Equipment Inspection Training Service | in Dammam - Riyadh - Jeddah - Makkah

1. Introduction to Equipment Inspection

• Equipment inspection purpose including (safety assurance, reliability, regulatory compliance, failure prevention, asset protection, operational continuity)

• Regulatory framework including (OSHA 29 CFR 1910 various subparts, ANSI equipment standards, API inspection codes, manufacturer specifications)

• Inspector qualifications including (competent person definition per OSHA, technical knowledge, inspection training, equipment familiarity, certification requirements)

• Inspection categories including (pre-operational, periodic, in-service, post-repair, incident investigation, regulatory compliance)

• Common equipment failure modes including (wear, fatigue, corrosion, overload, improper use, lack of maintenance, design deficiency)

• Inspection documentation importance including (legal evidence, maintenance planning, trend analysis, regulatory compliance, liability protection)

• Safety during inspections including (lockout/tagout per OSHA 1910.147, confined space, working at heights, PPE, hazard awareness)

2. Inspection Planning and Preparation

• Inspection scope definition including (equipment boundaries, systems included, inspection depth, acceptance criteria, reference standards)

• Information gathering including (equipment specifications, operating history, previous inspection reports, manufacturer manuals, maintenance records)

• Inspection checklist development including (critical components, inspection points, measurement requirements, acceptance criteria, regulatory compliance items)

• Tool and equipment preparation including (measuring instruments, testing equipment, cameras, PPE, calibration verification, spare parts)

• Access and staging including (scaffolding, platforms, equipment positioning, lighting, ventilation, clearances)

• Permits and authorizations including (work permits, lockout/tagout, confined space entry, hot work, lifting operations)

• Pre-inspection safety briefing including (hazards, controls, emergency procedures, communication, team coordination)

3. Visual Inspection Techniques

• Systematic visual examination including (methodical approach, complete coverage, surface preparation, lighting optimization, magnification aids)

• Surface condition assessment including (cleanliness, coating condition, corrosion, staining, discoloration, deposits)

• Structural integrity evaluation including (cracks, deformation, alignment, distortion, buckling, sagging, settlement)

• Wear pattern analysis including (normal wear, abnormal wear, excessive wear, galling, scoring, erosion, cavitation)

• Leak detection including (active leaks, weeping, staining, deposits, pressure testing evidence, tracer methods)

• Vibration and alignment indicators including (unusual wear patterns, fretting, loose components, mounting damage, misalignment evidence)

• Corrosion assessment including (general corrosion, pitting, crevice corrosion, galvanic corrosion, stress corrosion cracking, corrosion under insulation)

• Photographic documentation including (overview, detail shots, measurements in frame, sequential documentation, defect labeling)

4. Pressure Vessel and Tank Inspection

4.1 Pressure Vessel Inspection per ASME and API

• ASME Boiler and Pressure Vessel Code requirements including (Section VIII design, construction requirements, nameplate data verification)

• API 510 Pressure Vessel Inspection Code including (inspection intervals, thickness measurements, fitness-for-service, remaining life calculation)

• External inspection including (shell, heads, nozzles, supports, insulation, coatings, attachments, nameplate)

• Internal inspection including (surface condition, corrosion, erosion, cracking, deposit buildup, coating degradation, weld examination)

4.2 Tank Inspection per API Standards

• API 653 Tank Inspection, Repair, Alteration, and Reconstruction including (in-service inspection, internal inspection, thickness requirements, foundation)

• Atmospheric storage tank inspection including (shell courses, bottom, roof, nozzles, appurtenances, foundation settlement)

• Ultrasonic thickness testing including (UT equipment, grid pattern, minimum thickness, corrosion rate, remaining life calculation)

• Leak testing methods including (hydrostatic test, vacuum box, acoustic emission, tracer gas, visual observation)

4.3 Defect Recognition and Acceptance Criteria

• Crack detection including (visual examination, dye penetrant, magnetic particle, location significance, orientation, depth estimation)

• Corrosion measurement including (general thinning, localized pitting, depth measurement, remaining thickness, allowable limits)

• Weld defects including (lack of fusion, porosity, undercut, overlap, cracks, acceptance standards per ASME Section V)

• Deformation assessment including (dents, bulges, out-of-roundness, acceptance criteria, structural analysis requirements)

5. Rotating Equipment Inspection

5.1 Pump Inspection

• Pump types including (centrifugal, positive displacement, vertical turbine, submersible, application-specific)

• Pump casing inspection including (wear, corrosion, erosion, cracks, seal area, mounting, alignment marks)

• Impeller examination including (wear, cavitation damage, erosion, balance, clearances, coating condition)

• Shaft and bearing inspection including (wear, scoring, runout, coupling condition, bearing clearances, lubrication)

• Seal and packing assessment including (leakage, wear, proper installation, cooling/flush system, seal faces)

5.2 Motor and Drive Inspection

• Electric motor inspection per NEMA standards including (mounting, alignment, ventilation, electrical connections, grounding, insulation)

• Motor condition indicators including (temperature, vibration, noise, bearing condition, winding insulation resistance)

• Coupling inspection including (wear, alignment, guards, lubrication, bolting, clearances, runout)

• Belt and chain drive inspection including (tension, wear, alignment, guarding, sprocket/sheave condition, lubrication)

5.3 Compressor and Blower Inspection

• Compressor types including (reciprocating, rotary screw, centrifugal, axial, specific inspection requirements)

• External inspection including (foundation, vibration, alignment, piping supports, pulsation dampeners, cooling systems)

• Internal inspection including (cylinders, valves, pistons, rotors, bearings, clearances, wear patterns, deposits)

• Performance monitoring including (discharge pressure, temperature, flow, power consumption, efficiency trending)

6. Material Handling Equipment Inspection

6.1 Forklift and Industrial Truck Inspection

• OSHA 1910.178 requirements including (daily inspection, documented inspection, operator responsibility, defect reporting)

• Pre-operational inspection including (brakes, steering, controls, mast, forks, hydraulics, lights, horn, seatbelt)

• Fork inspection per ANSI B56.1 including (cracks, bends, wear, heel thickness reduction max 10%, mounting, positioning)

• Hydraulic system inspection including (leaks, cylinder condition, hose condition, oil level, control function, lift/lower operation)

• Battery inspection including (electrolyte level, connections, cable condition, charging equipment, ventilation, cleanliness)

6.2 Overhead Crane Inspection

• OSHA 1910.179 inspection requirements including (frequent inspection, periodic inspection, records, qualified person, deficiency correction)

• Structural components per ASME B30.2 including (bridge, trolley, end trucks, runway beams, supports, cracks, deformation)

• Hoist and trolley inspection including (wire rope, sheaves, drums, brakes, limit switches, electrical components, load testing)

• Wire rope inspection criteria including (broken wires per lay, wear, kinking, crushing, corrosion, lubrication, end terminations)

• Load testing requirements including (rated load testing, test weight, hold time, post-test examination, documentation, frequency)

6.3 Rigging and Lifting Accessories

• Sling inspection per ASME B30.9 including (wire rope, synthetic, chain, capacity verification, damage assessment, tagging)

• Shackle and hardware inspection per ASME B30.26 including (body cracks, pin condition, deformation, wear, capacity markings)

• Rejection criteria application including (specific damage limits, measurement requirements, when in doubt removal, competent person evaluation)

• Color coding and tagging including (capacity identification, inspection status, next inspection due, ownership, tracking)

7. Piping and Valve Inspection

7.1 Piping System Inspection

• API 570 Piping Inspection Code including (inspection planning, risk-based inspection, thickness monitoring, remaining life)

• Visual inspection including (external corrosion, insulation condition, support condition, vibration, leaks, coating)

• Thickness measurement locations including (straight runs, elbows, tees, reducers, downstream of injection points, corrosion susceptible areas)

• Support and hanger inspection including (loading, alignment, clearances, corrosion, functionality, spring hangers, guides, anchors)

• Expansion joint inspection including (bellows condition, tie rods, limit rods, anchors, guides, leaks, corrosion, cycling)

7.2 Valve Inspection and Testing

• Valve types including (gate, globe, ball, butterfly, check, relief, control, application-specific requirements)

• External inspection including (body condition, bonnet, stem packing, actuator, position indication, accessibility, identification)

• Operational testing including (stroke testing, opening/closing function, seat leakage, actuator response, limit switches, position indicators)

• Relief valve inspection per API 576 including (set pressure verification, discharge piping, corrosion, installation orientation, test requirements)

• Control valve inspection including (trim condition, actuator function, positioner calibration, packing leaks, response time, performance)

8. Heat Exchanger and Fired Equipment Inspection

8.1 Heat Exchanger Inspection

• Heat exchanger types including (shell and tube, plate and frame, air-cooled, spiral, specific inspection requirements)

• Tube bundle inspection per API 660 including (tube condition, tube-to-tubesheet joints, baffles, tie rods, tube plugging)

• Shell side inspection including (corrosion, erosion, deposits, nozzle condition, internal components, shell thickness)

• Tube testing including (eddy current testing, hydrostatic testing, air testing, leak detection, tube plugging criteria)

• Performance assessment including (heat transfer efficiency, pressure drop, fouling, vibration, temperature profiles)

8.2 Furnace and Heater Inspection

• API 560 Fired Heater Inspection including (tubes, refractory, burners, supports, stack, safety systems)

• Fired heater tube inspection including (external scaling, hot spots, bowing, bulging, thickness measurement, metallurgical damage)

• Refractory inspection including (cracking, spalling, erosion, hot spots, anchors, expansion joints, insulation effectiveness)

• Burner and combustion system including (burner tips, flame pattern, fuel supply, air registers, ignition system, flame detection)

• Draft and stack inspection including (draft measurement, stack condition, dampers, breeching, structural integrity)

9. Non-Destructive Testing (NDT) Overview

• NDT methods overview including (visual, ultrasonic, radiographic, magnetic particle, liquid penetrant, eddy current)

• Visual testing (VT) including (direct visual, remote visual, borescope, criteria per ASME Section V)

• Ultrasonic testing (UT) including (thickness measurement, flaw detection, weld examination, corrosion mapping, qualified technicians)

• Magnetic particle testing (MT) including (surface crack detection, ferromagnetic materials, wet versus dry method, acceptance criteria)

• Liquid penetrant testing (PT) including (surface-breaking defects, non-magnetic materials, dye versus fluorescent, developer application)

• Radiographic testing (RT) including (internal defects, weld quality, film versus digital, interpretation, qualified personnel)

• NDT technician qualification per ASNI/ASNT CP-189 including (Level I, Level II, Level III, certification, recertification)

10. Inspection Documentation and Record Management

10.1 Inspection Reporting

• Inspection report components including (equipment identification, inspection date, inspector, scope, findings, recommendations, next inspection)

• Deficiency description including (location, nature, dimensions, severity, photos, sketches, code references)

• Condition assessment including (satisfactory, minor deficiency, major deficiency, critical, immediate action required)

• Recommendation development including (repair, replace, monitor, re-inspect, testing, operational restrictions, timing)

• Approval and distribution including (responsible engineer review, management approval, maintenance notification, operations, regulatory submittal)

10.2 Record Keeping and Compliance

• Record retention per OSHA and API including (inspection reports, test results, repairs, modifications, minimum periods)

• Equipment files including (original specifications, drawings, inspection history, repair history, test results, certifications)

• Regulatory documentation including (ASME data reports, API inspection reports, OSHA compliance records, insurance requirements)

• Digital record systems including (database management, document scanning, searchability, backup, controlled access)

10.3 Inspection Scheduling and Tracking

• Risk-based inspection per API 580/581 including (probability of failure, consequence of failure, risk matrix, inspection planning)

• Inspection frequency determination including (regulatory requirements, manufacturer recommendations, operating conditions, inspection findings, risk assessment)

• Inspection scheduling systems including (calendar-based, operating hour-based, condition-based, automated reminders, work order integration)

• Overdue inspection management including (tracking, escalation, temporary restrictions, risk acceptance, compliance reporting)

11. Specialized Equipment Inspection

11.1 Pressure Relief Device Inspection

• Relief valve types per API 520/521 including (conventional, balanced bellows, pilot-operated, rupture disk, applications)

• API 576 Inspection of Pressure-Relieving Devices including (in-service inspection, removal criteria, testing requirements, set pressure verification)

• Visual inspection including (corrosion, damage, leaks, vent piping, installation orientation, discharge location, accessibility)

• Testing and certification including (pop test, set pressure verification, seat leakage, capacity verification, documentation, frequency typically 5 years)

11.2 Instrumentation and Control System Inspection

• Instrument inspection including (transmitters, gauges, switches, analyzers, calibration, condition, functionality)

• Control valve inspection including (actuator, positioner, I/P converter, limit switches, stroke testing, response time, performance)

• Safety instrumented systems per IEC 61511 including (proof testing, partial stroke testing, functional testing, failure rate, diagnostic coverage)

• Electrical component inspection including (junction boxes, conduit, wiring, grounding, area classification compliance, intrinsic safety)

11.3 Safety and Emergency Equipment

• Fire protection equipment including (extinguishers per NFPA 10, sprinkler systems per NFPA 25, fire pumps, detection systems)

• Emergency shower and eyewash per ANSI Z358.1 including (flow testing, accessibility, signage, activation, temperature, weekly activation)

• Emergency lighting and alarms including (battery backup, functionality, illumination levels, audibility, testing frequency)

• Personal protective equipment including (SCBA, gas detection, safety harnesses, rescue equipment, inspection, testing, certification)