubrication excellence
 10 roadblocks to achieving 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
 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

 14 key additives that enhance lubricant performance

 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

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 thickenersv • Advantages and
disadvantages of food-grade lubricants Lubricating Grease Application Methods
 Seven tips for avoiding incompatible grease mixtures
 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

Selecting Lubricants

 Journal and rolling-element bearings

 Open and closed gears
 Gas engine and gas compressors
 Air compressors
 Hydraulic fluids
 Steam and gas turbines
  Process pumps
 Multipurpose grease
 Oil mist lubricants

Contamination Control

 Building reliability through contamination control

 Seven most destructive contaminants and how to control them
 Three steps to proactive maintenance
 Understanding the ISO Solid Contaminant Code
 10 ways to maximize filter cart usage

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

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

Design and Inspect for Lube Excellence

 World-class strategies for accessorizing equipment for lubrication excellence

 Seven critical accessories for inspection and sampling
 Seven critical accessories for contamination control prevention
 Eight essential lubrication accessories
 What your breather is telling you about your machine

Used Oil Analysis Basics

 When to use 11 common used oil analysis tests

 Oil sampling best practices
 Oil analysis for condition-based oil changes
 Detecting and analyzing machine wear debris
 Easy field tests for quick inspections

Essential Field Inspections

 12 questions your filter will answer about your machine

 Which visual inspections can provide big results
 Quick tips for using scent, sound and touch to inspect lubricants

MACHINERY LUBRACATION 2
The Role of Lubrication in Machine Reliability

 The journey to world-class maintenance

  The importance of spending time and money on your machines
 Creating a cultural change for machinery lubrication
 How to benchmark your lubrication program

Lubrication Fundamentals

 Five types of friction and the role friction plays in the health of your machine
 Three ways lubrication affects energy consumption
 How to find the lubrication “sweet spot” for energy conservation

The Value of Base Oils and Grease Thickeners

 Understanding mineral oil and base oil properties

 Compatibility – how synthetics match up with seals and mineral oils
 Base oils that offer extended drain intervals
 How to select grease thickeners for your applications

Lubricant Performance Properties

 The role of base oils and additives

 Six key items that influence viscosity
 The importance of Viscosity Index
 Effects of oxidation on the oil, grease and machine life
 Four ways to measure oxidation stability
 What you must know about thermal stability, varnish and sludge
 Four critical techniques to reduce corrosion
 Eight ways aeration affects the life of your lubricants
 Nine dominant causes of poor demulsification and how it affects your critical machines
 Four main triggers of grease dry out

Food-grade and Environmentally Friendly Lubricants

 Government regulations regarding food-grade lubricants

 NSF food-grade lubrication classifications
 Advantages and disadvantages of food-grade lubricants

Lubricant Degradation

 How and why lubricant performance properties are irreparably changed

 10 influencing factors that affect stored lubricants
 Understanding the remaining useful life of lubricants

Accessorizing New Equipment for Lubrication Excellence

 How to design for maintainability

 31 simple ways to improve your overall lubrication program
 The value of new equipment documentation and the 10 top conditions to document

Oil Drains, Flushing and Reservoir Management

 Top 10 reasons to change your oil

 Two approaches to oil drain scheduling
 How to extend oil change intervals
 Best practices for draining and refilling
New Lubricants

 The four phases of lubricant consolidation

 Six essential reasons to create lubricant standards
 The most important variables when selecting a vendor
 Five considerations for testing new lubricants

Lubrication PM Optimization and Design

 The Five ‘Rs’ of a proper lubrication procedure

 How to conduct lubrication audits and surveys
 How to write a proper PM procedure
 Setting effective lubrication PM intervals and schedules
 How to conduct lubrication audits and surveys

Leakage Stability

 How to identify and classify leaks

 Strategies for locating and correcting leaks
 Leakage management strategies for lubrication excellence

Advanced Lubricant Selection and Application

 Selection and use of automotive and crankcase lubricants

 Journal bearing lubricants
 Rolling element bearing lubricants
 Lubricating grease application
 Gear lubricants
 Mechanical coupling lubricants
 Compressor lubricants
 Refrigeration compressor lubricants
 Steam and gas turbine lubricants
 Hydraulic fluids
 Miscellaneous lubricants
 Wire rope and chain lubrication

Troubleshooting Lubrication Problems

 Gearbox lubrication problems

 Journal bearing problems
 Rolling element bearing problems
 Diesel engine problems
 Compressor problems
 Hydraulic system problems

Lubrication and Oil Analysis Metrics

 Lubrication performance charting

 Using the Overall Lubrication Effectiveness (OLE) metric
 Tracking return on net assets for your program
 How to use software and the Internet for program metrics
Effective Contamination Control Course Outline

Course Outline

Level I

How Contamination Control Affects Machine Reliability

 Building reliability through contamination control

 The most destructive contaminants
 How contaminants attack base oil, additives, machine surfaces and impair lubrication
 Proactive maintenance and contamination control
 Proactive maintenance in three steps
 Contamination control and the oil drain interval
 Financial benefits of a top drawer contamination control program

How Lubricants are Formulated to Resist or Control Contaminants

 Base oils and contaminants

 Additives that control contaminants
 Oil oxidation and the role of contamination
 Contamination-based lubricant selection strategies

Heat Contamination

 When is heat a contaminant?

 The Arrhenius Rate Rule and the drain interval
 Mitigating heat effects with lubricant selection
 Thermal stability of oils and grease
 When is hot oil good
 Setting operating temperature limits
 Causes of heat contamination
 Controlling heat contamination in grease
 When to use coolers to control heat
 Heat monitoring strategies and thermography

Particle Contamination

 Wear caused by particle contamination

 Silt lock failure modes
 Machinery contaminant sensitivity by type
 How particles influence oil oxidation
 Describing and quantifying particle contamination
 Particle ingression categories
 How to use the ISO Solid Contaminant Code
 How to set target cleanliness levels for lubricants
 Particles counters
 Patch testing and microscopic analysis of particles
 Particle contamination in grease

Controlling Soft Contaminants

 What are soft contaminants?

 Where do they come from?
  The harm caused by soft contaminants
 Strategies for the analysis of soft contaminants
 Strategies for removing soft contaminants

Moisture Contamination

 Water in oil, states of coexistence

 Harm caused by water contamination on the oil
 Demulsibility characteristics of lubricants
 How water makes other contaminants
 Sensitivity of machines to water contamination by type
 Water and corrosion
 How to set target dryness levels for lubricants
 Technologies and methods for detecting and quantifying moisture levels
 Moisture effects on grease

Air and Gas Contamination

 Air in oil, states of co-existence

 Sources of air contamination
 Troubleshooting air ingression problems
 Air release, foam tendency, and foam stability
 Harm cause by air to the oil and lubrication properties
 How air influences heat and bulk modulus
 Air effects on adiabatic compressive heating and cavitation
 Air and tank design issues

Glycol Contamination

 The destructive potential of glycol (antifreeze) contamination

 Sources of coolant leaks
 Reaction products of glycol/oil mixtures
 Strategies for detecting glycol in oil

Fuel and Soot Contamination

 Sources of fuel and soot contamination in engine oil

 Harm fuel and soot causes engines and lubrication performance
 Methods to detect and monitor fuel and soot
 Soot load versus soot dispersancy
 Soot and EGR engines
 The role of bypass filters and separators in controlling soot

Microbial Contamination

 Types of biological contaminants in lubricants

 Lubricants and applications of highest risk for microbial contaminants
 Harm caused by biological contaminants
 Detecting and controlling microbial contaminants

The Lubricant as a Contaminant

 Incompatible grease and harm caused

 Acidic byproducts of degraded and contaminated lubricants
 Cross contamination, or mixing, of incompatible lubricants
  How to detect a mixed lubricant
 Ways to mitigate the risk of lubricant mixing

Controlling Contaminant Ingression

 Cleanliness of new lubricants

 Controlling contamination during lubricant storage
 Controlling contamination during lubricant handling
 How to inspect machines for contaminant ingression sources
 Breathers and headspace management
 Roll-off machinery cleanliness (new and rebuilt)
 Controlling ingression during machinery inspection and repair
 Parts storage and handling influences on ingression
 How machine design influences contaminant ingression
 Selecting seals for controlling contaminant ingression
 Sources of water contamination
 Using grease to exclude contamination
 Contamination control in laid-up and stand-by equipment

How Lubricant Application Methods Cause or Control Contamination

 Which application methods most effectively control contaminant ingression

 Using a grease gun to reduce contaminant ingression
 Application methods to avoid
 Benefits of oil mist lubrication in controlling ingression
 How to introduce make-up oil to reduce ingression

Contaminant Removal

 Filter type and location options

 Filter construction and media options
 Off-line filtration and it’s unique benefits
 By-pass filters use in diesel and gasoline engines
 When to retrofit filters on bath and splash lubricated machines
 Strategies for filtering high viscosity oils
 Filter performance tests and the Beta Ratio
 How to select a filter for a specific target cleanliness
 Strategies for optimizing the filter change interval
 Strategies for using filter carts
 Settling tanks and reservoir design considerations
 Oil reclamation and Reconditioning Strategies
 Degassing systems
 Magnetic separation of particles
 Air stripping and vacuum dehydration
 Coalescence and water removing filtration
 Electrostatic and charged particle separators
 Centrifugal separators
 Acid scavenging technologies including ion-exchange resins

Flushing Strategies

 What conditions require flushing

 How avoid the need for a flush
 Selecting the correcting flushing strategy
 Defining the use of flushing fluids and equipment
 Common flushing problems
Contamination Control Case Studies

 Gearbox and rolling element bearing applications

 Papermills
 Power plants
 Steel mills
 Petrochemical plants
 General manufacturing
 Transformer Maintenance by SD Myers Corporation/ Transformer Maintenance Institute
 Airborne Ultrasound Training & Certification by SDT Corporation
 Thermography Level 1 by Snell Infrared Training
 Vibration Analysis by VTrainer Corporation

Compressed Air Pretreatment

Compressed Air Treatment Products available. Water Separators, Coalescers,

Aftercoolers, Dryers, Pressure Tanks available. Systems can be provided to meet
relevant ISO classifications. Applications include Industrial, Instrumentation Air, Food
Grade (high and low risk), Breathing Air, Medical, and Utility Air. Compressed Air testing
services available that include pressure, temperature, particulates and dew point.
Contact us for more information.