Course Details

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

• Maintenance Engineers
• Mechanical Engineers
• Reliability Engineers
• Plant Supervisors
• Maintenance Technicians
• Operations Personnel

• 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 will be able to:

• Understand valve types and applications
• Identify valve components and failure modes
• Perform valve inspection and condition assessment
• Apply maintenance and repair techniques
• Troubleshoot common valve problems
• Improve valve reliability and performance
• Maintain actuators and accessories
• Implement valve maintenance best practices
• Optimize maintenance planning and documentation
• Enhance plant safety and asset integrity management

DAY 1

Fundamentals of Industrial Valves and Maintenance Principles

• Functions, Applications, and Classification of Industrial Valves 
• Valve Terminology, Standards, and Industry Codes 
• Gate, Globe, Ball, Butterfly, Plug, and Check Valves 
• Control, Pressure Relief, and Safety Valve Applications 
• Valve Materials of Construction and Selection Criteria 
• Valve Components, Internal Parts, and Actuator Types 
• Common Valve Failure Mechanisms and Root Causes 
• Corrosion, Erosion, Cavitation, Flashing, and Wear 
• Valve Inspection and Condition Assessment Techniques 
• Preventive, Predictive, and Corrective Maintenance Strategies

DAY 2

Valve Maintenance, Repair, and Overhaul Techniques

• Maintenance Requirements for Gate, Globe, Ball, and Butterfly Valves 
• Maintenance Requirements for Plug, Check, Diaphragm, and Pinch Valves 
• Maintenance Requirements for Pressure Relief and Safety Valves 
• Valve Disassembly, Component Inspection, and Repair Procedures 
• Packing, Gland, Mechanical Seal, and Leakage Prevention Techniques 
• Seat Leakage Analysis, Lapping, and Seat Refurbishment 
• Stem Repair, Alignment, Gasket Replacement, and Fastener Torque 
• Valve Reassembly, Functional Testing, and Leak Testing 
• Pneumatic, Hydraulic, and Electric Actuator Maintenance 
• Positioners, Solenoids, Limit Switches, and Field Repair Considerations

DAY 3

Advanced Valve Maintenance, Diagnostics, and Reliability Improvement

• Valve Reliability, Performance Optimization, and Condition Monitoring 
• Advanced Valve Diagnostics, Signature Analysis, and Performance Trending 
• Control Valve Calibration, Troubleshooting, Stiction, and Hysteresis 
• Actuator Calibration and Troubleshooting of Instrument Air Problems 
• Troubleshooting Leakage, Cavitation, Noise, Vibration, and Passing Valves 
• Safety Relief Valve Performance, Fugitive Emissions, and Compliance 
• Maintenance KPIs, Reliability Metrics, and Quality Assurance 
• Risk-Based Inspection, Reliability-Centered Maintenance, and Asset Integrity 
• Spare Parts Optimization, Maintenance Documentation, and Lifecycle Cost 
• Smart Valve Technologies, Shutdown/Turnaround Practices, and Failure Case Studies