Abstract: A real-time control system includes a faulty variable identification technique to implement a data-driven fault detection function that provides an operator with information that enables a higher level of situational awareness of the current and likely future operating conditions of the process plant. The faulty variable identification technique enables an operator to recognize when a process plant component is behaving abnormally to potentially take action, in a current time step, to alleviate the underlying cause of the problem, thus reducing the likelihood of or preventing a stall of the process control system or a failure of the process plant component.

Abstract: Heat tracing systems and related methods are disclosed. An example valve includes a valve body defining a fluid flow passageway between a primary inlet and a primary outlet. The body valve has a first face adjacent the main inlet, the first face including a first groove. A first cover is positioned over the first groove to define a first heat tracing path. A secondary inlet is formed in the valve body and fluidly coupled to the first heat tracing path. A secondary outlet formed in the valve body and fluidly coupled to the first heat tracing path.

Abstract: Valve handles and dual-valve assemblies having handles are disclosed herein. An example dual-valve assembly includes a first valve having a first shaft. The first valve has a plate with a notch. The dual-valve assembly also includes a second valve having a second shaft. The dual-valve assembly further includes a handle coupled to the first and second shafts, such that when the handle is rotated, the first and second shafts are rotated simultaneously. The handle includes a body and a flexible arm coupled to and extending from the body. The flexible arm has a lock edge sized to fit within the notch to limit rotation of the handle relative to the first and second valves.

Abstract: A process characteristic parameter determination system uses a process model and a tuning module to accurately determine a value for a process characteristic parameter within a plant without measuring the process characteristic parameter directly, and may operate on-line or while the process is running to automatically determine a correct value of the process characteristic parameter at any time during on-going operation of the process. The process characteristic parameter value, which may be a heat transfer coefficient value for a heat exchanger, can then be used to enable the determination of a more accurate simulation result and/or to make other on-line process decisions, such as process control decisions, process operational mode decisions, process maintenance decisions such as implementing a soot blowing operation, etc.

Abstract: A control system having a first pressure regulator, a downstream fluid control device, first pilot, and second pilot. The first pressure regulator has a fluid inlet, fluid outlet, and actuator assembly with a cavity divided into a first chamber and a second chamber. The downstream fluid control device has a second fluid inlet and a second fluid outlet. The first pilot has a first setpoint and the second pilot has a second setpoint, less than the first setpoint. The first and second pilots fluidly couple the second chamber to the second fluid outlet in a first mode of operation, isolate the second chamber from the second fluid outlet in a second mode of operation, and fluidly couple the second chamber to the fluid inlet in a third mode of operation.

Abstract: Balanced plug assemblies and pressure regulators having balanced plug assemblies are described herein. A pressure regulator disclosed herein includes a device body defining a fluid passageway between an inlet and an outlet. The device body defines a channel between the fluid passageway and a pressure sense chamber. The pressure regulator includes a seat in the fluid passageway, a stem having a flange, and a plug coupled to the stem. The pressure regulator also includes a stem guide disposed in the channel of the device body. The flange of the stem disposed in a balance chamber of the stem guide and divides the balance chamber into a first balance chamber portion and a second balance chamber portion. The stem guide at least partially forms a balance passage that fluidly couples the pressure sense chamber and the second balance chamber portion.

Abstract: Control valves and cages that are adapted to reduce flashing and cavitation. A cage for use with a control valve having an inlet, an outlet, and defining a flow passage between the inlet and the outlet. The cage includes a generally cylindrical body and having a central bore, an upper portion, and a lower portion and an inner wall, an outer wall, and an intermediate wall disposed between the inner wall and the outer wall. The inner wall includes an inlet opening and the outer wall including an outlet opening. The inner wall, the outer wall, and the intermediate wall cooperate to define a portion of the flow passage that extends from the inlet opening, through the cage along the inner wall, along the intermediate wall, past a terminal portion of the intermediate wall, along the outer wall, to the outlet opening.

Abstract: An adjustable cage assembly for a flow control device can include a first cage body and a second cage body. The first cage body can be rotationally fixed relative to the second cage body at a plurality of alignments to provide a flow opening of variable size for adjustable control of fluid flow areas through the adjustable cage assembly.

Abstract: A real-time control system includes a simulation system to implement a predictive, look-ahead function that provides an operator with information that enables a higher level of situational awareness of the expected transitional events of future steps within the control program or sequence logic. The simulation system enables future steps and transitions to be monitored before they actually occur, which enables the operator to recognize and potentially take action, in a current time step, to alleviate the underlying cause of the problem, thus reducing the likelihood of or preventing a sequence stall of the control program.

Abstract: A method of custom manufacturing a flame arrestor assembly configured to extinguish a flame propagating therethrough. The method includes creating a customized flame cell using an additive manufacturing technique, which generally includes forming a body and forming one or more channels in the body. The one or more channels define a flow path configured to transfer heat from a flame front propagating through the flow path to the body. The method also includes providing a housing, and securely arranging the flame cell within the housing.

Abstract: Plates and plate assemblies for noise attenuators and other devices and methods of making the same are described herein. An example plate assembly includes a support frame to be coupled to a body of the noise attenuator. The support frame has a plurality of radially extending ribs. The plate assembly also includes a disc-shaped plate having a plurality of openings forming flow paths to attenuate noise. The disc-shaped plate is coupled to the support frame such that pressure-induced loads on the disc-shaped plate are distributed to the plurality of radially extending ribs of the support frame.

Abstract: Methods, apparatus, systems and articles of manufacture are disclosed for leak detection from a thief hatch. An example thief hatch includes a vent control stem coupled to first and second sealing plates, the first and second sealing plates to control fluid flow through the thief hatch based on translation of the vent control stem, and an indicator extending from the vent control stem to provide a visual indication of a condition of the fluid flow.

Abstract: A laser detection system comprises a sample chamber configured to receive and contain a volume of sample gas, one or more lasers within at least one laser housing, wherein each laser is configured to produce a respective laser beam for excitation of one or more different materials in the sample gas and the one or more lasers are outside the sample chamber, a detector apparatus for detecting light output from the sample chamber, a first optical interface to the sample chamber having at least one window that is at least partially transparent to the laser beams from the one or more lasers, wherein the at least one laser housing is positioned in a close-coupling arrangement relative to the at least one window of the first optical interface such that, in use, the laser beams are substantially unmodified by passage between the laser housing and the at least one window.

Abstract: A vent limiting device adapted to be operably coupled to an exhaust vent of a fluid regulator. The vent limiting device includes a housing, a poppet disposed in the housing, and a retaining element arranged to retain the poppet in the housing. The housing has a fluid passageway extending between a fluid inlet and a fluid outlet. The poppet is movably disposed in the housing, responsive to pressure at the fluid outlet, to control fluid flow through the fluid passageway. The housing includes one or more retaining features that engage the retaining element to retain the retaining element in the housing.

Abstract: Testable, redundant pneumatic control assemblies and related systems and methods are described herein. An example pneumatic control assembly described herein includes first, second, and third parallel supply channels between a compressed air supply and valve header, first, second, and third parallel vent channels between a vent and the valve header, and first, second, third, fourth, fifth, and sixth logic valves. The first and sixth logic valves are disposed in the first parallel supply channel and the first parallel vent channel, the second and third logic valves are disposed in the second parallel supply channel and second parallel vent channel, and the fourth and fifth logic valves are disposed in the third parallel supply channel and third parallel vent channel. The pneumatic control assembly also includes a first, second, and third solenoid valves to control certain ones of the logic valves.

Abstract: A real-time control system includes a fault detection training technique to implement a data-driven fault detection function that provides an operator with information that enables a higher level of situational awareness of the current and likely future operating conditions of the process plant. The fault detection training technique enables an operator to recognize when a process plant component is behaving abnormally to potentially take action, in a current time step, to alleviate the underlying cause of the problem, thus reducing the likelihood of or preventing a stall of the process control system or a failure of the process plant component.

Abstract: Methods and apparatus to optimize ramp rates in combined cycle power plants are disclosed herein. An example method disclosed herein includes predicting a first setpoint for a gas turbine in a combined cycle power plant over a prediction horizon and predicting a second setpoint for a steam generator over the prediction horizon. The example method includes identifying a first steam property of steam generated by the steam generator in the combined cycle power plant based on the second setpoint. The example method includes comparing the first steam property to a second steam property of steam associated with a steam turbine in the combined cycle power plant and dynamically adjusting at least one of the first setpoint or the second setpoint based on the comparison.

Abstract: An actuator of a process control device continuously monitors actuator force and records high force values at each position point by continuously executing a routine in a processor of the actuator. The routine includes receiving from a position sensor a current position value indicating a position of a valve element in the valve, and from a force sensor a current force value indicating a force applied by the actuator. The routine also includes retrieving, from a memory device coupled to the processor, a previous force value measured at the current position, and comparing the current force values for the current position with the previous force value for the current position. If the current force value for the current position exceeds the previous force value for the current position, the routine replaces the previous force value for the current position with the current force value for the current position in memory.

Abstract: Methods and apparatus are disclosed to determine material parameters of a turbine rotor. An example apparatus includes a rotor geometry determiner to determine a geometry of the rotor, a node radius calculator to calculate radial node locations of radial nodes including a first radial node, a thermocouple interface to record first temperature values over an interval, a first thermal stress calculator to calculate first thermal stress values at one or more of the radial nodes over the interval, a node temperature calculator to calculate second temperature values at respective internal nodes of the first radial node, a reference value lookup to lookup first material parameter information, a second thermal stress calculator to determine second thermal stress values, a thermal stress comparator to calculate a difference between the thermal stress values, and, in response to the difference not satisfying a threshold, a material parameter adjuster to determine material parameters.

Abstract: A control assembly can be configured for use with a pressure regulator having a valve body defining a fluid flow path. The control assembly can include a control member, a stem, and a lever, and can be disposed within the pressure regulator to selectively control fluid flow. The control assembly can include a primary control member and a secondary control member, or a mechanical stop that can operate to restrict flow along the fluid flow path, including when the stem disconnects from the lever.