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Ball Valves Overview and Maintenance Training

From $5250 per attendee

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Course Information

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
• 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.


• 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


• 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


• ‘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

Ball Valves Overview and Maintenance Training Course

This course provides comprehensive learning for all aspects relating to Ball Valve Maintenance. The course will cover theory and practical demonstration by Video of the techniques needed to maintain Ball Valves. The course covers from the basics right through to the latest techniques for Ball Valve condition monitoring using Acoustic leak testing and on line in situ partial stroke testing. Safety aspects to include PPE requirements, safe isolation and hazards relating to pressure testing are addressed.

To provide an in-depth knowledge of the theoretical and practical aspects of Ball valve maintenance. At the end of the course delegates will learn about the many processes related to Ball Valves. From this information effective and safe planning and execution of Ball Valve maintenance will be possible.

This course is a comprehensive course intended for anyone responsible for Planning, Supervising, Inspection and execution of Ball Valve Maintenance both in the Workshop and on-site.

Continuing Professional Development