I-care headquarters. Rue R. Descartes 7000 Mons - Belgium T. +32 (0) BE@icareweb.com

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1 TRAINING PORTFOLIO

2 I-care headquarters Rue R. Descartes 7000 Mons - Belgium

3 Table of contents GROUP 1: CONDITION MONITORING F001 PREDICTIVE MAINTENANCE TECHNOLOGIES F002 VIBRATION ANALYSIS - iso : level 1 F003 VIBRATION ANALYSIS - iso : LEVEL 2 F004 VIBRATION ANALYSIS - iso : LEVEL 3 F006 oil ANALYSIS - ISO : LEVEL 1 F007 oil ANALYSIS - ISO : LEVEL 2 F008 Ultrasonic Maintenance F009 INFRARED THERMOGRAPHY - ISO : LEVEL 1 F010 INFRARED THERMOGRAPHY - ISO : LEVEL 2 F011 LASER ALIGNMENT F012 DYNAMIC BALANCING GROUP 2: SOFTWARE & HARDWARE S001 Predictive Hardware and softwares

4 Table of contents GROUP 3: RELIABILITY 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! p Lubrication Plan Setup ISO : DESCRIPTION 1. ISO (VIBRATION ANALYSIS) 2. iso (field lubricant analysis) 3. iso (INFRARED THERMOGRAPHY)

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6 F001 PREDICTIVE MAINTENANCE TECHNOLOGIES PREREQUISITES: DURATION: 2 days Operators, technicians or maintenance managers 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.

7 F002 VIBRATION ANALYSIS - LEVEL 1 (ISO ) PREREQUISITES: Basic maintenance training ; 6 months of relevant experience in vibration analysis. DURATION: 4 days (certification included) 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. Operators, technicians or maintenance/method/planning managers Content: Certified according ISO 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 ISO

8 F003 VIBRATION ANALYSIS - LEVEL 2 (ISO ) PREREQUISITES: ISO (level 1) certificate required ; 18 months of practical experience in vibration analysis. DURATION: 4 days (certification included) 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. Reliability engineer ; support and method engineer & manager ; maintenance managers LANGUAGUES: Certified according ISO 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.

9 F004 VIBRATION ANALYSIS - LEVEL 3 (ISO ) PREREQUISITES: ISO (level 2) certificate required ; 36 months of practical experience. DURATION: 4 days (certification included) 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. Operators, technicians or maintenance/method/planning managers. CONTENT: Certified according ISO 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 analysis and 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.

10 F006 Oil analysis - level 1 (ISO ) PREREQUISITES: 12 months of practical experience in lubrication field ; Basis technical training. DURATION: 3 days (certification included) 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: Operators, technicians or maintenance managers. 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 lubrications principles ; How to chose lubricant ; Contamination control and proactive maintenance ; Existing tests and tools overview ; Presentation of real case studies for each fault ; Questions/answers ; Certified according ISO

11 F007 OIL ANALYSIS - level 2 (ISO ) PREREQUISITES: DURATION: 3 days (certification included) 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: Lubricant manager, laboratory management Recap on Level 1 ; Detect, solve and avoid machine wear ; Detailed analysis of physical and chemical properties ; Definition of lubricant requirements specification with lubricant 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. Certified according ISO

12 F008 ULTRASONIC MAINTENANCE - LEVEL 1 PREREQUISITES: No specific prerequisite. DURATION: 1 day: Theory 1 day: Pratice (optional) OBJECTIVES: Ability to use ultrasound device ; Knowing ultrasound measurement theory ; Knowing ultrasounds measurement applications. TRAINING EQUIPMENT: Ultrasonic guns. Operators, technicians or maintenance/method/ planning managers 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.

13 F009 INFRARED THERMOGRAPHY - LEVEL 1 (iso ) PREREQUISITES: Practical experience of 12 months in infrared thermography. DURation: 3 days (certification included) Objectives: Ability to use an infrared thermographic camera; Ability to recognize infrared thermography applications. Operators, maintenance technicians Certified according ISO 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.

14 F010 INFRARED THERMOGRAPHY - LEVEL 2 (iso ) PREREQUISITES: Practical experience of 24 months in infrared thermography. DURation: 3 days (certification included) Objective: Ability to use an expert infrared thermographic camera. Operators, maintenance technicians Certified according ISO 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.

15 F011 LASER ALIGNMENT Objective: Laser alignment technics for training rotating machines. DURation: 1 day: Theory 1 day: Pratice (optional) TRAINING EQUIPMENT: Simulation rig or on-site machine. Operators, maintenance technicians 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.

16 F012 DYNAMIC BALANCING Objective: Balancing a rotating equipment on site. DURation: 1 day TRAINING EQUIPMENT: Balancing machine. 6 persons Operators, maintenance technicians 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.

17 Software Hardware

18 S001 PREDICTIVE hardware and softwares ObjectiVEs: DURation: To be defined 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 CSI CSI 2140 ; VIBRATION ANALYSIS ONLINE: Operators, technicians or reliability engineers Emerson/CSI: CSI CSI CSI CSI 9420 ; ULTRASOUNDS TECHNOLOGY: UE systeme: UP UP 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: Content: CSI/SPECTRO 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.

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20 P001 PREDICTIVE MAINTENANCE INTEGRATION DURation: 2 days Objective: Ability to deploy different predictive maintenance technics in an efficient and targeted way for an existing or future maintenance plan. Reliability engineers ; method engineers ; method/maintenance managers 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.

21 P002 CRITICaliTY ASSESSMENT AND MAINTENANCE PLAN SETUP Objectives: DURation: 2 x 1 day (independent or combined) Ability to conduct a criticality study by integrating fundamental concepts and parameters ; Ability to implement or optimize a maintenance plan according to key parameters. Reliability engineer ; support and method engineer ; support and method manager ; maintenance managers 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.

22 P003 Dependability Fundamentals Objective: DURation: 1 day To be able to understand theroritical probability defining maintenance methods Content: Introduction: Reliability engineer ; support and method engineer ; support and method manager ; maintenance managers The maintenance function Life cycle cost of an asset Maintenance strategy definition Concepts of operational security Theoretical reminder of probabilities Operational security or failure science Basis 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 exercices Questions/answers.

23 P004 INVENTORY AND SPARE PARTS MANAGEMENT Objectives: Awareness to spare parts inventory management problem ; DURation: Presentation of tools to define or optimize spare parts storage. 2 days Maximum 8 persons Reliability engineer ; support and method engineer ; support and method manager ; maintenance managers 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.

24 P005 RELIABILITY ENGINEERS TOOLS PREREQUISITES: P003 - Reliability, Maintainability, Availability, Safety. DURation: 2 jours Objective: Learn and understand tools and methods to ensure and improve equipment reliability. Content: Reliability engineer ; support and method engineer ; support and method manager ; maintenance managers 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.

25 P006 Total productive maintenance Objective: Understand TPM concepts and tools ; Understand the TPM Setup on a production site. DURation: 2 days CONTENt: Reliability engineer ; support and method engineer ; support and method manager ; maintenance managers LANGUES: 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.

26 P007 RELIABILITY ENGINEERING ObjectiVEs: Awareness of maintenance aspects during equipment design ; DURation: 1 day Know and understand means to integrate reliability concepts within a design or a complete or partial plant revamping project. Design engineer ; application engineer ; reliability/supports and methods engineer ; energy manager ; maintenance manager. 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.

27 P008 ENERGY EFFICIENCY Objectives: DURation: 2 days Awareness of energy management problems ; Know the key element of analysis and energy improvement assistance. CONTENt: Design engineer ; application engineer ; reliability/supports and methods engineer ; energy manager ; maintenance manager. Introduction ; Awareness (key indicators on the different energy vectors) ; Energy management method : 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.

28 P009 RELIABILITY PROJECT MANAGEMENT PREREQUISITES: p005 - Tools for reliability engineers DURation: 1 day 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. Reliability/supports and methods engineer ; maintenance supervisor ; maintenance manager ; reliability project manager. 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/installation/facility ; Illustrative concrete example : Achievement of a targeted maintenance 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.

29 P010 time to care! Objectives: DURation: 1 day 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. This collaborative role game stages situations which refer to the whole maintenance and production actors, from the operator to the direction. 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.

30 P011 LUBRICATION PLAN SET UP ObjectiVE: Ability to implement a proactive lubrication plan. DURation: 3 days TARGET GROUP Operators ; maintenance supervisors ; maintenance managers 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.

31 ISO 18436: DESCRIPTION

32 ISO (Vibration analyst) Category 1: Individuals meeting the requirements for Category I are recognized as being qualified to perform a range of simple single-channel machinery vibration condition monitoring and diagnostics of machines activities in accordance with ISO and ISO 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-established 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 time 3. 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.

33 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 and ISO 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.

34 Subject Hours of training Category 1 Category 2 Category 3 Principes of vibration Date acquisition Signal processing Condition Monitoring Fault analysis Corrective action Equipment knowledge Acceptance testing Equipment testing and diagnostics Reference standards Reporting and documentation Fault severity determination Total hours

35 ISO (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;

36 10. prepare reports for appropriate personnel on basic lubricant and machine condition, recommend corrective 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. Subject Hours of training Category 1 Category 2 Maintenance strategies Lubrication theory/fundamentals 4 1 Lubricant selection Principles of lubricant application 4 - Lubricant storage and management Lubricant contamination measurement and control Oil sampling Lubricant health monitoring, diagnostics, prognostics and generic maintenance recommendations Lubricant analysis programme development and management Total hours 24 24

37 ISO (Infrared Thermography) Category 1: Individuals classified as Category I are qualified to perform infrared thermography according 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; and 10. provide guidance to and supervise Category I personnel.

38 Subject Hours of training 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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