Lubrication Fundamentals
A general overview of the functions, types, properties and limitations of a lubricant.

• Physical and Chemical Properties (viscosity, pour point, etc.)
• Performance Properties (oxidation stability)
• Base Oils (API Group I to V)
• Additives (types and what they do)
• Oil Films & Regimes (hydraulic, boundary)
• Grease Properties & Performance Characteristics

Maintenance Philosophies
Like death and taxes, maintenance is inevitable. How we approach maintenance has a significant bearing on the success, reliability and profitability of an operation.

• Reactive
• Preventive
• Predictive
• Proactive
• Reliability Centered Maintenance (RCM)

Failure Modes
This lecture takes an in-depth look at how and why equipment fails and the mechanisms that lead to these failures.

• Probability of Failures (early, random)
• Equipment Wear Phases (break-in, normal)
• The 12 Basic Wear Mechanisms
• Lubrication Degradation (thermal, oxidative)
• Contamination (chemical, particulate)

Oil Sampling Techniques and Practices
How to avoid the “garbage in/garbage out” pitfalls of oil sampling. This area reviews the various methods and procedures for taking representative samples.

• Sampling methods and locations
• Representative samples (Where/How/Why?)
• Oil Sampling frequency (matching equipment type, operating conditions & goals)

Oil Cleanliness and Contamination Control
This section takes an in-depth look at understanding the criticality of oil cleanliness in the operating equipment.

• New Oil Cleanliness (How clean is clean?)
• Understanding ISO Particle Counts
• Filter Types & Ratings
• Filtration Methods (oil line, off-line, filter carts)
• Storage & Handling Practices

Fluid Testing
This section examines all of the various fluid testing equipment and techniques including a brief look at the purpose and limitations of each instrument. The test equipment is categorized into the following three groups:

• Fluid Properties (viscosity)
• Contamination Tests (glycol/fuel)
• Wear Debris Analysis (Ferrography, Filter Analysis)

Setting Up a Successful Program
A success of any program or initiative begins with the first few critical steps that are well thought out and organized.

• Why do we need oil analysis?
• Building a road map to success
• Identifying opportunities
• Plan your attack
• Management justification and buy-in
• Implementation
• Review & Continuous Improvement

Data Interpretation
This section brings clarity and understanding to evaluating and interpreting the oil analysis data into meaningful information directly related to the condition of the operating equipment.

• Establishing test limits
• Interpretation of the analysis results
• Determining the proper course of action

Functions of Coolant/Antifreeze

• Removes Heat
• Prevents Boiling and Freezing
• Prevents Scaling and Corrosion
• Prevents Wet Sleeve Cavitation in Diesel Engines

Types of Glycol

• Ethylene Glycol
• Advantages vs. Propylene
• Propylene Glycol
• Advantage vs. Ethylene

Suggested Water Quality Limits

• Total Solids
• Total Hardness
• Chlorides
• Sulphates
• pH

Groups of Coolants

• Group 1 - Traditional
• Group 2 - OAT (Organic Acid Technology)
• Group 3 - Hybrid

Types and Functions of Coolant Additives

• Silicate
• Nitrite
• Nitrate
• Phosphate
• Borate
• Molybdate
• Carboxylates
• Dicarboxylates
• Mercaptobenzothiazole (MBT)
• Tolytriazole (TT)
• Silicones
• Block Polymers
• Dispersants
• Surfactants

Cooling System Problems

• Stray Current
• Positive Voltage
• Negative Voltage
• Localized Overheating
• Exhaust Gas Blow-by

Cooling System Degradation

• Erosion
• Corrosion
• Electrolysis

Characteristics of Coolant System Deposits

• Iron Deposit
• Carbonate Deposit
• Silica Deposit
• Sulphate Deposit

Water Properties That Produce Acid

• Acid Processes
• Chloride
• Sulphate
• Conductance

Engine Problems Due to Acid

• Wet Sleeve Liner Pitting
• Radiator Pitting
• Oil Cooler Pitting
• Pump Damage

pH Concerns

• Alkaline
• Acidic

Benefits of Coolant Analysis

• Fluid Condition
• Component Failure
• Predictive Maintenance
• Management Practices

Coolant Test Program

• Level 1 Test - Basic Coolant Analysis
• Visual Observations
• Boiling and Freeze Point
• pH
• Conductivity
• Total Dissolved Solids
• Ion Chromatography
• Chlorides, Formates, Glycolates, Nitrites, Nitrates, Phospates, Sulphates, Molybdates
• Level 2 Test - Full Coolant Analysis
• Level 1 Test Package Plus:
• Reserve Alkalinity
• Wear & Additive Elements
• Iron, Copper, Aluminum, Lead, Tin, Zinc, Calcium, Magnesium, Phosphorous, Boron, Molybdenum, Silicon

Understanding the Analysis Tests

Data Interpretation

• The seminar will culminate with a hands-on data interpretation exercise providing the attendees with a clear understanding of the coolant analysis report and interpretation of the data.