|
I.
Lubricant roles and functions (10%)
A.
Base oil
1.
Functions
2.
Properties
B.
Additive types and functions
1.
Surface active additives and their functions
2.
Bulk oil active additives and their functions
C.
Synthetic lubricants
1.
Synthetic lubricant types
2.
Conditions dictating their use
D.
Lubrication regimes
1.
Hydrodynamic
2.
Elasto-hydrodynamic
3.
Boundary
II.
Sample handling and preparation (5%)
A.
Sample cleanliness
B.
Contaminant resuspension
1.
Bottle Ullage
2.
Sample Agitation
III.
Lubricant health monitoring (20%)
A.
Fluid properties test methods and measurement units
1.
Kinematic Viscosity (ASTM D445)
2.
Absolute (Dynamic) Viscosity (ASTM D2893)
3.
Viscosity Index (ASTM D2270)
4.
Total Acid Number (ASTM D974 et al)
5.
Total Base Number (ASTM D974 et al)
6.
Insolubles (D893)
7.
Fourier Transform Infrared (FTIR) analysis
8.
Rotating Pressure Vessel Oxidation Test (ASTM D2272)
9.
Atomic Emission Spectroscopy (ASTM D5185, 6595)
B.
Testing for wrong or mixed lubricants
1.
Baselining physical and chemical properties tests
2.
Identifying additive discrepancies
C.
Testing for oxidative degradation
1.
Common test methods and units
2.
Effects on the lubricant
3.
Effects on the machine
D.
Testing for thermal degradation
1.
Common test methods and units
2.
Effects on the lubricant
3.
Effects on the machine
E.Testing
for additive depletion/degradation
1.
Common test methods and units
2.
Effects on the lubricant
3.
Effects on the machine
IV.
Lubricant contamination monitoring (20%)
A.
Particle contamination
1.
Methods and units for measuring particle contamination
a)
ISO solid contamination code (ISO 4406)
b)
Optical particle counting (ISO 11500, ISO 11171)
c)
Pore block particle counting
2.
Effects on the lubricant
3.
Effects on the machine
B.
Moisture contamination
1.
States of coexistence of water in oil
2.
Methods and units for measuring moisture contamination
a)
Crackle test
b)
FTIR analysis
c)
Co-distillation
d)
Karl Fischer titration (ASTM D1744 & D6304)
3.
Water demulsibility
a)
Test methods and units (ASTM D1401 & 2711)
b)
Causes of poor water demulsibility
4.
Effects of water contamination on the lubricant
5.
Effects of water contamination on the machine
C.
Glycol coolant contamination
1.
Methods and units for measuring glycol contamination
a)
Elemental spectroscopy
b)
FTIR analysis
c)
Schiff's Reagent (ASTM D2982)
2.
Effects on the lubricant
3.
Effects on the machine
D.
Soot contamination
1.
Methods and units for measuring soot contamination
a)
Thermogravimetric analysis (TGA) - (ASTM D5967-A4)
b)
FTIR analysis
c)
Pentane Insolubles (ASTM D893)
2.
Effects on the lubricant
3.
Effects on the machine
E.
Fuel contamination (fuel dilution in oil)
1.
Methods and units for measuring fuel contamination
a)
Viscosity effects (ASTM D445)
b)
FTIR analysis
c)
Flash point test (ASTM D92, D93 & D3828)
d)
Gas chromatography (ASTM D3524)
2.
Effects on the lubricant
3.
Effects on the machine
F.
Air contamination (air in oil)
1.
States of coexistence
2.
Methods for assessing air contamination
a)
Air release characteristics (ASTM D3427)
b)
Foam stability characteristics (ASTM D892)
3.
Effects on the lubricant
4.
Effects on the machine
V.
Wear Debris Monitoring and Analysis (20%)
A.
Common wear mechanisms
1.
Abrasive wear
a)
Two-body
b)
Three-body
2.
Surface fatigue (contact fatigue)
a)
Two-body
b)
Three-body
3.
Adhesive wear
4.
Corrosive wear
5.
Cavitation wear
6.
Size distribution of wear particles from common wear mechanisms
B.
Detecting abnormal wear
1.
Atomic emission spectroscopy methods
a)
Inductively coupled plasma (ICP) spectroscopy
b)
Arc-spark emission spectroscopy
2.
Wear particle density measurements
C.
Wear debris analysis
1.
Ferrogram preparation
2.
Filtergram preparation
3.
Light effects
4.
Magnetism effects
5.
Heat treatment
6.
Chemical microscopy
7.
Basic morphological analysis
VI.
Data Interpretation (10%)
A.
Limits
1.
Statistical limits
2.
Aging limits
3.
Goal based limits
B.
Graphical trend analysis
1.
Rate of change analysis
2.
Effects of make-up oil
3.
Lock-step trending
VII.
Reagent Management (5%)
A. Equipment and glassware
1. Cleaning and
preparation
B. Chemicals
1. Preparation
2. Labeling
3. Storage
4. Safety
5. Disposal
VIII.
Instrument Calibration (5%)
A. Reference materials
1. Primary and secondary
standards
B. Record keeping
IX.
Quality Control (5%)
A. Record management
1. Record generation
2. Record storage
B. Quality control samples
1. Types
2. Control charts
C. Audits
1. Internal audit
2. External audit
Domain
of Knowledge
| 2001 Annual Book of ASTM Standards, Section 5, Petroleum Products. |
| |
| Bloch, H. (2000) Practical Lubrication for Industrial Facilities. Marcel Dekker, Inc., New York, NY, USA. |
| |
| Denis, J., J. Briant, and J. Hipeaux (1997) Lubricant Properties Analysis and Testing. Editions TECHNIP, Paris, France. |
| |
| Fitch, E. (1992) Proactive Maintenance for Mechanical Systems. FES, Inc., Stillwater, OK, USA. |
| |
| Fitch, J. (2001) Sourcebook of Used Oil Elements. Noria Publishing, Tulsa, OK, USA. |
| |
| Prichard, E. (1995) Quality in the Analytical Chemistry Laboratory. John Wiley & Sons, Chichester, West Sussex, UK. |
| |
| Roylance, B. and T. Hunt (1999) Wear Debris Analysis. Coxmoor Publishing, Oxford, UK. |
| |
| Shugar, G. and Ballinger, J. (1996) The Chemical Technicians' Ready Reference Handbook. McGraw-Hill, Inc. |
| |
| Standard Practice of In-Service Monitoring of Mineral Turbine Oil for Steam and Gas Turbines. American Society for Testing and Materials (ASTM), D4378-92. |
| |
| Standard Practice of In-Service Monitoring of Lubricating Oil for Auxiliary Power Plant Equipment. American Society for Testing and Materials (ASTM), D6224-98. |
| |
| The Lubrication Engineer's Manual, 2nd Edition. (1996) Association of Iron and Steel Engineers, Pittsburgh, PA, USA. |
| |
| Toms, L. (1998) Machinery Oil Analysis. Coastal Skills Training, Virginia Beach, VA, USA. |
| |
| Totten, G., Editor (2000) Handbook of Hydraulic Fluid Technology. Marcel Dekker, Inc., New York, NY, USA. |
| |
| Troyer, D. and J. Fitch (1999) Oil Analysis Basics. Noria Publishing, Tulsa, OK, USA. |
| |
| These
references can be purchased from the following organizations: |
| |
| Amazon.Com |
| |
| ASTM |
| |
| Barnes
and Noble |
| |
| Noria
Corporation |
|
