Safety Relief Valve Sizing, Selection, Operation, Inspection, Maintenance and Troubleshooting (PRV and POPRV/PORV): API 520/521/526/527

Introduction

This hands-on, highly-interactive course includes various practical sessions and exercises. Theory learnt in the class will be applied using the following practical methods:-

• Industrial Facility Visit: Course participants will be taken to an industrial facility where they will practice valve dismantling, assembling, inspection and testing. In case that this course is organized inside client premises (In-House), then the client shall provide access to its valve workshop for practical sessions.
• Valve Demo Kit: Various safety relief valves will be distributed in the class to the participants by the course instructor for a hands-on demonstration. These demo kits will be returned to the instructor at the end of the training day.
• Valve Simulator: Participants will use in the class our state-of-the-art valve simulators to practice some of the skills learnt. A safety or pressure relief valve can be considered the most important single safety device on a boiler or pressure vessel. If it fails to function in the manner for which it was intended and an overpressure condition develops, the result could be catastrophic.

Like all mechanical devices, pressure relief valves require periodic maintenance and repair. To properly carry out repairs, it is essential that the work is done by trained personnel under controlled conditions, using proper parts and procedures. This State-of-the-Art course is developed by The American “National Board of Boiler and Pressure Vessel Inspectors”. The National Board of Boiler and Pressure Vessel Inspectors’ Executive Committee, realizing the importance of proper and adequate repair of safety relief valves, approved the issuance of a National Board Certificate of Authorization for Valve Repair and a “VR” stamp to qualified organizations. Such organizations are required to maintain a quality control system covering valve repairs and be able to adequately demonstrate this system. In addition, a committee was formed to develop administrative procedures and rules for the repair of valves. This committee recommended a course on valve repair to help ensure that those who carry out this work are capable and knowledgeable. Hence, don't blow off this chance to learn the latest information on pressure relief systems from the ones who developed the Standard of the Safety Relief Valves. This course is full of case studies, classroom exercises, and ready-to-use information. The course covers the conventional spring-loaded Pressure Relief Valves (PRV) and the Pilot Operated Pressure Relief Valves (POPRV).

Objectives

• Size, select, operate, inspect, maintain and troubleshoot safety relief valves (PRV and POPRV/PORV) in accordance with the API 520/521/526/527 standards
• Apply the requirements and guidelines for the “VR” accreditation program and use the National Board Inspection Code and ASME PTC 25
• Employ the ASME Code Sections I and VIII and explain the pressure relief valve operation
• Identify the development and application of pressure relief valves and determine the installation requirements for pressure relief valves
• Recognize the operational malfunctions of pressure relief valves and identify the testing facilities for pressure relief valves
• Implement the pressure relief device certifications and repair procedures
• Determine the method of nameplate data interpretation and demonstrate the disassembly of pressure relief valves
• Perform critical inspection, lapping & grinding, assembly, testing and sealing of safety relief valves
• Apply troubleshooting procedures for safety relief valves and illustrate the process of nameplate stamping
• Calibrate safety relief valves and perform a nondestructive examination for safety relief valves
• Implement the “VR” administrative rules and procedures and carry out the steps for obtaining the National Board “VR” stamp
• Training and qualification of personnel
• Pilot-operated pressure relief valves

Training Methodology

The training methodology is interactive with group exercises and is suitable for all employees involved in functions management. The pace and level of the training workshop is customized to the understanding of the delegates. On-going back-up and support is available after the training on request to the supplier, and the training course is also available for in-house presentation as well as for “Competency Transfer”.

Who Should Attend?

This course provides an overview of all significant aspects and considerations of the safety relief valve in accordance with the international standards for those who are involved in the sizing, selection, operation, inspection, maintenance and troubleshooting of valves. This includes process engineers, mechanical engineers, piping engineers, pipelines and pressure vessels engineers and supervisors. Further, it is suitable for inspection and QA & QC engineers, boilers and process plant equipment owners, maintenance staff who inspect and install pressure relief devices and engineers involved in plant turnaround and upgrade projects.

Course Outline

Day 1 :    

• Welcome & Introduction
• Principles of pressure relief valve operation
• Development and application of pressure relief valves
• Installation and operation of pressure relief valves
• Operational malfunctions of pressure relief valves
• Testing facilities
• End of  Day One    

  Day 2 :        

• Pressure relief device certifications
• Pressure relief valve repair
• Nameplate data interpretation and stamping
• Pressure relief valve disassembly
• Critical inspection
• End of  Day Two 

 Day 3 :        

• Lapping and grinding
• PRV assembly
• Setting, testing and sealing
• Quality control systems
• Nondestructive examination
• End of  Day Three 

Day 4 :        

• Pilot-operated pressure relief valves
• National Board Inspection Code and PTC 25
• ASME Code Sections I and VIII
• "VR" certification program
• "VR" administrative rules and procedures
• End of  Day 4 

 Day 5 :        

•   Review and Open Discussion