Abstract: A method for replacing a controller on a process device that avoids downtime on a process line. The method may include retrieving data from a first controller on a valve assembly, the data comprising information that defines values for operating parameters on the first controller, removing the first controller from the valve assembly, coupling a second controller to the valve assembly, and storing data on the second controller, the data comprising information that defines the values for operating parameters corresponding with the first controller.

Abstract: A system and method for predicting failure conditions on a valve assembly. The method can include stages for comparing a maintenance variable to a threshold criteria, each related to an operating feature that uses operating data to quantify operation of a valve assembly, the threshold criteria associating an operating pattern found in the operating data with a failure mode on the valve assembly. The method can also include stages for selecting a maintenance task according to a relationship between the maintenance variable and the threshold criteria, the maintenance task related to the failure mode. The method can further include stages for generating an output conveying the maintenance task.

Abstract: A system receives a plurality of data samples associated with a control valve with each of the plurality of data samples associated with a setpoint and a position. A first subset of the data samples that are in a control zone associated with normal operation of the control valve is determined. In a case that a second subset of the data samples are determined to be (i) not in the first subset and (ii) close to a minimum position of the plurality of data samples and (iii) have setpoints less than their associated positions, an alert associated with a low obstruction is indicated. In a case that a second subset of the data samples are determined to be (i) not in the first subset and (ii) close to the maximum position of the plurality of data samples and (iii) have setpoint greater than their associated position, an alert is indicated.

Abstract: A board-level assembly that is useful to expand functions of a valve positioner on a valve assembly. The board-level assembly can incorporate a main circuit board and a peripheral “smart” circuit board. The main circuit board may be configured to communicate with the smart circuit board, find a storage memory on the second circuit board, retrieve data from the storage memory, and use the data to configure functions on the first circuit board. In one implementation, the smart circuit board can release and engage the main circuit board. This configuration can allow different configurations of the smart circuit board to swap into the board-level assembly, each of the different configurations providing data the main circuit board can exploit to change the functions of the valve positioner.

Abstract: A method to detect cycling of components that result from use of a tight shut-off mode on a valve assembly. Embodiments of the method use operating data from the valve assembly. This operating data includes data that reflects a position for the closure member relative to the seat. This position often corresponds with a measured position of one or more components (e.g., the valve stem) on the valve assembly. In one embodiment, the method includes steps for comparing the measured position to a boundary criteria that defines one or more boundary values proximate, and often equal to, the threshold levels of the tight shut-off mode. The method can also includes steps for identifying patterns in the data that indicate that the closure member is cycling from its closed position to a second position due to tight shut-off mode.

Abstract: A method for replacing a controller on a process device that avoids downtime on a process line. The method may include retrieving data from a first controller on a valve assembly, the data comprising information that defines values for operating parameters on the first controller, removing the first controller from the valve assembly, coupling a second controller to the valve assembly, and storing data on the second controller, the data comprising information that defines the values for operating parameters corresponding with the first controller.

Abstract: A method for replacing a controller on a process device that avoids downtime on a process line. The method may include retrieving data from a first controller on a valve assembly, the data comprising information that defines values for operating parameters on the first controller, removing the first controller from the valve assembly, coupling a second controller to the valve assembly, and storing data on the second controller, the data comprising information that defines the values for operating parameters corresponding with the first controller.

Abstract: A valve positioning system controls a valve and exchanges information related to the valve. The valve positioning system includes a valve positioner in operative association with the valve such that the valve positioner receives status information related to the valve. The valve positioner includes one or more lights that are selectively illuminated in a predetermined order based on the status information. By selectively illuminating the one or more lights in the predetermined order, the valve positioner is optically transmits the status information to a computing device that is in a line of sight with the one or more lights of the valve positioner. A method of exchanging information related to a valve in a valve positioning system is also provided.

Abstract: A method to detect cycling of components that result from use of a tight shut-off mode on a valve assembly. Embodiments of the method use operating data from the valve assembly. This operating data includes data that reflects a position for the closure member relative to the seat. This position often corresponds with a measured position of one or more components (e.g., the valve stem) on the valve assembly. In one embodiment, the method includes steps for comparing the measured position to a boundary criteria that defines one or more boundary values proximate, and often equal to, the threshold levels of the tight shut-off mode. The method can also includes steps for identifying patterns in the data that indicate that the closure member is cycling from its closed position to a second position due to tight shut-off mode.

Abstract: A method for replacing a controller on a process device that avoids downtime on a process line. The method may include retrieving data from a first controller on a valve assembly, the data comprising information that defines values for operating parameters on the first controller, removing the first controller from the valve assembly, coupling a second controller to the valve assembly, and storing data on the second controller, the data comprising information that defines the values for operating parameters corresponding with the first controller.

Abstract: A board-level assembly that is useful to expand functions of a valve positioner on a valve assembly. The board-level assembly can incorporate a main circuit board and a peripheral “smart” circuit board. The main circuit board may be configured to communicate with the smart circuit board, find a storage memory on the second circuit board, retrieve data from the storage memory, and use the data to configure functions on the first circuit board. In one implementation, the smart circuit board can release and engage the main circuit board. This configuration can allow different configurations of the smart circuit board to swap into the board-level assembly, each of the different configurations providing data the main circuit board can exploit to change the functions of the valve positioner.

Abstract: A valve positioning system for controlling a valve and exchanging information related to the valve is provided. The valve positioning system includes a valve positioner in operative association with the valve such that the valve positioner receives status information related to the valve. The valve positioner includes a graphical display that displays a graphical representation based on the status information. By displaying the graphical representation, the valve positioner optically transmits the status information to a computing device that is in a line of sight with the graphical display of the valve positioner.

Abstract: A method for correcting calibration of a closure member on a valve assembly. The method can include comparing a calculated value to an expected value, each relating to a position of a closure member of the valve assembly relative to a seat of the valve assembly, the calculated value being calculated using a calibration variable and an input value corresponding to a measured position of the closure member. The method can also include identifying a deviation between the calculated value and the expected value. The method can further include changing the calibration variable from a first value to a second value in response to the deviation, the second value equating the calculated value at the input value with the expected value for the position.

Abstract: A method to detect cycling of components that result from use of a tight shut-off mode on a valve assembly. Embodiments of the method use operating data from the valve assembly. This operating data includes data that reflects a position for the closure member relative to the seat. This position often corresponds with a measured position of one or more components (e.g., the valve stem) on the valve assembly. In one embodiment, the method includes steps for comparing the measured position to a boundary criteria that defines one or more boundary values proximate, and often equal to, the threshold levels of the tight shut-off mode. The method can also includes steps for identifying patterns in the data that indicate that the closure member is cycling from its closed position to a second position due to tight shut-off mode.

Abstract: A system and method for predicting failure conditions on a valve assembly. The method can include stages for comparing a maintenance variable to a threshold criteria, each related to an operating feature that uses operating data to quantify operation of a valve assembly, the threshold criteria associating an operating pattern found in the operating data with a failure mode on the valve assembly. The method can also include stages for selecting a maintenance task according to a relationship between the maintenance variable and the threshold criteria, the maintenance task related to the failure mode. The method can further include stages for generating an output conveying the maintenance task.

Abstract: A valve positioning system for controlling a valve and exchanging information related to the valve is provided. The valve positioning system includes a valve positioner in operative association with the valve such that the valve positioner receives status information related to the valve. The valve positioner includes a graphical display that displays a graphical representation based on the status information. By displaying the graphical representation, the valve positioner optically transmits the status information to a computing device that is in a line of sight with the graphical display of the valve positioner.

Abstract: A method for correcting calibration of a closure member on a valve assembly. The method can include comparing a calculated value to an expected value, each relating to a position of a closure member of the valve assembly relative to a seat of the valve assembly, the calculated value being calculated using a calibration variable and an input value corresponding to a measured position of the closure member. The method can also include identifying a deviation between the calculated value and the expected value. The method can further include changing the calibration variable from a first value to a second value in response to the deviation, the second value equating the calculated value at the input value with the expected value for the position.

Abstract: A valve positioning system controls a valve and exchanges information related to the valve. The valve positioning system includes a valve positioner in operative association with the valve such that the valve positioner receives status information related to the valve. The valve positioner includes one or more lights that are selectively illuminated in a predetermined order based on the status information. By selectively illuminating the one or more lights in the predetermined order, the valve positioner is optically transmits the status information to a computing device that is in a line of sight with the one or more lights of the valve positioner. A method of exchanging information related to a valve in a valve positioning system is also provided.

Abstract: Embodiments of methods that are useful to avoid overflow in fixed-length buffers. In one embodiment, the methods dynamically adjust parameters (e.g., sample time) and reconfigure data in the buffer to allow new data samples to fit in the buffer. These embodiments allow data collection to automatically adapt, e.g., by adjusting the sample rate to allow the data to fit in the limited buffer size. These embodiments can configure hardware and/or software on a valve positioner of a valve assembly to improve data collection for use in on-line valve diagnostics and other data processing techniques.

Abstract: A system receives a plurality of data samples associated with a control valve with each of the plurality of data samples associated with a setpoint and a position. A first subset of the data samples that are in a control zone associated with normal operation of the control valve is determined. In a case that a second subset of the data samples are determined to be (i) not in the first subset and (ii) close to a minimum position of the plurality of data samples and (iii) have setpoints less than their associated positions, an alert associated with a low obstruction is indicated. In a case that a second subset of the data samples are determined to be (i) not in the first subset and (ii) close to the maximum position of the plurality of data samples and (iii) have setpoint greater than their associated position, an alert is indicated.