COURSE OVERVIEW:

Pressure Safety Valves (PSVs) are the most critical mechanical devices for overpressure protection, acting as the final safeguard against catastrophic vessel failure. This course provides a comprehensive guide to the lifecycle management of PSVs, from initial calibration and installation to periodic testing and repair. Participants will examine the internal mechanics of conventional, bellows, and pilot-operated valves to understand how they respond to system pressure changes.

The scope of this training involves the detailed application of international codes such as API 576 and ASME Section VIII. Attendees will learn the step-by-step procedures for bench testing, including the determination of set pressure, cold differential test pressure (CDTP), and seat tightness. The course emphasizes the importance of proper handling and transportation of valves, as well as the documentation required to maintain a compliant and auditable safety system.

Coverage includes the common failure modes of PSVs, such as leakage, sticking, and premature popping, along with their root causes. Participants will explore advanced maintenance techniques, including lapping of seats, spring inspection, and bellows replacement. By integrating mechanical precision with regulatory compliance, this course equips maintenance technicians and safety engineers with the skills to ensure that every relief device in the plant functions reliably when called upon.

COURSE OBJECTIVES:

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

1.  Explain the operational differences between PRVs, PSVs and Pilot-operated valves.

2.  Interpret nameplate data and manufacturing specifications for relief valves.

3.  Execute a professional bench test for set pressure and blowdown.

4.  Calculate Cold Differential Test Pressure (CDTP) for back-pressure conditions.

5.  Perform seat tightness testing according to API 527 standards.

6.  Identify common causes of valve simmer, chatter and leakage.

7.  Utilize specialized lapping tools to restore nozzle and disc surfaces.

8.  Evaluate the condition of springs and bellows during overhaul.

9.  Oversee the safe removal and installation of valves in a live plant.

10.  Manage a PSV database for tracking test intervals and history.

11.  Implement "In-situ" testing methods using Electronic Valve Testing (EVT).

12.  Conduct root cause analysis for valves that fail "as-found" tests.

13.  Formulate a comprehensive maintenance and spare parts plan for relief devices.

TARGET AUDIENCE:

Mechanical Technicians, Valve Shop Supervisors, Maintenance Engineers, Inspectors, and Process Safety Professionals.

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.