I.
Lubricant roles and functions (5%)
A. Base oil
1. Functions
2. Properties
B. Additive 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.
Oil Analysis Maintenance Strategies (5%)
A. Fundamental aspects of Reliability-Centered
Maintenance (RCM)
B. Fundamental aspects of Condition-Based
Maintenance (CBM)
1. Predictive maintenance
strategies
2. Proactive maintenance
strategies
III.
Oil Sampling (30%)
A. Objectives for lube oil sampling
B. Equipment specific sampling:
1. Gearboxes with
circulating systems
2. Engines
3. Single and multi-component
circulating oil systems with separate reservoirs
4. Hydraulic systems
5. Splash, ring
and collar lubricated systems
C. Sampling methods
1. Non-pressurized
systems
2. Pressurized systems
- Low
3. Pressurized systems
- High
D. Managing interference
1. Bottle cleanliness
and management
2. Flushing
3. Machine conditions
appropriate for sampling
E. Sampling process management
1. Sampling frequency
2. Sampling procedures
3. Sample processing
IV.
Lubricant health monitoring (20%)
A. Lubricant failure mechanisms
1. Oxidative degradation
a)
The oxidation process
b)
Causes of oxidation
c)
Effects of oxidative degradation
2. Thermal degradation
a)
The thermal failure process
b)
Causes of thermal failure
c)
Effects of thermal degradation
3. Additive depletion/degradation
a)
Additive depletion mechanisms
b)
Additives at risk for depletion/degradation by the various
mechanisms.
B. Testing for wrong or mixed lubricants
1. Baselining physical
and chemical properties tests
2. Additive discrepancies
C. Fluid properties test methods and measurement
units
1. Kinematic Viscosity
(ASTM D445)
2. Absolute (Dynamic)
Viscosity (ASTM D2893)
3. Viscosity Index
(ASTM D2270)
4. Acid Number (ASTM
D974 et al)
5. Base Number (ASTM
D974 et al)
6. Fourier Transform
Infrared (FTIR) analysis
7. Rotating Pressure
Vessel Oxidation Test (ASTMD2272)
8. Atomic Emission
Spectroscopy
V.
Lubricant contamination measurement and control (25%)
A. Particle contamination
1. Effects on the
machine
2. Effects on the
lubricant
3. Methods and units
for measuring particle contamination
4. Techniques for
controlling particle contamination
B. Moisture contamination
1. Effects on the
machine
2. Effects on the
lubricant
3. States of coexistence
4. Methods and units
for measuring moisture contamination
5. Demulsibility
measurement
6. Techniques for
controlling moisture contamination
C. Glycol coolant contamination
1. Effects on the
machine
2. Effects on the
lubricant
3. Methods and units
for measuring glycol contamination
4. Techniques for
controlling glycol contamination
D. Soot contamination
1. Effects on the
machine
2. Effects on the
lubricant
3. Methods and units
for measuring soot contamination
4. Techniques for
controlling soot contamination
E. Fuel contamination (fuel dilution in
oil)
1. Effects on the
machine
2. Effects on the
lubricant
3. Methods and units
for measuring fuel contamination
4. Techniques for
controlling fuel contamination
F. Air contamination (air in oil)
1. Effects on the
machine
2. Effects on the
lubricant
3. States of coexistence
4. Methods for assessing
air contamination
a)
Air release characteristics (ASTM D3427)
b)
Foam stability characteristics (ASTM D892)
5. Techniques for
controlling air contamination
VI. Wear Debris Monitoring and Analysis (15%)
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
B. Detecting abnormal wear
1. Atomic emission
spectroscopy methods
a)
Inductively coupled plasma (ICP) spectroscopy
b)
Arc-spark emission spectroscopy
2. Wear particle
density measurement
C. Wear debris analysis
1. Ferrogram preparation
2. Filtergram preparation
3. Light effects
4. Magnetism effects
5. Heat treatment
6. Basic morphological
analysis
Domain
of Knowledge
| 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. |
| |
| Roylance, B. and T. Hunt (1999) Wear Debris Analysis. Coxmoor Publishing, Oxford, UK. |
| |
| 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. |
| |
| Toms, L. (1998) Machinery Oil Analysis. Coastal Skills Training, Virginia Beach, VA, 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 |
|
