COURSE OVERVIEW:

Pressure Safety Valves (PSVs) are the final line of defense in protecting pressurized systems from catastrophic overpressure events. This course provides a technical deep-dive into the mechanical principles and regulatory requirements governing the maintenance, testing, and overhauling of these critical safety devices. Participants will explore the intricate internal mechanics of direct-acting and pilot-operated valves, understanding how seat tightness and spring rates impact the valve’s ability to open and close at precise set points.

The overhauling phase of the training emphasizes the precision required to restore a PSV to its original manufacturer specifications. The scope includes the disassembly of high-pressure valve bodies, the inspection of nozzles and discs for microscopic defects, and the advanced techniques for lapping seats to achieve a "bubble-tight" seal. Participants will learn how to handle different types of media, including steam, gas, and liquid, and the specific challenges each presents during the reconditioning process.

Testing and certification form the core of the final phase, ensuring that every valve complies with international standards such as ASME Section VIII and API 527. Coverage includes the use of test benches for cold differential test pressure (CDTP) verification and the documentation required for statutory compliance. By the end of this course, attendants will be equipped to manage the entire lifecycle of a PSV, from initial diagnostic testing to the final stamping and installation, ensuring maximum plant safety.

COURSE OBJECTIVES:

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

1.  Explain the fundamental differences between Relief Valves, Safety Valves, and Safety Relief Valves.

2.  Identify all internal components of a spring-loaded PSV and their functions.

3.  Conduct a pre-overhaul "As-Found" pop test to determine valve condition.

4.  Execute the disassembly and cleaning of valves according to manufacturer guidelines.

5.  Inspect valve parts for corrosion, erosion, and mechanical fatigue.

6.  Perform precision seat lapping to achieve API 527 leakage standards.

7.  Calculate the Cold Differential Test Pressure (CDTP) based on operating conditions.

8.  Adjust the blowdown ring to achieve the correct opening and closing characteristics.

9.  Troubleshoot the causes of "Simmering," "Chattering," and "Bellows failure."

10.  Utilize specialized test benches for nitrogen and water testing.

11.  Manage the maintenance and testing of pilot-operated safety valves.

12.  Document all repair and test data for statutory audit requirements.

13.  Apply the safety protocols for handling heavy valves and high-pressure test media.

TARGET AUDIENCE:

Valve Technicians, Maintenance Engineers, Safety Inspectors, and Quality Control Personnel responsible for the integrity of pressure-relieving systems.

TRAINING COURSE METHODOLOGY:

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