BME301S

Unit Description and General Aims

The objective in presenting this unit is to provide students with a thorough overview of Tribology fundamentals, comprehension of the key lubricant properties and types, and the knowledge to select the right lubricant for a particular application. The emphasis is on enabling students to get the most up-to-date information on lubrication related issues and best practices.

Students will also be instructed on the many aspects of maintenance, the latest maintenance techniques and technologies, be equipped with the skills to perform condition monitoring tasks and to recognize and solve precision maintenance issues in a structured manner towards improved reliability and performance.

The subject matter covered in this unit will include the fundamental Tribology concepts; lubricant and additive properties; the identification of the different lubricant types; lubricant storage and stability; preventive and predictive maintenance strategies; condition monitoring tasks; and, precision maintenance programs. Students will also undertake project work involving a sample preventive maintenance strategy for a given application and carry out failure analysis for a given equipment/system.

Detailed knowledge of Tribology concepts and lubricants is key to effective and efficient maintenance. Many operational problems can be traced to inadequate knowledge of lubricants, lack of basic maintenance, and poor asset management skills. It is through the detailed knowledge of Tribology concepts, lubricants, and timely implementation of maintenance practices, that failures can be averted and/or their symptoms can be accurately identified, and corrective measures initiated well in time to prevent unscheduled and sometimes even catastrophic failures. At the conclusion of this unit, students will have been imparted with the requisite knowledge of lubricants and maintenance issues to appreciate this and ensure that effective products and effective maintenance strategies, plans, and programs are utilised, established, and perpetually sustained.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Explain the fundamental Tribology concepts.
   Bloom's Level 2
2. Examine lubricant and additive properties.
   Bloom's Level 4
3. Identify the different lubricant types.
   Bloom's Level 3
4. Deal with issues related to lubricant storage and stability.
   Bloom's Level 6
5. Optimizes preventive and predictive maintenance strategies.
   Bloom's Level 5
6. Perform condition monitoring tasks.
   Bloom's Level 3
7. Manage your precision maintenance program.
   Bloom's Level 3

Student assessment

Prescribed and Recommended Readings

Textbook

Machinery Vibration Analysis and Predictive Maintenance, IDC Technologies, Perth
Practical Lubrication Engineering for Engineers and Technicians, IDC Technologies, Perth
Reliability Centred Maintenance, IDC Technologies, Perth

Reference

Rao, BKN 1996, Handbook of Condition Monitoring, 1st edn, Elsevier Science Ltd, ISBN-13: 978-1856172349

Mohanty, AR 2014, Machinery Condition Monitoring: Principles and Practices, CRC Press, ISBN-13: 978-1466593046

Journal, website

http://www.plant-maintenance.com/maintenance_articles.shtml
https://www.wbdg.org/resources/rcm.php
www.scirp.org/journal/PaperDownload.aspx?paperID=3165

Notes and Reference Texts

IDC Technologies
Other material advised during the lectures

Unit Content

Topic 1

Tribology

1. Cause and effects of friction
2. Fluid and hydro-dynamic lubrication
3. Boundary lubrication
4. Lubricant characteristics under varying conditions
5. Lubricant types and applications

Topic 2

Properties of Lubricants

1. Viscosity
2. Flashpoint and volatility
3. Oxidation and thermal stability
4. Demulsibility
5. Foaming and gas solubility
6. Corrosion prevention
7. Compatibility

Topic 3

Additives

1. Oxidation inhibitors
2. Rust and corrosion inhibitors
3. Pour point depressants
4. Viscosity Inhibitor (VI) improvers
5. Anti-wear additives
6. Extreme Pressure (EP) additives
7. Anti-foam additives
8. Detergents and dispersants additives
9. Demulsifiers and emulsifiers
10. Tackiness additives

Topic 4

Lubricant Types

1. Greases and grease lubrication
2. Internal combustion lubricants
3. Hydraulic systems and fluids
4. Miscellaneous lubrication – pump, motor, turbine, compressor

Topic 5

Stability and Storage

1. Fluid contamination
2. Leakage stability
3. Fluid chemical stability
4. Temperature stability
5. Wear stability
6. Safety issues
7. Shelf life
8. Contamination potential

Topic 6

Maintenance Fundamentals

1. Purpose of maintenance
2. Maintenance objectives
3. Evolution of maintenance processes
4. Maintenance types
5. Reliability in maintenance

Topic 7

RCM

1. Introduction to RCM
2. Steps in RCM process
3. Identification of functions, failures, effects, and causes
4. Failure patterns
5. Selecting maintenance tasks

Topic 8

Predictive Maintenance

1. Introduction and overview
2. Benefits of predictive maintenance
3. Role of predictive maintenance ineffective asset management
4. Introduction to predictive maintenance technologies and techniques

Topic 9

Preventive Maintenance (PM)

1. Development of a PM program
2. Reasons for a PM program
3. Risk involved in a PM program
4. Planning and scheduling in PM
5. PM implementation

Topic 10

Condition Monitoring Tasks

1. Tighten, Lubricate, Clean (TLC)
2. Chemical and particle analysis
3. Ultrasonic inspection
4. Temperature monitoring
5. Performance monitoring
6. Failure analysis

Topic 11

Managing Your Precision Maintenance Program

1. Criteria for choosing baselines
2. Trending
3. Which machines to monitor?
4. Managing data
5. Software for trending
6. Scheduling maintenance
7. Interruptive and non-interruptive

Topic 12

Unit Review

(Distribute Case Study in Week 9). In the final week, students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

Software/Hardware Used

Software

• Software: N/A

• Version: N/A

• Instructions:  N/A

• Additional resources or files: N/A

Hardware

• N/A