How do you calculate actuator sizing workload?

Multiply the number of valve-actuator pairs by the average engineering hours per sizing, then add the review and coordination overhead. For 24 pairs at 2.5 hours each, base work is 9.6 hours and total workload is 12 hours at 25% overhead.

How long does it take to size one actuator?

A straightforward quarter-turn on/off sizing runs 1-2 hours; a modulating valve needing dynamic torque, stiffness, and supply-air checks can take 3-4 hours. The default 2.5 hr/pair reflects a mixed but mostly routine package.

What is a good safety factor for actuator sizing?

Common practice is 1.25 to 2.0 on required torque depending on service and standard, higher for dirty or infrequently cycled valves. The safety factor is part of the sizing time captured in the hours-per-pair input, not a separate field here.

Why include a review and coordination overhead?

Sizing outputs feed P&IDs, supply-air sizing, and vendor confirmation, and they get revised when valve data or process conditions change. The 25% overhead captures checking, revision rounds, and coordination with the valve and instrument groups.

How do I reduce actuator sizing hours per pair?

Standardize on a torque database, use vendor sizing software with vetted valve torque tables, and template the calculation sheet so reviewers check the same fields every time. Reducing revision rounds drops the overhead, not just the base hours.

Actuator sizing vs valve sizing workload?

Valve sizing solves for Cv and trim against process flow conditions; actuator sizing solves for torque or thrust to operate the chosen valve against differential pressure and friction. They are sequential tasks, and this calculator covers the actuator-sizing half.

Industrial Valves, Actuators & Flow Control calculator

Actuator Sizing Workload Calculator

Actuator sizing workload converts a list of valve-actuator pairs into the engineering hours needed to specify each actuator correctly. Application and project engineers use it to staff a sizing package, set delivery dates for an EPC submittal, and avoid the trap of promising actuator selections faster than the torque math, safety-factor checks, and supply-air calculations actually allow. Each sizing involves pulling required valve torque (including breakaway and seating), applying a safety factor, matching it to actuator output across stroke, and confirming air or motor supply — then it gets reviewed and revised. This calculator captures both the raw sizing time and the review and coordination churn that always surrounds it.

What this calculator does

Estimate total engineering hours needed to complete actuator sizing calculations for a project, based on valve count, average sizing time per valve-actuator pair, and review and revision overhead.
Use this when scoping engineering hours for an automation project that requires sizing pneumatic, electric, or hydraulic actuators to match valve torque or thrust requirements.
It computes total engineering hours to size a batch of valve-actuator pairs by multiplying pairs by hours-per-sizing and adding a review, revision, and coordination overhead.

Formula used

Base sizing hours = valve-actuator pairs x hours per sizing
Total actuator sizing workload = base hours x (1 + overhead / 100)

Inputs explained

Valve-actuator pairs to size:
Average engineering hours per sizing:
Review, revision, and coordination overhead:

How to use the result

Use it when planning a project's actuator selection package, staffing the application-engineering desk, or quoting sizing effort to an EPC or end user.
It assumes uniform complexity per pair, so it understates time when the batch mixes simple on/off ball valves with modulating control valves requiring detailed torque-versus-position and stiffness analysis.

Current U.S. benchmarks

The U.S. has 21,668 machinery manufacturing establishments employing about 1,086,146 workers (Census County Business Patterns, 2023).

Common questions

How do you calculate actuator sizing workload? Multiply the number of valve-actuator pairs by the average engineering hours per sizing, then add the review and coordination overhead. For 24 pairs at 2.5 hours each, base work is 9.6 hours and total workload is 12 hours at 25% overhead.
How long does it take to size one actuator? A straightforward quarter-turn on/off sizing runs 1-2 hours; a modulating valve needing dynamic torque, stiffness, and supply-air checks can take 3-4 hours. The default 2.5 hr/pair reflects a mixed but mostly routine package.
What is a good safety factor for actuator sizing? Common practice is 1.25 to 2.0 on required torque depending on service and standard, higher for dirty or infrequently cycled valves. The safety factor is part of the sizing time captured in the hours-per-pair input, not a separate field here.
Why include a review and coordination overhead? Sizing outputs feed P&IDs, supply-air sizing, and vendor confirmation, and they get revised when valve data or process conditions change. The 25% overhead captures checking, revision rounds, and coordination with the valve and instrument groups.
How do I reduce actuator sizing hours per pair? Standardize on a torque database, use vendor sizing software with vetted valve torque tables, and template the calculation sheet so reviewers check the same fields every time. Reducing revision rounds drops the overhead, not just the base hours.

Last reviewed 2026-05-12.