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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 on 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

• To introduce the participant to different type of Control Valves and Safety Relief Valves.
• To familiarize the participant with the valve characteristics including the valve tightness class and the flow characteristics
• To upgrade the participants understanding of the application, operation and design of different types of valves
• To provide skills, knowledge and understanding of the principles and practices of the related Codes and Standards related to Control Valves and Safety Relief Valves
• To learn the methods for valve selection, specifications and sizing that suit a particular application
• To learn methods of valve testing, inspection and troubleshooting based on the industrial and manufacturer codes and standards

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

$5,250 per attendee including training material/handouts, morning/afternoon coffee breaks and Lunch.