Module 1 – Intro to Level 1 and Principles of Ultrasound (Part 1) – 2 Hours
Become acquainted with your instructor and the unique training approach taken in the Live Online version of SDT’s popular Level 1 ultrasound certification. Become familiar with our training platform, how inter-module quizzing works, and their relevance to your overall grading. A briefing of each of the sixteen modules sets the stage for Part 1 of The Principles of Ultrasound.
Part 1 of The Principles of Ultrasound is an overview about the principal concepts of ultrasound and wave propagation theory as they apply to ultrasound for asset condition monitoring, energy conservation, and performing safe inspections in industrial environments.
Module 2 – Principles of Ultrasound (Part 2) & Basic Equipment Knowledge – 2 Hours
Part 2 of The Principles of Ultrasound picks up from Module 01 with a focus on waves, the relationship between frequency and period, amplitude and energy, and our human perception of sound. Discover the importance of the Inverse Distance Law for airborne ultrasound and acoustical impedance for contact inspections. Finally, tackle the sometimes tricky, but important concepts of how ultrasound is measured using the reference scale of the decibel.
Module 3 – Basic Equipment Function, FIT, and Eight Application Pillars – 2 Hours
Module 03 delivers an overview of ultrasound data collectors and the various sensors that connect to them. Understand how ultrasonic data collectors receive and process sound pressure waves into signals that are audible, repeatable, measurable, and able to be trended and analyzed. Discover the many sensors and how their design suits every possible inspection you’ll encounter.
The basic principles of FIT (Friction, Impacting, and Turbulence) are explained, and related to the Eight Application Pillars of ultrasound.
Module 4 – The Inspector’s Philosophy and Condition Monitoring – 2 Hours
To understand the significant place ultrasound holds within any reliability program, one must be in tune with the basic concepts of condition monitoring and asset management. Module 04 discusses Asset Condition Monitoring, Predictive Maintenance, ISO 55000, and the ultrasound inspector’s philosophy of Inspect > Detect > Measure > Trend > Analyze > Act.
Module 5 – Data Storage Management and Condition Indicators – 2 Hours
Module 05 addresses the importance of working with databases, storage of ultrasound data, and most importantly, the ability to retrieve it when needed. As this is an SDT Certification Course, this module takes an “under-the-hood” look at Ultranalysis™ Suite (UAS); the data management software that drives all SDT data collectors.
Learn the importance of correct nomenclature when creating an asset database, how to backup and restore your data, disposition of anomalies, signal clipping, and the unique and important SDT Condition Indicators.
Module 6 – Basic Instrument Function for Inspect & Detect – 2 Hours
Learn the basics of SDT data collectors as they function for Inspecting and Detecting asset defects and inefficient operations. Our primary course objectives are to create competent, capable, SAFE inspectors. Module 06 really sets apart the differences between vendor-neutral courses that forbid specific instrument instruction and vendor-driven certification where safe operation of SDT instruments is necessary.
Module 7 – Application Pillar 1; Leaks (Part 1) – 2 Hours
The first of our eight application pillars is Leak Detection. In this module our instructor introduces the many disciplines of leak detection. Contrast the different methods used for the many types of leaks encountered in manufacturing. Discover the factors that affect leak detectability and how to handle difficult inspection environments.
Supplementary reading for this module includes a case study on vacuum leak detection in a pulp production facility.
Module 8 – Application Pillar 1; Leaks (Part 2) – 2 Hours
Part 2 of Leaks delves deeper into the most popular of the leak applications, compressed air. Understanding compressed air, its advantages and disadvantages, but also our misconceptions about the actual cost to produce, store, and distribute this utility are all addressed in Module 08. Finally, as our goal is to prepare inspectors for fieldwork, we look at strategies for managing compressed air leaks as well as reporting their existence and their potential impact on cost reduction once repaired.
Module 9 – Application Pillar 2 & 3; Steam Systems and Valves – 2 Hours
Steam systems play an integral role in many manufacturing processes, as well as facilities. At the heart of the steam system is the steam trap; an often-neglected asset that plays a vital role in the preservation of pure steam, quality production, and energy efficiency. Students understand what steam is, the cost of producing it as well as the benefits of maintaining a healthy steam system. Real live examples of working and faulty steam traps are presented to contrast and prepare inspectors for fieldwork.
Valves are similar in function, if not design, to steam traps. They too play an integral role in so many processes, yet they too often fall victim to a run-to-failure mentality. Learn the basic types of valves used in industry, their typical failure modes, which ultrasound equipment is best suited to inspections, as well as proven methods for inspection in a variety of environments.
Module 10 – Application Pillar 4 & 5; Hydraulics and Tightness Testing – 2 Hours
Hydraulic systems can be both simple and complex in design and function. Learn the basic types of hydraulic systems, what their failure modes are, and how they are best detected with ultrasound. Recommended equipment selection, sensor types, as well as inspection methods are discussed.
Tightness testing is one of the oldest and most widely used applications for ultrasound inspection. Everything leaks, and most of those leaks are detectable using some form of either contact or airborne ultrasound inspection. This module discusses asset tests using both pressurized and non-pressurized techniques. There is a specific focus on heat exchangers and shell and tube condensers. Module 10 also looks at using ultrasound for wind noise, weather tightness, and building envelope inspections.
Module 11 – Application Pillar 6; Electrical – 2 Hours
This module addresses the deadliest of all physical assets, electrical. Electrical assets not only cost millions of dollars a year in downtime, they have the potential to maim and kill. More than 1000 Americans are killed each year by electrocution; most on the job. Thus, the focus in Module 11 is how to perform SAFE inspections.
Understand what partial discharge is, how it degrades electrical assets, and what technologies and techniques are best at finding these elusive symptoms of defects. Learn to distinguish between arcing, tracking, and corona discharge. Know which data collectors and sensors are best, and most safe, for performing inspections. Appreciate the symbiotic relationship between infrared thermography and ultrasound for various electrical systems and failure modes.
Module 12 – Analyst’s Philosophy Measure/Trend/Analyze/Act – 2 Hours
In this module we revisit the Inspector’s Philosophy from Module 04, thereby advancing the Inspect > Detect approach for binary defect hunting by looking at problems that are best left to trending and analysis. This second stage approach has actually become mainstream for ultrasound inspectors and is driven by recent innovations to technology; innovations affecting measurement quality, interpretation, and the ability to manage it with software.
Student’s focus is on classification of defects, acquiring data, creating alarms, creating surveys, and producing results that trigger maintenance interventions in proactive ways.
Module 13 – Application Pillar 7; Mechanical (Part 1) – 2 Hours
Mechanical applications represent the lion’s share of asset failure modes detectable with ultrasound inspection. Therefore, this seventh application pillar is split in two across Modules 13 and 14.
In Module 13 we look at familiar mechanical systems, often referred to as “Typical and Non-Typical Rotating Equipment”. As ultrasound is NOT vibration, your instructor explains how ultrasound extends beyond rotating assets to assess systems with linear movements.
Understand the various components that make up a bearing including its inner ring, outer race, cage and rolling element. Learn basic bearing fault frequency terminology, demodulation, and fault frequency exercises. This module also looks at applications for gearboxes, pumps, and systems controlled by variable frequency drives.
Module 14 – Application Pillar 7; Mechanical (Part 2) – 2 Hours
In Module 14, the Mechanical application pillar continues as a closer look at using ultrasound for shaft coupling inspections, encoders, slow speed bearings, belts, and chain drives. Three case studies are presented:
- Using ultrasound for Hoists and Cranes
- Using ultrasound for reliable coupling inspections
- Slow speed bearing monitoring in methanation ovens
As in previous modules, correct data collector selection, usage, and sensor selection are discussed for each asset type.
Module 15 – Application Pillar 8; Lubrication (Part 1) – 2 Hours
It is generally accepted amongst reliability professionals that poor lubrication practices are the leading contributor to unplanned downtime. Some industry experts cite as high as 80% of all failures are attributed to lubrication. Modules 15 and 16 focus on this most important application for ultrasound technology.
In Module 15 learn about the history of poor lubrication practices, failure modes related to lubrication, as well as the basic make-up of grease. Understand how grease ages, and how ultrasound should be deployed to ensure the grease replenishment task is performed with precision.
Module 16 – Application Pillar 8; Lubrication (Part 2) – 2 Hours
There are two themes for Module 16:
- Lubrication related Failure Modes for bearings. Why they happen and what we now know to reduce and even eliminate them from happening in the future.
- Learning how to use the LUBExpert and UAS software to achieve precision lubrication while driving your lubrication strategy based on data.
Understand the importance of building a grease gun database, validating all the grease guns in use, minimizing risk from contamination, using bearing dimensions, rotational speed, and other metrics to determine replenishment quantities, and then using results to adjust re-greasing intervals.
Earning your Certificate
Students are required to complete the 32 hours of course content & finish the combined 16 post module quizzes & final exam with no less than the passing requirement of 70% to earn their SDT Level One Ultrasound Certificate.
Each of the 16 modules are completed with a short 5 question quiz specific to topics covered during that module. The final exam includes questions on topics covered throughout the 16 module course and is comprised of 70 questions.
In total, students will need to complete 80 quiz questions & 70 final exam questions, while achieving a grade of no less than 70% to receive their certification.
This course exceeds the ISO 18436-8 and corresponds with the required practices of the American Society for Non-Destructive Testing.