Lubrication School. the eventful group. Level 1 & 2 Training Courses for Maintenance & Reliability Professionals. Facilitation & Training Course by:

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1 Lubrication School Level 1 & 2 Training Courses for Maintenance & Reliability Professionals Facilitation & Training Course by: A part of: Produced by: the eventful group

2 You ll gain practical new skills that you can use right away: 1. The secrets of lubricant selection Participating in Lubrication School will empower you with the knowledge to understand important lubricant properties and strategies to select the correct lubricant for each machine application 2. How correct storage, handling and dispensing extends oil life Learn how award-winning maintenance programs design lube storage areas, dispensing stations and transfer carts that can immediately be implemented 3. The four Rs of lubrication Right lubricant, right time, right quality and right place. If these four basic elements aren t properly addressed, you could be doing your equipment more harm than good. Learn the newest methods for implementing the best lubrication practices 4. Grease gun or lethal weapon? In the hands of an untrained operator, a grease gun can deliver pressure up to 15,000 psi. That s 30 times what a typical bearing seal can handle. Once the bearing seal is broken, the bearing is on its way to early failure. This course will teach you proper grease gun practices 5. Effective methods to reduce downtime and increase uptime The course is full of results-oriented procedures that can increase productivity by 15 percent 6. Latest and best strategies for lubricating machines Lubrication School will help you develop strategies to be effective and productive We will teach you the most effective lubrication methods for machine reliability, how to build a safe lubricant storage and handling program, how to rate filters and select the right filtration for the job, what works and what doesn t when it comes to lubricant labelling and coding, and how to get the right lubricant, in the right place, at the right time, and in the right amount. 2

3 Lubrication School Level 1 Fundamentals of Machinery Lubrication How Lubrication Affects Machine Reliability Financial benefits from achieving lubrication excellence Four equipment maintenance strategies, and when each applies Important implementation steps to lubrication excellence Lubrication Fundamentals Six important functions of lubricating oils How oils and greases are formulated and why it is important How friction is generated in lubricated machinery The importance of oil film thickness and critical clearances Understanding Additives, Base Oils and Grease Thickeners How lubricant properties irreparably change Seven important physical properties of a base oil The importance of API s five base oil categories What causes grease to dry out and 18 ways to prevent it How to detect the root causes of lubricant oxidation When to select one of the six most commonly used synthetic base oils How to use temperature to determine the right base oil for your machine How to select grease thickeners for your application Lubricant Performance Properties Key additives that enhance lubricant performance Viscosity grades, measurement, and reporting Why Viscosity Index is important What causes oil viscosity to change and how to set monitoring limits Lubricant performance tests and reporting - what you need to know How water contamination generates other contaminants How to control and eliminate aeration problems Food-grade and Environmentally-friendly Lubricants Important USDA requirements and government regulations for food-grade lubricants What you need to know about food-grade additives, base oils and grease thickeners Guidelines for food-grade lubricants Lubricating Grease Application Methods How to protect against incompatible grease mixtures Advantages and disadvantages of centralized lubrication systems Best practices for greasing motor bearings How to control pressure when greasing bearings The unique problems caused by over-greasing - specific steps to eliminate 3 critical instructions to give your electric motor rebuild shop Comparing single - and multi-point lubrication options How to calculate greasing intervals and quantity Best practices for ultrasonic/sonic-based greasing Lubricating Oil Application Methods Overview of oil lubrication methods and devices How to use oil mist and other automatic lubrication methods Using pressure spray methods for gearboxes Best practices for the maintenance of grease guns and fittings How to protect against problems caused by constant-level oilers Overview of single-point direct lubrication systems Journal Bearing Lubricants The 8 most common journal bearing lubrication problems How to select journal bearing viscosity based on speed Rolling-element Bearing Lubricants The nine critical factors affecting rolling-element bearing lubricant selection How to convert required operating temperature viscosity to ISO viscosity grades Gear Lubricants 5 key requirements for gear oil How to select the best viscosity for a gear lubricant Best practice guidelines for storing spare gearboxes - lubrication matters! 10 conditions that may require synthetic gear lubricants Lubrication best practices for enclosed gears - a 12 point checklist Mastering the challenges of open gear lubrication Automotive and Mobile Equipment Drive-line Lubricants How to read a motor oil label: what really matters The 6 critical objectives a motor oil must accomplish Understanding API service classifications for engine and gear oils The #1 reason automatic transmission fluids fail and how to protect against it Service classifications for automotive greases - how to select Extending engine life - surprising engine oil filter study results Compressor Lubricants Steps you can take right now to combat compressor lubricant failure The most common compressor lubricant stressors When to use synthetic compressor lubricants and why Steam and Gas Turbine Lubricants Why turbine/generator lubricants are the #1 contributor to forced outages Comparing steam and gas turbine oils - how they differ Checklist for best practice steam turbine lubrication Hydraulic Fluids How to select the ideal hydraulic fluid viscosity for gear, vane and piston pumps Nine key hydraulic fluid requirements and why they matter Specific conditions that may require a synthetic hydraulic fluid Fire-resistant hydraulic fluids - what you need to know Hydraulic system maintenance best practices - 21 point checklist Contamination Control Strategies for building reliability through contamination control The seven most destructive contaminants and how to control them Specific steps for managing a proactive lubricant maintenance program The ISO Solid Contaminant Code - understand it, track it 10 ways to get more mileage out of portable filter carts How dirt, metal particles and soot mechanically destroy machine surfaces Guidelines for controlling machine surface fatigue and extending machine life The #1 cause of machine wear and how to manage it How to set realistic cleanliness levels for lubricants Effective lubricant contamination control strategies for extending machine life 4 ways water contamination attacks lubricant additives How to set limits for water-in-oil contamination Managing the root causes of foam and aeration Best practices for excluding and removing contaminants The right way to control contamination in tanks and sumps How oil filters are rated Calculating the clean-up rate for portable filters Best practices for removing water contamination from oil The unique problems created by varnish - how to remove and stop it Oil Drains, Flushing and Reservoir Management How to optimize and extend oil change intervals Interval vs. condition-based oil changes - pros and cons Metrics for monitoring lubricant consumption Best practices for oil changes Know how and when to perform a flush The best procedures for oil draining and refilling How and when to use the bleed-and-feed strategy for extending oil drains Selecting the right cleaning and flushing procedures Storing, Handling and Managing Lubricants How to set up a world-class lube room How to know when to reject a new oil delivery How to optimize your lubricant selection and procurement process How to implement a lubricant consolidation program and select suppliers Used lubricant storage, handling, and disposal best practices Bulk lubricant storage do s and don ts Guidelines for storing and handling drums Lubricant dispensing options and what you must avoid Lubricant coding and identification systems - what works and what doesn t Portable oil transfer and filter carts selection advice How and where to store oil transfer and filter carts Understanding and managing lubricant storage life Keeping grease fresh - best practices for storage Design and Inspect for Lube Excellence World-class strategies for accessorizing equipment for lubrication excellence Seven critical accessories for lubricant inspection and sampling The right machine accessories for effective contamination control Used Oil Sampling and Analysis Fundamentals What oil analysis can tell you Types and categories of oil analysis Applications for oil analysis Overview of oil analysis tests Elements of a successful oil analysis program How clean should oil sample bottles be? How to find the best sampling locations Oil sampling valve and hardware recommendations A quick method for optimizing sampling intervals An oil sampling technique that ruins trending The importance of primary and secondary sampling points Advice for sampling hard-to-reach machines How to properly sample circulating systems Safe, effective high-pressure sampling from hydraulic systems Essential Field Inspections 12 questions your oil filter will answer about your machine Visual inspections you can get big results from right now Quick tips for using scent, sound, and touch to inspect lubricants 4 5

4 Lubrication School Level 2 Advanced Machinery Lubrication 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 Lubrication Theory Friction and 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 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 Synthesised 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 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 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 - 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 Lubricant Testing and Performance Analysis Viscosity Flash/fire point Pour ASTM D97/Cloud point ASTM D2500 Foam ASTM D892 Air release properties ASTM D Neutralisation 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 D Vickers wear pump test ASTM D SRV Test Extreme pressure - Four ball EP test ASTM D Timken Extreme Pressure Test ASTM D Falex EP/Wear Test ASTM D 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 Lubricant Application Procedures for: - Oil drain - Reservoir/system flushing - Disassembling/cleaning reservoirs and sumps - Filling - Top-up - Grease packing - Re-greasing - Grease changeout 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 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.) 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: - Air/gas - Particles - Oxidation products - Additive depletion Lube reclamation - Requirements - Feasibility - Procedures for reclaiming/reconditioning - Use of oil analysis to approve reclaimed/reconditioned lubricants Lube Storage and Management Designing optimum storage room Defining maximum storage time according to environmental conditions/lubricant type Safety/health requirements Proper sampling procedures/locations for stored lubricants Procedures for reconditioning/filtering stored lubricants 6 7

5 Getting Value from Lubrication School Attending Lubrication School will enable you to answer these most pressing questions about Lubrication: How do I choose the correct viscosity for each of my applications? What is the difference between single-grade and multi-grade engine oils and which is best? How do I make management understand the importance of proper lubrication? How do I design a safe and efficient oil storage area? When is a flush required prior to refilling a system? Should I use oil reclamation to reduce our consumption of lubricants? Should I choose an oil with a lower viscosity in the winter? How can I extend drain intervals without risking machine health? Should I just go with my OEM s lubricant recommendation or is there a better alternative? What inspections should be done when new lubricants are delivered? Is it a good idea to add more additives to used oils? How do I know the optimum point to change an oil? How do I clean tanks, reservoirs, and lube storage containers? When should I use a synthetic lubricant? What people say about this training: 1000 s of Maintenance Professionals around the world have participated in Lubrication School - here s what some them have to say about the real business benefits derived: The information I learnt can improve our hydraulic systems by 40 percent Vernon Player - PDM Tech, International Paper This course has provided me an in-depth view on how to create a world-class lubrication program Dennis Hill - Facility Engineer, Alcoa The knowledge I have now will reduce downtime 50 percent Johnny Dominquez - Mechanic, Phelps Dodge Mining ABSOLUTELY AWESOME! Should reduce downtime 25 to 50 percent Scott Gilreath - Lube Tech, UNNICO Who Will Benefit From This Training? Profile of Maintenance & Reliability Professionals who have participated in this course: Craftsman or Millwrights Condition Monitoring Engineers Equipment Operators Laboratory Analysts Lubrication Engineers Maintenance Managers Maintenance Supervisors Manufacturing and Industrial Engineers Operations Managers Predictive Maintenance Technicians Reliability Engineers Vibration Instrument Specialists This Training is highly recommended for people working with the following machines: Blowers/Fans Compressors Diesel Engines Final Drives Gas Turbines Gear Boxes Hydraulic Systems Hydrostatic Transmissions Motor Bearings Paper Machines Process Pumps Rolling Mills Steam Turbines The information from this course could save my company as much as $20,000 in monthly oil costs Jeff Smith - Maintenance Planner, Mueller Copper Tubes Packed with powerful information that can be applied with measurable results. This seminar provides the right training to influence a cultural change in maintenance and operation organisations Brian Baldwin - Reliability Engineering Manager, Dynergy Midwest Generation 8 9

6 Get Certified to Enhance Your Professional Development Your registration fee includes the option to get certified through the International Council for Machinery Lubrication (ICML). Why Certify? Certification is an important part of the training process because it confirms you possess the skills to do the job. Combining training with certification creates a knowledgeable and valuable employee. Which Certifications? Lubrication School 1 (Fundamentals of Machinery Lubrication) is designed to help you prepare for the following ICML certification exams: Level 1 Machine Lubricant Analyst (MLA1) Level 1 Machine Lubrication Technician (MLT1) Lubrication School 2 (Advanced Machinery Lubrication) is designed to help you prepare for the following ICML certification exam: Level II Machine Lubrication Technician (MLT2) You can find out more about these ICML exams at the ICML web site: What is ICML? The International Council for Machinery Lubrication (ICML) is a vendor neutral, not-for-profit organisation founded to facilitate growth and development of machine lubrication. Among its various activities, ICML offers skill certification testing for individuals in the fields of machine condition monitoring, lubrication and oil analysis. How to Certify? Please indicate on your registration form if you wish to sit the certification exam. Testing will be held on the afternoon following the training. Please visit to view the prerequisites for completing the exam. About Noria Noria offers globally-recognised training to help your organisation become world-class through the dissemination of knowledge and information in the fields of lubrication, oil analysis and machine reliability. In addition to training and publishing Machinery Lubrication Magazine, Noria s team of technical consultants combines in-plant experience and specialised skills to provide a wide range of maintenance and reliability consulting services for industry. From lubrication program audits and design, to failure investigations, to oil analysis and contamination control, Noria deliver outstanding results and help you achieve peak equipment performance. For more information, take a look at About The Eventful Group At The Eventful Group we are passionate about connecting Maintenance and Reliability people who share common goals. Since 1996 more than 10,000 people have attended our Maintenance and Reliability events and training courses in Australia, New Zealand and the US. We take special care of each and every customer. And we are focused on creating an environment of open communication. It s this spirit of community that encourages delegates, facilitators and speakers to break through barriers, engage in brave conversations and form lasting relationships. To explore our portfolio of Maintenance and Reliability events, take a look at or call us on (+61 2)