Oil Analysis School Level 2 & 3 Training Courses for Maintenance & Reliability Professionals Facilitated by: A part of: Produced by: the eventful group
You ll gain practical new skills that you can use right away: Get Answers To These and All Your Questions About Oil Analysis How often should I use oil analysis? Where is the best place to get an oil sample? What are the benefits and drawbacks of screening oil samples before sending them to my lab? How clean should I keep my oil and what type of filter should I use? What are all these numbers I see on my oil analysis report? How do I know which oil analysis lab is right for me? How do I set caution and critical alarms for wear metals and additives? What steps can I take to ensure that I get a good sample each time? How do I determine the remaining useful life of my oil? How do I know if I should occasionally sweeten my oil with additives? What is the best temperature to trend viscosity at? What are the secrets to catching bearing faults with wear debris analysis? Are there any good field tests for oil that don t involve expensive instruments? What are the five most important things I should be looking for on my oil analysis report? What are the best cost reducing strategies using oil analysis? Excellent learning forum. Provided substantial information that will be immediately useful in improving our existing oil analysis program. Steve Fox, Maintenance Engineer, Aera Energy Instructors JIM FITCH is regarded as one of the world s leading experts and educators in lubrication, oil analysis, tribology and machinery failure investigations. Over the past two decades he has given hundreds of lectures on these subjects and has a wealth of in the trenches experience with more than 100 organisations including Michelin Tyre, John Deere, Caterpillar, Duke Energy, EPRI, ExxonMobil, International Paper, NASA and U.S. Steel. Jim has over 200 publications and is a senior editor of Machinery Lubrication magazine. He serves as U.S. delegate to ISO of the tribology and oil analysis working group. Since 2002, he has been Director and Board Member of the International Council for Machinery Lubrication (ICML). In 1997, he co-founded Noria Corporation as Chairman and CEO. Jim Fitch holds degrees from Georgia Tech and the University of Tulsa. DREW TROYER is a renowned maintenance and reliability educator and thought leader, with a passion for lubrication and the importance of lubrication to overall plant reliability. Widely published, Drew has authored more than 125 technical papers, articles, books and book chapters on industrial reliability management. Drew specialises in quantifying the financial benefits of plant reliability management and in conveying those opportunities to senior-level managers in the language and style to which they re accustomed. He has developed dozens of proprietary processes and software applications to help define the strategic goals for managing plant reliability, economically justifying the plant s elements and successfully implementing the strategy. Drew is a Certified Reliability Engineer (CRE), a Certified Maintenance & Reliability Professional (CMRP), holds an MBA and a post-master s graduate study in reliability engineering technology management and measurement theory. You will learn how to easily interpret oil analysis reports, squeeze maximum life from your lubricants, pull oil samples for optimum results, and reduce oil consumption for real savings. BOB SCOTT has 25 years of technical experience with lubricants, lubrication and related machinery, ten of which include owning and operating his own lubrication consulting and contracting firm. Bob spent almost 20 years with Shell Canada Products Ltd. where he gained extensive laboratory and field experience in the development of lubricants and statistical process control. Bob has written and presented technical papers to lubricant technical societies and lubrication conferences and has developed and presented training sessions for maintenance and lubricant sales personnel. He holds a Bachelor of Science degree in chemistry from the University of Waterloo in Ontario, Canada. He has been certified as a Lubrication Specialist (CLS) and Oil Monitoring Analyst (OMA) Levels I and II by the Society of Tribologists and Lubrication Engineers (STLE). Bob is also ICML Level I MLT certified. JEREMY WRIGHT has been a valuable member of the Noria team since 2004 shortly after finishing his bachelor s of science degree in Mechanical Engineering from the University of Oklahoma. As an Associate Technical Consultant, his attention was focused on machinery lubrication and maintenance in support of Noria s Lubrication Program Design (LPD). In 2006, Jeremy s promotion to Senior Technical Consultant has him furthering his skills as a lubrication specialist by teaching onsite seminars for a variety of clients and conducting LPD consulting services for several industries such as steel, mining, power generation, petroleum, plastics, oilseeds, corn milling, wood pulp and paper. Jeremy is a certified Machinery Lubricant Analyst (MLA) Level I and Level II and Machinery Lubrication Technician (MLT) Level I by the International Council for Machinery Lubrication (ICML). In addition, he is a Certified Maintenance Reliability Professional (CMRP) by the Society for Maintenance and Reliability Professionals (SMRP). 2 www.reliabilityschool.com/oilanalysis 3
Oil Analysis School Level 2 Practical Oil Analysis World-class Maintenance Philosophies Five prevailing features of world-class maintenance programs The 80:20 rule for maintenance Three successful elements of a CBM program Introduction to Machinery Lubrication 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 Oil Analysis Fundamentals Interpreting the language your oil is speaking Prevailing myths about oil analysis Common applications for sampling and analysis Three categories of oil analysis Oil Sampling The Very Best Practices 11 elements of a successful oil analysis program How clean should sample bottles be? How to find the best sampling locations Sampling valves and hardware recommendations A quick method for optimising sampling intervals The importance of primary and secondary sampling points How to properly sample circulating systems Safe, effective high-pressure sampling from hydraulic systems Best practices for sampling splash, collar and ring-lubricated systems Fluid Property Analysis Four common root causes of oil degradation Recognising and controlling oil oxidation Monitoring lubricant degradation using acid number Monitoring lubricant health using FTIR Determining oil life using RPVOT Recognising and controlling thermal failure How to recognise 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 Contamination Control and Proactive Maintenance Seven common contaminants Oil cleanliness and oil life extension benefits Using the ISO Solid Contamination Code Proactive maintenance in three easy steps Case studies for proactive maintenance Oil filter and breather recommendations Portable filtration carts - three 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 Fault Detection and Wear Particle 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 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 Instrument Free On-site Tests How to inspect vents and breathers Tips for effective sight 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 Interactive Case Studies Individual and group participation in problem-solving exercises Exercises in how to read an oil analysis report 4 www.reliabilityschool.com/oilanalysis 5
Oil Analysis School Level 3 Advanced Oil Analysis 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 five 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 Detecting and Troubleshooting Machine Wear Four primary sources of friction in lubricated machinery 10 wear mechanisms that reduce machine life The secret to fault detection and analysis Why clean oil helps you detect faults earlier The importance of controlling water in your lubricants Understanding the progression of mechanical wear Using analytical ferrography for advanced root cause failure analysis Tips for chemical microscopy oil analysis forensics The advantages and disadvantages of XRF spectrometers for large particle detection Using SEM-EDX for root cause failure analysis Characterising particle composition by visual inspection LaserNetTM - automating ferrographic analysis Fluid Properties Analysis Differentiating between oxidation and other base oil degradation pathways 20 causes and characteristics of lubricant change 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 remaining useful life tests How antioxidants alter oil life Troubleshooting air release and foaming problems 6 ways to test for varnish in your oil Identifying the addition of incorrect oil using oil analysis What you need to know about thermal stability How oil colour plays a role in oil life Using Oil Analysis to Define Lubricant Standards Setting up a basic QA program for incoming lubricants Designing an Oil Analysis Program Using RCM and FMECA to guide your 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 lubrication team Best practices for setting up a successful on-site lab 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 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 grease analysis Obtaining samples for in-service grease analysis Identifying possible grease compatibility issues using grease analysis Determining oxidation and the remaining useful life of a grease Troubleshooting wear problems in grease-lubricated bearings 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 (KPIs) Interactive Case Studies Workshop Individual and group participation in advanced problemsolving exercises, including designing and implementing an oil analysis program, analysing data and making decisions on continuous improvement. 6 www.reliabilityschool.com/oilanalysis 7
Getting Value from Oil Analysis School What people say about this training: 1000 s of Maintenance & Reliability Professionals around the world have participated in Oil Analysis School here s what some of them have to say about the real business benefits derived: Who Will Benefit From This Training? I learned more in two days than I have in the past year. This training has opened up some issues I have in my plant that I would have never thought of. Burt Jimenez, Maintenance Planner, Inland Steel Profile of Maintenance & Reliability Professionals who have participated in this course: All Maintenance Professionals Laboratory Analysts Vibration Instrument Specialists Craftsman or Millwrights Manufacturing and Industrial Engineers Lubrication Engineers Maintenance Managers Maintenance Supervisors Equipment Operators Operations Managers Reliability Engineers Predictive Maintenance Technicians This Training is highly recommended for people working with the following machines: Blowers/Fans Hydraulic Systems Gear Boxes Compressors Final Drives Hydrostatic Transmissions Rolling Mills Motor Bearings Paper Machines Diesel Engines Process Pumps Gas Turbines Steam Turbines For any program looking to start a fluid sampling program, this is the place to start. Justin Youtz, Hydraulics IPT Lead, General Dynamics Amphibious Systems Excellent combination of introductory and advanced material. Ben Staats, Reliability Maintenance Engineer, Cariboo Pulp & Paper One of the most useful courses I have ever attended. Not bogged down with theory, just the facts. Dave Roycraft, Maintenance Manager, Chrysler Excellent learning forum. Provided substantial information that will be immediately useful in improving our existing oil analysis program. Steve Fox, Maintenance Engineer, Aera Energy This class is a true pathway into world-class maintenance. Gary Stamper, Maintenance Superintendent, Meadwestvaco This course produced instantly usable knowledge which will definitely result in changes in the way we handle lubricants and lubrication systems. Joe Kelly, Maintenance Engineer, Akzo Nobel Easy to understand, very informative and delivered in a professional way. Terry Craswell, Maintenance Technician, Alberta Pacific Forest Inc. 8 www.reliabilityschool.com/oilanalysis 9
Get Certified to Enhance Your Professional Development Registration Mr/Mrs/Ms First Name Position Organisation Address Surname Your registration fee includes the option to get certified through the International Council for Machinery Lubrication (ICML). Why Certify? Certification is an important part of the training process because it confirms you possess the skills to do the job. Combining training with certification creates a knowledgeable and valuable employee. Which Certifications? Oil Analysis Level 2 (Practical Oil Analysis) is designed to help you prepare for the following ICML certification exam: Level 2 Machine Lubrication Analyst (MLA) Oil Analysis Level 3 (Advanced Oil Analysis) is designed to help you prepare for the following ICML certification exam: Level 3 Machine Lubrication Analyst (MLA) You can find out more about these ICML exams at the ICML web site: www.lubecouncil.org What is ICML? The International Council for Machinery Lubrication (ICML) is a vendor neutral, not-for-profit organisation founded to facilitate growth and development of machine lubrication. Among its various activities, ICML offers skill certification testing for individuals in the fields of machine condition monitoring, lubrication and oil analysis. How to Certify? Please indicate on your registration form if you wish to sit the certification exam. Testing will be held on the afternoon following the training. City Postcode Country Phone Email Mobile Which phone number would you prefer on the Networking List? Phone Mobile Special Dietary Requests Approving Manager Position Email Please send the tax invoice to my approving manager DATES 14-16 November 14-16 November CERTIFICATION CITY/TOWN Newcastle Perth COURSE Level 2 Level 2 Please send the tax invoice to me EARLY BIRD INVESTMENT On/before 30 September AU$2095 (+GST) / participant On/before 30 September AU$2095 (+GST) / participant STANDARD INVESTMENT After 30 September AU$2195 (+GST) / participant After 30 September AU$2195 (+GST) / participant I would like to sit the ICML certification exam at the end of the course (Oil Analysis will conclude at 12H30 on the third day, and the exam will start at 13H30 and finish at 16H30). About Noria Noria offers globally-recognised training to help your organisation become world-class through the dissemination of knowledge and information in the fields of lubrication, oil analysis and machine reliability. In addition to training and publishing Machinery Lubrication Magazine, Noria s team of technical consultants combines in-plant experience and specialised skills to provide a wide range of maintenance and reliability consulting services for industry. From lubrication program audits and design, to failure investigations, to oil analysis and contamination control, Noria deliver outstanding results and help you achieve peak equipment performance. For more information, take a look at www.noria.com About The Eventful Group At The Eventful Group we are passionate about connecting Maintenance and Reliability people who share common goals. Since 1996 more than 10,000 people have attended our Maintenance and Reliability events and training courses in Australia, New Zealand and the US. We take special care of each and every customer. And we are focused on creating an environment of open communication. It s this spirit of community that encourages delegates, facilitators and speakers to break through barriers, engage in brave conversations and form lasting relationships. To explore our portfolio of Maintenance and Reliability events, take a look at www.theeventfulgroup.com or call us on (+61 2) 9955 7400. ACCOMMODATION Please indicate whether you require The Eventful Group to organise your accommodation. We have secured a block booking at a discounted rate for participants of Oil Analysis School. Yes, Please call me to organise PAYMENT OPTIONS Special Note: Payment required prior to the event. Please include accommodation (if required). Cheque made payable to: The Eventful Group Conferences and Events Pty Ltd Visa Mastercard Bankcard AMEX Diners Card Number Name of Cardholder: No thankyou. I don t require accommodation / Card Expiry Signature: 10 www.reliabilityschool.com/oilanalysis Contact The Eventful Group to Register Mail: Suite 6, 5-7 Holt Street McMahons Point NSW, 2060, Australia Phone: +61 2 9955 7400 Fax: +61 2 9955 3899 Web: www.reliabilityschool.com/oilanalysis Email: register@reliabilityschool.com (Please photocopy for additional participants) Cancellations Cancellations must be advised in writing at least 21 days prior to the event. Where an alternate delegate is not possible, an administration fee of $550 (+ GST) per delegate will be incurred for cancellations. A refund will not be given if a delegate fails to attend or cancels within 21 days prior to the event. *The Eventful Group reserves the right of admission. 11
suite 6, 5-7 holt street mcmahons point nsw 2060 australia p +61 2 9955 7400 f +61 2 9955 3899 w www.theeventfulgroup.com