PSV Fundamentals and PSV Test Bench Operations

Upcoming Sessions

Classroom sessions
Online sessions

Course Introduction

Pressure Safety Valves (PSVs) are essential safety devices in industrial systems, designed to release excess pressure and prevent equipment failure. These valves act as the final barrier against overpressure, protecting plant assets, personnel, and the environment. When PSVs are incorrectly selected, improperly installed, or poorly maintained, the risk of severe safety incidents and non-compliance increases significantly. Therefore, understanding PSV fundamentals is critical for maintaining reliable operations and ensuring safe plant performance.

The PSV Fundamentals and PSV Test Bench Operations Training Course by COPEX provides a complete learning path from basic valve principles to hands-on testing. Participants will gain a strong foundation in PSV design, sizing, and operational behavior. The course also covers practical test bench procedures, including calibration, lift testing, and performance verification, aligned with international standards such as API, ASME, and ISO. With real-life case studies and interactive exercises, attendees will learn how to manage PSV systems effectively and maintain regulatory compliance.

Key learning outcomes of this PSV training course include:

  • Understanding PSV operation and safety functions in pressurized systems
  • Learning PSV sizing principles and the impact of backpressure
  • Familiarization with API, ASME, and ISO standards for PSV systems
  • Practical experience in test bench operations, calibration, and performance checks
  • Identifying common PSV faults and implementing maintenance best practices

Objectives

This PSV Test Bench Operations Course is designed to develop the knowledge and practical skills required for managing pressure safety valve systems safely and efficiently. By completing the training, participants will be able to apply industry best practices in inspection, testing, and documentation of PSV performance.

Upon completion of this PSV training course, participants will be able to:

  • Explain PSV operation, classification, and sizing fundamentals
  • Apply international standards (API, ASME, ISO) to PSV procedures
  • Inspect PSV installations and identify common operational faults
  • Perform test bench setup, calibration, and lift testing techniques
  • Verify set pressure, seat tightness, and performance parameters
  • Document PSV performance and compliance for audit readiness
  • Implement preventive maintenance and troubleshooting strategies

Training Methodology

This PSV Test Bench Operations Training Course uses a structured and interactive learning approach designed for deep understanding and practical skill development. Sessions combine instructor-led presentations with visual demonstrations and real-world case studies to make complex concepts easy to grasp. The training is highly engaging, encouraging active participation through group discussions and interactive exercises that simulate actual plant conditions.

The course also includes hands-on activities focused on test bench calibration and performance verification. Participants will work with test equipment and calibration rigs to practice setup procedures, lift testing, and blowdown recording. These exercises are supported by guided supervision to ensure correct application of techniques and safe handling of equipment. Overall, the training methodology ensures that participants leave with practical knowledge they can immediately apply in their operational roles, improving PSV reliability and compliance.

Who Should Attend?

This PSV Fundamentals Training Course is ideal for professionals involved in safety, maintenance, and operational reliability of pressurized systems. It is designed for those who need practical knowledge of PSV selection, installation, testing, and troubleshooting to ensure safe and compliant plant operations.

This course is suitable for:

  • Mechanical and Process Engineers
  • Maintenance and Reliability Engineers
  • HSE and Safety Officers
  • Quality Control and Inspection Personnel
  • Valve Service and Testing Technicians

Course Outline

Day 1: Introduction to Pressure Safety Valves

  • Role in process safety & typical applications
  • Types: conventional, balanced bellows, pilot-operated
  • PSV sizing basics and backpressure effects
  • Group calculation exercises

Day 2: Codes, Standards, and Installation

  • API 520/526, ASME VIII, ISO 4126 overview
  • Correct installation practices to avoid chatter & blowdown issues
  • Managing cold differential test pressures
  • Workshop: reviewing real plant layouts

Day 3: Common Faults and Maintenance

  • Causes of PSV leakage, seat damage, and flutter
  • Developing PM programs for PSVs
  • Troubleshooting case studies

Day 4: PSV Test Bench Operations

  • Introduction to calibration rigs and test equipment
  • Step-by-step on test bench setup and blowdown recording
  • Demonstration of lift tests, seat tightness, and set pressure verification

Day 5: Compliance, Documentation, and Wrap-Up

  • Test reports and audit-ready documentation
  • Preparing for regulatory inspections
  • Group simulation: design a PSV maintenance & testing program

Providers and Associations

Anderson
Aztech Training
Coventry

Certificate

  • COPEX Certificate of Attendance will be provided to delegates who attend and complete the course

Material published by Copex shown here is copyrighted. All rights reserved. Any unauthorized copying, distribution, use, dissemination, downloading, storing (in any medium), transmission, reproduction or reliance in whole or any part of this course outline is prohibited and will constitute an infringement of copyright.

Whats Makes Copex Courses Unique?

COPEX Training is your gateway to professional growth, with over 20 years of experience turning potential into success. Each year, we deliver over 1,000 courses in 50+ countries, earning a stellar 98% satisfaction rate. Trusted by global giants like BP, the United Nations, and HSBC, we partner with top certification bodies to provide career-focused training that empowers individuals and drives organizational breakthroughs. Our mission? To transform the way professionals learn and grow in today’s fast-changing industries. Through expert insights, cutting-edge methods, and hands-on approaches, we equip you with the skills and confidence to tackle challenges, seize opportunities, and thrive in your career.

Led by a passionate leadership team and supported by a network of world-class trainers, COPEX Training connects professionals worldwide with life-changing opportunities. We are committed to excellence, ensuring every participant leaves with the tools, expertise, and confidence to conquer an ever-evolving world.

Related Categories

Operational and Quality Excellence Maintenance Management

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Our cancellation policy varies depending on the circumstances presented. Generally, cancellations must be initiated in formal writing at least 14 days prior to the commencement date of the training course. Further, the option to shift an existing registration to another training course on a later date is possible. Otherwise, a full refund will be initiated.

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Our training courses will run for 5 hours per day. The standard daily timing is from 8:30 am – 3:30 pm including the coffee/tea breaks and lunch.

The training course fee can be settled by either:

  • Bank transfer
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Published training course fees are inclusive of the training venue, training manual, writing materials, lunch and coffee breaks with refreshments over the entire duration of the training course.

Upon successful registration, processing window will take not more than 24 hours from the time of registration. An email including the registration confirmation, invoice and joining instructions will be sent to the provided email address.

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