Course Details

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

• Mechanical Engineers
• Maintenance Engineers
• Piping Engineers
• Plant Operators
• Inspection Personnel
• Reliability & Asset Integrity Staff

• 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 flange types and applications
• Select suitable gasket materials
• Apply correct bolting practices
• Identify common leakage causes
• Understand valve operation principles
• Improve piping system reliability

DAY 1

Fundamentals of Piping Flanges and Gaskets

• Piping system functions and the relationship between pipes, flanges, gaskets, fittings, and valves
• Pressure-containing components and piping system integrity
• Industry codes and standards: ASME, ANSI, API, ASTM, MSS, and ISO
• Flange functions, terminology, dimensions, and pressure-temperature ratings
• Types of flanges: Weld Neck, Slip-On, Socket Weld, Threaded, Lap Joint, Blind, Orifice, and Reducing Flanges
• Flange materials, corrosion considerations, and compatibility with process fluids
• Flange facing types: Raised Face (RF), Flat Face (FF), Ring Type Joint (RTJ), Tongue and Groove, and Male and Female
• Gasket functions, sealing mechanisms, compression, recovery, and leakage prevention
• Gasket types: non-metallic, metallic, semi-metallic, spiral wound, RTJ, kammprofile, jacketed, and sheet gaskets
• Gasket selection based on pressure, temperature, chemical compatibility, flange facing, service, and safety requirements
   

DAY 2

Flange Assembly, Bolting, Inspection and Maintenance

• Role of bolting in flange joints, bolt load, and gasket seating stress
• Stud bolts, machine bolts, bolt materials, specifications, nuts, and washers
• Flange joint design principles, load distribution, joint strength, and pressure containment
• Common causes of flange leakage and factors affecting joint reliability
• Joint preparation, pre-assembly inspection, gasket installation, alignment, and assembly procedures
• Bolt installation techniques and correct flange tightening sequences
• Torque tightening, cross-pattern and multi-pass tightening methods
• Hydraulic tensioning and controlled bolting practices for critical services
• Flange, gasket, bolt, and dimensional inspection with appropriate documentation
• Flange troubleshooting, preventive maintenance, leakage repair, gasket and bolt replacement, and safe disassembly practices

DAY 3

Valve Types, Operation, Maintenance and Troubleshooting

• Valve functions, classification, terminology, flow control, isolation, and regulation principles
• Valve types and operating principles: Gate, Globe, Ball, Butterfly, Plug, Needle, Diaphragm, Pinch, and Check Valves
• Safety Relief, Pressure Reducing, and Control Valves and their applications
• Valve construction: body, bonnet, trim, seats, seals, stems, packing systems, actuators, and accessories
• Valve material selection based on pressure, temperature, corrosion, erosion, and service requirements
• Manual, pneumatic, hydraulic, and electric actuation systems, including solenoids and positioners
• Valve sizing and selection fundamentals, including flow characteristics, pressure drop, Cv, and process requirements
• Valve installation, orientation, pre-startup inspection, functional testing, and commissioning
• Valve maintenance and troubleshooting: leakage, wear, corrosion, cavitation, flashing, packing, seats, and actuator problems
• Integrated flange, gasket, and valve reliability management, including leak prevention, reliability-centered maintenance, asset life extension, and industry case studies