Expanding Your Safety Valve Testing Services with In-Line Testing: What Repair Shops Need to Know
As industrial plants face growing pressure to minimize downtime, reduce costs, and comply with strict safety regulations, in-line (or on-line) safety valve testing is becoming an increasingly common request, especially during routine maintenance and shutdowns.
For valve repair and service companies, this shift in demand offers an opportunity to expand capabilities and adapt to changing customer expectations. In-line testing does not replace traditional repair work but can serve as a valuable extension of a service offering, particularly when accuracy and documentation are a priority.
This article outlines what valve service providers should consider when evaluating whether to add in-line testing to their capabilities.
Why In-Line Testing Is in Demand
Conventional safety valve testing requires removing valves from the system, transporting them to a test bench, and reinstalling them after inspection and recertification. While this approach remains essential in many situations, it can be time- and labor-intensive, particularly for facilities operating on tight outage schedules.
In-line testing offers an alternative: verifying a valve’s set pressure and operation while it remains installed on the system. This approach helps plant operators:
- Avoid disassembly and reinstallation
- Reduce risks associated with transport and handling
- Complete testing with minimal interruption to operations
As plants look for ways to improve efficiency and reliability, many are turning to service providers to deliver accurate, well-documented in-line testing on-site.
Accuracy and Repeatability: Core Considerations
While in-line testing provides convenience, the quality of the test results remains critical. Test results often inform regulatory compliance and risk decisions. As such, the accuracy and repeatability of the testing method matter significantly.
Some in-line testing systems rely on manual methods, such as applying force using a hand jack. While functional, these tools can introduce variability due to differences in operator technique or environmental factors.
On the other hand, automated testing systems apply force through hydraulic or pneumatic actuators under controlled conditions. These systems often include digital instrumentation that captures and stores the test data automatically. This improves consistency and allows for better traceability.
Service providers considering in-line testing should carefully evaluate whether their methods can deliver the precision and documentation clients increasingly expect.
What Valves Are Typically Tested In-Line?
Not all valves are suitable for in-line testing. In-line testing is most commonly used for:
- Spring-loaded safety relief valves
- Valves with a known maintenance history
- Systems where temporary isolation and lift conditions can be simulated safely
Valves that may not be suitable for in-line testing include:
- Pilot-operated relief valves
- Valves requiring internal cleaning or mechanical inspection
- Valves in critical service with suspected damage or history of failure
In-line testing can function as a screening tool to help identify which valves require further evaluation or repair in the shop.
How Valve Testing Service Providers Can Prepare
Adding in-line testing to your services does not necessarily require major operational changes, but it does require attention to a few key areas:
- Equipment: In-line testing systems may be manual or fully automated. Accuracy, reliability, and data capture should all be considered when selecting equipment.
- Training: Technicians must understand how to operate the system safely, interpret results, and follow applicable standards or client procedures.
- Documentation: Clients may require timestamped digital records or reports aligned with internal standards, inspections, or audits.
- Communication: In-line testing requires clear coordination with plant maintenance teams, especially during outage windows or production downtime.
Complement, Don’t Compete
It’s important to remember that in-line testing isn’t a replacement for valve repair—it’s a complement.
You’re not giving up repair work; you’re giving clients a way to:
- Identify which valves need shop service
- Reduce unnecessary disassembly
- Test more frequently, creating new cycles of engagement
This diagnostic-first model improves everyone’s efficiency and strengthens your role as a trusted maintenance partner.
Stay Competitive. Stay Compliant. Start In-Line Testing.
In-line safety valve testing is becoming a standard expectation in industrial maintenance programs. For valve repair shops, it represents an opportunity to respond to customer needs while supporting more efficient, data-driven inspection practices.
By understanding the requirements, limitations, and tools involved, service providers can integrate in-line testing into their workflow to complement existing services and align with modern plant operations.
About AccuTEST Systems
AccuTEST Systems provides advanced, fully automated in-line safety valve testing systems designed to deliver accurate, consistent, and code-compliant results—directly in place. Our systems are trusted by valve repair shops and industrial facilities alike to reduce downtime, eliminate manual variability, and ensure traceable digital documentation for every test.
Interested in offering in-line testing as a service? Talk to an AccuTEST expert today. We’ll help you get started with the tools and support you need to grow.
