Smart Valve with Integrated Electronics

Abstract

The embodiments disclosed herein relate to an apparatus for monitoring a valve having a control element, wherein the control element is actuated by an actuator, having: a valve stem, wherein the valve stem is connected to the control element; a cavity defined within the valve stem; an electronics module embedded within the cavity of the valve stem, wherein the electronics module further has one or more sensors within the valve stem; and wherein the electronic module further has a microprocessor within the valve stem; and a conductor connecting the electronics module to the actuator.

1 . An apparatus for monitoring a valve having a control element, wherein the control element is actuated by an actuator, comprising:
 a valve stem, wherein the valve stem is connected to the control element;   a cavity defined within the valve stem;   an electronics module embedded within the cavity of the valve stem,
 wherein the electronics module further comprises one or more sensors within the valve stem; and wherein the electronic module further comprises a microprocessor within the valve stem; and 
   a conductor connecting the electronics module to the actuator.   
     
     
         2 . The apparatus according to  claim 1 , wherein the microprocessor within the valve stem further comprises an analysis unit configured to predict a condition of the valve. 
     
     
         3 . The apparatus according to  claim 2 , wherein the one or more sensors comprise a vibration sensor. 
     
     
         4 . The apparatus according to  claim 3 , wherein the one or more sensors further comprise a thermocouple. 
     
     
         5 . The apparatus according to  claim 4 , wherein the one or more sensors further comprise a strain gauge. 
     
     
         6 . The apparatus according to  claim 5 , wherein the strain gauge is mounted on an end of the electronics module. 
     
     
         7 . The apparatus according to  claim 6 , further comprising an epoxy between the electronics module and the cavity of the valve stem. 
     
     
         8 . The apparatus according to  claim 6 , wherein the cavity is defined along the length of the valve stem. 
     
     
         9 . The apparatus according to  claim 6 , wherein the cavity is a bore extending lengthwise through the valve stem. 
     
     
         10 . The apparatus according to  claim 6 , wherein the cavity is a slot extending lengthwise along the valve stem. 
     
     
         11 . A method for directly measuring a metric of a valve, comprising the steps of:
 providing a valve stem, wherein the valve stem defines a cavity;   embedding an electronics module in the cavity of the valve stem, wherein the electronics module further comprises a microprocessor within the valve stem;   connecting a conductor at one end of the conductor to the electronics module;   supplying power to the electronics module with the conductor;   receiving data from the electronics module with the conductor;   transmitting data to the electronics module with the conductor; and   providing a sensor in the electronics module, wherein the sensor is within the valve stem.   
     
     
         12 . The method according to  claim 11 , further comprising the steps of observing and recording the metric of the valve with the sensor;
 transmitting the metric from the sensor to the electronics module; and   comparing the observed and recorded metric with a stored data.   
     
     
         13 . The method according to  claim 12 , further comprising the step of predicting at least one of: a failure of the valve, a servicing interval of the valve, or a maintaining step for the valve. 
     
     
         14 . The method according to  claim 13 , further comprising the step of alerting of the predicted valve failure through a visual alarm. 
     
     
         15 . The method according to  claim 12 , wherein the metric comprises a torque of the valve and the sensor comprises a strain gauge in the valve stem. 
     
     
         16 . The method according to  claim 12 , wherein the metric comprises a vibration of the valve and the sensor comprises an accelerometer in the valve stem. 
     
     
         17 . The method according to  claim 12 , further comprising the step of providing a second sensor attached to an exterior wall of the valve stem, wherein the second sensor is a strain gauge. 
     
     
         18 . A method for acquiring data from a valve in a process system, comprising the steps of:
 embedding a microprocessor within a valve stem, wherein the valve stem is connected to the valve;   embedding a sensor within the valve stem;   transmitting signals representative of the valve data from the sensor to the microprocessor; and   receiving the transmitted valve data signals in the microprocessor within the valve stem to determine a valve condition.   
     
     
         19 . The method of  claim 18 , further comprising the steps of analyzing the transmitted valve data signals via the microprocessor and predicting the valve condition via the microprocessor. 
     
     
         20 . The method of  claim 19 , wherein the sensor comprises a strain gauge; and further comprising a temperature sensor embedded within the valve stem, and a vibration sensor embedded within the valve stem. 
     
     
         21 . An apparatus for monitoring a valve, comprising:
 a valve stem of the valve;   an electronics module in the valve stem, wherein the electronics module further comprises one or more sensors within the valve stem, wherein the one or more sensors are configured to collect data from the valve;   a microprocessor unit within the valve stem, and wherein the microprocessor unit is configured to receive data from the one or more sensors; and further wherein the microprocessor unit comprises:
 a data collection unit configured to receive data regarding the valve from the one or more sensors; 
 a risk assessment analysis unit configured to predict a condition of the valve based on the received data; 
 a historical data unit configured to compile data over time; 
 a comparative analysis unit configured to compare data via analysis; and 
 an implementation unit configured create and execute an implementation plan for remediation of the valve. 
   
     
     
         22 . The apparatus for monitoring the valve according to  claim 21 , wherein the microprocessor unit is configured to generate a report on the condition of the valve, wherein the condition of the valve is selected from: an actual failure of the valve, a likelihood of a potential failure of the valve, a probability of future failure of the valve, a need for service of the valve, and combinations thereof. 
     
     
         23 . The apparatus for monitoring the valve, according to  claim 21  wherein the one or more sensors is at least two sensors selected from the group of sensors consisting of a load cell, a strain gauge, a pressure sensor, an accelerometer, a 3-axis accelerometer, a temperature sensor, a thermocouple, a flow sensor, a current sensor, a pressure transducer, an emissions sensor, and a torque sensor.