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Control Valve Sizing & Selection
Published 9/2026
Created by ProjectEngPro Engineering and Project Management
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Level: Intermediate | Genre: eLearning | Language: English | Duration: 20 Lectures ( 3h 50m ) | Size: 2.2 GB
Cv and gas sizing, choked flow, cavitation, flashing, noise, trim and characteristic, actuators, diagnosis
What you'll learn
Work the liquid sizing equation through to a Cv, and convert between Cv and Kv with confidence Size gas and vapour service using expansion factor and pressure drop ratio, and identify choked flow Recognise flashing and two-phase service and size for it rather than finding it at commissioning Check a vendor sizing against first principles and know which inputs dominate the result Allocate pressure drop between valve and system, and defend the allocation to process and pump sizing Calculate valve authority and predict the installed characteristic from the inherent one Select linear, equal percentage or quick opening trim for the loop rather than by habit Predict cavitation from vena contracta pressure and match mitigation to the severity Predict aerodynamic noise and decide between low-noise trim and path treatment Diagnose stiction, deadband and hysteresis, and separate valve problems from tuning problemsRequirements
No prior control valve experience is required - Cv, pressure drop ratio, authority and characteristic are built up from the start Any engineering, technical or operations background is enough to follow the course Comfortable with basic algebra - the sizing equations are worked step by step, in full Helpful but not essential: a control valve datasheet or a vendor sizing printout from your own plant to check against No software or purchases needed - no sizing package, licence or standard needs to be boughtDescription
This course contains the use of artificial intelligence.
▸ The loop will not hold setpoint, and the valve is the reason far more often than the tuning is.
A control valve is the only part of a loop that has to move, and it is the part that is usually chosen last, sized on the wrong flow case and specified for a pressure drop that the pump was never asked to provide. The result is a valve that spends its whole life between five and fifteen percent open, where the installed characteristic is distorted, the gain is wrong and no amount of controller tuning will fix it.
The costs are ordinary and constant. A loop that oscillates and gets left in manual. A valve that cuts out its seat in eight months because the vena contracta pressure falls below vapour pressure on every stroke. A gas letdown valve that has to be lagged after commissioning because nobody predicted the noise. A pump running against a valve that is throttling away most of its head, every hour of every year, because the drop allocation was decided by whoever needed the margin most.
This course teaches sizing and selection as one activity: the sizing coefficient and the equations behind it, compressible flow and the choked condition, flashing and two-phase service, pressure drop allocation, valve authority and the installed characteristic, cavitation and noise prediction and their mitigation, then the datasheet, leakage class, commissioning and diagnosis that turn a specification into a working final element.
▸ Sizing, then the consequences of the sizing
Anyone can run a vendor sizing program. This course spends its time on the two things the program does not tell you - whether the inputs you gave it were the right ones, and what the resulting valve will be like to live with. The three flow cases are treated as a set rather than a maximum, because a valve sized only on maximum flow is a valve that cannot control at minimum flow.
Cavitation, flashing and choked gas flow are taught side by side because they are routinely confused and the remedies are entirely different. Cavitation can be designed out with staged pressure letdown or moved by changing back pressure. Flashing cannot - it can only be tolerated with geometry and materials. Choked gas flow limits capacity and drives noise. Telling them apart from the damage pattern is a skill the course teaches directly.
Five focused sections, worked through in an afternoon.
▸ What you will master
• Work the liquid sizing equation from first principles to a Cv, and convert confidently between Cv and Kv
• Size for gas and vapour service using the expansion factor and pressure drop ratio, and identify the critical flow condition where the valve chokes
• Recognise flashing and two-phase service, and size for it rather than discovering it at commissioning
• Check a vendor sizing against first principles and know which inputs move the answer most
• Allocate pressure drop between valve and system defensibly, and argue the allocation with process and pump sizing rather than accepting a rule of thumb
• Calculate valve authority, predict how the installed characteristic diverges from the inherent one, and choose linear or equal percentage trim to compensate
• Quantify what oversizing does to rangeability and low-flow control, and recognise it before the valve is bought
• Predict cavitation from vena contracta and vapour pressure, read the damage location as evidence, and match the mitigation to the severity
• Predict aerodynamic noise, decide whether to treat it at source with low-noise trim or in the path, and recognise when noise governs the selection
• Specify the valve on a datasheet - body, trim, actuator, fail position, leakage class and accessories - then diagnose stiction, deadband and hysteresis on the installed valve
▸
Who this course is for
Instrumentation and control engineers specifying and troubleshooting final control elements Process engineers producing control valve datasheets and setting the three flow cases Piping and mechanical engineers dealing with valve noise, vibration and downstream erosion Maintenance and reliability engineers working valves that cut out, stick or will not hold setpoint Commissioning engineers calibrating positioners and proving loops on site Graduate engineers moving into process, control or instrumentation rolesHomepage
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