Maintenance of ON/OFF and Control Valves

Course Introduction

Grab the opportunity to attend an exciting Process Control Valves and Actuators training course that equips you with all the necessary knowledge to enter the world of valves and actuators. This training course is highly interactive, and is suitable for all delegates, regardless of their background. Whether you are part of the team purchasing the valves, or a key member involved in implementing maintenance activities, or a process control specialist, this is the one training course that you should not miss out on! Valves, actuators, associated equipment, process control using valves – this and much, much more are covered in 5 knowledge-filled days.

The Process Control Valves and Actuators training course focuses on applications and examples deemed to be relevant to your industry and is cognizant of your working environment. At least 50% of the training course is devoted to practical exercises and discussions, to keep attention spans at optimal levels.

This training course will feature:

• Essentials of control valves
• Actuators and associated valve equipment
• Theoretical and practical sizing aspects
• Selection, installation and maintenance essentials
• Tuning and optimizing a process using control valves

Objectives

By the end of this training course, participants should be able to:

• Comprehend valve operation
• Understand and appreciate assorted common valve types
• Size and select the correct valve set (including actuators), suited to each specific application
• Choose suitable positioners, based on prevailing conditions
• Use multiple techniques to tune a valve-controlled process

Training Methodology

This training course starts off from basics and builds up to an advanced level, as far as control and using valves and actuators, are concerned. None-the-less, it is presented in such a way that even total novices will feel comfortable from the very beginning. No-one is left behind and the instructor takes pride in guiding all delegates along the way, with personal assistance, where required.

Delegates are encouraged to keep an open mind and to immerse themselves in all exercises and discussions, to ensure that maximum learning takes place. Preference will always be given to applications and examples that tie up with the working environment encountered by the delegates.

Target Audience

It is irrelevant whether delegate valve knowledge and experience ranges from novice to advanced. The training course starts from first principles, and builds up, with the emphasis on delegate participation. Instructor guidance is delivered on a personal level, and delegates are encouraged to ask as many questions as necessary.

This training course is suitable to a wide range of professionals but will greatly benefit:

• Instrumentation, electrical, mechanical, process and maintenance engineers, specialists and staff
• Management
• Design teams
• Budgeting and financial staff
• Team leaders, supervisors and foremen

Daily Topics

Day 1: Introduction to Valve Types and Operation

    Overview of Valve Types

        ON/OFF valves: globe, ball, gate, and butterfly valves.

        Control valves: pressure-reducing, pressure-relief, flow-control, and modulating valves.

        Key differences between ON/OFF and control valves in industrial applications.

    Basic Principles of Valve Operation

        Understanding the working principles of ON/OFF and control valves.

        Valve actuation: manual, pneumatic, electric, and hydraulic actuators.

        Function of control valves in process control systems (e.g., PID loops).

        Valve components: body, seat, stem, disc, actuator, positioner, and seals.

    Common Valve Materials and Applications

        Valve materials: carbon steel, stainless steel, brass, and special alloys.

        Understanding the compatibility of materials with different fluids and environments.

        Applications of valves in various industries: oil and gas, water treatment, HVAC, and power plants.

Day 2: Valve Maintenance Fundamentals

    Routine Maintenance and Inspection Procedures

        Importance of regular valve maintenance and inspections.

        Safety protocols during valve maintenance.

        Valve condition monitoring: visual inspection, torque testing, and seat leakage testing.

        Cleaning and lubrication practices for extending valve life.

    Common Valve Failures and Troubleshooting

        Identifying valve failure modes: leakage, sticking, cavitation, and noise.

        Causes of valve failures: corrosion, erosion, wear, and improper installation.

        Troubleshooting techniques for common valve issues.

    Hands-on Session: Valve Disassembly and Inspection

        Participants will disassemble a sample valve and perform an initial inspection.

        Identification of wear, damage, and parts requiring replacement.

Day 3: Control Valve Maintenance and Calibration

    Maintenance of Control Valves

        Types of control valves: globe valves, ball valves, and diaphragm valves.

        Actuator and positioner maintenance: calibration, cleaning, and testing.

        Valve seat and seal maintenance: checking for wear and replacing seals.

        Understanding control valve loops: calibration and tuning for optimal performance.

    Control Valve Troubleshooting

        Diagnosing control valve performance issues: erratic control, excessive noise, and instability.

        Techniques for testing control valve response: stroke time, hysteresis, and dead time.

        Calibrating controllers and positioners for better control accuracy.

    Hands-on Session: Control Valve Calibration and Adjustment

        Participants will practice calibrating control valves and positioners.

        Troubleshooting exercises to identify and resolve control valve issues.

Day 4: Preventive and Corrective Maintenance of ON/OFF Valves

    ON/OFF Valve Maintenance

        Preventive maintenance strategies for gate, ball, and butterfly valves.

        Stem and seat inspection: checking for wear and preventing leakage.

        Repair and replacement of valve seats, seals, and packing.

        Actuator maintenance for ON/OFF valves: inspecting electric, pneumatic, and hydraulic actuators.

    Corrective Maintenance Procedures

        Strategies for dealing with valve failures: diagnosing root causes and implementing corrective actions.

        Handling valve seat leakage, stem damage, and actuator failure.

        Rebuilding and refurbishing valves to restore functionality.

    Hands-on Session: Preventive Maintenance of ON/OFF Valves

        Participants will perform preventive maintenance on ON/OFF valves, including seat inspection, actuator checks, and seal replacements.

Day 5: Advanced Troubleshooting and Performance Optimization

    Advanced Troubleshooting Techniques

        Using diagnostic tools and instruments for valve troubleshooting: valve positioners, controllers, and field transmitters.

        Identifying and resolving issues with valve actuation: speed, accuracy, and response time.

        Optimizing valve operation to minimize wear and tear.

    Performance Optimization

        Enhancing the performance of control and ON/OFF valves through better maintenance practices.

        Best practices for optimizing valve longevity and reducing the frequency of failures.

        Leveraging condition monitoring and predictive maintenance technologies for valves.

    Final Hands-on Session: Complete Valve Overhaul

        Participants will perform a complete valve overhaul, including disassembly, inspection, troubleshooting, reassembly, and testing.

    Course Review and Certification

        Recap of key concepts and techniques learned during the course.

        Final assessment of participants’ skills in valve maintenance and troubleshooting.

        Certification awarded to successful participants.

For registration & more information please contact

NAYEL Training Centre 

T: +971 4 379 7245 | M: +971 50 249 6876 WhatsApp +971 50 249 6876

Email [email protected]