Select and size control valve trim, actuators and positioners for throttling, on-off and safety shutdown duties.
Engineering & Maintenance
Control Valve and Actuator Maintenance and Diagnostic Testing
Builds skills in control valve trim selection, actuator and positioner configuration, valve signature analysis and partial stroke testing of safety instrumented valves.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
A control loop that hunts, a shutdown valve that fails a proof test, or a seat that leaks past its rated class almost always traces back to the valve and actuator assembly rather than the controller. This course covers control valve trim selection, actuator sizing and smart positioner configuration, then moves into the diagnostic techniques that separate a genuine valve fault from a process or tuning problem. Participants learn to run and interpret valve signature tests, configure partial stroke testing on safety instrumented valves, and diagnose packing friction, seat leakage, cavitation and fugitive emissions. Hands-on sessions cover positioner calibration, bench-set adjustment and trim overhaul, alongside root-cause troubleshooting of control loop instability using signature and trend data together. The course closes with the criticality classification and spares strategy needed to run a structured valve maintenance programme, leaving participants able to keep a plant's control and safety valves performing to specification.
Expected Learning Outcomes
Perform valve signature analysis to distinguish packing friction, seat contact and actuator faults.
Configure and interpret partial stroke tests on safety instrumented valves without disrupting production.
Diagnose seat leakage, cavitation and packing emissions and select the correct repair or upgrade.
Calibrate positioners and adjust actuator bench-set to restore accurate fail-safe control response.
Troubleshoot control loop instability by separating valve-induced from process-induced oscillation.
Build a criticality-based maintenance and spares programme for a plant control valve fleet.
Who Should Attend
Instrumentation and control engineers maintaining process control valves.
Maintenance technicians who overhaul actuators, positioners and valve trim.
Reliability engineers building predictive testing programmes for critical valves.
Functional safety engineers responsible for safety instrumented valve testing.
Process engineers investigating control loop performance issues.
Asset engineers planning valve fleet spares and criticality strategies.
Course Modules
Select any module to see its sessions and points.
01Control Valve and Actuator Fundamentals
2 sessions · 8 points
Session 1Valve Types, Trim Design and Sizing
- Compare globe, ball, butterfly and eccentric-disc control valve characteristics for throttling and on-off service.
- Select valve trim, characterised cages and anti-cavitation trim to manage pressure drop and noise in severe service.
- Verify valve sizing coefficients against process conditions to avoid oversizing that causes poor control resolution.
- Identify cavitation, flashing and choked flow conditions from pressure and temperature process data.
Session 2Actuator Types and Positioner Technology
- Distinguish pneumatic diaphragm, piston and electric actuator designs and their fail-safe action requirements.
- Configure smart digital positioners with HART or Fieldbus communication for diagnostics and travel calibration.
- Size actuator thrust or torque against valve breakout, seating and dynamic unbalance forces.
- Select booster relays, volume boosters and solenoid valves for fast-stroking or emergency shutdown applications.
02Diagnostic Testing Techniques
2 sessions · 8 points
Session 1Valve Signature Analysis and Friction Testing
- Perform valve signature dynamic tests to plot actuator pressure against stem travel and identify friction anomalies.
- Interpret signature curves to distinguish packing friction, seat contact and hysteresis from actuator faults.
- Trend signature test results over time to detect gradual degradation before it causes a control loop upset.
- Correlate signature test findings with control loop performance data to prioritise maintenance actions.
Session 2Partial Stroke Testing and Safety Instrumented Valves
- Configure partial stroke testing on safety instrumented system valves without interrupting process operation.
- Interpret partial stroke test results to confirm valve and solenoid readiness against dangerous failure modes.
- Coordinate partial stroke testing schedules with functional safety requirements and proof test intervals.
- Document partial stroke test evidence to support safety integrity level verification during audits.
03Preventive Maintenance and Overhaul
2 sessions · 8 points
Session 1Packing, Seat and Seal Maintenance
- Select packing materials and live-loading arrangements to control fugitive emissions on hazardous service valves.
- Diagnose seat leakage using acoustic emission or bubble testing and classify leakage class against recognised standards.
- Plan valve trim replacement and lapping procedures to restore shutoff performance on worn seats.
- Inspect actuator diaphragms, springs and pistons for fatigue, corrosion and air leakage during overhaul.
Session 2Calibration and Bench-Set Adjustment
- Calibrate positioner zero, span and characterisation curves to match process control requirements.
- Adjust actuator bench-set spring range to achieve correct fail-safe position and stroking speed.
- Verify travel indicator and limit switch accuracy after actuator or positioner replacement.
- Record calibration certificates and as-found and as-left data to support instrument maintenance history.
04Reliability Programme and Troubleshooting
2 sessions · 8 points
Session 1Root Cause Troubleshooting of Control Loop Instability
- Trace control loop hunting or slow response to valve stiction, oversized trim or positioner tuning faults.
- Distinguish process-induced oscillation from valve-induced oscillation using trend and signature data together.
- Investigate repeated seat erosion or trim damage against process upset history and flashing conditions.
- Recommend trim, material or positioner upgrades where recurring failures indicate a design limitation.
Session 2Building a Valve Maintenance and Criticality Programme
- Classify control valves by process criticality to set inspection, testing and spares priorities.
- Develop a predictive maintenance plan combining signature testing, partial stroke testing and visual inspection.
- Define a spares holding strategy for actuators, positioners and trim kits based on lead time and criticality.
- Present valve fleet health and improvement recommendations to maintenance and process engineering teams.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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