Course Objectives:

By the end of this training, participants will be able to:

1. Introduction to Rotating Equipment and Lubrication

• Understand the role of rotating equipment in industrial applications, including pumps, compressors, turbines, motors, and gearboxes.
• Learn about the importance of lubrication in maintaining the performance, efficiency, and reliability of rotating equipment.
• Explore the impact of improper lubrication on wear, friction, heat generation, and equipment failure.

2. Principles of Lubrication

• Study the fundamental principles of lubrication, including the types of lubrication regimes:
• Hydrodynamic Lubrication: Full fluid film lubrication.
• Boundary Lubrication: Partial lubrication with contact between surfaces.
• Mixed Lubrication: Combination of full and partial lubrication.
• Understand the concepts of viscosity, oil film thickness, and the factors that influence lubrication performance.
• Learn how lubricants reduce friction, cool components, and protect against wear and corrosion.

3. Types of Lubricants for Rotating Equipment

• Study the different types of lubricants used in rotating equipment:
• Oil-Based Lubricants: Mineral oils, synthetic oils, and bio-based oils.
• Greases: Lithium-based, calcium-based, and synthetic greases.
• Solid Lubricants: Molybdenum disulfide, graphite, and other dry lubricants.
• Learn the differences between various lubricants, including their composition, properties, and application areas.
• Understand the significance of selecting the appropriate lubricant for different types of equipment and operating conditions.

4. Lubricant Properties and Selection Criteria

• Study the key properties of lubricants, including:
• Viscosity: How it affects the lubricant’s ability to form a film between moving parts.
• Additives: Detergents, dispersants, anti-wear agents, and antioxidants.
• Oxidation Stability: The ability of a lubricant to resist degradation over time.
• Pour Point: The lowest temperature at which a lubricant remains fluid.
• Learn the criteria for selecting the right lubricant, considering factors like equipment type, load conditions, temperature, and speed.

5. Lubrication Methods and Systems

• Understand the different lubrication methods used for rotating equipment:
• Manual Lubrication: Hand greasing and oiling.
• Automatic Lubrication: Centralized systems, automatic grease dispensers, and oil mist systems.
• Splash Lubrication: Lubricants splashed onto moving parts through rotation.
• Pressure Lubrication: Forced delivery of lubricant to specific points under pressure.
• Study the design and working principles of lubrication systems used in different rotating equipment, such as pumps, compressors, and turbines.

6. Lubrication in Different Types of Rotating Equipment

• Explore lubrication requirements for various types of rotating equipment:
• Electric Motors: Lubrication of bearings and couplings.
• Pumps: Bearings, shafts, and seals.
• Compressors: Lubrication of pistons, rotors, and bearings.
• Turbines: Lubrication of bearings, gears, and seals.
• Gearboxes: Proper lubrication of gear teeth and bearings.
• Learn how to tailor lubrication strategies to the specific needs of each type of rotating equipment.

7. Lubrication System Components and Maintenance

• Study the components of lubrication systems, such as pumps, filters, coolers, and reservoirs.
• Understand the role of filters in removing contaminants and the importance of regular filter maintenance.
• Learn about the importance of monitoring lubricant levels, temperatures, and pressures within the system.
• Study the maintenance requirements for lubrication systems, including cleaning, replenishment, and replacement of lubricants.

8. Lubricant Contamination and Failure

• Understand the causes and effects of lubricant contamination, such as dirt, water, air, and chemical degradation.
• Learn how to detect and manage contaminants in lubricants using oil analysis, particle counters, and other diagnostic tools.
• Study the different modes of lubricant failure and their impact on rotating equipment, including:
• Oxidation: Breakdown of the lubricant due to exposure to heat and oxygen.
• Thermal Degradation: High temperatures causing the lubricant to break down.
• Wear and Abrasive Particles: Contaminants causing damage to surfaces.
• Explore the preventive measures to avoid lubrication-related failures and the importance of timely lubricant replacement.

9. Monitoring and Oil Analysis

• Learn about the role of oil analysis in proactive maintenance of rotating equipment.
• Study common oil analysis tests, such as viscosity testing, particle count, wear metal analysis, and water content determination.
• Understand how to interpret oil analysis results and use the data to make informed maintenance decisions.
• Explore condition-based maintenance strategies for rotating equipment based on oil analysis findings.

10. Safety and Environmental Considerations

• Study the safety considerations for working with lubricants, including handling, storage, and disposal.
• Understand the risks associated with lubricant leaks, spills, and contamination, and how to minimize them.
• Learn about environmentally friendly lubricants and sustainable lubrication practices, such as biodegradable oils and recycling lubricants.
• Understand the regulatory requirements for lubricant disposal and environmental impact mitigation.

11. Case Studies and Troubleshooting

• Review real-world case studies of rotating equipment failures due to lubrication issues.
• Learn from failures related to improper lubricant selection, contamination, or insufficient lubrication.
• Study the process of troubleshooting lubrication problems in rotating equipment and implementing corrective actions.
• Discuss best practices for ensuring the longevity and performance of rotating equipment through proper lubrication.

Target Audience

This training is designed for professionals involved in the operation, maintenance, and lubrication of rotating equipment. The target audience includes:

1. Maintenance Engineers and Technicians

2. Reliability Engineers

3. Operations Personnel

4. Equipment Manufacturers and Designers

5. Health, Safety, and Environmental (HSE) Professionals