Abstract: The claimed method and system identifies faults and/or deterioration of components in a process control valve. The system may use different sensor combinations to provide the necessary data to compute irregular component integrity. Alerts may be generated to indicate potential component integrity problems. In particular, the system may detect potential deterioration and/or faults in actuator springs, pneumatic tubing and piping, and bellows seals. The claimed system may be communicatively coupled to a process control network to provide a more elaborate alarm system. Moreover, additional statistical methods may be used to refine the detection accuracy of the system.

Abstract: A method of diagnosing pressure boundary integrity of a control includes choosing a control valve having a valve body, determining a velocity profile within the control valve, choosing an area of the velocity profile, choosing a surface on an exterior of the valve body at or adjacent to the area, forming a pad on the exterior surface overlying the point, applying a testing device to the pad, and measuring a reference thickness of a wall of the valve body through the pad using the testing device. The method further includes applying the testing device to the pad at a time subsequent to measurement of the reference thickness, measuring a first thickness, and comparing the first thickness to the reference thickness. The comparison of the first thickness to the reference thickness can be used to calculate the amount of valve body wall lost during using and the remaining life of the control valve.

Abstract: A control valve assembly is capable of diagnosing malfunctions in the control valve assembly and discerning a location of a control fluid leak in the control valve assembly. The control valve assembly includes a control valve, an actuator and a positioner. The actuator includes an actuator vent in an actuator housing, the actuator vent being connected to a flow switch. By determining a flow condition through the actuator vent, the positioner determines whether a control fluid leak is located in a control line or in a diaphragm.

Abstract: A trim assembly for a control valve includes a seal for sealing a leak path, where the seal is provided to perform advantageously in high-temperature applications, e.g., applications including temperatures of at least 450° F. (232.22° C.). The control valve comprises a valve body and control element. The control element is disposed within the valve body for controlling the flow of fluid therethrough. The trim assembly comprises a valve seat and a retention ring. The valve seat is fixed to the valve body, and the retention ring is threadably connected to the valve seat. The seal can be effected by an annular graphite seal compressed between the trim assembly and the valve body, or by a metal-to-metal contact between the retention ring and the valve body.

Abstract: A trim assembly for a control valve includes a seal for sealing a leak path, where the seal is provided to advantageously in high-temperature applications, e.g., applications including temperatures of at least 450° F. (232.22° C.). The control valve comprises a valve body and control element. The control element is disposed within the valve body for controlling the flow of fluid therethrough. The trim assembly comprises a valve seat and a retention ring. The valve seat is fixed to the valve body, and the retention ring is threadably connected to the valve seat. The seal can be effected by an annular graphite seal compressed between the trim assembly and the valve body, or by a metal-to-metal contact between the retention ring and the valve body.

Abstract: The claimed method and system identifies faults and/or deterioration of components in a process control valve. The system may use different sensor combinations to provide the necessary data to compute irregular component integrity. Alerts may be generated to indicate potential component integrity problems. In particular, the system may detect potential deterioration and/or faults in actuator springs, pneumatic tubing and piping, and bellows seals. The claimed system may be communicatively coupled to a process control network to provide a more elaborate alarm system. Moreover, additional statistical methods may be used to refine the detection accuracy of the system.