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Oil
Analysis 1 & 2 – by Noria Corporation
Developed by Jim Fitch, these courses teach the “best
practices” of oil analysis. Jim has worked with hundreds
of maintenance professionals, researched countless world-class
oil analysis programs, and helped numerous Fortune 500 companies
turn oil analysis into centers of excellence and profitability.
All
of this knowledge has been distilled into an easy- to-implement
plan for transforming your current oil analysis program into
the envy of your industry.
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Course
Outlines
Oil
Analysis 1 |
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Introduction
to Machinery Lubrication
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Oil formulation and its importance in effective machinery lubrication
• Six key functions of lubricating oils
• Three primary lubrication regimes
• Introduction to base oils and additives
• Choosing the correct base-stock
• Conditions that dictate use of synthetic oils
• Antioxidant additives and their role in oil life
• Dispersants and Detergents - the key to controlling
soot
• Controlling wear with additive chemistry |
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Oil
Sampling - The Very Best Practices
• Six steps to reliable and easy oil sampling
• How to find the best sampling location
• Sampling splash, collar and ring lubricated systems
• How to sample circulating systems
• Safe, effective high pressure sampling from hydraulic
systems
• Using primary and secondary sampling points
• A quick method for optimizing sampling intervals
• How clean should sample bottles be?
• Sampling valves and hardware recommendations |
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Fundamentals
of Friction and Machine Wear
• Four primary sources of friction in lubricated machinery
• The 10 wear mechanisms that reduce machine life
• The most common wear modes in plain, rolling element
and thrust bearings
• Understanding gear wear
• Understanding wear in hydraulic systems |
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Machine
Fault Detection and Debris Analysis
• How wear metals are measured using RDE and ICP spectrometers
• Measuring larger particles with Rotrode Filter spectroscopy
• Using ferrous density to determine the severity of a
wear problem
• Using analytical ferrography for advanced fault detection
• Using ferrography for root cause analysis |
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Fluid
Properties Analysis
• Four common root causes of oil degradation
• Recognizing and controlling oil oxidation
• Monitoring lubricant degradation using acid number
• Monitoring lubricant health using FTIR
• Determining oil life using RPVOT
• Recognizing and controlling thermal failure
• How to recognize additive depletion or degradation
• Using paper chromatography (blotter spot test) to detect
additive and base oil degradation
• Four ways to detect the addition of wrong oil |
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Contamination
Control and Proactive Maintenance
• Seven common contaminants
• Oil cleanliness and oil life extension benefits
• Using the ISO Solid Contamination Code
• Proactive maintenance in 3 easy steps
• Case studies for proactive maintenance
• Oil filter and breather recommendations
• Portable filtration carts - 3 ways to use them
• Setting targets for oil cleanliness
• Detecting and controlling moisture contamination
• Selecting moisture removal/filtration methods
• The effects of heat on lubricants
• Controlling air entrainment and foam
• Glycol contamination
• Dealing with soot
• Understanding fuel contamination |
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Instrument
Free Onsite Tests
• How to inspect vents and breathers
• Tips for effective site glass inspection
• Getting valuable information from used filters
• Inspecting reservoirs for clues about lube trouble
• Scenting lubricants to find problems
• Getting visual clues from the oil sample before mailing
it out
• Getting into particle analysis for under $100
• Turn your kitchen blender into a test for demulsibility
and foam tendency
• Screening for water with a simple hot plate
• How an unwanted business card can reveal oil degradation |
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Interactive
Workshop
• Individual and group participation in problem-solving
exercises
• Exercises in how to read oil analysis reports
• ICML MLA Level I flashcard review session |
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| Oil
Analysis 2 |
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Lubrication
Fundamentals
• Understanding full film, elastohydrodynamic and boundary
lubrication
• Comparing solvent-refined, hydro-treated and hydro-cracked
mineral base oils
• Advantages and disadvantages of the four most common
synthetic base oil types
• Understanding API's five base oil categories
• Other base oil classification systems
• Overview of the 14 key additives that enhance lubricant
performance
• Antioxidant additives and their role in oil life
• Controlling wear with additive chemistry |
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Detecting
and Troubleshooting Machine Wear
• Four primary sources of friction in lubricated machinery
• The 10 wear mechanisms that reduce machine life
• Beyond elemental spectroscopy - detecting “large”
wear particles
• Using analytical ferrography for advanced root cause
failure analysis
• Using magnetism, light and heat treatment with ferrograms
• Tips for chemical microscopy - oil analysis forensics
• The advantages and disadvantages of XRF spectrometers
for large particle detection
• Using SEM-EDX for route cause failure analysis
• LaserNetTM; automating ferrographic analysis |
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Fluid
Properties Analysis
• Differentiating between oxidation and other base oil
degradation pathways
• Troubleshooting additive depletion with some common
and not so common oil analysis tools
• Using FTIR for advanced lubricant chemical analysis
• Determining oil life using RPVOT and RUL tests
• Troubleshooting air release and foaming problems
• Identifying the addition of wrong oil using oil analysis |
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Using
Oil Analysis to Define Lubricant Standards
• Setting up a basic QA program for incoming lubricants
• Defining minimum performance standards for new lubricants
using oil analysis
• Conducting lubricant cross compatibility testing
• Using oil analysis viscometric properties to guide and
troubleshoot lubricant selection |
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Grease
Analysis
• Obtaining samples for in-service grease analysis
• Identifying possible grease compatibility issues using
grease analysis
• Determining oxidation and the RUL of a grease
• Troubleshooting wear problems in grease lubricated bearings |
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Oil
Analysis Program Design
• Using RCM and FMECA analysis to guide analysis program
design
• Designing an oil analysis program to ensure proactive
and predictive maintenance success
• Integrating oil analysis with other condition-monitoring
technologies
• Ensuring oil analysis quality on-site and off-site
• Selecting machine-specific oil analysis test slates
• Creating effective oil analysis procedures
• How to scope training for the rest of the oil analysis
and lubrication team
• Tips to setting up an effective on-site lab |
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Managing
an Oil Analysis Program
• Selling oil analysis to management - how to write
an effective oil analysis proposal
• Using financial data to justify lubrication and oil
analysis program costs
• Using statistics to set level limits
• Modifying limits to account for operational changes
• Calculating and using rate-of-change limits
• How to set condition-based oil change limits
• Learning multi-parameter diagnostic techniques
• How to effectively manage oil analysis data
• Using oil analysis to develop lubrication Key Performance
Indicators (KPI’s)
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Data
Interpretation Workshop
• Individual and group participation in advanced problem-solving
exercises, including designing and implementing an oil analysis
program, analyzing data and making decision on continuous improvements
• ICML MLA Level I flashcard review session |
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