TRAINING PORTFOLIO - I-care · table of contents f001 predictive maintenance technologies f002 vibration analysis - iso 18436-2: level 1 f003 vibration analysis - iso 18436-2: level

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Table of contents

F001 PREDICTIVE MAINTENANCE TECHNOLOGIES

F002 VIBRATION ANALYSIS - ISO 18436-2: LEVEL 1



F006 OIL ANALYSIS - ISO 18436-4: LEVEL 1 F007 OIL ANALYSIS - ISO 18436-4: LEVEL 2

F008 ULTRASONIC MAINTENANCE

F009 INFRARED THERMOGRAPHY - ISO18436-7: LEVEL 1

F010 INFRARED THERMOGRAPHY - ISO18436-7: LEVEL 2

F011 LASER ALIGNMENT

F012 DYNAMIC BALANCING

GROUP 1: CONDITION MONITORING

GROUP 2: SOFTWARE & HARDWARE

S001 PREDICTIVE HARDWARE AND SOFTWARES

P001 PREDICTIVE MAINTENANCE INTEGRATION P002 CRITICALITY ASSESSMENT AND MAINTENANCE PLAN SETUP

P003 DEPENDABILITY FUNDAMENTALS

P004 INVENTORY AND SPARE PARTS MANAGEMENT

P005 RELIABILITY ENGINEER TOOLS

P006 TOTAL PRODUCTIVE MAINTENANCE P007 RELIABILITY ENGINEERING

P008 ENERGY EFFICIENCY

P009 RELIABILITY PROJECT MANAGEMENT

P010 TIME TO CARE !

P01 1 LUBRICATION PLAN SETUP

ISO 18436 : DESCRIPTION

1. ISO 18436-2 (VIBRATION ANALYSIS)

2. ISO 18436-4 (FIELD LUBRICANT ANALYSIS)

3. ISO 18436-7 (INFRARED THERMOGRAPHY)

GROUP 3: RELIABILITY

Table of contents

F001

DURATION:

2 days

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Operators, technicians or maintenance managers

LANGUAGES:

English, French, Italian, German, Polish, Dutch

PREREQUISITES: Technical /basic maintenance background.

OBjEcTIvES:

Basics about various predictive maintenance technics ;Understand advantages and limits of each technology ;Ability to apply the suitable technology to a problem.

cONTENT:

Maintenance concepts overview ;Predictive maintenance presentation;Vibration analysis in predictive maintenance ;Lubricants analysis in predictive maintenance ;Infrared thermography in predictive maintenance ;Ultrasound analysis in predictive maintenance ;Electric motor analysis in predictive maintenance ;Other non-destructive technics in predictive maintenance ;Practical applications exercises of predictive maintenance ;Questions/answers.

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PREDIcTIvE MAINTENANcE TEcHNOLOGIES

F002

DURATION:

4 days (certification included)

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Operators, technicians or maintenance/method/planning

managers

LANGUAGES:


Certified according ISO18436-2

PREREQUISITES:

Basic maintenance training ;6 months of relevant experience in vibration analysis.

OBjEcTIvES:

Understand basics about vibration analysis ;Understand advantages and limits of vibration analysis ;conduct measurements on standard equipments.

TRAINING EQUIPMENT:

Vibration test bench or rotating equipment if available on-site.

cONTENT:

Presentation of material needed to vibration control achievements ;Vibration sensors, measurements and applications ;Basic vibration measurements: theory and practice ;Maintenance concepts presentation ;Predictive maintenance presentation ;Predictive technologies overview ;Simplified mechanical problems description: unbalance, misalignment, mechanical looseness, bearing problem,… ;Presentation of real case studies for each fault ;Practical exercises on the test bench ;Questions/answers ;Certification examination according to ISO18436-2.

VIBRATION ANALYSIS - LEVEL 1 (ISO18436-2)


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F003

DURATION:


NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Reliability engineer ;support and method

engineer & manager ; maintenance managers

LANGUAGUES:


Certified according ISO 18436-2


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VIBRATION ANALYSIS - LEVEL 2 (ISO 18436-2)

PREREQUISITES:

ISO 18436-2 (level 1) certificate required ;18 months of practical experience in vibration analysis.

OBjEcTIvES:

Ability to diagnose basic faults of rotating machinery ;Ability to configure vibration measurements ;Introduction to vibration expertise.

TRAINING EQUIPMENT:

Vibration test bench or rotating equipment if available on-site.

cONTENT:

Recap on Level 1 ;Vibration analysis of rotary equipment (imbalance, bearings,...) ;Basic knowledge and analysis of vibration phase ;Detection of early bearing defects using demodulation and Peakvue TM ;Vibration analysis on gearboxes ;Detection of electrical problems using current analysis and spectral analysis ;Detection of resonance problems ;Vibration analysis on sleeve bearing ;Presentation of real case studies for each fault ;Practical examples on the test rig ;Questions/answers.

F004


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DURATION:


NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Operators, technicians or maintenance/method/planning

managers.

LANGUAGES:


PREREQUISITES:

ISO 18436-2 (level 2) certificate required ;36 months of practical experience.

OBjEcTIvES:

Diagnose faults on complex machinery ;Diagnose faults on sleeve bearings ;Structural analysis (Modal, ODS,…) ;Achieve basic vibration expertises.

TRAINING EQUIPMENT:

Vibration fault simulation rig/rotating equipment if available on-site.

cONTENT:

Recap on Level 2 ;Vibration phase definition and analysis ;Vibration analysis applied to slow speed shafts (settings,diagnostics, …) ;Vibration analysis applied to sleeve bearings (orbits, …) ;Detection of electrical problems with current analysisand spectral analysis ;Resonance problems detection ;Impact testing (configuration, measurement, analysis) ;ODS (Operating Deflection Shape) ;Introduction to continous measurements on critical machines ;Recording waveforms (post treatment) ;Transient measurements (Run Up – Coast Down) ;Presentation of real case studies for each fault ;Practical examples on the test rig ;Questions/answers.

VIBRATION ANALYSIS - LEVEL 3(ISO 18436-2)




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OIL ANALYSIS - LEVEL 1(ISO 18436-4)

DURATION:


NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Operators, technicians or maintenance managers.

LANGUAGES:


PREREQUISITES:

12 months of practical experience in lubrication field ;Basis technical training.

OBjEcTIvES:

Knowing the importance of lubircation on reliability ;Knowing the main lubricant characteristics to follow ;Knowing the best (re)lubrication methods and practices ;Knowing the standard analysis tests.

cONTENT:

Maintenance concepts presentation ;Predictive maintenance presentation ;Predictive technologies overview ;Introduction to machine lubrication ;Good practices of sampling ;Frictions and machines wear ;Defaults detection and basic wear debris analysis ;Physico-chemical properties : Solid and liquid lubricationsprinciples ;How to chose lubricant ;Contamination control and proactive maintenance ;Existing tests and tools overview ;Presentation of real case studies for each fault ;Questions/answers ;

F006


F007


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DURATION:


NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Lubricant manager, laboratory management

LANGUAGES:

English, French, Italian,German, Polish, Dutch

PREREQUISITES:

24 months of practical experience in lubrication field ;Basis knowledge in chemistry.

OBjEcTIvES:

Ability to understand lubricant analysis report ;Ability to use on-site data provided by lubricant analysis ;Ability to define tests to achieve for relevant analysis ;Ability to define analysis material adapted to the needs.

cONTENT:

Recap on Level 1 ;Detect, solve and avoid machine wear ;Detailed analysis of physical and chemical properties ;Definition of lubricant requirements specification withlubricant analysis ;Implementation and management of a lubricant analysis plan ;Presentation of real case studies for each fault ;Practical examples on the test rig ;Questions/answers ;Recap of all the existing analysis tests.

OIL ANALYSIS - LEVEL 2(ISO 18436-4)

F008


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ULTRASONIC MAINTENANCE - LEVEL 1

DURATION:

1 day: Theory1 day: Pratice (optional)

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Operators, technicians or maintenance/method/

planning managers

LANGUAGES:


PREREQUISITES:

No specific prerequisite.

OBjEcTIvES:

Ability to use ultrasound device ;Knowing ultrasound measurement theory ;Knowing ultrasounds measurement applications.

TRAINING EQUIPMENT:

Ultrasonic guns.

cONTENT:

Maintenance concepts presentation ;Predictive maintenance presentation ;Predictive maintenance technics overview ;Ultrasound analysis theory ;Leak detection (air, gas) by ultrasounds on pressure system ;Leak detection (air, gas) by ultrasounds on vacuum system ;Calculation of costs generated by leaks ;Ultrasonic control of steam traps/valves ;Ultrasonic lubrication control on bearings ;Electrical control by ultrasound ;Device settings according to applications types ;Implementation and management of a leak detection plan ;Presentation of real case studies for each fault ;Practical examples on the test rig ;Questions/answers ;Optional practical working day on your production site.


F009


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INFRARED THERMOGRAPHY - LEVEL 1 (ISO 18436-7)

DURATION:


NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Operators, maintenance technicians

LANGUAGES:


PREREQUISITES:

Practical experience of 12 months in infrared thermography.

OBjEcTIvES:

Ability to use an infrared thermographic camera;Ability to recognize infrared thermography applications.

TRAINING EQUIPMENT:

Infrared thermographic camera.

cONTENT:

Maintenance concepts presentation ;Predictive maintenance presentation ;Predictive maintenance technics overview ;Introduction to infrared thermography ;How to use a camera (basic and advanced settings) ;Thermal scenes interpretation ;Thermal scenes technical analysis ;Qualitative analysis ;Infrared measurement ;Presentation of real case studies for each fault ;Practical examples on the test rig ;Questions/answers.


F010


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INFRARED THERMOGRAPHY - LEVEL 2(ISO 18436-7)

DURATION:


NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:


LANGUAGES:


PREREQUISITES:

Practical experience of 24 months in infrared thermography.

OBjEcTIvE:

Ability to use an expert infrared thermographic camera.

TRAINING EQUIPMENT:

Infrared thermographic camera.

cONTENT:

Recap on level 1 ;How to use a camera (basic and advanced settings) ;Thermal scenes interpretation ;Thermal scenes analysis ;Qualitative and quantitative analysis ;Infrared measurement ;Electrical applications ;Building applications ;Mechanical applications ;Heat transfer applications ;Pratical examples on site ;Questions/answers.

F011


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LASER ALIGNMENT

DURATION:

1 day: Theory1 day: Pratice (optional)

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:


LANGUAGES:


OBjEcTIvE:

Laser alignment technics for training rotating machines.

TRAINING EQUIPMENT:

Simulation rig or on-site machine.

cONTENT:

Why align a rotating machine?• Technical justifications,• Economic justificatons ;

Misalignment definition :• Angular misalignment,• Parallel misalignment,• Complexe misalignment ;

Different couplings types ;Material presentation ;Vibration generated by misalignment ;On-site alignment ;Ruler method ;Comparator method ;Laser method ;Machines preparation ;Soft feet correction ;On site precision alignment ;Alignment quality standards ;Questions/answers ;Optional working day requiring available on-site equipment.

F012


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DYNAMIc BALANcING

DURATION:

1 day

NUMBER OF PERSONS:

6 persons

TARGET GROUP:

Operators, maintenancetechnicians

LANGUAGES:


OBjEcTIvE:

Balancing a rotating equipment on site.

TRAINING EQUIPMENT:

Balancing machine.

cONTENT:

Why balance a rotating equipment?• Technical justifications,• Economic justifications ;

Imbalance definition:• Static imbalance,• Torque imbalance,• Dynamic imbalance ;

How to detect an imbalance?Phase concept ;Resonance concept ;Difference between imbalance and resonance ;Solutions to resonance problems ;On site balancing ;3 points method ;Phase method ;Balancing on rig ; Balancing standards quality ; Practical vibration measurement exercise on model ;Practical exercise of imbalance/resonance distinction on model ; Practical exercise of balancing ;Questions/answers.

SoftwareHardware


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PREDIcTIvE HARDwARE AND SOFTwARES

DURATION:

To be defined

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Operators, technicians or reliability engineers

LANGUAGES:


OBjEcTIvES:

Ability to use hardware and associated software ;Acquisition of the theoretical and practical basis of the relevant technology.

CONCERNED MATERIALS (NON-EXHAUSTIVE LIST):

vIBRATION ANALYSIS OFFLINE:Emerson/CSI: CSI 2125 - CSI 2130 - CSI 2140 ;

vIBRATION ANALYSIS ONLINE:Emerson/CSI: CSI 4500 - CSI 6500 - CSI 2600 - CSI 9420 ;

ULTRASOUNDS TEcHNOLOGY:UE systeme: UP 9000 - UP 15000 - UP 201 ;SDT270 ;

INFRARED THERMOGRAPHY:FLIR E5, E6, E8, E50, E60, E80, T335, T420, T440, T600 ;FLUKE ;

LASER ALIGNMENT:Prüftechnik: Shaftalign, optalign, rotalign ;

LUBRIcANT ANALYSIS:CSI/SPECTRO 5200.

cONTENT:

Material and associated software presentation ;Configuration/commissioning of the equipment ;Validation of equipment’s smooth running ;Technical presentation ;Practical examples on simulation rig or client’s rotating machine ;Questions/answers.

S001

P001


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OBjEcTIvE:

Ability to deploy different predictive maintenance technics in anefficient and targeted way for an existing or future maintenance plan.

cONTENT:

Introduction: maintenance concepts overview ;Presentation of predictive maintenance and its technics ;Predictive maintenance integration overview ;Review and main tools presentation needed to implement the method:

• Criticality analysis,• Study of occurence/recurrence failures,• Definition of equipment/technology matrix,• Economic aspects: cBA/ROI,• KPI implementation and monitoring ;

Presentation of case study implementing the method ;Questions/answers.

PREDIcTIvE MAINTENANcE INTEGRATION

DURATION:

2 days

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Reliability engineers ; method engineers ;

method/maintenance managers

LANGUAGES:


P002

OBjEcTIvES:

Ability to conduct a criticality study by integrating fundamental concepts and parameters ;

Ability to implement or optimize a maintenance plan according to key parameters.

cONTENT:

Day 1: Criticality study:

Introduction: concept of criticitality ;Definition, context and tools of criticality study ;Theory of criticality study ;Questions/answers ;

Practical exercise of criticality study on a real case.

Day 2: Maintenance plan:

Concept, type, level and definition of maintenance ;What is a maintenance plan ;General method to implement a maintenance plan ;Theory of the tools required to implement the maintenance plan ;Practical exercise implementing a maintenance plan on a real case ;Questions/answers.

DURATION:

2 x 1 day(independent or combined)

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Reliability engineer ;support and method engineer ;support and method manager ;

maintenance managers

LANGUAGES:


cRITIcALITY ASSESSMENT AND MAINTENANcE PLAN SETUP


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P003


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OBjEcTIvE:

To be able to understand theroritical probability defining maintenance methods

cONTENT:

INTRODUcTION:

The maintenance functionLife cycle cost of an assetMaintenance strategy definition

cONcEPTS OF OPERATIONAL SEcURITY

Theoretical reminder of probabilitiesOperational security or failure scienceBasis concept of operational security:

1. Reliability• Definitions• Survival laws and failure rate• Life time• MTTF• Failure laws

2. Maintenability• Definitions• Instantaneous repair rate • Repair time• MTTR• The maintenance

3. Avaibility• Definition• How to improve it?• MTBF

4. Security• Definition• Risks management

Recaps practices exercicesQuestions/answers.

DEPENDABILITY FUNDAMENTALS

DURATION:

1 day

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Reliability engineer ; support and method engineer ; support and method manager ;


LANGUAGES:


P004

DURATION:

2 days

NUMBER OF PERSONS:

Maximum 8 persons

TARGET GROUP:



LANGUAGES:



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OBjEcTIvES:

Awareness to spare parts inventory management problem ;

Presentation of tools to define or optimize spare parts storage.

cONTENT:

Introduction ;What are the different types of stocks held by the company ?Highlighting spare parts importance ;Spare parts management ;Support tools to optimize spare parts storage ;Support tools to define minimum stock ;Analysis of existing stocks and good practices ;Performance indicators ;Common failings ;What are the possibilities offered by CMMS?Rigour, the key word in spare parts storage management ;Practical exercises ;Economic analysis ;Questions/answers.

INvENTORY AND SPARE PARTS MANAGEMENT

P005


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PREREQUISITES:

P003 - Reliability, Maintainability, Availability, Safety.

OBjEcTIvE:

Learn and understand tools and methods to ensure and improve equipment reliability.

cONTENT:

Introduction: Reliability engineer role and liabilities ;Recap: Maintenance based on reliability including reliability, maintainability and availability theories ; Initial situation measurement through reliability audit ;Definition of priorities through criticality analysis ;Maintenance plan concepts presentation ;Introduction to predictive maintenance ;Initiation to different tools :« as-built » statement, scheduling, critical management of spare parts, search of problems through occurence/recurrence failures study, obsolescence analysis, costs and profits analysis (CBA) and return on Investments (ROI) ;Performance indicators ;Equipment and installations design according to ROMSI (Reliable, Operable, Maintainable, Safe and Inspectable) including an AMDEC initiation and an help for requirements specification drafting ;Advantages of a CMMS software ;Questions/answers.

RELIABILITY ENGINEERS TOOLS

DURATION:

2 jours

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:



LANGUAGES:


P006

DURATION:

2 days

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Reliability engineer ;support and method engineer ; support and method manager ;


LANGUES:



[email protected]

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OBjEcTIvE:

Understand TPM concepts and tools ;

Understand the TPM Setup on a production site.

cONTENT:

Introduction:• TPM definition: a « total » approach lead in partnership

between maintenance and production ;

Key concepts of the method:• Overall equipment effectiveness ;• The 16 reasons for effectiveness losses : losses due to a lack

of equipment reliability, lack of organization, methods and process ;

TPM foundations:• Loss causes individual eradication : TRG tools, AMDEC, 5

Why, 5M,• Autonomous maintenance: visual management,• Planned maintenance: maintenance types, state of the

art review on the field of preventive and predictive maintenance,

• Improvement of know-how: actors skills, P-D-A-c cycle, • Mastering design: ROMSI method,• Mastering quality,• TPM in offices,• Mastering safety, work conditions and environment ;

Implementation:• Prerequisites,• Actors roles, • Ways of implementation : practical examples,• Traps to avoid.

TOTAL PRODUcTIvE MAINTENANcE

P007


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OBjEcTIvES:

Awareness of maintenance aspects during equipment design ;

Know and understand means to integrate reliability concepts within a design or a complete or partial plant revamping project.

cONTENT:

Introduction: ROMSI concepts ;Seller/Machine manufacturer Vs Owner/Operator: different business models ;Lifetime costs, long-terms operations and economic justifications ;Maintenance/operator place againt engineering:

• Integration of maintenance prerequisites through project planning :v model for engineering,

• Framing communication, « RACI » matrix,• Documents to revise and how,• Functional decomposition, arborescence and CMMS ;

Maintenance prerequisites in specifications requirements:• Technical documentation : spare parts, maintenance

actions, etc,• Accessibility and ergonomics aspects,• RMAS clauses (reliability, maintainability, availability,

safety),• Periods and guarantee conditions,• Supports: trainings, maintenance contracts, repairs

contracts ;Reliability tools in design :

• AMDE(C),• Risks preliminary scans,• Reliability diagram,• Fault tree,• Markov graph ;

Conclusions and concrete examples.

RELIABILITY ENGINEERING

DURATION:

1 day

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Design engineer ;application engineer ;

reliability/supports and methods engineer ; “energy” manager ;

maintenance manager.

LANGUAGES:


P008

DURATION:

2 days

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Design engineer ;application engineer ;

reliability/supports and methods engineer ;

“energy” manager ;maintenance manager.

LANGUAGES:



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OBjEcTIvES:

Awareness of energy management problems ;Know the key element of analysis and energy improvement assistance.

cONTENT:

Introduction ;Awareness (key indicators on the different energy vectors) ;Energy management method :

• 500001 standard,• PDcA,• KPI ;

Current situation analysis: Mapping:• Statement,• Energy accountancy ;

Prioritization & planning:• Major consumers highlighting ;

Suggested improvements & quick wins (investments & ease of implementation):

• Ac vector,• Steam vector,• Elec vector,• cold vector,• …

RSI calculation and eventual (re)prioritization ;Case study ;Practical exercises ;Conclusion ;Questions/answers.

ENERGY EFFIcIENcY

PREREQUISITES:P005 - Tools for reliability engineers

OBjEcTIvES:

Awareness to constraints and specifities of a reliability project ;Ability to organize, structure and follow a project linked to equipment reliability and new or existing process ;Ability to square and direct problems, of short or long term.

TRAINING EQUIPMENT:

The project management software is not imposed, the method is still generic and suitable to the most common management tools.

cONTENT:

Introduction ;Basic principles of project management ;Definition and specifications requirements understanding ;Project decomposition and its scope ;Global budget estimate of a reliability project ;Monitoring tools :

• Kick-Off meeting : who, what, how, for when, • Internal and external resources management,

« RACI » matrix, competences and trainings, Costs and efficiency,

• Key indicators (linked to costs, delays and quality),• Reporting and visual communication,• Hand-Over ;

Features between reliability project under construction of a new plant/installation/facility and a project for an existing plant/installa-tion/facility ;Illustrative concrete example : Achievement of a targeted main-tenance plan with aim to control costs in a steel industry (metal profiles manufacturing) ;Open exercise on the basis of your needs and contributions ;Questions/answers.

P009


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RELIABILITY PROjEcT MANAGEMENT

DURATION:

1 day

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

Reliability/supports and methods engineer ; maintenance supervisor ;

maintenance manager ;reliability project manager.

LANGUAGES:


P010

DURATION:

1 day

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP:

This collaborative role game stages situations which refer to the whole maintenance and production actors, from the operator to the direction.

LANGUAGES:



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OBjEcTIvES:

Perceive parameters and constraints inherently linked to preventive and predictive maintenance plan creation of industrial machines through a collaborative role game ;Understand the assets of a good collaboration between all the members and departments of a plant.

cONTENT:

General presentation and operation rules ;Industrial context presentation ;Profiles attribution, reading and functions description presentation ;This game has to be played in 3 phases :

“The game will be controlled by a game master. He will lead the

players to the finale OBJECTIVE: composing a maintenance plan

according to industrial context.

Each phase of the game will be punctuated by events and actions

bringing the players to manage together common situations and

others more complex according to the profiles.”

Explanations of different game steps by practical examples ;A reporting points system allows to assess the team at the end of the game ;Review of the game progress and conclusions.

TIME TO cARE !

OBjEcTIvE:

Ability to implement a proactive lubrication plan.

cONTENT:

Maintenance concepts presentation ;Predictive maintenance presentation ;Predictive technics overview ;Lubrication effects on machines reliability ;Introduction to machine lubrication ;Basic lubricants and grease thickeners ;Lubricant performances (main properties) ;Food and environmental lubricants ;Additives degradation ;Best practices of grease lubrication ;Best practices of oil lubrication ;How to well drain, clean and manager its tanks ;Lubricants storage and handling ;Implementation and optimization of predictive lubrication plans ;Automotive lubricants ;Contamination control ;Key indicators monitoring and evaluation ;Practical case stuyd of lubricant plan implementation ;On site practical exercise ;Questions/answers.

P011


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LUBRIcATION PLAN SET UP

DURATION:

3 days

NUMBER OF PERSONS:

6 to 8 persons

TARGET GROUP

Operators ;maintenance supervisors ;


LANGUAGES:



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DESCRIPTIONISO 18436:

ISO 18436-2 (Vibration analyst)

Category 1:

Individuals meeting the requirements for Category I are recognized as being qualified to per-form a range of simple single-channel machinery vibration condition monitoring and diagnos-tics of machines activities in accordance with ISO 17359 and ISO 13373-1.

They shall not be responsible, for example, for the choice of sensor or for any analysis to be conducted, nor for the assessment of test results, except for identifying alert conditions against a pre-established alert setting or settings.

They shall be qualified:

1. to operate portable instrumentation on pre-assigned or pre-programmed routes,2. to acquire readings from permanently installed instrumentation,3. to input results into a database and download routes from a computer,4. to conduct testing under steady-state operating conditions following predefined procedures,5. to be able to recognize that no signal is present,6. to be able to compare overall or single value vibration measurements against pre-estab-

lished alert settings.

category 2:

Vibration measurements and basic vibration analysis using single-channel measurements, with or without phase trigger signals, according to established and recognized procedures. Personnel certified to Category II require all the knowledge and skills expected of Category I, and shall also be qualified:

1. to select the appropriate machinery vibration measurement technique,2. to set up instruments for basic resolution of amplitude, frequency and time3. to perform basic vibration analysis of machinery and components, such as shafts,

bearings, gears, fans, pumps and motors, using spectrum analysis,4. to maintain a database of results and trends,5. to perform basic (single-channel) impact tests to determine natural frequencies,6. to classify, interpret and evaluate the test results (including acceptance tests) in

accordance with applicable specifications and standards,7. to recommend minor corrective actions,8. to understand basic single-plane field balancing concepts,9. to be aware of some of the causes and effects of bad measurement data.


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Category 3:

Individuals certified to Category III are qualified to perform and/or direct and/or establish programmes for vibration condition monitoring and diagnostics of machines in accordance with ISO 17359 and ISO 13373-1. Personnel classified to Category III require all the knowledge and skills expected of personnel classified to Category I and Category II, and shall also be qualified:

1. to select the appropriate machinery vibration analysis technique,2. to specify the appropriate vibration instrumentation hardware and software for both

portable and permanently installed systems,3. to measure and perform diagnosis of single-channel frequency spectra, as well as time

domain plots such as waveforms and orbits, under both steady-state and unsteady operating conditions, with or without a phase trigger,

4. to establish vibration monitoring programmes, including determination of machines for periodic/continuous monitoring, frequency of testing, route plans,

5. to establish programmes for the specification of vibration levels and acceptance criteria for new machinery,

6. to measure and analyse basic operating deflection shapes,7. to understand and be able to direct the use of alternative condition monitoring

technologies (such as acoustic emission, thermography, motor current and oil analysis),8. to recommend field corrective actions, such as balancing, alignment and replacement of

machine parts,9. to be able to use acceleration enveloping (demodulation),10. to perform basic single-plane field balancing,11. to report to management regarding programme objectives, budgets, cost justification

and personnel development,12. to prepare reports for appropriate personnel on machine condition, recommend

corrective action and report on the effectiveness of repairs,13. to provide instructions and technical direction to vibration trainees.


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SubjectHours of training

Category 1 Category 2 Category 3

Principes of vibration 6 4 2

Date acquisition 8 4 2

Signal processing 2 4 3

Condition Monitoring 2 4 3

Fault analysis 2 4 8

Corrective action 2 4 6

Equipment knowledge 8 4 4

Acceptance testing 2 2 2

Equipment testing and diagnostics - 2 3

Reference standards - 2 2

Reporting and documentation - 2 2

Fault severity determination - 2 3

Total hours 32 38 40


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ISO 18436-4 (Field Lubricant Analyst)

Category 1:

Individuals classified as Category I are qualified to perform field lubricant analysis according to established and recognized procedures. Personnel classified as Category I shall be able to:

1. dispense lubricants, re-lubricate and/or inspect lubricants on a pre-programmed route, as appropriate in accordance with established procedures;

2. properly maintain lubrication devices and equipment;3. install sampling hardware deemed appropriate, safe and non-intrusive by category II or

higher personnel (any intrusive sampling hardware installation shall be undertaken by a suitably qualified person authorized by the customer);

4. verify that analysis instruments are calibrated and report to the appropriate personnel where action is needed;

5. operate (and maintain) portable lubricant analysis instrumentation on pre-programmed routes;

6. download and upload raw test data from portable lubricant analysis instrumentation;7. acquire lubricant samples from machine systems, equipment, and/or storage containers in

accordance with established procedures;8. prepare samples for transport and/or testing in accordance with established procedures.

category 2:

Individuals classified as Category II are qualified to perform basic field lubricant testing and analysis according to established and recognised procedures. Personnel classified as Category II shall be able to:

1. set up instruments for basic on-site testing;2. perform calibration checks on instruments used for on-site testing;3. establish procedures for sample acquisition, preparation and transport;4. select sample point locations, methods and hardware and oversee installation of sampling

hardware;5. apply selected test methods for on-site testing and wear debris analysis;6. liaise with an off-site laboratory;7. classify, interpret and evaluate basic test results (including acceptance tests) in accordance

with applicable specifications and standards;8. employ basic lubricant analysis techniques to troubleshoot lubricant, machinery and

components;9. maintain a database of analysis schedules, results and diagnosis;


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10. prepare reports for appropriate personnel on basic lubricant and machine condition, recommend cor-rective action (non-intrusive maintenance) and report on effectiveness of repairs/changes;

11. be aware of the use of alternative or supplementary condition monitoring technologies;12. provide guidance and supervision to category I personnel.


Category 1 Category 2

Maintenance strategies 2.5 1

Lubrication theory/fundamentals 4 1

Lubricant selection 2.5 -

Principles of lubricant application 4 -

Lubricant storage and management 2.5 -

Lubricant contamination measurement and control 2.5 6

Oil sampling 2.5 7

Lubricant health monitoring, diagnostics, prognostics and generic maintenance recommendations 2.5 5

Lubricant analysis programme development and management 1 4

Total hours 24 24


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ISO 18436-7 (Infrared Thermography)

Category 1:

Individuals classified as category I are qualified to perform infrared thermography accord-ing to established and recognized procedures. Personnel classified as category I shall be able to:

1. apply a specified thermographic measurement technique;2. set up and operate the thermal imaging equipment for safe thermographic data

collection;3. identify, prevent, minimize and control poor data acquisition and error sources;4. perform basic fault detection, severity assessment and diagnosis in accordance with

established instructions;5. perform basic image post-processing (measurement tools, emissivity adjustments, span

and scale adjustments, etc.);6. maintain a database of results and trends;7. verify the calibration of thermographic measurement systems;8. evaluate and report test results and highlight areas of concern.

category 2:

Individuals classified as Category II are qualified to perform infrared thermography according to established and recognized procedures. Personnel classified as Category II shall be able to:

1. select the appropriate infrared thermography technique and understand its limitations;2. apply thermography theory and techniques, including measurement and interpretation of

survey results;3. specify the appropriate hardware and software;4. perform advanced fault diagnoses;5. recommend appropriate field corrective actions;6. perform advanced image post-processing (image, trending, montage, subtraction,

superimposition, statistical analysis, etc.);7. use generally recognized advanced techniques for infrared thermography and fault

diagnosis in accordance with established procedures;8. prepare reports on equipment condition, fault diagnoses, corrective actions and the

effectiveness of repairs;9. be aware of the use of alternative or supplementary condition monitoring technologies; and10. provide guidance to and supervise category I personnel.


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Category 1 Category 2

Introduction 0,5 -

Principles of infrared thermography (IRT) 6 7

Equipment and data acquisition 5 3

Image processing 6 2

General applications 4,5 0

Diagnostics and prognostics 1 2

Condition monitoring applications 4 10,5

Corrective actions - 3

Reporting and documentation 1 0,5

Condition monitoring program desing 0,5 0,5

Condition monitoring programme implementation 1 1

Condition monitoring programme management 0,5 0,5

Training examination 2 2

Total hours 32 32


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