Abstract: The claimed method and system develops a useful lifetime profile for a component of a process control device, such as a valve, and uses that lifetime profile to determine a projected remaining lifetime for the device component in operation. The lifetime profile is developed from using real world operational data of similar process control devices, used under substantially the same operating conditions as to be experienced during operation. Profiles may be developed for numerous device components, from which a projected lifetime profile for the entire process control device is developed. Based on the projected remaining lifetime, notification warnings may be sent to remote computers and maintenance scheduling may be automatically achieved.

Abstract: The claimed method and system develops a useful lifetime profile for a component of a process control device, such as a valve, and uses that lifetime profile to determine a projected remaining lifetime for the device component in operation. The lifetime profile is developed from using real world operational data of similar process control devices, used under substantially the same operating conditions as to be experienced during operation. Profiles may be developed for numerous device components, from which a projected lifetime profile for the entire process control device is developed. Based on the projected remaining lifetime, notification warnings may be sent to remote computers and maintenance scheduling may be automatically achieved.

Abstract: The claimed method and system develops a useful lifetime profile for a component of a process control device, such as a valve, and uses that lifetime profile to determine a projected remaining lifetime for the device component in operation. The lifetime profile is developed from using real world operational data of similar process control devices, used under substantially the same operating conditions as to be experienced during operation. Profiles may be developed for numerous device components, from which a projected lifetime profile for the entire process control device is developed. Based on the projected remaining lifetime, notification warnings may be sent to remote computers and maintenance scheduling may be automatically achieved.

Abstract: The claimed method and system develops accelerated aging test protocols for a component of a process control device, such as a polymeric component of a valve assembly, where the accelerated aging test protocol is specifically developed in response to expected operating conditions to be used during operation of the process control device in a process plant installation. Test data from the developed accelerated aging tests is analyzed to determine a projected lifetime profile of the component that profiles the component through failure under those expected operating conditions. Particular profiling for polymeric features includes oxidation failure profiling and other fatigue conditions.

Abstract: Methods and apparatus to use vibration data to determine a condition of a process control device are disclosed. An example apparatus includes a vibration monitoring circuit to: collect first vibration data associated with a process control device during calibration of the process control device; calculate an operating threshold of the process control device based on the first vibration data; collect usage information associated with the process control device, the usage information indicative of a remaining portion of useful life associated with the process control device; adjust the operating threshold based on the usage information, the adjusted operating threshold reflective of the remaining portion of useful life associated with the process control device; and determine a condition of the process control device if second vibration data associated with the process control device collected after the calibration exceeds the adjusted operating threshold.

Abstract: Example composite valve plugs and related methods are disclosed. Example apparatus disclosed herein include a valve plug tip, a valve plug body, and an additively deposited material. The valve plug tip includes a head portion and a tail portion extending from the head portion. The valve plug body includes a cavity extending from a first end of the valve plug body toward a second end of the valve plug body. The cavity matably receives the tail portion of the valve plug tip. The additively deposited material is bonded to the valve plug body to retain the tail portion of the valve plug tip in the valve plug body.

Abstract: Example composite valve plugs and related methods are disclosed. Example apparatus disclosed herein include a valve plug tip, a valve plug body, and an additively deposited material. The valve plug tip includes a head portion and a tail portion extending from the head portion. The valve plug body includes a cavity extending from a first end of the valve plug body toward a second end of the valve plug body. The cavity matably receives the tail portion of the valve plug tip. The additively deposited material is bonded to the valve plug body to retain the tail portion of the valve plug tip in the valve plug body.

Abstract: Methods and apparatus to use vibration data to determine a condition of a process control device are disclosed. An example apparatus includes a vibration monitoring circuit to: collect first vibration data associated with a process control device during calibration of the process control device; calculate an operating threshold of the process control device based on the first vibration data; collect usage information associated with the process control device, the usage information indicative of a remaining portion of useful life associated with the process control device; adjust the operating threshold based on the usage information, the adjusted operating threshold reflective of the remaining portion of useful life associated with the process control device; and determine a condition of the process control device if second vibration data associated with the process control device collected after the calibration exceeds the adjusted operating threshold.

Abstract: Methods and apparatus to use vibration data to determine a condition of a process control device are disclosed. An example method includes collecting first vibration data from a first sensor operatively coupled to a process control device during a calibration. The example method further includes calculating an operating threshold of the process control device based on the first vibration data, and determining a condition of the process control device if second vibration data associated with the process control device collected after the calibration exceeds the operating threshold.

Abstract: The claimed method and system develops accelerated aging test protocols for a component of a process control device, such as a polymeric component of a valve assembly, where the accelerated aging test protocol is specifically developed in response to expected operating conditions to be used during operation of the process control device in a process plant installation. Test data from the developed accelerated aging tests is analyzed to determine a projected lifetime profile of the component that profiles the component through failure under those expected operating conditions. Particular profiling for polymeric features includes oxidation failure profiling and other fatigue conditions.

Abstract: Methods and apparatus for estimating a condition of a seal of a rotary valve are disclosed. An example apparatus includes a housing and a processor positioned within the housing. The processor is to determine a seal wearing cycle of a flow control member of a rotary valve, the seal wearing cycle includes movement of the flow control member between a first position in contact with a seal and a second position. The processor is to determine a torque of an actuator operating the flow control member for the seal wearing cycle and estimate a condition of the seal based on the torque.

Abstract: Methods and apparatus for estimating a condition of a seal of a rotary valve are disclosed. An example method includes determining a seal wearing cycle of a flow control member of a rotary valve. The seal wearing cycle includes movement of the flow control member between a first position in contact with a seal and a second position. The example method further includes determining a torque of an actuator operating the flow control member for the seal wearing cycle and estimating a condition of the seal based on the torque.

Abstract: The claimed method and system develops a useful lifetime profile for a component of a process control device, such as a valve, and uses that lifetime profile to determine a projected remaining lifetime for the device component in operation. The lifetime profile is developed from using real world operational data of similar process control devices, used under substantially the same operating conditions as to be experienced during operation. Profiles may be developed for numerous device components, from which a projected lifetime profile for the entire process control device is developed. Based on the projected remaining lifetime, notification warnings may be sent to remote computers and maintenance scheduling may be automatically achieved.

Abstract: Methods and apparatus for estimating a condition of a seal of a rotary valve are disclosed. An example method includes determining a seal wearing cycle of a flow control member of a rotary valve. The seal wearing cycle includes movement of the flow control member between a first position in contact with a seal and a second position. The example method further includes determining a torque of an actuator operating the flow control member for the seal wearing cycle and estimating a condition of the seal based on the torque.

Abstract: A valve packing assembly for a control valve includes a seal assembly, a loading assembly, and a packing retainer. The seal assembly has a seal component to provide a fluid seal around a valve stem and an anti-extrusion component to substantially prevent extrusion of the seal component about the valve stem. The loading assembly is configured to advantageously provide a predetermined packing stress to the seal assembly that is in the same direction as a process stress applied to the seal assembly by a process fluid, thereby substantially reducing packing friction and packing wear in the control valve assembly.

Abstract: Methods and apparatus to use vibration data to determine a condition of a process control device are disclosed. An example method includes collecting first vibration data from a first sensor operatively coupled to a process control device during a calibration. The example method further includes calculating an operating threshold of the process control device based on the first vibration data, and determining a condition of the process control device if second vibration data associated with the process control device collected after the calibration exceeds the operating threshold.

Abstract: A valve packing assembly for a control valve includes a seal assembly, a loading assembly, and a packing retainer. The seal assembly has a seal component to provide a fluid seal around a valve stem and an anti-extrusion component to substantially prevent extrusion of the seal component about the valve stem. The loading assembly is configured to advantageously provide a predetermined packing stress to the seal assembly that is in the same direction as a process stress applied to the seal assembly by a process fluid, thereby substantially reducing packing friction and packing wear in the control valve assembly.

Abstract: The rubber compositions described herein have been found to have an exceptionally long life as a spring-biased actuator diaphragm material that maintains its position compressed, e.g., bolted, between opposed flanges, while maintaining excellent compressibility, low temperature flexibility, hydrocarbon resistance, abrasion resistance and mechanical strength. The compositions include a copolymer rubber component; a plasticizer for the copolymer rubber; a vulcanizing agent for the copolymer rubber; a silica filler; and a coupling agent, such as a silane coupling agent, capable of coupling the silica filler to the copolymer rubber.

Abstract: A valve packing assembly for a control valve includes a seal assembly, a loading assembly, and a packing retainer. The seal assembly has a seal component to provide a fluid seal around a valve stem and an anti-extrusion component to substantially prevent extrusion of the seal component about the valve stem. The loading assembly is configured to advantageously provide a predetermined packing stress to the seal assembly that is in the same direction as a process stress applied to the seal assembly by a process fluid, thereby substantially reducing packing friction and packing wear in the control valve assembly.