Course Objectives

The purpose of this course is to improve technician performance both in practical terms and in
underpinning knowledge.

Course Description

The course will cover the subjects described on the enclosed syllabus. The course will comprise practical and theoretical instruction. The purpose of this course is to improve technician performance both in practical terms and in underpinning knowledge. Each trainee will benefit from the latest technologies, taught both practically and by formal lecture/demonstration.

Assessment will be by practical assignments and simulations. Valve positioners will also be taught along with split-range control systems. Each trainee will carry out the practical tasks of stroke checking a pneumatic valve, mounting a positioner and calibrating a positioner.

Who should attend

This course is aimed at those maintenance technicians that require knowledge of the maintenance aspects of a variety of valve types.

Pre-Requisites

All Attendees should have a sound power generation and electrical background.

Course Outcome

At the end of this course you will be able to maintain valves.

Course Outline

Day 1

• Introduction

Introduction to Control Valves

• Types of valves
• Globe valves and piston operated valves
• Needle valves
• Choke and throttling valves
• Solenoid valves
• Ball valves
• Butterfly valves (This is a brief introduction only)

Day 2

Types of Control Valves (operating details)

• Globe valves
• Cage guided globe valves
• Stem and post guided globe valves
• Ball valves
• V-notch ball segment valves
• Eccentric rotary plug valves
• Butterfly valves
• Eccentric disk butterfly valves

Selection Parameters

• Pressure ratings
• Pressure drop ratings
• Temperature ratings
• Material selection
• Capacity requirements
• Flow characteristics
• Shut-off
• Cavitation & flashing
• Noise considerations
• End connections
• Cost considerations
• Maintenance

Day 3

Valve Actuators

• Identify the parts of an actuator and valve assembly
• The actuator data plate

The Single Acting Positioner

• Identify the parts of a positioner
• Advantages of the positioner
• Using the manufacturers manual

Operation of a Pneumatic Diaphragm Valve & Positioner

• Direct and indirect operation
• Positioner operation
• The beam
• The bellows & flapper
• The cam
• The relay unit

Day 4

• Practical Task
  • Mount and stroke a valve actuator.
  • General maintenance procedure for a valve actuator
• Mount a Positioner
  • Using vendor manual, mount a positioner to the actuator.
  • Calibrate the positioner
  • General maintenance procedure for a valve positioner
• The Piston Operated Valve
  • Construction of a piston operated valve
  • Operation of a piston operated valve
  • General maintenance procedure for a piston operated valve
• Maintenance & Serviceability
  • Maintenance of globe valves
  • Maintenance of Rotary valves
  • Removal from pipeline for servicing a rotary valve
  • Separating the valve body from the actuator for servicing a globe valve
  • Other maintenance considerations

Day 5

• Other Types of Valves
  • The needle valve
  • Safety & relief valves
  • None return valves
  • Angle valves
  • Plug valves
  • Check valves
  • Gauge cock valve
  • Cryogenic valves
• Split Range Control
  • Reasons for using split range control
  • Furnace fuel control system
  • Advantages of split range control
• Valves & Safety
  • Fail safe positions
  • The solenoid valve
  • Air Fail Open and Air Fail Close valve systems
     

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