COURSE OVERVIEW:

The meaning of Pressure Relief Device (PRD) integrity refers to the guaranteed functionality of safety valves, rupture disks, and pilot-operated valves to protect pressurized equipment from overpressure events. This course provides a technical foundation for managing these critical safety elements, which are often the last line of defense in a process plant. By understanding the mechanical and operational factors that can cause a valve to fail to open, leak, or chatter, participants can develop a robust maintenance strategy that aligns with international safety standards and prevents catastrophic vessel ruptures.

The scope of the training encompasses the inspection, testing, and maintenance requirements outlined in API 576 and API 520/521. Participants will explore the various types of relief devices, their specific applications, and the environmental factors that lead to common failure modes such as corrosion, fouling, and spring fatigue. The course emphasizes the importance of the "as-found" pop test and the systematic documentation of test results to determine appropriate inspection intervals based on the reliability and historical performance of each device.

The coverage of the program is organized into eleven modules that follow the lifecycle of a PRD from selection and installation to shop overhaul and re-certification. Key topics include the identification of "Pre-installation" damage, the technical challenges of inspecting rupture disks, and the role of PRDs in a Risk-Based Inspection (RBI) framework. The course also addresses the practicalities of bench testing versus in-situ testing and provides a toolkit for troubleshooting valve leakage and instability. The program concludes with a focus on the regulatory requirements for record-keeping and the management of spare parts.

COURSE OBJECTIVES:

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

• Classify different types of Pressure Relief Devices and their operating principles.
• Apply the requirements of API 576 for the inspection of relief devices.
• Identify common failure modes: Leakage, stuck-shut valves, and premature opening.
• Evaluate the impact of process fluids on valve trim and spring integrity.
• Interpret "As-Found" test results to determine the health of the safety system.
• Understand the installation requirements to prevent chatter and inlet pressure loss.
• Analyze the pros and cons of conventional versus balanced bellows valves.
• Determine optimal inspection and testing frequencies using RBI principles.
• Manage the shop repair and overhaul process according to industry best practices.
• Utilize rupture disks in combination with relief valves for corrosive service.
• Perform root cause analysis on recurring PRD failures and "simmering" issues.
• Document inspection findings to satisfy jurisdictional and insurance requirements.

TARGET AUDIENCE:

This course is intended for Inspection Engineers, Valve Technicians, Maintenance Planners, Process Safety Professionals, and Reliability Engineers.

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.