Smart Valve Adaptor with Integrated Electronics

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.