Abstract: A system and method for controlling a field device includes a valve coupler having a first portion configured to couple to an actuator rod of an actuator, a second portion configured to couple to a movable component of a control valve, and one or more sensors measuring one or more parameters indicative of the health and/or remaining service life of the control valve assembly and/or one or more components of the valve assembly. Further, at least one of the one or more sensor devices may generate energy from the control valve assembly and/or the operating environment of the control valve assembly for operation of the electronics.

Abstract: A bellows energized seal assembly includes a seal body, a main seal that is axially slidable within the seal body, and a bellows connected to the seal body and the main seal. The bellows both biases the main seal and provides a seal between the seal body and the main seal.

Abstract: In a process plant, a first series of measurements from a coupling interface are received. The first series of measurements are stored. A second series of measurements from a coupling interface are received. The second series of measurements. The first series and second series of measurements are compared. An indication of loss of clamping force is generated if the first series of measurements deviates from the second series of measurements.

Abstract: A control element for a fluid flow control device includes a stem, a plug, and a fastener. The stem includes an elongated member with a first end and a second end. The first end is adapted to be operably coupled to an actuator and the second end including a fastener recess including a plurality of internal threads. The plug is disposed adjacent to the second end of the stem. The fastener fixing the plug to the stem and includes a threaded portion extending from the plug and engaging the plurality of internal threads of the fastener recess.

Abstract: In a process plant, a first series of impedance measurements from a valve body are received. The first series of impedance measurements are stored. A second series of impedance measurements from the valve body are received. The second series of impedance measurements from the valve body are stored. The first series and second series of impedance measurements are compared. An indication of loss of integrity of the valve body is generated if the first series of impedance measurements deviates from the second series of impedance measurements.

Abstract: A system and apparatus for detecting and monitoring cavitation inside a flow control device, such as a control valve, includes an acoustic emission sensor coupled to the flow control device in a manner to acquire acoustic signals caused by cavitation. A processor receives acoustic information from the acoustic emission sensor. The processor selectively identifies cavitation events from the acoustic information that meet certain predefined criteria. Cavitation levels are monitored based on at least one of a rate of cavitation events and intensity of individual cavitation events. The cavitation levels may be used to identify the presence of cavitation in the flow control device, to track accumulated cavitation in the flow control device, and/or to identify significant changes in the cavitation levels over time. This information may be used to reduce cavitation, estimate repair and maintenance, and/or monitor performance of the flow control device.

Abstract: A control element for a fluid flow control device includes a stem, a plug, and a fastener. The stem includes an elongated member with a first end and a second end. The first end is adapted to be operably coupled to an actuator and the second end including a fastener recess including a plurality of internal threads. The plug is disposed adjacent to the second end of the stem. The fastener fixing the plug to the stem and includes a threaded portion extending from the plug and engaging the plurality of internal threads of the fastener recess.

Abstract: A process control device is provided. The process control device includes a process control valve, an actuator, a digital valve controller (“DVC”), and a processor. The actuator is coupled to the process control valve and is configured to control a position of the process control valve. The DVC is communicatively coupled to the process control valve and the actuator. The DVC is configured to obtain first data and second data, the first data associated with a fluid flow through the actuator or the DVC at a first point in time, and the second data associated with the fluid flow through the actuator or the DVC at a second point in time different from the first point in time. The processor is configured to aggregate the first data and the second data, and perform diagnostic and/or prognostic techniques based on the aggregated data.

Abstract: An intelligent actuator for a control valve includes an actuator body, an actuator rod, a biasing device, a controller, and at least one sensor. The actuator body includes an actuator casing defining a cavity. The actuator rod is adapted to be coupled to a control element of a control valve. The biasing device is disposed in the cavity of the actuator housing and operably coupled to the actuator rod for biasing the actuator rod into a predetermined position. The controller is carried by the actuator body and includes a memory, a processor, and logic stored on the memory. The at least one sensor is operably coupled to the controller for measuring various parameters of the actuator and transmitting those parameters to the controller. The at least one sensor can include one or more vibration sensors, one or more acoustic sensors, one or more temperature sensors, etc.

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: A control element for a fluid flow control device includes a stem, a plug, and a fastener. The stem includes an elongated member with a first end and a second end. The first end is adapted to be operably coupled to an actuator and the second end including a fastener recess including a plurality of internal threads. The plug is disposed adjacent to the second end of the stem. The fastener fixing the plug to the stem and includes a threaded portion extending from the plug and engaging the plurality of internal threads of the fastener recess.

Abstract: A fluid valve includes a valve body having a fluid inlet and a fluid outlet connected by a fluid passageway. A valve seat is disposed within the fluid passageway. A fluid control member is movably disposed within the fluid passageway, the fluid control member cooperating with the valve seat to control fluid flow through the fluid passageway. A seal assembly is disposed within the valve body, the seal assembly preventing fluid from leaking through the valve body when the fluid control member is in a closed position. The seal assembly is made, at least in part, from a shape-memory alloy.

Abstract: A control valve monitoring system is disclosed. The control valve monitoring system includes at least one sensor connected to one of a valve stem or valve shaft, and the at least one sensor detects a change in mechanical integrity of one of the valve stem or valve shaft. A device for providing data regarding the change in mechanical integrity of one of the valve stem or valve shaft is provided, allowing maintenance of the valve shaft or valve stem to be conducted in an efficient manner.

Abstract: A bellows energized seal assembly includes a seal body, a main seal that is axially slidable within the seal body, and a bellows connected to the seal body and the main seal. The bellows both biases the main seal and provides a seal between the seal body and the main seal.

Abstract: In a process plant, a first series of impedance measurements from a valve body are received. The first series of impedance measurements are stored. A second series of impedance measurements from the valve body are received. The second series of impedance measurements from the valve body are stored. The first series and second series of impedance measurements are compared. An indication of loss of integrity of the valve body is generated if the first series of impedance measurements deviates from the second series of impedance measurements.

Abstract: In a process plant, a first series of measurements from a coupling interface are received. The first series of measurements are stored. A second series of measurements from a coupling interface are received. The second series of measurements. The first series and second series of measurements are compared. An indication of loss of clamping force is generated if the first series of measurements deviates from the second series of measurements.