COURSE OVERVIEW:

The mechanical integrity of valves, flanges, and bolted joints is the primary defense against fugitive emissions and catastrophic loss of containment in pressurized systems. This course provides a deep technical exploration of the engineering principles required to achieve and maintain leak-free connections in refineries, chemical plants, and power generation facilities. Participants will examine the complex interaction between gasket performance, bolt preload, and flange alignment, focusing on why joints fail even when high-quality components are utilized. The program emphasizes a holistic approach to joint integrity, moving beyond simple tightening to a comprehensive management of the entire sealing system.

The scope of this training involves a detailed analysis of valve sealing technologies and the structural mechanics of bolted flange assemblies. Coverage includes the selection of gaskets for extreme temperatures and pressures, the physics of "creep-relaxation" in bolting materials, and the critical importance of flange face condition. Participants will explore the diverse range of valve types—including gate, globe, ball, and check valves—and the specific integrity challenges associated with their stems, seats, and bonnets. The curriculum addresses the root causes of "passing" valves and flange leaks, providing practical solutions for troubleshooting and preventing recurrent failures in the field.

Detailed coverage is provided on the application of international standards such as ASME PCC-1 for pressure boundary bolted flange joint assembly and API 598 for valve inspection and testing. The course teaches participants how to develop and execute "controlled bolting" procedures using hydraulic torque and tensioning equipment. By analyzing case studies of joint failures and subsequent environmental and safety impacts, attendees will develop the technical proficiency to implement a robust "zero-leak" culture. The program concludes with strategies for managing joint integrity during large-scale turnarounds, ensuring that every connection is verified and documented as fit for service.

COURSE OBJECTIVES:

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

• Identify the critical components and sealing mechanisms of various valve types and flange assemblies.
• Explain the relationship between bolt load, gasket stress, and internal pressure containment.
• Detect and evaluate flange face damage, including pitting, grooving, and warping.
• Select appropriate gaskets and bolting materials based on process chemistry and temperature.
• Execute controlled bolting procedures using torque and tensioning tools per ASME PCC-1.
• Identify the root causes of valve seat leakage and stem packing failures.
• Evaluate the impact of flange misalignment and external piping loads on joint integrity.
• Implement a formal "Flange Tagging and Tracking" system for turnaround management.
• Apply NDT techniques to identify cracking or thinning in valve bodies and flange necks.
• Recognize the symptoms of "Galvanic Corrosion" and "Stress Corrosion Cracking" in bolting.
• Develop a proactive maintenance plan for critical valves to prevent "passing" and sticking.
• Coordinate the documentation and quality control for critical joint assemblies.

TARGET AUDIENCE:

This course is specifically designed for Mechanical Engineers, Piping Specialists, Maintenance Technicians, Turnaround Coordinators, and Reliability Engineers. It is also highly beneficial for Quality Assurance (QA/QC) Inspectors and Safety Officers who are responsible for ensuring the leak-free operation of pressurized systems and the prevention of fugitive emissions in high-hazard environments.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize 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.