Industrial Lubrication Course

Lesson 1 • Core Functions of Lubricants

Defines the five primary lubricant functions: friction reduction, cooling, sealing, cleaning, and corrosion protection. Links each function to machine reliability.

Lesson 2 • Lubrication Regimes

Explains hydrodynamic, elastohydrodynamic, mixed, and boundary lubrication regimes. Students match operating conditions to the correct regime.

Lesson 3 • Lubricant Physical Properties

Introduces viscosity, density, flash point, and pour point as key selection criteria. Connects each property to specific machine operating requirements.

Lesson 4 • Overview of Lubricant Types

Surveys mineral oils, synthetic fluids, semi-synthetics, and greases at an introductory level. Sets the stage for detailed study in later chapters.

Lesson 1 • Synthetic Base Stock Chemistry

Covers PAOs, esters, polyglycols, and silicones as synthetic base stocks. Highlights performance advantages over mineral oils in extreme conditions.

Lesson 2 • Mineral Base Oil Chemistry

Analyzes paraffinic, naphthenic, and aromatic hydrocarbon structures in mineral oils. Explains how molecular composition drives viscosity and oxidation stability.

Lesson 3 • Grease Composition and Thickeners

Explains soap and non-soap thickener systems, base oil content, and additive packages in grease. Connects thickener type to temperature and load performance.

Lesson 4 • Additive Chemistry and Function

Details antioxidants, anti-wear agents, extreme-pressure additives, and detergents. Students explain how each additive class extends lubricant service life.

Lesson 1 • Selecting Lubricants for Machine Elements

Guides selection for rolling bearings, plain bearings, gears, and hydraulic systems. Integrates viscosity, additive, and base stock decisions into one process.

Lesson 2 • Load, Speed, and Viscosity Selection

Applies bearing DN values, gear pitch-line velocity, and load factors to viscosity selection. Ensures film thickness adequacy under real operating conditions.

Lesson 3 • Viscosity Measurement and Standards

Covers ISO VG, SAE, and AGMA viscosity classification systems and measurement methods. Enables accurate cross-referencing across industry standards.

Lesson 4 • Environmental and Operational Constraints

Incorporates ambient temperature range, contamination risk, and regulatory requirements into lubricant selection. Balances performance with environmental compliance.

Lesson 1 • Automatic Lubricators and Grease Systems

Examines single-point automatic lubricators and multi-point grease systems. Addresses setting discharge rates and verifying delivery to remote lubrication points.

Lesson 2 • Centralized Lubrication Systems

Covers single-line, dual-line, progressive, and oil-mist centralized systems. Students match system type to machine complexity and lubrication frequency needs.

Lesson 3 • Circulating Oil Systems

Details forced-feed circulating systems including pumps, filters, coolers, and reservoirs. Connects system components to continuous film maintenance in critical machinery.

Lesson 4 • Manual Lubrication Methods

Covers oil cans, grease guns, wick oilers, and drip-feed systems used in manual lubrication. Establishes baseline practices before introducing automated systems.

Lesson 1 • Water and Gas Contamination Removal

Addresses dehydration methods including vacuum dehydration, coalescers, and desiccant breathers. Covers dissolved and free gas removal from circulating systems.

Lesson 2 • Sources and Types of Contamination

Classifies particulate, water, air, and chemical contamination sources in lubricated systems. Establishes the contamination control mindset central to reliability programs.

Lesson 3 • Contamination Control Program Design

Integrates exclusion, removal, and monitoring into a plant-wide contamination control program. Students build a contamination control plan for a representative facility.

Lesson 4 • Filtration Technology and Selection

Covers filter media types, beta ratio, micron rating, and filter placement strategies. Students select filters that achieve target cleanliness without excessive pressure drop.

Lesson 1 • Physical and Chemical Oil Tests

Covers viscosity, acid number, base number, water content, and oxidation tests. Students interpret each result against new-oil and alarm limits.

Lesson 2 • Correct Oil Sampling Techniques

Demonstrates live-zone sampling, vacuum pump extraction, and sample bottle handling to prevent contamination. Correct technique is the single largest variable in data quality.

Lesson 3 • Oil Analysis Program Design

Establishes sampling frequency, sample point selection, and laboratory test slate for a new program. Aligns program scope with machine criticality and failure risk.

Lesson 4 • Report Interpretation and Action Limits

Teaches statistical trending, alarm limit setting, and corrective action decision trees. Students convert lab data into maintenance work orders and fluid change decisions.

Lesson 1 • Lubricant Consolidation and Rationalization

Reduces the number of lubricant products on-site through compatibility analysis and OEM requirement review. Fewer products lower cost, training burden, and cross-contamination risk.

Lesson 2 • Lubrication Routes and Scheduling

Organizes tasks into efficient technician routes and integrates them with the maintenance management system. Reduces travel time and ensures no lubrication point is missed.

Lesson 3 • Lubricant Storage and Handling

Establishes standards for lubricant receiving, storage, labeling, and dispensing to prevent contamination and cross-mixing. Proper storage protects lubricant quality before use.

Lesson 4 • Lubrication Task Development

Creates lubrication task descriptions including lubricant type, quantity, method, and interval. Proper task definition is the foundation of consistent field execution.

Lesson 1 • Compressor and Turbine Lubrication

Examines lubricant requirements for reciprocating, rotary screw, and centrifugal compressors and gas turbines. Addresses varnish, oxidation, and deposit control.

Lesson 2 • Extreme Condition Lubrication Strategies

Develops lubrication solutions for very high temperatures, cryogenic conditions, vacuum environments, and radiation exposure. Applies specialty lubricants to non-standard operating conditions.

Lesson 3 • Gear and Gearbox Lubrication

Applies viscosity selection, additive requirements, and thermal management to enclosed and open gear systems. Covers worm, helical, bevel, and planetary gear types.

Lesson 4 • Lubrication of Rolling Element Bearings

Covers grease quantity calculation, relubrication intervals, and purge methods for rolling bearings. Addresses over-greasing as the leading cause of bearing failure.