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I.
Maintenance Strategies (10%)
A.
Why machines fail
B.
The impact of poor maintenance on company profits
C.
The role of effective lubrication in failure avoidance
D.
Lube routes and scheduling
E.
Oil analysis and technologies to assure lubrication effectiveness.
F.
Equipment tagging and identification.
II.
Lubrication Theory/Fundamentals (18%)
A.
Fundamentals of tribology
B.
Functions of a lubricant
C.
Hydrodynamic lubrication (sliding friction)
D.
Elasto-hydrodynamic lubrication (rolling friction)
E.
Mixed-film lubrication
F.
Base-oils
G.
Additives and their functions
H.
Oil lubricant physical, chemical and performance
properties and classifications.
I.
Grease lubrication
1.
How grease is made
2.
Thickener types
3.
Thickener compatibility
4.
Grease lubricant physical, chemical and performance
properties and classifications.
III.
Lubricant Selection (10%)
A.
Viscosity selection
B.
Base-oil type selection
C.
Additive system selection
D.
Machine specific lubricant requirements
1.
Hydraulic systems
2.
Rolling element bearings
3.
Journal bearings
4.
Reciprocating engines
5.
Gearing and gearboxes
E.
Application and environment related adjustments.
IV.
Lubricant Application (18%)
A.
Basic calculations for determining required lubricant volume.
B.
Basic calculations to determine re-lube and change frequencies.
C.
When to select oil; when to select grease.
D.
Effective use of manual delivery techniques.
E.
Automatic delivery systems.
1.
Automated deliver options.
a.
Automated grease systems
b.
Oil mist systems
c.
Drip and wick lubricators
2.
Deciding when to employ automated lubricators.
3.
Maintenance of automated lubrication systems.
V.
Lube Storage and Management (10%)
A.
Lubricant receiving procedures.
B.
Proper storage and inventory management.
C.
Lube storage containers
D.
Proper storage of grease-guns and other lube application devices.
E.
Maintenance of automatic grease systems.
F.
Health and safety assurance.
VI.
Lube Condition Control (10%)
A.
Filtration and separation technologies.
B.
Filter rating.
C.
Filtration system design and filter selection.
VII.
Oil Sampling (10%)
A. Objectives for lube oil sampling
B. Sampling methods
C. Managing interference
1. Bottle cleanliness
and management
2. Flushing
3. Machine conditions
appropriate for sampling
VIII.
Lubricant health monitoring (10%)
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 - applications
and limitations.
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
IX.
Wear Debris Monitoring and Analysis (4%)
A. Common machine wear mechanisms
Domain
of Knowledge
| Bannister, K. (1996) Lubrication for Industry. Industrial Press, Inc., New York, NY, USA. |
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| Bloch, H. (2000) Practical Lubrication for Industrial Facilities. Marcel Dekker, Inc., New York, NY, USA. |
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| Fitch, E. (1992) Proactive Maintenance for Mechanical Systems. FES, Inc., Stillwater, OK, USA. |
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| Hodges, P. (1996) Hydraulic Fluids. Arnold Publish, London, England, UK and John Wiley & Sons, New York, NY, USA. |
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| Landsdown, A. (1994) High Temperature Lubrication. Mechanical Engineering Publications, Ltd., London, England, UK. |
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| Landsdown, A. (1996) Lubrication and Lubricant Selection. Mechanical Engineering Publication, Ltd., London, England, UK. |
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| Leugner, L. (2000) The Practical Handbook of Machinery Lubrication. Maintenance Technology International, Inc., Edmonton, Alberta, Canada. |
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| Lubricating Grease Guide, 4th Edition. (1996) The National Lubricating Grease Institute, Kansas City, MO, USA. |
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| Ludema, K. (1996) Friction, Wear, Lubrication: A Textbook in Tribology. CRC Press, Boca Raton, FL, USA. |
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| Pirro, D.M. and Wessol, A.A. (2001) Lubrication Fundamentals, 2nd Edition, Revised and Expanded. Marcel Dekker, Inc., New York, NY, USA. |
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| The Lubrication Engineer's Manual, 2nd Edition. (1996) Association of Iron and Steel Engineers, Pittsburgh, PA, USA. |
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| Troyer, D. and J. Fitch (1999) Oil Analysis Basics. Noria Publishing, Tulsa, OK, USA. |
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| These
references can be purchased from the following organizations: |
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| Amazon.Com |
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| ASTM |
| |
| Barnes
and Noble |
| |
| Noria
Corporation |
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