Manufacturing, Engineering and Technology Engineering and Related Design

Fault Finding And Repair Of Level Equipment Training

SAQA US 116050 | NQF 4 | Credits 10 | Duration 7 Days
From $1,523 per delegate

Description

This course equips learners with the skills to diagnose and repair faults in level measurement equipment used in industrial processes. Participants will gain practical knowledge of common fault-finding techniques, calibration procedures, and safety protocols to ensure reliable operation. The training prepares technicians to maintain accurate level measurement systems, reducing downtime and enhancing process efficiency.

Learning Outcomes

  • Apply systematic fault-finding techniques to diagnose malfunctions in level measurement equipment.
  • Analyze circuit diagrams and technical documentation to identify potential failure points.
  • Demonstrate safe isolation and testing procedures in compliance with South African health and safety regulations.
  • Perform calibration and adjustment of level transmitters, switches, and indicators to restore proper function.
  • Evaluate repair outcomes through functional testing and documentation of corrective actions.

Target Audience

This course is designed for instrumentation technicians, maintenance engineers, and process control specialists who are responsible for the installation, calibration, and repair of level measurement equipment in industrial settings.

Prerequisites

None — open enrollment. However, learners should have basic numeracy and literacy skills.

Course Outline

Day 1: Introduction to Level Equipment and Safety

Objectives:
• Explain the purpose and types of level measurement equipment.
• Identify key components and their functions.
• Apply safety procedures for working with level equipment.
• Interpret basic manufacturer documentation.

Topics:
• Overview of level measurement principles.
• Types of level equipment: differential pressure, radar, ultrasonic, capacitive.
• Key components: sensors, transmitters, displays.
• Safety protocols: lockout/tagout, electrical safety.
• Reading datasheets and manuals.

Day 2: Principles of Level Measurement

Objectives:
• Describe operating principles of common level technologies.
• Calculate level from process variables.
• Differentiate between direct and inferential measurement.
• Understand calibration basics.

Topics:
• Hydrostatic pressure and differential pressure level measurement.
• Radar (guided and non-guided) principles.
• Ultrasonic and capacitive principles.
• Level calculation formulas.
• Calibration concepts: zero, span, trim.

Day 3: Installation and Configuration

Objectives:
• Install level equipment correctly per specifications.
• Configure settings using local interfaces or software.
• Verify installation against best practices.
• Document configuration parameters.

Topics:
• Mounting requirements: distance from walls, nozzles.
• Wiring and power supply connections.
• Configuration via HART, Fieldbus, or proprietary tools.
• Setting range, units, damping.
• Installation verification checklists.

Day 4: Fault Finding Techniques and Diagnostics

Objectives:
• Apply systematic fault-finding methods.
• Use diagnostic tools and built-in diagnostics.
• Interpret error codes and alarm signals.
• Identify common fault causes.

Topics:
• Fault-finding process: observe, define, isolate, correct.
• Using multimeters, oscilloscopes, and communicators.
• Interpreting device status and error logs.
• Common faults: power issues, wiring faults, sensor fouling.
• Environmental factors: temperature, vibration, humidity.

Day 5: Repair and Component Replacement

Objectives:
• Safely replace faulty components.
• Perform repairs according to manufacturer guidelines.
• Verify repair effectiveness through testing.
• Document repair actions.

Topics:
• Replacement procedures for sensors, transmitters, cables.
• Handling and disposal of electronic components.
• Post-repair testing: loop check, calibration verification.
• Repair documentation and reporting.
• Spare parts management.

Day 6: Calibration and Performance Verification

Objectives:
• Perform calibration using standard procedures.
• Adjust zero and span accurately.
• Verify linearity and repeatability.
• Complete calibration certificates.

Topics:
• Calibration equipment: pressure calibrators, reference standards.
• Step-by-step calibration for differential pressure and radar.
• Trim adjustments for analog outputs.
• Performance tests: accuracy, hysteresis, drift.
• Creating calibration records.

Day 7: Advanced Troubleshooting and Practical Integration

Objectives:
• Troubleshoot complex multi-device systems.
• Integrate level equipment with control systems.
• Apply predictive maintenance strategies.
• Demonstrate competence in a simulated scenario.

Topics:
• Intermittent faults and noise issues.
• Communication problems: HART, Modbus, Fieldbus.
• System integration with PLCs and DCS.
• Predictive maintenance: trend analysis, diagnostics.
• Practical assessment: fault-finding and repair exercise.

Practicals

No practicals for this training.

This course is made up of exercises and case studies delivered alongside the theory — no separate practical sessions are required to complete it.

Summatives

Each delegate is assessed continuously throughout the course and a final summative test at the end.

Daily Exercises — 30%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 30% to the final total.

Final Test — 70%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 70% to the overall mark.

Final Total
Component Out of Weight
Daily Average (multiple choice) 100% 30%
Final Test (multi-answer multiple choice) 100% 70%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Daily Average 30% + Final Test 70%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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