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SE07

Practical Valve Technology:

Selection, Operation, Maintenance and Troubleshooting

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 a 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.

This five day course will address all aspects of Selection, Operation and Maintenance and Troubleshooting of industrial valves.         

Course Objectives

At the end of this seminar participants will have:  

• An understanding of different parameters affecting the operation of valves

• The ability to select the right valve for the particular application

• The ability to perform the necessary calculation for valve sizing

• An understanding of the problems associated with valves like flashing, slamming and water hammer

• The ability to perform troubleshooting of systems involving valves

• The ability to decide on the right maintenance plan concerning different types of valves

Training Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximise the amount and quality of information and knowledge transfer. Questions, comments and personal experience from every participant will have a chance to be heard and discussed. Tests of multiple-choice types will be made available on a daily basis to examine the effectiveness of delivering the course.

Case studies are encouraged to be brought by the participant. These case studies will be discussed thoroughly and will be shared by all participants.

Organizational Impact

Deep understanding of different types of valves would have a great impact on the plant reliability, operation stability and overall running cost reduction. Selection of the right valve for the appropriate application does have important impact on the processes quality.

Personal Impact

Safety and relief valves play a vital rule for the safety concerning equipment and personnel.

Competencies Emphasised

• Deepen the understanding of the function of different types of valves

• Understanding the characteristics of valves

• Ability to carry out the selection and sizing process

• Understand the problems and phenomenon associated with valves operation

• Ability to carryout troubleshooting of valves and systems that valves are connected to

Who Should Attend?

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

Course Outlines

Day 1 - Basics of the Valve Technology

Valves Technology

• Types of Valves

• Valves characteristics 

• Sealing performance

  • Leakage Criterion

  • Leakage Classifications

  • Sealing Mechanisms

  • Valve stem seals

• Flow characteristics

  • Flow through valves

  • Valve flow characteristics

• Linear & equal %

Manual Valves

• Functions of manual valves

• Methods of regulation

• Valve Types:

  • Stopping/starting valves

  • Control valves

• Valve end connections

• Valves rating

• Valves seating

• Types of manual valves

  • Gate Valves

  • Plug Valves

  • Ball Valves

  • Butterfly Valves

  • Pinch Valves

  • Diaphragm Valves

Check Valves

• Applications

• Types of Check Valves

  • Lift check valves

  • Swing check valves

  • Tilting-disc check valves

  • Diaphragm check valves

• Check Valves Operation

• Selection of Check Valves

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

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

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

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

  • Electrohydraulic Actuators

• Actuator Performance

• Valve Positioner

• Operation of Positioners

  • Positioner calibration

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 valves characteristics

• Examples