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ICTD International Centre for Training and Development

Lubrication and Maintenance of Industrial Machinery: Best Practices and Reliability

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About the course

To remain globally competitive, today’s manufacturing operations have greatly improved, but there is one last link in the advancement evolution. The reliability of manufacturing equipment must be improved in order to maximize the productive life of the equipment, eliminate unscheduled shut downs, and reduce operating costs. These are key components to maintaining a smooth work flow and a competitive edge.

Lubrication and Maintenance of Industrial Machinery: Best Practices and Reliability provides the necessary tools for maintenance professionals who are responsible for the overall operational functions. This course is more specialized and focused work supplies critical lubrication information that can be used on a daily basis to achieve greater machine reliability. Incorporating lean methods, this resource can be used by everyone involved in the production process, from supervisors to floor personnel.

In addition to lubrication program development and scheduling, this course also covers critical elements of the reliability equation, such as:

  • Deterioration detection and measurement
  • Lubrication cleanliness and contamination control
  • Environmental implications of various lubricants
  • Energy conservation
  • Storage and handling
  • Recycling of used oils

Course Objectives

Upon the successful completion of this course, the delegates will be able to:

  • Introduce and establish the role of precision lubrication and analysis for improving machine reliability
  • Provide an overview of lubricant construction and the general principles involved in lubricant selection for common plant machinery
  • Review handling and application practices for both oils and greases
  • Introduce contamination control strategies as a way to improve machine performance
  • Provide a thorough introduction to the principles of lubricant analysis and introduce appropriate methods to collect samples as the first step in lubricant based machine condition assessment

Course Outline

Day 1

Precision Lubrication and Machine Management Strategies

  • Planned maintenance strategies
  • The role of lubrication in machine reliability and failure avoidance
  • Oil Analysis and technologies to assure lubrication effectiveness
  • Fundamentals of Tribology: Lubrication, Friction, Wear and Corrosion
  • Lubricant Construction and categories

Applied Tribology

  • Surface interaction modes sliding and rolling
  • Friction, wear and corrosion
  • Protective Lms: hydrodynamic and elastohydrodynamic

Lubricant Construction

  • Lubricant categories
  • Base oils, additives, thickeners, greases

Day 2

Lubricant Performance Properties

  • Oil, grease and additive performance measurement
  • Lubricant Application Grease and Oil
  • Basic calculations for re-lubrication intervals
  • Lubricant Automatic Application: Systems and Maintenance

Lubricant Selection Practices

  • Lubricant selection – bearings, gears, hydraulics, engines

Lubricant Application - Grease

  • Dispensing tools, metrics • and automatic systems

Day 3

Lubricant Application - Oil

  • Dispensing tools, metrics, automatic systems

Lubricant Storage and Handling

  • Lubricant Consolidation
  • Bulk and Packaged Product Receipt and Storage
  • Lubricant storage containers
  • Storage of grease guns and other lube application devices
  • Health and Safety Assurance

Day 4

Lubricant Condition and Contamination Control

  • Types of contaminants and removal
  • Filtration and Separation Technologies
  • Sump management

Lubricant Storage and Handling

  • Lubricant consolidation
  • Bulk and packaged product receipt and storage
  • In plant handling and management
  • Introduction to sampling and oil analysis
  • Lubricant sampling methods
  • Monitoring chemistry, contamination and wear debris
  • Post-course exam
  • Lubricant sampling: objectives, methods, quality, intervals

Day 5

Lubricant Health Monitoring

  • Failure mechanisms: oxidation and thermal degradation
  • Additive depletion and degradation
  • Mixed lubricants, viscosity and additive discrepancies
  • Lubricant test methods: properties and contaminants

Spectroscopy and Atomic Measurement

  • Wear Debris Measurement and wear mechanisms.

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course is intended for professionals who are responsible for the overall operational functions and who’s involved in the production process, from supervisors to floor personnel.

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