Lifecycle Playbooks
Stage 10 · Ongoing asset management
Maintenance & Spares Strategy
Valve maintenance strategy is three lists: what to service on interval, what to hold as spares, and what to replace on failure. This playbook builds the three lists from criticality and service severity instead of habit.
For: Maintenance planners and spares/inventory owners
You are here if
- The same valve tag is consuming gland packing every quarter
- A criticality review asks which valves actually need capital spares
- An obsolete brand fails and the spare does not exist anywhere
Where this stage goes wrong
- Flat maintenance intervals across services that age valves at completely different rates
- Spares held by purchase history instead of criticality - the critical tag has no spare, the harmless one has three
- Obsolete-brand tags with no interchangeable spare identified before the failure
The Playbook
- 1Classify tags by criticality and severityProcess criticality x service severity (corrosive, cycling, solids, temperature) sets the strategy per class, not per habit.
- 2Set intervals by service, not calendarSevere-service tags get condition checks and shorter intervals; benign utility tags get run-to-failure with a spare.
- 3Build the spares list from the classificationCapital spares for long-lead critical tags; trim/packing kits for the serviceable middle; nothing for the trivial.
- 4Resolve obsolete brands before they failIdentify legacy-brand tags and pre-qualify the interchangeable replacement - dimensions, materials and standards - while the plant is running.
- 5Feed failure history backRepeat offenders trigger material/trim upgrade at the next opportunity, not another identical spare.
Stage deliverables
Criticality-based maintenance planRationalised spares listObsolete-brand replacement register
Tools for this stage
Reviewed by Process Engineering, Vajra Industrial SolutionsDiscipline: Valve Service SpecificationLast reviewed: 20 June 2026
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