ISA-TR96.05.02:2022

ISA-TR96.05.02-2022, In-Situ Proof Testing of Automated Valves, provides comprehensive guidance on in-situ proof testing of automated on/off valves (excluding control valves) used in process safety applications. This technical report emphasizes the critical connection between valve design engineering and proof testing methods to make sure valves maintain functional integrity under normal and worst-case conditions. It details valve and actuator performance models, explains various test levels from basic full stroke testing without instrumentation to advanced external condition monitoring with calibrated sensors and discusses how to establish meaningful acceptance criteria based on margin analysis. It identifies common valve degradations and failure causes through a detailed failure mode and effects analysis (FMEA), ranks their likelihood and correlates them with the detection capabilities of different test approaches. This report stresses that effective proof testing must detect degradation early enough to prevent failures during accidents, discourages preconditioning before tests and emphasizes the importance of validated measurements and clear acceptance limits to enhance reliability and reduce the risk of failure on demand.