Control Valves: Sizing, Selection and Maintenance

Overview

Control valves are the final elements in most process control loops, and their performance determines how well a plant can be controlled. A poorly sized, badly selected or worn control valve can cause oscillating loops, product quality problems, high energy use, noise, vibration and even safety incidents. In refineries, gas plants and petrochemical facilities, control valves often handle severe services involving high pressure drops, flashing, cavitation, erosive or corrosive fluids, so correct sizing, selection and maintenance are essential for safe and efficient operation.

This course provides a practical understanding of control valve sizing, selection and maintenance. Participants learn control valve functions, the main valve body types, trims and flow characteristics, and how valves interact with process control loops. The course covers sizing calculations for liquids and gases, the effects of flashing, cavitation and choked flow, noise prediction and control, and the selection of materials and trims for severe services. It also explains actuators, positioners and accessories, fail-safe actions, valve diagnostics and digital positioners, calibration and stroke testing, common problems such as stiction, hysteresis and leakage, and practical maintenance and overhaul procedures.

Objectives

• Explain control valve functions and their role in process control loops
• Compare valve body types, trims and inherent and installed characteristics
• Size control valves for liquid and gas services using standard methods
• Recognise flashing, cavitation, choked flow and noise and select solutions
• Select actuators, positioners, accessories and fail-safe actions
• Use diagnostics, calibration and stroke testing to assess valve condition
• Troubleshoot and maintain control valves to improve loop performance

Who should attend

Training methodology

The course combines explanation of control valve principles with real data sheets, sizing calculations, diagnostic reports and maintenance records. Participants size valves for liquid and gas services, check for cavitation and choked flow, select trims and materials for severe services, specify actuators and positioners and interpret valve signature and step test results. Cutaway valves and positioners are used to explain construction where available. Control loop trends are analysed to separate valve problems from tuning problems. Troubleshooting cases are solved in small groups, and each day ends with a short quiz.

Programme outline

Dates and fees

Certificate

Frequently asked questions