ourse C D NCE A V D A
EFFECTIVE LUBRICATION & BEARING FAILURE ANALYSIS
ACHIEVING EXCELLENCE AND EFFICIENCY THROUGH BEARING FAILURE ANALYSIS AND WORLD-CLASS LUBRICATION MANAGEMENT STANDARDS
YOUR EXPERT TRAINER
S. NADEEM AHMED Sr. Power Plants Engineer Organized By :
EFFECTIVE LUBRICATION & BEARING FAILURE ANALYSIS 8 - 10 OCTOBER 2012, HCMC - VIETNAM
COURSE OBJECTIVES ∙
To provide pertinent information to improve the performance of rotating equipment and bearings through effective lubrication programs.
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To focus on reliability improvement as integrated with lubrication system in plant equipment.
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Understanding the various kinds of wear, wear mechanisms, and equipment failure modes, includes the condition monitoring, failuar analysis and techniques.
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An overview of thermal properties of lubricants, lubricant viscosity theory & index improvers (VI), low & high shear rate properties of lubricants and How these properties are measured.
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This course is designed for industrial professionals to have complete understanding of lubrication and bearings in industrial plant environment. This also covers the reuirements of level II & level III machinery lubrication & oil analysis programs.
WHO SHOULD ATTEND This training program is uniquely designed to provide valuable insight for : ● Maintenance Managers, Supervisors, Technicians & Engineers ● Rotating equipment engineers & performance analyst ● Reliability Engineers ● Condition monitoring staff ● Plant Managers (operation / maintenance) ● Maintenance planner ● Lubricant industry proffesionals ● Labotory analysts ● Lubricant Engineers, Equipment operators, Manufacturing & industrial engineers.
ABOUT INBI INBI (International Business Intelligence) are progressing to best provider of bespoke training company in South East Asia. INBI’s desire to create partnership and empower our clients with in-depth analysis, critical and practical knowledge covering current trends and ideas and world-class skilled trainer. Our course are well researched through the market segment & design the customized course to meet your unique requirements.
INHOUSE TRAINING Cost effective in-house courses, tailored specifically to your organization needs, can be arranged at your preferred location and time. If you would like to discuss further, please contact our In-house division at
[email protected]
EFFECTIVE LUBRICATION & BEARING FAILURE ANALYSIS 8 - 10 OCTOBER 2012, HCMC - VIETNAM DAY 1 | 8TH OCTOBER 2012 1. Understanding Plant environment ● ● ● ●
Types of Plants / Equipment Classifications, Categories & Rotating Equipment Design requirements for performance & reliability Plant reliability standards & programs
2. Fundamentals of Machine wear & Failures ● Common Machine wear mechanisms - Abrasive wear (two-body & three-body method) - Adhesive wear, surface fatique - Corrosve, Fretting wear - Erosive wear - Electrical wear - Cavitation wear (Gaseous & Vaporous ) ● Common Machine specific wear modes - Gearing & Plain Bearings - Rolling element bearings & Hydraulics ● Plant life Cycle analysis, Design material used ● Understanding types and design of failures ● Understanding bath tub Curve ● Advanced analysis tools & techniques - Root cause failure analysis method - Weibull analysis in Machinery Failure
DAY 2 | 9TH OCTOBER 2012 1. Lubricant selection standards development ● ● ● ● ● ● ●
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3. Maintenance Strategy ● The impact of lubrication on machine reliability ● Maintenance program strategies for lubrication excellence
4. Understanding Lubrication Theory Friction & Tribology Types of friction & wear Wear Modes and influencing factors Machine frictional surface most at risk for specific wear modes ● Mechanisms for lubrication regimes ● Boundary, Mixed film, Hydrodynamic and Elasto-hydrodynamic ● ● ● ●
5. Lubrication Categories & Formulation ● ● ● ●
Viscosity selection/adjustments Machinery Condition/environmental conditions When to use synthetic lubricants / biodegradable lubricants Lubricating Oils - Fire Resistant applications - Hydraulics - Mobile / industrial - Turbines, Compressors & Bearings - Chains/conveyors, Mist applications - Gear - Automotive/industrial, Engines Diesel/Gas/Gasoline - Pneumatic tools, Spindles, Ways/slides
● Selecting Greases - Chassis, Couplings, Anti Friction bearings - Journals bearings, Automotive bearings - Automatic Lubrication systems
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Procedures testing, quality assurance & approval Testing & Performance analysis Viscosity, Flash/fire point Pour ASTM D97/cloud point ASTM D2500 Foam ASTM D892 Air release Properties ASTM D3247-99 Neutralization number - Acid Number ASTM D664/D974 - Base Number ASTM D974/D2896 Filterability ISO 13357 Oxidation Stability - Turbine Oil Oxidation Test ASTM D943 - Rotary Pressure Vessel Oxidation Test ASTM D2272 Rust & Corrosion Tests - Turbine Oil Rust Test ASTM D665 - Copper strip Corrosion ASTM D130 Anti-wear Tests - Four ball wear test ASTM D2266 - Vickers wear pump test ASTM D2882 - SRV Test Extreme Pressure - Four Ball EP test ASTM D2596 - Timken Extreme Pressure Test ASTM D2509 - Falex EP/Wear Test ASTM D2670 - FZG Four Square Gear Test Rig ASTM D5182.97 Demulsibility ASTM D1404 Greese Consistency ASTM D217 Dropping Point of greese ASTM D2265 Mechanical Stability of greases ASTM D217A Rolling Stability of greases ASTM D1831 Water washout test for greases ASTM D1264 Water Spray test for greases ASTM D4049 Rolling bearing rush test ASTM D1743 Koppers Centrifugal Stability Test Oil Separation in grease storoge ASTM D1742 Oxidation stability - greases ASTM D942
2. Lubrication Application ● Procedures for: - Oil Drain, Reservoir/system flushing - Disassembling/cleaning reservoirs and sumps - Filling, Top-up, Grease packing - Re-greasing, Grease changeout ● Calculating correct amount for re-greasing ● Calculating correct frequesncy interval for regreasing ● Optimum equipment/systems for lubricant application ● SMS for lubricant application ● Maintenance of lubrication equipment/system ● Lube survey, Record of lube program ● Proactive management & detecction of leaks ● Waste oil / filters management / Disposal
EFFECTIVE LUBRICATION & BEARING FAILURE ANALYSIS 8 - 10 OCTOBER 2012, HCMC - VIETNAM DAY 3 | 10TH OCTOBER 2012
DAY 2 | 9TH OCTOBER 2012 (Cont)
3. Preventive & Predictive Maintenance ● Lube Pms & routes ● Lubrication inspection check list ● Oil Analysis - determine optimumcondition based oil changes - troubleshoot abnormal lubricant degradation condition - troubleshoot abnormal wear related to lubricant deg rada tion/ contamination ● Procedures & methods for identifying root cause of lubricants failure ● Determining optimum re-grease frequency/quantity ● Tools (ultrasonic, temperature monitoring, shock impulse, etc)
4. Lubricant Condition Control Proper Sampling Procedures, locations Proper Selection of breathers/vents Filter rating - Beta Ratio Sump/Tank management to reduce: - Air entrainment / foam - Particles, Water, Sediments - Heat, Silt / sediments - Over lubricant volume ● Proper Selection of reconditioning systems for - Water, Air/Gas, Particles - Oxidation products, Additive depletion ● ● ● ●
5. Lube Reclamation ● Requirements, Feasibility ● Procedures for reclaiming/reconditioning ● Use of oil analysis to approve reclaimed/reconditioned lubricants
DAY 3 | 10TH OCTOBER 2012 1. Lube Storage & Management Design Optimum storage room Defining maximum storage time Safety/health requirements Proper sampling procedures/locations for sampling stored lubricants ● Procedures for reconditioning/filtering stored lubricants ● ● ● ●
2. Wear Debris Analysis ● Analytical Ferrography - Wear Debris analysis techniques + Light effects, Magnetism effects, Heat treatment + Chemical treatment, Morphology, Surface detail - Wear Particle types, origins & probable causes + Cutting wear particles, Spherical particles + Chunky particles, Laminar particles + Red oxide particles, Black oxide particles + Corrosion particles, Non-ferrous particles + Friction polymers
(Cont) ● Atomic emission elemental spectroscopy - Basic determination of elemental composition - Evaluating sequential trends, lock-step trends - Particle size limitations of common atomic emission spec trometers - Advanced techniques - Acid / microwave digestion - Rotrode filter spectroscopy - X-ray fluorescence (XRF) & other advanced elemental spectroscopy methods
3. Analyzing Lubrication Degradation ● Oxidative base oil failure - Cause of oxidative base oil failure - Risk lubricants & applications - Strategies for deterring or mitigating base oil oxidation - Recognizing the effects of base oil oxidation ● Thermal Failure of base oil - Causes of thermal degradation - Hot surface degradation - Adiabatic compression induced degradation ● Addictive depletion / degradation - Assesing risk for common additive depletion/degradation mechanisms - Strengths, Limitations, and applicability of methods for mea suring additive depletion/degradation ● Detecting wrong lubricant addition
4. Oil Analysis program development & Program Management Machine-specific test slate selection Optimizing frequency of analysis Setting alarms & limits Rate of Change limits Setting aging limits for fluid properties Managing oil analysis information Creating and managing oil analysis procedures Scoping oil analysis training for reliability technician , trades people & management ● Performing cost/benefit analysis for oil analysis and contamination control programs + Calculating program cost + Estimating program benefits + Calculating ROI metrics ● Quality Assurance + of onsite oil analysis + of Offsite oil analysis providers ● ● ● ● ● ● ● ●
EFFECTIVE LUBRICATION & BEARING FAILURE ANALYSIS 8 - 10 OCTOBER 2012, HCMC - VIETNAM
ABOUT YOUR COURSE FACILITATOR Mr Syed Nadeem Ahmed has twenty 20 years plus of diverse engineering experience in Industrial sectors with career as a Mechanical Engineer with Manufacturing and Engineering Maintenance Repair Overhaul Industry. For the past 14 years working with PIA Engineering MRO facility onMaintenance Repair , Overhaul , Testing and Evaluation of Turbo Machinery including Aero and Aero derivative Gas Turbine Power Plants . Diversified Experience on General Electric, Rolls Royce and Pratt & Whitney Machines . Present assignments include the Lean Six Sigma Integration with Reliability Programs and third Party MRO Business Development of Aero Gas Turbine / Aero derivative Gas Turbine Repair, Refurbishment and Overhaul. International Conference Speaker/ Event Trainer globally addressing Gas Turbine Power Plants, Rotating equipment, Reliability Asset Management Management , lean Six Sigma. Trained Number of professionals in the same area within and outside organization. Provisioned Process companies ( Power Generation , Oil and Gas etc ) on Effective Reliability Improvement Programs , Maintenance Management Strategies , Lean Maintenance and Six Sigma Process Improvement Strategies integrating the same with reliability solutions. Mr Syed Nadeem Ahmed has Masters in Mechanical Engineering from University of Engineering & Technology Lahore Pakistan with Major in Thermal Power Systems Engineering. Six Sigma Master Black Belt from SME USA. Well versed with Microsoft Office and various other Quality and Power Plant Equipment Reliability Analysis Software’s. With over 20 years of experience, Mr. S. Nadeem Ahmed has built up a wealth of practical experience with organizations throughout the world. His partial clients are:
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PRE-COURSE QUESTIONAIRE To ensure that you gain maximum value from this course, a detailed questionnaire will be forwarded to you upon registration to establish your exact training needs and issues of concern. Your completed questionnaire will be analyzed by the course trainer and addressed during the event.
