Course Details

Objective

By the end of this course, participants will be able to:

1. Understand the principles of lubrication and their application in rotating equipment.
2. Select appropriate lubricants for various types of rotating equipment and operating conditions.
3. Identify and troubleshoot lubrication-related failures to minimize downtime.
4. Implement effective lubrication systems and maintenance practices.
5. Monitor lubricant condition and use analysis to optimize performance and maintenance schedules.
6. Apply advanced lubrication technologies to improve efficiency and reliability.

Content

COURSE PROGRAM:

Day 1: Fundamentals of Lubrication and Rotating Equipment

• Introduction to Rotating Equipment
  • Overview of rotating equipment used in oil and gas operations: pumps, compressors, turbines, and motors.
  • The role of lubrication in rotating equipment: reducing friction, minimizing wear, and dissipating heat.
  • Key operational challenges and the impact of lubrication on equipment performance.
• Basics of Lubrication
  • Principles of lubrication: friction, wear, and lubrication mechanisms.
  • Types of lubrication: hydrodynamic, boundary, mixed, and elastohydrodynamic lubrication.
  • Properties and characteristics of lubricants: viscosity, thermal stability, oxidation resistance, and additive packages.
• Lubricant Types and Applications
  • Overview of lubricants: mineral oils, synthetic oils, and greases.
  • Selection criteria for lubricants based on equipment type, operating conditions, and environmental factors.
  • Applications of lubricants in rotating equipment: bearings, seals, and gears.

Day 2: Advanced Lubrication Technologies

• Lubrication Systems for Rotating Equipment
  • Centralized lubrication systems: design, operation, and maintenance.
  • Automated lubrication systems: advantages and implementation in modern facilities.
  • Manual vs. automatic lubrication methods: benefits, challenges, and best practices.
• Lubricant Selection and Compatibility
  • Understanding lubricant specifications: API, ASTM, and OEM guidelines.
  • Compatibility considerations: mixing lubricants, seal compatibility, and avoiding contamination.
  • Factors affecting lubricant selection in high-pressure, high-temperature, and offshore environments.
• Condition Monitoring and Lubricant Analysis
  • Importance of lubricant condition monitoring in predictive maintenance.
  • Key tests for lubricant analysis: viscosity, water content, particle count, and oxidation levels.
  • Using lubricant analysis to diagnose equipment issues and optimize maintenance schedules.

Day 3: Lubrication-Related Failures and Troubleshooting

• Common Lubrication Issues in Rotating Equipment
  • Identifying and addressing lubrication-related problems: overheating, contamination, and improper lubrication.
  • Common causes of lubrication failures: wrong lubricant selection, over-lubrication, under-lubrication, and degradation.
• Troubleshooting and Failure Analysis
  • Systematic approach to diagnosing lubrication-related failures.
  • Interpreting failure patterns in bearings, seals, and gears.
  • Case studies of lubrication-related equipment failures and lessons learned.
• Contamination Control and Filtration
  • Sources of lubricant contamination: dirt, water, wear particles, and microbial growth.
  • Methods for contamination prevention: sealing systems, filtration, and proper storage practices.
  • Role of filtration systems in extending lubricant and equipment life.

Day 4: Best Practices in Lubrication Management

• Developing an Effective Lubrication Program
  • Steps to design and implement a lubrication program tailored to oil and gas operations.
  • Integrating lubrication management into reliability-centered maintenance (RCM).
  • Tools for tracking lubrication schedules and performance metrics.
• Training and Documentation
  • Importance of training operators and technicians in lubrication practices.
  • Documenting lubrication procedures and maintaining records for compliance and audits.
  • Using software tools to manage lubrication schedules and inventory.
• Sustainability and Environmental Considerations
  • Reducing lubricant waste and environmental impact: biodegradable and eco-friendly lubricants.
  • Strategies for safe disposal and recycling of used lubricants.
  • Adhering to environmental regulations and sustainability initiatives in oil and gas operations.

Day 5: Emerging Trends, Case Studies, and Hands-On Application

• Emerging Technologies in Lubrication
  • Advances in synthetic lubricants for extreme conditions.
  • Smart lubrication systems: IoT-enabled sensors and real-time monitoring.
  • Predictive maintenance powered by AI and machine learning for lubrication management.
• Case Studies and Practical Applications
  • Real-world examples of successful lubrication programs and their impact on operational reliability.
  • Hands-on exercises in lubricant selection, condition monitoring, and contamination control.
  • Group discussion: challenges and solutions in implementing lubrication best practices.
• Future of Lubrication in Oil and Gas
  • Trends in lubricant formulation and technology.
  • Innovations for improving energy efficiency and equipment reliability.
  • Preparing for future challenges in lubrication management in evolving oil and gas operations.

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions