COURSE OVERVIEW:

Lube oil system design and troubleshooting is a specialized discipline essential for the sustained operation of high-speed rotating machinery. This course provides an in-depth exploration of the engineering principles governing the delivery of clean, cool, and pressurized lubricant to critical interfaces such as bearings, gears, and seals. Participants will examine the architectural requirements of API 614 and other industry standards, focusing on the integration of reservoirs, pumps, heat exchangers, and filtration arrays into a cohesive, reliable system.

The scope of this training encompasses the complex hydraulic calculations required to size piping and components, ensuring adequate flow under all operating temperatures. Coverage includes the selection of main and standby pumps, the design of degasification arrangements within reservoirs, and the logic behind control systems that manage pressure regulation and emergency shutdowns. Emphasis is placed on the mechanical integrity of the system, including the prevention of static discharge and the management of thermal expansion in large-scale piping networks.

Furthermore, the course offers a systematic approach to diagnosing and resolving system malfunctions. Trainees will develop the analytical skills needed to troubleshoot common issues such as aeration, foam formation, pressure instability, and temperature excursions. By blending design theory with practical case studies of system failures, this program empowers engineers and senior technicians to optimize existing lubrication infrastructure and design robust systems for new installations in the power and process industries.

COURSE OBJECTIVES:

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

• Apply API 614 standards to the design and selection of lubrication system components.
• Calculate the required flow rates and pressure drops across complex oil circuits.
• Size and select appropriate centrifugal and positive displacement lube oil pumps.
• Design oil reservoirs with adequate residence time for air release and moisture settling.
• Evaluate the efficiency of shell and tube versus plate and frame oil coolers.
• Implement advanced filtration strategies to maintain specific ISO cleanliness levels.
• Interpret control logic diagrams for automatic pump cut-in and system protection.
• Troubleshoot the root causes of oil foaming and air entrainment in the return lines.
• Diagnose the reasons for unexpected pressure fluctuations and relief valve chatter.
• Optimize the settings of thermostatic valves to maintain stable operating temperatures.
• Analyze the impact of piping layout on suction conditions and pump cavitation.
• Conduct a functional test of the emergency oil system and accumulator performance.
• Manage the transition between manual and automated lubrication control modes.

TARGET AUDIENCE:

This course is designed for Mechanical Design Engineers, Rotating Equipment Specialists, Maintenance Managers, and Senior Plant Engineers responsible for the design, procurement, and reliability of machinery lubrication systems.

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.