COURSE OVERVIEW:

The implementation of a robust oil analysis program is a cornerstone of proactive maintenance and machine condition monitoring. This course delves into the intricate details of establishing a world-class laboratory testing and field sampling regime designed to identify lubricant degradation and mechanical wear before catastrophic failure occurs. By focusing on the chemistry of lubricants and the physics of particle contamination, participants will understand how to transform raw laboratory data into actionable maintenance decisions.

Beyond the basics, the course explores the critical importance of the ISO 4406 cleanliness standard and its application in industrial environments. Participants will examine the methodologies for counting and classifying particles, understanding how microscopic contaminants impact the service life of bearings, gears, and hydraulic components. The scope extends to the integration of oil analysis with other predictive technologies, ensuring a holistic approach to asset management that emphasizes precision and reliability.

The coverage of this training includes the selection of appropriate test slates based on specific machine types and environmental operating conditions. We will analyze the nuances of viscosity changes, acid and base numbers, oxidation stability, and moisture content. By the end of the course, attendants will have a comprehensive framework for designing a sampling strategy that ensures data representative of the true machine condition, thereby optimizing lubricant life and reducing unplanned downtime.

COURSE OBJECTIVES:

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

1.  Design a comprehensive oil analysis program tailored to specific industrial assets.

2.  Interpret ISO 4406 cleanliness codes to assess fluid contamination levels.

3.  Identify the primary modes of lubricant degradation including oxidation and nitration.

4.  Establish scientifically sound primary and secondary alarm limits for various machines.

5.  Select the correct sampling points to ensure the delivery of representative oil samples.

6.  Evaluate the effectiveness of different filtration systems in achieving target cleanliness.

7.  Correlate wear debris analysis results with specific internal component failures.

8.  Utilize Moisture analysis techniques to prevent corrosion and hydrogen embrittlement.

9.  Differentiate between various base oils and additive packages and their performance.

10.  Implement a rigorous quality control process for incoming new lubricant shipments.

11.  Justify the return on investment for oil analysis through cost-savings reports.

12.  Integrate oil analysis data into a broader predictive maintenance software platform.

13.  Execute proper sampling procedures using vacuum pumps and specialized valves.

TARGET AUDIENCE:

Maintenance Engineers, Reliability Professionals, Lubrication Technicians, Plant Managers, and Condition Monitoring Specialists involved in the maintenance of rotating equipment and hydraulic 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.