COURSE OVERVIEW:

Safety relief valves (SRVs) are the final line of defense in processed plants, designed to protect life, property, and the environment by preventing catastrophic overpressure events. Because they remain idle for long periods and are only called upon during emergencies, their reliability must be absolute. This course provides a comprehensive technical overview of the design, function, and regulatory requirements of SRVs, ensuring that participants understand the critical nature of these devices and the precision required for their maintenance and testing.

The scope of this course covers the mechanical principles of spring-loaded, pilot-operated, and weight-loaded relief valves. Participants will explore the nuances of "set pressure," "blowdown," and "accumulation," learning how these parameters are dictated by ASME and API codes. The Coverage includes a detailed look at the internal components—such as the nozzle, disc, and adjusting ring and how small amounts of wear or corrosion on these surfaces can lead to simmering, leaking, or failure to open.

Furthermore, the course emphasizes the practical aspects of inspection and repair in a workshop environment. Attendees will learn how to perform "pre-pop" testing, disassembly, lapping of seating surfaces to optical flatness, and final calibration on test benches. Troubleshooting common issues such as "chatter," which can destroy a valve in seconds, is a key component of the curriculum. By the end of this program, participants will be equipped to manage the entire lifecycle of a safety relief valve, ensuring compliance with statutory inspection intervals and maintaining the highest safety standards in their facilities.

COURSE OBJECTIVES:

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

1. Define the role and importance of pressure relief devices in process safety.
2. Differentiate between Safety Valves, Relief Valves, and Safety Relief Valves.
3. Identify the internal components and operation of spring-loaded SRVs.
4. Explain the advantages and operation of pilot-operated relief valves.
5. Apply ASME Section VIII and API 520/526/527 standards to valve tasks.
6. Conduct thorough visual inspections for corrosion, fouling, and mechanical damage.
7. Perform disassembly and cleaning procedures for various valve types.
8. Execute precision lapping of seats and discs using optical flats for verification.
9. Troubleshoot common SRV problems such as leakage, simmering, and chattering.
10. Calculate and adjust "blowdown" and "cold differential test pressure" (CDTP).
11. Perform seat tightness testing according to API 527 standards.
12. Manage SRV documentation, including nameplate data and maintenance history.
13. Organize and conduct "pre-pop" testing to evaluate as-found conditions.
14. Ensure safe installation and piping practices to prevent backpressure issues.

TARGET AUDIENCE:

This course is intended for Valve Technicians, Maintenance Engineers, Plant Inspectors, Safety Officers, and Operators responsible for the integrity of pressure-containing 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.