Ball Valves Overview and Maintenance Training

Day 1

Introductions and Safety Briefing
• Introductions
• Present and discuss course outline.
• Course timings, Meal and refreshment breaks.
• Muster Point / Emergency Assembly Point if training is done on site.
• Daily Safety Topic relating to Ball Valves.

Types of Ball Valves
• Trunnion Mounted
• 3 piece Split Body Design
• 2 piece Split Body Design
• Removal of Trunnion & Ball
• Trunnion Mounted / Ball Key
• Plate Trunnion Mounted
• Plate Trunnion Disassembly
• Dual Ball / Tandem
• One Piece Top Entry
• 2 Piece Split Body
• 3 Piece Split Body
• ESDV
• 2” 300 # and 6” x 4” 300# RF
• 3 – Way Ball
• Stem Sealing
• Reduction of the static charge generated on the ball due to friction
• Seat Arrangement Explanations
• Seat Arrangement – Standard Design Single Piston
• Double Piston Effect

Oral Question and Answer session to gauge learning

Day 2

• Daily Safety Topic relating to Ball Valves.

Ball Valve Flange Management
• Objectives of Flange Management
• Flange Standards
• Types of Flange
• Creating a seal and resisting internal forces
• Flange sealing systems / Gasket Types /Gasket selection
• Types of Gasket
• Flange Inspection
• Studs and Bolts
• Flange Alignment
• Torque Issues
• Hydraulic Tensioning
• Bolt Tightening Sequence
• Nut Engagement
• Preparation
• Hose attachment and Safety
• Flange Status Tag
• Nut Splitter

Oral Question and Answer session to gauge learning

Day 3

• Daily Safety Topic relating to Ball Valves.

Maintenance

• Marking of valve components
• Ball Valve disassembly and reassembly
• Top entry ball extraction and seat removal
• Greasing, stem seals, sealant injector, cartridges, Sealweld ACTIV-8 Pump
• Hot bolting

Troubleshooting

• Ball Valve internal leakage
• Ball Valve external leakage
• Ball Valve not operation or partial operation
• Incorrect setting of closed position
• ‘ O ‘ ring or seal damaged
• Heavy corrosion in seal area

Oral Question and Answer session to gauge learning

Day 4

• Daily Safety Topic relating to Ball Valves

Pre-commissioning of Ball Valves installed in pipework

• Definition of pre-commissioning
• Pipeline cleaning ( pigging )
• Hydro testing
• Setting ESD ball valve response times

SOFT SEALS AND GASKETS

• ‘O’ rings
• Lip seals
• Graphite gaskets

Safe Isolation

• Double Block and Bleed (DBB ) vs. Double Isolation and Bleed (DIB)
• Isolation techniques

Pressure Tests

• Standards
• Ball valve service and test pressures API and ANSI
• Hydro test hook up
• Workshop testing
• High pressure gas test
• Leakage rates
• Valves testing on line
• Functional Tests
• Fugitive emission tests

Oral Question and Answer session to gauge learning

Day 5

• Daily Safety Topic relating to Ball Valves.

Non Destructive Testing ( NDT )

• Visual inspection
• Magnetoscopic Test (MP or MPI)
• Dye Penetrant Inspection (DPI or PT)
• Ultrasonic Test (UT)
• Radiographic Test (RT)
• Standard FCT NDE

Ball Valve Condition Monitoring Techniques

Topworx partial stroke and ESD ball valve testing

• Advantages of partial stroke testing
• Common methods partial stroke testing
• TopWorx exploded view and parts breakdown
• Theory of operation
• Workshop training and testing of ESD Ball Valve partial stroke test
• Method statement

Midas acoustic emission (AE) valve lead detection

1. Terminology
2. Specification
3. Acoustics explained
4. How the MIDAS Meter® works
5. Using the Midas Meter
6. Demonstration by Video of workshop tests to check leaking ball valves
7. Risks to avoid / mitigate