Flow Equipment Fault Finding And Repair Training

Objectives:
• Understand the role of flow equipment in industrial processes
• Identify common types of flow equipment (pumps, valves, compressors)
• Apply relevant OHS Act and safety procedures for working with flow equipment
• Recognise basic principles of fluid dynamics and flow measurement

Topics:
• Overview of flow equipment in SA industry
• Types of pumps: centrifugal, positive displacement
• Types of valves: gate, globe, ball, butterfly
• Introduction to compressors and blowers
• Fluid properties: pressure, flow rate, viscosity
• Safety protocols: lockout/tagout, PPE, hazard identification
• Relevant SA legislation: OHS Act, SANS standards

Objectives:
• Apply systematic fault-finding methodologies (e.g., 5 Whys, fishbone)
• Use diagnostic tools: multimeters, pressure gauges, flow meters
• Interpret equipment manuals and schematic diagrams
• Identify common failure modes in flow equipment

Topics:
• Systematic fault-finding process: observe, analyse, isolate, correct
• Diagnostic tools and their applications
• Reading P&IDs and equipment schematics
• Common failure modes: cavitation, wear, misalignment, leakage
• Case studies on pump and valve failures
• Introduction to condition monitoring (vibration, temperature)

Objectives:
• Identify mechanical components: seals, bearings, impellers
• Understand electrical components: motors, starters, VSDs
• Perform basic electrical tests on motor circuits
• Diagnose common mechanical and electrical faults

Topics:
• Mechanical seals: types, installation, failure causes
• Bearings: types, lubrication, failure analysis
• Impellers and volutes: wear patterns and clearance
• Electric motors: types, wiring, protection devices
• Variable speed drives (VSDs): principles and troubleshooting
• Measuring insulation resistance and continuity
• Common electrical faults: phase imbalance, overload, short circuit

Objectives:
• Diagnose pump performance issues (low flow, low pressure, noise)
• Perform pump disassembly and inspection
• Repair or replace worn components (seals, bearings, impellers)
• Reassemble and test pump operation

Topics:
• Centrifugal pump troubleshooting: cavitation, air binding, reverse rotation
• Positive displacement pump troubleshooting: slip, relief valve issues
• Step-by-step pump disassembly procedure
• Inspection of wear rings, shaft sleeves, and mechanical seals
• Seal replacement techniques
• Bearing replacement and alignment
• Pump reassembly and alignment (coupling, baseplate)
• Performance testing: flow, head, power consumption

Objectives:
• Diagnose valve faults: leakage, sticking, improper operation
• Disassemble and inspect valve internals
• Repair or replace seats, discs, stems, and packing
• Test valve operation and seat tightness

Topics:
• Valve types and applications: isolation, control, check, safety
• Common valve faults: seat leakage, stem seal leakage, actuator failure
• Valve disassembly: gate, globe, ball, butterfly valves
• Seat and disc refurbishment techniques (lapping, replacement)
• Packing and gasket replacement
• Actuator troubleshooting: pneumatic, electric, hydraulic
• Valve testing: hydrostatic, seat leakage, operational cycle test

Objectives:
• Diagnose compressor faults: low capacity, overheating, vibration
• Inspect and repair compressor components (valves, pistons, rotors)
• Perform compressor maintenance: oil changes, filter replacement
• Test compressor performance and safety devices

Topics:
• Compressor types: reciprocating, rotary screw, centrifugal
• Common faults: valve failure, ring wear, oil carryover, overheating
• Reciprocating compressor: valve plate inspection, piston ring replacement
• Rotary screw compressor: rotor clearance, oil system troubleshooting
• Blower maintenance: belt tension, bearing replacement
• Safety devices: pressure relief valves, temperature switches
• Performance testing: capacity, pressure, power consumption

Objectives:
• Apply fault-finding to integrated flow systems
• Commission repaired equipment and verify performance
• Complete maintenance reports and documentation
• Demonstrate compliance with SAQA unit standard requirements

Topics:
• System approach: interaction of pumps, valves, compressors in a circuit
• Commissioning procedures: start-up, parameter checks, safety interlocks
• Performance verification against specifications
• Maintenance reporting: fault logs, repair actions, parts used
• Continuous improvement: root cause analysis and preventive maintenance
• Final assessment: practical fault-finding and repair scenario
• Course review and Q&A