COURSE OVERVIEW:

Steam system troubleshooting is a hands-on technical discipline focused on identifying and resolving the chronic issues that plague industrial steam networks. Water hammer, failed steam traps, and excessive heat loss are not merely efficiency problems; they are significant safety hazards and drivers of equipment damage. This course provides a systematic approach to diagnosing these faults, using a combination of mechanical principles, field observation, and advanced diagnostic tools to restore system stability and safety.

The scope of this course centers on the "Root Cause" of steam system malfunctions. Participants will explore the mechanics of water hammer, learning why it occurs and how to eliminate the slugs of condensate that lead to catastrophic pipe ruptures. The Coverage includes a deep dive into steam trap technology, where attendees will learn to distinguish between the various failure modes of mechanical and thermostatic traps. Furthermore, the course addresses the "silent thief" of heat loss, teaching participants how to identify compromised insulation and air-binding in heat exchangers that reduce thermal productivity.

Throughout the training, the emphasis is on practical, field-ready solutions. Attendees will learn how to use ultrasonic detectors and infrared cameras to "see" into the system and verify the internal state of components without disassembly. By mastering these troubleshooting techniques, participants will be able to eliminate dangerous system shocks, reduce fuel costs by preventing steam waste, and ensure that the steam delivered to the process is of the highest quality and energy content.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Identify the symptoms and root causes of Water Hammer in steam lines.
2. Differentiate between thermal, hydraulic, and differential-shock water hammer.
3. Conduct a comprehensive field survey of steam traps using diagnostic tools.
4. Diagnose failed-open, failed-closed, and undersized steam traps.
5. Identify areas of excessive heat loss through thermographic analysis.
6. Troubleshoot air-binding and condensate flooding in heat exchangers.
7. Solve pressure and temperature fluctuations in steam headers.
8. Evaluate the impact of improper piping slopes and drainage on system health.
9. Diagnose the causes of "wet steam" and its impact on turbines and valves.
10. Implement effective insulation repair and management strategies.
11. Troubleshoot malfunctioning pressure-reducing and control valves.
12. Design and verify the placement of drip legs and separators.
13. Resolve issues with condensate return pumps and backpressure.
14. Ensure safe operation through the identification of relief valve deficiencies.

TARGET AUDIENCE:

This course is intended for Maintenance Technicians, Pipefitters, Utility Operators, Steam System Engineers, and Facility Managers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.