Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical and Maintenance Engineers
• Process and Operations Engineers
• Inspection and Reliability Engineers
• Maintenance Technicians and Supervisors
• Pressure Vessel and Piping Engineers
• Anyone responsible for safety valve operation, inspection, or maintenance

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

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

• Understand the principles and design of safety and relief valves
• Identify valve types, components, and functions
• Perform inspection, maintenance, and testing in accordance with standards
• Troubleshoot valve problems and identify causes of malfunction
• Apply proper procedures for disassembly, repair, and reassembly
• Ensure reliability and compliance with safety and quality regulations

DAY 1

Introduction to Safety and Relief Valves

• Welcome and Introduction
• Pre-Test
• Purpose and Function of Pressure Relief Devices
• Types of Safety and Relief Valves and Their Applications
• Basic Design and Operating Principles
• Key Components and Flow Paths
• Applicable Standards and Codes (ASME, API, ISO)
• Safety Considerations in Valve Operation

DAY 2

Valve Design, Sizing and Selection

• Principles of Pressure Relief and Set Pressure Control
• Sizing Calculations and Flow Capacity Determination
• Material Selection and Compatibility
• Valve Selection for Liquids, Gases, and Steam Service
• Installation Requirements and Piping Configurations
• Overpressure Protection Scenarios
• Documentation and Certification Requirements

DAY 3

Inspection, Testing and Maintenance Procedures

• Visual and Functional Inspection Procedures
• In-Service and Bench Testing of Relief Valves
• Calibration and Set Pressure Adjustment
• Leakage Testing and Seat Tightness Evaluation
• Preventive Maintenance Planning
• Common Maintenance Errors and How to Avoid Them
• Recordkeeping and Test Documentation

DAY 4

Troubleshooting and Repair Techniques

• Common Safety Valve Problems and Their Causes
• Chattering, Leakage, and Improper Lift Issues
• Disassembly, Cleaning, and Reassembly Procedures
• Lapping, Seat Grinding, and Component Replacement
• Workshop Repair Best Practices
• Root Cause Failure Analysis (RCFA) for Recurrent Issues
• Safety Precautions During Repair and Testing

DAY 5

Operational Reliability

• Best Practices for Reliability and Performance Assurance
• Integration with Plant Safety and Maintenance Programs
• Case Studies of Valve Failures and Lessons Learned
• Post-Test
• Certificate Ceremony