Level I Machine Lubricant Analyst (MLA I)
Details :
The Level I Machinery Lubricant
Analysist (MLA) training course is designed to help candidates passing the International
Council for Machinery Lubricants (ICML) examination in accordance with ISO
18436-4, Category I, Annex A.
Throughout this course, you will
learn a range of essential topics related to lubricant analysis. We will start
by covering the fundamentals of lubrication and its importance in machinery
operation. You will gain an understanding of key lubrication principles and
learn how different lubricant properties impact equipment performance. In
addition, we will build the fundamentals for the lubricant storage, selection,
and application with the basic calculations.
Next, we will delve into the various
techniques for sampling lubricants. You will learn the proper methods for
selecting sample points, collecting representative samples, and minimizing
contamination. Effective sampling is crucial to ensure that the analysis
results accurately reflect the condition of the lubricant and the machinery.
We will then explore the different
analysis methods used to assess lubricant condition. From basic tests, such as
viscosity measurement to more advanced techniques like elemental analysis and
spectroscopy.
Additionally, we will discuss how
lubricant analysis fits into condition-based maintenance strategies. You will
learn how to set alarm limits, establish maintenance actions based on analysis
results, and integrate lubricant analysis as a predictive maintenance tool.
By end of the course, we will have an
intensive review with solved questions similar to the ICML exam questions.
The course aims to equip participants
with the necessary knowledge, skills for successfully pass the ICML
certification exam. As a minimum, following objectives will be achieved:
- Understanding the
importance of lubrication: Participants will learn about the critical role
of lubrication in machinery performance and maintenance. They will
understand how lubricants reduce friction, prevent wear, dissipate heat,
and protect against corrosion.
- Knowledge of
lubricant properties: Participants will gain a comprehensive understanding
of lubricant properties, including viscosity, viscosity index, oxidation
stability, additive packages, and base oil types. They will learn how
these properties influence lubricant performance and selection.
·
Lubrication Management: Discuss lubrication management
best practices, including storage and handling of lubricants, and lubricant
selection.
·
Sampling Techniques: Teach proper sampling techniques,
including sampling point selection, sample bottle preparation, and sample
collection methods to ensure representative and accurate results.
- Lubricant analysis
techniques: Participants will learn various techniques used for lubricant
analysis, such as viscosity measurement, acid number determination, water
content analysis, particle counting, and spectroscopy (such as infrared
analysis and elemental analysis).
- Implementing an
effective lubrication program: Participants will gain knowledge about
developing and implementing an effective lubrication program within their
organization. They will learn about best practices for establishing proper
lubrication schedules and oil change intervals.
- Safety and
environmental considerations: Participants will be made aware of safety
protocols and environmental regulations related to lubricant handling and
disposal. They will learn how to handle lubricants safely and responsibly
to minimize health risks and environmental impact.
A machinery lubricant analysis course is beneficial for a
wide range of professionals who are involved in machinery maintenance,
reliability, and lubrication. The course is typically attended by:
- Maintenance
Engineers: Maintenance engineers who are responsible for the overall
health and performance of machinery can benefit greatly from attending the
course. They will learn how lubricant analysis can help identify potential
issues, optimize maintenance schedules, and improve machinery reliability.
- Reliability
Engineers: Reliability engineers focus on maximizing the reliability and
availability of machinery. By attending the course, they can enhance their
understanding of lubrication principles, lubricant analysis techniques,
and how to integrate lubricant analysis into their reliability strategies.
- Lubrication
Technicians: Technicians involved in lubrication activities, such as oil
sampling, lubricant application, and oil analysis, can gain valuable
knowledge and skills from the course. They will learn how to perform
effective lubricant analysis tests, interpret results, and make informed
decisions regarding lubrication practices.
- Maintenance
Planners/Schedulers: Maintenance planners and schedulers who develop
maintenance plans and schedules can benefit from understanding the role of
lubricant analysis in optimizing maintenance activities. They will learn
how to use lubricant analysis data to develop predictive maintenance plans
and determine optimal oil change intervals.
- Operations
and Production Managers: Operations and production managers who oversee
the performance and efficiency of machinery can benefit from attending the
course. They will gain insights into the importance of lubrication, how
lubricant analysis can improve machinery performance, and how to integrate
lubricant analysis into their operational strategies.
- Condition
Monitoring Professionals: Professionals involved in condition monitoring
programs, such as vibration analysts or thermographers, can expand their
knowledge by adding lubricant analysis to their skillset. Understanding
lubricant analysis complements other condition monitoring techniques and
provides a more comprehensive picture of machinery health.
Module 1: Maintenance Strategies (10%)
·
Why machines fail
·
The impact of poor
maintenance on company profits
·
The role of effective lubrication
in failure avoidance
·
Lube routes and scheduling
·
Oil analysis and
technologies to assure lubrication effectiveness.
·
Equipment tagging and
identification.
Module 2: Lubrication Theory/Fundamentals (18%)
·
Fundamentals of tribology
·
Functions of a lubricant
·
Hydrodynamic lubrication
(sliding friction)
·
Elasto-hydrodynamic
lubrication (rolling friction)
·
Mixed-film lubrication
·
Base-oils
·
Additives and their
functions
·
Oil lubricant physical,
chemical and performance properties and classifications.
·
Grease lubrication
o
How grease is made?
o
Thickener types
o
Thickener compatibility
o
Grease lubricant physical,
chemical and performance properties and classifications.
Module 3: Lubricant Selection (10%)
·
Viscosity selection
·
Base-oil type selection
·
Additive system selection
·
Machine specific lubricant
requirements
o
Hydraulic systems
o
Rolling element bearings
o
Journal bearings
o
Reciprocating engines
o
Gearing and gearboxes
·
Application and environment
related adjustments.
Module 4: Lubricant Application (18%)
·
Basic calculations for
determining required lubricant volume.
·
Basic calculations to
determine re-lube and change frequencies.
·
When to select oil; when to
select grease.
·
Effective use of manual
delivery techniques.
·
Automatic delivery systems.
o
Automated deliver options.
§
Automated grease systems
§
Oil mist systems
§
Drip and wick lubricators
·
Deciding when to employ
automated lubricators.
·
Maintenance of automated
lubrication systems.
Module 5: Lube Storage and Management (10%)
·
Lubricant receiving
procedures.
·
Proper storage and inventory
management.
·
Lube storage containers
·
Proper storage of
grease-guns and other lube application devices.
·
Maintenance of automatic
grease systems.
·
Health and safety
assurance.
Module 6: Lube Condition Control (10%)
·
Filtration and separation
technologies.
·
Filter rating.
·
Filtration system design
and filter selection.
Module 7: Oil Sampling (10%)
·
Objectives for lube oil
sampling
·
Sampling methods
·
Managing interference
o
Bottle cleanliness and
management
o
Flushing
o
Machine conditions
appropriate for sampling
Module 8: Lubricant health monitoring (10%)
·
Lubricant failure
mechanisms
o
Oxidative degradation
§
The oxidation process
§
Causes of oxidation
§
Effects of oxidative
degradation
o
Thermal degradation
§
The thermal failure process
§
Causes of thermal failure
§
Effects of thermal degradation
·
Additive
depletion/degradation
o
Additive depletion
mechanisms
o
Additives at risk for
depletion/degradation by the various mechanisms.
·
Testing for wrong or mixed
lubricants
o
Baselining physical and
chemical properties tests
o
Additive discrepancies
·
Fluid properties test
methods and measurement units - applications and limitations.
o
Kinematic Viscosity (ASTM
D445)
o
Absolute (Dynamic)
Viscosity (ASTM D2893)
o
Viscosity Index (ASTM
D2270)
o
Acid Number (ASTM D974 et
al)
o
Base Number (ASTM D974 et
al)
o
Fourier Transform Infrared
(FTIR) analysis
o
Rotating Pressure Vessel
Oxidation Test (ASTMD2272)
o
Atomic Emission
Spectroscopy
Module 9: Wear Debris Monitoring and Analysis (4%)
·
Common machine wear
mechanisms
Here
is a breakdown of the methodologies used in these courses:
- Classroom lectures: The course may begin with classroom lectures to
provide participants with a theoretical foundation. Experienced
instructors or subject matter experts will cover topics such as lubricant
properties, lubrication principles, lubricant analysis techniques, and
interpretation of analysis results. Visual aids like slides, charts, and
diagrams may be used to enhance the learning experience.
- Group discussions and Q&A sessions: Throughout the course,
there will be opportunities for group discussions and question-and-answer
sessions. Participants can share their experiences, ask questions, and
engage in discussions with the instructor. This promotes knowledge
sharing, critical thinking, and a deeper understanding of the subject
matter.
- Training materials and resources: Participants may receive training
materials such as course handbooks, reference guides, and checklists to
supplement their learning. These resources provide additional information,
practical tips, and serve as references for future use.
- Assessments and evaluations: The course may include assessments or
evaluations to gauge participants' understanding of the concepts and their
ability to apply the learned skills. This could be in the form of quizzes,
assignments, or practical tests. Feedback from instructors can help
participants identify areas for improvement and reinforce their learning.
- Case studies and real-world examples: Case studies and real-world
examples will be discussed to show case the practical application of
lubricant sampling and analysis techniques.
09:00 to 16:00 with customised cofee and lunch breaks