Flow control valve with integral sensor and controller and related method

A valve for measuring and controlling a fluid flow parameter, comprising:

• a valve assembly having an inlet, an outlet, and a passageway therebetween;
• a variable area flow orifice mounted in the passageway;
• a differential pressure sensor operable to sense a differential pressure across the variable area flow orifice and supply a differential pressure signal;
• an upstream conduit having an inlet coupled to the passageway upstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;
• a downstream conduit having an inlet coupled to the passageway downstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;
• a flow venturi coupled to the downstream conduit inlet and positioned proximate the variable area flow orifice;
• a pressure sensor coupled to the passageway, the pressure sensor operable to sense fluid pressure within the passageway and supply a fluid pressure signal;
• a temperature sensor coupled to the passageway and operable to sense fluid temperature and supply a fluid temperature signal;
• a position sensor operable to sense a position of the variable area flow orifice and supply a position signal;
• a processor coupled to receive the differential pressure signal, the upstream fluid pressure signal, the fluid temperature signal, and the position signal and operable to (i) determine the fluid flow rate in the passageway therefrom, and (ii) generate an orifice position control signal based on the determined fluid flow rate;
• and
• an actuator coupled to receive the orifice position control signal from the processor and operable, in response thereto, to vary an area of the variable area flow orifice, whereby fluid flow rate through the passageway is controlled.

A flow control valve for controlling the flow of a fluid in one or more parts of a system, the valve comprising:

• a) a valve assembly including:
• (i) a passageway having a flow passage extending between a fluid inlet and a fluid outlet, and
• (ii) a valve disk rotationally mounted within the flow passage and moveable through a plurality of positions each corresponding to a different flow area;
• b) a temperature sensor coupled to the passageway and operable to sense fluid temperature and supply a fluid temperature signal;
• and
• c) a housing assembly coupled to the valve assembly, the housing assembly enclosing:
• (i) a first pressure sensor in fluid communication with the passageway and operable to sense a first fluid pressure within the passageway and supply a first fluid pressure signal,
• (ii) a second pressure sensor coupled to the duct, the second pressure sensor operable to sense fluid pressure within the passageway and supply a second fluid pressure signal,
• (iii) a position sensor coupled to the valve element, the position sensor operable to sense a position of the valve element and supply a position signal, and
• (iv) a processor coupled to receive the first fluid pressure signal, the second fluid pressure signal, the fluid temperature signal, and the position signal and operable to determine a fluid flow parameter through the passageway therefrom.

A valve for measuring and controlling a fluid flow parameter, comprising:

• a valve assembly having an inlet, an outlet, and a passageway therebetween;
• a variable area flow orifice mounted in the passageway;
• a differential pressure sensor operable to sense a differential pressure across the variable area flow orifice and supply a differential pressure signal;
• an upstream conduit having an inlet coupled to the passageway upstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;
• a downstream conduit having an inlet coupled to the passageway downstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;
• a flow venturi coupled to the downstream conduit inlet and positioned proximate the variable area flow orifice;
• and
• a processor coupled to receive the differential pressure signal and operable to determine the fluid flow parameter in the passageway therefrom.

A method of determining a fluid flow parameter in a passageway having a variable area flow orifice, comprising:

• determining differential pressure across the variable area flow orifice;
• determining fluid pressure upstream of the variable area flow orifice;
• determining fluid temperature in the duct;
• determining a position of the variable area flow orifice;
• and
• determining the fluid flow rate parameter in the passageway based on the measured differential pressure, the measured upstream fluid pressure, the measured fluid temperature, and the determined valve position.