Smart Valve Adaptor 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: an adaptor between the control element and the actuator, wherein the adaptor couples a valve stem of the control element to the actuator; and an electronics module contained within the adaptor, wherein the electronics module further comprises one or more sensors.

1 . An apparatus for monitoring a valve having a control element, wherein the control element is actuated by an actuator, comprising:
 an adaptor between the control element and the actuator, wherein the adaptor couples a valve stem of the control element to the actuator; and   an electronics module contained within the adaptor, wherein the electronics module further comprises one or more sensors.   
     
     
         2 . The apparatus according to  claim 1 , further comprising a conductor connecting the electronics module to the actuator. 
     
     
         3 . The apparatus according to  claim 2 , wherein the electronics module further comprises a microprocessor. 
     
     
         4 . The apparatus according to  claim 3 , further comprising a cable connected to the adaptor, wherein the cable is configured to provide data communication and power to the adaptor and electronics module. 
     
     
         5 . The apparatus according to  claim 3 , wherein the one or more sensors comprise an accelerometer. 
     
     
         6 . The apparatus according to  claim 3 , wherein the one or more sensors comprise a thermocouple. 
     
     
         7 . The apparatus according to  claim 3 , wherein the one or more sensors comprise a strain gauge mounted on an end of the electronics module. 
     
     
         8 . The apparatus according to  claim 3 , wherein the one or more sensors comprise an emissions sensor. 
     
     
         9 . The apparatus according to  claim 3 , further comprising a flexible mylar circuit coiled around the valve stem. 
     
     
         10 . A method for directly measuring a metric of a valve, wherein the valve is actuated by an actuator, comprising the steps of:
 coupling a valve stem of the valve to the actuator with an adaptor;   embedding an electronics module in the adaptor;   connecting a conductor at one end 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.   
     
     
         11 . The method according to  claim 10 , further comprising the step of encasing the electronics module in epoxy in the adaptor. 
     
     
         12 . The method according to  claim 11 , further comprising the steps of observing and recording a 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 the 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 pressure sensor on 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 on the valve stem. 
     
     
         17 . The method according to  claim 12 , further comprising the step of providing a second sensor attached to 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:
 coupling a valve stem of the valve to an actuator of the valve with an adaptor;   embedding a microprocessor within the adaptor;   embedding a sensor within the adaptor;   transmitting signals representative of the valve data from the sensor to the microprocessor; and   receiving the transmitted valve data signals to determine various valve parameters.   
     
     
         19 . An apparatus for monitoring a valve, comprising:
 a flow control element in the valve;   a valve stem connected to the flow control element;   an adaptor coupled to the valve stem and an actuator of the valve; and   an electronics module in the adaptor, wherein the electronics module further comprises one or more sensors proximate the flow control element.   
     
     
         20 . An apparatus for monitoring a valve, comprising:
 a flow control element in the valve;   a valve stem connected to the flow control element;   an adaptor coupled to the valve stem;   an electronics module in the adaptor, wherein the electronics module further comprises one or more sensors proximate the flow control element;   a plurality of sensors configured to collect data from the valve;   a microprocessor unit configured to receive data from the sensors;   wherein the microprocessor unit comprises:
 a data collection unit configured to receive data regarding the valve from the sensors; 
 a risk assessment analysis unit configured to evaluate a condition of the valve based on the received data; 
 a historical data unit to compile data over time; 
 a comparative analysis unit to compare data, determine or predict via analysis and responsive to the data collection unit, the risk analysis unit, and the historical data unit configured to generate a report detailing actual failure, a likelihood of a failure and/or a probability of future failure or need for service; and 
 an implementation unit configured create and execute an implementation plan for remediation of the valve. 
   
     
     
         21 . The apparatus for monitoring the valve, according to  claim 20  wherein the plurality of 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. 
     
     
         22 . The apparatus for monitoring the valve according to  claim 21 , wherein power and data is communicated to the valve, electronics module, and the sensors via a flexible circuit. 
     
     
         23 . The apparatus for monitoring the valve according to  claim 21 , wherein power and data is communicated to the valve, electronics module, and the sensors wirelessly.