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BRICATION
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MACHINERY LUBRICATION
LEVEL - I
Learn precision lubrication skills for
maximizing machine reliability in this
course

Certification by ICML

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The Role of Lubrication in Machine Reliability

. The Journey To World-class Maintenance

. The Economics of Maintenance and Lubrication
. The Pareto Principle
. Applying Pareto The Reliability of Rolling Element
Bearings Modern Maintenance Technologies
. The Human Body Parallel To Machine Maintenance
. Root Cause-driven Maintenance = Proactive Maintenance
. The Optimum Reference State (ORS)
. Roadmap To Lubrication Excellence
. Case Study - Condition Monitoring Saving - Baltimore
Gas And Electric
. Case Study - Nippon Steel Corporation
. Machine Maintenance Philosophies

Lubrication Fundamentals - Base Oils

. How Lubricants Are Formulated

. Common Generic Lubricant Types
. Base Oils
. Base Stock Physical Properties
. Mineral Oil Properties
. API Base Oil Categories
. Base Oil Types Vs. Service Temperature Range
. Properties of Common Synthetic Base Oils
. Synthetic Lubricant Properties
. How Synthetic Oil Properties Compare

Lubricant Fundamentals - Additives

. Additives - What They Are

. Characteristics of Polar Additives
. Antioxidants / Oxidation Inhibitors
. Viscosity Index Improvers
. Over-base Detergents Additives
. Defoamants - How They Work
. Corrosion Inhibitors

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Lubricant Fundamentals - Grease

. Anatomy of Lubricating Grease

. Grease Advantages and Disadvantages
. Grease Manufacturing Process
. Grease Thickener Performance Table
. Grease Thickener Compatibility
. Grease Consistency
. NLGI Grease Consistency Numbers
. Selecting Grease According to Consistency and Base
Oil Viscosity
. What Causes Grease Dry-Out ?
. Grease Properties - Requirements By Application

Lubricant Fundamentals - Viscosity and

Viscosity Index

. Viscosity
. Measurement of Kinematic Viscosity
. Measurement of Absolute Viscosity
. ISO Viscosity Grades (ISO 3448)
. SAE J-300 Engine Oil Viscosity Classification
. SAE Grades
. SAE J-306 Gear Oil Viscosity Classifications
. Comparative Viscosity Classifications
. Viscosity / Temperature Chart
. Viscosity Selection Balance
. Optimum Selection of Viscosity and Film Strength Additives
Can Lower Friction, Heat
. What is Viscosity Index?

Food Grade and Environmentally Friendly

Lubricants
. How are Food - Grade Lubricants Regulated ?
. NSF Food - Grade Lubricant Classifications
. Environmentally Friendly Lubricants

Lubricant Failure - Base Oils and Additives

. How Lubricant Properties Change

. Dual Course of Oxidation
. Thermal Stability of Lubricants
. Varnish Formation

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Lubricating Grease Application Methods
. Grease Application - Manual Grease Gun
. Grease Gun Operation
. Grease Fittings
. Managing Pressure When Re-greasing
. Re-lubrication
. Sealed and Shielded Bearing
. Comparison of Bearing Configurations
. Example Bearing Initial Fill Levels
. Re-lubrication Volume Methods for Electric Motors
Volume
. Rolling Element Bearing Re-greasing Intervals
. Motor Bearing Re-lubrication Frequency
. Electric Motor Re-grease Procedures
. Electric Motor Grease Selection
. Sonic / Ultrasonic Greasing
. Options for Sonic / Ultrasonic Measurements
. Strategy for Ultrasonic / Sonic-based
. Bearing Types-Journal (plain) and Thrust Bearings
. Journal Bearing
. Plain Bearings - Lubrication Problems
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Greased System Troubleshooting Guide
- Roller Bearings
. Manual Vs. Automatic Grease Supply
. Single-Point Lubricators (SPLS)
. Spring-Loaded Grease Cups
. Gas-Activated Single-Point Lubricators
. Positive Displacement Pump-Type Units
. Factors That Influence Single-Point Lubricator
Grease Flow
. Centralized Multi-Point Lubrication Systems
. Single-line Parallel System
. Single-line (Series) Progressive
. Dual-line Parallel
. Dual-line Parallel System in a Paper Mill
Lubricating Oil Application Methods
. Lubricating Oil Delivery Options
. Manual Lubrication
. Drop And Wick Feed Cups
. Constant-level Oilers
. Avoiding Problems With Constant - Level Oilers
. Limitations of Some Oil Lifting Devices
. Splash-lubricated Gear Drives
. Dip Level For Non-circulating Gear Drives
. Pressure Spray Lubrication
. Oil Mist Lubrication
. Mist Lubrication Considerations
. Oil Mist Options
. Continuous Forced-oil Circulation
Journal Bearing Lubricants
1. Viscosity Selection Based on Load and Speed
2. Viscosity Selection Based on Load ond
Surface Speed
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Rolling - Element Bearing Lubricants Gear Lubricants

. What’s Up With Speed Factors ? . Gear Oil Requirements

. Using Speed Factor to Determine Oil Vs. Grease . Gear Design Basics
. Typical Lubricant Formulations For Gear Drives
. Ball Bearing Minimum Viscosity Calculation
. Gear Lubrication - Synthetic Lubricants
. Converting Required Operating Temperature Viscosity
. Guidelines For Storage of Spare Gearboxes
to ISO Viscosity Grades
. Lubrication Best Practices
1. For Enclosed Gears
2. For Open Gears

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Compressor Lubricants

. Compressor Lubrication
. Compressor Lubrication Challenges
. Synthetic Lubricants For Compressors

Selection And Use of Automotive and Mobile Equipment

Drive - Line Lubricants

. Abnormal Engine Wear . Fuel Contamination in Engine Oil (Fuel Dilution)

. API Service Classifications
. Dry Engine Starts
. Benefits of Diesel Engine Prelube System
. Cold Engine Starts (Viscosity Too High)
. Glycol / Antifreeze Contamination in Engine Oil
. Mechanism of “Oil Ball” Formation From Glycol
(Antifreeze)
. Contamination of Crankcase Oil
. Best Practices For Diesel Engine Lubrication
. API Automotive Gear Oil Service Designations
Functions of An Automatic Transmission Fluid
. NLGI Automotive Grease Classifications*
. Case Study : General Motors Testing on The
Influence of Filter Performance on Engine Life

Steam and Gas Turbine Lubricants

. Influence of Lubrication on Turbine / Generator
Reliability Turbine Oils
. Comparing Turbine Oil Exposure and Operating
Conditions Technical Sheets - Turbine Oils
. Oxidation Stability Test Reveals Incompatibility
of Mixed Turbine Oils
. Best Practices For Steam Turbine Lubrication
. Hydraulic System
. Hydraulic Pumps
. Viscosity Selection For Hydraulic Fluids Based on
Pump Type
. Hydraulic Fluids
. Conditions Under Which A Synthetic Fluid May Be
Required
. Properties And Characteristics of Fire-resistant
Fluids
. Best Practices For Hydraulic System Maintenance

Hydraulic Fluids

. Hydraulic System
. Hydraulic Pumps
. Viscosity Selection For Hydraulic Fluids Based on Pump
Type Operating Pressure
. Hydraulic Fluids
. Properties and Characteristics of Fire-resistant Fluids
. Best Practices For Hydraulic System Maintenance

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The Effects of Contamination

. Contamination Control - Building Reliability
. Damage Caused By Oil Contamination
. Three - Body Abrasive Wear
. Surface Fatigue
. Particle Contamination
. Particle Size and Particle Count
. Proactive Maintenance
. ISO Solid Contaminant Code Controlling Contaminants
. Target Cleanliness Grid (TCG) . Particle Population Growth Life Cycle
. Machine Life Extension Table . Contamination Induced By Transfer Container
. Tank and Sump Ventilation
Water Contamination
. Spin - On or Cartridge Filters
. Water Contamination
. Desiccant Filter Breathers
. How Low Should Moisture Limits (Targets) Be Set ?
. Controlling Hydraulic Cylinder Ingression
. Water - Related Damage to Rolling Element
. Contamination Control Balance
Bearings
(Calorie Control Balance)
. Life Extension Table For Setting ORS Dryness
. Multipass Beta Ratio Test For Filters
Targets
. Portable Filtration
. Oil / Water Demulsibility
. Determining Clean-up Rate For Portable Filters
. Moisture Detection By Vision
. Filter Cart Applications
Air Contamination . Normalized Engine Life Curve On Improved
. Air Contamination Filtration - GM Study.
. Cavitation Wear . Engine Oil Filtration
. Water Ingression Sources
Oil Drains, Flushing and Reservoir . High Head Space Humidity Plus Frequent
Management Temperature Changes
. Oil Drain Scheduling . Spin Your Oil Dry And Clean
. Is a Condition - Based Oil Change The Best Choice ? . Super Absorbent Filters
. Diesel Engine Oil Drain Intervals . Oil Dehydration By Vacuum
. Oil Draining - Best Practices . Vacuum Column and Separation Configurations
. Refilling - Best Practices . Dehydration By Sparging and Dialysis
. Flushing Tactics . Oil Dehydration By Coalescence
. Controlling Varnish-potential
Design and Inspect for Lubrication . Electrostatic and Charged-particle Separators
Excellence
. Electrostatic Filtration
. Considerations For Accessorizing Equipment For
Lubrication Excellence . Balanced Charge Agglomeration

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Used Oil Analysis Basics

. Oil Analysis
. What Oil Analysis Can Tell You
. Common Oil Analysis Applications
. Types of Oil Analysis
. Sampling
. Sampling Location
. Drop-Tube Vacuum Sampling of Reservoirs and Tanks
. Sample Bottles
. Clean Oil Sampling Procedure-Best Practice
. Sampling Frequencies
. Viscosity
. TAN / TBN
. Fourier Transform Infrared Spectroscopy (FTIR)
. Rotating Pressure Vessel Oxidation Test (RPVOT)*
. Achieving Excellence In Oil Analysis

Lube Room, Handling, Storage and . Lubrication Tags

Management of Lubricants
. Lubricant Supply Options
. Bulk Storage and Handling
. Bulk Storage Spill Protection
. Intermediate Bulk Containers
. Outdoor Drums Stroge
. Protecting Drums From Contaminant Ingression
. Drum Handling Safety
. Tote and Drum Spill Containment
. Lubricant Store Room
. Features of a Proper Lubricant Storage Room
. Lube Room Transfer and Filter Cart Storage Area
. Properly Equipped Lube-dispensing Rack
. Rack-mount Lube Dispensing Station - Drums and
Totes
. Bulk Oil Dispensing Done Right
. Check Out These Lube Rooms / Trucks
. Drum Pump Dispensing
. Lube Room Safety Considerations
. Best Practice - Oil Cans And Top-Up Containers
. Oil Cans And Top-up containers - Things to Avoid
. Best Top-Up Container Options
. Tips to Best Use of S&R Containers
. Comparison of One-Shot And S&R Top-up
Containers
. Portable Transfer Equipment
. Funnel Management - Best Practices
. Storing Grease - NLGI Best Practices
. Product Storage Life
. Lube Code Tags
. Grease Fitting Tags And Caps
. Lubricant Identification System (LIS)
1. For Oil
2. For Grease
Field inspections - Basic Machine Care and
Daily Round
. Field Tests And Inspections
. Using Oil Color as a Field Test
. Field Test For Oil And Water Separation
. Visual Internal Machinery Inspections
. Visual External Machinery Inspections
. Routine Inspection of Sight Glasses is Oil Analysis
. Field Test For Ferrous Particles
. Simple Field Method For Preparing Patch
. Field Test : Blotter Spot
. Field Test For Viscosity Measurement
. Field Tests For AN and BN
. Other Audible Inspections
. Audible Bearing Symptoms
. How To Analyze Filter Debris
. Used Filter Inspections
. Moisture Detection By Vision
. Crackle Test
. Using Oil Odor AS a Field Test

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