Shutdown & Turnaround Valve Checklist

Planned Outage Procurement Worksheet — Print or save as PDF

Vajra Industrial Solutions

SHUTDOWN & TURNAROUND VALVE CHECKLIST

Planned Outage Procurement & Installation Worksheet

Doc: VIS-TAR-004 Rev.01

Plant / Unit: ____________

TAR Date: ______________

Prepared By: ___________

URGENCY CLASSIFICATION & EMERGENCY SOURCING TRIGGERS

Trigger Condition	Urgency Level	Target Lead Time
Active external leakage (packing or body joint)	Immediate — Emergency sourcing	24–72 hours
Failed seat test — passing to downstream	Priority — same shutdown window	1–5 days
Seized / failed to operate on demand	Priority — same shutdown window	1–5 days
Visible cracks or major corrosion on body	High — before next startup	1–2 weeks
Class A / safety-critical valve approaching inspection interval	Plan ahead — order with 12-week lead	12–20 weeks
Class B / process-critical — 2+ failures in rolling year	Plan for next TAR	8–16 weeks
Class C / utility — minor leakage manageable	Next TAR or planned outage	4–12 weeks

Contact: sales@vajravyuh.com | WhatsApp: +91 9979774557 | Emergency sourcing response within 4 hours

PHASE 1 — PRE-SHUTDOWN AUDIT (12–24 Weeks Before TAR)

#	Task	Done	Notes / Tag Reference
1	Extract valve asset register from CMMS — all valves in scope
2	Review valve inspection history — flag items with recurring failures
3	Review last shutdown NCR (non-conformance reports) for valves
4	Walk the plant — physically inspect valve condition (stem, packing, handwheel)
5	Identify valves with visible external corrosion, leaking packing, or seizure risk
6	Check valve positions on P&IDs — verify size, class, service fluid
7	Classify each valve: Replace / Repair / Inspect / Monitor
8	Identify safety-critical valves (PSV, ESD, blowdown) — mandatory inspection
9	Flag any valves on regulatory inspection schedule (IBR, PESO, statutory)
10	Review utility valve status — cooling water, steam, air isolation valves

PHASE 2 — SPARE CLASSIFICATION & CRITICALITY RATING (10–20 Weeks Before TAR)

#	Task	Done	Notes / Tag Reference
1	Assign criticality: A = Safety-critical (PSV/ESD), B = Process-critical, C = Utility
2	Check warehouse stock — existing spare valves / repair kits available
3	Identify long-lead items (alloy bodies, Class 900+, actuated packages)
4	Place orders for long-lead items immediately (12–24 week lead time typical)
5	Raise RFQs for standard replacement valves (API 6D, BS EN, IS standard)
6	Confirm vendor lead times and delivery schedule vs. TAR start date
7	Request Mill Test Certificates (EN 10204 3.1) at time of order — not after delivery
8	Identify valves requiring TPI witness (Class B / A criticality)
9	Arrange third-party inspection agency for FAT if required
10	Confirm IBR Form III-C / III-E for steam service replacements

PHASE 3 — RECEIVING & PRE-INSTALLATION INSPECTION (2–4 Weeks Before TAR)

#	Task	Done	Notes / Tag Reference
1	Receive valves — verify packing list against purchase order
2	Check for visible transit damage — dents, cracked handwheels, bent stems
3	Verify material markings on body: material grade, class, NPS, heat number
4	Verify MTC heat numbers match valve body stamping (traceability check)
5	Verify face-to-face dimension against ASME B16.10 table
6	Verify end connection facing (RF/RTJ/BW) matches P&ID spec
7	Check valve operation — open/close with no binding before storage
8	Store valves in dry, covered location with end caps fitted
9	Tag each valve with P&ID tag number and TAR work order number
10	File all documentation (MTC, test certs, IBR forms) in project folder

PHASE 4 — INSTALLATION SCOPE (During TAR)

#	Task	Done	Notes / Tag Reference
1	Remove old valve — photograph in-situ before removal (record condition)
2	Inspect piping flange faces for corrosion, pitting, or damage
3	Clean flange faces — remove old gasket material entirely
4	Verify new valve bore is clear — no packing, shipping covers, or debris
5	Install correct gasket type (spiral wound, Kammprofile, PTFE) per P&ID
6	Torque flange bolts per ASME PCC-1 torque table and pattern (cross pattern)
7	Verify valve stem orientation — rising stem visible after installation
8	Verify direction arrow (flow direction) for check valves
9	Install packing correctly — do not over-tighten gland; leave room for live-loading
10	Functional test after installation — operate 3 times before system pressurisation

PHASE 5 — POST-INSTALLATION PRESSURE TEST & HANDOVER

#	Task	Done	Notes / Tag Reference
1	Conduct line pressure test — leak test all new flange joints with soapy water or N2
2	Verify seat tightness — check for leakage across closed valve
3	Verify packing is not leaking at operating conditions
4	Update P&ID redline — mark replaced valves as 'New'
5	Update CMMS / asset register with new valve serial number and installation date
6	File installation records, torque records, and pressure test results
7	Return all MTCs and test certificates to plant documentation system
8	Raise NCR if any defects found during installation — photograph and document
9	Close out TAR work order — sign off completion
10	Update next inspection schedule in CMMS (typically 4 years for most process valves)

VIS-TAR-004 Rev.01 — Vajra Industrial Solutions — www.vajravyuh.comEmergency: +91 9979774557 | sales@vajravyuh.com

Emergency valve sourcing

For urgent valve replacement during shutdown — contact Vajra for same-day quote response and priority dispatch from stock.