COURSE OVERVIEW:

The purpose of this course focuses on the critical engineering and operational principles of final control elements, which are the physical components that execute the commands of a control system. In any automated process, the control valve and its associated actuator act as the "hands" of the system, directly modulating the flow of fluids to maintain process stability. This program provides a comprehensive technical foundation for understanding how these mechanical assemblies respond to electronic signals to manage pressure, flow, and temperature in demanding industrial environments.

The scope of this training encompasses the selection, sizing, and maintenance of various valve types, including globe, ball, butterfly, and plug valves, alongside their pneumatic, hydraulic, and electric actuators. Participants will explore the physics of fluid flow through a valve, addressing complex phenomena such as cavitation, flashing, and aerodynamic noise. The curriculum is designed to provide practical insights into how different trim designs and material selections impact the longevity and performance of the valve under high-pressure and corrosive conditions.

Coverage includes the advanced integration of smart positioners and digital accessories that enable predictive maintenance and real-time diagnostics. Attendees will learn the systematic procedures for valve calibration, bench-set adjustment, and troubleshooting of common mechanical failures like stiction and hysteresis. By focusing on both the mechanical hardware and the digital interface, the course ensures that participants can optimize the reliability of final control elements to enhance overall plant safety and efficiency.

COURSE OBJECTIVES:

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

• Analyze the fundamental role of final control elements in a closed-loop system.
• Differentiate between various valve body types and their specific applications.
• Select appropriate valve trim and materials for erosive and corrosive services.
• Calculate valve flow coefficients and perform accurate valve sizing.
• Evaluate and mitigate the effects of cavitation and flashing in control valves.
• Compare the performance of pneumatic, hydraulic, and electric actuators.
• Configure and calibrate smart digital valve positioners for precision control.
• Implement fail-safe strategies and select appropriate failure modes.
• Troubleshoot mechanical issues such as seat leakage and packing friction.
• Utilize diagnostic signatures to predict valve wear and internal damage.
• Apply international standards (ANSI/ISA, IEC) to valve specification and testing.
• Develop comprehensive maintenance and overhaul plans for control valve assemblies.

TARGET AUDIENCE:

This course is intended for Instrumentation Engineers, Mechanical Maintenance Technicians, Process Control Specialists, and Reliability Engineers responsible for the selection and upkeep of control valves and actuators.

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.