What a valve condition survey covers

1. Start with identity and duty

A useful survey begins by proving which valve is being assessed. Asset tags, nameplates and drawings should agree.

Record valve type, size, operator, normal position, service medium and operating conditions. Also note its isolation or control duty.

Missing or conflicting identification is itself a finding. It limits product choice, test interpretation and any later injection plan.

Surveyors should also review previous faults, repairs, injections and test results. History gives context for present condition.

The valve integrity management guide shows how surveys support a wider programme.

2. Inspect the complete visible boundary

The external inspection records condition before movement or connection. Common checks include:

1. body, bonnet, joints and exposed pressure-boundary surfaces;
2. stem area, packing region and signs of external leakage;
3. operator, gearbox, actuator, couplings, stops and position indication;
4. injection fittings, caps, adapters and visible corrosion or damage;
5. supports, access, chamber condition and safe working space;
6. nearby pipework or process conditions affecting the test.

Noise, staining and instrument readings may suggest a fault. They remain screening evidence until the proper test confirms it.

3. Check movement only within operating limits

A movement check needs operations approval and an agreed process response. Some valves cannot move during normal production.

Where permitted, record travel range, direction, operating effort, timing and indication. Stop for abnormal torque, leakage, noise or process change.

Full travel does not prove tight shut-off. It proves movement only when the actual position is also checked.

A seat test must confirm isolation performance. Pressure rise, flow indication and sound can guide screening, but they cannot confirm passing alone.

Our live valve exercising guide covers limits and stop-work conditions.

4. Test the required function, not every possible function

The valve’s duty determines the confirming test. An isolation valve needs evidence of closure performance, while a control valve needs different evidence.

Pressure decay or a controlled bleed check may confirm seat performance where the arrangement permits. Use the site’s approved method and acceptance basis.

External leaks need their own checks. A seat test cannot locate a stem, bonnet or body-joint leak.

Record test arrangement, process conditions, instrument identity, result and uncertainty. A result without conditions cannot support later comparison.

5. Assess injection suitability as a gated finding

A survey may find a valve that could accept cleaner, lubricant or sealant. That is not yet a treatment recommendation.

Injection fittings must be suitable and in good condition. Valve design and service must suit injection, OEM guidance applies, and operations must permit work.

Record fitting function, rating evidence, access and visible condition. Unknown ratings or damaged fittings lead to assessment, not connection.

The sealant injection guide explains the full suitability test and honest limits.

6. A good report separates facts, findings and actions

Each valve record should show observed facts, test evidence and the resulting finding. Recommendations must state their evidence and limits.

1. Immediate controls. Address active leakage, unsafe access or an unreliable isolation duty.
2. Planned maintenance. Define suitable cleaning, lubrication, injection or operator work.
3. Further assessment. Resolve missing identity, ratings or ambiguous test results.
4. Isolation work. Plan internal inspection, repair or replacement where online work cannot help.

A baseline becomes valuable when later surveys use the same evidence. Trends then show worsening torque, leakage or fitting condition.

Use per-valve service records to keep that evidence consistent across each visit.

Our valve survey service records field condition and next actions. Visit the knowledge hub for related guides.