Pressure Equipment Fault Finding And Repair Training

Objectives:
• Understand the scope and importance of pressure equipment in industry.
• Identify common types of pressure equipment and their components.
• Explain the fundamental principles of fault finding and systematic troubleshooting.
• Recognize relevant safety regulations and standards (e.g., SANS 347, OHS Act).
• Describe the role of documentation and records in fault finding.

Topics:
• Overview of pressure equipment: boilers, pressure vessels, piping, valves.
• Key components: shells, heads, nozzles, supports, safety devices.
• Principles of fault finding: observation, testing, analysis, isolation.
• Safety considerations: lock-out/tag-out, pressure isolation, PPE.
• Introduction to relevant standards: SANS 347, ASME VIII, OHS Act.
• Documentation: equipment registers, maintenance logs, defect reports.

Objectives:
• Understand basic design parameters: pressure, temperature, material selection.
• Explain operating principles of typical pressure equipment.
• Identify failure modes: fatigue, corrosion, erosion, overpressure.
• Interpret pressure equipment nameplates and design data.
• Apply knowledge of design to anticipate potential faults.

Topics:
• Design codes and material selection (carbon steel, stainless steel, alloys).
• Pressure and temperature ratings, design margins.
• Operating principles: boilers (fire-tube, water-tube), heat exchangers, storage tanks.
• Common failure modes: stress corrosion cracking, pitting, creep, brittle fracture.
• Reading nameplates: MAWP, MDMT, test pressure, serial numbers.
• Correlating design with operational faults: thermal shock, water hammer.

Objectives:
• Apply systematic fault finding methodologies: 5 Whys, fishbone diagram, FMEA.
• Use diagnostic tools: visual inspection, pressure testing, ultrasonic thickness gauging.
• Interpret test results to identify faults.
• Develop a fault finding plan for common pressure equipment issues.
• Document findings accurately for repair planning.

Topics:
• Fault finding methodologies: 5 Whys, cause-and-effect analysis, failure mode and effects analysis.
• Visual inspection techniques: cracks, distortion, leaks, corrosion.
• Non-destructive testing basics: ultrasonic thickness, magnetic particle, dye penetrant.
• Pressure testing: hydrostatic, pneumatic – procedures and safety.
• Interpreting test data: thickness loss, crack detection, pressure decay.
• Creating a fault finding report: observations, tests, conclusions.

Objectives:
• Identify common faults: leaks, corrosion, mechanical damage, valve failures.
• Perform root cause analysis for each fault type.
• Understand the impact of operational conditions on fault development.
• Prioritize faults based on risk and severity.
• Relate faults to repair methods and material compatibility.

Topics:
• Common faults: flange leaks, gasket failures, valve seat wear, tube failures.
• Corrosion mechanisms: uniform, galvanic, pitting, crevice, under-deposit.
• Mechanical damage: impact, vibration-induced fatigue, thermal fatigue.
• Root cause analysis techniques: fault tree analysis, event tree analysis.
• Risk assessment: likelihood vs. severity, criticality ranking.
• Linking faults to repair: weld repair, overlay, replacement, re-rating.

Objectives:
• Understand approved repair methods: welding, grinding, sleeving, replacement.
• Apply repair procedures in accordance with codes and standards.
• Select appropriate repair materials and techniques.
• Perform pre-repair preparation: cleaning, dimension checks, preheat.
• Document repair procedures and quality control steps.

Topics:
• Approved repair methods: weld repair (full penetration, fillet), cladding, sleeving.
• Repair standards: API 510, API 570, ASME PCC-2.
• Material selection for repairs: matching base metal, filler metals.
• Pre-repair preparation: surface preparation, dimensional measurements, preheat.
• Welding procedures: WPS, PQR, welder qualifications.
• Post-repair heat treatment: stress relief, normalization.
• Quality control: visual inspection, NDT after repair, pressure test.

Objectives:
• Conduct a simulated fault finding exercise on a pressure vessel or system.
• Develop a repair plan based on identified faults.
• Perform a mock repair procedure following code requirements.
• Demonstrate proper use of diagnostic tools and safety protocols.
• Complete documentation: fault report, repair plan, and quality records.

Topics:
• Simulated fault scenarios: corrosion thinning, crack in weld, valve leakage.
• Hands-on use of ultrasonic thickness gauge, dye penetrant kit.
• Developing a repair plan: scope, materials, procedures, safety.
• Mock repair: surface preparation, welding simulation, NDT.
• Documentation: defect report, repair procedure, inspection records.
• Team exercise: collaborative fault diagnosis and repair planning.

Objectives:
• Integrate all knowledge into a comprehensive fault finding and repair process.
• Complete a summative assessment: written test and practical demonstration.
• Review case studies of pressure equipment failures and repairs.
• Discuss continuous improvement: preventive maintenance, condition monitoring.
• Reflect on personal learning and areas for further development.

Topics:
• Comprehensive fault finding and repair workflow: from detection to sign-off.
• Summative assessment: written examination covering theory and standards.
• Practical assessment: fault finding and repair simulation (timed).
• Case studies: lessons learned from industry incidents.
• Continuous improvement: preventive maintenance planning, RBI (risk-based inspection).
• Course review and feedback session.
• Certification and next steps for professional development.