Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Instrumentation and Control Technicians
• Control and Automation Engineers
• Process, Mechanical, and Production Engineers
• Maintenance Engineers and Technicians
• Plant Operators and Engineering Support Staff
• Anyone involved with flow control, valve selection, or maintenance activities

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants will be able to:

• Understand control valve components, functions, and operating principles
• Select appropriate valves and actuators based on process requirements
• Perform control valve sizing and flow capacity calculations
• Identify valve characteristics, cavitation, flashing, and noise issues
• Conduct diagnostic testing and troubleshoot common valve problems
• Implement effective maintenance practices to improve valve reliability

DAY 1

Introduction to Control Valves and Basic Principles

• Welcome and Introduction
• Pre-Test
• Role of Control Valves in Process Control
• Valve Components and Terminology
• Types of Control Valves: Globe, Ball, Butterfly, Plug, Diaphragm
• Basic Flow Principles and Valve Characteristics (Linear, Equal %, Quick-Opening)
• Exercise

DAY 2

Valve Sizing, Flow Calculations and Selection Criteria

• Control Valve Sizing Methodology
• Flow Coefficient (Cv) and Valve Capacity Calculations
• Pressure Drop, Flow Regimes, and Rangeability
• Cavitation, Flashing, and Noise Prediction
• Selecting the Right Valve for Application and Fluid Properties
• Exercise

DAY 3

Actuators, Positioners and Accessories

• Pneumatic, Electric, and Hydraulic Actuators
• Actuator Sizing and Selection
• Valve Positioners: Smart and Conventional
• I/P Converters, Air Supply, and Valve Accessories
• Control Signal Types and Response Characteristics
• Exercise

DAY 4

Valve Operation, Diagnostic Testing and Performance Evaluation

• Control Valve Operation Under Different Process Conditions
• Diagnostic Testing and Valve Signature Analysis
• Stroke Testing: Manual and Automated
• Identifying Stiction, Hysteresis, and Deadband Problems
• Using Digital Valve Controllers for Diagnostics
• Exercise

DAY 5

Valve Troubleshooting, Maintenance and Course Wrap-up

• Common Control Valve Faults and Failure Modes
• Maintenance Procedures and Best Practices
• Packing, Seals, Seats, and Trim Inspection
• Calibration and Loop Verification
• Post-Test
• Certificate Ceremony