At SofTek Engineering, Profiler diagnostics are built around one core principle: you can’t trust advanced data if the mechanical fundamentals aren’t right.
That’s exactly where Level 2 testing fits in.
Level 2 is the corrective phase of Profiler diagnostics. It goes beyond basic verification and focuses on eliminating mechanical variables that directly impact valve response, repeatability, and data integrity. The goal is simple—prepare the valve’s actuator so that higher-level testing reflects true valve behavior.
Below is a breakdown of what’s addressed during Level 2 testing—and why it matters.
1. Eliminate Actuator Air Leaks
Even small air leaks introduce instability into actuator performance. Pressure loss, delayed response, and inconsistent stroke behavior can all distort diagnostic results.
During Level 2 testing, actuator air circuits are inspected and leaks are corrected to ensure:
Stable supply and balance pressure
Consistent actuator response
Reliable stroke and force data
Without this step, any advanced diagnostics are compromised from the start.
2. Adjust or Replace Springs (Bench Set Correction)
The actuator spring range—commonly referred to as the bench set—defines how the valve responds to control pressure and where it fails on loss of air.
In Level 2 testing, springs are:
Replaced if damaged or fatigued
Re-set to match the required bench set
Correct spring loading restores:
Proper fail position
Full, repeatable stroke
Predictable control behavior
3. Replace the Actuator (When Required)
If an actuator is undersized, damaged, or mismatched for the service conditions, no amount of tuning will correct performance issues.
When necessary, Level 2 testing includes actuator replacement to:
Match actuator output to valve requirements
Restore proper seating forces
Ensure reliable and stable control
This step prevents misdiagnosing valve internals when the root cause is actuator-related.
4. Replace Stem Packing
Worn or hardened packing increases stem friction, affects response time, and introduces variability into diagnostic results.
During Level 2 testing, packing is evaluated and replaced when needed to:
Reduce stem friction
Improve repeatability
Minimize leakage and fugitive emissions
Healthy packing is essential for accurate force and motion measurements.
5. Re-Torque Packing to Specification
Not all packing issues require replacement. Improper gland loading alone can cause inconsistent valve behavior.
Level 2 testing includes re-torquing packing to manufacturer or applicable standard specifications to:
Restore correct stem compression
Eliminate unnecessary friction
Stabilize valve response
This step ensures the valve operates as designed—without overloading or leakage.
Why Level 2 Testing Matters
Level 2 testing is not a “tune-up.” It’s a controlled correction phase that ensures mechanical integrity before deeper diagnostics begin.
By resolving actuator and packing-related issues early, Level 2 testing:
Removes false indicators from diagnostic data
Improves confidence in Level 3 results
Prevents unnecessary valve disassembly or replacement
In short—it makes every data point count.
Just Test It—The Right Way
Level 2 testing sets the foundation for accurate, defensible valve diagnostics. When mechanical variables are addressed first, Profiler can do what it does best: reveal true valve performance and internal health.
SofTek Engineering supports engineers and technicians with hands-on testing, training, and clear diagnostic reporting.
If you’re ready to strengthen your valve maintenance program,
JUST TEST IT.
