Refinery valve maintenance between turnarounds

Use the period between turnarounds deliberately

A turnaround provides access for work that needs isolation or dismantling. Between turnarounds, teams still need to inspect, test and control faults without assuming every defect can wait.

Start with the process boundary, valve function, service and available isolation. Connect findings to the valve integrity management programme so the next decision uses history rather than memory.

The honest endpoint may be monitoring, controlled online work or planned repair. Severe or uncertain conditions require a proper assessment.

Separate three refinery valve problems

External leakage, internal passing and restricted movement can appear together. They still need separate evidence and actions.

1. External leakage: product escapes through a stem, flange, body or fitting path.
2. Seat passing: product crosses the closed seat and weakens the isolation boundary.
3. Operating restriction: the valve does not travel correctly or needs abnormal force.

Pressure rise, flow indication and noise can suggest passing, but they do not prove it. Use an approved seat test. Our passing-valve guide explains the distinction.

Connect emissions findings to maintenance

A study reported in Chemical Engineering magazine traced 60 percent of refinery fugitive emissions to leaking valves. That share belongs to the study population and may differ between sites.

Leak detection findings should identify the valve and leak path, not only the process unit. Repeated findings can show weak packing, damaged fittings or poor intervention results.

ISO 15848 addresses valve fugitive-emissions type testing. It does not prove that every installed valve remains tight throughout service. Read the ISO 15848 maintenance connection.

Gate online work before recommending it

Continued operation does not make in-service treatment suitable. Process hazards, valve design and site controls can rule it out.

Before recommending cleaner, lubricant or sealant, confirm that injection fittings are in good condition. The valve design and process service must suit injection, OEM guidance must allow it, and operations must permit the work.

1. Define the fault and confirming test before selecting a material.
2. Verify fitting and equipment ratings against the approved work plan.
3. Use controlled amounts while watching uptake and pressure response.
4. Stop on abnormal response, no uptake or an approaching approved limit.
5. Repeat the confirming test and record whether the fault changed.

Online treatment cannot rebuild a broken trim or badly damaged seat. Our field services start with suitability checks, not an assumed treatment.

Build the turnaround decision file

Every deferred defect needs a clear operating basis and an owner. Record the evidence that supports continued operation and the condition that ends it.

1. Identify the valve, process duty, isolation role and known fault.
2. Keep test results, emissions findings, photographs and intervention history.
3. State monitoring method, review point and stop condition.
4. Define the inspection, repair or replacement scope for the turnaround.
5. Carry temporary treatment status into shift and turnaround handovers.

An injected seal is not a permanent repair. It needs monitoring and a planned endpoint. The planned injected-seal management guide covers that handover.