COURSE OVERVIEW:

Lube oil flushing is a vital pre-commissioning and maintenance activity designed to ensure that the lubrication systems of critical rotating machinery are free from harmful contaminants. This course focuses on the technical procedures required to remove mill scale, welding slag, moisture, and debris from piping and reservoirs before they can damage bearings and seals. Participants will explore the principles of turbulent flow and how high-velocity oil circulation is used to dislodge stubborn particles from internal surfaces.

The scope of this training covers the entire lifecycle of a flushing project, from the initial engineering of the flush loops to the final verification of oil cleanliness. Coverage includes the selection of flushing fluids, the setup of temporary high-flow pumps, and the strategic placement of bypasses to protect sensitive machine components. Emphasis is placed on the mechanical aspects of system preparation, including the vibration of piping and the use of thermal cycling to enhance the effectiveness of the flushing process.

Furthermore, the course provides deep insights into the acceptance criteria based on international standards such as ISO 4406 and NAS 1638. Trainees will learn how to use visual indicators, such as polished metal screens, and advanced particle counters to determine when a system has reached the required level of purity. By understanding the rigorous demands of modern high-speed machinery, this program ensures that maintenance teams can execute flushing operations that significantly extend the operational life of turbines, pumps, and compressors.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Explain the necessity of lube oil flushing for machinery reliability.
• Calculate the Reynolds number required to achieve turbulent flow during a flush.
• Design effective flushing loops that bypass critical machine internals.
• Select appropriate temporary pumps and auxiliary filtration units.
• Implement thermal cycling techniques to dislodge internal pipe scale.
• Use mechanical agitation and "hammering" methods safely during flushing.
• Identify the types of contaminants typically found in new and repaired systems.
• Interpret oil analysis reports and particle count data accurately.
• Apply acceptance criteria based on ISO 4406 and NAS 1638 standards.
• Document the flushing process for quality assurance and warranty compliance.
• Monitor filter differential pressure to track cleaning progress.
• Perform final system restoration and oil charge procedures.
• Manage the environmental disposal of flushing fluids and spent filters.

TARGET AUDIENCE:

This course is intended for Commissioning Engineers, Mechanical Maintenance Technicians, Lubrication Specialists, and Rotating Equipment Engineers involved in the startup and overhaul of industrial machinery.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.