PSV Testing and Overhauling: 5-Day Professional Certification Course

Comprehensive Pressure Safety Valve Training | API 576 & ASME Compliance

Master pressure safety valve (PSV) testing, overhauling, and maintenance with this industry-leading 5-day certification program covering API 576, ASME Section VIII, PSV sizing, inspection procedures, and failure analysis.

DAY 1: PSV Fundamentals and Design

Module 1: Introduction to Pressure Safety Valves (08:30-10:00)

• Overview of pressure-relieving devices (PRDs) and process safety

• Industry standards: ASME Section VIII, API 526/527/576, API 520/521, ISO 4126

• Economic impact of PSV failures and maintenance importance

• Regulatory compliance requirements (OSHA PSM, EPA RMP)

Module 2: PSV Types and Operating Principles (10:15-12:00)

• Conventional spring-loaded PSVs: Design, applications, limitations

• Balanced bellows PSVs: Back pressure compensation and selection

• Pilot-operated relief valves (PORVs): Two-stage operation and advantages

• Rupture disks and combination devices

• Safety valve vs. relief valve vs. safety relief valve terminology

Module 3: Components, Materials, and Metallurgy (13:00-15:00)

• Body, bonnet, nozzle, and seat construction

• Spring selection and characteristics

• Disc, guide, and stem mechanisms

• Sealing materials and chemical compatibility

• Material selection for corrosive, high-temperature, and cryogenic service

• Corrosion and erosion considerations

Module 4: Set Pressure and Performance Parameters (15:15-17:00)

• Set pressure determination and MAWP relationship

• Overpressure allowances (10%, 16%, 21% per ASME)

• Blowdown calculations and adjustment methods

• Accumulated pressure and capacity certification

• Back pressure effects and correction factors

DAY 2: PSV Sizing, Selection, and Installation

Module 5: PSV Sizing Calculations (08:30-10:30)

• API 520 Part 1 sizing methods for gas, vapor, liquid, steam, and two-phase flow

• Relief load calculations for various overpressure scenarios

• Fire relief sizing per API 521

• ASME orifice sizes and selection (D through T)

• Computer-aided sizing tools and validation

Module 6: PSV Selection and Application (10:45-12:30)

• Selection criteria: service conditions, capacity, materials, cost

• Configuration selection: conventional vs. bellows vs. pilot-operated

• Special service considerations: corrosive, toxic, cryogenic, viscous fluids

• Vendor selection and PSV datasheet preparation

Module 7: Installation and Piping Requirements (13:30-15:30)

• API 520 Part 2 installation guidelines

• Inlet piping: 3% pressure drop rule, straight pipe requirements

• Outlet piping: Back pressure calculations, reaction forces, discharge sizing

• Support systems, isolation valves, and drain connections

• Common installation errors and prevention

Module 8: Testing Standards Overview (15:45-17:00)

• Test-only vs. full overhaul philosophy

• In-situ (online) testing vs. bench testing

• Testing frequency per API 576 and risk-based inspection

DAY 3: PSV Testing Procedures

Module 9: Pre-Testing Inspection (08:30-10:00)

• API RP 576 inspection requirements and documentation

• Visual inspection techniques and “as-received” assessment

• Nameplate data verification and code stamp identification

• Leak detection methods: OVA, TVA, acoustic, ultrasonic, thermal imaging

• Common failure mode identification

Module 10: Bench Testing Procedures (10:15-12:30)

• Test bench setup, calibration, and safety systems

• Digital test gauges (XP2i, XP3i) and pressure transducers

• Cold set pressure testing: Step-by-step procedure, pop vs. simmer test

• Pressure ramp rates and multiple test repetitions

• Acceptance criteria: ±3% tolerance, blowdown limits

• Seat tightness testing (API 527): Bubble testing, leak rate measurement, Class I-VI

Module 11: Advanced Testing Techniques (13:30-15:00)

• High-temperature and cryogenic testing

• Steam service and corrosive fluid testing

• Body leak and back pressure testing

• In-situ online testing: Acoustic emission, vibration analysis, partial stroke testing

Module 12: Documentation and Reporting (15:15-17:00)

• Test report generation and required data elements

• Pass/fail criteria and non-conformance reporting

• Digital documentation systems and CMMS integration

• Quality control and traceability requirements

DAY 4: PSV Overhauling and Repair

Module 13: Disassembly and Inspection (08:30-10:30)

• Safety precautions and decontamination procedures

• Safe disassembly: Spring compression, bonnet removal, component extraction

• Detailed component inspection:

  • Seat/nozzle: corrosion, erosion, pitting, dimensional measurements

  • Springs: corrosion, permanent set, fatigue, free length

  • Disc: wear patterns, coating integrity

  • Guide/stem: wear, galling, alignment

  • Bellows: crack detection, leak testing

• Measurement techniques and failure analysis

Module 14: Cleaning, Repair, and Reassembly (10:45-12:30)

• Cleaning methods: solvent, ultrasonic, vapor degreasing

• Seat lapping and refacing: Hand lapping, surface finish requirements (32 RMS)

• Acceptable repair limits per API 576

• Component replacement decisions and parts selection

• Spring adjustment and soft insert replacement

• Reassembly procedures: Torque specifications, bolt tightening patterns, gasket selection

Module 15: Advanced Repair Techniques (13:30-15:00)

• Field modifications: set pressure changes, orifice changes, material upgrades

• National Board NB-23 requirements and code compliance

• Welding, hard-facing, and special coatings

• Bellows replacement procedures

Module 16: Post-Repair Testing and Certification (15:15-17:00)

• Post-overhaul testing and final inspection checklist

• Capacity certification requirements

• ASME stamping: National Board “VR” (repair) and “UV” stamps

• Complete documentation packages and material traceability

• Preservation for reinstallation

DAY 5: Troubleshooting, Failure Analysis, and Modern Practices

Module 17: Comprehensive Troubleshooting (08:30-10:30)

• Systematic troubleshooting methodology

• Common problems and solutions:

  • Chattering/flutter: causes and corrections

  • Premature opening (simmering): investigation and resolution

  • Failure to open: diagnosis and repair

  • Excessive blowdown: adjustment procedures

  • Seat leakage: detection and corrective actions

  • Corrosion/fouling: prevention strategies

• Installation/piping issues and environmental factors

Module 18: Root Cause Failure Analysis (10:45-12:30)

• Failure analysis methodology and common mechanisms

• Real-world case studies:

  • Spring failure in offshore platforms (stress corrosion cracking)

  • Seat erosion in steam service

  • Bellows rupture from back pressure

  • Chattering-induced catastrophic failure

  • Process contamination and fouling

• Lessons learned and reliability improvement programs

Module 19: Predictive Maintenance and Technology (13:30-15:00)

• Risk-based inspection (RBI): API 580/581 principles

• Reliability-centered maintenance (RCM) and FMEA

• Digital PSV monitoring: Acoustic sensors, IoT integration, wireless monitoring

• Smart valve technology and predictive analytics

• CMMS integration and digital asset management

• Spare parts and PSV population management

Module 20: Compliance, Trends, and Final Assessment (15:15-17:00)

• Regulatory requirements: OSHA, EPA, NBIC

• Recent standard updates and industry trends

• Emerging technologies: Advanced materials, 3D printing, AR maintenance, machine learning

• Sustainability and cybersecurity considerations

• Professional development and certification pathways

• Final examination and certificate award

Who Should Attend?

Maintenance technicians, mechanical engineers, inspectors, plant operators, reliability engineers, process safety professionals, valve shop technicians, HSE personnel

Course Benefits

✅ Hands-on training with real equipment
✅ Expert instructors (20+ years experience)
✅ Latest API 576, ASME VIII, API 520/521 standards
✅ Real failure case studies
✅ Certificate of completion + CEU/PDH credits
✅ Career advancement and certification preparation

Materials Provided

Comprehensive manual (500+ pages), API/ASME references, testing templates, troubleshooting flowcharts, inspection checklists, digital resources, certificate

Register today and become a certified PSV expert! This comprehensive training ensures regulatory compliance, improves plant safety, and advances your career in oil & gas, petrochemical, power generation, and process industries.

Keywords: PSV training, pressure safety valve certification, API 576 course, ASME Section VIII, relief valve testing, PSV overhauling, valve inspection training, PSV maintenance, process safety certification