Abstract:
The present invention relates to a system and method of inspecting and relieving pressure and fluid from a pipeline in a safe and environmentally friendly manner. An adjustable insert is placed within a flange of the pipeline, where the adjustable insert has a valve stem capable of moving into contact with a valve device to regulate fluid or gas from the pipeline and one or more outlets for relieving pressure or withdrawing fluid from the pipeline. The system and method provided are capable of operating in a closed process without loosening or removing a flange of the pipeline, thereby improving pipeline operator safety.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 62/222,649, filed on Sep. 23, 2015. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to a novel system that can be used in a safe and environmentally friendly manner to measure the pressure and remove the fluid behind a flange in a pipeline in a closed process without loosening or removing the flange, and to related methods to make and use the system. 
       BACKGROUND OF THE INVENTION 
       [0003]    The efficient transportation of petroleum products (crude oil, gasoline, chemicals, natural gas) is critical to meeting the world&#39;s energy demands. Pipelines, rail cars, tankers, ships, and trucks all work in harmony in the transportation network to deliver energy to consumers. The most critical component of this network is the pipeline. North America alone depends on over 185,000 miles of liquid petroleum pipelines, 320,000 miles of gas transmission pipelines, and more than two million miles of gas distribution pipelines. Petroleum products will spend the majority of their transportation time in the pipeline. 
         [0004]    Ideally, the pipeline is constantly transporting petroleum products with little or no downtime. However, in certain circumstances, transportation may stop for repair or maintenance purposes to the pipeline or distribution equipment. During the oil pipeline repair or maintenance, it is often required to remove a blind flange at the end of an oil pipe. To ensure a technician&#39;s safety and environmental safety, prior to the removal of the blind flange, it is critical that there is no significant amount of oil in the pipeline and there is no pressure build-up behind the flange. If there is any remaining oil or higher than atmospheric pressure inside the pipeline, the oil should be removed and the pressure should be released before removing the flange. However, currently there is no apparatus, safe and closed process, or method that can measure the pressure, remove oil, and release high pressure gases without removing the flange. Pipeline operators normally complete the check by loosening a few bolts/studs holding the blind flange in place and wait to see if oil leaks out. This is risky from both an environmental and safety perspective. Fluids in the pipeline, such as oil, may be sprayed onto personnel or nearby objects, and cannot be stopped except for quickly tightening the flange. Additionally, using this method can give a false indication that the product is continually filling what should be a void space. 
         [0005]    U.S. Pat. No. 4,082,002 discloses an apparatus for mounting a pressure gauge or pressure transducer for measuring the pressure in a high pressure manifold or line. Some commercially available diaphragm flange devices can also be used to measure the pressure behind a flange in a pressure manifold or line. However, there is no known disclosure for an apparatus that can both measure pressure within a pipeline as well as remove fluid such as oil from a pipeline in a closed process without removing the flange. In addition, the apparatus disclosed in the prior art is not suitable for oil pipelines that are buried in the soil for extended period of time because the complicated underground soil conditions may damage the pressure measuring devices due to moisture level and other potential corrosive conditions. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    There remains a need for some safe and environmentally friendly apparatus and method to first find if there is high pressure behind the flange and then second, remove the oil inside the pipe without removing the flange. If there is no pressure reading higher than atmospheric pressure behind the flange, operators can safely remove the flange. However, if there is a higher than atmospheric pressure found behind the flange, operators can remove the oil or other potentially dangerous materials out of the pipeline prior to removing the flange for repair or maintenance work. 
         [0007]    Thus, embodiments of the present invention provide a novel system and safe and environmentally friendly method for measuring the pressure behind a flange of a pipeline and also providing a way of removing fluid from behind the flange in a closed process (i.e. without having to loosen and remove the flange) thereby ensuring personal and environmental safety. 
         [0008]    In an embodiment of the present invention, a pipeline inspection system is provided comprising a flange body having opposing first and second surfaces and a bore extending therethrough. The flange body is coupled to a pipeline and includes a valve device positioned within the flange body and an adjustable insert having a valve stem capable of moving within a tube to selectively contact and open the valve device, thereby allowing a flow of pipeline contents to pass through the valve device and to one or more outlets. The valve stem is adjustably-coupled to the tube where the valve stem has a first end and opposing second end, where the second end is sized to engage the valve device. A sealing mechanism, such as an O-ring, is positioned between the valve stem and the tube. 
         [0009]    In an alternate embodiment of the present invention, a method of adjusting a valve in a pipeline flange is provided. The method comprises removing a fastener from a bore of the flange body and placing an adjustable insert in the bore, where the adjustable insert comprises a tube and adjustable valve stem. The valve stem translates to move towards and into contact with a valve device, causing the valve device to open. 
         [0010]    In yet another alternate embodiment of the present invention, a method of removing fluid from a pipeline is provided comprising removing a fastener from a bore of the pipeline, placing an adjustable insert in the bore, where the adjustable insert comprises a tube and adjustable valve stem, and attaching a vacuum device to an outlet of the tube. The valve stem is then translated towards and into contact with a valve device, causing the valve device to open and permitting fluid from behind the flange to be removed by the vacuum device through an outlet in the tube of the adjustable insert. 
         [0011]    The present invention is designed to regulate and control movement of a valve device located within a flange body for an underground pipeline. As such, portions of the present invention may be safely buried in the soil and other elements of the present invention may not be buried so as to be more accessible. Through the present invention, methods of measuring pressure inside a pipeline and behind a flange are provided as well as a method of removing fluid from behind the flange body of the pipeline. 
         [0012]    These and other features of the present invention can be best understood from the following description and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0013]    The present invention is described in detail below with reference to the attached drawing figures. It is understood that the dimensions such as the thickness, length or width of each section in any part of the illustrated apparatus may be exaggerated in each figure for the sole purpose of illustration. They should not be considered the actual or relative thickness, length or width of any section of the apparatus of the present invention in each FIG. 
           [0014]      FIG. 1  depicts a perspective view of an embodiment of the present invention. 
           [0015]      FIG. 2  depicts a cross section view of the embodiment of the present invention in  FIG. 1 . 
           [0016]      FIG. 3  depicts a cross section view of a portion of the present invention. 
           [0017]      FIG. 4  depicts a cross section view of an alternate portion of the present invention. 
           [0018]      FIG. 5  depicts a cross section view of an alternate portion of the present invention in accordance with an alternate embodiment. 
           [0019]      FIG. 6  depicts a cross section view of the present invention where a portion of the present invention is in an alternate position than that depicted in  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    The present invention is intended for use in a pipeline containing oil, gas, or other potentially dangerous fluid, where it is important to know pressure in the pipeline prior to accessing the pipeline. The present invention provides an improved system and method for understanding and determining the pressure within a pipeline, thereby improving personnel and environmental safety. The present invention is designed to operate underground, above ground, or in a combination of locations, as may be needed depending upon the location of the pipeline and access points. The apparatus and methods provided will be better understood in view of  FIGS. 1-6 . 
         [0021]    Referring initially to  FIGS. 1-3 , a pipeline inspection system  100  is provided comprising a flange body  1  having a first surface  1 A, an opposing second surface  1 B, and a bore  5  extending through the flange body  1  and between the flange body surfaces. The bore  5  may comprise a larger portion and a smaller portion, as shown in  FIG. 3 , but is designed to house a valve device  10  positioned within the flange body  1 . In an embodiment of the present invention, the flange body  1  also includes a plurality of threads  7  in the inner surface of bore  5 , as shown in  FIGS. 2 and 3 . The threads  7  are used for engaging a fastener  90 , such as a bolt or cap, as well as for engaging a tube portion of an adjustable insert  30 , as will be discussed in more detail below. 
         [0022]    The valve device  10  comprises a retainer  12  that is positioned in contact with the second surface  1 B of the flange body  1  and is also in direct contact with the contents in the pipeline. The valve device  10  also includes a spring  15 , a stopper  20 , and a seat  25 . The seat  25  is in contact with internal walls of the bore  5 , and the stopper  20  and spring  15  are positioned such that the stopper  20  is in contact with the seat  25  and provides a sealing surface when the valve device is in a closed position. 
         [0023]    The stopper  20  can take on a variety of configurations depending on the specific pipeline inspection system. One such acceptable stopper  20  configuration is a ball valve, such as that depicted in  FIGS. 2, 3, and 6 . When the ball is in contact with the seat  25 , as shown in  FIG. 2 , a seal is created in the valve device  10 . However, when the ball moves away from the seat  25  and compresses the spring  15 , the retainer  12  moves away from the second surface  1 B of the flange body  1 , thereby opening the valve device  10 . Although not shown, it is envisioned that the valve device  10  may take on other configurations, such as a plunger valve, check valve, butterfly valve, choke valve, plate valve, or other similar configuration designed to restrict the flow of a liquid or gas. For example, the stopper  20  may take on configurations such as a plunger or a plate arrangement. 
         [0024]    The inspection system  100  also comprises an adjustable insert  30  as shown in  FIGS. 2 and 4-6 . The adjustable insert  30  comprises a tube  35  that is coupled to the flange body  1 . One such acceptable way of coupling the tube  35  to the flange body  1  is through a plurality of external threads  40  proximate a first tube end  45 . The tube  35  may also comprise a plurality of internal threads  50  proximate a second tube end  55 . The tube  35  also comprises one or more outlets  60  extending through a wall of the tube  35 .  FIG. 4  depicts a tube  35  with one outlet  60  while  FIG. 5  depicts a tube  35  with two outlets  60 . Depending on the embodiment of the present invention, the outlet  60  may be connected to a pressure gauge to measure the internal pressure of a pipeline behind the flange body  1  or it may be connected to a vacuum device to remove fluid from the pipeline. It is also possible for the one or more outlets  60  to provide a connection point for other instrumentation or equipment. The one or more outlets  60  may comprise a male outlet, female outlet or a combination thereof. In one embodiment, the two outlets  60  are both female outlets and have internal threads configured to receive a vacuum device and/or pressure gauge. A person of ordinary skill in the art will appreciate that the outlet(s)  60  may have means other than threads for connecting to a vacuum device, pressure gauge, or other instrumentation. 
         [0025]    The adjustable insert  30  also comprises a valve stem  65  adjustably-coupled to the tube  35 . The valve stem  65  has a first end  70  and opposing second end  75  where the second end  75  is sized to engage the valve device  10 . For the embodiment described above, the valve stem  65  is coupled to the tube  35  by a threaded engagement where threads  80  positioned along the outer surface of the valve  65  are coupled to internal threads  50  in tube  35  and operate to move the valve stem  65  up and down within tube  35  upon rotation of valve stem  65 . 
         [0026]    The second end  75  of the valve stem  65  is sized to engage the stopper  20  of the valve device  10  such that, upon rotation of the first end  70 , the valve stem  65  rotates and moves towards the valve device  10  due to its threaded engagement with the tube  35 . Through continued rotation of the valve stem  65  within the tube  35 , the valve stem  65  comes into contact with the stopper  20  and presses on the stopper  20 , causing the spring  15  to compress and overcome the force applied by spring  15 , and moving the retainer  12  downward to an open position. The contents within the pipeline are then permitted to flow upwards through bore  5 , through the opening in the seat  25 , through a passageway  37  located between an inner diameter of the tube  35  and an outer diameter of the valve stem  65 , and exits through an outlet  60 . The distance retainer  12  is opened as well as the size of the flow passage created between the valve stem  65  and the tube  35  may vary depending on the contents of the pipeline. 
         [0027]    The contents of the pipeline can be measured at an outlet  60  by a pressure gauge or withdrawn from the pipeline by a vacuum device coupled to an outlet  60 . Once the pressure is at an acceptable level or fluid is removed, the valve stem  65  can be returned to its initial, or closed, position by rotating the valve stem  65  in an opposite direction, allowing the ball  20  to seal against the seat  25 .  FIG. 2  depicts the system  100  in a closed valve condition, while  FIG. 6  depicts the system  100  in an open valve condition where the valve stem  65  has moved downwards and into contact with stopper  20 . 
         [0028]    The valve stem  65  may be moved by a variety of mechanisms. For example, the valve stem  65  may have a mechanism comprising a handle extending from its main body in order to provide leverage for turning the valve stem. Alternatively, the valve stem  65  may have a configuration proximate its first end  70  to allow for connection of a tool or other device to assist with turning the valve stem  65 . One such acceptable configuration is a hex head opening in the first end  70  such that a wrench or socket may be coupled to the first end  70  to turn the valve stem  65 . 
         [0029]    The inspection system  100  also comprises a sealing mechanism  85  for sealing between the tube  35  and the valve stem  65 , as shown in  FIGS. 2, 4, and 5 . Although a variety of seals can be used, an acceptable sealing configuration for the region between the tube  35  and adjustable insert  65  is an O-ring. This O-ring maybe fabricated of rubber, a composite material or metal. 
         [0030]    Referring back to  FIG. 3 , the pipeline inspection system  100  also comprises a fastener  90 , such as a bolt or cap, sized to be received within the bore  5  of flange body  1  when the adjustable insert  30  is not being utilized. The fastener  90  may be threaded in order to engage internal threads of the bore  5 . The fastener  90  can be removed and replaced with the adjustable insert  30  when there is a need to check a pressure level behind the flange body  1  or to remove a fluid in the pipeline behind the flange body  1 . 
         [0031]    Although threaded engagements are disclosed at a number of locations for the present invention, it is to be understood that the scope of the invention is not limited to threaded couplings, but could include alternative forms of engagement. Such alternate forms include snap fits, compression seals, or other removable forms of engagement. 
         [0032]    Attachment of the flange body  1  to the pipeline can occur through several means. In one embodiment, the flange body  1  of the present invention comprises evenly distributed plurality of bolt holes  3  extending through the flange body  1  for connecting the flange body  1  to a pipeline or vessel (not shown). In another example, the flange body  1  and a pipeline vessel are connected via a compression coupling, such as a C-clamp or plurality of C-clamps. Alternatively, a circumferential clamp can be used to join the outer circumference of the flange body  1  and the pipeline or vessel. 
         [0033]    In an alternate embodiment of the present invention, a method of adjusting a valve in a pipeline flange is disclosed where the method comprises removing a fastener from a bore of a flange body and placing an adjustable insert in the bore, where the insert comprises a tube and an adjustable valve stem as discussed above. The valve stem is then adjusted towards and into contact with a valve device, causing the valve device to open. Once the valve device opens, a pressure measurement from behind the flange can be obtained. If the pressure behind the flange body is higher than atmospheric pressure, it suggests that there is oil, gas, or other fluid behind the flange. Operators can remove the oil, gas, or other fluid from the pipeline before removing the flange by venting gases out or drawing the pipeline contents out with a vacuum. Thus, the apparatus and method provided by this invention will ensure the safety of operators and avoid pollution problems caused by the leak or spillage of oil, gas, or other fluid. 
         [0034]    In yet another embodiment of the present invention, a method of removing fluid from within a pipeline is provided. The method comprises a removing a fastener from a flange of a pipeline and placing an adjustable insert in the bore of the flange body, where the insert comprises a tube and valve stem adjustably-coupled to the tube, as discussed above. Then, a vacuum device is attached to an outlet of the tube, and the position of the valve stem is adjusted towards and into contact with a valve device, causing the valve device to open. Once the valve device is open, fluid can be removed from behind the flange and inside the pipeline. 
         [0035]    Metals or other materials that do not corrode in petroleum products are preferably used to manufacture the apparatus of the present invention. Such metals include steel (including carbon steel, HASTELLOY®, and stainless), aluminum, aluminum alloys, titanium, and combinations thereof. Non-metal materials include ceramic, carbon fibers, nylon, propylene, ethylene, and polyester. The apparatus of the present invention can also be made by a mixture of metals and non-metals. 
         [0036]    Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. The present invention is not to be limited to the shape and sizes as disclosed above. Instead, one of ordinary skill in the art will appreciate that the specific sizes and shapes of the components discussed may vary. For that reason, the following claims should be studied to determine the true scope and content of this invention. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. 
         [0037]    From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. 
         [0038]    It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.