Manufacturing, Engineering and Technology Engineering and Related Design

Final Control Element Equipment Fault Finding And Repair Training

SAQA US 116046 | 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 final control elements, such as valves, actuators, and positioners, commonly used in process control systems. It covers systematic fault-finding techniques, safety protocols, and practical repair procedures to minimize downtime and ensure operational reliability.

Learning Outcomes

  • Apply systematic fault-finding techniques to identify malfunctions in final control elements.
  • Analyze the operational characteristics of valves, actuators, and positioners to determine root causes of failures.
  • Implement safe isolation and lockout/tagout procedures before commencing repair work.
  • Demonstrate correct disassembly, inspection, and reassembly of final control element components.
  • Evaluate repair effectiveness through functional testing and performance verification.
  • Design a preventive maintenance schedule to reduce future equipment failures.

Target Audience

This course is designed for instrumentation technicians, maintenance engineers, and process control specialists who are responsible for the maintenance and repair of final control elements in industrial settings.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Introduction to Final Control Elements and Safety

Objectives:
• Understand the role of final control elements in process control systems.
• Identify different types of final control elements (valves, actuators, positioners).
• Apply workplace safety procedures and lockout/tagout protocols.
• Interpret basic P&ID symbols for final control elements.

Topics:
• Overview of process control loops and final control elements
• Types of valves: gate, globe, ball, butterfly, diaphragm
• Actuators: pneumatic, electric, hydraulic
• Positioners and their function
• Safety procedures: lockout/tagout, hazard identification
• P&ID symbols and documentation

Day 2: Valve Characteristics and Selection

Objectives:
• Describe valve flow characteristics (linear, equal percentage, quick opening).
• Select appropriate valve types for specific applications.
• Calculate valve sizing (Cv) for given process conditions.
• Understand cavitation, flashing, and noise in valves.

Topics:
• Flow characteristics and trim design
• Valve sizing fundamentals and Cv calculation
• Cavitation and flashing: causes and prevention
• Noise prediction and mitigation
• Material selection for valve components
• High-pressure and high-temperature applications

Day 3: Actuators and Positioners

Objectives:
• Explain the operation of pneumatic, electric, and hydraulic actuators.
• Troubleshoot actuator malfunctions.
• Calibrate and adjust valve positioners.
• Perform bench set and span adjustments.

Topics:
• Pneumatic actuator types: diaphragm, piston, rotary
• Electric actuator operation and control
• Hydraulic actuator systems
• Positioner types: pneumatic, electro-pneumatic, smart
• Calibration procedures: zero, span, and linearity
• Troubleshooting common actuator and positioner faults

Day 4: Control Valves and Accessories

Objectives:
• Identify control valve accessories (I/P converters, boosters, limit switches).
• Install and test solenoids and position switches.
• Understand valve failure modes (fail-open, fail-closed).
• Perform loop checks and signal testing.

Topics:
• I/P converters: operation and calibration
• Volume boosters and quick exhaust valves
• Limit switches and proximity sensors
• Solenoid valves and their application
• Failure mode analysis and valve action
• Loop checking: 4-20 mA signal testing

Day 5: Fault Finding Techniques and Diagnostics

Objectives:
• Apply systematic fault-finding methods (half-split, input-to-output).
• Use diagnostic tools (multimeter, HART communicator, software).
• Identify common valve and actuator faults.
• Interpret diagnostic data from smart positioners.

Topics:
• Systematic fault-finding approach
• Using multimeters and signal generators
• HART communicator: reading and writing parameters
• Smart positioner diagnostics: travel deviation, friction
• Common faults: sticking, leakage, hysteresis
• Case studies and practical exercises

Day 6: Repair and Maintenance Procedures

Objectives:
• Perform valve disassembly, inspection, and reassembly.
• Replace packing, gaskets, and seat rings.
• Lap valve seats and test for leakage.
• Document maintenance activities and complete work orders.

Topics:
• Valve disassembly procedures
• Packing and gasket replacement
• Seat lapping and leak testing
• Actuator diaphragm and seal replacement
• Torque specifications and bolt tightening
• Maintenance documentation and reporting

Day 7: Practical Assessment and Integration

Objectives:
• Demonstrate fault finding and repair on a simulated system.
• Complete a full valve maintenance cycle from isolation to testing.
• Apply all safety procedures and documentation requirements.
• Integrate knowledge into a comprehensive troubleshooting scenario.

Topics:
• Practical assessment: valve fault diagnosis and repair
• Simulated process loop: start-up, tuning, and shutdown
• Final control element performance verification
• Safety compliance and lockout/tagout demonstration
• Written test and competency evaluation
• Course review and feedback

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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