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Certification Services Division 1 Spencer Parade, Northampton NN1 5AA, United Kingdom Tel: +44 (0) 1604-259-056.

Fax: +44 (0) 1604-231-489. E-mail: pcn@bindt.org

CM/GEN APPENDIX C- Issue 1 Rev H SPECIFIC REQUIREMENTS FOR QUALIFICATION AND CERTIFICATION OF CONDITION MONITORING AND DIAGNOSTIC PERSONNEL FOR LUBRICATION MANAGEMENT AND ANALYSIS

CONTENTS
Introduction .......................................................................................................................................... 2 1. 2. 3 4. 5. Scope ....................................................................................................................................... 2 Classification of Personnel....................................................................................................... 2 Eligibility for Examination and Certification.............................................................................. 3 Certification Available .............................................................................................................. 3 Qualification Examinations....................................................................................................... 3

Annex A1 Training syllabus (normative)........................................................................................... 3 Annex A2 - Detailed list of topics and hours of Instruction .................................................................. 3 Annex B Reading references (normative) ........................................................................................ 3 Annex C- Suggested List of sub-topics for Level 2 (informative) ........................................................ 3

The British Institute of Non-Destructive Testing is an accredited certification body offering personnel and quality management systems assessment and certification against criteria set out in international and European standards through the PCN Certification Scheme.

Introduction The use of Lubrication Management and Analysis in condition monitoring and diagnosis of faults in machinery has become a key activity in predictive maintenance programmes for many industries. The effectiveness of this technology depends on the capabilities of individuals who perform the measurements and analyse the data. This document is appended to CM/GEN (General requirements for qualification and certification of condition monitoring and diagnostic personnel). Other Appendices cover: Appendix A Appendix B Appendix D Acoustic Emission Infra-red Thermography Vibration Analysis

This series of documents is designed to provide comprehensive information for users of the PCN Scheme. The complete list of published PCN condition monitoring documents is detailed in publication reference PSL/8A-CM, which is posted on the Institute's web site at www.bindt.org, where all documents are available for download free of charge. It is intended, through publication of these documents, to provide industry, PCN candidates and certificate holders with all relevant information. However, if further information or advice is required on any certification matter, contact the Certification Services Division of BINDT on telephone number +44 (0) 1604 259056, or email pcn@bindt.org. Organisations requiring at all times to be in possession of the most up to date PCN documents may register with the "PCN Update Scheme" which, for a small annual fee, guarantees that they automatically receive all new and revised PCN documents. 1. Scope 1.1. This appendix to PCN CM/GEN sets out the specific requirements for qualification and certification of personnel engaged in Condition Monitoring using Lubrication Management and Analysis. In the event of a conflict between the requirements of PCN CM/GEN and this Appendix, the PCN CM/GEN requirements shall prevail. Certification to this specification will provide evidence of the qualification and competence of individuals to (1) perform lubricant sample acquisition and analysis, (2) perform lubrication management and analysis field-based machinery condition monitoring on systems that include synthetic fluids, lubricating oils, hydraulic fluids and greases, (3) identify machine and lubricant faults and recommend corrective action and (4) perform laboratory-based testing, machine condition monitoring and technical analysis, for the diagnostics of machines.
The scope and content of the PCN scheme specification for lubricant analysis personnel at levels 1 and 2 are comprised of the scope and content of both draft documents ISO18436-4 (industrial lubricant analysis) and ISO 18436-5 (laboratory lubricant analysis). The scope and content of the PCN scheme level 3 specifications are compliant to that of level 3 defined in ISO 18436-5, comprising laboratory-based tribology and wear debris analysis and condition-based maintenance management. Thus, the three levels of competence defined in this appendix are compliant with, and exceeds the requirements for, the equivalent levels in ISO18436, with no distinction of field and/or laboratory duties. Consequently, certification to this document is equivalent to certification to both ISO18436 parts 4 and 5, and certificated persons to this document are qualified to work both in the field and laboratory.

1.2.

2.

Classification of Personnel 2.1. General 2.1.1. Individuals certificated in accordance with this specification are classified in one of three levels and have demonstrated competence in the concepts of machinery Lubrication Management Analysis as defined in the scope (clause 1.2) for their classification level as indicated in the examination syllabus at Annex A1.

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2.1.2.

Personnel classified as Level 2 require all the knowledge and skills expected of personnel classified as Level 1, and personnel classified as Level 3 require all the knowledge and skills expected of personnel classified as Level 2. The competencies listed in clause 2.2, 2.3 and 2.4 are not necessarily in chronological order, as they apply to both field and laboratory, and are in accordance with ISO 17025 and ISO 18436 parts 4 and 5.

2.1.3.

2.2.

Lubrication Management and Analysis Level 1 PCN Certificated Lubrication Management and Analysis Level 1 personnel are qualified to supervise industrial machinery lubrication, lubricant sampling, and basic lubricant testing and analysis according to established and recognised procedures and may be authorised (within the scope and limitations of the certification held) to: 2.2.1. 2.2.2. 2.2.3. install sampling hardware for sample acquisition; properly maintain lubrication devices and equipment; manage the transport, receipt, storage, handling, dispensing and application of lubricants, and take lubricant samples in accordance with established procedures; using simple techniques, select lubricants appropriate to machines commonly found in general industrial; re-lubricate and/or inspect lubricants on pre-programmed routes; operate portable oil analysis instrumentation on pre-programmed sampling routes; collect lubricant samples from machine systems and equipment; perform simple on-site tests and maintain portable oil analysis instrumentation and data download/upload; perform common (basic) laboratory tests using established procedures; verify the integrity of collected data and prevent or control poor data;

2.2.4. 2.2.5. 2.2.6. 2.2.7. 2.2.8. 2.2.9.

2.2.10. input results into a database/spreadsheet; 2.2.11. set up instruments and/or equipment for basic on-site testing and/or basic laboratory testing, including calibration checks, in accordance with established procedures; 2.2.12. maintain basic lubricant analysis of machinery systems and components such as engines, transmissions, hydraulics, turbines, compressors, gearboxes, etc. using in-field or testing laboratory analysis; 2.2.13. maintain a data base of results and trends; 2.2.14. report test results in accordance with instructions and established criteria, identifying whether data is reasonable ; 2.2.13 undertake basic machine systems and equipment visual inspections; 2.2.15. demonstrate basic quality knowledge and laboratory good practice in accordance with ISO 17025; Level 1 certificated personnel shall not be responsible for the choice of test method or technique to be used, nor for the assessment or diagnosis of test results. 2.3 Lubrication Management and Analysis Level 2 PCN Certificated Lubrication Management and Analysis Level 2 personnel are qualified to undertake all competencies of level 1 and additionally, to schedule and direct machinery lubricant management and lubricant analysis according to established and recognised procedures, and may be authorised (within the scope and limitations of the certification held) to:

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2.3.1 2.3.2 2.3.3

Prepare samples for field and/or laboratory analysis, as defined by the technique or procedure chosen; select the appropriate machinery lubricant analysis technique; specify the appropriate lubricant analysis instrumentation hardware and software for portable on-site lubricant testing and laboratory testing, and perform the tests; set-up laboratory testing schedules and test slates; employ and/or operate basic field or laboratory techniques to troubleshoot lubricant, hydraulic, machinery, grease and components problems; classify, interpret and evaluate basic test results, including acceptance tests, in accordance with established procedures; establish lubricant analysis monitoring programmes, including determination of machines for periodic/continuous monitoring, frequency of testing, route plans, etc; establish programmes for the specification of lubricant analysis levels and acceptance criteria for new machinery; manage a database of results, with trends and diagnostics (including fault analysis);

2.3.4 2.3.5 2.3.6 2.3.7

2.3.8 2.3.9

2.3.10 recommend corrective actions, such as failure analysis and replacement of machine parts and diagnose lubricant failure mechanisms; 2.3.11 perform basic failure mode and criticality analysis; 2.3.12 verify the calibration of portable and fixed on-site and laboratory lubricant analysis instrumentation; 2.3.13 report to management regarding programme objectives, budgets, cost justification, and personnel development; 2.3.14 Prepare reports on machine condition, recommend corrective action (nonintrusive maintenance) and effectiveness of repairs and changes; 2.3.15 operate wear debris analysis equipment and perform evaluation of particles themselves; 2.3.16 recommend the use of alternative CM technologies, including motor current method, with an awareness of the principles of all other condition monitoring (CM) technologies specified in CM/GEN at least to Level 1; 2.3.17 Carry out, supervise and instruct all level 1 duties; 2.3.18 Provide technical direction for personnel at or below level 2; 2.3.19 Demonstrate advanced laboratory quality knowledge in accordance with ISO17025. 2.4 Lubrication Management and Analysis Level 3 Individuals certificated as Lubrication Management and Analysis Level 3 are qualified to perform all competencies specified for level 2 and additionally, to manage and implement lubricant condition monitoring programmes, and will be competent to: 2.4.1 2.4.2 2.4.3 2.4.4 Select the appropriate lubricant or wear debris analysis technique, both in the field and/or laboratory; Apply advanced lubricant analysis theory and techniques, including trending, interpretation, FMECA analysis and fault severity determination; manage lubricant analysis information and associated software programmes, both in the field and laboratory; determine the optimal inspection frequencies using probability density function, cost and risk criteria;

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2.4.5 2.4.6

determine the operating characteristics of machines and economic life cycles and recommend strategies for optimisation; use generally recognised advanced techniques for lubricant analysis, failure potential identification, lubricant and machine failure mechanism diagnosis and fault diagnosis; apply the basic principles of tribology to correct problems; establish acceptance and severity criteria, and lubricant monitoring programmes for acceptance, for new, in-service and faulty equipment, using periodic or continuous monitoring, defining the frequency and type of testing, route plans etc establish programmes for the specification of targets, alarms and limits for machinery;

2.4.7 2.4.8

2.4.9

2.4.10 perform prognostics for fault conditions; 2.4.11 recommend all generally recognised types of corrective actions including statistical analysis and modification of machine systems and components; 2.4.12 evaluate the performance of outside lubricant analysis services and make corrective changes as required; 2.4.13 interpret and evaluate Standards, Codes, specifications and procedures; 2.4.14 direct the use of alternative CM technologies, including motor current method, with an understanding of the principles of other condition monitoring (CM) technologies specified in CM/GEN, including electrical signature analysis, at least to Level 1; 2.4.15 instruct or supervise trainees and level 1 and 2 personnel; 2.4.16 guide personnel below level 3; 2.4.17 carry out, manage and supervise PCN CM qualification examinations on behalf of the British Institute of NDT, if so appointed; 2.4.18 understand and apply the principles of predictive and condition-based maintenance programmes; 2.4.19 carry out internal laboratory audits in accordance with ISO 17025; 2.4.20 establish the laboratory certification documentation, where applicable. programme and management

Eligibility for Examination and Certification 3.1. General Candidates shall have a combination of education, training and experience to ensure that they understand the principles and procedures applicable to machinery Lubrication Management and Analysis. 3.2. Education 3.2.1 It is recommended that level 1 and 2 candidates have at least a secondary school science or technical qualification, or its equivalent. Lubrication Management and Analysis personnel must be able to manipulate simple algebraic equations, use a basic scientific calculator (including statistical functions), and be familiar with the operation of personal computers.

3.3 Training 3.3.1 To be eligible to apply for examination based on this Specification, the candidate shall provide documentary evidence of successful completion of a

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BINDT approved or recognised course of formal training based on the requirements of Annex A2. Sources of technical information are listed in Annex B. The minimum duration of training shall be as shown in Table 1. Further guidance for content of the level 2 training syllabus is given in Annex C. 3.3.2 The training syllabus indicated includes a requirement for practical knowledge and practical skills training within the relevant topics.

TABLE 1. Minimum Cumulative Duration of Training (hours) Level 1 Level 2 Level 3 40 100 158 3.4 Experience 3.4.1 To be eligible to apply for certification the candidate shall provide evidence of experience (practical and theoretical) in the disciplines of machinery lubrication management condition monitoring appropriate to the level sought. The minimum experience requirements are shown in Table 2. Certification at Level 2 and Level 3 requires previous certification at the lower Levels.
The PCN scheme will allow mature candidates direct entry to Level 2 only, without the need to have previously held certification at level 1, providing they can produce verifiable documentary evidence of training and experience that satisfies the requirement for both level 1 and level 2 qualifications. This delta will apply for the duration of the transition period indicated in the General Requirements for Qualification and Certification of Condition Monitoring personnel (CM/GEN) clause 20.1.

3.4.2

TABLE 2. Minimum Cumulative Experience Requirements (months) Level 1 Level 2 Level 3 12 36 48 (290 hours)* (860 hours)* (1150 hours)*
Work experience is based on 160 hour/month, while experience defined in hours* are based on approximately 24 hr/month of actual sampling, field and/or laboratory testing and interpretation time, based over a 1, 3 and 4 year time period, respectively, accrued either in filed or laboratory duties, or both.

3.4.3

Candidates must maintain a log of hours and nature of work on PCN document CP16-CM.

3.5 Additional training on tribology and lubrication management In addition to the training hours shown in Table 1, level 2 candidates only should have completed formal or on-the-job training on machinery knowledge, covering machinery and components, of a similar duration to that in Table 1. This training should cover design, manufacture, installation, operation and maintenance principles of machines and lubrication systems, and include failure mechanisms associated with each principle. 4. Certification Available 4.1 4.2 4.3 5. Level 1 (General- Lubrication management and analysis condition monitoring) Level 2 (General- Lubrication management and analysis condition monitoring) Level 3 (General- Lubrication management and analysis condition monitoring)

Qualification Examinations 5.1 Application for qualification examinations

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5.1.1

Application for qualification examination is made on PCN form PSL/57-CM and supported by PSL/30-CM and PSL/33-CM forms.

5.2

Examination content (Theory and practical knowledge) 5.2.1 For each certification level, the candidates shall be required to answer the number of multiple choice questions indicated in Table 3. 10% of the number of questions on the level 3 examination paper will consist of narrative questions. Each narrative question will be worth 10 marks. The content of the examination paper shall contain multiple-choice question(s) for each subject in Annex A2, and in the same weighting as indicated by the percentage of time spent on each subject indicated in Annex A2, together with the indicated narrative questions. Questions will test the candidates knowledge of the principles and procedures required to conduct machinery lubrication management testing and analysis. Some questions will include the interpretation of practical data, charts, plots and images. Simple mathematical calculations using a basic scientific calculator may be required.

5.2.2

5.2.3

5.2.4

TABLE 3 Qualification examination content Levels Level 1 Level 2 Level 3 Number of questions 70 100 100 Time (hours)* 2 3 4 Passing Grade (%) 75 75 75

*Examination times include a 30 minute reading period to assist candidates with English as a second language or any disability in accordance with CMGEN clause 9.3. Additional time has been provided at Level 3 for narrative questions.

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Annex A1 Training syllabus (normative) HOURS OF TRAINING SUBJECT 1. Principles of Lubrication Management 2. Lubricant Sample Acquisition 3. Pro-action & Basics of Reliability 4. Condition Monitoring (oil analysis programme design, implementation and management) 5. Fault Analysis 6. Corrective Action 7. Generic Equipment Knowledge 8. Lubricant Acceptance Testing 9. Equipment testing and diagnosis 10. Lubricant Analysis Methods 11. Reference Standards 12. Reporting and Documentation 13. Fault Severity Determination 14. Inspection Optimisation 15. Machine Systems Reliability 16. Training examination Total Hours for each level Level 1 4 3 2 2 4 2 6 10 2 2 2 1 40 Level 2 6 3 5 7 2 4 4 2 4 10 4 2 4 2 1 60 Level 3 4 1 4 5 6 4 4 2 6 6 2 1 4 6 10 2 58

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Annex A2 - Detailed list of topics and hours of Instruction SUBJECT 1. Principles of Lubrication Management 1. Lubrication Theory and Fundamentals 2. Lubricant Management and application 3. Lubrication, storage, handling, management 2. Lubricant Sample Acquisition 1. Sample point identification 2. Methods for sampling (oil and grease) 3. Bottles, labels, identification 4. Operational condition 5. Sample interval or frequency 6. Sample planning and testing procedures 3. Pro-action & Basics of Reliability 1. Maintenance Philosophies, strategies, CBM and RCM 2. Basic Reliability Methodologies 4. Condition Monitoring (oil analysis programme design, implementation and management) 1. Equipment audit and Prioritisation 2. Alarms; levels & status 3. Baseline Assessments, Trending 4. Route Planning 5. Alternate Technologies: Vibration Analysis, Infrared Thermography, Acoustic Emission 6. Procedure writing 5. Corrective Action 1. Breakdown 2. Scheduled 6. Generic Equipment Knowledge 1. Engines 2. Transmissions 3. Turbines & Compressors 4. Gear reduction Systems 5. Hydraulic Systems 6. Pumps 7. Bearings 8. Filtration 4 * * * * * * * * 4 * * 4 * * * * * * * * * * Level 1 Hours 4 * * * 3 * * * * * * 2 * * 2 Level 2 Hours 6 * * * 3 * * * * * * 5 * * 7 * * * * * 1 * * * * * * 4 * * 6 * * * * * * 4 * * 4 * * * * * * * * Level 3 Hours 4 * *

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SUBJECT 7. Lubricant Acceptance Testing 1. Standard of Cleanliness 2. Viscosity Grade 8. Equipment testing and Diagnosis 1. Lubricant condition- chemical & physical 2. Machine wear Mechanisms 3. Effects of contamination 4. On-site testing 5. Off-site testing 6. Report Interpretation 7. Diagnostics & Prognostics 9. Lubricant Analysis Methods 1. Lubricant health monitoring 2. Viscosity 3. Acid & Base Numbers 4. Wear debris monitoring and analysis 5. Contaminant levels 5a. Liquids 5b. Particulate 5c. Gases

Level 1 Hours 2 * * 6 * * * * *

Level 2 Hours 2 * * 4 * * * * * * *

Level 3 Hours 2 * * 6 * * * * * * * 6 * * * * * * *

10 * * * * * * *

12 * * * * * * * *

10. Reference Standards 1. ISO 2. ASTM 3. SAE 4. Others 11. Reporting and Documentation 1. Condition Monitoring reports 12. Inspection Optimisation 1. Time-base policies 2. Data collection 3. Bathtub Hazard Rate Curve 4. Potential failure (P-F) Curve 5. Proportional Hazards Modeling 6. Cumulative Distribution function 7. Probability density functions 8. Risk and Cost of Failure 13. Machine Systems Reliability 1. Failure Mode Effects & critical analysis

2 * *

4 * * * *

2 * * * * 1 * 6 * * * * * * * *

2 * 2 * * *

2 * 2 * * * *

10 *

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SUBJECT 2. Root cause analysis 3. Fault severity determination 14. Training Examination Total Hours

Level 1 Hours

Level 2 Hours

Level 3 Hours * *

1 40

1 60

2 58

Note 1 The symbol * indicates the subjects to be covered within the time allotted. Note 2 Level II includes the knowledge of Level 1; Level 3 includes the knowledge of Levels 1 & 2. Note 3 If the symbol * appears in more than one level for a subject item, it must be understood that at level X deeper knowledge of the subject is required than at level X-1.

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Annex B Reading references (normative) Essential reading (material from which examination questions can be developed) Level 1, 2, 3 Title The Wear Debris Analysis Handbook Oil Analysis Basics Author(s) B. J. Roylance and T. M. Hunt, 1999. D Troyer and J. Fitch. 1999. Larry A Toms, 1998. M. J. Neale, 2nd edition. A Davies 1998 Chapman & Hall Elsevier Prentice Hall 0412613204 Publisher Coxmoor ISBN 1901892026

1, 2, 3

Noria Publishing. USA 0-9664604-05

1, 2, 3 1, 2, 3 1, 2, 3

Machinery Oil Analysis The Tribology Handbook Handbook of condition monitoring- techniques and methodology. Handbook of Condition Monitoring Machinery Malfunction Diagnosis and Correction Machinery Analysis and Monitoring Oil Analysis Infrared ThermographyTheory & Practice Acoustic emission and ultrasonics Vibration monitoring handbook Reliability centred Maintenance

1, 2, 3 1, 2, 3

B K N Rao, 1996 Sr R. C. Eisenmann, 1998 J. S. Mitchell, 1993 Evans and Hunt N Walker T Holroyd C W Reeve John Moubray

1856172341 013240946-1

1, 2, 3 1,2,3 1, 2, 3 3 3 2,3

PenWell Publishing Co Coxmoor BINDT Coxmoor Coxmoor, 1998 Elsevier

087814401-3 1901892050 0903132338 1901892077 190189200X 075063358

Standards and specifications (material from which examination questions can be developed) (normative) 1. 2. 3. 4. 5. 6. 7. ASTM D 6224-02 Standard practice for In-Service Monitoring of Lubricating Oil for Auxiliary Power Plant Equipment, (2002). ASTM D 4378-03 Standard practice of In-Service Monitoring of Mineral Turbine Oils for Steam and gas Turbines. ISO 13379: 2003, Condition monitoring and diagnostics of machines- Data interpretation and diagnostic techniques.- General guidelines ISO 13372: 2004, Condition monitoring and diagnostics of machines- vocabulary ISO 13374. Part 1. 2003. Condition monitoring and diagnostics of machines- Data processing, communication and presentation, Part 1: General guidelines ISO 17359: 2003, Condition monitoring and diagnostics of machines- general guidelines SAE J300: 2004, Surface Vehicle standard- engine oil viscosity classification.

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8. 9. 10.

CMGEN: 2004, General requirements for qualification and certification of condition monitoring and diagnostic personnel ISO 13381-1: 2004, Condition monitoring and diagnostic of machines; prognostics: Part 1 general Guidelines ISO 18436-1: 2004, Condition monitoring and diagnostics of machines; requirements for training and certification of personnel Part 1, Requirements for certifying bodies and the certification process ISO/IEC 17024: 2003, Conformity assessment- general requirements for bodies operating certification of persons ISO 4406: 1999, Hydraulic Fluid Power. Fluids. Method for coding the level of contamination by solid particles SAE J310: 2000, Automotive lubricating greases: recommended practice ISO 11500, Hydraulic fluid power. Determination of particulate contamination by automatic counting using the light extinction principle. ISO 11171, Hydraulic fluid power. Calibration of automatic particle counters for liquids. ISO/DIS 18436, Condition monitoring and diagnostics of machines; requirements for training and certification of personnel- Part 4: Industrial lubricant analysis. ISO/NP 18436, Condition monitoring and diagnostics of machines; requirements for training and certification of personnel- Part 5: Laboratory lubricant analysis ISO/DIS 14830, Condition monitoring and diagnostics of machines- Tribology Based Monitoring- Part 1: General Guidelines. ISO 17025, General requirements for the competence of testing and calibration laboratories BS 5760-5: 1991. Reliability of systems, equipment and components: Guide to failure modes, effects and criticality analysis (FMEA and FMECA) ISBN 0580 196607 BS 5760-7: 1991 (IEC 61025: 1990). Reliability of systems, equipment and components. Fault tree analysis. ISBN 0580 203387

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Recommended reading (material which contains helpful information on a related subject) (informative) Level 1, 2, 3 Title Condition monitoring of mechanical and hydraulic plant- concise introduction and guide Level, Leakage & Flow. Practical lubrication for industrial facilities Quality in the analytical chemistry laboratory Handbook of hydraulic fluid technology High temperature lubrication Lubricating Grease Guide Author(s) T M Hunt 1996 Publisher Chapman & Hall, UK ISBN 0412707802

1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 2, 3

T M Hunt 2001 H Bloch, 2000 E Prichard, 1995 G Totten, 2000 A Landsdown, 1994 The National Lubricating Grease Institute, 1996

Coxmoor, UK Marcel Dekker, NY John Wiley & Sons, UK Marcel Dekker, NY Mechanical Engineering Publications, UK NLGI, USA

1901892085

1, 2

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Annex C- Suggested List of sub-topics for Level 2 (informative) (Training should satisfy Annex A2 but it is suggested that it could also incorporate these sub-topics where specified, and the sub-topics apply to both levels 1 and 3, where appropriate). ISO 18436-4 and ISO 18436-5 provide additional detail of training topics. Topic 1. Principles of Lubrication Management 1. Lubrication Theory and Fundamentals * Hydro-dynamics; properties of greases; additives; definitions; oil physical and chemical properties, performance and classifications; fundamentals of tribology and wear debris; functions of lubricants; lubrication regimes (hydrodynamic, elastohydrodynamic, boundary); base oils; greases, hydraulic fluids; additives functions; Selection and applications; basic calculations for determining required lubricant volume, re-lube and change frequencies; Configuration of storage containers; tanks, baffles; lubricant selection; additive system selection; base-oil type selection; application and environment related adjustments; when to select; manual delivery techniques; automatic delivery systems; receiving procedures; storage of equipment [guns etc]; maintenance of automatic grease systems; health and safety requirements; Required Sub-topics

2. Lubricant Management and application 3. Lubricant storage, handling and management

4. 2. Lubricant Sample Acquisition 1. Sample point identification 2. Methods for sampling (oil and grease) 3. Bottles, labels, identification 4. Operational condition 5. Sample interval or frequency 6. Sample planning, Testing procedures 3. Pro-action & Basics of Reliability 1. Maintenance Philosophies * Strategies; maintenance actions; primary mission; methods; data interpretation; why machines fail; fundamentals of RCM and CBM including predictive maintenance, proactive maintenance strategies; lube routes and scheduling; equipment tagging and identification; Method selection; diagnostic and prognostic methodologies; data management; applications; * * Basic methodologies; objectives for lube sampling; Optical techniques; conductive sensors; sample quantities; sampling methods (non-pressurised systems, low and high pressurised systems; Container material; managing interference (bottle cleanliness and management);

* * * *

Sampling process management (sampling frequency, procedures); sample processing; Sampling point location; equipment specific sampling;

2. Basic Reliability Methodologies 4. Condition Monitoring (oil analysis programme design, implementation and management)

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Topic 1. Equipment audit and Prioritisation 2. Alarms; levels & status 3. Baseline Assessments, Trending 4. Route Planning 5. Alternate Technologies: Vibration Analysis, Infrared Thermography, Acoustic Emission 6. Procedure writing 5. Corrective Action 1. Breakdown 2. Scheduled 6. Generic Equipment Knowledge 1. Engines 2. Transmissions 3. Turbines & Compressors 4. Gear reduction Systems 5. Hydraulic Systems 6. Pumps 7. Bearings 8. Filtration

Required * * * * *

Sub-topics Baselines, limits and objectives; equipment knowledge; Goal-based targets; establishing limits; setting alarms and limits; Trend interpretation; Test parameters; methodology applications; optimizing frequency of analysis; IRT, VA and AE basic principles; NDT methodologies;

Not applicable at level 2

* *

Maintenance philosophies; failure types and analysis; Maintenance philosophies and actions;

* * * * * * * *

Fault analysis; components; reciprocating engines; Primary function; components; Primary function; components; Gear types; lubrication choice and applications; components; gearing and gearboxes; System categorisation; components; contamination; Hydraulics; pump types and applications; components; Operation; components; lubrication choice and properties; rolling element bearings; journal bearings; Components; applications and system specifications; wear debris analysis; de-aeration; filtration and separation technologies; filter rating; filtration system design and filter selection;

7. Lubricant Acceptance Testing 1. Standard of Cleanliness 2. Viscosity Grade 8. Equipment testing and Diagnosis 1. Lubricant conditionchemical & physical 2. Machine wear Mechanisms * Test (mechanical, physical, chemical) programmes; defect analysis; degeneration; defect prevention; viscosity; limitations; Corrosion; wear types (adhesive, corrosive, cavitation, abrasive, surface [2-body, 3-body]); terminology; failure analysis; Wear mechanisms; In-line testing; Test methods; * * Viscosity values and limits;

3. Effects of contamination 4. On-site testing 5. Off-site testing

* * *

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Topic 6. Report Interpretation 7. Diagnostics & Prognostics 9. Lubricant Analysis Methods 1. Lubricant health monitoring

Required * *

Sub-topics

Condition prediction; numerical methods; parameters;

Testing (chemical, physical); additives; defect analysis; lubricant failure mechanisms (oxidative degradation, thermal degradation, additive degradation/depletion); testing from mixed or wrong lubricants, sensory inspection; FTIR, thermal stability and thermal degradation tests; neutralization; shear-down; hydrolysis; surface adsorption; filtration; TGA, AAS, ICP, SEM, crackle test, co-distillation, Karl Fischer titration, rotating pressure vessel oxidation test (RPVOT), foam stability characteristics, GC, GCMS, exception testing, kinematic and absolute viscosity, viscosity index, pentane insolubles Measurement units; ranges; definitions; types; viscosity techniques (kinematic and absolute); Methods and benefits; definitions; result interpretation; AN, BN; Indications of wear modes; elemental analysis; morphological characteristics; causes; ferrography; compositional analysis; rubbing contact; common machine wear mechanisms and machine-specific wear modes; particle sizing; ICP; arc-spark emission spectroscopy; acid-microwave digestion; rotrode filter spectroscopy; XRF; XRD; size distribution of wear particles from common wear mechanisms; Air contamination; Contaminant determination and levels; test methods; moisture contamination; effects on machine and lubricant; glycol coolant contamination; fuel contamination; FTIR; condensation settling; AAS; atomic emission spectroscopy; effect of water, glycol, coolant or fuel contamination on lubricant and the machine Particle contamination; effects on the machine and lubricant; methods of testing for; techniques of controlling particle contamination; soot contamination; ultracentrifuge of carbon insolubles; particle scrubbing; aggregate adsorption; AAS; ICP; FTIR; blotter spot test; SEM;

2. Viscosity 3. Acid & Base Numbers 4. Wear debris monitoring and analysis

* * *

5. Contaminant levels 5a. Liquids

* *

5b. Particulate

5c

Gases

10. Reference Standards 1. ISO 2. ASTM 3. SAE 11. Reporting and Documentation 1. Condition Monitoring reports 12. Inspection Optimisation * Format and content; results interpretation; future actions * * * Oil condition; test methods and philosophies; Oil condition; test methods and philosophies; SAE J300, SAE J310

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Topic 1. Time-base policies 2. Data collection 3. Bathtub Hazard Rate Curve 4. Potential failure (P-F) Curve

Required * * * *

Sub-topics

Understanding statistical limits (wear debris), ageing limits, targets, goal-based limits Trend analysis; graphical representation;

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