Course Details

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

• Mechanical, Maintenance, and Process Engineers
• Plant and Utilities Engineers
• Instrumentation and Control Technicians
• Maintenance Supervisors and Technicians
• Operations and Reliability Personnel
• Anyone involved in valve selection, operation, 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 functions of different types of valves
• Identify key valve components and materials of construction
• Select appropriate valves for various applications and operating conditions
• Perform valve inspection, maintenance, and testing procedures
• Troubleshoot common valve problems and prevent premature failures
• Apply safety and reliability practices in valve operation and maintenance

DAY 1

Introduction to Valves and Their Applications

• Welcome and Introduction
• Pre-Test
• Role of Valves in Process and Utility Systems
• Basic Flow Control Principles
• Classification of Valves – Isolation, Control, and Check
• Valve Standards and Specifications (API, ASME, ISO)
• Terminology and Operating Characteristics

DAY 2

Valve Types, Design and Construction

• Gate, Globe, Ball, Plug, and Butterfly Valves
• Check Valves and Non-Return Valves
• Pressure Relief and Safety Valves
• Control Valves and Actuators
• Valve Body, Trim, and Sealing Elements
• Materials of Construction and Service Compatibility
• Flow Coefficients (Cv, Kv) and Sizing Basics

DAY 3

Valve Operation and Installation

• Manual, Pneumatic, Hydraulic, and Electric Actuation
• Valve Installation Requirements and Alignment
• Torque, Bolting, and Flange Connections
• Start-up and Shutdown Considerations
• Testing and Commissioning Procedures
• Leak Testing and Seat Tightness Verification
• Safety and Lockout Procedures

DAY 4

Valve Maintenance and Inspection

• Routine Inspection and Preventive Maintenance
• Packing, Gasket, and Seal Replacement
• Stem and Bonnet Maintenance
• Corrosion, Erosion, and Wear Prevention
• Valve Calibration and Adjustment Procedures
• Maintenance Documentation and Records
• Extending Service Life Through Proper Practices

DAY 5

Troubleshooting and Reliability Improvement

• Common Valve Problems and Their Causes
• Leakage, Sticking, and Seat Damage Analysis
• Troubleshooting Techniques and Diagnostic Tools
• Root Cause Failure Analysis (RCFA) for Valves
• Best Practices for Reliability and Safety Improvement
• Post-Test
• Certificate Ceremony