MACHINE LUBRICANTION - MLT II ICML Certification -

Transcription

1 Organized By LUBETRAIN RESOURCES SDN BHD MACHINE LUBRICANTION - MLT II ICML Certification - ENROLL TODAY! Call : or / : mail@lubetrainresources.com

2 INTRODUCTION Machine Lubrication is a three-day (3) intensive course structured after the Body of Knowledge specified by the International Council for Machinery Lubrication (ICML) for Level II Machinery Lubrication Technician (MLT) certification. This course covers the skill and knowledge necessary for a lubrication technician or specialist who is involved in the correct selection, application and condition monitoring of lubricants and greases. These responsibilities might include managing lubricant delivery, storage and dispensing, oil changes and top-ups, selection and application of greases, maintaining automatic lubrication systems, applying basic oil analysis techniques and managing a route for machinery relubrication and/or inspection. Objectives With the knowledge and skills acquired at the end of the training program, the participants will be able to: Select the right lubricant for specific machine : Determine when to select grease or oil as the lubricant of choice Write dependable equipment lubrication procedures Optimize lubricant storage and handling procedures Correctly manage lubricants in reservoirs and sumps Determine the lubrication methods that can increase mean-time-between-failure Who Should Attend? This course is designed for all personnel involved with lubrication and machine condition monitoring including: Maintenance technicians, Lubrication technicians, Motor technicians, Pump technicians, Plant Engineer, Operation Managers, Maintenance Managers, Industrial and Manufacturing Engineer, Purchasing Managers, Chemical Engineers and anyone interested in lubrication.

3 Course Outline I. Maintenance Strategy The impact of lubrication on machine reliability The impact of lubrication on lubricant life and consumption Maintenance program strategies for achieving lubrication excellence II. Lubrication Theory 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 Lubricant categories Gaseous Liquid Cohesive Solid III. Lubricant Formulation Base-oil Refining Methods and API categories Solvent-refined Hydro-treated Severely Hydro-treated Hydrocracked Mineral Base Oils Naphthenic Paraffinic Aromatic Vegetable Base Oils & Biolubes Synthetic lubricant characteristics/applications/compatibility Synthesized hydrocarbons (e.g., Polyalphaolifins) Dibasic acid esters Polyol esters Phosphate esters Polyalkylene glygol Silicones Fluorocarbons Polyphenil esters Food Grade lubricant Classification Types and Functions of additives Types and Functions of solid additives Modes of additive depletion V. Grease Application and Performance Grease applications requiring high consistency Grease applications requiring low consistency Causes of grease separation Multipurpose greases Performance and application of specific grease thickeners High temperature greases Coupling greases

4 Course Outline VI. Lubricant Selection Viscosity selection/adjustments according to machinery condition/environmental conditions When to use synthetic lubricants When to use biodegradable lubricants Lubricant consolidation 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 Selecting greases for: Chassis Couplings Anti friction bearings Journal bearings Automotive bearings Automatic Lubrication Systems Lubricant Selection standards development Procedures for testing and quality assurance of incoming lubricants Procedures for approval of candidate lubricants VII. Lubricant Testing and Performance Analysis Viscosity Flash/Fire point Pour ASTM D97/Cloud point ASTM D2500 Foam ASTM D892 Air release properties ASTM D Neutralization number Acid Number ASTM D 664/D974 Base Number ASTM D 974/D2896 Filterability ISO Oxidation stability Turbine Oil Oxidation Test ASTM D943 Rotary Pressure Vessel Oxidation Test ASTM D2272 Rust and Corrosion tests Turbine Oil Rust Test ASTM D665 Copper strip corrosion ASTM D130 Anti-wear tests Four ball wear test ASTM D2266 Vickers wear pump test ASTM D2882 SRV Test 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 D Demulsibility ASTM D 1404 Grease consistency ASTM D217 Dropping point of grease ASTM D2265 Mechanical Stability of greases ASTM D217A Rolling Stability if Greases ASTM D1831 Water washout test for greases ASTM D1264 Water spray test for greases ASTM D4049 Rolling bearing rust test ASTM D1743 Koppers Centrifugal Stability Test Oil separation in grease storage ASTM D1742 Oxidation Stability - Greases ASTM D942

5 Course Outline VII. Lubricant Application Procedures for: Oil drain Reservoir/system flushing Disassembling/cleaning reservoirs and sumps Filling Top-up Grease packing Re-greasing Grease change out Determine/calculate correct amount for re-greasing Determine/calculate correct frequency interval for re-greasing Select and manage optimum equipment/systems for lubricant application according to machinery requirements Safety/health requirements for lubricant application Manage proper maintenance of lubrication equipment Manage proper maintenance of automatic lubrication systems Create/update lube survey Record execution of lube program Proactive management and detection of leaks Waste oil/filters management/disposal Writing a lubrication PM VIII. Preventive and Predictive Maintenance Creating and managing lube PMs and routes Creating and manage lubrication inspection check list Used oil analysis to determine optimum condition based oil changes Used oil analysis to troubleshoot abnormal lubricant degradation conditions Used oil analysis to troubleshoot abnormal wear related to lubricant degradation/contamination Procedures and methods for identifying root cause of lubricant failure Use of technology aids to determine optimum re-grease frequency/quantity (ultrasonic, temperature monitoring, shock impulse, etc.) IX. Lubricant Condition Control Proper sampling procedures Proper sampling locations Proper selection of breathers/vents Proper selection of filters according to cleanliness objectives Filter rating - Beta Ratio Sump/Tank Management to reduce: Air entrainment/foam Particles Water Sediments Heat Silt/sediments Unnecessary lubricant volume Proper selection of reconditioning systems for: Water Air/gas Particles Oxidation products Additive depletion Lube reclamation Requirements Feasibility Procedures for reclaiming/reconditioning Use of oil analysis to approve reclaimed/reconditioned lubricants X. Lube Storage and Management Design optimum storage room Defining maximum storage time according to environmental conditions/lubricant type Safety/Health requirements Proper sampling procedures/locations for sampling stored lubricants Procedures for reconditioning/filtering stored

6 OUR TRAINER MR. Mohd Zubil Bahak As a certified Machinery Lubricant Analyst (MLA) Level III and certified Machinery Lubrication Technician (MLT) Level II from the International Council for Machinery Lubrication (ICML) and certified as engineer for the state of Tennessee, USA, Mr. Mohd Zubil Bahak is currently working as a lecturer at the Fakulti Kejuruteraan Mekanikal, Universiti Teknologi Malaysia, Skudai since 1989 specialized in Fluid Mechanics and Tribology. Mr. Mohd Zubil graduated from University of Tennessee, USA with a double degrees; Bachelors Degree in Engineering (Mechanics) and Bachelors Degree in Engineering (Thermal Sciences). Prior to joining UTM, he worked at Osborne & Chappel International Sdn as a mechanical engineer in a mining industry. He also went for one year intensive training in tribology at the Institute of Tribology, University of Leeds, United Kingdom. His expertise in a subject of tribology was recognized by the School of Professional and Continuing Education, Universiti Teknologi Malaysia by engaging him as a speaker for their professional course since 2006 titles Understanding Lubricating Oil Analysis, Lubrication for Machinery, and Lubrication for Industries. He also giving in-house training on the same titles to the industries including Petronas Gas Berhad, Petronas Carigali Berhad, Negeri Sembilan Cement Industries Sdn Bhd, Jimah O&M Sdn Bhd, and Malaysian Navy. ENROLL TODAY! Call : or / : mail@lubetrainresources.com

7 Seminar Registration Form Register Now!! ATTENDEE NAME : COMPANY INFORMATION PLEASE RETURN THIS FORM TO : LUBETRAIN RESOURCES SDN BHD LUBETRAIN RESOURCES SDN BHD (Signature) (Company s Chop) (Date)