Lifecycle Playbooks
Stage 08 · Construction / pre-startup
Installation & Commissioning
A valve that passed FAT can still fail startup - installation direction, flushing debris and untested actuation are the usual culprits. This playbook takes valves from crate to first flow without creating new failures.
For: Construction and commissioning engineers
You are here if
- Flushing is about to start and nobody has protected the soft-seated valves
- A valve passes FAT but leaks at line test and the blame hunt begins
- Actuated valves need stroking and the settings were never documented
Where this stage goes wrong
- Debris from flushing destroying seats because valves were not blocked open or spooled out
- Check valves and globe valves installed against flow direction
- Bolting and gasket errors at the flanges blamed on the valve at line test
The Playbook
- 1Verify tag against line before boltingTag, rating, material and flow-direction arrow vs the line designation - the cheapest check on the project.
- 2Protect valves during flushingSoft-seated and control valves spooled out or locked open per the flushing plan; strainers in and inspected after.
- 3Torque flanges to procedureCorrect gaskets, lubricated studs and staged bolt torque - most 'valve leaks' at startup are joint leaks.
- 4Stroke and set actuated valvesFull-travel stroking, limit and torque settings, fail-action verification - recorded per tag before loop checks.
- 5Walk the line testWitness line/system tests with valve positions per the test plan; packing gland adjustments only after test.
Stage deliverables
Installation verification recordsActuated valve stroking recordsLine test punch list
Tools for this stage
Reviewed by Process Engineering, Vajra Industrial SolutionsDiscipline: Valve Service SpecificationLast reviewed: 20 June 2026
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