Valves & Actuators Technology
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INTRODUCTION
Research studies within the process industry routinely indicate that the fluid control valve is responsible for 60 to 70% of poor-functioning control systems. Furthermore, valves in general are consistently wrongly selected, are regularly misapplied, and are often incorrectly installed. The problems lie not just within the valve itself but also with its associated ancillaries that form the final control element: the valve actuator, I/P converter and positioner. So Valves are synonymous with just about every industry around the world. Having said that, anyone dealing with this type of equipment knows that there is a lot to learn, and many choices to be made. Of course, a special component or mechanism is also required to operate the valve, and it must have a source of energy. This is known as the actuator, and it takes this energy and converts it into mechanical motion, which is transferred through to the valve.
In this course we will provides a total in-depth insight into valve and actuator technology – looking not just at control valves, but a whole host of other types including: check valves, shut-off valves, solenoid valves, and pressure relief valves. A methodology is presented to ensure the optimum selection of size, choice of body and trim materials, components, and ancillaries. Whilst studying the correct procedures for sizing, delegates will also learn the correct procedures for calculating the spring ‘wind-up’ or ‘bench set’. on the other hand this course aims to take the mystery out of all aspects pertaining to valves and actuators, and to assist delegates in seamlessly going through all the important thought processes related to these devices, from selection to installation, and everything in between.
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COURSE OBJECTIVES
At the end of this course you will be able to:
- Differentiating between the different types of valves available, and focusing on their advantages and disadvantages
- perform flow and system pressure head loss calculations
- Sizing valves correctly, whilst identifying and gaining familiarity with ANSI / DIN pipe sizes and pressure ratings
- gain an overview of the different types of control, shut-off, and check valves
- appreciate the principles of cavitation control and noise reduction
- select optimum materials of construction to avoid corrosion and erosion
- understand the correct requirements for trim selection
- appreciate the differences between inherent and installed characteristics
- understand control valve characterisation and characteristic profiling
- identify ANSI/DN pipe sizes and pressure ratings
- understand the major technologies used in the final control element
- appreciate the basic theory of flow through a control valve
- calculate the valve flow coefficient Cv
- use the control valve seat leakage classifications
- pick the optimum valve-actuator combination
- apply on-line valve testing and diagnostics for deadband and hysteresis, stick-slip and non-linearity
- understand the principles of preventive maintenance through the application of signature analysis
- perform a bench set and calculate actuator spring wind-up
- pick the correct positioner using our set of guidelines
- gain an insight into the application and limitations of safety relief valves
- Developing a system, using the specific actuators that will provide the greatest benefit, based on their individual advantages and disadvantages
- Selecting the appropriate additional equipment (and, combinations of equipment, where necessary)
- Learning to take any installation from the specification and selection process, right through to installation and maintenance phases
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COURSE AUDIENCE
This course is made for
- Installation and Maintenance Technicians
- Instrument Fitters
- Chemical Engineers
- Consulting Engineers
- Design Engineers
- Electrical Engineers
- Electricians
- Automation Engineers
- Maintenance Engineers
- Mechanical Engineers and Technicians
- Production Managers
- Project Managers
- System Integrators
- Operations Engineers
- Process Engineers
- Process Operators
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COURSE OUTLINE
Day One
Valve Basics – What happens inside the Valve from a Process Point of View, Valve Types and Associated Hardware
- Valve Purposes, Principles, Flow Conditions and Operation
- Signals, Pressure Drops, Flow Profiles and Reynolds Numbers
- Cv, Choked Flow and Flashing and Cavitation
- The Requirements – Classification and Selected associated Hardware for Valves and Actuators
- The Operation – as well as the Advantages and Disadvantages of an Assortment of Different Types of Valves, including Cage, Split-body, Globe, Needle, Angled, Y-styled, 3-Way, Pinch, Gate (including slab gate and expending gate), Choke, Check (including rubber duck-bill, tilting disc & swing), Single vs. Double-seated, and Balanced Valves
Day Two
A Continuation of Valve Types, Associated Equipment and Characteristics
- The Operation – as Advantages and Disadvantages of an Assortment of Different Types of Valves not covered on Day 1 (including butterfly, ball, rotary plug, diaphragm, ARV / ARC, Bellow sealed (both forged and welded), Breathe / Vacuum Release, Orbit, Pressure Seal, Fixed Cone and Annular Valves
- Miscellaneous Equipment – closely associated with Valves and Actuators
- P&ID Diagrams (using valves) and Valve Seat Leakage Rates
- Characteristics associated with Valves
- Inherent vs. Installed Characteristics
Day Three
Manual and Software Valve Sizing, Actuators and Positioners, Trims and Maintenance
- Manually Sizing a Valve
- Sizing a Valve – using software from manufacturers
- Actuators – Benchsetting and Valve Positioners
- Cavitation and Noise Trims and Valve Material Selection
- Valve Maintenance – Fault-finding, Dead Band and Stiction
Day Four
Pressure Relief, SIS, Valve Action, Combinations, Terminology, Codes and Standards
- Pressure Relief Devices and the Limitation of Safety Relief Valves
- Valves associated with Safety Instrumented Systems
- Valve Action (fail safe), ANSI / DN Pipe Sizes and Applicable Pressure Ratings
- Optimizing Valve-actuator Combinations for Various Applications, Terminology Used, and Valve and Actuator Maintenance Aspects and Issues
- Codes and Standards as well as Piping & Installation Guidelines
Day Five
Using Control Valves in an Assortment of Control Strategies
- PID and Loop Tuning Strategies
- Feedback – Feed Forward, Cascade and Ratio Control
- Dealing with Long Dead Times
- Non-linear Control Valve Applications
- Valve Control – using a Specialized Controller such as a PLC
