Methods and apparatus for quantifying pneumatic volume usage via valve controllers

A method, comprising:

• receiving a first input signal at a valve controller operatively coupled to a pneumatic actuator, the pneumatic actuator being operatively coupled to a control valve, the first input signal indicating that the valve controller is to operate the pneumatic actuator to move a flow control member of the control valve in a first direction;
• in response to receiving the first input signal, commanding, via one or more processors of the valve controller, a first current-to-pressure (I/P) converter of the valve controller to pulse, with a control signal, a first relay valve of the valve controller between a first closed position and a first open position, the control signal having (i) at least one pulse of a first duration during a first time interval and (ii) at least one pulse of a second duration different from the first duration during a second time interval, the second time interval non-overlapping with the first time interval, the pulsing of the first relay valve causing the pneumatic actuator to move the flow control member in the first direction, the pulsing of the first relay valve for the second duration to causing the pneumatic actuator to move the flow control member in the first direction;
• and
• calculating, via the one or more processors, a first pneumatic volume usage associated with the moving of the flow control member in the first direction, wherein the first pneumatic volume usage is calculated based on predetermined volumes of pneumatic pulses associated with the pulsing of the first relay valve during the first and second durations, and further based on (i) timing of the first and second time durations, and (ii) supply pressure data corresponding to the first and second durations, the supply pressure data measured by a first pressure sensor of the valve controller operatively positioned between a control fluid inlet of the valve controller and the first relay valve.

A non-transitory computer-readable storage medium comprising instructions that, when executed cause one or more processors of a valve controller to at least:

• obtain a first input signal, the first input signal indicating that the valve controller is to operate a pneumatic actuator operatively coupled to the valve controller to move a flow control member of a control valve in a first direction, the control valve being operatively coupled to the pneumatic actuator;
• in response to the first input signal, command a first current-to-pressure (I/P) converter of the valve controller to pulse a first relay valve of the valve controller between a first closed position and a first open position with a control signal having (i) at least one pulse of a first duration at a first time interval and (ii) at least one pulse of a second duration different from the first duration at a second time interval, the second time interval non-overlapping with the first time interval, the pulsing of the first relay valve for the first duration causing the pneumatic actuator to move the flow control member in the first direction, the pulsing of the first relay valve for the second duration to cause the pneumatic actuator to move the flow control member in the first direction;
• and
• calculate a first pneumatic volume usage associated with the moving of the flow control member in the first direction, wherein the first pneumatic volume usage is calculated based on predetermined volumes of pneumatic pulses associated with the pulsing of the first relay valve during the first and second durations, and further based on (i) timing of the first and second time durations, and (ii) supply pressure data corresponding to the first and second durations, the supply pressure data measured by a first pressure sensor of the valve controller operatively positioned between a control fluid inlet of the valve controller and the first relay valve.