Pressure relief valves inspector training course


Introduction 

Within the boiler, piping and pressure vessel industry, safety relief valves are of most essential importance. Pressure relief valves are the last line of defense against catastrophic failure or even loss of life. The course covers safety valve types, codes & standards and designs, materials, specification and selection, sizing, installation & testing, preventive maintenance procedures, operation and troubleshooting.

A number of different instructional methods are used throughout the course to allow interactive learning and to give practical examples from the manufacturing and service industry to enable the delegates to operate select, size, install, test and troubleshoot safety valves upon course completion.

Safety Relief Valve Sizing Software “ Valvestar “ from LESER Germany will be demonstrated for sizing & selection of relief valves. (Sizing of Safety Valves as per codes, two-phase flow / fire case as per API, pressure loss, back pressure, reaction forces, noise level). Pentair PRV Size Software will demonstrate for sizing Relief Valves.

Who should attend?

  • Engineers / Supervisors / Technicians from Maintenance Operations Department
  • Maintenance Service Department and Inspection & Materials Technology Section.

Learning objectives

The course provides participants with the knowledge in:

  • Familiarize participants with the functions and applications of safety relief valves, their types, designs and components.
  • Enable appropriate safety valve sizing and selection for liquid, gas and vapor applications
  • Train participants to install, inspect, test & troubleshoot a variety of safety valves.
  • To increase the participant’s awareness and understanding that the mechanical integrity of relief valves depends jointly on the proper design, operation, condition assessment, and maintenance of the equipment.
  • To provide the participants with a clear understanding of the degradation mechanisms that relief valves could be subjected to over their operating life, how to identify them, predict and determine their impact, and what appropriate measures can be taken to prevent and control the resultant damage.
  • To provide the participants with the knowledge and failure analysis skills they need to conduct damage and failure analysis so as to prevent similar failures from happening.
  • To understand requirements of industry codes/standards and approval authorities.
  • In-situ Testing Techniques – Onsite Testing of Safety Relief Valves.
  • Emerging Technologies in Pressure Relieving Devices
  • Use Valve Star / PRV size software for Safety Relief Valve Sizing & selection from Leser and CROSBY.

Course benefits

This course also prepares delegates for the following certification scheme:

  • TUV/IICS 2.6 CERTIFIED PRESSURE RELIEF VALVES INSPECTOR

Course outline

Time   Activities
Day 1
CHAPTER 1 - INTRODUCTION –SAFETY RELIEF VALVES
  • History
  • Pressure Relief Devices ( ReClosing, Non- ReClosing)
  • Reclosing Pressure Relief Devices
    • Pressure Relief Valves
    • Safety Valves
    • Relief Valves
    • Safety Relief Valve
  • Non Reclosing Pressure Relief Devices
    • Rupture Disk
    • Breaking Pin devices
    • Buckling Pin devices
    • Shear Pin devices
    • Fusible Plug devices
CHAPTER 2 - OVERPRESSURE PROTECTION
  • Safety Relief Valves in a Process
  • Causes of Overpressure (Blocked Discharge, Fire Case, Thermal Expansion
  • Runaway Reaction, Tube Rupture in Heat Exchangers)
  • Overpressure Protection Requirements
CHAPTER 3 - PRESSURE RELIEF VALVES – WORKING PRINCIPLE & COMPONENTS & SPECIFICATION
  • Conventional Pressure Relief Valves
  • Pilot Operated Pressure Relief Valves
  • Balanced Bellow Pressure Relief Valves
  • Power & Temperature Actuated Pressure Relief Valves
  • Relief Vs Safety Valve
  • Components & Accessories of Relief Valves
  • Specifying Pressure Relief Valves
CHAPTER 4 - SAFETY VALVES – WORKING PRINCIPLE & COMPONENTS, SPECIFICATION
  • Working Principle
  • Classification ( Actuation, Lift, Seat Design, lever, bonnet )
  • Major Components / Accessories
  • Locations
  • Specifying Safety Valves
Day 2
CHAPTER 5 - CODES & STANDARDS
  • Overview operational requirements
  • ASME & API codes and standards-clarifications
  • National Board approval
  • Main paragraph excerpts from ASME VIII
  • Main excerpts from American Petroleum Institute (API) recommended practices related to safety relief valves
  • NACE
  • PED
CHAPTER 6 - TERMINOLOGY
  • Testing
  • Type of devices
    • Reclosing pressure-relieving devices
    • Non-reclosing pressure relief devices
  • Dimensional terms
  • Operational terms
  • Component terms
  • Clarification of the terms: set pressure, overpressure, accumulation, MAWP and design pressure (PED versus ASME)
CHAPTER 7 - DESIGN FUNDAMENTALS
  • Materials of Construction
  • Direct spring-operated Safety Relief Valves
    • Introduction
    • Functionality
    • General design
    • Design of main assemblies
    • Design differences
    • Types of spring-operated SRV's
  • Controlled safety pressure relief system (CSPRS)
  • Pilot Operated Safety Relief Valves
    • Introduction
    • Functionality
    • Types of POSRV
    • Summary
  • DIN designs
  • Non re-closing pressure relief devices
CHAPTER 8 - SIZING & SELECTION
  • Introduction
  • Gas and vapor sizing
  • Steam sizing (sonic flow)
  • Liquid sizing
    • Combination devices
  • Two phases or flashing flow
    • Two phase liquid/ vapor flow
    • Two phase system with flashing or non-condensable gas
    • Sub cooled liquid flashing
    • Two phase system with flashing and non-condensable gas
Day 3
CHAPTER 9 - SAFETY RELIEF VALVE SELECTION
  • Seat tightness
  • Blowdown
  • Service temperature
  • Weight and/ or height
  • Back pressure
  • Orifice size – sizing
  • Two phase flow
  • Type of fluid
  • Reciprocating compressors
  • Liquid
  • Materials
CHAPTER 10 - INSTALLATION
  • Inlet and outlet piping
    • Calculating piping losses
    • Calculating outlet piping
  • Location of installed SRVs
  • Reaction forces and bracing
  • Temperature transmission on installed SRVs
  • Installation guidelines
CHAPTER 11 - TESTING
  • In situ testing of spring-operated SRVs
  • In situ testing of pilot-operated SVs
CHAPTER 12 - MAINTENANCE
  • Determining maintenance frequency and cost
  • Transportation and dirt
    • Preinstallation handling and testing of the pressure relief valve
  • Maintenance procedure ( Pretest, Disassembly, Repair, Assembly & Testing)
Day 4
CHAPTER 13 - TROUBLESHOOTING SRV’S

  • Seat leakage
  • Chatter
  • Premature opening
  • Valve will not open
  • Valve open above set pressure
  • Valve does not reclose
  • Bellows failure
  • Springs
CHAPTER 14 - NOISE
  • Noise from SRV, open vent and associated pipe
  • Noise Calculations by SRV Vendor
CHAPTER 15 - SPECIFYING SAFETY RELIEF VALVES
  • Summary of overall requirements
  • Materials, design, identification, inspection, testing, preparation and shipment
CHAPTER 16 - LOW PRESSURE PROTECTION DEVICES
  • Breather valves
  • Emergency vents
  • Pilot valves
  • Tank blanketing
Day 5
  • Recap and Q&A
  • Examination


What's included?

Organizational information

  • More information about International Inspector Certification Scheme (IICS), www.international-inspector-certification.com
  • Daily schedule: 8:30 am - 5:30 pm (Workshop)
  • Delegates should bring the following items to the class
    • Calculator
    • Lots of Questions
    • A “CAN-DO” Attitude
    • Other documents (i.e. standards), as appropriate
  • Delegates should note that there are evening works during the course
  • The minimum number of delegates for this course is 4 and the maximum is 20. If the students are less than 4, the course will be postponed.
  • The participants should have the capability to use their own PC, laptop notebook, or suitable mobile devices to access the LMS.
  • This course is run in collaboration with IDC Training House SDN BHD and Plant Technology (Malaysia)

Last modified: Saturday, 30 January 2021, 1:53 PM