COURSE OVERVIEW:

The purpose of this course is to provide a technical understanding of the relationship between control logic and the physical devices that manipulate process streams. While sensors detect change and controllers decide on action, the final control element—most often a valve—is the only component that actually performs work on the process. This program focuses on the mechanical and operational integrity of these elements, ensuring they respond accurately and reliably to control signals.

The scope of this training encompasses the diverse range of final control elements, including globe, ball, and butterfly valves, as well as variable speed drives and electric heaters. Participants will explore the mechanics of actuators, the role of digital positioners, and the impact of valve sizing on loop stability. The curriculum is specifically designed to address the critical interface where electronic signals are converted into mechanical movement within high-pressure and high-temperature environments.

Coverage includes the practical aspects of valve selection, actuator calibration, and the troubleshooting of mechanical failures like stiction and leakage. Attendees will learn how to interpret valve characteristics, maintain packing seals, and ensure that fail-safe positions are correctly implemented for safety. By focusing on the final stage of the control loop, the course ensures that participants can maintain the physical hardware that ultimately determines the success of process automation.

COURSE OBJECTIVES:

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

• Analyze the role of final control elements in a closed-loop system.
• Differentiate between sliding-stem and rotary control valves.
• Identify the components of pneumatic, hydraulic, and electric actuators.
• Configure and calibrate digital valve positioners (HART/Foundation Fieldbus).
• Interpret valve flow characteristics: Linear, Equal Percentage, and Quick Opening.
• Select appropriate valve packing and trim materials for specific fluids.
• Troubleshoot mechanical issues such as "Stiction," "Hunting," and "Dead-band."
• Implement fail-safe configurations (Fail Open, Fail Closed, Fail Last).
• Evaluate the impact of Cavitation and flashing on valve longevity.
• Perform stroke testing and seat leakage verification.
• Maintain Variable Speed Drives (VSD) as final control elements.
• Adhere to safety standards for pressurized valve maintenance.

TARGET AUDIENCE:

This course is intended for Maintenance Technicians, Mechanical Engineers, Instrumentation Staff, and Project 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.