Course Details

Objective

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

• Understand the importance of valve maintenance in industrial operations and safety.
• Learn the proper procedures for inspecting, maintaining, and repairing different types of valves.
• Gain knowledge of the safety protocols associated with valve maintenance.
• Be familiar with common hazards related to valve operations and how to mitigate them.
• Understand relevant industry regulations and standards for safe valve maintenance.

Content

Day 1: Introduction to Valve Maintenance and Safety

• Overview of valves and their role in industrial systems
• Types of valves: gate, globe, ball, check, and pressure relief valves
• Key components of a valve and how they function
• Safety risks associated with valve maintenance and handling
• Safety regulations and standards in valve maintenance (e.g., OSHA, ANSI, ASME)

Day 2: Valve Inspection and Maintenance Procedures

• Valve inspection procedures: visual checks, testing for leaks, and performance evaluations
• Common wear and failure modes of valves (e.g., corrosion, erosion, fouling)
• Maintenance techniques for extending valve lifespan
• Lubrication and seal replacement for valves
• Tools and equipment required for safe valve maintenance

Day 3: Safe Valve Operation and Troubleshooting

• Safe operation and isolation procedures during valve maintenance
• Troubleshooting common valve issues: leakage, sticking, noise, and vibration
• Step-by-step procedures for valve disassembly, cleaning, and reassembly
• Pressure testing and seat testing procedures for valves
• Handling hazardous fluids and materials during valve maintenance

Day 4: Hazard Identification and Risk Mitigation

• Identifying potential hazards associated with valve maintenance (e.g., chemical spills, leaks, pressure surges)
• Personal Protective Equipment (PPE) requirements for safe valve maintenance
• Lockout/Tagout (LOTO) procedures during valve maintenance
• Proper handling and disposal of hazardous materials
• Emergency response plans and first aid for valve-related accidents

Day 5: Industry Standards, Compliance, and Case Studies

• Understanding industry standards for valve maintenance safety (e.g., API, IEC, ISO)
• Regulatory requirements and compliance in valve maintenance (e.g., environmental, health, and safety laws)
• Developing and implementing a valve maintenance safety program
• Continuous improvement and safety audits in valve maintenance procedures

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions