Valve Inspection Checklist (PDF): Visual, Dimensional & Testing

Quick Summary — Valve Inspection Checklist (for Featured Snippet):
A valve inspection checklist is a practical sequence for documentation, visual/markings, dimensional checks, materials/traceability, NDE (if required), and pressure/functional tests. Record measured results and apply acceptance exactly as referenced by your project spec (e.g., API 598, ISO 5208, EN 12266). Use it to streamline witness points and release.

 

How to Use This Valve Inspection Checklist

Use this valve inspection checklist at vendor FAT, incoming/receipt inspection, or pre-install checks. It is written for QA/QC managers, supplier quality engineers, and freelance inspectors.

1. Confirm inputs: PO, datasheet, drawings/BOM, ITP/QCP, referenced standards (API/ASME/ISO/EN), approved test procedures, calibration certificates.
2. Plan witness/hold points per ITP. Note which tests you will witness vs. review.
3. Work in sequence: documentation → visual/markings → dimensional → materials/traceability → NDE (if specified) → pressure & functional tests.
4. Record facts, not opinions: measured values, clause references, photo IDs, gauge tags.
5. Apply acceptance exactly as referenced by the project spec (e.g., “per API 598/ISO 5208/EN 12266-1” in the procedure).
6. Close out properly: punch list, NCRs/dispositions, sign-off, and release note.
7. File everything in the valve dossier: signed checklist, calibrated charts, certificates, photos, and concessions.

Download the printable Valve Inspection Checklist (PDF) at the end of this article.

 

Pre-Inspection Documentation Review (foundation of your valve QC checklist)

A strong documentation screen prevents most downstream findings. This section of the valve inspection checklist ensures paperwork is complete, current, and traceable.

Required documents to have on the table

• Purchase Order, datasheet, approved drawings/BOM (latest rev)
• ITP/QCP with defined witness/hold points
• Test procedures referencing the governing standard (e.g., API 598 / ISO 5208 / EN 12266-1)
• Calibration certificates for gauges/recorders used in hydrostatic and seat leak tests
• Material Test Certificates (MTCs), Certificates of Conformity, heat/serial lists
• Previous deviations/NCRs and approved concessions (if any)

Acceptance criteria (apply what your spec references)

• Document completeness and revision status per project procedure
• Procedures cite the correct standard and edition as required by the PO/ITP
• Calibration certificates valid and traceable to instruments that will be used
• MTCs traceable to heat numbers and components listed on drawings/BOM
• Any open NCR/deviation has an approved disposition before tests proceed

Document Check Log (example)

Document	Rev/Date	Standard/Spec Ref	Status (OK/Missing)	Remarks / Action Owner
Datasheet & GA drawing	C / 2025-07-15	PO 450123; project spec §…	OK	—
ITP/QCP	2 / 2025-07-10	ITP VP-001; witness points	OK	Shell/seat tests “W”
Hydrostatic test procedure	1 / 2025-07-10	per API 598 / EN 12266-1	OK	Gauge IDs listed
Seat leak (air/water) procedure	1 / 2025-07-10	per ISO 5208	OK	Category to be confirmed
Calibration certs (gauges/rec.)	—	per project calibration control	MISSING	Vendor to upload before FAT
MTCs & heat/serial list	—	BOM; per order	OK	Heats cross-check in Materials section

 

Visual Inspection & Markings (quick, high-value checks)

Goal: Catch obvious nonconformities before you invest time in pressure tests. This part of the valve inspection checklist focuses on visible condition, marking and nameplate checks, coatings/preservation, and documentation of defects.

External condition (visual inspection of valves)

• Body/bonnet: casting/forging integrity; no cracks, dents, arc strikes, or weld spatter.
• Sealing surfaces: no nicks, burrs, corrosion, or coating on seat faces.
• Threads/end prep: clean, correct form, protective caps/plugs installed.
• Internals (when accessible): debris-free; seat/ball/disc/gate undamaged.
• Operator/gear/actuator: mounting secure; travel stops set; indicator present.
• Preservation: rust inhibitor where specified; ends sealed; desiccants if required.

Acceptance: Per drawing and the standard referenced by the project spec.

Markings & nameplate check

Verify manufacturer, size, pressure class, material grade, trim, flow direction, tag/serial, and heat/heat code (where required) are present, legible, and match the order/datasheet. Cross-check tag numbers to test charts and the release documents.

Acceptance: Per order/drawing and applicable marking clauses in the referenced standard.

Coatings & DFT (if applicable)

Confirm coating/lining type, batch reports, curing notes, and dry film thickness at sample points (do not state numeric criteria; reference the project coating spec).

Visual & Marking Checklist (pass/fail log)

Item	Requirement Ref (drawing/standard)	Observed	Photo/ID	Result (Pass/Fail)	Action Owner/Deadline
Body/bonnet surfaces	Order; visual criteria per project spec	Clean, no damage	IMG_112	Pass	—
Seat faces clean	Procedure §…	No coating/burrs	IMG_115	Pass	—
End protection	PO clause §…	Caps installed	IMG_117	Pass	—
Nameplate data	Drawing MD-001	All fields match	IMG_121	Fail	Vendor to replace plate
Flow arrow present	Standard marking clause	Present, correct	IMG_122	Pass	—

Tip: attach defect photos with labels (arrow + part name) to speed review and NCR disposition.

 

Dimensional Verification (measure what matters)

Goal: Confirm fit-up with mating piping/equipment. Keep it efficient: measure critical features, record values, and cite the acceptance reference (drawing/ASME/EN) rather than rewriting tolerances.

What to measure (dimensional inspection of valves)

• Face-to-face / End-to-end length
• Flange geometry (OD, bolt circle, hole qty/size, raised face)
• Threaded ends (type, size, pitch, taper) or weld ends (bevel, land)
• Bore/port and any reduced/full-port requirement
• Stem/packing box dimensions, actuator interface, keyway/square
• Auxiliary ports (drains/vents/test connections) where specified

Tools & references

Use calibrated calipers, micrometers, depth gauges, thread gauges, and templates.
Acceptance is per drawing and the dimensional standard referenced by the project (e.g., ASME B16.34, B16.10/B16.5 as applicable).

Dimensional Check Sheet (example)

Feature	Drawing Ref	Required	Measured	Acceptance Ref	Result
Face-to-face (DN100)	D-201 §A	—	229.9 mm	Drawing D-201; per referenced standard	Pass
Flange BCD	D-201 §B	—	180.1 mm	Drawing D-201; per referenced standard	Pass
Raised face height	D-201 §C	—	—	Project spec coating note As per the referenced standard e.g. ASME B 16.5	Pass
Thread type (NPT/BSPT)	D-201 §D	NPT	NPT verified	Drawing D-201	Pass
Bore	D-201 §E	Full port	Ø99.8	Drawing D-201	Pass

Don’t copy tolerances into the sheet; instead, cite the clause or drawing that governs acceptance.

 

Material Verification & Traceability (MTCs, PMI, hardness)

Goal: Ensure the installed materials match the order and risk profile. This section of the valve QC checklist covers MTC review, PMI/hardness when required, and full heat/serial traceability.

MTC review (how to read valve MTCs)

• Check grade, product form, heat number, melt practice, and any impact/sour notes against the BOM/datasheet.
• Match heat/serials on body/bonnet/trim to the MTC list (where stamping or tagging is required).
• Confirm MTCs are certified and edition-aligned with the project spec.

Need a refresher? See our MTC interpretation guide.

PMI/Hardness (if specified by the project)

• Define locations/extent (e.g., body, bonnet, weld overlays, trim) in the ITP.
• Use calibrated instruments and approved procedures; acceptance per project spec and the standard it references.
• Record method, instrument ID, readings, location map, and disposition of any outliers.

Material & PMI Log (template)

Component	Tag/Serial	Heat No.	MTC Ref	PMI/Hardness Result	Acceptance Reference	Status
Body (WCB)	VLV-1001	H12345	MTC-WCB-07	PMI OK	Per order & referenced standard	Pass
Trim (13Cr)	VLV-1001	T67890	MTC-TRIM-13Cr	PMI OK	Per order & referenced standard	Pass
Overlay (if any)	—	—	—	Hardness pending	Project sour note §…	Hold

Traceability rule of thumb: every reading, photo, and chart must map back to one valve tag/serial.

 

NDE (If Required by the Project Spec)

Purpose: Confirm surface and volumetric integrity where risk or code requires it. Extent and acceptance must follow the standard referenced by your project spec.

Methods & typical use

• VT (visual testing): always; surface condition, welds, seat faces.
• PT/MT: sealing surfaces, repair welds, hardfacing, stem welds.
• UT/RT: production or repair welds; critical sections where specified.
• Hardness mapping / ferrite (if applicable): sour service or overlay controls.

Acceptance: Per the procedure and clause cited by the project spec.

NDE Checklist (log template)

Component/Area	Method	Procedure Ref	Extent	Indications	Disposition	Acceptance Ref	Result
Body-to-bonnet weld	MT	NDE-MT-012	100%	None	—	Per referenced standard	Pass
Seat overlay	PT	NDE-PT-021	100%	1 linear	Blend & re-test	Per referenced standard	Closed/Pass

Tip: add a simple indication map (sketch or photo with coordinates) to speed NCR review.

 

Pressure & Functional Tests (core of the valve inspection checklist)

All test parameters and acceptance must be as per the standard named in your PO/ITP (e.g., API 598, ISO 5208, EN 12266-1) and any project-specific overrides.

Hydrostatic Shell Test (pressure boundary)

• Media & temperature, pressurization, hold: run per approved procedure; gauge/recorder calibration verified.
• Monitoring: leakage, sweating, body/bonnet joints, test blinds, taps.
• Acceptance: Per API 598 / ISO 5208 / EN 12266-1 referenced by the project spec.
• Want a refresher on method differences? See the hydrostatic vs seat leak test.

Seat Leak Test (tightness)

• Direction(s): with/against flow as specified; single or double isolation seats.
• DP/Category: apply exactly what your procedure cites (no ad-hoc categories).
• Media: air/gas or water as specified; stabilization time recorded.
• Acceptance: Per the standard referenced, e.g., categories/rates as per API 598 or ISO 5208.
• Compare frameworks here: API 598 vs ISO 5208.

Functional Checks (operability & accessories)

• Actuation/torque: smooth travel, no binding; verify gear/actuator settings.
• Position indication & stops: open/closed alignment; limit switch setpoints recorded.
• Packing/stem seal: check for visible leakage during cycles.
• Accessories: solenoids, regulators, positioners, air sets, feedback—wired and tagged per drawings.

Test Matrix (vertical template)

Field	Value
Test
Standard Ref
Setpoint/DP
Duration
Media
Instrument IDs
Acceptance Ref
Result

Example — Shell Hydrostatic

Field	Value
Test	Shell hydrostatic
Standard Ref	Per procedure (e.g., API 598)
Setpoint/DP	—
Duration	—
Media	Water
Instrument IDs	G-245, R-009
Acceptance Ref	Per referenced clause
Result	Pass

Example — Seat Leak (Both Seats)

Field	Value
Test	Seat leak (both seats)
Standard Ref	Per procedure (e.g., ISO 5208)
Setpoint/DP	Category X
Duration	—
Media	Air
Instrument IDs	G-311
Acceptance Ref	Per referenced clause
Result	Pass

Example — Functional Stroke

Field	Value
Test	Functional stroke
Standard Ref	Project spec §…
Setpoint/DP	N/A
Duration	N cycles
Media	—
Instrument IDs	—
Acceptance Ref	Per procedure §…
Result	Pass

Always tie charts/readings to a unique valve tag/serial and keep gauge IDs visible in photos.

 

Common Nonconformities & How to Prevent Them

• Wrong end prep / face-to-face → Early dimensional verification against drawings.
• Seat damage / debris → Cleanliness check and protective caps before tests.
• Marking/nameplate mismatch → Visual & markings review before hydrotest.
• Incorrect leak test category → Cross-check procedure to PO/ITP and cited standard.
• Expired calibration → Calibration certificate screen before any testing.
• Traceability gaps → Heat/serial map completed during MTC/PMI step.

Preventive controls: FAT dry-run, standard-referenced procedures attached to ITP, labeled/dated gauges, and a single source-of-truth tag list.

 

Recording Results, Punch List & Release

1. Record facts: measured values, clause references, instrument IDs, photo IDs.
2. Punch list: log defects with owner/deadline; verify corrective action and re-test.
3. NCR handling: contain, correct, verify; concessions only by buyer approval.
4. Final dossier (example contents): signed valve inspection checklist (PDF), calibrated test charts, MTCs/CoC, NDE reports, photos, deviations/waivers, and release note—as required by the project spec.

 

FAQs — Valve Inspection & Testing

Which standard governs valve testing?
Use the one named in your PO/ITP (commonly API 598, ISO 5208, or EN 12266-1). Apply acceptance strictly per that reference.

How do I choose the seat leakage category?
Don’t choose ad-hoc. Follow the category specified by the procedure and project spec (e.g., as per API 598 or ISO 5208).

Do I need PMI and hardness on every valve?
Only if required by risk/service or the project. Acceptance criteria and extent are per the referenced standard/procedure.

What proves my gauges were valid?
Current calibration certificates mapped to instrument IDs used on the charts.

Can I accept minor visual defects?
Only if allowed by the referenced standard and they don’t affect function or pressure boundary; otherwise repair/rework and re-inspect.

What belongs on the nameplate?
Manufacturer, size/class, material, tag/serial, and other markings per drawing and the standard’s marking clauses.

 

Download: Valve Inspection Checklist (PDF)

Valve_Checklist.pdf

• Printer-friendly valve inspection checklist (docs → visual/dimensional → materials/PMI → NDE → hydrostatic & seat leak → functional).
• Acceptance placeholders that point to API 598 / ISO 5208 / EN 12266-1 as referenced by your project.
• Built-in tables for measurements, witness/hold points, punch list & disposition.

CTA: Download the Valve Inspection Checklist (PDF) and use it at your next FAT or incoming inspection.

 

Where to go next

• Select the right tightness framework: API 598 vs ISO 5208
• Understand test method differences: Hydrostatic vs Seat Leak Test
• Brush up on materials: MTC interpretation guide

Ready to upskill your team?
Join our hands-on course: Industrial Valve Inspection & Testing Training — practical leaks, procedures, and acceptance as per the standards your projects reference.