control valve commissioning pre functional checklist

General pre-functional checks

Verify that all required documentation is available

Ensure that the control valve is installed correctly according to manufacturer's specifications

Check for any physical damage or defects on the control valve

Verify that all necessary tools and equipment are available for the commissioning process

Confirm that the control valve is properly aligned with the piping system

Check for proper labeling and identification of the control valve

Ensure that the control valve is properly insulated and protected from environmental factors

Verify that all necessary safety precautions have been taken before starting the commissioning process

Electrical checks

Verify that the control valve is correctly wired to the control system

Ensure that the power supply to the control valve is within the specified range

Check for any loose or damaged electrical connections

Inspect the grounding of the control valve to ensure it is properly connected

Verify that the control valve actuator is receiving the correct signal from the control system

Test the emergency shutdown system to ensure it properly de-energizes the control valve

Check the operation of any solenoid valves or electrical accessories connected to the control valve

Verify that all electrical components are properly labeled and identified for easy troubleshooting in the future

Pneumatic checks

Verify that the control valve is correctly connected to the pneumatic system

Ensure that the air pressure to the control valve is within the specified range

Check for any leaks in the pneumatic system

Verify that the pneumatic tubing is properly routed and secured

Confirm that the air filter and regulator are functioning properly

Ensure that the pneumatic actuator is operating smoothly and without any sticking or binding

Check the air supply line for any moisture or contaminants

Verify that the pneumatic accessories, such as positioners or volume boosters, are correctly installed and functioning as intended

Instrumentation checks

Verify that the control valve positioner is correctly calibrated

Ensure that the control signal to the control valve is within the specified range

Check for any faults in the instrumentation system

Verify that the control valve positioner is properly connected to the control valve and receiving the correct signal

Confirm that the control valve positioner is responding accurately to changes in the control signal

Check for any leaks or blockages in the tubing or air supply to the control valve positioner

Ensure that the valve position indication matches the actual position of the control valve

Verify that the control valve positioner is able to maintain the desired setpoint and respond to changes in process conditions

Functional tests

Perform a stroke test to verify that the control valve opens and closes correctly

Check the control valve response to various control signals

Verify that the control valve meets the required performance specifications

Measure the control valve's flow capacity at different valve positions

Conduct a leak test to ensure there are no leaks in the control valve assembly

Test the control valve's ability to maintain setpoint under varying process conditions

Verify that the control valve can respond accurately to changes in process conditions

Perform a partial stroke test to ensure the control valve's safety function is working properly

Check the control valve's ability to handle emergency shutdown situations

Final checks

Ensure that all documentation is updated with the results of the commissioning tests

Verify that the control valve is ready for operation

Sign off on the commissioning checklist to confirm that all checks have been completed

Conduct a final visual inspection of the control valve for any signs of damage or leaks

Verify that all connections are secure and properly tightened

Check that the control valve is properly calibrated and set to the correct operating parameters

Confirm that all safety features and emergency shutdown procedures are functioning correctly

Ensure that all control valve accessories, such as positioners and solenoids, are properly installed and functioning as intended

Review the control valve operation manual to ensure proper operation and maintenance procedures are understood

Coordinate with operations personnel to ensure a smooth transition for control valve operation