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9 - MMS - Mechanical Engineering and Material Sciences


MMS 230 B - Valve and Actuator Integrity (10 Days)

Code Start Date Duration Venue
MMS 230 B 12 September 2022 5 Days Istanbul Registration Form Link
MMS 230 B 07 November 2022 5 Days Istanbul Registration Form Link
MMS 230 B 12 December 2022 5 Days Istanbul Registration Form Link
Please contact us for fees

 

Course Description

The training course has been designed to focus on applications and practical examples that would be deemed relevant, and the working environment of the delegates will be very carefully enquired about, so that all exercises remain work-related, for the delegates. This course intentionally has a 60-40 split between theoretical and practical work, in order to keep attention spans at optimum levels, as much as possible.

The training course starts off from basics, and builds up to an advanced level, as far as control and using valves and actuators, are concerned. None-the-less, it is presented in such a way, that even total novices will feel comfortable from the very beginning. No-one is left behind, and the instructor takes pride in guiding all delegates along the way, with personal assistance, where required.

Delegates are encouraged to keep an open mind, and to ask as many questions as necessary, to ensure that maximum learning takes place. Preference will always be given to applications and examples that tie up with the SCADA processes encountered by the delegates.

Course Objectives

  • Identify the principles and practice of the following elements:
  • Recognize the concepts of the Process Control and acquire the Knowledge relating to the characteristics and properties of a control valve.
  • Recognize the PID and diagram of actuator and positioner.
  • Identify and competently apply the above techniques and principles to be used  in valve  Maintenance and troubleshooting.
  • Realize and recognize the Specification, Inspection, Testing of valves and Actuators.
  • Recognize and understand how a valve works
  • Appreciate the different types of valves available
  • Apply valve sizing techniques, using software and other methods of calculation
  • Appraise the advantages and disadvantages of various types of positioners
  • Experiment with correctly tuning a control valve

Who Should Attend?

  • Designers
  • Process Control Engineers
  • Electrical Engineers
  • Mechanical Engineers
  • Industrial Engineers

Course Details/Schedule

Day 1

  • Purpose of Valves, Control valve, ROTORK Valves, Petrol valves and Block Valves, 
  • The principles of a control valve
  • The various flow conditions that can be experienced, inside a control valve
  • Dealing with pressure drops, inside a control valve
  • Various signals that are associated with control valves and actuators
  • Reynolds numbers, Laminar flow & Turbulent flow
  • Vortices and flow separation
  • What happens to pressures and flows, in a liquid application, controlled by a valve?
  • What happens to pressures and flows, in a gas application, controlled by a valve?
  • Understanding CV, Choked flow, the vena contracta & Vapour pressure
  • Flashing & Cavitation
  • The requirements of a control valve
  • The broad classification of control valves
  • The classification of valves, by operation and by function
  • Various hardware, associated with valves
  • Cage valves, Split-body valves
  • Globe valves, Needle valves
  • Angled valves, Y-styled valves & 3-way valves
  • Pinch valves & Gate valves
  • Choke valves & Check valves
  • Single-seated versus double-seated valves
  • Balanced valves
  • The principles of valve guiding
  • Butterfly valves & Ball valves
  • Rotary plug valves & Diaphragm valves

Day 2

  • Pinch valves
  • Valve type selection, making use of a flow chart
  • Additional equipment, associated with valves
  • Valves and how they fit into the greater scheme of P&ID diagrams
  • Leakage in valves
  • Calculation of seat leakage rates
  • Equal percentage characteristics
  • Linear valve characteristics
  • Quick opening valve characteristics
  • Inherent versus installed characteristics
  • Manually sizing a control vale, for a liquid application

Day 3

  • Understanding valve sizing software, what it can do, and what you can achieve
  • Actuators, and how they fit into the greater scheme of control valves
  • Pneumatic actuators
  • Diaphragm pneumatic actuators
  • Piston pneumatic actuators
  • Rotary vane pneumatic actuators
  • Electric actuators
  • Hydraulic actuators
  • Benchset and stroking of a control valve
  • The purpose of a valve positioner
  • Using SMART positioners
  • Cavitation, within a control valve
  • Cavitation control trims
  • Disc stacks, used for cavitation control
  • Other examples of devices used for cavitation control
  • Dealing with noise in a valve
  • Making use of low-noise cages
  • Making use of diffuser plates
  • Gas diffuser silencers
  • Sonic chokes
  • Choosing the best form of noise limitation
  • Materials that are used, in the construction of various valves
  • Dealing with corrosion and erosion
  • Control valve maintenance
  • Backlash, inside a valve
  • Stiction as found in some valves
  • Pressure relief devices
  • Safety Instrumented System (SIS) valves
  • The PID controller, as used with various control valves

Day 4

  • Selecting the right controller action for a control valve (as some valves fail in the OPEN position, whereas others fail in the CLOSED position)
  • Understanding the Proportional Band Percent / Gain option, of a PID controller which will be used to operate a control valve
  • Understanding the Reset / Integral option, of a PID controller which will be used to operate a control valve
  • Combining various aspects, such as PI control, when operating a control valve
  • Understanding the Rate / Derivative option, of a PID controller which will be used to operate a control valve
  • How to tune a PID controller, by making use of an open-loop tuning methodology, when you are working with a control valve that operates on a self-regulating process
  • Non-formalized (and therefore well suited to times when you do not have access to a calculator / computer) methods of tuning a controller, for a control valve out in the field
  • Control valves that can be used, in cascade loops
  • Control valves that can be used in ratio-control loops
  • Dealing with control valves, which are subject to long dead times, and how to get around this
  • Dealing with a control valve that has been installed in a process, which responds in a non-linear fashion, and which has different Process Gains in different regions
  • Making use of a PLC, to implement the required control of a control valve

Day 5

  • ROTORK VALVES OPERATION
  • Basic Setup
  • Status Alarm Menu
  • Fault History Menu
  • Default Menu
  • Advanced MenuMaintenance
  • Operation

 

Day 6

  • STANDARD API 6 D Specification for Pipeline Valves:
  • API 598, Valve inspection and testing
  • ISA 96.03, Pneumatic actuators
  • ISA 96.04, Hydraulic Actuators

Day 7

  • Understanding how valves operate, linear vs rotary, and single-action
  • Why is it important to achieve stability, when making use of a control valve? Can this stability be demonstrated?
  • Calculate a pressure drop that can be experienced
  • Converting from mA to percentage
  • Converting from percentage to mA
  • Working with voltage signals, that range from negative to positive
  • Dealing with, and understanding resolution, as can be expected, when sending a signal to a control valve
  • Reynolds number calculations
  • Do an assortment of pressure conversions, either using tables, or else provided software
  • Dealing with cavitation and flashing in a real-world scenario
  • Labelling of a control valve, from a diagram
  • Demonstrate how a valve can be utilized in an application, where there is combined feed forward and feedback control
  • Understanding the pressure drops that can be experienced, in pipelines that will contain control valves
  • Determining how long a tank will take to empty, should you need to fully open a control valve

Day 8

  • Making use of computer software, to size a control valve for a liquid application
  • Making use of computer software, to size a control valve for a gas application
  • How anti-reset windup can be a useful tool, with control valve applications. Delegates will work through a simulator, explaining this out in meticulous detail
  • Understanding what a valve positioner does, and how it will affect the operation of a control valve
  • Dealing with the issue of noise (as presented in a signal to the control valve), as well as the effects of a sticky valve, and how to counteract this
  • Making use of a table, choose the best material to use on a control valve
  • Making use of a table, evaluate the various corrosive effects that you may encounter, whilst using control vales
  • Making use of a table, evaluate whether your valve is going to be subject to noise / other damage, as a result of cavitation
  • Understanding the AUTO / MANUAL aspects of a controller, which will operate on a loop that has a control valve
  • The size of a control valve can cause significant changes to the Gain of the Process. This exercise calculates the Gain of a Process, for a specific control valve
  • Understanding the effects of Dead Time, on a control valve, and determining what this Dead Time is

Day 9

  • Choose the appropriate action that will be required, given a number of scenarios that the delegates will encounter
  • Experimenting with the P settings of a controller, understanding what the advantages and disadvantages are, and becoming fully comfortable with how changes will influence the operation of the control valve
  • Experimenting with the I settings of a controller, understanding what the advantages and disadvantages are, and becoming fully comfortable with how changes will influence the operation of the control valve
  • Experiment with a process, which has both adjustable P and I settings, and how this will affect the operation of a control valve
  • Experimenting with the D settings of a controller, understanding what the advantages and disadvantages are, and becoming fully comfortable with how changes will influence the operation of the control valve
  • Using the Ziegler-Nichols open-loop tuning methodology
  • Using the Ziegler-Nichols closed-loop tuning methodology
  • Making use of a Trial and error methodology, in the closed loop strategy
  • Making use of a Trial and error methodology, in the open loop strategy
  • Experimenting with a control valve, that has been placed inside a cascade loop
  • Experimenting with a control valve, that has been placed inside a ratio-control loop
  • Coming up with a practical, useable solution, when excessive dead time is present in a loop that contains a control valve
  • Making use of a PLC simulator, get a control valve to work, using ON / OFF strategies
  • Demonstrate the PID blocks, used on a PLC, to control a control valve out in the field

Day 10

  • Choose the best valve to use, from a table, given specific criteria
  • Choose the best valve to use, from a flow chart-type diagram, given specific criteria
  • Convert signals from current, to their respective pressure equivalents
  • Interpret a P&ID diagram, that contains a control valve
  • Design a P&ID diagram, for a loop containing a control valve, using specific criteria that has been provided
  • Perform the amount of leakage that can be expected, based on criteria that has been provided
  • Understanding the equal percentage characteristics of a control valve
  •  Understanding the linear characteristics of a control valve
  • Choosing the right characteristic, for various control scenarios and strategies that can be encountered
  • Visually see how the inherent characteristics can be altered, into installed characteristics, when a valve is installed in the field
  • Do all of the calculations, to come up with a control valve, that can be used in a specific application