Methods and systems providing operational surveillance of valves used in industrial applications

A method for monitoring operations of a valve at an industrial site, the method comprising:

• providing a cloud computing system located remotely from the industrial site;
• providing at least one sensor mounted on the valve at the industrial site, the at least one sensor including an acceleration sensor configured to acquire high-frequency valve acceleration sensor data corresponding to acceleration of the valve;
• providing a data acquisition unit located at the industrial site, the data acquisition unit including an interface to the at least one sensor;
• and
• providing a gateway device located at the industrial site that interfaces to the data acquisition unit and to the cloud computing system, the gateway device including:
• a first interface to the data acquisition unit;
• and
• a second interface to the cloud computing system,
• receiving, by the data acquisition unit, at least one sensor signal supplied by the at least one sensor;
• processing, by the data acquisition unit, the at least one sensor signal to extract time-series sensor data for supply to the gateway device, the time-series sensor data including the high-frequency valve acceleration sensor data acquired by the acceleration sensor;
• detecting, by the data acquisition unit, a valve actuation event based on sensor signals corresponding to valve actuation pressure and valve position;
• responsive to the detecting the valve actuation event:
• selectively extracting, by the data acquisition unit from the high-frequency valve acceleration sensor data, valve acceleration sensor data corresponding in time to the valve actuation event;
• discarding, by the data acquisition unit, high-frequency valve acceleration sensor data acquired during time intervals that do not correspond to the valve actuation event;
• and
• supplying, by the data acquisition unit, the time-series sensor data to the gateway device, the time-series sensor data including, for the high-frequency valve acceleration sensor data, only the selectively-extracted valve acceleration sensor data of the high-frequency valve acceleration sensor data;
• forwarding, by the gateway device, the time-series sensor data supplied by the data acquisition unit to the cloud computing system;
• and
• receiving, storing, and processing, by the cloud computing system, the time-series sensor data communicated from the gateway device for remote monitoring of operation of the valve at the industrial site.