Course at a Glance

Schedule

Code: CCK
Course Length: 3 Months

In this interactive 3 month LIVE ONLINE course, you will:

  • Gain an understanding of SDV and BDV criticality in the context of a safety system, valve inherent reliability, availability requirements and operational constraints
  • Differentiate between types of SDV, BDV and severe service / choke valve designs
  • Understand valve design codes including ISO 1431, API 6D, ISO 17292
  • Learn about material selection for SDV, BDV and severe service / choke valves body and trim including NACE requirements
  • Study seat leakage classifications and standards (ANSI, IEC, ISO, BS)
  • Limit and control fugitive emissions and gland packing
  • Learn about the fire safety code, requirements and fire safe design
  • Understand the torque required, break, run and shear
  • Learn about specification of SDV, BDV and severe service / choke valves, including preparing a typical Datasheet for an actuated ball valve
  • Identify severe service applications and have an appreciation for the methods of tackling the problems associated with such applications
  • Differentiate the types of valve actuators; pneumatic spring return, hydraulic spring return, electric spring return
  • Understand size actuators and torque requirements
  • Learn about SDV/BDV accessory selection including position switches, external indication and solenoids
  • Know the use of smart positioners
  • Understand the need for closed loop hookups and the selection of instrument tubing
  • Learn about valve failure to operate on demand
  • Learn how to order valves, the supplier document schedule and the documentation list required

 

 

Course Details

Overview

Emergency Shutdown Systems (ESD) are a fundamental part of the safety systems associated with oil and gas, utility and other hazardous processes. Associated with these systems are specific valves which are used to isolate and blowdown the processes. These are referred to as Shutdown (SDV) and Blowdown (BDV) Valves respectively. Under emergency situations it is critical that these valves operate correctly. Thus the engineering of the valves and their associated actuators is paramount in ensuring plant safety. They must meet the Fire Safe and Reliability criteria determined by IEC16508 and IEC16511. This Professional Certificate of Competency (PCC) covers the requirements in detail.


In addition, the course addresses Severe Service Valves and Wellhead Choke Valves. Severe Service Valves are required where the process can cause damage to conventional valves through erosion, high noise, cavitation, high vibration, possible mechanical damage to the valve trim, other components and the process equipment around the valve. These valves are generally specialist designs that overcome these issues by "smart" design.


Course Outline

MODULE 1: Introduction

Basic concepts of SDV/BDV valves and their use as part of an Emergency Shutdown System
The requirements of safety standards applicable to SDV/BDV valves – IEC16508 / IEC16511
SIL levels, failure rates, MTBF, hardware fault tolerance, avoiding systematic failures, failure to operate on demand, redundancy
Reliability requirements of SDV/BDV valves
Valve cycle times
Applicable codes and regulations
Definitions and terminology


MODULE 2: Types of SDV/BDV Valves

Full bore ball valve
Reduced bore valve – Sizing considerations apply
Butterfly valve
Control valves (special considerations apply)
Linear versus rotary
Valve sizing considerations – liquid and gas
Maximum noise calculations
Material selection – Body, trim, seals, O-Rings, gaskets,
Valve end connection options – Flanged/Clamplock
Valve trim
Leak rates – Maximum allowable seat leakage, maximum allowable backseat leakage
Fire safe valves, standards, codes and tests


MODULE 3: Actuators

Types of actuators – Pneumatic /Hydraulic/Electric/Spring Return/Dual Action/ Scotch Yoke
Selection – Prolonged position (long stand still) break torque requirement
Sizing
Actuator trim
Torque requirements for blowdown valves – Spring start to open torque, opening torque, running torque, start to close (air start torque), reseat torque (end of close stroke)
Torque requirements for shutdown valves – Spring start to close torque, closing torque, running torque, start to open (air start torque), reseat torque (end of open stroke)
Stem shear torque
Minimising size on offshore applications – Dual acting hydraulic
Maximum operating pressure and maximum allowable working pressure
Actuator dimension limitations
Pneumatic hookups – Closed loop breathing systems
Hydraulic systems for remote operation of SDV/BDV valves
Fire safe actuators and fire blankets
Accumulators


MODULE 4: Specification, Selection, Procurement and Factory Witness Testing (FWT) of SDV/BDV Valves

Preparation of a detailed technical specification
Datasheets for SDV/BDV
Accessories for SDV / BDV – Solenoid valves, redundant solenoid valves, exhaust valves, smart positioners, position switches and indicators
Important details for purchase orders – Handling and transportation, spare requirements, quality assurance requirements, certification of materials, supplier documentation requirements, instructions to suppliers, weight control (offshore)
Protective coating specification
“As Built” updates to documentation
Testing – Performance testing, leak test, verification of fire safe testing, inspector competency


MODULE 5: Commissioning, Maintenance and Operational Performance Testing of SDV/BDV Valves

Commissioning of SDV/BDV valves – Important considerations during pressure testing and flushing, construction waste and sea water issues.
Failure to operate on demand - Jerky operation, slow operation, failure to fully open or close, valve leakage
Operational performance testing of SDV/BDV valves - Proof testing periods, reliability centred maintenance techniques, partial stroke testing
The use of “Smart Positioners” to verify valve status
Maintenance of SDV/BDV Valves – Preparation of a standard for factory overhaul of SDV/BDV valves to return valve and actuator to “as new” specification


MODULE 6: Riser Emergency Shutdown Valves (RESDV)

Specific requirements and description of  Riser Emergency Shutdown Valves (RESDV), the associated systems and parts – These valves are high criticality devices – Specific consideration of RESDV location
Ensuring the valve design assures the ability of valve to close on demand independently of the length of time the valve has been in service
Regulatory requirements
Reopening criteria – “Locked closed” until authorised via independent master control panel
Achieving maximum reliability
Ensuring review of common mode failure points – failure modes effects and criticality analysis
RESDV valve selection - Engineering to ensure maximum reliability, availability and durability
Actuator requirements – Spring return, closing thrust requirement
Valve closure rate
Protection for Fire, explosion and impact, active and passive fire protection, RESDV fire safe time period, fire protection failure criteria specific engineering requirements
Ensuring fail safe operation – Protection of control lines, redundancy of control lines
Factory witness testing – Full pressure and leakage test, competency of inspecting test verification engineer
Specific considerations for large valves requiring double acting hydraulic actuators
Testing objectives - Partial and full closure tests, leakage test, failure to operate on demand or within required specification actions
Inspection and testing of RESDV in operation; partial stroke testing considerations, test record, proof testing time periods, inspection procedures
Maintenance considerations
Commissioning considerations


MODULE 7: High Integrity Protection Systems (HIPPS)

Specific requirements and description of HIPPS
Standards and regulations pertaining to HIPPS, IEC16508/IEC16511
The advantages of using HIPPS – Lower pressure rating of headers, flare system and piping
The disadvantages of HIPPS
HIPPS device integrity and architecture
Mechanical and electric HIPPS
Redundancy of devices
Safety Integrity Levels (SIL) of HIPPS – Determining the required SIL level, verification of SIL with Markov models, fault tree analysis and other methods
HIPPS justification
Design of HIPPS in accordance with IEC16511 and justification associated with API521
HIPPS hazard analysis - “What-if”  analysis; “What-if”/checklist analysis; Hazard and Operability study (HAZOP); Failure Modes, Effects, and Criticality Analysis (FMECA); Fault Tree Analysis (FTA), or Event Tree Analysis (ETA)
Preparation of a HIPPS specification and datasheet
Subsea HIPPS – API RP 17O recommended practice for subsea High Integrity Pressure Protection System (HIPPS)
Common cause failures study
The need for a safety requirement specification
Maintenance diagnostics and smart positioners
Maintenance of HIPPS
Testing frequencies
Ongoing change management of documentation, design, operation, maintenance, and testing to ensure compliance with regulations and standards
Competency of Personnel working on HIPPS


MODULE 8: Severe Service Control Valves

Understanding and recognising the need for a severe service control valve
Identifying root causes for problems and selecting the correct technology to rectify
Severe service control valve applications
Severe service valve designs
Sizing severe service valves
Specifying control valves for severe service applications
Preparation of a severe service control valve specification and datasheet
Commissioning and maintaining severe service control valves
Specific hookups for severe service control valve applications
Accessories for severe service control valve


MODULE 9: Wellhead Choke Valves

Oil and gas surface and subsurface wellhead choke valves
Actuators – Stepping and linear
Preparation of a typical choke valve design specification and datasheet – Process data / Production profile / Service conditions / Wellstream conditions / Mechanical requirements
Design requirements – Standards, valve body, trim, actuator, positioner, accessories
Test and certification requirements
Calculations and sizing
Noise calculations and standards
Smart positioner option
Choke valve orientation and sizes
Provision for marine conditions
Choke valve maintenance and inspection – Criticality of regular inspection, FMECA
Use of predictive instrumentation to assess erosion / corrosion, sand and erosion monitoring
Proof testing and maintenance scheduling
Common choke valve problems and solutions – Corrosion, erosion, cavitation, leaking
Subsea choke valves

 


NB: The course description of all EIT "Certificate" courses has been changed to "Professional Certificate of Competency". Some course brochures are not yet updated. The actual certificate received by successful students will include the new title.

 

Learning and Teaching

Benefits of eLearning to Students

  • Cost effective: no travel or accommodation necessary
  • Interactive: live, interactive sessions let you communicate with your instructor and fellow students
  • Flexible: short interactive sessions over the Internet which you can attend from your home or office. Learn while you earn!
  • Practical: perform exercises by remotely accessing our labs and simulation software
  • Expert instructors: instructors have extensive industry experience; they are not just 'academics'
  • No geographical limits: learn from any location, all you need is an Internet connection
  • Constant support: from your instructor(s) and a dedicated Learning Support Officer for the complete duration of the course
  • International insight: interact and network with participants from around the globe and gain valuable insight into international practice 


Benefits of eLearning to Employers

  • Lower training costs: no travel or accommodation necessary
  • Less downtime: short webinars (60-90 minutes) and flexible training methods means less time away from work
  • Retain employees: keep staff who may be considering a qualification as full time study
  • Increase efficiency: improve your engineering or technical employees’ skills and knowledge
  • International insight: students will have access to internationally based professional instructors and students

 

How Does it Work?

EIT eLearning courses involve a combination of live, interactive sessions over the Internet with a professional instructor, set readings, and assignments. The courses include simulation software and remote laboratory applications to let you put theory to practice, and provide you with constant support from a dedicated Learning Support Officer.


Practical Exercises and Remote Laboratories

As part of the groundbreaking new way of teaching, our online engineering courses use a series of remote laboratories (labs) and simulation software, to facilitate your learning and to test the knowledge you gain during your course. These involve complete working labs set up at various locations of the world into which you will be able to log to and proceed through the various practical sessions.

These will be supplemented by simulation software, running either remotely or on your computer, to ensure you gain the requisite hands-on experience. No one can learn much solely from lectures, the labs and simulation software are designed to increase the absorption of the materials and to give you a practical orientation of the learning experience. All this will give you a solid, practical exposure to the key principles covered and will ensure that you obtain maximum benefit from your course.

 

Endorsed by ISA

School of Industrial Automation