Wireless valve actuator system and method

A gas-over-oil actuator system for use with a valve in a natural gas pipeline. The system includes a gas-over-oil actuator and a wireless position monitor operatively coupled to the gas-over-oil actuator. The wireless position monitor includes an integral opened spool valve and is adapted to be communicatively coupled to a remote workstation via a wireless network and a wireless gateway. At least one switching relay is operatively coupled to the gas-over-oil actuator and the wireless position monitor. Upon receiving a wireless command from the remote workstation, the wireless position monitor drives a pressure signal from the opened center spool valve to the at least one switching relay to manage high pressure supply to the gas-over-oil actuator and move the valve to a desired position.

FIELD OF THE DISCLOSURE

The present invention relates generally to valve actuator systems, and more specifically, to a wireless gas-over-oil actuator system and method for use with a valve in a natural gas pipeline.

BACKGROUND OF THE DISCLOSURE

Gas-over-oil actuators (also called gas/hydraulic actuators or gas powered actuators) are typically installed on valves, such as isolating valves, in a natural gas distribution pipeline and used to control the valves with high-pressure natural gas. For example, the gas-over-oil actuator may be powered by natural gas pressure taken directly from the natural gas pipeline, e.g., 75 bar. In this conventional system, all electrical equipment must be certified for the specific hazardous area, as does any electrical connection between a control room and the gas-over-oil actuator.

In one example, and referring now toFIGS. 1A and 1B, a conventional gas-over-oil actuator10includes an open side gas hydraulic tank12, and a closed side gas hydraulic tank14. A mounting bracket16may be used to install the gas-over-oil actuator10on a valve disposed in a natural gas pipeline (not shown).

As depicted inFIG. 1B, the gas-over-oil actuator10further includes an opening solenoid valve18and a closing solenoid valve20, both of which may be installed on an actuator control, for example. A command, such as an open/close command, from wired powered inputs, e.g., two different 24 VDC, are sent to the opening solenoid valve18and the closing solenoid valve20to control and operate the valve. In addition, a limit switch22(FIG. 1A) is installed on top of the gas-over oil-actuator10and is used for an open/closed position feedback. Two different wired signals are used as open/closed position feedback.

In addition, two different manual override systems, the oil override system (not shown) and the solenoid valve manual override system (not shown), are typically installed on the gas over-oil actuator10. The oil override system moves the valve if the pipeline is empty or if the natural gas pressure is insufficient. The solenoid valve manual override system moves the valve if the electrical equipment or power supply fails.

The gas-over-oil actuator10can be remotely operated by local electric pushbuttons or from a main dispatching center. In one example, one or more lights on a control panel (HSV) may depict the open/closed valve position, and the electrical control panel (HSV) is located in a safe area. In some plant layout configurations, two pressure transmitters are also installed in the pipeline, one upstream and the other downstream the valve. The pressure transmitters monitor the gas pressure in the pipeline and verify any gas leakage once the valve is in a closed position, for example.

In the foregoing conventional system, all the instruments installed in the plant are physically wired with armored cables and cable glands, for example, to the control panel installed in the control room. Due to inherent porosity of cable insulation layers, permeation phenomena has been experienced. In addition, all electric wiring is arranged by implementing suitable trays along the cable paths to prevent mechanical stress.

SUMMARY OF THE DISCLOSURE

In accordance with a first exemplary aspect of the disclosure, a gas-over-oil actuator system for use with a valve in a natural gas pipeline is disclosed and includes a gas-over-oil actuator and a wireless position monitor operatively coupled to the gas-over-oil actuator. The wireless position monitor has an integral open center spool valve and is adapted to be communicatively coupled to a remote workstation. At least one switching relay is operatively coupled to the gas-over-oil actuator and the wireless position monitor. The at least one switching relay receives a signal from the opened center spool valve of the wireless position monitor. Upon wirelessly receiving a command from the remote workstation, the wireless position monitor drives a signal from the opened center spool valve to the at least one switching relay to manage pressure supply to the gas-over-oil actuator and to move the valve to a desired position.

According to another exemplary aspect of the present disclosure, a process control system comprises a valve installed in a natural gas pipeline and a gas-over-oil actuator system operatively coupled to the valve. The gas-over-oil actuator system includes a gas-over-oil actuator and a wireless position monitor operatively coupled to the gas-over-oil actuator. The wireless position monitor has an integral pneumatic pilot valve. In addition, at least one switching relay is operatively coupled to the gas-over-oil actuator and the wireless position monitor, the at least one switching relay for receiving a signal from the pneumatic pilot valve of the wireless position monitor. The process control system further comprises a workstation having a controller communicatively coupled to the wireless position monitor via a wireless network. Thus, upon receiving a command from the controller via the network, the wireless position monitor drives a signal from the pneumatic pilot valve to the at least one switching relay to manage pressure supply to the gas-over-oil actuator, moving the valve to a desired position.

According to a further exemplary aspect of the present disclosure, a wireless actuator system for use with a valve in a natural gas pipeline is disclosed. The wireless actuator system comprises an actuator adapted to be operatively coupled to a valve disposed in a natural gas pipeline and a wireless position monitor operatively coupled to the actuator. The wireless position monitor has an integral opened center spool valve and is adapted to be communicatively coupled to a remote workstation via a wireless network. At least one switching relay is operatively coupled to the actuator and the wireless position monitor. The at least one switching relay is for receiving a pressure signal from the opened center spool valve of the wireless position monitor. Upon receiving a wireless command from the remote workstation, the wireless position monitor drives the pressure signal from the opened center spool valve to the at least one switching relay to manage pressure supply to the actuator and move the valve to a desired position.

In yet another exemplary aspect of the present disclosure, a method of operating a valve disposed within a natural gas pipeline is disclosed. The method comprises integrating a wireless position monitor into an actuator operatively coupled to the valve, the wireless position monitor communicatively coupled to a workstation via a wireless network, and transmitting, via one or more transmitters, a command from a controller of the workstation to the wireless position monitor via the wireless network. The method further includes sending a pressure signal from a pneumatic pilot valve of the wireless position monitor to at least one switching relay upon receiving the command, the at least one switching relay operatively coupled to the wireless position monitor and the actuator. The method further includes managing a high pressure supply to the actuator via the at least one switching relay to move the valve to a desired position in response to the pressure signal received from the pneumatic pilot valve.

In further accordance with any one or more of the exemplary aspects, the gas-over-oil actuator system, the process control system and/or the actuator system of the present disclosure may include any one or more of the following further preferred forms.

In some preferred forms, the remote workstation may include the remote workstation comprising one or more of a controller, a network gateway communicatively coupled to the controller, a laptop coupled to the network gateway, a control panel operatively coupled to the controller, and an LCD screen operatively coupled to the controller. In addition, the gas-over-oil actuator may further comprise a first gas/oil tank, a second gas/oil tank, and a manual override system disposed adjacent to and between the first and second gas/oil tanks. In addition, the system may include an open switching relay and a closed switching relay, the open and closed switching relays operatively coupled to the gas-over-oil actuator and the wireless position monitor. Further, the gas-over-oil actuator may further comprise a first tank and a second tank, the first tank in communication with the open switching relay and the second tank in communication with the closed switching relay, and each of the open and closed switching relays may include a vent.

In some other preferred forms, the signal from the opened center spool valve driven to the at least one switching relay is a low pressure signal, and the pressure supply to the gas-over-oil actuator is a high pressure supply. In another example, the signal from the opened center spool valve driven to the at least one switching relay is a high pressure signal, and the pressure supply to the gas-over-oil actuator is the same pressure level as the high pressure signal.

In some preferred forms, the system further includes a pressure regulator operatively coupled to the wireless position monitor. The pressure regulator may have a relief valve and may limit the inlet pressure from the natural gas pipeline to the opened center spool valve of the wireless position monitor. In addition, the at least one switching relay may include a manual override to allow local manual operation if the wireless position monitor fails.

In other preferred forms, the system further includes at least one solenoid valve disposed external to and operatively coupled to the wireless position monitor, the at least one solenoid valve driven by the wireless position monitor to provide high pressure gas supply from the natural gas pipeline through the opened center spool valve and into the at least one switching relay.

Also, a bleed valve may be included for maintaining the at least one switching relay in an open position for a time required by the valve to complete a desired travel distance. In one example, the bleed valve may have a locking nut to prevent tampering and may further be disposed within a lockable cabinet.

In still other preferred forms, the system may further comprise at least one torque limiting device disposed between the wireless position monitor and the at least one switching relay to prevent excess torque from the gas-over-oil actuator.

Additional optional aspects and features are disclosed, which may be arranged in any functionally appropriate manner, either alone or in any functionally viable combination, consistent with the teachings of the disclosure. Other aspects and advantages will become apparent upon consideration of the following detailed description.

DETAILED DESCRIPTION OF THE DISCLOSURE

Generally, a gas-over-oil actuator system for use with a valve in a natural gas pipeline is disclosed. The gas-over-oil actuator system includes a gas-over-oil actuator and a wireless position monitor operatively coupled to the gas-over-oil actuator. The wireless position monitor includes an integral opened spool valve and is communicatively coupled to a remote workstation via a wireless network. The system further includes at least one switching relay operatively coupled to the gas-over-oil actuator and the wireless position monitor.

Upon receiving a command from the remote workstation via the wireless network, the wireless position monitor drives a pressure signal from the opened center spool valve to the at least one switching relay to manage pressure supply to the gas-over-oil actuator and to move the valve to a desired position without any hardwired connection. In other words, the new gas-over-oil actuator system allows wireless, remote operation of the valve without any hardwired connection needed to maintain all the functionality of the conventional wired system. The new gas-over-oil actuator system further allows acquisition and feedback of one or more of the valve or actuator, as explained in more detail below.

Referring now toFIG. 2, a process control system100includes a gas-over-oil actuator system110operatively coupled to a valve112installed or disposed in a natural gas pipeline114. The gas-over-oil system110includes a gas-over-oil actuator116and a wireless position monitor118operatively coupled to the gas-over-oil actuator116. The wireless position monitor118replaces the limit switches of conventional systems and monitors the valve112position using a magnetic linkage system. In one example, and as depicted inFIG. 2, the gas-over-oil actuator116includes first gas/oil tank120, and a second gas/oil tank122, and the wireless position monitor118is disposed between the first and second gas/oil tanks120,122. This position of the wireless position monitor118helps the wireless position monitor118measure differential pressure across the gas-over-oil actuator116, such as a piston of the gas-over-oil actuator116.

In one example, the wireless position monitor118is a Fisher 4320/TopWorx 4310 Wireless Position Monitor with on/off control option. The integrated diagnostic capability of the Fisher 4320/TopWorx 4310 Wireless Position Monitor, such as feedback in percentage of travel, close time, open time, and alerts, allows acquisition and feedback of both the valve112and the gas-over-oil actuator116travel position and stroking time. In addition, the Fisher 4320/TopWorx 4310 Wireless Position Monitor can raise alarms and/or warnings according to customer requirements. While the Fisher 4320/TopWorx 4310 Wireless Position Monitor is the wireless position monitor118of the process control system100in one example, one of ordinary skill in the art will appreciate that other wireless position monitors may alternatively be used and still fall within the scope of the present disclosure.

The wireless position monitor118includes an integral pneumatic pilot valve123(FIG. 3A), such as an opened center spool valve, and one or more of an antenna126or a network interface (not shown) for receiving signals from a remote source via a wireless network, as explained in more detail below. The wireless position monitor118further includes at least one switching relay124(FIG. 3A) operatively coupled to the gas-over-oil actuator116and the wireless position monitor118. The at least one switching relay124receives a signal from the pneumatic pilot valve123, such as an opened center spool valve123, to manage pressure supply to the gas-over-oil actuator116, as also explained more below relative toFIG. 3A.

The gas-over-oil actuator system110may further include a bleed valve130for maintaining the at least one switching relay124(FIG. 3A) in a desired position, such as an open position or a closed position, for a time required by the valve112to complete a desired travel distance, for example. The bleed valve130may include a locking nut132to prevent tampering and is disposed within a lockable cabinet134. In one example, the lockable cabinet134having the bleed valve130is disposed adjacent to the second gas/oil tank122of the gas-over-oil actuator116.

When the valve112does not complete the desired travel distance and a value of torque is acceptable, the wireless position monitor118may again send the pressure signal to the at least one switching relay124to complete the travel. Alternatively, an alert message may be sent to the LCD or other display, such that the message reads “Alert: Valve Not in Correct Position,” for example.

The process control system100further includes a workstation140having at least one wireless gateway142, such as a Fisher Smart Wireless Gateway1410/1420. The Fisher Smart Wireless Gateway142connects WirelessHART self-organizing networks with host systems and data applications. The Smart Wireless Gateway also includes layered security to ensure any network stays protected. As further depicted inFIG. 2, a second or redundant “hot” backup gateway142is further provided in the event the first gateway142is compromised or fails. A controller144is operatively connected to the wireless gateway142via Modbus communications, in one example, and is further communicatively coupled to the wireless position monitor118via a wireless network150. More specifically, the wireless gateway142may include one or more of at least one antenna146, at least one transmitter, and at least one receiver for one or more of transmitting signals to and receiving signals from the wireless position monitor118via the wireless network150. In one example, the controller144is a FloBoss FB107 controller and includes a processor148, a memory149executable by the processor148, and a transmitter151. One of skill in the art will appreciate that the controller144may alternatively be various other controllers and may further be connected to the wireless gateway142via other communications and still fall within the scope of the present disclosure.

The workstation140of the process control system100may further include a laptop156coupled to the wireless gateway142via an Ethernet LAN, for example. In addition, and in some examples, a local control panel158may be operatively coupled to the controller144and a LCD screen160, which may include a touch screen, and may also be operatively coupled to the controller144of the remote workstation140. An operator may actuate one or more of a button or key on the laptop156or the local control panel158, or a touchscreen of the LCD screen160to initiate a wireless open/close command from the controller144to the wireless position monitor118to operate the valve112. In addition, the LCD screen may display diagnostic information and alarms for the operators. Further, and in one example, the remote workstation140may be disposed within one of a local control room159or a main dispatching center159and still fall within the scope of the present disclosure.

In addition, the workstation140further includes a central control system108. As depicted inFIG. 2, for example, the control system108is operatively coupled to one or more of the wireless gateway142, the controller144, and the laptop156. A user may initiate certain commands through the control system108, for example, to remotely operate the gas-over-oil actuator system110.

More specifically, upon receiving the command, such as an open/close command, from the controller144and/or the control system108via the wireless gateway142and the wireless network150, the wireless position monitor118drives a pressure signal from the pneumatic pilot valve123(FIG. 3A) to the at least one switching relay124. In one example, the signal is a low pressure signal, such as a low pressure signal of 7 bar. This allows the at least one switching relay124to manage the pressure supply to the gas-over-oil actuator116to move the valve112to a desired position and monitor the position of the valve112. In addition, the pressure supply to the gas-over-oil actuator116is a high pressure supply, such as a high pressure supply of up to 75 bar.

In addition, to minimize battery drainage, the control command from the controller144may be maintained for only a few seconds, in one example. The bleed valve130is then set to maintain the at least one switching relay124in a desired position for a desired time.

As further depicted inFIG. 2, the process control system100may further include a differential pressure transmitter162. The differential pressure transmitter162is operatively coupled to the gas-over-oil actuator116and may measure one or more of a differential pressure across the gas-over-oil actuator116or an opening torque of the valve112, for example. The differential pressure transmitter162is further communicatively coupled to the workstation140via the wireless network150and the wireless gateway142. This allows data acquisition and feedback relative to the differential pressure across the gas-over-oil actuator118and the operating torque of the valve112, for example. In one example, a memory of the laptop156saves such data relative to the differential pressure of the gas-over-oil actuator118and the operating torque of the valve112and displays the data on a screen of the laptop156for further analysis.

In yet another example, the process control system100may further include a first pressure transmitter164disposed within the natural gas pipeline114upstream the valve112to measure pressure upstream the valve112. In addition, a second pressure transmitter166may be disposed within the natural gas pipeline114downstream the valve112to measure pressure within the natural gas pipeline114downstream the valve112. The first and second pressure transmitters162,164are each communicatively coupled to the wireless gateway142of the workstation140via the wireless network150. This allows data acquisition and feedback relative to the pressure in the natural gas pipeline114both upstream and downstream the valve112, for example.

Referring now toFIG. 3A, a schematic view of the gas-over-oil actuator system110ofFIG. 2is depicted. As also depicted inFIG. 2, the gas-over-oil actuator system110includes the gas-over-oil actuator116having the first gas/oil tank120and the second gas/oil tank122. Each of the first and second gas/oil tanks120,122are in fluid communication with a high pressure supply, such as a high pressure supply of up to 75 bar. A manual override system128is disposed adjacent to the first and second gas/oil tanks120,122.

The at least one switching relay124may include a closed switching relay124a, which is in fluid communication with the first gas/oil tank120, and an open switching relay124b, which is in fluid communication with the second gas/oil tank122. Each of the switching relays124a,124bincludes a vent125and a manual override (not depicted) in the event the switching relays124a,124bfail.

The wireless position monitor118includes a first piezo valve119, a second piezo valve121, and a pneumatic pilot valve123. In one example, the pneumatic pilot valve123is the opened center spool valve123, a close up of which is depicted inFIG. 3B.

The opened center spool valve123of the wireless position monitor118is operatively coupled to a pressure regulator170that includes a relief valve172. The pressure regulator170limits an inlet pressure from the pipeline114(FIG. 2) to the opened center spool valve123of the wireless position monitor118. The opened center spool valve123allows low pressure gas, e.g., 7 bar, taken from the high pressure natural gas pipeline114by the pressure regulator170to flow through the spool valve123and into the switching relays124a,124b.

As depicted inFIG. 3B, and in one example, the opened center spool valve123of the wireless position monitor118is a 5/3 opened center spool valve, as one of ordinary skill in the art will appreciate. The opened center configuration allows the low pressure signal from the pressure regulator170to flow through the spool valve123of the wireless position monitor118and into the first and second switching relays124a,124b. This allows the switching relays124a,124bto manage the high pressure supply to the gas-over-oil actuator116to ultimately operate and control the valve112. Having a closed center spool valve, for example, would prevent the low pressure gas from the pressure regulator170to flow through the spool valve123and into the switching relays124a,124band effective management of the high pressure gas supply to the gas-over-oil actuator116.

In addition, because the power media of natural gas is taken directly from the pipeline114, a filter174has been disposed adjacent to and in fluid communication with the pressure regulator170to protect downstream devices, for example. In yet another example, a pressure gauge176is disposed adjacent to the relief valve172to measure and display the low pressure supply, e.g., 7 bar, flowing from the pressure regulator170to the wireless position monitor118and the switching relays124a,124b.

In yet another example, the gas-over-oil actuator system110may further include at least one torque limiting device180, as depicted inFIG. 4. More specifically, and for clarity, the gas-over-oil actuator system110ofFIG. 4is the gas-over-oil actuator system110ofFIG. 3A, further including the at least one torque limiting device180. For example, a first torque limiting device181may be disposed between the wireless position monitor118and the first switching device124a. In addition, a second torque limiting device182may be disposed between the wireless position monitor118and the second switching device124b. In this manner, each of the first and second torque limiting devices181,182prevents excess torque that may be developed by the gas-over-oil actuator116.

Referring now toFIG. 5, another process control system200is depicted with another example wireless actuator system210operatively coupled to a valve212installed or disposed in a natural gas pipeline214. The wireless actuator system210includes an actuator217and the wireless position monitor118operatively coupled to the actuator217. In one example, the actuator217includes a housing219, and the wireless position monitor118is disposed on the housing219.

As described relative to the gas-over-oil actuator system110ofFIGS. 2, 3A and 3B, the wireless position monitor118of the wireless actuator system210also includes the integral pneumatic pilot valve123(FIG. 3A), such as an opened center spool valve, and one or more of an antenna126or a network interface (not shown) for receiving signals from a remote source via a wireless network250, as explained in more detail below. The wireless position monitor118further includes at least one switching relay124(FIG. 3A) operatively coupled to the actuator217and the wireless position monitor118. The at least one switching relay128receives a signal from the pneumatic pilot valve123, such as the opened center spool valve123in one example, to manage pressure supply to the actuator217, as also explained more below.

Like the process control system100ofFIG. 2, the process control system200also includes a workstation240having a wireless gateway242, such as a Smart Wireless Gateway1410/1420. A controller244is operatively coupled to the wireless gateway242and communicatively coupled to the wireless position monitor118. More specifically, the wireless gateway242may include one or more of at least one antenna246, at least one transmitter, and at least one receiver for one or more of transmitting signals to and receiving signals from the wireless position monitor118via a wireless network250, such as a WirelessHART network. In one example, the controller244includes a processor248, a memory249executable by the processor248, and a transmitter251. One of skill in the art will appreciate that the controller244may alternatively be various other controllers and still fall within the scope of the present disclosure.

The workstation240of the process control system200may further include a laptop256coupled to the wireless gateway242. An operator may actuate one or more of a button or key on the laptop256or the controller244to initiate a wireless open/close command from the controller244to the wireless position monitor118to the actuator217to operate the valve212. In addition, the remote workstation240may be disposed within one of a local control room159or a main dispatching center159and still fall within the scope of the present disclosure.

In addition, the workstation240may further include a central control system208. As depicted inFIG. 5, for example, the control system208is operatively coupled to one or more of the wireless gateway242, the controller244, and the laptop256. A user may initiate certain commands through the control system208, for example, to remotely operate the gas-over-oil actuator system210.

More specifically, and similar to the gas-over-oil actuator system110ofFIG. 2, the wireless position monitor118drives a signal from the pneumatic pilot valve123(FIG. 3A) to the at least one switching relay124upon receiving the command from the controller244and/or the control system208via the wireless gateway242and the wireless network250. In one example, the signal is a low pressure signal, such as a low pressure signal of 7 bar. This allows the at least one switching relay124to manage the pressure supply and the actuator217to move the valve212to a desired position and monitor the position of the valve212. In another example, the actuator217is a high pressure supply, such as a high pressure supply in the range of 1 bar-75 bar.

Like the process control system100ofFIG. 2, the process control system200depicted inFIG. 5may also further include a first pressure transmitter264disposed within the natural gas pipeline214upstream the valve212to measure pressure upstream the valve212. In addition, a second pressure transmitter266may be disposed within the natural gas pipeline214downstream the valve212to measure pressure within the natural gas pipeline214downstream the valve212. The first and second pressure transmitters264,266are each communicatively coupled to the wireless gateway242of the workstation240via the wireless network250. This allows data acquisition and feedback relative to the pressure in the natural gas pipeline214upstream and downstream the valve212, for example.

In still another example, and referring now toFIG. 6A, a schematic view of the another exemplary gas-over-oil actuator system310according to the present disclosure is depicted. The gas-over-oil actuator system310may be operatively coupled to a valve312, which may be installed or disposed in the natural gas pipelines114,214depicted inFIGS. 2 and 5, respectively, for example. In addition, the gas-over-oil actuator system310may be operatively coupled to the workstation140via the wireless network150of the process control system100(FIG. 2), replacing the gas-over-oil actuator system110ofFIG. 2. In another example, the gas-over-oil actuator system310may be operatively coupled to the workstation240of the process control system200(FIG. 5) via the wireless network250, replacing the wireless actuator system210ofFIG. 5, for example. In either case, the workstations140,240operate relative to the gas-over-oil actuator system310in the same manner explained above relative to the gas-over-oil actuator system110or the wireless actuator system210, respectively.

More specifically, and as depicted inFIG. 6A, the gas-over-oil actuator system310includes the gas-over-oil actuator316having the first gas/oil tank320and the second gas/oil tank322. Each of the first and second gas/oil tanks320,322are in fluid communication with a high pressure supply, such as a high pressure supply of up to 75 bar. A manual override system328is disposed adjacent to the first and second gas/oil tanks120,122.

The gas-over-oil actuator system310further includes at least one switching relay324having a closed switching relay324a, which is in fluid communication with the first gas/oil tank320, and an open switching relay324b, which is in fluid communication with the second gas/oil tank322. Each of the switching relays324a,324bincludes a vent325and a manual override (not depicted) in the event the switching relays324a,324bfail.

The system310further includes a wireless position monitor318having a pneumatic pilot valve323. In one example, the pneumatic pilot valve323is an opened center spool valve323, a close up of which is depicted inFIG. 6B. As further depicted inFIG. 6A, and in this example, a solenoid valve system317is disposed external to the wireless position monitor318and is electrically wired to the wireless position monitor318. Said another way, the solenoid valve system317is operatively coupled to the wireless position monitor318via physical wires. More specifically, the solenoid valve system317includes at least one solenoid valve, such as a first piezo valve319and a second piezo valve321, both of which are directly wired to the wireless position monitor318. In addition, the solenoid valve system317may also include an manual override system340, as further depicted inFIG. 6A, which may be operated in the event the solenoid system317fails.

Unlike the opened center spool valve123of the wireless position monitor118depicted inFIG. 3A, the opened center spool valve323of the wireless position monitor318is not operatively coupled to any pressure regulator that limits an inlet pressure from the pipeline114,214(FIGS. 2 and 5) to the opened center spool valve323. Rather, upon receiving a command from the controller144,244via the wireless network150,250, the wireless position monitor318drives the at least one solenoid valve of the solenoid valve system317, such as the first and second piezo valves319,321, with a high pressure supply from the natural gas pipeline114,214. This high pressure supply from the at least one solenoid valve system317is driven through the open ended center spool valve323and into the at least one switching relay324a,324b. As a result, only one pressure level, which is the same pressure level as the gas pressure in the natural gas pipeline114, for example, is used in the system310. Said another way, the signal from the opened center spool valve323driven to the at least one switching relay324a,324bis a high pressure signal, and the pressure supply to the gas-over-oil actuator316is the same pressure level as the high pressure signal. As a result, no pressure regulator is required to step down and/or reduce the high pressure before going through the opened center spool valve323, for example.

As depicted inFIG. 6B, and in one example, the opened center spool valve323of the wireless position monitor318is a 5/3 opened center spool valve, as one of ordinary skill in the art will appreciate. The opened center configuration allows the pressure signal from the first and second piezo valves319,321and/or the at least one solenoid valve, to flow through the spool valve323of the wireless position monitor318and into the first and second switching relays324a,324b. This allows the switching relays324a,324bto manage the high pressure supply to the gas-over-oil actuator316to ultimately operate and control the valve312. Having a closed center spool valve, for example, would prevent the pressure gas from flowing through the spool valve323and into the switching relays324a,324band effective management of the high pressure gas supply to the gas-over-oil actuator316.

In view of the foregoing, one of ordinary skill in the art will appreciate the following example method of operating the valve112,212,312within the natural gas pipeline114,214. More specifically, the method for operating the valve112,212,312within the natural gas pipeline114,214includes integrating the wireless position monitor118,318into the actuator116,217,316operatively coupled to the valve112,212,312the wireless position monitor118,318communicatively coupled to the workstation140,240via the wireless network150,250. The method further includes transmitting, via one or more transmitters151,251, a command from the controller144,244, such as an open/close command, to the wireless position monitor118,318via the wireless gateway142,242and the wireless network150,250.

The method still further comprises sending a pressure signal from the pneumatic pilot valve123,323of the wireless position monitor118,318to at least one switching relay124,124a,124b,324a,324bupon receiving the command. The method further includes managing high pressure supply, e.g., up to 75 bar, to the actuator116,217,316via the at least one switching relay124a,124b,324a,324bto move the valve112,212,312to a desired position, e.g., an open position, a closed position, in response to the pressure signal received from the pneumatic pilot valve123.

In addition, in one example, the method further comprises monitoring the position of one or more of the valve112,212,312or actuator116,217,316via the wireless position monitor118,318. In another example, monitoring the position of one or more of the valve112,212,312or actuator116,217,316via the wireless position monitor118,318may comprise acquiring data relative to one of the valve112,212,312or the actuator116,217,316including data relative to a travel position or a stroke time, via the wireless position monitor118,318the wireless network150,250, and the workstation140,240.

In yet another example, the method may further comprise maintaining the at least one switching relay124,324in an open position for a time required by the valve112,212,312to complete a desired travel distance via the bleed valve130(FIG. 2). In addition, the method may further comprise limiting the inlet pressure from the natural gas pipeline114,214to the pneumatic pilot valve123via the pressure regulator170operatively coupled to the wireless position monitor118.

In still yet another example, the method may further comprise measuring one or more of the differential pressure across the actuator116,217,316or an operating torque of the valve112,212,312via the differential pressure transmitter162operatively coupled to the actuator116. Still further, the method may comprise preventing excess torque from the actuator116,217via the at least one torque limiting device180(FIG. 4) disposed between and operatively coupled to the wireless position monitor118and the at least one switching relay124. In addition, the method may also comprise measuring pressure upstream and downstream the valve112,212via the first pressure transmitter164,264disposed upstream the valve112,212and the second pressure transmitter166,266disposed downstream the valve112,212, respectively.

Overall, one of ordinary skill in the art will appreciate the various advantages of the new wireless actuator system110,210,310and method. For example, the new system and method allows an on/off valve with an actuator, such as a gas-over-oil actuator116,316to be moved using the wireless pneumatic position monitor118,318that is powered by natural gas from the natural gas pipeline114,214. No cable or air supply is needed to perform valve movement and position monitoring.

Moreover, with the wireless technology, it is now possible to send the open/close command to the actuator116,217,316and receive feedback about the open and/or closed position of the valve112,212,312without cables or air supply. The communication with the actuator116,217,316and all the relevant equipment in the process control system100,200described above is completely wireless with more diagnostic information acquired by the workstation and control station.

Said another way, integrating the wireless position monitor, e.g., such as Fisher 4320/TopWorx 4310 Wireless Position Monitor, with an on/off option, into the actuator system110,210,310allows remote operation of the valve112,212,312without any hardwired connection. This minimizes various problems, such as interference, deterioration, damage and/or failure, of any part of a hardwired connection, for example, while maintaining the functionality of any other wired components of the process control system100,200.

Still further, the wireless system includes many other benefits, such as improved worker and production efficiency and reduced lost batches. Moreover, the wireless system and method of present disclosure also reduce unwanted emissions and improve worker safety.

As used herein any reference to “one example” or “an example” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one example” in various places in the specification are not necessarily all referring to the same example.

This detailed description is to be construed as examples and does not describe every possible embodiment, as describing every possible embodiment would be impractical, if not impossible. One could implement numerous alternate embodiments, using either current technology or technology developed after the filing date of this application.