WO2005097792A1

WO2005097792A1 - Device and method for pneumatic valve control

Info

Publication number: WO2005097792A1
Application number: PCT/US2005/011566
Authority: WO
Inventors: Leo Minervini; Eric Jordan
Original assignee: Westlock Controls Corporation
Priority date: 2004-04-05
Filing date: 2005-04-05
Publication date: 2005-10-20
Also published as: EP1733161A4; WO2005097792A8; EP1733161A1

Abstract

A valve control apparatus (10) includes an enclosure (12, 14) that defines first and second chambers (16), an indicator (24) that is proximate the first and second chambers (16), an operating media distribution system (20) that is disposed in the first chamber (12), an electronic control unit that is disposed in the second chamber and a plurality of connection ports (34). The first and second chambers (16) are spaced from each other along a longitudinal axis. The indicator (24) has a visual symbol (388) that identifies an operational state of at least one process valve (3).

Description

DEVICE AND METHOD FOR PNEUMATIC VALVE CONTROL

Cross-Reference to Related Applications This application claims the benefit of the earlier filing date of U.S. Provisional Application No. 60/559,002, filed 5 April 2004, which is incorporated by reference herein in its entirety.

Field of the Invention The present invention relates generally to a valve controller, further to an actuator within an integrated valve controller. The present invention also relates to systems that include the valve controller and operational methods for monitoring the operational characteristics of a valve through knowledge-based valve performance criteria.

Background of the Invention Valve control systems are known in the related art. A valve control system may be used, for example, to continuously control the position of a valve based on pneumatic pressure. A valve control system may also have the capability to indicate valve position. A valve control system may further have the capability to monitor valve operation and signal an error message, if a failure condition occurs.

Summary of the Invention The present invention relates to a low profile multi-purpose pneumatic valve controller with an operating media distribution system. The valve controller may be used to control one process valve with increased air flow dynamics, provide redundant control for one process valve, or control two independent valves. The valve controller may be configured with integral pressure sensors to allow for advanced diagnostics that can be tailored to a particular valve and/or actuator. The valve controller may also be configured to automatically acquire and process data to create advanced diagnostic methods and systems. The valve controller may have an enclosure that includes various features that can be utilized to achieve other functions in addition to simply house the valve controller. For example, the valve controller may have separate enclosures for mechanical and electronic components, and the separate enclosures may define chambers for all components to avoid exposure to operative conditions. The valve controller enclosure may be configured to integrate with an actuator, such that the integrated valve controller may have separate chambers for mechanical and electronic components. The integrated actuator and valve controller with separate chambers may allow for a method of maintenance for the valve controller that only requires access to either mechanical or electrical chambers. The valve controller may have a height profile of no more than 3 inches. The valve controller with a height profile of no more than 3 inches may be capable of providing two pneumatic control signals from a single pneumatic control supply, and may be provided with an integrated actuator. According to a preferred embodiment, a valve control apparatus includes an enclosure that defines first and second chambers, an indicator proximate the first and second chambers, an operating media distribution system disposed in the first chamber, an electronic control unit disposed in the second chamber, and a plurality of connection ports. The first and second chambers are spaced from each other along a longitudinal axis. The indicator has a visual symbol that identifies an operational state of at least one valve. The operating media distribution system includes an operating media supply passage, an operating media exhaust passage, at least three operating media transmission passages, and a plurality of valves in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least three operating media transmission passages. The electronic control unit operates at least one of the plurality of valves to control operating media flow in the operating media distribution system. And the plurality of connection ports communicate with the operating media supply passage, the operating media exhaust passage, and the at least three operating media transmission passages. According to another preferred embodiment, a valve control apparatus includes an enclosure, an operating media distribution system that is disposed in the enclosure, an electronic control unit that is disposed in the enclosure, at least one sensor that is disposed in the enclosure, and a plurality of connection ports. The operating media distribution system includes an operating media supply passage, an operating media exhaust passage, at least two operating media transmission passages, and a valve that is in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least two operating media transmission passages. The electronic control unit operates the valve to control operating media flow in the operating media distribution system. The sensor evaluates the operating media distribution system and provides information to the electronic control unit about at least one operating condition in at least one of the passages. And the plurality of connection ports are in fluid communication with the operating media supply passage the operating media exhaust passage, and the at least two operating media transmission passages. The valve controller may have a beacon (position indicator) located between separate chambers for mechanical and electronic components. The size of the beacon (position indicator) may be selected to allow for viewing by an observer from a remote location. The beacon (position indicator) may operate via a non-contact position sensor. The valve controller with a beacon (position indicator) disposed adjacent operative components may be viewed from a site range both above and below the centerline of a position indicator. The position indicator may be a rotary or linear configuration. The valve controller and beacon (position indicator) may also be integrated with an actuator to provide an integrated actuator and valve controller, the valve controller having a beacon (position indicator) located between separate chambers for mechanical and electronic components. The integrated actuator and valve controller may be configured to provide the valve controller with a beacon (position indicator) disposed adjacent operative components so that it can be viewed by an observer from a site range both above and below the center line of a position indicator. Design aspects of the valve controller package are unique. For example, the valve controller enclosure or package may have a housing with the enclosure being a bow-tie configuration, or may be contained within a limited size space. According to a preferred embodiment, an apparatus that distribμtes operating media includes an enclosure, an indicator proximate the enclosure, an operating media distribution system disposed in the enclosure, and a plurality of connection ports that communicate with the operating media distribution system. The enclosure includes upper and lower surfaces that respectively define first and second parallel planes, and the enclosure is located entirely within a distance between the first and second planes. The indicator includes a visual symbol that identifies an operational state of the at least one process valve. The visual symbol is visible from above the first plane and from below the second plane. According to another preferred embodiment, a valve control apparatus for at least one process valve that has a maximum exterior package dimension. The apparatus includes an enclosure that is disposed entirely between first and second parallel planes. The first and second parallel planes are spaced apart a distance that is less than or equal to the exterior package dimension. The apparatus further includes an indicator that is proximate the enclosure, an operating media distribution system, an electronic control unit and at least one sensor that are disposed in the enclosure, and a plurality of connection ports that communicate with the operating media distribution system. The indicator includes a visual symbol that identifies an operational state of the at least one process valve. The visual symbol is visible from above the first plane and from below the second plane. And the at least one sensor evaluates the operating media distribution system and provides the electronic control unit information about at least one operating condition in the operating media distribution system. The valve controller may have a manifold assembly having one, two three or four integral coils and one or two spools. The valve controller may use the same fasteners to secure the cover to the manifold and the manifold assembly to the base of a housing. The valve controller may include a pneumatic manifold assembly that uses a cover to define pneumatic operative paths. The valve controller may have a housing with a single pneumatic supply path, two separate pilot paths, a single exhaust path, and an individual pressure sensor for each path. Two of the sensors can be differential pressure sensors. According to a preferred embodiment, a manifold apparatus that distributes operating media includes a first member that defines an operating media supply cavity, an operating media exhaust cavity, and at least four operating media transmission cavities in communication with the operating media supply cavity and the operating media exhaust cavity. The apparatus further includes a surface that communicates a flow of operating media flow between a minimum of two of the at least four operating media transmission cavities. According to another preferred embodiment, an apparatus for distributing an operating media includes a manifold that has an operating media supply passage, an operating media exhaust passage, and first, second, third and fourth operating media transmission passages. The apparatus further includes a means for directing the operating media from the operating media supply passage to the first and third operating media transmission passages, and a means for directing the operating media to the operating media exhaust passage from the second and fourth operating media transmission passages. The valve controller may provide for different operative arrangements. The valve controller may have a single pneumatic supply port that allows for two operational control signals. The two operational control signals may provide a first command signal and a second command signal to a single valve. The first command signal may be a discrete command signal. The second command signal may be a modulating command signal. The valve controller may be integrated with an actuator, the valve controller having a single pneumatic supply port that allows for two operational control signals. The valve controller may be used to operate a valve with two different command signals from a single pneumatic supply port. The valve controller may be used in a method of operating an integrated actuator with two different command signals from a single pneumatic supply port. The valve controller may have a single pneumatic supply port that allows for two operational control signals. The two operational control signals may provide a discrete command signal to a first valve and a separate discrete command signal to a second valve. The valve controller may be integrated with an actuator, the valve controller having a single pneumatic supply port that allows for two separate and identical operational control signals. The valve controller may be configured to provide a method of controlling fail-safe operation of two valves with a single supply. According to a preferred embodiment, a system, which controls two process valves, includes a manifold, a surface, and first and second process valves. The manifold defines a member that defines an operating media supply cavity, an operating media exhaust cavity, and at least four operating media transmission cavities in communication with the operating media supply cavity and the operating media exhaust cavity. The surface communicates a flow of operating media between a minimum of two of the at least four operating media transmission cavities. The first process valve actuator includes a first operating media port that is connected to the first operating media transmission cavity, and a second operating media port that is connected to the second operating media transmission cavity. And the second process valve actuator includes a third operating media port that is connected to the third operating media transmission cavity, and a fourth operating media port that is connected to the fourth operating media transmission cavity. According to another preferred embodiment, a method of distributing operating media includes introducing an operating media supply to a manifold, allotting within the manifold the operating media supply to at least four operating media transmission passages, transporting to a first actuator operating media from a first minimum of two of the at least four operating media transmission passages, and collecting in an operating media exhaust passage exiting the manifold operating medium from a minimum of two of the at least four transmission passages. According to another preferred embodiment, a method of distributing operating media include connecting an operating media supply to a manifold. The manifold defines an operating media supply passage, an operating media exhaust passage, a first operating media transmission passage, a second operating media transmission passage, a third operating media transmission passage, and a fourth operating media transmission passage. The method further includes directing operating media from the operating media supply to the first and third operating media outlet passages, and directing operating media from the second and fourth operating media outlet passages to the operating media exhaust passage. The valve controller may have knowledge-based valve performance

("performance") attributes. The functionality of the microprocessor and methods for implementing performance attributes are developed by generic process flow charts that relate the evaluated pressures and the valve condition determined from the evaluated pressures. The valve controller with integral pressure sensors can be used to profile pressures of a single supply port and a single exhaust port so that diagnostics and fault monitoring can be accomplished with a microprocessor. Diagnostics for the performance attributes may include: (1) a "Factory Torque Profile", (2) a "Commissioned Torque Profile" and (3) a "Maintenance Torque Profile". Performance attribute fault monitoring may include: (1) "Insufficient Line Pressure to Guarantee Correct Operation", (2) "Supply Pressure Failure", (3) "Naive Shaft Bent", (4) "Naive Not Achieving Full Stroke", (5) "Backlash Detection", (6) "Torque Demand of Naive Approaching Actuator limit", (7) "Valve Seating/ Break-Out Torque Monitoring", (8) "Torque Limit Exceeded", (9) "Close on Torque", (10) "Shaft Broken", (11) "Naive Exercise", (12) "Naive Packing Torque", (13) "Line Filter and Silencers Conditions", and (14) "Solenoid Spool Sticking". Methods of valve diagnostics and fault monitoring provided by a valve controller with integrated pressure sensors are described. Each of the diagnostic capabilities of the valve controller has a separate method. For example, the "Commissioned Torque Profile" or "Maintenance Torque Profile" may be used to compare with a factory torque profile to detect any fouling of the valve disc or deformation of the valve seat. In another example, the "Insufficient Line Pressure to Guarantee Correct Operation" fault monitoring can be used to indicate that the air supply pressure to a valve may not be sufficient to guarantee either opening or closing. In another example, the "Supply Pressure Failure" fault monitoring may be used to indicate that supply line pressure has fallen bellow a required amount. In yet another example, "Naive Shaft Bent" fault monitoring may be used with a phase shift of torque profile to determine if a valve shaft is bent. Remote communication with the valve controller can be provided via wire or wireless technology. Each of the features for protection with respect to the valve operative arrangements and knowledge based valve performance can be used with a short-range wireless protocol, or a communication method via the Internet. The combination of knowledge based valve performance with remote communications via the Internet provides various opportunities to implement maintenance and monitoring of valves at a location remote from the location of maintenance staff. For example, the valve controller can be used with a method of maintaining the operative performance of two valves, including evaluating the operative conditions of two valves with a single valve controller, communicating the operative conditions of the two valves to a remote location via an internet communication link, and changing operative commands of the valve controller via an internet communication link. Sub-components of the valve controller may have preferred embodiments. For instance, features of the pneumatic manifold assembly/manifold may have a preferred embodiment. In one example, the manifold assembly may include a manifold with coils and spools. In another example, the manifold assembly may have a single supply path, two pilot paths, and a single exhaust path. The manifold assembly may further be a monolithic member or a two-piece member. The two-piece member may include a base and a cover, the cover defining paths within the base. In another example, the manifold assembly may include a manifold with two coils, two spools, and sensors. In another example, the manifold assembly may a single supply path, two pilot paths, and single exhaust path that can be used as a stand alone valve controller island. In yet another example, the manifold assembly may be operatively associated with an electronic controller disposed in the enclosure, the manifold assembly having a single supply path, two pilot paths, and single exhaust path. In another embodiment, the manifold assembly may be operatively associated with existing smart valve controllers. Moreover, features of the mechanical enclosure may be preferred. For example, in one embodiment the mechanical enclosure may include a pneumatic manifold assembly and a manifold block. In another embodiment, the mechanical enclosure may be packaged together with a separate electronic enclosure. In another embodiment, the mechanical enclosure may be used as a stand-alone valve controller island. Additionally, features of the beacon (position indicator) housing and beacon (position indicator) may be preferred. For example in one embodiment, the beacon (position indicator) may have a housing that defines a viewing window for a position indicator and a mounting surface generally parallel to a longitudinal axis of the position sensor. According to a preferred embodiment, a manifold apparatus, which distributes operating media, includes first and second members. The first member has a plurality of cavities, including an operating media supply cavity, that transport operating media, and the second member defines a surface that cooperates with the first member so as to contain and transport operating media between at least two cavities. Systems that include the valve controller or utilize a feature on the valve controller are described. For example, the valve controller can be used in a system of piping including a first pipe, a second pipe proximate the first pipe, a valve disposed between the first pipe and the second pipe, a valve actuator that operates the valve, and a valve controller that operates the valve actuator, the valve controller including a housing having a single supply path that feeds two separate pilot paths, the two separate pilot paths having a common exhaust path. Further details of the system are described to specify various illustrative uses of the valve controller. For example, piping to the controller can be defined. According to a preferred embodiment, a piping system includes a first pipe, a first process valve that is connected to the first pipe, a first actuator that operates the first process valve, and a device that controls the first actuator. The device includes an enclosure that defines first and second chambers, an indicator proximate the first and second chambers, an operating media distribution system disposed in the first chamber, and an electronic control unit disposed in the second chamber. The first and second chambers are spaced from each other along a longitudinal axis. The indicator has a visual symbol that identifies an operational state of at least one valve. The operating media distribution system includes an operating media supply passage, an operating media exhaust passage, at least three operating media transmission passages, and a plurality of valves in fluid communication with the operating media supply passage, the' operating media exhaust passage, and the at least three operating media transmission passages. And the electronic control unit operates at least one of the plurality of valves to control operating media flow in the operating media distribution system. According to another preferred embodiment, a piping system includes a first pipe, a first process valve that is connected to the first pipe, a first actuator that operates the first process valve, and a device that controls the first actuator. The device includes an enclosure, an operating media distribution system disposed in the enclosure, an electronic control unit that is disposed in the enclosure, and at least one sensor that is disposed in the enclosure. The operating media distribution system includes an operating media supply passage, an operating media exhaust passage, at least two operating media transmission passages, and a valve that is in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least two operating media transmission passages. The electronic control unit operates the valve to control operating media flow in the operating media distribution system. And the sensor evaluates the operating media distribution system and provides information to the electronic control unit about at least one operating condition in at least one of the passages. According to yet another preferred embodiment, a piping system includes a first pipe, a first process valve that is proximate the first pipe, a first actuator that operates the first process valve, and an operating media distribution system that controls the first actuator. The operating media distribution system includes a manifold. The manifold defines an operating media supply passage that introduces operating media into the operating media distribution system from outside the housing, an operating media exhaust passage that discharges operating media from the operating media distribution system to outside the housing, and at least four operating media transmission passages that are in fluid communication with the operating media supply and exhaust passages. A minimum of two of the at least four operating media transmission passages are in fluid communication with the first actuator.

Brief Descriptions of the Drawings The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate an embodiment of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention. Figure 1 A is a perspective view of an exemplary embodiment of a system including a preferred embodiment of a pneumatic valve controller, the valve controller having separate chambers for mechanical and electrical components. Figure IB is a perspective view, with the cover removed, of the valve controller illustrated in Figure 1 A. Figure 2 is a view, taken along line 2-2 in Figure 1 A, showing in cross-section an enclosure for the pneumatic valve controller illustrated in Figure IB, and showing in elevation internal components of the pneumatic valve controller. Figure 3 A is a perspective view of a pneumatic manifold assembly for the valve controller illustrated in Figure IB. Figure 3B is a schematic diagram of selected features of the manifold assembly illustrated in Figure 3 A. Figures 4A is a top plan view, showing internal cavities in hidden lines, of a bottom portion of the manifold assembly illustrated in Figure 3 A. Figures 4B is a left-side plan view of a bottom portion of the manifold assembly illustrated in Figure 3 A. Figures 4C is a back plan view of a bottom portion of the manifold assembly illustrated in Figure 3 A. Figures 4D is a bottom plan view, showing internal cavities in hidden lines, of a bottom portion of the manifold assembly illustrated in Figure 3 A. Figures 4E is a right-side plan view of a bottom portion of the manifold assembly illustrated in Figure 3A. Figures 5 A is a left-side plan view of a top portion of the manifold assembly illustrated in Figure 3 A. Figures 5B is a top plan view of a top portion of the manifold assembly illustrated in Figure 3A. Figures 5C is a right-side plan view of a top portion of the manifold assembly illustrated in Figure 3 A. Figures 5D is a front plan view of a top portion of the manifold assembly illustrated in Figure 3 A. Figures 5E is a bottom plan view of a top portion of the manifold assembly illustrated in Figure 3 A. Figure 5F is a back plan view of a top portion of the manifold assembly illustrated in Figure 3 A. Figure 6 is a front plan view of the pneumatic manifold assembly illustrated in Figure 3A. Figures 6A is a cross-section view taken along line 6A-6A in Figure 6. Figures 6B is a cross-section view taken along line 6B-6B in Figure 6. Figures 6C is a cross-section view taken along line 6C-6C in Figure 6. Figures 6D is a cross-section view taken along line 6D-6D in Figure 6. Figures 6E is a cross-section view taken along line 6E-6E in Figure 6. Figures 6F is a cross-section view taken along line 6F-6F in Figure 6. Figures 6G is a cross-section view taken along line 6G-6G in Figure 6. Figures 6H is a cross-section view taken along line 6H-6H in Figure 6. Figure 7 A is a top plan view of a cap portion of the manifold assembly illustrated in Figure 3 A. Figure 7B is a front plan view of a cap portion of the manifold assembly illustrated in Figure 3 A. Figure 7C is a bottom plan view of a cap portion of the manifold assembly illustrated in Figure 3 A. Figure 8 is a partial top plan view including tubing connecting pressure sensors to monitoring ports on the manifold assembly illustrated in Figure 3 A. Figure 9 A is a view, taken along a portion of line 2-2 in Figure 1A, showing in cross-section an enclosure for the pneumatic valve controller illustrated in Figure IB, and showing partially in cross-section and partially in elevation a valve position indicator of the pneumatic valve controller. Figure 9 A accurately depicts the scale and relative proportion of the features shown therein. Figure 9B is a perspective view of the valve position indicator illustrated Figure 9 A. Figure IB accurately depicts the scale and relative proportion of the features shown therein. Figure 10A is a plan view of electrical components of the valve controller illustrated in Figure IB. Figure 1 OB is a front view of electrical components illustrated in Figure 10A. Figures 11 A, 1 IB and 11C are schematic diagrams illustrating an electrical circuit of the valve controller illustrated in Figure IB. Figure 12A is a schematic diagram illustrating a first preferred embodiment of a piping system with a valve controller, as shown in Figure IB, in an exemplary configuration for independently controlling two process valves. Naive actuators for both process valves are show in a zeroed position. Figure 12B is a schematic diagram similar to Figure 12A except showing in a spanned position the valve actuators for both process valves. Figure 13 A is a schematic diagram illustrating a second preferred embodiment of a piping system with a valve controller, as shown in Figure IB, in an exemplary configuration for controlling one process valve. The valve actuator for the process valve is shown in a zeroed position. Figure 13B is a schematic diagram similar to Figure 13 A except showing in a spanned position the valve actuator for the process valve. Figure 13C is a schematic diagram similar to Figures 13A and 13B except showing in a partially stroke position the valve actuator for the process valve. Figure 14A is a schematic diagram illustrating a third preferred embodiment of a piping system with a valve controller, as shown in Figure IB, in an exemplary configuration for controlling one process valve. The valve actuator for the process valve is shown in a zeroed position. Figure 14B is a schematic diagram similar to Figure 14A except showing in a spanned position the valve actuator for the process valve. Figure 15 is a chart showing exemplary data describing the relationship between valve controller air supply pressure and valve position. Figures 1A, IB, 2, 3A, 4A-4E, 5A-5F, 6, 6A-6H, 7A-7C, 8, 9A and 9B accurately depict the scale and relative proportion of the features shown therein.

Detailed Description of the Preferred Embodiments Figure 1A illustrates an exemplary embodiment of a piping system 1 including a process valve 3, an actuator 5 for the process valve 3, and a valve controller 10 with enclosures 12,14 for mechanical and electronic components. Referring additionally to Figure IB, the enclosures define chambers 16 for all components to avoid exposure to operative conditions. Referring back to Figure 1 A, releaseably securable enclosure covers 18a, 18b, which may be independently removed, separately cover enclosures 12,14, respectively. The enclosure covers 18a,18b allow for maintenance of the valve controller 10 such that access to either the mechanical or electrical chamber only is required for service. Alternatively, a single cover could be used in place of separate enclosure covers 18 a, 18b. As shown in Figure IB, the valve controller 10 may have separate enclosures 12,

14 for mechanical and electronic components, one enclosure 12 may provide housing for mechanical components such as a pneumatic manifold assembly 20 and another enclosure 14 may provide space in the chamber 16 for electronic components such as circuit boards including a microprocessor and/or other circuits, as will be described further with respect to Figure 10A. The enclosures may have any shape and configuration as long as they define at least one chamber for all components to avoid exposure to operative conditions. For instance, the separate enclosures 12,14 may abut or be situated adjacent to one another, and form a particular shape. For example, the valve controller 10 may have a polygonal shape with each enclosure 12,14 forming a portion of the polygonal shape. According to a preferred embodiment, the valve controller 10 may have a bow-tie shape. The enclosures 12,14 for mechanical and electrical components may be separated by a third enclosure 22 for housing a valve position indicator 24. The third enclosure 22 may include an independently and releasably securable cover 22a. The third enclosure cover 22a may also have a bow tie configuration, the tapered sides of the third cover 22a allowing the valve position indicator 24 to be directly visible from a site range above the centerline of the position indicator 24. The third enclosure cover 22a, however, may have any shape or configuration provided it allows the valve position indicator to be viewed from a position above the valve controller. Further, the three enclosures 12,14,22, may have any configuration that provides direct visibility of the position indicator 24. For example, the valve controller 10 may have a suitable shape such as, for example, square, rectangular, oval-like or circular configuration such that the shape allows the valve position indicator 24 to be directly visible to an observer from a site range both above and below the center line of the position indicator 24. Similarly, any number of members may be used to cover the enclosures provided the members cooperate with the enclosures to define at least one chamber for all components to avoid exposure to operative conditions. Thus, in one example, the cover may be a unitary member. In another example, the cover may have two members. The valve controller enclosures 12,14,22 and covers 18a,18b,22a may be formed from any suitable metal, alloy, composite, or plastic material. For example, one or more of the independently removable enclosure covers 18a,18b,22a may be formed from a transparent plastic material. Similarly, as shown in Figure 1 A, one or more of the enclosures 12,14 and enclosure covers 18a, 18b may be fashioned from opaque plastic materials. The valve controller enclosures 12,14,22 and covers 18a,18b,22a may further be made from corrosion resistant materials such as polypropylene. The enclosure and covers may also be adapted for approved use in hazardous atmospheres. As shown in Figure 2, the valve controller 10 of Figure IB has a height profile h that is measured from between parallel planes 17a, 17b. According to a preferred embodiment, the top and bottom surfaces of the enclosure of valve controller 10 coincide with parallel planes 17a,17b. Essentially, the process valve 3, including the actuator 5, has a maximum exterior package dimension, i.e., the distance between the distal most points of the combination process valve 3 and actuator 5, that is greater than the height profile h. Preferably, height profile h of the enclosure of valve controller 10 is about three inches. In the preferred embodiment illustrated in Figure 2, height profile h is about 2.725 inches. Referring back to Figures 1 A and IB, the valve position indicator 24 may also have a beacon or position indicator 26 or visual signal for identifying the position or operating state of one or more process valves that are being controlled by the controller. For example, the beacon 26 may provide a distinct visual signal for a process valve operating under normal conditions in an open position, closed position, or an intermediate position between the open and span position. As described further below with respect to Figure 9B, the valve position indicator 24 may also have a distinct visual beacon signal 26 for identifying the state of at least one, and preferably two, independent process valves that are being controlled by the controller. The valve position indicator 24 may be a rotary or linear, and may be located between separate chambers 12,14 for mechanical and electronic components. The size of the beacon 26 may be selected to allow for viewing from a remote location. The valve position indicator 24 may be disposed adjacent operative components so that beacon 26 can be viewed from a site range both above and below the* centerline of the position indicator. The beacon 26 may operate, for example, via a non-contact position sensor (not shown) such that the valve controller 10 need not be integrally connected to a process valve actuator. Alternatively, the valve position indicator 24 may have a shaft (not shown) that is operatively coupled directly to the actuator for the process valve 3, so that movement of the actuator directly rotates the beacon 26 to indicate the position of the process valve 3. Referring to Figure 3 A, valve controller 10 has one manifold inlet operating media supply port 28, one manifold outlet operating media exhaust port 30, and four operating media transmission ports 32 for process valve actuator operation. The ports 28,30,32 are adapted to connect to one-half inch NPT or M20 conduit (not shown) with suitable conduit attachment members 34 on a port manifold 36 of the valve controller 10. The port manifold 36 is located at the base of manifold assembly 20. Manifold assembly 20 includes port manifold 36 (lower manifold portion), manifold 38 (upper manifold portion), spool valve assembly 40, manifold cap 42, and coil bank assembly 44. As shown in Figure IB, manifold assembly 20 may also include one or more pressure sensors (two exemplary pressure sensors 346 and 356 are indicated in Figure IB). Referring to Figures 3 A and 3B, manifold assembly 20 has one inlet air supply that is directed to two spool valves 48,50, via separate supply cavities 52,54. The inlet air supply is also directed to four separate poppet cavities 56,58,60,62, which set the configuration of the spool valves 48,50. The supply of inlet air to the poppet cavities 56,58,60,62 is regulated by four actuators, for example, electromagnetic solenoid valves or micro-poppets 64,66,68,70. For example, valves 64,66,68,70 can be part number A00SC231P solenoid valves manufactured by Parker Hannifin Corporation® (Richland, Michigan). The single exhaust outlet 30 is diverted into eight exhaust cavities 72,74,76,78,80,82,84,86. Exhaust cavities 80,82,84,86 are not depicted in Figure 3B, but are shown in Figures 5 A-5F as described further below. Exhaust cavities 72,74,76,78 of manifold 38 join four cavities 88,90,92,94 of port manifold 36. Referring additionally to Figures 4A-4E, port manifold 36 accepts an external operating media, e.g., air, supply to inlet air supply port 28, which transports the inlet air supply to the manifold 38 via a pair of supply cavities 52,54. Inlet air supply cavity 28 also has a secondary external port 96 for possible emergency pressure relief. Port manifold 36 collects manifold 38 exhaust for discharge to the ambient atmosphere at exhaust port 30. Port manifold 36 separately collects and transports spool valve 48,50 exhaust from four cavities 72,74,76,78 in the manifold 38 to external ports 88,90,92,94, which can be used to operate up to two pneumatic valve actuators. Port manifold 36 can also serve as a structural base for seating the manifold 38, spool valve assemblies 48,50 and/or the mechanical enclosure 12. Port manifold 36 has a groove 36a for receiving a gasket 98, four fastener holes 100 for securing the port manifold 36 to the manifold 38, and four fastener holes 102 for securing the manifold assembly 36,38 to the medial portion of the enclosure 12. Referring to Figures 5A-5F, manifold 38 contains and transports compressed air between the port manifold 36, spool valves 48,50 and coil bank assembly 44 in conjunction with the manifold cap 42. Manifold 38 preferably includes a monolithic member 104. As it is used herein, the term "monolithic" refers to a single, uniform whole member, preferably formed of a homogeneous material. The monolithic member 104 has at least one outer surface 106. As shown in Figures 5A-5E, the manifold 38 preferably includes six outer surfaces or sides 108,110,112,114,116,118 (e.g., "left-side", "top", " right-side", "front", "bottom", and "rear" surfaces). The six outer surfaces 108,110,112,114,116,118 form a rectangular block having a length, width and height, such that a distance measured between the front and rear surfaces 114,118 defines the length of the block, a distance measured between the top and bottom surfaces 110,116, defines the height of the block, and a distance measured between the right-side and left- side surfaces 108,112 defines the width of the block. Preferably, the length of the manifold 38 is greater than the width, and the width is greater than the height. As described further below the outer surfaces 108,110,112,114,116,118 of the manifold 38 have openings that are in fluid communication with a plurality of internal cavities. The manifold has openings on five sides 108,110,112,114,116, such that the rear side 118 of the block does not have a cavity opening. The manifold 38 can be made of any suitable material, such as for example, metal, alloy, composite, and plastic materials. At ambient temperatures, the block material and internal cavity configuration should be capable of containing and transporting operating media, for example, non-lubricated air filtered to about 20 microns (or some other fluid), at temperatures between about -4 degrees Fahrenheit to 180 degrees Fahrenheit and at pressures of between about 45 to 120 pounds per square inch gauge. As shown in Figure 5 A, left side surface 108 includes three fastener holes 150, one inlet air supply cavity 52 and one inlet air supply transfer cavity 132f, two poppet cavity transfer cavities 124,138, two spool valve exhaust cavities 72,74, and two poppet cavity exhaust cavities 80,82. As shown in Figure 5B, top surface 110 includes four fastener holes 120, four spool valve exhaust pressure momtoring port cavities 72,74,76,78, four poppet cavity exhaust cavities 80,82,84,86, one manifold exhaust cavity 122, four poppet cavity transfer cavities 124,126,128,130, and two inlet air supply transfer cavities 132,134. As shown in Figure 5C, right side surface 112 includes three fastener holes 150, one inlet air supply cavity 54 and one inlet air supply transfer cavity 132e, two poppet cavity transfer cavities 140,128, two spool valve exhaust cavities 76,78, and two poppet cavity exhaust cavities 84,86. As shown in Figure 5D, front surface 114 includes four fastener holes 136, four inlet air supply transfer cavities 132a, 132b, 132c, 132d, four poppet cavity transfer cavities 138,126,130,140, and four solenoid (or micro-poppet) exhaust cavities 142,144,146,148. The four solenoid exhaust cavities discharge to poppet cavity exhaust cavities 82,86. As shown in Figure 5E, bottom surface 116 includes four fastener holes 120, two manifold inlet air supply cavities 52,54, four spool valve exhaust cavities 72,74,76,78, one manifold exhaust cavity 122, and one gasket seat cavity 152. As shown in Figure 5F, the rear surface 118 does not include any openings. Figures 6A-6H illustrate the internal pathways, connections and spatial relationships between the internal cavities identified in Figures 4A-4E and 5A-5F. These pathways, connections and spatial relationships between the internal cavities provide means for directing operating media flow between the operating media supply passage 28, the operating media exhaust passage 30, and the media transmission passages 32. Referring to Figure 6H, spool valve 48 and spool valve 50 direct airflow though the manifold 38 to operate one or more pneumatic valve actuators. Each spool valve 48,50 includes a spool valve assembly 40. Each spool valve 48,50, which may be constructed according to known techniques, includes a valve body 154 and a spool assembly 156, and two valve caps 158. For example, spool valves 48,50 can be part number 92273U-1 spool assemblies manufactured by Numatics® (Highland, Michigan). As shown in Figure 6H, valve body 154 encloses spool assembly 156 and includes and two poppet cavities 160, 162 that operate to contain operating media from poppet transport cavities (e.g., 128,140) in manifold 38, and to direct manifold inlet air supply to an appropriate exhaust cavity (e.g., 78,76). Valve body 154 includes outer surfaces (e.g., six according to the preferred embodiment), some or all of which may have openings in fluid communication with a plurality of internal cavities. According to a preferred embodiment, the manifold assembly 20 includes a first operating media distribution valve, e.g., spool valve 48, in fluid communication with the operating media supply cavity 28, first and second ones of the operating media transmission cavities 32, and the operating media exhaust cavity 30. The first operating media distribution valve 48 includes a first configuration that A) connects the operating media supply cavity 28 with the first one of operating media transmission cavities 32, and B) connects the second one of the operating media transmission cavities 32 with the operating media exhaust cavity 30. The first operating media distribution valve 48 also includes a second configuration that C) connects the operating media supply cavity 28 with the second one of the operating media transmission cavities 32, and D) connects the first one of the operating media transmission cavities 32 with the operating media exhaust cavity 30. The manifold assembly 20 also includes a second operating media distribution valve, e.g., spool valve 50, in fluid communication with the operating media supply cavity 28, first and second ones of the operating media transmission cavities 32, and the operating media exhaust cavity 30. The second operating media distribution valve 50 includes a third configuration that A) com ects the operating media supply cavity 28 with the third one of operating media transmission cavities 32, and B) connects the fourth one of the operating media transmission cavities 32 with the operating media exhaust cavity 30. The second operating media distribution valve 50 also includes a fourth configuration that C) connects the operating media supply cavity with the fourth one of the operating media transmission cavities 40, and D) connects the third one of the operating media transmission cavities 32 with the operating media exhaust cavity 30. The first, second, third and fourth configurations provide means for directing operating media flow between the operating media supply passage 28, the operating media exhaust passage 30, and the media transmission passages 32. The valve body 154 can be made of any suitable material, such as for example, metal, alloy, composite, and plastic materials. At ambient temperatures, the valve material and internal cavity configuration should be capable of containing and transporting operating media, for example, non lubricated air filtered to about 20 microns (or some other fluid), at a temperature between about -4 degrees Fahrenheit to 180 degrees Fahrenheit and at pressures of between about 45 to 120 pounds per square inch gauge. The valve material and internal cavity configuration should also be capable of containing and transporting operating media, preferably air, at a flow rate of about 5 standard cubic feet per minute at about 40 pounds per square inch to about 100 standard cubic feet per minute at about 120 pounds per square inch. Referring additionally to Figure 3 A, the valve body 154 includes at least one fastener 164 (e.g., three are shown per valve body 154) securing the valve body 154 to the manifold 38. Each of the valve caps 158 is secured to the valve body 154 by at least one fastener 166 (e.g., two are shown per valve cap 158). Individual valve caps 158 are configured and dimensioned to be releasably secured to opposite surfaces of valve body 154 so as to retain spool assembly 156 within valve body 154 and to contain operating media in spool valve poppet cavities 160,162. Spool assembly 156 selectively directs spool valve inlet air supply from cavity 180 to one of two spool valve exhaust cavities 182,184. The spool assembly 156, in a known manner, has a length measured from end to end that is less than the length of a bore of the valve body 154. Spool assembly 156 includes at least one internal bore (not shown) and a plurality of apertures 214 extending from the outer surface of spool assembly 156 to the bore. Apertures 214 are preferably of equal size and are preferably spaced in a uniform pattern uniformly about at least one designated portion of spool assembly 156. According to a preferred embodiment, a pattern including five rings of radially aligned apertures 214 is alternately disposed with six radial grooves 215 spaced equidistant along spool assembly 156. Each radial groove 215 is configured and dimensioned to receive a gasket material such as an o-ring (not shown). The inner surface of the bore of valve body 154 is generally smooth and has a diameter that is sized and configured to telescopically receive spool assembly 156. Referring to Figures 7A-7C, as well as to Figures 6A-6G, manifold cap 42 is releasably securable to manifold 38 to contain and transport operating media, such as compressed air, between four poppet cavity exhaust cavities 80,82,84,86 and the manifold exhaust cavity 122, two pairs of poppet cavity transfer cavities 124,126,128,130, and one pair of inlet air supply transfer cavities 132,134. Manifold cap 42 includes a generally planar member having top and bottom surfaces 288,290 and four bores or fastener holes 292 extending from the top surface 288 to the bottom surface 290. The bores 292 are generally located around the periphery of the top surface 288. The bottom surface 290 is generally flat and smooth. The bottom surface 290 has four recesses 294 extending from the bottom surface toward the top surface. One recess 294a is generally U-shaped and three recesses 294b-294d are generally linear in shape. Each recess 294 has a bottom surface generally parallel in orientation to the bottom surface 290 of the manifold cap 42, and one or more sidewalls extending from the bottom surface of each recess 294 to the bottom surface 290 of manifold cap 42. The sidewalls are generally perpendicular to the bottom surfaces of both recess 294 and manifold cap 42. The bottom surface of one or more of the recesses 294 may be located above a portion of the top surface 286 of the manifold cap 42, such that one or more of the recesses 294 may form a structure in relief relative to a base area of top surface 288 of manifold cap 42. Each recess 294 defines an isolated portion in the manifold cap 42. When the manifold cap 42 is secured to the manifold 38, each of the recesses 294a-d form a separate chamber, and each chamber communicates with two or more cavity openings on top surface 110 of manifold 38. The recesses, however, may have any shape provided each recess defines a separate chamber and each chamber communicates with the proper cavity openings as described below. A manifold cap gasket may be placed between the manifold cap 42 and the manifold 38 to maintain chamber isolation. Figures 6A-6G show four "air ports" 396a-d formed by recesses 294 in the manifold cap 42 when the manifold cap 42 is secured to the manifold 38. U-shaped "air port" 396a communicates with four poppet cavity exhaust cavities 80,82,84,86, and one manifold exhaust cavity 122. A first linear "air port" 396b communicates with one pair of poppet cavity transfer cavities 124,126. A second linear "air port" 396c communicates with a second pair of poppet cavity transfer cavities 128,130. And, a third linear "air port" 396d communicates with a pair of inlet air supply transfer cavities 132,134. As shown in Figure 3 A, the manifold cap 42 can also include external sample ports 302 that are in fluid communication with underlying cavities. The sample ports 302 can also have attachment sites for plastic tubing, as shown in Figures IB and 2. Fastener holes 292 in the manifold cap 42 allow at least one fastener 102 (see

Figure 6F) to secure the manifold cover 42 to manifold 38, and to secure the manifold 38 to the base of the port manifold 36. The manifold cap 42, manifold 38, and port manifold 36, therefore, may be fastened together using a set of common fasteners. For instance, the fasteners may be screws. Any number of fasteners or type of mechanical fastening system may be used to sure the manifold cap 42, manifold 38, and port manifold 36 together provided the assembly is securely fastened and capable of operation. Referring to Figure 3 A, coil bank assembly 44 selectively diverts inlet air and exhaust from the poppet cavities 56,58,60,62 of the two spool valves 48 and 50 to control the position of the respective process valve shafts. The four micro-poppet solenoids 64,66,68,70 are individually and independently associated with a corresponding poppet cavity in spool valves 48 and 50. Solenoid valves 64,66,68,70 are operatively associated with poppet cavities 144,142,146,148, respectively. Coil bank assembly 44 includes four micro-poppet solenoid valves 64,66,68,70, a coil bank gasket 310, a coil plate 312, and coil bank gasket 314. The front of the each micro-poppet solenoid valve 64,66,68,70 has a receptacle 318 for receiving an electrical signal, and two holes 320 for receiving fastening elements. The back surface of each micro-poppet solenoid valve 64,66,68,70 has three openings 324 for receiving or conveying airflow with the manifold 38. Coil bank gasket 310 includes a thin flexible sheet gasket with openings 312 for transmitting airflow and fastening elements. One side of the coil bank gasket 310 abuts the rear side of the coil bank assembly 44, and a second side of the coil bank gasket 310 abuts coil plate 312. Coil plate 312 includes a planar member having first and second sides and a side surface between the first and second sides. The first side abuts the coil bank gasket 310 and the second side abuts coil bank gasket 314. Coil plate 312 has sixteen bores extending from the first side to the second side. Twelve of the bores are for transmitting airflow, and four are for receiving fastening elements. The four fastener bores are countersunk on the first side. Coil plate 312 also has eight bores extending into the coil plate 312 from the first side. Coil bank gasket 314 includes a planar member or thin flexible sheet with openings for transmitting airflow and fastening elements. One side of coil bank gasket 314 abuts the rear side of coil plate 312. A second side of coil bank gasket 314 abuts manifold 38. Referring to Figure 8, pressure sensors can be used to measure manifold inlet air pressure, manifold exhaust air pressure, and the differential pressure across the exhaust cavities of each spool valve. Inlet air pressure and manifold exhaust air pressure sensors 344,346 are pressure transducers with one port for receiving airflow. Each pressure transducer 344,346 has six leads 350 for receiving electrical current and transmitting electrical signals to the electronic controller. The inlet air pressure sensor and manifold air pressure sensor are mounted to a bracket 352 adjacent the coil bank assembly 44 within the enclosure. Differential pressure sensors 354,356 are pressure transducers with two ports 358,360 for receiving airflow. The pressure transducers 354,356 have six leads 362 for receiving electrical current and transmitting electrical signals to the electronic controller. The differential pressure sensors 354,356 are each individually mounted adjacent their respective spool valve 48,50. Plastic tubing 366 is used to connect each pressure transducer to the designated sample ports. Referring also to Figure 8, one-half of a so-called "bow-tie" shape is illustrated with respect to enclosure 12. As it is used herein, the term "bow-tie" refers to a shape of an elongated body that extends along a longitudinal axis between end portions, and has a middle portion that is relatively constricted with respect the end portions. According to a preferred embodiment, enclosure 12, for example, includes a wall that extends around the manifold assembly 20. The wall includes a first segment 12a and a second segment 12b that, at least in part, mutually define a portion of the chamber 16 in which the manifold assembly 20 is disposed. As shown in Figure 8, the first and second segments 12a, 12b extend transversely with respect to a longitudinal axis L, and have respective lengths L1,L2 One-half of the "bow tie" shape is achieved when the first segment 12a, which is closer to enclosure 14 than second segment 12b, is also shorter than segment 12b (i.e., LI is less than L2). Although segments 12a, 12b are shown extending transversely with respect to longitudinal axis L, they may alternatively extend obliquely and/or may not extend along a line, e.g., they may be curved. In any event, one -half of the bow-tie shape is still formed as long as a projection along the longitudinal axis of the segment 12b has a transverse length L2 with respect to the longitudinal axis L that is greater than the transverse length LI of a similar projection along the longitudinal axis of the segment 12a, which is closer than segment 12b to the middle of valve controller 10. Referring to Figures 1 A, 9A and 9B, the valve position indicator 24 includes a cage 374 and a beacon (position indicator) 376. The cage 374 is preferably formed integrally with either or both of the enclosures 12,14, but may be separately formed and subsequently secured to the enclosure for the mechanical components 12 and/or the enclosure for the electronic components 14. Cage 374 defines a volume 378 in which the beacon 376 is received and includes a projection 386 for slidably receiving beacon (position indicator) 376. As shown in Figure 9B, an exemplary beacon (position indicator) 376 has markings 388 that show the position of two valves. The cage 374 and exemplary beacon (position indicator) 376 can be mounted on to a rotary actuator or remotely wired to a position sensor on the actuator. For instance, the position sensor can be a non-contact Hall effect sensor as described in Avid position monitors technical publications "tech-251/DW011930", "tech-260/D.W.0.11030", and "tech- 300/D.W.0.13882", the contents of each of these publication are herein incorporated by reference herein their entirety, and were attached as Appendix A to U.S. Provisional Application No. 60/559,002, filed 5 April 2004, which is also incorporated by reference herein in its entirety. Referring to Figures 1A, 9A and 9B, the valve controller 10 may also have a separate enclosure 14 and enclosure cover 18b for electronic components so that an electronic controller may be disposed on or within the electronic enclosure 14 in manner which may provide for access to the electronic components independently from the mechanical assembly. As is the case for the enclosure cover 18a for mechanical components in the enclosure 12, the electronic enclosure cover 18b may be attached or releasably securable to the enclosure 14 by any suitable means. For instance, the covers 18a, 18b may be fastened to the enclosures 12,14 with one or more fasteners, such as a screw. Referring to Figures 10A and 10B, electronic components 390 may be arranged or disposed in any suitable fashion within the enclosure 14. For example, circuit boards 392 and other electronic components in the enclosure may be stacked vertically and connected by cable. As shown in Figure 10B, an exemplary configuration of electronic components has four circuit boards 392 stacked over top each other and spaced apart by varying distances as may be appropriate for the components of each circuit board. Some or all of the components on lower boards 392 located vertically below one or more other boards may still be visible from a plan view. For example, solenoid valve output connections may be located on the third circuit board as enumerated from the top board, yet may still be visible and accessible from the top of the electronic enclosure. Such an arrangement may facilitate installation, maintenance, testing or ascertaining faulty electronic components or circuits. Referring to Figures 11 A-l 1C, the electronic components of the valve controller may include a universal mother board having: a 2 Line by 16 Character liquid-crystal display (LCD) 400; Programming buttons (e.g., Select, Nextf, NextJ,) 402; Analog Inputs (e.g., one position sensor for measuring valve position from 0.0 to 100.0% (e.g., a Hall Effect Position Sensor), and five Pressure Sensors for measuring air pressure of the supply and manifold) 404; Analog Outputs (e.g., one primary 0-5 milliamps output for driving a transducer, and one secondary 0-5 milliamps output for driving a transducer) 406; Discrete Outputs (e.g., four open collectors for driving solenoids, and one open collector for driving an light emitting diode) 408; Discrete Inputs (e.g., two dry contact sensing inputs for "Open & Close Limit Switches", one dry contact sensing input for "Partial Stroke Switch", and one voltage input for "Sensing SIS Power") 410. The valve controller electronics may further include: a communications port (e.g., one RS232 for local diagnostics), 412; and a microprocessor 414 with associated peripherals such as, for example, various memory, controllers and converters. For instance, microprocessor CPU 414 can be a Motorola® MC68CK331CPV16 32 bit Microprocessor; Program Memory 416 can include AMD® Am29LV400BT-55REI, 256K x 16bit Flash memory; Data Memory 418 can include a CYPRESS® CY62146VLL-70ZI, 256K x 16 bit Static RAM; and Non-Volatile Memory 420 can include an ATMEL® AT25256W-10SI-2.7, 32K x 8 bit EEPROM. The valve controller electronics may also include: an Analog to Digital Converter 422 (e.g., Maxim® MAX1295BEEI, 6 Channel 12 bit); a Digital to Analog Converter 424 (e.g., Analog

Devices® AD5342BRU, 2 Channel 12 bit); and Analog Instrument Amplifiers 426 (e.g., Texas Instruments® TLC27L4BID, Op-Amps). The valve controller electronics may further include: Discrete Output drivers 428 (e.g., Fairchild® NDS9945, 60V FET's); and Inter-processor communication circuitry 430 (e.g., TI® CD74HC40105M96, 16 Word FIFO). The valve controller electronics has a power supply 432, and may further have a plug-in network card 434 (e.g., ASi®, DeviceNet®, Profibus®, Foundation Fieldbus®, Modbus®, and/or HART®) for additional communication and other capabilities. The valve controller may include short-range radio links 436 for local interface with the electronic components to provide for a peer-to peer wireless area network. The wireless network may be used, for example, to configure, calibrate, or perform diagnostics on the valve controller electronic systems. As described in more detail below, the wireless network may also be used to monitor and implement knowledge based performance systems. One known technology that uses short-range radio links for local interface is Bluetooth® technology. The valve controller electronics may include a "Bluetooth" radio module so that the controller is Bluetooth-capable. When Bluetooth- capable devices 438 (e.g., Personal Digital Assistants (PDAs), laptop computers, hand phones) come within range of one another, an electronic conversation takes place to determine whether one needs to control the other. The user does not have to press a button or give a command — the electronic conversation happens automatically. Once the conversation has occurred, the devices form a personal-area network or "piconet." Once the piconet is established, the members randomly hop frequencies in unison so they stay in touch with one another. The wireless system may further include one or more security measures which restricts access to the piconet. In use, the electronic controller monitors electrical signals from the pressure sensors and valve position indicator to control the flow of an appropriate operating medium such as, for example, air through the manifold assembly. Specifically, each solenoid valve or micro poppet 64,66,68,70 opens and closes pathways to one spool valve poppet cavity 144,142,146,148, respectively. In one configuration, the solenoid valve or micro-poppet allows inlet air supply to the spool valve poppet cavity. In a second configuration, the solenoid valve or micro-poppet blocks inlet air supply to the spool valve poppet cavity, and opens an exhaust path to the atmosphere via the mamfold. In this fashion, spool valve poppet cavities are energized or de-energized. Each spool valve 48,50 has a pair of opposing poppet cavities. For example, poppet cavity 142 and 144 can constitute the poppet cavities of spool valve 48, and poppet cavities 146 and 148 can constitute the poppet cavities of spool valve 50. When one spool valve cavity is energized, (i.e., 142) the opposing poppet cavity (i.e., 144) is de-energized. Energizing one poppet cavity while de-energizing another poppet cavity causes a pressure differential across the spool valve assembly, that pushes the spool shaft toward the de- energized cavity and allows segments on the shaft to selectively direct inlet air supply to the spool cavity of one of two exhaust cavities. Reversing the state of the poppet cavities moves the position of the shaft, and allows segments on the shaft to direct the inlet air supply to the second exhaust cavity. Exhaust from the spool valve drives the process valve actuator. Figures 12A and 12B illustrate an exemplary manifold design for an operative arrangement that provides control for two independent valves. In particular, the schematic of Figures 12A and 12B describe two independent valve controls with one inlet air supply and one exhaust outlet. The single inlet air supply (I/A) is diverted into six separate supply cavities. The single exhaust outlet (E) is diverted into eight exhaust cavities. The inlet air supply cavities are as follows: • Cavity I/A 1 is to spool cavity S A, 52 ~ This feeds I/A to a primary pneumatic actuator, which energizes and de-energizes a critical valve and / or damper. • Cavity I/A 2 is to spool cavity SB, 54 ~ This feeds I/A to a secondary pneumatic actuator, which energizes and de-energizes a non-critical valve and / or damper. • Cavity I/A 3 is to poppet cavity Al, 56 ~ This feeds I/A to the poppet coil E 1 , 64 that energizes primary spool A, 48. • Cavity I/A 4 is to poppet cavity A2, 53 ~ This feeds I/A to the poppet coil A2, 66 which de-energizes primary spool A, 48. This cavity may not be required if the application uses a spring return primary spool. • Cavity I/A 5 is to poppet cavity Bl, 60 ~ This feeds I/A to the poppet coil Bl, 68 that energizes secondary spool B, 50. • Cavity I/A 6 is to poppet cavity B2, 62 ~ This feeds I/A to the poppet coil B2, 70 which de-energizes secondary spool B, 50. This cavity may not be required if the application uses a spring return secondary spool.

The EX exhaust cavities are as follows: • Cavity EX 1 is to exhaust cavity EA1, 72 ~ This allows exhaust to atmosphere of the energizing primary pneumatic actuator port on a de- energizing command of the primary valve. • Cavity EX 2 is to exhaust cavity EA2, 74 ~ This allows exhaust to atmosphere of the de-energizing primary pneumatic actuator port on an energizing command of the primary valve. • Cavity EX 3 is to exhaust cavity EB1, 76 ~ This allows exhaust to atmosphere of the energizing secondary pneumatic actuator port on a de- energizing command of the secondary valve. • Cavity EX 4 is to exhaust cavity EB2, 78 — This allows exhaust to atmosphere of the de-energizing secondary pneumatic actuator port on an energizing command of the secondary valve. • Cavity EX 5 is to exhaust cavity PEA1, 80 ~ This allows exhaust to atmosphere of the energizing primary poppet coil port on a de-energizing command of the primary valve. • Cavity EX 6 is to exhaust cavity PEA2, 82 ~ This allows exhaust to atmosphere of the de-energizing primary poppet coil port on an energizing command of the primary valve. • Cavity EX 7 is to exhaust cavity PEB1, 84 ~ This allows exhaust to atmosphere of the energizing secondary poppet coil port on a de-energizing command of the secondary valve. • Cavity EX 8 is to exhaust cavity PEB2, 86 ~ This allows exhaust to atmosphere of the de-energizing secondary poppet coil port on an energizing command of the secondary valve. Figures 13A-C illustrate an exemplary manifold design for an operative arrangement that provides control for a single process valve. In particular, the schematics of Figures 13A-C describe a single valve control by two dependent spool valves with one inlet air supply and one exhaust outlet. The single inlet air supply (I/A) is diverted into five (5) separate supply cavities. The single exhaust outlet (EX) is diverted into eight exhaust cavities. The I/A supply cavities are as follows: • Cavity I/A 1 is to spool cavity SB, 54 ~ This feeds I/A to the secondary spool B, 50, which when energized will supply I/A to the primary spool A, 48, authorizing control of the pneumatic actuator. This is intended for use in Emergency Shut Down and Partial Stroke Testing of a critical valve and / or damper. • Cavity I/A 2 is to poppet cavity Al, 56 ~ This feeds I/A to the poppet coil Al, 64 that energizes primary spool A, 48. • Cavity I/A 3 is to poppet cavity A2, 58 — This feeds I/A to the poppet coil A2, 66, which de-energizes primary spool A, 48. (This cavity may not be required if the application uses a spring return primary spool.) • Cavity I/A 4 is to poppet cavity Bl, 60 — This feeds I/A to the poppet coil Bl, 68 that energizes secondary spool B, 50. • Cavity I/A 5 is to poppet cavity B2, 62 ~ This feeds I/A to the poppet coil B2, 70 which de-energizes secondary spool B, 50. (This cavity may not be required if the application uses a spring return secondary spool.)

The EX exhaust cavities are as follows: • Cavity EX 1 is to exhaust cavity EA1, 72 ~ This allows exhaust to atmosphere of the energizing pneumatic actuator port on a de-energizing command of the valve and / or damper under normal operating conditions. • Cavity EX 2 is to exhaust cavity EA2, 74 ~ This allows exhaust to atmosphere of the de-energizing pneumatic actuator port on an energizing command of the valve and / or damper under normal operating conditions. • Cavity EX 3 is to exhaust cavity EB 1 , 76 ~ This allows exhaust to atmosphere of the energizing port of the authorization spool B on a de- energizing command for Emergency Shut Down and / or Partial Stroke Test requirements. • Cavity EX 4 is to exhaust cavity EB2, 78 ~ This allows exhaust to atmosphere of the de-energizing of the authorization spool B on an energizing command for normal operating conditions. • Cavity EX 5 is to exhaust cavity PEA1, 80 ~ This allows exhaust to atmosphere of the energizing primary poppet coil port on a de-energizing command of the valve and / or damper under normal operating conditions. • Cavity EX 6 is to exhaust cavity PEA2, 82 ~ This allows exhaust to atmosphere of the de-energizing primary poppet coil port on an energizing command of the valve and/or damper under normal operating conditions. • Cavity EX 7 is to exhaust cavity PEB1, 84 — This allows exhaust to atmosphere of the energizing authorization poppet coil port on a de- energizing command for Emergency Shut Down and / or Partial Stroke Test requirements. A data sheet for "Foundation Fieldbus Partial Stroke ESD Valve Monitor, Model 7345-ESD," by Westlock Controls Corp., Saddle Brook, New Jersey, describes a known Emergency Shut Down valve monitor and discusses of partial stroke testing. The contents of this publication is herein incorporated by reference herein its entirety, and was attached as Appendix B to U.S. Provisional Application No. 60/559,002, filed 5 April 2004, which is also incorporated by reference herein in its entirety. • Cavity EX 8 is to exhaust cavity PEB2, 86 ~ This allows exhaust to atmosphere of the de-energizing authorization poppet coil port on an energizing command for normal operating conditions. According to the preferred embodiment shown in Figures 13A-13C, a valve controller 10 with a single operating media supply port 28 allows for two operational control signals via . The two operation control signals can provide a first command signal and a second command signal to a single process valve 3. The first command signal could be a discrete command signal, e.g., to produce full and generally immediate operation by the process valve actuator 5, such as OPEN/CLOSE. The second command signal could be a modulating command signal, e.g., to produce a progressive and measured operation by the process valve actuator 5, such as to move between different partially open positions, e.g., 15%, 42%, 75%, etc. Figures 14A and 14B illustrate another exemplary manifold design for an operative arrangement that provides control of a single process valve by two spool valves. In particular, the schematics of Figures 14A and 14B describe two dependent spool valves controlling one primary pneumatic actuator with one inlet air supply and one exhaust outlet. These operative arrangements may allow for increased airflow dynamics for the pneumatic actuator while utilizing a single inlet supply and single outlet exhaust. The single inlet air supply (I/A) is diverted into six (6) separate supply cavities. The single exhaust outlet (EX) is diverted into eight exhaust cavities. The I/A supply cavities are as follows: • Cavity I/A 1 is to spool cavity S A, 52 ~ This feeds I/A to a primary pneumatic actuator, which energizes and de-energizes a valve or damper. • Cavity I/A 2 is to spool cavity SB, 54 ~ This feeds I/A to a primary pneumatic actuator, which energizes and de-energizes a valve or damper. • Cavity I/A 3 is to poppet cavity Al, 56 -- This feeds I/A to the poppet coil Al, 64 that energizes spool A, 48. • Cavity I/A 4 is to poppet cavity A2, 58 ~ This feeds I/A to the poppet coil A2, 66 that de-energizes spool A, 48. This cavity may not be required if the application uses a spring return spool. • Cavity I/A 5 is to poppet cavity Bl, 60 - This feeds I/A to the poppet coil Bl, 68 that energizes spool B, 50. • Cavity I/A 6 is to poppet cavity B2, 62 ~ This feeds I/A to the poppet coil B2, 70 that de-energizes spool B, 50. This cavity may not be required if the application uses a spring return spool.

The EX exhaust cavities are as follows: • Cavity EX 1 is to exhaust cavity EA1 , 72 ~ This allows exhaust to atmosphere of the energizing pneumatic actuator port on a de- energizing command of the valve. • Cavity EX 2 is to exhaust cavity EA2, 74 — This allows exhaust to atmosphere of the de-energizing pneumatic actuator port on an energizing command of the valve . • Cavity EX 3 is to exhaust cavity EB1, 76 at the same time as the EA1, 72 ~ This allows exhaust to atmosphere of the energizing pneumatic actuator port on a de-energizing command of the valve. • Cavity EX 4 is to exhaust cavity EB2, 78 at the same time as the EA2, 74 ~ This allows exhaust to atmosphere of the de-energizing pneumatic actuator port on an energizing command of the valve. • Cavity EX 5 is to exhaust cavity PEA1 , 80 this allows exhaust to atmosphere of the energizing poppet coil port on a de-energizing command of the valve. • Cavity EX 6 is to exhaust cavity PEA2, 82 this allows exhaust to atmosphere of the de-energizing poppet coil port on an energizing command of the valve. • Cavity EX 7 is to exhaust cavity PEB1, 84 at the same time as the PEA1, 80 this allows exhaust to atmosphere of the energizing poppet coil port on a de-energizing command of the valve. • Cavity EX 8 is to exhaust cavity PEB2, 86 at the same time as the PEA2, 82 this allows exhaust to atmosphere of the de-energizing poppet coil port on an energizing command of the valve. The electronic and mechanical components of the valve controller according to the preferred embodiments may further provide for intelligent diagnostics for integrated actuator/valve packages. For instance, operational data from the valve controller may be collected and analyzed to signal maintenance information and/or prevent potentially dangerous process conditions. Enviromnental learning and diagnostics and fault monitoring may be referred to collectively as developing and implementing a knowledge based valve performance program. For example, a valve controller with integral pressure sensors may be used to profile pressures of a single supply port and a single exhaust port so that diagnostics and fault monitoring can be accomplished with a microprocessor. The diagnostics may comprise developing the following non-limiting and exemplary profiles: • a "Factory Torque Profile" - this function may record the un-installed valve/actuator torque demand versus position; and • a "Commissioned and/or Maintenance Torque Profile" - this function may record the installed valve actuator torque demand. It may be used, for example, for comparison to the Factory Torque Profile to determine whether any fouling of the disc or deformation of the seat to has occurred. In addition, during shutdown a "Maintenance Profile" may be obtained for comparison to an initial installed Torque profile and/or the factory torque profile. Moreover, a commission torque profile may also be developed during start-up operations (a start-up profile) that may be used as the reference profile for use by the continuous diagnostics. Initially, such comparisons would require the skill and knowledge of the commissioning and maintenance engineers. However, such comparisons may also be analyzed by an integrated actuator controller according to the preferred embodiments. The fault monitoring may comprise the following non-limiting exemplary functions: • "Insufficient Line Pressure to Guarantee Correct Operation" - the purpose of this function may be to warn that air supply pressure may not be sufficient to guarantee either opening or closing of the valve;

• "Supply Pressure Failure" - the purpose of this function may be to raise an alarm if line pressure falls below the maximum average differential requirements or is zero;

• "Valve Shaft Bent" - the purpose of this function may be to detect if the shaft is bent (for example, this may be achieved by detecting a phase shift of the torque profile); • "Valve Not Achieving Full Stroke" — the purpose of this function may be to evaluate the span of movement of the valve and issue a warning if pre-defined limits are exceeded;

• "Backlash Detection" - the purpose of this function may be to detect and identify dynamic loading on the valve and provide an opportunity to prevent premature valve/actuator failure (the torque/speed profile and the transients produced by conditions of dynamic loading may be used to detect the presence of backlash, which may be caused by a worn actuator, slack mountings, ill fitting of shaft to valve or other correctable features of the valve actuator system; • "Torque Demand of Valve Approaching Actuator limit" - the purpose of this function may be to raise a warning or alarm if differential pressure reaches 90% of the line pressure at any time during cycle (a bypass time, however, may be included to inhibit or suppress the warning or alarm, immediately after control signal is received; • "Valve Seating/ Break-Out Torque Monitoring" - the purpose of this function is to identify the torque required to seat and unseat the valve and then give an indication of seat wear, liner failure and/or other mechanical conditions that may require maintenance or immediate attention (values may be compared to acceptable limits for particular valve types and warnings issued under triggering conditions);

• "Torque Limit Exceeded" — the purpose of this function may be to prevent the torque on the valve stem from exceeding a pre-set limit that may be programmable and which may be set as a function of a published limit (an alarm may be set if appropriate); • "Close on Torque" ~ the purpose of this function may be to ensure that actuators would have sufficient torque to unseat the valve, remove any dependence on spring rate vs. air supply pressure to achieve a closing torque, and may relate to the use of a dual coil spring center of spool to limit torque output; • "Shaft Broken" - the purpose of this function may be to determine whether the valve shaft is broken or the valve actuator is not attached to the valve, each of these conditions may have a torque profile with a torque level lower than the historical demand; • "Valve Exercise" - the purpose of this function may be to exercise and monitor valves that remain in one position, such as the closed or open position, for extended periods; • "Valve Packing Torque" - the purpose of this function may be to extract valve packing hysteresis between the open and closed cycle for applications such as BFV applications with sufficient dynamic torques; • "Line Filter and Silencers Conditions" - the purpose of this function may be to identify and signal whether air supply or air exhaust is restricted by measuring and evaluating time constants of charging and discharging of actuator cylinder pressures; • "Solenoid Spool Sticking" - this function may be used to identify and signal whether the solenoid valve is sticking by measuring and evaluating the time from solenoid control signal to pressure response. Safety integration levels may be used to define the goals and identify unacceptable levels of operational risk. The techniques and methods for identifying and quantifying safety integrity levels, calculating average probability of failure on demand, and failure and test strategies to reduce the overall failure rate are known from the related art. Thus, the electronic components of the valve controller according to the preferred embodiments may combine real time monitoring data with risk assessment models and safety algorithms identified in a logic solver either remotely or through the use of an on- board microprocessor to reduce the average probability of potentially dangerous failures of process valves and ancillary equipment and systems. To implement such a diagnostic program, a data-sampling rate can be used to develop an accurate representation of all the valve failure trends of interest. For example, Figure 15 shows a graph with 200 samples representing a valve movement, which may detect many if not all valve failure trends. The hardware and software of the valve controller according to the preferred embodiments may be configured to handle 4000 samples to further ensure that valve failure trends of interest are captured by the diagnostic program. Hardware requirements may be determined as follows. If 100 samples per second were collected and each sample consists of reading the analog value of the valve position, and 5 analog pressure readings and each analog value requires 2 bytes then approximately 100 Samples/Second X 6 Analog Values X 2 bytes/Analog Value or 1200 bytes/Second would be required. In addition, if 4000 bytes for one Sequence of Samples were collected, this may provide about 3.3 seconds worth of data for one Sequence of Samples. A slower moving valve may require more time than this to complete it's movement, so a sampling rate of 50 Samples/Second, 25 Samples/Second, or 12.5 Samples/Second may be used to give times of 6.3 seconds, 12.6 seconds or 25.2 seconds. Moreover, there may be a need to store the Initial Sequence of Samples (captured at installation) for the valve opening and for the valve closing. A number of recent

Sequence of Samples for valve opening and for valve closing may also need to be stored. Thus, the Initial and most recent Sequence of Samples may be stored in Non-Volatile memory, which may require about 4 times 4000 or 16000 bytes of Non- Volatile memory. To achieve such a non-volatile memory storage, the EEPROM for non-volatile storage may be increased to a 32K x 8 EEPROM. In addition, some Network Cards may have less than IK of RAM so transferring all this data over to the Network Card may have to be done in fragmented messages (small pieces such as 6-8 bytes at a time), where each piece may be individually identified, for example, by a 2 byte fragment address. A similar technique may further be used to transfer this data over the network, as each network protocol also has a limit to the amount of data that can be sent in one message. Thus, for example, in the DeviceNet network card a typical message consists of a CAN Header of 19 bit, followed by, a Data Field of up to 64 bits (8 byte), followed by a CAN Trailer of 25 bits. There is a minimum Interframe Space time of 3 bits. This would be 19 + 64 + 25 + 3 or 111 bits for one fragment (six bytes) of the Sequence of Samples. At a rate of 125 kbps this would take 888 uSec. To send the entire 4000 byte Sequence of Samples would require 667 DeviceNet messages. If this were the only device on the network and it could continually broadcast these messages this could take 667 X 888 uSec or 0.592 seconds for the 4000 bytes. Because there are also messages to the device, not just from the device, and because the device would likely need to send status information, not just Sample data, this time may increase significantly and could be doubled. If there are 64 devices on a network and each were sending data this time could be 64 X 2 X 0.592 or 75.8 seconds. As this amount of time may be unacceptable in some applications, other steps may be added to the process to further reduce this time. For example, one may lower the number of samples taken in each Sequence of Samples, compress the data, and/or process some of the data locally, on the motherboard. For these reasons, the valve controller according to the preferred embodiments may be configured with hardware and software robust enough to allow for all three cases. Wireless technology may be used in combination with a valve controller having the specific valve operative arrangements and knowledge based valve performance discussed above. For example, each of the features for protection with respect to the valve operative arrangements and knowledge based valve performance may be individually protected for use with a short-range wireless protocol, and a communication method via the Internet. Combining the knowledge based valve performance methods with remote communications via the Internet may provide various opportunities to protect new methods of maintenance of valves at a location remote from the location of a maintenance staff. For example, a method of maintaining the operative performance of two valves may be performed. The method includes, for example, evaluating the operative conditions of two valves with a single valve controller; communicating the operative conditions of the two valves to a remote location via an Internet communication link; and changing operative commands of the valve controller via an Internet communication link. Systems that utilize features on the valve controller may be protected. For example, a system of piping including a first pipe, a second pipe proximate the first pipe, a valve disposed between the first pipe and the second pipe, a valve actuator that operates the valve, and a valve controller that operates the valve actuator, the valve controller including a housing having a single supply path that feeds two separate pilot paths, the two separate pilot paths having a common exhaust path may be protected by the valve controller. The operative performance of the system may likewise be protected. Further details of the system may be added to specify the various uses of the valve controller. For example, piping to the controller could be defined and protection of written materials specifying the valve controller and its use may also be protected on a system wide basis. Based on the foregoing, valve controller 10 may include a manifold assembly 20 including a manifold with integral coils and spools. The manifold assembly may further include a manifold having a single supply path, two pilot paths, and single exhaust path. The manifold may be a monolithic member or a two-piece member. For example, a two- piece manifold may include a base and a cover. The cover can define paths within the base. Thus, the manifold assembly may use a cover to define pneumatic operative paths of the valve controller. Moreover, the valve controller may have a manifold assembly that uses the same fasteners to secure the cover to the base of a housing. The manifold may also include one or more sensors. The sensors may monitor airflow through the manifold and signal other mechanical or electronic components. The valve controller may have a housing with a single pneumatic supply path, two separate pilot paths, a single exhaust path, and an individual pressure sensor for each path. In one embodiment, two of the sensors may be differential pressure sensors. The valve controller may also have valve position indicator or beacon (position indicator) located between separate chambers for mechanical and electronic components. The size of the beacon ( position indicator) being selected to allow for viewing from a remote location. The beacon ( position indicator) can operate via a non-contact position sensor. Moreover, the valve controller may provide for different operative arrangements. The valve controller may have a single pneumatic supply port that allows for two operational control signals. The two operational control signals may provide a first command signal and a second command signal to a single valve. The first command signal may be a discrete command signal. The second command signal may be a modulating command signal. The valve controller may be integrated with an actuator, the valve controller having a single pneumatic supply port that allows for two operational control signals. The valve controller may be used to operate a valve with two different command signals from a single pneumatic supply port. The valve controller may be used in a method of operating an integrated actuator with two different command signals from a single pneumatic supply port. The valve controller may have a single pneumatic supply port that allows for two operational control signals. The two operation control signals may provide a discrete command signal to a first valve and a separate discrete command signal to a second valve. The valve controller may be integrated with an actuator, the valve controller having a single pneumatic supply port that allows for two separate and identical operational control signals. The valve controller may be configured to provide a method of controlling fail-safe operation of two valves with a single pneumatic supply port While the present invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present invention, as defined in the appended claims. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims, and equivalents thereof.

Claims

What is claimed is:

1. A valve control apparatus comprising: an enclosure defining a first chamber and a second chamber, the first and second chambers being spaced from each other along a longitudinal axis; an indicator proximate the first and second chambers, the indicator having a visual symbol that identifies an operational state of at least one valve; an operating media distribution system disposed in the first chamber, the operating media distribution system including: an operating media supply passage; an operating media exhaust passage; at least three operating media transmission passages; and a plurality of valves in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least three operating media transmission passages; an electronic control unit disposed in the second chamber, the electronic control unit operates at least one of the plurality of valves to control operating media flow in the operating media distribution system; and a plurality of connection ports that communicate with the operating media supply passage, the operating media exhaust passage, and the at least three operating media transmission passages.

2. The apparatus of claim 1, further comprising: at least one sensor disposed in the enclosure, the sensor evaluates the operating media distribution system and provides information to the electronic control unit about at least one operating condition in at least one of the passages.

3. A piping system comprising: a first pipe; a first process valve connected to the first pipe; a first actuator operating the first process valve; and a device controlling the first actuator, the device including: an enclosure defining a first chamber and a second chamber, the first and second chambers being spaced from each other along a longitudinal axis; an indicator proximate the first and second chambers, the indicator having a visual symbol that identifies an operational state of at least one valve; an operating media distribution system disposed in the first chamber, the operating media distribution system including: an operating media supply passage; an operating media exhaust passage; at least three operating media transmission passages; and a plurality of valves in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least three operating media transmission passages; and an electronic control unit disposed in the second chamber, the electronic control unit operates at least one of the plurality of valves to control operating media flow in the operating media distribution system.

4. A valve control apparatus comprising: an enclosure; an operating media distribution system disposed in the enclosure, the operating media distribution system including: an operating media supply passage; an operating media exhaust passage; at least two operating media transmission passages; and a valve in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least two operating media transmission passages; an electronic control unit disposed in the enclosure, the electronic control unit operates the valve to control operating media flow in the operating media distribution system; at least one sensor disposed in the enclosure, the sensor evaluates the operating media distribution system and provides information to the electronic control unit about at least one operating condition in at least one of the passages; and a plurality of connection ports that communicate with the operating media supply passage, the operating media exhaust passage, and the at least two operating media transmission passages.

5. The apparatus of claim 4, wherein the enclosure comprises first and second chambers, and the first chamber is spaced along a longitudinal axis from the second chamber.

6. The apparatus of claim 5, further comprising: an indicator proximate the first and second chambers, the indicator having a visual symbol that identifies an operational state of at least one valve.

7. A piping system comprising: a first pipe; a first process valve connected to the first pipe; a first actuator operating the first process valve; and a device controlling the first actuator, the device including: an enclosure; an operating media distribution system disposed in the enclosure, the operating media distribution system including: an operating media supply passage; an operating media exhaust passage; at least two operating media transmission passages; and a valve in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least two operating media transmission passages; an electronic control unit disposed in the enclosure, the electronic control unit operates the valve to control operating media flow in the operating media distribution system; and at least one sensor disposed in the enclosure, the sensor evaluates the operating media distribution system and provides information to the electronic control unit about at least one operating condition in at least one of the passages.

8. A valve control apparatus for at least one process valve having a maximum exterior package dimension, the apparatus comprising: an enclosure disposed entirely between first and second parallel planes, the first and second parallel planes being spaced apart a distance less than or equal to the exterior package dimension; an indicator proximate the enclosure, the indicator includes a visual symbol that identifies an operational state of the at least one process valve, and the visual symbol is visible from above the first plane and from below the second plane; an operating media distribution system disposed in the enclosure; an electronic control unit disposed in the enclosure; at least one sensor disposed in the enclosure, the at least one sensor evaluates the operating media distribution system and provides the electronic control unit information about at least one operating condition in the operating media distribution system; and a plurality of connection ports that communicate with the operating media distribution system.

9. The apparatus of claim 8, wherein the distance between the first and second parallel planes is less than or equal to three inches.

10. The apparatus of claim 8, wherein the enclosure comprises first and second chambers, and the first chamber is spaced along a longitudinal axis from the second chamber.

11. The apparatus of claim 8, wherein the operating media distribution system comprises: an operating media supply passage; an operating media exhaust passage; at least two operating media transmission passages; and a valve in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least two operating media transmission passages.

12. The apparatus of claim 8, wherein the electronic control unit controls media flow in the operating media distribution system to operate the at least one process valve.

13. An apparatus for distributing an operating media, the apparatus comprising: a manifold defining: an operating media supply passage; an operating media exhaust passage; a first operating media transmission passage; a second operating media transmission passage; a third operating media transmission passage; and a fourth operating media transmission passage; means for directing the operating media from the operating media supply passage to the first and third operating media transmission passages, and means for directing the operating media to the operating media exhaust passage from the second and fourth operating media transmission passages.

14. The apparatus of claim 13, further comprising: means for directing the operating media from the operating media supply to the second and fourth operating media transmission passages; and means for directing the operating media to the operating media exhaust passage from the first and third operating media transmission passages.

15. The apparatus of claim 14, further comprising: an electronic control unit; means for evaluating operating media pressure in each of the passages and for providing information to the electronic control unit about the operating media pressure in each of the passages.

16. The apparatus of claim 14, further comprising: means for evaluating valve position and for providing valve position data to the control unit.

17. The apparatus of claim 16, further comprising: means for monitoring valve performance and for developing at least one diagnostic performance attribute profile.

18. The apparatus of claim 17, wherein the at least one diagnostic performance attribute profile is selected from the group consisting essentially of a Commissioned Torque Profile and a Maintenance Torque Profile.

19. The apparatus of claim 17, further comprising: means for fault monitoring valve performance by comparing the at least one diagnostic performance attribute profile with stored valve data.

20. The apparatus of claim 19, further comprising, means for calculating an average probability of valve failure; and means for predicting valve failure by comparing the average probability of valve failure with stored valve data.

21. A piping system comprising: a first pipe; a first process valve proximate the first pipe; a first actuator operating the first process valve; and an operating media distribution system controlling the first actuator, the operating media distribution system includes a manifold defining: an operating media supply passage introducing operating media into the operating media distribution system from outside the housing; an operating media exhaust passage discharging operating media from the operating media distribution system to outside the housing, and at least four operating media transmission passages in fluid communication with the operating media supply and exhaust passages, and a minimum of two of the at least four operating media transmission passages are in fluid communication with the first actuator.

22. The system of claim 21 , wherein a minimum of two of the four operating media transmission passages are in fluid communication with a second actuator.

23. The system of claim 22, further comprising: a second process valve being operated by the second actuator.

24. The system of claim 23, further comprising: a second pipe proximate the second process valve.

25. The system of claim 21, wherein the operating media distribution system includes a plurality of valves in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least four operating media transmission passages.

26. The system of claim 25, further comprising: an electronic control unit operating the plurality of valves to control operating media flow in the operating media distribution system; at least one sensor evaluating the operating media distribution system and providing information to the electronic control unit about at least one operating condition in at least one of the passages; and a plurality of connection ports that communicate with the operating media supply passage, the operating media exhaust passage, and the at least four operating media transmission passages.

27. The system of claim 21, wherein the manifold is disposed entirely between first and second parallel planes, the first and second parallel planes being spaced apart a distance less than or equal to three inches.

28. An apparatus for distributing an operating media, the apparatus comprising: an enclosure that includes upper and lower surfaces respectively defining first and second parallel planes, the enclosure is located entirely within a distance between the first and second planes; an indicator proximate the enclosure, the indicator includes a visual symbol that identifies ah operational state of the at least one process valve, and the visual symbol is visible from above the first plane and from below the second plane; an operating media distribution system disposed in the enclosure; and a plurality of connection ports that communicate with the operating media distribution system.

29. The apparatus of claim 28, wherein the distance between the first and second planes is less than or equal to three inches.

30. The apparatus of claim 28, wherein the enclosure comprises first and second chambers, and the first chamber is spaced along a longitudinal axis from the second chamber.

31. The apparatus of claim 28, wherein the operating media distribution system comprises: an operating media supply passage; an operating media exhaust passage; at least two operating media transmission passages; and _ a valve in fluid communication with the operating media supply passage, the operating media exhaust passage, and the at least two operating media transmission passages.

32. The apparatus of claim 31 , further comprising: an electronic control unit operating the valve to control operating media flow in the operating media distribution system; at least one sensor evaluating the operating media distribution system and providing information to the electronic control unit about at least one operating condition in at least one of the passages.

33. A method of distributing operating media, the method comprising: introducing an operating media supply to a manifold; allotting within the manifold the operating media supply to at least four operating media transmission passages; transporting to a first actuator operating media from a first minimum of two of the at least four operating media transmission passages; and collecting in an operating media exhaust passage exiting the manifold operating medium from a minimum of two of the at least four transmission passages.

34. The method of claim 33 , further comprising : transporting to a second actuator operating media from a second minimum of two of the at least four operating media transmission passages.

35. The method of claim 33, wherein the introducing comprises connecting the operating media supply to an operating media supply passage of the manifold.

36. The method of claim 35, wherein the allotting comprises connecting the operating media supply passage to at least one of a first operating media transmission passage, a second operating media transmission passage, a third operating media transmission passage, and a fourth operating media transmission passage.

37. The method of claim 36, wherein the wherein the allotting comprises connecting the operating media supply passage to the first and third operating media transmission passages.

38. The method of claim 33, wherein the operating media comprises air.

39. The method of claim 33, wherein the manifold is disposed entirely between first and second parallel planes, the first and second parallel planes being spaced apart a distance less than or equal to three inches.

40. A method of distributing operating media comprising: connecting an operating media supply to a manifold, the manifold defining an operating media supply passage, an operating media exhaust passage, a first operating media transmission passage, a second operating media transmission passage, a third operating media transmission passage, and a fourth operating media transmission passage; directing operating media from the operating media supply to the first and third operating media outlet passages; and directing operating media from the second and fourth operating media outlet passages to the operating media exhaust passage.

41. The method of claim 40, wherein the operating media comprises air.

42. A manifold apparatus for distributing operating media, the apparatus comprising: a first member defining: an operating media supply cavity; an operating media exhaust cavity; at least four operating media transmission cavities in communication with the operating media supply cavity and the operating media exhaust cavity; and a surface communicating a flow of operating media flow between a minimum of two of the at least four operating media transmission cavities.

43. The apparatus of claim 42, further comprising: a second member defining at least one surface that cooperates with the first member to contain and transport operating media between a minimum of two of the at least four operating media transmission cavities.

44. A manifold apparatus for distributing operating media, that apparatus comprising: a first member having a plurality of cavities for transporting operating media, the plurality of cavities including an operating media supply cavity, and a second member defining a surface that cooperates with the first member to contain and transport operating media between at least two cavities.

45. The apparatus of any of claims 43 and 44, wherein the at least one surface comprises an interior surface that defines a recess, the recess cooperates with the first member to form a chamber in fluid communication with at least two cavities.

46. The apparatus of claim 45, wherein the at least one surface defines a plurality of recesses that cooperate with the first member to form a plurality of chambers.

47. The apparatus of any of claims 42 and 46, wherein the second member comprises a manifold cover.

48. The apparatus of any of claims 42 and 44, further comprising a plurality of external ports that connect to the operating media supply cavity, the operating media exhaust cavity, and the first, second, third and fourth operating media transmission cavities.

49. ^■ The apparatus of claims 48, further comprising: a first operating media distribution valve in fluid communication with the operating media supply cavity, the first and second operating media transmission cavities, and the operating media exhaust cavity, the first operating media distribution valve including: a first configuration connecting the operating media supply cavity with the first operating media transmission cavity and connecting the second operating media transmission cavity with the operating media exhaust cavity; and a second configuration connecting the operating media supply cavity with the second operating media transmission cavity and connecting the first operating media transmission cavity with the operating media exhaust cavity; and a second operating media distribution valve in fluid communication with the operating media supply cavity, the third and fourth operating media transmission cavities, and the operating media exhaust cavity, the second operating media distribution valve including: a third configuration connecting the operating media supply cavity with the third operating media transmission cavity and connecting the fourth operating media transmission cavity with the operating media exhaust cavity; and a fourth configuration connecting the operating media supply cavity with the fourth operating media transmission cavity and connecting the third operating media transmission cavity with the operating media exhaust cavity

50. The apparatus of claim 49, further comprising: a first operational mode including the first configuration of the first operating media distribution valve and the third configuration of the second operating media distribution valve.

51. The apparatus of claim 49, further comprising: a second operational mode including the second configuration of the first operating media distribution valve and the fourth configuration of the second operating media distribution valve.

52. The apparatus of claim 49, further comprising: a third operational mode that includes occluding one of the plurality of connection ports corresponding to one of the first, second, third and fourth operating media transmission passages.

53. The apparatus of claim 49, further comprising: an enclosure defining a first chamber, the first and second members being disposed in the first chamber, the enclosure is disposed entirely between first and second parallel planes, and the first and second parallel planes being spaced apart a distance less than or equal to tliree inches.

54. The apparatus of claim 48, wherein the plurality of external ports are disposed in a third member proximate the first member.

55. A system controlling two process valves, the system comprising: a manifold defining a member that defines an operating media supply cavity, an operating media exhaust cavity, and at least four operating media transmission cavities in communication with the operating media supply cavity and the operating media exhaust cavity; a surface communicating a flow of operating media between a minimum of two of the at least four operating media transmission cavities; a first process valve actuator including: a first operating media port connected to the first operating media transmission cavity, and a second operating media port connected to the second operating media transmission cavity; and a second process valve actuator including: a third operating media port connected to the third operating media transmission cavity, and a fourth operating media port connected to the fourth operating media transmission cavity.

56. A system controlling two process valves, the system comprising: a manifold defining first and second members, the first member having a plurality of cavities for transporting operating media, the plurality of cavities including an operating media supply cavity, and the second member defining a surface that cooperates with the first member to contain and transport operating media between at least two cavities; a first operating media distribution valve in fluid communication with the operating media supply cavity, the first and second operating media transmission cavities, and the operating media exhaust cavity, the first operating media distribution valve including: a first configuration connecting the operating media supply cavity with the first operating media transmission cavity and connecting the second operating media transmission cavity with the operating media exhaust cavity; and a second configuration connecting the operating media supply cavity with the second operating media transmission cavity and connecting the first operating media transmission cavity with the operating media exhaust cavity; a second operating media distribution valve in fluid communication with the operating media supply cavity, the third and fourth operating media transmission cavities, and the operating media exhaust cavity, the second operating media distribution valve including: a third configuration connecting the operating media supply cavity with the third operating media transmission cavity and connecting the fourth operating media transmission cavity with the operating media exhaust cavity; and a fourth configuration connecting the operating media supply cavity with the fourth operating media transmission cavity and connecting the third operating media transmission cavity with the operating media exhaust cavity; a first process valve actuator including: a first operating media port connected to the first operating media transmission cavity, and a second operating media port connected to the second operating media transmission cavity; and . a second process valve actuator including: a third operating media port connected to the third operating media transmission cavity, and a fourth operating media port connected to the fourth operating media transmission cavity.

57. The system of any of claims 55 and 56, further comprising: an electronic control unit controlling the first process valve actuator by operating the first operating media distribution valve and controlling the second process valve actuator by operating the second operating media distribution valve.

58. The system of claim 57, wherein the electronic control unit operates the first and second operating media distribution valves to select the first operational mode.

59. The system of claim 57, wherein the electronic control unit operates the first and second operating media distribution valves to select the second operational mode.

60. A piping system comprising: a first pipe; a first process valve connected to the first pipe; a first actuator operating the first process valve; and a device controlling the first actuator, the device including: a manifold defining a member that defines an operating media supply cavity, an operating media exhaust cavity, and at least four operating media transmission cavities in communication with the operating media supply cavity and the operating media exhaust cavity; a surface communicating a flow of operating media flow between a minimum of two of the at least four operating media transmission cavities; a first process valve actuator including: a first operating media port connected to the first operating media transmission cavity, and a second operating media port connected to the second operating media transmission cavity; and a second process valve actuator including: a third operating media port connected to the third operating media transmission cavity, and a fourth operating media port connected to the fourth operating media transmission cavity.

61. A piping system comprising : a first pipe; a first process valve connected to the first pipe; a first actuator operating the first process valve; and a device for controlling the first actuator, the device including: a manifold defining first and second members, the first member having a plurality of cavities for transporting operating media, the plurality of cavities including an operating media supply cavity, and the second member defining a surface that cooperates with the first member to contain and transport operating media between at least two cavities; a first operating media distribution valve in fluid communication with the operating media supply cavity, the first and second operating media transmission cavities, and the operating media exhaust cavity, the first operating media distribution valve including: a first configuration connecting the operating media supply cavity with the first operating media transmission cavity and com ecting the second operating media transmission cavity with the operating media exhaust cavity; and a second configuration connecting the operating media supply cavity with the second operating media transmission cavity and connecting the first operating media transmission cavity with the operating media exhaust cavity; a second operating media distribution valve in fluid communication with the operating media supply cavity, the third and fourth operating media transmission cavities, and the operating media exhaust cavity, the second operating media distribution valve including: a third configuration connecting the operating media supply cavity with the third operating media transmission cavity and connecting the fourth operating media transmission cavity with the operating media exhaust cavity; and a fourth configuration connecting the operating media supply cavity with the fourth operating media transmission cavity and connecting the third operating media transmission cavity with the operating media exhaust cavity; a first process valve actuator including: a first operating media port connected to the first operating media transmission cavity, and a second operating media port connected to the second operating media transmission cavity; and a second process valve actuator including: a third operating media port connected to the third operating media transmission cavity, and a fourth operating media port connected to the fourth operating media transmission cavity.

62. A method of method of maintaining operative performance of first and second valves, the method comprising: evaluating with a single valve controller operative conditions of the first and second valves; communicating the operative conditions of the first and second valves to a remote location via an internet communication link; and changing operative commands of the single valve controller via the internet communication link.

63. The method of claim 62, further comprising: operating the first and second valves with the single valve controller, the single valve controller including an operating media distribution system including a third valve in communication with an operating media supply passage, an operating media exhaust passage, and at least four operating media transmission passages.

64. The valve controller of claim 63, wherein the operating comprises an electronic control unit proximate the operating media distribution system and operating the third valve to control operating media flow in the operating media distribution system.

65. The valve controller of claim 64, further comprising: evaluating the air distribution system with a plurality of sensors and providing the electronic control unit information about at least one operating condition in each of the passages.

66. The apparatus of any of claims 4, 8 and 28, wherein the enclosure comprises at least one cover that provides access to the operating media distribution system.

67. The apparatus of claim 66, wherein the at least one cover is secured to the enclosure by at least one fastening element.

68. The apparatus of claim 67, wherein the enclosure has at least one fastening element attachment site, and the at least one fastening element cooperates with the at least one fastening element attachment site to secure the at least one cover to the enclosure.

69. The apparatus of any of claims 1, 5, 10 and 30, wherein the enclosure comprises at least one cover providing access to the first and second chambers.

70. The apparatus of claim 69, wherein the at least one cover is secured to the enclosure by at least one fastening element.

71. The apparatus of claim 70, wherein the enclosure has at least one fastening element attachment site, and the at least one fastening element cooperates with the at least one fastening element attachment site to secure the at least one cover to the enclosure.

72. The apparatus of claim 69, wherein the at least one cover comprises first and second covers, the first cover provides access to only the first chamber and the second cover provides access to only the second chamber.

73. The apparatus of any of claims 1 and 6, wherein the enclosure is disposed entirely between first and second parallel planes, the first and second parallel planes being spaced apart a distance less than or equal to three inches.

74. The apparatus of claim 73, wherein the visual symbol is visible from above the first plane and is visible from below the second plane.

75. The apparatus of any of claims 1, 5, 10 and 30, wherein the enclosure comprises: a first wall including first and second segments that define portions of the first chamber, a projection along the longitudinal axis of the first segment has a first length transverse to the longitudinal axis, and a projection along the longitudinal axis of the second segment has a second length transverse to the longitudinal axis, the second length being greater than the first length; and a second wall including third and fourth segments that define portions of the second chamber, a projection along the longitudinal axis of the third segment has a third length transverse to the longitudinal axis, and a projection along the longitudinal axis of the fourth segment has a fourth length transverse to the longitudinal axis, the fourth length being greater than the third length.

76. The apparatus of claim 75, wherein the first segment is proximate to the second wall, the second segment is distal to the second wall, the third segment is proximate to the first wall, the fourth segment is distal to the first wall, and the second segment of the first wall and the fourth segment of the second wall are parallel.

77. The apparatus of any of claims 1, 6, 8 and 28, wherein the indicator comprises: a first member defining an interior space; and a second member disposed within the interior space, the second member including the visual symbol that identifies the operational state of the at least one valve.

78. The apparatus of claim 77, wherein the second member oscillates with respect to the first member.

79. The apparatus of any of claims 1, 4, 11, 26, 31 and 44, wherein the operating media transmission passages comprise first, second, third and fourth operating media transmission passages and the operating media distribution system includes a manifold assembly comprising: a first operating media distribution valve in fluid communication with the operating media supply passage, the first and second operating media transmission passages, and the operating media exhaust passage, the first operating media distribution valve including: a first configuration connecting the operating media supply passage with the first operating media transmission passage and connecting the second operating media transmission passage with the operating media exhaust passage; and a second configuration connecting the operating media supply passage with the second operating media transmission passage and connecting the first operating media transmission passage with the operating media exhaust passage; and a second operating media distribution valve in fluid communication with the operating media supply passage, the third and fourth operating media transmission passages, and the operating media exhaust passage, the second operating media distribution valve including: a third configuration connecting the operating media supply passage with the third operating media transmission passage and connecting the fourth operating media transmission passage with the operating media exhaust passage; and a fourth configuration connecting the operating media supply passage with the fourth operating media transmission passage and connecting the third operating media transmission passage with the operating media exhaust passage.

80. The apparatus of claim 79, wherein the manifold assembly consists of a single operating media exhaust passage.

81. The apparatus of claim 79, wherein the manifold assembly comprises a monolithic manifold defining: a first outer surface portion including first, second, third and fourth openings, the first opening being in fluid communication with the operating media supply passage, the second opening being in fluid communication with the operating media exhaust passage, the third opening being in fluid communication with the first operating media transmission passage, and the fourth opening being in fluid communication with the second operating media transmission passage; and a second outer surface portion including fifth, sixth, seventh and eighth openings, the fifth opening being in fluid communication with the operating media supply passage, the sixth opening being in fluid communication with the operating media exhaust passage, the seventh opening being in fluid communication with the third operating media transmission passage, and the eighth opening being in fluid communication with the fourth operating media transmission passage.

82. The apparatus of claim 79, wherein the manifold assembly comprises first and second manifold parts.

83. The apparatus of claim 82, wherein the manifold assembly comprises at least one fastener commonly securing together the first manifold part, the second manifold part, and the enclosure.

84. The apparatus of claim 79, wherein the manifold assembly comprises a cover defining at least one operating media path.

85. The apparatus of claim 79, further comprising: a first operational mode including the first configuration of the first operating media distribution valve and the third configuration of the second operating media distribution valve.

86. The apparatus of claim 85, wherein the electronic control unit operates the first and second operating media distribution valves to select the first operational mode.

87. The apparatus of claim 85, further comprising: a second operational mode including the second configuration of the first operating media distribution valve and the fourth configuration of the second operating media distribution valve.

88. The apparatus of claim 87, wherein the electronic control unit operates the first and second operating media distribution valves to select the second operational mode.

89. The apparatus of claim 87, further comprising: a third operational mode that includes occluding one of the plurality of connection ports corresponding to one of the first, second, third and fourth operating media transmission passages.

90. The apparatus of claim 79, wherein the first and second operating media distribution valves comprise spool valves.

91. The method of any of claims 37 and 40, further comprising: directing operating media from the operating media supply passage to the second and fourth operating media transmission passages: and directing operating media from the first and third operating media transmission passages to the operating media exhaust passage.

92. The apparatus of any of claims 2, 4, 11, 26 and 32, wherein the at least one sensor comprises a plurality of sensors that evaluate at least one operating condition in at least one of the passages.

93. The apparatus of claim 92, wherein the plurality of sensors evaluate the operating media distribution system and provide information to the electronic control unit about at least one operating condition in each of the passages.

94. The apparatus of claim 92, wherein the plurality of sensors evaluate operating media pressure.

95. The apparatus of claim 92, wherein at least one of the plurality of sensors comprises a differential pressure sensor.

96. The apparatus of claim 92, wherein the indicator comprises a position sensor that evaluates valve position and provides valve position data to the electronic control unit.

97. The apparatus of claim 92, wherein the electronic control unit monitors valve performance and develops at least one diagnostic profile.

98. The apparatus of claim 97, wherein the at least one diagnostic profile is selected from the group consisting of Insufficient Line Pressure to Guarantee Correct Operation, Supply Pressure Failure, and Valve Shaft Bent.

99. The apparatus of claim 97, wherein the at least one diagnostic profile is selected from the group consisting of Valve Not Achieving Full Stroke, Backlash Detection, and Torque Demand of Valve Approaching Actuator Limit.

100. The apparatus of claim 97, wherein the at least one diagnostic profile is selected from the group consisting of Valve Seating/Break-out Torque Monitoring, Torque Limit Exceeded, and Close-on Torque.

101. The apparatus of claim 97, wherein the at least one diagnostic profile is selected from the group consisting of Shaft Broken, Valve Exercise, Valve Packing Torque, Line

Filter and Silencer Conditions, and Solenoid Spool Sticking.

102. The method of any of claims 36 and 40, further comprising: sensing operating media pressure in each of the passages; and evaluating in a control unit information about the operating media pressure in each of the passages.

103. The method of claim 102, further comprising: sensing a valve operative position; and evaluating in the electronic control unit information about the valve operative position.

104. The method of claim 103, further comprising : developing a valve diagnostic performance attribute profile.

105. The method of claim 104, further comprising: developing a Commissioned Torque Profile.

106. The method of claim 104, further comprising: developing a Maintenance Torque Profile.

107. The method of claim 104, further comprising: monitoring valve performance fault by comparing the valve diagnostic performance attribute profile with stored valve data.

108. The method of claim 107, further comprising: indicating operating media pressure is insufficient to guarantee opening of the valve.

109. The method of claim 107, further comprising: indicating Insufficient Line Pressure to Guarantee Correct Operation.

110. The method of claim 107, further comprising: indicating Supply Pressure Failure.

111. The method of claim 107, further comprising: indicating Valve Not Achieving Full Stroke.

112. The method of claim 107, further comprising: indicating Backlash Detection.

113. The method of claim 107, further comprising: indicating Torque Demand of Valve Approaching Actuator Limit.

114. The method of claim 107, further comprising: monitoring Valve Seating/Break-out Torque.

115. The method of claim 107, further comprising: indicating Torque Limit Exceeded.

116. The method of claim 107, further comprising: indicating Close-on Torque.

117. The method of claim 107, further comprising: indicating Shaft Broken.

118. The method of claim 107, further comprising: indicating Line Filter and Silencer Conditions.

119. The method of claim 107, further comprising: indicating Solenoid Spool Sticking. '

120. The method of claim 107, further comprising: indicating Valve Exercise.

121. The method of claim 107, further comprising: indicating Valve Packing Torque.

122. The method of claim 107, further comprising: calculating average probability of failure on demand; and predicting valve failure by comparing the calculated average probability of failure with stored valve data.

123. The apparatus of any of claims 1, 4, 8, 26 and 28, wherein the electronic control unit comprises at least one printed circuit board.

124. The apparatus of claim 123, wherein the electronic control unit comprises a microprocessor.

125. The apparatus of any of claims 123 to 124, wherein the electronic control unit comprises a liquid crystal display.

126. The apparatus of any of claims 123 to 125, wherein the electronic control unit comprises an analog input.

127. The apparatus of any of claims 123 to 126, wherein the electronic control unit comprises an analog output.

128. The apparatus of any of claims 123 to 127, wherein the electronic control unit comprises a discrete output.

129. The apparatus of any of claims 123 to 128, wherein the electronic control unit comprises a discrete input.

130. The apparatus of any of claims 123 to 129, wherein the electronic control unit comprises a communications port.

131. The apparatus of any of claims 123 to 130, wherein the electronic control unit comprises a Flash memory.

132. The apparatus of any of claims 123 to 131, wherein the electronic control unit comprises a Data memory.

133. The apparatus of any of claims 123 to 132, wherein the electronic control unit comprises a Non-volatile memory.

134. The apparatus of any of claims 123 to 133, wherein the electronic control unit comprises a Discrete Output driver.

135. The apparatus of any of claims 123 to 134, wherein the electronic control unit comprises an Inter-processor communication circuitry.

136. The apparatus of any of claims 123 to 135, wherein the electronic control unit comprises a power supply.

137. The apparatus of any of claims 123 to 136, wherein the electronic control unit comprises a plug in network card.

138. The apparatus of any of claims 123 to 137, wherein the electronic control unit comprises a radio module interfacing with a peer-to-peer wireless area network.

139. The apparatus of any of claims 1, 4, 8, 21 and 28, wherein the operating media distribution system distributes an operating media comprising air.

140. The apparatus of claim 139, wherein the operating media in the operating media supply passage comprises the air having a pressure of about 40 to 120 pounds per square inch.

141. The apparatus of claim 139, wherein the operating media in the operating media supply passage comprises the air having a pressure of about 15 to 45 pounds per square inch.

142. The apparatus of claim 139, wherein the operating media in the operating media supply passage comprises the air having a pressure of less than about 120 pounds per square inch.

143. The apparatus of claim 142, wherein the pressure of the air in the operating media supply passage is less than about 40 pounds per square inch.

144. The apparatus of claim 139, wherein the operating media in the operating media supply passage comprises the air having a temperature of about -40 to 180 degrees Fahrenheit.

145. The apparatus of claim 139, wherein the operating media in the operating media supply passage comprises the air having a flow rate of about 5 standard cubic feet per minute at about 40 pounds per square inch to about 100 standard cubic feet per minute at about 120 pounds per square inch.

146. The system of any of claims 3, 7, 60 and 61, further comprising: a second process valve; and a second actuator operating the second process valve; wherein the device controls the first and second actuators.

147. The system of claim 146, further comprising: a second pipe connected to the first process valve.

148. An operating media distributor comprising: a first operating media distribution valve in fluid communication with an operating media supply passage, first and second operating media transmission passages, and an operating media exhaust passage, the first operating media distribution valve including: a first configuration connecting the operating media supply passage with the first operating media transmission passage and connecting the second operating media transmission passage with the operating media exhaust passage; and a second configuration connecting the operating media supply passage with the second operating media transmission passage and connecting the first operating media transmission passage with the operating media exhaust passage; and a second operating media distribution valve in fluid communication with the operating media supply passage, third and fourth operating media transmission passages, and the operating media exhaust passage, the second operating media distribution valve including: a third configuration connecting the operating media supply passage with the third operating media transmission passage and connecting the fourth operating media transmission passage with the operating media exhaust passage; and a fourth configuration connecting the operating media supply passage with the fourth operating media transmission passage and connecting the third operating media transmission passage with the operating media exhaust passage.

149. The distributor of claim 148, further comprising: a first operational mode including the first configuration of the first operating media distribution valve and the third configuration of the second operating media distribution valve.

150. The distributor of claim 149, further comprising: a second operational mode including the second configuration of the first operating media distribution valve and the fourth configuration of the second operating media distribution valve.

151. The distributor of claim 150, further comprising: a third operational mode that includes occluding one of the plurality of comiection ports corresponding to one of the first, second, third and fourth operating media transmission passages.

152. The subject of any of the preceding claims, wherein the operating media comprises compressed air.