COURSE OVERVIEW:

Valve technology is a cornerstone of process engineering, dictating the flow, pressure, and safety of industrial operations across the globe. This comprehensive course provides a 360-degree view of the valve lifecycle, ranging from the fundamental engineering principles of design and material selection to advanced field troubleshooting. Participants will examine the diverse array of valve architectures, including gate, globe, ball, butterfly, and check valves, analyzing how their mechanical configurations suit specific process conditions and fluid types.

The scope of this training extends deeply into the technical criteria for valve selection, emphasizing the importance of Cv values, pressure drops, and cavitation resistance. We will investigate the intricacies of valve actuation, focusing on the synchronization of pneumatic, hydraulic, and electric systems with the plant’s control architecture. The curriculum covers rigorous inspection protocols and non-destructive testing (NDT) methods used to identify internal erosion, corrosion, and structural fatigue before they lead to operational failure.

Coverage also includes systematic maintenance strategies and the troubleshooting of common malfunctions such as stem leakage, seat bypass, and actuator hunting. By focusing on the integration of smart valve positioners and digital diagnostics, the course ensures that participants are equipped to handle the modern "smart" plant environment. Through this intensive study, attendants will gain the expertise necessary to optimize valve performance, extend service intervals, and make informed decisions that enhance the overall reliability of the piping system.

COURSE OBJECTIVES:

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

1. Categorize all major valve types based on their function and design.
2. Apply engineering formulas to calculate Valve Flow Coefficients (Cv).
3. Select appropriate valve materials for corrosive, cryogenic, and high-temperature service.
4. Evaluate the performance characteristics of linear versus rotary valves.
5. Design and size valve actuators for specific torque and thrust requirements.
6. Implement comprehensive valve inspection programs using visual and NDT methods.
7. Diagnose and mitigate the effects of cavitation, flashing, and noise in valves.
8. Troubleshoot control valve instabilities and positioner calibration issues.
9. Execute precision maintenance tasks, including packing replacement and seat lapping.
10. Manage the transition from manual to automated valve systems.
11. Apply international standards such as API, ASME, and MSS for valve procurement.
12. Analyze valve failure modes through Root Cause Analysis (RCA).
13. Develop a risk-based maintenance schedule for a plant's valve population.

TARGET AUDIENCE:

This course is designed for Mechanical Engineers, Maintenance Managers, Process Engineers, Piping Designers, and Instrumentation Technicians responsible for valve assets.

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.