Trainer Maintenance, Troubleshooting & Overhaul of Solenoid Valves & Internal Assemblies

Freelance Trainer on “Maintenance, Troubleshooting & Overhaul of Solenoid Valves (1”, 2” & 3”) and Internal Assemblies”

Course Overview

This 5-day intensive program is designed for technicians and maintenance engineers responsible for inspection, servicing, troubleshooting, and overhaul of industrial solenoid valves (1”, 2” and 3”).
The course focuses on field-relevant maintenance skills including diaphragm replacement, bleed screw servicing, flow control stem adjustment, internal cleaning, coil testing, and root cause analysis of failures.

The program blends theory with extensive hands-on sessions using real valves, cut-section models, and fault simulation rigs to ensure participants gain practical confidence.

Learning Objectives

By the end of the course, participants will be able to:

• Identify all major components of 1”, 2” and 3” solenoid valves.
• Understand the working principle of different solenoid valve types (Direct Acting, Semi-Direct Acting, Pilot Operated).
• Diagnose common field failures in solenoid valves.
• Safely disassemble, inspect, and reassemble solenoid valves.
• Service and replace critical internal parts:
• Diaphragms
• Bleed screws
• Flow control stems
• Seals & springs
• Pilots and plungers
• Perform electrical testing on solenoid coils.
• Set and calibrate flow and pressure adjustments.
• Implement preventive maintenance schedules.
• Reduce recurrence of solenoid valve failures through root cause analysis.

Target Audience

This course is ideal for:

• Maintenance Technicians
• Mechanical Fitters
• Electrical Technicians
• Instrumentation & Control Technicians
• Maintenance Supervisors
• Utility & Plant Engineers
• Water Treatment / HVAC / Process Plant Maintenance Staff

Pre-requisite: Basic knowledge of mechanical maintenance or industrial equipment handling.

Training Methodology

The course uses a balance of:

• Classroom Theory Sessions
• Hands-on Practical Exercises
• Live Valve Disassembly & Assembly
• Fault Simulation and Troubleshooting
• Case Studies from Industrial Scenarios
• Tool Handling & Measurement Practice
• Daily Recap & Q&A
• Final Practical Assessment & Certification

Detailed 5-Day Course Structure

Day 1: Fundamentals & Construction of Solenoid Valves

Theory:

• Introduction to solenoid valves (applications & classifications)
• Types: Direct Acting, Semi-Direct Acting, Pilot Operated
• Valve sizing concepts for 1”, 2”, and 3” lines
• Materials of construction: Brass, SS, Cast Iron
• Pressure, temperature, and fluid considerations

Component Breakdown:

• Coil and enclosure
• Plunger/armature
• Diaphragm assembly
• Bleed screw mechanism
• Flow control stem
• Orifice & pilot ports
• Seals, springs, and gaskets

Practical:

• Identification of components using cutaway models
• Reading and understanding manufacturer datasheets
• Safe isolation and tagging procedures

Day 2: Internal Assemblies & Their Functions

Theory:

• Function of diaphragm & pilot orifice
• Working of bleed screw mechanism
• Role of flow control stem in flow regulation
• Internal pressure balancing mechanism
• Typical wear patterns and failure mechanisms

Practical:

• Full disassembly of 1” and 2” solenoid valves
• Inspection of diaphragms for cracks, warping, and stiffness
• Examination of bleed screws and pilot holes for blockages
• Flow control stem dismantling and cleaning

Day 3: Troubleshooting & Failure Diagnosis

Theory:

• Common problems:
• Valve not opening/closing
• Coil burning
• Leakage through diaphragm
• Slow response time
• Valve chatter
• Electrical troubleshooting basics:
• Coil resistance testing
• Voltage supply verification
• Insulation testing
• Mechanical troubleshooting methods

Practical:

• Simulated faults in test rigs
• Root cause identification
• Replacement of faulty parts
• Reassembly with correct torque and sealing

Day 4: Servicing, Calibration & Preventive Maintenance

Theory:

• Servicing procedures for:
• Diaphragms
• Bleed screws
• Flow control stems
• O-rings and seals
• Valve cleaning methods (chemical & mechanical)
• Adjustment of flow control stems
• Setting pressure limits

Practical:

• Complete overhaul of:
• 2” and 3” solenoid valves
• Flow calibration testing
• Leak testing using test bench
• Maintenance documentation & checklists

Day 5: Advanced Maintenance & Final Assessment

Theory:

• Advanced maintenance strategies
• Designing preventive maintenance intervals
• Failure trends and lifecycle management
• Spare parts planning & storage practices

Practical:

• Complete maintenance cycle simulation:
• Fault detection
• Isolation
• Dismantling
• Repair
• Testing
• Recommissioning

Assessment:

• Written knowledge test
• Practical hands-on evaluation
• Feedback & Certification

Job Types: Part-time, Temporary, Contract
Contract length: 12 months

Pay: AED50.00 per hour

Expected hours: 40 per week