Valve Inspection at Turnaround: Planning and Execution

Planned turnarounds provide the opportunity to inspect, repair, and replace valves that cannot be maintained during normal operation. Systematic planning and disciplined execution maximize the maintenance value achieved within the turnaround window.

Pre-Turnaround Valve Assessment

Before the turnaround, valve condition data should be compiled from maintenance records, LDAR monitoring results, operator observations, and online monitoring data. This allows prioritization of valves requiring disassembly and inspection versus those requiring only external inspection or packing adjustment.

Valve Scope Development

• Mandatory: valves flagged from online monitoring, recurring leaks, or inspection findings

• Scheduled: valves on fixed inspection intervals per maintenance program

• Opportunistic: valves in areas that are difficult to access during normal operation

• Precautionary: valves in critical service that have not been inspected in several years

Inspection Execution

Valve inspection work during turnaround should follow written procedures. Each valve should be assigned to a qualified maintainer with the appropriate tools, documentation, and replacement parts available before work begins. Inspection findings should be recorded on job cards or electronic maintenance systems in real time.

Repair Decision Making

Inspection findings must be evaluated against acceptance criteria from engineering standards or plant-specific procedures. Minor seat erosion may be acceptable for continued service; significant wire-drawing or pitting typically requires rework. Repair decisions should be made by a qualified inspector or engineer, not by the maintainer alone.

Performance Testing After Repair

Repaired or re-seated valves must pass seat leakage tests before return to service. The test pressure and acceptance criterion should match the service requirements. Documentation of test results should be attached to the valve maintenance record.

Lessons Learned

Turnaround lessons learned should capture valve failures, unexpected findings, and opportunities to improve the maintenance scope for the next turnaround. This continuous improvement process improves reliability and reduces turnaround cost over time.