COURSE OVERVIEW:

Valve leakage testing and seat integrity verification are critical quality control processes that ensure the safety and efficiency of pressurized industrial systems. This course provides a comprehensive exploration of the technical standards and practical methodologies used to validate the sealing performance of various valve types. Participants will examine the mechanical factors that contribute to seat degradation and the specialized equipment required to detect even the most minute passage of fluid across a closed boundary.

The scope of this training encompasses the application of international testing standards, specifically API 598 and ANSI/FCI 70-2, which define the acceptable leakage rates for different service classes. We will investigate the nuances of hydrostatic and pneumatic shell testing, as well as the high-pressure seat tests required for critical isolation valves. The curriculum covers the setup and operation of valve test benches, emphasizing the importance of proper clamping, stabilization, and the use of calibrated measurement instrumentation to ensure repeatable and accurate results.

Coverage also includes the diagnostic interpretation of test failures and the corrective actions required to restore seat integrity through lapping and machining. By focusing on both bench testing in the workshop and in-situ testing in the field, the course provides a holistic view of valve performance verification. Through this detailed study, attendants will gain the expertise necessary to manage valve testing programs, certify equipment for service, and prevent the environmental and safety hazards associated with internal valve leakage.

COURSE OBJECTIVES:

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

1. Interpret international valve testing standards including API 598 and ISO 5208.
2. Differentiate between Class I through Class VI leakage rates as per ANSI/FCI 70-2.
3. Operate manual and automated valve test benches for various valve sizes.
4. Execute hydrostatic shell tests to verify the integrity of the valve body and bonnet.
5. Perform high-pressure and low-pressure seat leakage tests on isolation valves.
6. Evaluate the seat integrity of metal-to-metal versus soft-seated valve designs.
7. Conduct fugitive emission testing on valve packing and gaskets.
8. Diagnose the root causes of test failures such as misalignment or surface scoring.
9. Calibrate and maintain pressure transducers and flow meters used in testing.
10. Apply appropriate safety factors and relief settings during pneumatic testing.
11. Document test results through comprehensive certification and data logging.
12. Implement corrective maintenance techniques like seat lapping for failed valves.
13. Oversee the final inspection and tagging process for valves ready for field installation.

TARGET AUDIENCE:

This course is designed for Valve Technicians, Quality Control Inspectors, Maintenance Engineers, and Workshop Supervisors involved in the repair and certification of valves.

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.