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Introduction

Power Plant and other petrochemical industries do deal with different types of valves. All piping systems are fitted with valves for controlling purposes or safety requirements. Understanding the function of each valve type will have an important reflection on the process quality, equipment and plant reliability, and the economics of the whole activity. Different application needs to select the appropriate valve type of particular flow characteristics. Operation of the valve also affects the system and the process. Understanding the problems associated with valves is essential for diagnosis and troubleshooting and the needed maintenance for the particular type of valves.

Valves can be classified as manual or control valves. When a manual valve is operated via an actuator it becomes a control valve. Valves in general do control the rate of flow in a piping system, the direction of the flow, or act as a relieving device to protect the system from overpressurization. Valves like check valves would prevent the flow from reversing, thus protecting equipment from reverse flow. Such valves operated automatically without need for any type of actuation. Stop and close valves used mainly to isolate a system in situation of maintenance and/or putting the standby equipment in services. The function of a valve is what determines its design. The right selection of a valve in terms of its type and size, and its pressure class is what affect most the stability and reliability of the system. The nature of the fluid, the type of the process, the level of temperature and pressures are parameters affecting the valve selection.The flow through a valve will experience different effects, like cavitation, flashing, and noise. Water hammer is one of the effects that a check valve may cause. Such phenomenon might lead to different kind of problems, some would affect directly the valve itself and other might upset the process as a whole or result in system erosion or corrosion. Vibration and instrumentation false function could also be a result of faulty valve. Some of these problems can be avoided in the stage of selection and sizing of the valve. Others could be eliminated in the process of writing the specifications and through good communications with manufacturer or vendor. Understanding these different types of problems will help troubleshooting the valves and the systems and help curing the problems. Wrong installations could be the reason behind many of valves problem too.

Objective

Audience

Engineers and Technicians of mechanical, electrical and chemical engineering background will benefit largely from this workshop. Maintenance, Operation, people in workshop and R and D personnel are recommended to attend this course.

Content

The following topics including the valve technology, valve tightness and flow characteristics, control valves and safety relief valves types, operation and troubleshooting will be cover during the five-day duration of the course. 

Basics of Valve Technology

Ch 1 Valves Technology

Types of Valves 

Valves characteristics 

Sealing performance

Leakage Criterion

Leakage Classifications

Sealing Mechanisms

Valve stem seals

Flow characteristics

Flow through valves

Valve Characterizing Coefficients

Valve flow characteristics

Linear & equal %

Control Valves

Ch 2 Control Valves

  Functions of manual valves

  Methods of regulation

  Types of control valves

  Gate Valves

  Plug Valves

  Ball Valves

           Butterfly Valves

           Pinch Valves

           Diaphragm Valves

Ch 3 Control Valves & Actuators

Control Valves Types

Linear Valve Features

Rotary Valve Features

Control Valve Flow Characteristics

Quick Opening Characteristics

Linear & Equal %

Actuation systems

Types of actuators

Pneumatic Piston Actuator

Electric motors

Electro-hydraulic Actuators

Actuator Performance

Valve Positioner

Operation of Positioners

Positioner calibration

           Self Operated Valves

Ch 4 Check Valves

  Applications

  Types of Check Valves

           Lift check valves

           Swing check valves

           Tilting-disc check valves

           Diaphragm check valves

           Check Valves Operation

  Water Hammer

  Selection of Check Valves

Ch 5 Relief and Safety Valves

  Relief Valves Types

           Pressure-relieving devices

Automatically operated valves

Direct-acting & piloted pressure relief valves

Modulating, full-lift, and ordinary pressure relief valves

  Valve Loading

  Safety Valves

  Operation of Direct-acting pressure relief valves

  Blowdown

Relief valves problems

Ch 6 Rupture Valves

  Applications of Rupture Discs

  Rupture discs vs. Pressure relief valves

  Rupture discs in gases and liquid service

  Temperature and bursting pressure relationship

  Pressure tolerances

  Design and performance of ductile metal rupture discs

  Types of Rupture discs:

Prebulged rupture discs

  Reverse buckling discs

  Vent panels

  Graphite rupture discs

  Double disc assemblies

  Rupture disc and pressure relief valve combinations

  Selection of rupture discs

  Operation of Rupture Discs

Ch 7 Valve Sizing & Selection

  Valve-sizing criteria for manual valves

  Valve-sizing criteria for check valves

  Valve-sizing criteria for throttling valves

  Incipient and advanced cavitation

  Terminal pressure drop ratio

  Percent of Flashing

  Pressure Recovery Coefficient

  Valve Sizing & Selection Procedure

  Selecting a valve type

  Different valve characteristics

  Examples

Ch 8 Valves Problems and Troubleshooting

  High Pressure Drop

  Pressure Recovery Characteristics

  Cavitation in Valves

  Incipient and choked cavitation

  Flow curve cavitation index

  Cavitation-elimination devices

  Flashing versus Cavitation

  Flow Choking

  High Velocities

  Water Hammer

  What causes water hammer?

  Water Hammer Calculations

  Solutions for water hammer

          Surge Protection

  Check valve slamming

  Noise problems

  Clean air standards

  Life loading

  Packing for fugitive-emission control

Troubleshooting the Control Valves

Certificate

MAESTRO CONSULTANTS Certificate of Completion for delegates who attend and complete the training course.

Methodology

Our courses are highly interactive, typically taking a case study approach that we have found to be an effective method of fostering discussions and transferring knowledge. Participants will learn by active participation during the program through the use of individual exercises, questionnaires, team exercises, training videos and discussions of “real life” issues in their organizations.
The material has been designed to enable delegates to apply all of the material with immediate effect back in the workplace.

Fees

$4000