Smart valve with integrated electronics
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, including a valve stem having a bore therethrough, wherein the bore is defined by a wall of the valve stem, and further wherein the valve stem is connected at a first end to the actuator and at a second end to the control element; and an electronics module within the bore of the valve stem, wherein the electronics module further includes one or more sensors within the valve stem.
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 at a first end to the actuator and at a second end 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;
a conductor connecting the electronics module to the actuator;
wherein the electronics module further comprises a microprocessor;
an epoxy between the electronics module and the cavity of the valve stem; and
wherein the one or more sensors comprise a thermocouple.
2. The apparatus according to claim 1 , wherein the one or more sensors further comprise and accelerometer.
3. The apparatus according to claim 1 , wherein the one or more sensors further comprise a strain gauge mounted on an end of the electronics module.
4. The apparatus according to claim 1 , wherein the cavity is defined along the length of the valve stem.
5. 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 at a first end to the actuator and at a second end 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;
a conductor connecting the electronics module to the actuator;
wherein the electronics module further comprises a microprocessor;
an epoxy between the electronics module and the cavity of the valve stem; and
an aperture defined through the wall of the valve stem, and further wherein the one or more sensors comprise an emissions sensor.
6. 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;
connecting a conductor at one end to the electronics module, wherein the conductor is connected at an opposite end to an actuator of the valve;
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;
providing a sensor in the electronics module;
encasing the electronics module in epoxy in the cavity;
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;
wherein the metric comprises a torque of the valve and the sensor comprises a pressure sensor in the valve stem.
7. The method according to claim 6 , 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.
8. The method according to claim 7 , further comprising the step of alerting of the predicted valve failure through a visual alarm.
9. The method according to claim 6 , wherein the metric further comprises a vibration of the valve and further comprising an accelerometer in the valve stem.
10. The method according to claim 6 , 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.