| I.
Maintenance Strategy (5%)
A.
The impact of lubrication on
machine reliability
B.
The impact of lubrication on
lubricant life and consumption
C.
Maintenance program strategies
for achieving lubrication excellence
II.
Lubrication Theory (5%)
A.
Friction & Tribology
- Types
of friction and wear
- Wear
modes and influencing factors
- Machine
frictional surfaces most at risk for specific wear modes
(e.g., abrasion)
- Mechanisms
of Lubrication regimes
- Boundary
- Mixed
film
- Hydrodynamic
- Elastohydrodynamic
B.
Lubricant categories
- Gaseous
- Liquid
- Cohesive
- Solid
III.
Lubricant Formulation (10%)
A.
Base-oil Refining Methods
and API categories
- Solvent-refined
- Hydro-treated
- Severely
Hydro-treated
- Hydrocracked
B.
Mineral Base Oils
- Naphthenic
- Paraffinic
- Aromatic
C.
Vegetable Base Oils &
Biolubes
D.
Synthetic lubricant characteristics/applications/compatibility
- Synthesized
hydrocarbons (e.g., Polyalphaolifins)
- Dibasic
acid esters
- Polyol
esters
- Phosphate
esters
- Polyalkylene
glygol
- Silicones
- Fluorocarbons
- Polyphenil
esters
E.
Food Grade lubricant Classification
F. Types and Functions of additives
G. Types and Functions of solid additives
H. Modes of additive depletion
IV.
Grease Application and
Performance (5%)
A.
Grease applications requiring
high consistency
B. Grease
applications requiring low consistency
C. Causes of grease separation
D. Multipurpose greases
E. Performance and application of specific grease thickeners
F. High temperature greases
G. Coupling greases
V.
Lubricant Selection (15%)
A.
Viscosity selection/adjustments
according to machinery
condition/environmental
conditions
B.
When to use synthetic
lubricants
C.
When to use biodegradable
lubricants
D.
Lubricant consolidation
E.
Select lubricating oils
for:
- Fire-resistant
applications
- Hydraulics
- Mobile/industrial
- Turbines
- Compressors
- Bearings
- Chains/conveyors
- Mist
applications
- Gears
- Automotive/industrial
- Engines
- Diesel/Gas/Gasoline
- Pneumatic
tools
- Spindles
- Ways/slides
F. Selecting greases for:
- Chassis
- Couplings
- Anti
friction bearings
- Journal
bearings
- Automotive
bearings
- Automatic
Lubrication Systems
G. Lubricant Selection standards development
H. Procedures for testing and quality assurance of
incoming lubricants
I. Procedures for approval of candidate lubricants
VI.
Lubricant Testing and
Performance Analysis (10%)
A. Viscosity
B. Flash/Fire point
C.
Pour
ASTM D97/Cloud point ASTM D2500
D. Foam ASTM D892
E. Air release properties ASTM D3247-99
F. Neutralization number
- Acid
Number ASTM D 664/D974
- Base
Number ASTM D 974/D2896
G. Filterability ISO 13357
H. Oxidation stability
- Turbine
Oil Oxidation Test ASTM D943
- Rotary
Pressure Vessel Oxidation Test ASTM D2272
I. Rust and Corrosion tests
- Turbine
Oil Rust Test ASTM D665
- Copper
strip corrosion ASTM D130
J. Anti-wear tests
- Four
ball wear test ASTM D2266
- Vickers
wear pump test ASTM D2882
- SRV
Test
K. Extreme Pressure
- Four
ball EP test ASTM D2596
- Timken
Extreme Pressure Test ASTM D2509
- Falex
EP/Wear Test ASTM D2670
- FZG
Four Square
Gear Test Rig ASTM D5182.97
L. Demulsibility ASTM D 1404
M. Grease consistency ASTM D217
N. Dropping point of grease ASTM D2265
O. Mechanical Stability of greases ASTM D217A
P. Rolling Stability if Greases ASTM D1831
Q. Water washout test for greases ASTM D1264
R. Water spray test for greases ASTM D4049
S. Rolling bearing rust test ASTM D1743
T. Koppers Centrifugal Stability Test
U. Oil separation in grease storage ASTM D1742
V. Oxidation Stability - Greases ASTM D942
VII.
Lubricant Application
(15%)
A.
Procedures for:
- Oil
drain
- Reservoir/system
flushing
- Disassembling/cleaning
reservoirs and sumps
- Filling
- Top-up
- Grease
packing
- Re-greasing
- Grease
changeout
B. Determine/calculate correct amount for re-greasing
C. Determine/calculate correct frequency
interval for re-greasing
D. Select and manage optimum equipment/systems for
lubricant
application according to machinery
requirements
E. Safety/health requirements for lubricant application
F. Manage proper maintenance of lubrication equipment
G. Manage proper maintenance of automatic lubrication
systems
H. Create/update lube survey
I. Record execution of lube program
J. Proactive management and detection of leaks
K. Waste oil/filters management/disposal
L. Writing a lubrication PM
VIII.
Preventive and Predictive
Maintenance (10%)
A.
Creating and managing lube PMs and routes
B. Creating and manage lubrication
inspection check list
C. Used oil analysis to determine optimum condition
based oil changes
D. Used oil analysis to troubleshoot abnormal lubricant degradation
conditions
E. Used oil analysis to troubleshoot
abnormal wear related to lubricant
degradation/contamination
F. Procedures and methods for
identifying root cause of lubricant
failure
G. Use of technology aids to
determine optimum re-grease
frequency/quantity (ultrasonic,
temperature monitoring, shock
impulse, etc.)
IX.
Lubricant Condition Control (20%)
A. Proper sampling procedures
B. Proper sampling locations
C. Proper selection of breathers/vents
D. Proper selection of filters according to cleanliness
objectives
E. Filter rating - Beta Ratio
F. Sump/Tank Management to reduce:
- Air
entrainment/foam
- Particles
- Water
- Sediments
- Heat
- Silt/sediments
- Unnecessary
lubricant volume
G. Proper selection of reconditioning systems for:
- Water
- Air/gas
- Particles
- Oxidation
products
- Additive
depletion
H. Lube reclamation
- Requirements
- Feasibility
- Procedures
for reclaiming/reconditioning
- Use
of oil analysis to approve reclaimed/reconditioned lubricants
X.
Lube Storage and Management (5%)
A. Design optimum storage room
B. Defining maximum storage time according to environmental
conditions/lubricant type
C. Safety/Health requirements
D. Proper sampling procedures/locations for sampling
stored lubricants
E. Procedures for reconditioning/filtering stored lubricants
Domain
of Knowledge
| Bannister, K. (1996) Lubrication for Industry. Industrial Press, Inc., New York, NY, USA. |
| |
| Bloch, H. (2000) Practical Lubrication for Industrial Facilities. Marcel Dekker, Inc., New York, NY, USA. |
| |
| Hodges, P. (1996) Hydraulic Fluids. Arnold Publish, London, England, UK and John Wiley & Sons, New York, NY, USA. |
| |
| Landsdown, A. (1994) High Temperature Lubrication. Mechanical Engineering Publications, Ltd., London, England, UK. |
| |
| Landsdown, A. (1996) Lubrication and Lubricant Selection. Mechanical Engineering Publication, Ltd., London, England, UK. |
| |
| Leugner, L. (2000) The Practical Handbook of Machinery Lubrication. Maintenance Technology International, Inc., Edmonton, Alberta, Canada. |
| |
| Lubricating Grease Guide, 4th Edition. (1996) The National Lubricating Grease Institute, Kansas City, MO, USA. |
| |
| Ludema, K. (1996) Friction, Wear, Lubrication: A Textbook in Tribology. CRC Press, Boca Raton, FL, USA. |
| |
| Pirro, D.M. and Wessol, A.A. (2001) Lubrication Fundamentals, 2nd Edition, Revised and Expanded. Marcel Dekker, Inc., New York, NY, USA. |
| |
| The Lubrication Engineer's Manual, 2nd Edition. (1996) Association of Iron and Steel Engineers, Pittsburgh, PA, 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 |
|
