By: Al Gunnarson, VP of Sales and Marketing Warren Controls, Inc.

For decades, selecting and sizing control valves was a complex and time-consuming task. Only large control valve manufacturers provided the necessary tools, and they were often restricted to specialists with deep technical expertise. However, modern online control valve sizing and selection tools have dramatically changed the landscape, making the process more accessible and efficient.

Today, valve professionals can avoid spending hours crunching numbers or navigating complex equations. Instead, they can use intuitive software to select the right valve for each specific application. This shift in technology not only simplifies the process but also improves accuracy, reducing the risk of operational inefficiencies or system failures. This article delves into the benefits of using these online tools and offers practical advice for getting started.

The Evolution of Valve Sizing and Selection

Before the advent of online tools, valve professionals relied heavily on printed tables from manufacturers. These tables provided essential information such as flow coefficient (Cv) and flow rates for specific pressure drops. However, critical factors like aerodynamic noise, flow velocity, and special flowing conditions were often missing. As a result, engineers were forced to perform numerous complex calculations, often spending up to 45 minutes on a single valve—and that was just the beginning. Calculating the necessary details for actuators and other accessories added more time and complexity.

Today, modern online sizing and selection tools eliminate the need for manual calculations, providing quick, reliable results. With just a few inputs—such as the type of fluid, temperature, and pressure—these tools can generate a comprehensive report outlining the most suitable valves for a given application. What once took weeks of labor to complete a valve project can now be completed in hours, allowing engineers to focus on other critical aspects of their projects.

However, while the technology is more accessible, getting started with these tools can still be a challenge for some professionals. Many struggle with understanding the requirements needed before entering data into the tool. Knowing how to prepare is key to a smooth experience.

Preparing to Use Sizing and Selection Tools

To successfully use online control valve sizing tools, it's essential to do the groundwork. Based on insights from Warren Controls, professionals should follow a structured approach before even opening the software. The preparation ensures they have the necessary information to input into the system and understand the valve's operational context.

Field Experience and Customer Insights

Real-world experience in the field is irreplaceable. Valve professionals need to understand the environment in which the valve will operate. This means engaging directly with plant managers, team leaders, and maintenance personnel to gain insights into application functions and interdependencies. This knowledge helps professionals anticipate potential issues and make more informed decisions during the sizing and selection process.

Thorough Application Understanding

Before diving into the tool, professionals should clarify critical questions about the application. For example, is it a new installation or a replacement valve? If the latter, why did the previous valve fail? Knowing whether the control is for temperature, pressure, or flow also plays a crucial role in the selection. Additional factors, such as the fluid type (water, steam, or chemical), temperature, and pressure conditions, must be gathered upfront. Having this information at hand makes the online tool easier to navigate and reduces the chances of errors or the need for guesswork.

Familiarity with Valve Series and Types

A critical but often overlooked aspect of using these tools is familiarity with the manufacturer's product lines. Just like choosing the right type of vehicle—whether a sedan or a truck—professionals need to know which valve series fits their requirements. Educating oneself about the strengths and weaknesses of each valve series, as well as its specific applications, can make the selection process much more efficient.

For example, some customers may prefer quarter-turn rotary valves for cost or space-saving reasons, while others might require globe control valves for more precise flow control. Understanding these preferences upfront and knowing the product specifications reduces frustration and ensures the right valve is selected the first time.

Educated Assumptions and Documentation

It's important to recognize that you may not always have complete information at the beginning of a project. For example, pressure drop is often an unknown factor, but the sizing program will still require this information to size a value. In such cases, professionals must make educated assumptions and document them for customer review. This approach keeps the process moving forward while ensuring that all decisions can be revisited if needed.

Mastering the Tool: A Continuous Learning Process

Using online valve sizing and selection tools efficiently is not a one-time effort but a continuous learning journey. Professionals need to keep themselves updated on new products, sizing methodologies, and valve technologies.

At Warren Controls, this means ongoing product training—whether through webinars, factory training sessions, or real-time assistance. According to Warren's expert team, professionals who regularly use these tools can complete a sizing and selection task in just 10 minutes, generating a report that includes all the necessary data and even a quote if the feature is enabled.

However, mastery of these tools requires dedication. Professionals need to immerse themselves in product specifications, familiarize themselves with the valve market, and engage in continuous self-education. Only then can they fully leverage the capabilities of these tools and provide the most accurate and efficient solutions for their customers.

Despite the advantages of online sizing and selection tools, some professionals encounter problems. Many users struggle because they don't have all the necessary information upfront, leading to guesswork and errors later in the process. Additionally, professionals may not know the full range of product options available to them, resulting in suboptimal valve selections.

To avoid these pitfalls, professionals should ensure they gather all relevant data before starting the process. They should also engage with their manufacturers early on to understand which tools and product lines are best suited to their needs. Finally, they should not hesitate to seek help from manufacturer representatives when needed.

Online control valve sizing and selection tools are powerful resources that have revolutionized the valve selection process. However, to make the most of these tools, professionals must approach the task with thorough preparation, continuous learning, and the support of their manufacturers. By following these best practices, valve professionals can ensure accurate selections, streamlined workflows, and improved operational outcomes.