Abstract:
The current disclosure provides flanged fittings with features that provide enhanced structural integrity and function for use in pipeline operations.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present non-provisional Application claims the benefit of commonly owned provisional Applications having Ser. No. 61/917,631, filed on Dec. 18, 2013, entitled FLANGED FITTING FOR PIPELINE, and Ser. No. 62/030,859, filed on Jul. 30, 2014, entitled FLANGED FITTING FOR PIPELINE, which Applications are incorporated herein by reference in its entirety. 
     
    
     FIELD OF INVENTION 
       [0002]    The invention is directed to flanged fittings for pipelines. 
       BACKGROUND 
       [0003]    Flanged fittings are used for a variety of purposes in rigid piping systems. For example, in hot tapping operations a fitting can be welded to the pipeline at a location where the tap is to be made. The fitting can extend radially from the pipeline. After the fitting with flange is attached, a tapping valve can be attached to the flange and a tapping machine can then be mounted on the tapping valve. After the tapping operation is complete, the tapping machine can be removed from the tapping valve and replaced with a plugging machine to provide a non-permanent plug which blocks flow of material being transported through the pipeline so that maintenance can be performed on the pipeline. Following maintenance, the non-permanent plug can be withdrawn from the pipeline and replaced with a permanent plug which is positioned in the fitting. To complete the operation, a blind flange is connected to the flanged fitting on the pipeline. 
         [0004]    Flanged fittings may also be used in line stop assemblies in operations where it is desired to temporarily prevent fluid flow through a selected pipeline section, such as to provide maintenance or modifications a downstream pipeline section. In a line stop assembly a pipeline sleeve can be first mounted or clamped over a target segment of the pipeline. A flanged fitting can be attached to the pipeline through the pipeline sleeve to extend radially from the pipeline. Next, a temporary valve can be attached to the flanged fitting and the pipeline can be tapped. After the tapping process, a completion plug can be secured in the flanged fitting, the temporary valve can be removed, and a blind flange connected to the flanged fitting. 
         [0005]    Many flanged fittings have a “T” shape with a circular flange portion, a tubular neck portion with a distal end that can be attached to a pipeline, and a central bore extending through the flange and neck portions. Depending on the mode of attachment of the flange to the pipeline, it may be desired to modify the flange, such as by welding additional metal pieces to the neck of the fitting. However, such constructions may not be suitable for use in pipeline operations as the modifications may result in structural problems and cause the fitting to fail. 
       SUMMARY 
       [0006]    The invention provides flanged fittings with improved features that provide enhanced structural integrity and function for use in pipeline operations. 
         [0007]    The flanged fitting has proximal, central, and distal sections between proximal and distal ends of the fitting. The proximal section includes a flange portion having a circumference, and proximal, vertical, and distal surfaces, and a plurality of bolt holes extending from proximal to distal surface of the flange portion, circumferentially arranged in the flange portion. The flange has a central opening extending from its proximal to distal end, with a central axis, and an inner surface. 
         [0008]    In some embodiments, the central section has a tubular shape and in a proximal to distal arrangement: a first angled outer surface defining a first section of fitting wall between the inner surface that decreases in thickness; a second vertical surface defining a second section of fitting wall between the inner surface that is constant in thickness; and a second angled outer surface defining a third section of fitting wall between the inner surface that increases in thickness. The central section further includes a first curved transition surface between the first angled outer surface and the second outer vertical surface, and a second curved transition surface between the second outer vertical surface and the second angled outer surface. 
         [0009]    In other embodiments, the central section has a tubular shape and includes, in a proximal to distal arrangement: a first curved outer surface defining a first section of fitting wall between the inner surface that decreases in thickness; a second vertical surface, parallel to the central axis and defining a second section of fitting wall between the inner surface that is constant in thickness; and a second curved outer surface defining a third section of fitting wall between the inner surface that increases in thickness. 
         [0010]    The distal section has a third vertical surface defining a fourth section of fitting wall between the inner surface that is constant in thickness. The fourth section of fitting wall has a thickness that is greater than a thickness of the second section of fitting wall, and the outer diameter of the fourth section of fitting wall is greater than the outer diameter of the second section of fitting wall. 
         [0011]    In some embodiments, the inner surface of the flange comprises an inner threaded surface positioned between two inner non-threaded surfaces and capable of receiving a threaded plug. 
         [0012]    It has been found that by including first and second curved transition surfaces, or first and second curved outer surfaces, in the central portion of the flange, the flange has better structural integrity, and allows the presence of a bulkier distal end with greater outer diameter and wall thickness. 
         [0013]    In other embodiments of the invention, the invention provides systems comprising the flanged fitting, such as a system comprising the flanged fitting along with additional components such as a plug, a blind or capping flange, a pipeline sleeve, or combinations thereof. In other embodiments of the invention, the invention provides a method for accessing a pipeline comprising a step of attaching the flanged fitting to the pipeline. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a side cross-sectional view of an embodiment of a flanged fitting. 
           [0015]      FIG. 2  is a side perspective view of an embodiment of a flanged fitting. 
           [0016]      FIG. 3  is a top plan view of an embodiment of a flanged fitting. 
           [0017]      FIG. 4  is a side cross-sectional view a curved transitional surface of a flanged fitting. 
           [0018]      FIG. 5  is a side cross-sectional view of an embodiment of a flanged fitting. 
           [0019]      FIG. 6  is a side cross-sectional view of an embodiment of a flanged fitting. 
           [0020]      FIG. 7  is a side perspective view of another embodiment of a flanged fitting. 
           [0021]      FIG. 8  is another side perspective view of the flanged fitting of  FIG. 7 . 
           [0022]      FIG. 9  is a bottom/side perspective view of the flanged fitting of  FIG. 7 . 
           [0023]      FIG. 10  is a top/side perspective view of the flanged fitting of  FIG. 7 . 
           [0024]      FIG. 11  is a top perspective view of the flanged fitting of  FIG. 7 . 
           [0025]      FIG. 12  is a side perspective view of another embodiment of a flanged fitting. 
           [0026]      FIG. 13  is another side perspective view of the flanged fitting of  FIG. 12 . 
           [0027]      FIG. 14  is a bottom/side perspective view of the flanged fitting of  FIG. 12 . 
           [0028]      FIG. 15  is a top/side perspective view of the flanged fitting of  FIG. 12 . 
           [0029]      FIG. 16  is a top perspective view of the flanged fitting of  FIG. 12 . 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    The embodiments of the present invention described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the present invention. 
         [0031]    Embodiments of the invention include flange fittings as illustrated in  FIGS. 1-16 . With reference to  FIGS. 1 ,  2 ,  5 , and  6 , portions of flanged fitting ( 1 ,  101 ,  201 ) are described with reference to proximal ( 20 ,  120 ,  220 ), central ( 40 ,  140 ,  240 ), and distal ( 60 ,  160 ,  260 ) sections of the fitting. Reference to the arrangement of features of the fitting can be described with reference to the proximal ( 12 ,  112 ,  212 ) and distal end ( 66 ,  166 ,  266 ) of the fitting. 
         [0032]    The proximal section ( 20 ,  120 ,  220 ) of the fitting includes flange portion ( 10 ,  110 ,  210 ). The flange portion includes a proximal surface ( 14 ,  114 ,  214 ), a vertical surface ( 16 ,  116 ,  216 ), and a distal surface ( 18 ,  118 ,  218 ). Extending through the flange portion, as well as the length of the fitting (from the proximal ( 12 ,  112 ,  212 ) to distal end ( 66 ,  166 ,  266 ) of the fitting), is a central opening ( 30 ,  130 ,  230 ) having a central axis CA. 
         [0033]    A plurality of bolt holes ( 21 ,  121 ,  221 ) extend through the flange portion from the proximal surface ( 14 ,  114 ,  214 ) to distal surface ( 18 ,  118 ,  218 ).  FIG. 3  is a top view of an embodiment of the flanged fitting, showing the plurality of bolt holes  21  arranged circumferentially on the flange portion. The number of bolt holes can be chosen based on factors such as the flange size and use, with exemplary bolt hole numbers ranging from about 4 to about 16 (eight bolt holes are shown in  FIG. 3 ). 
         [0034]    Dimensions of the flange portion can be chosen based on factors such as the overall fitting size and use of the fitting. In exemplary designs, the flange has a thickness (from proximal surface ( 14 ,  114 ,  214 ) to distal surface ( 18 ,  118 ,  218 )) in the range of about 0.75 inches to about 1.25 inches, such as about 1 inches, and a diameter in the range of about 5 inches to about 8 inches, such as about 6.5 inches. Exemplary bolt hole diameters are in the range of about 0.65 inches to about 0.85 inches, such as about 0.75 inches. 
         [0035]    The proximal section ( 20 ,  120 ,  220 ) of the fitting can also include a raised portion ( 22 ,  122 ,  222 ) that extends proximally from the flange portion ( 10 ,  110 ,  210 ) and encompasses the diameter of the central opening ( 30 ,  130 ,  230 ). The height of the raised portion can be, for example, in the range of about 0.06 inches to about 0.3 inches, about 0.2 inches to about 0.3 inches, such as about 0.25 inches. The raised portion ( 22 ,  122 ,  222 ) has a circumference that is smaller than the flange circumference, for example, a diameter in the range of about 3 inches to about 4.5 inches, such as about 3.6 inches. 
         [0036]    Referring back to  FIGS. 1 ,  5 , and  6 , the central opening ( 30 ,  130 ,  230 ) is shown extending from the proximal ( 12 ,  112 ,  212 ) to distal end ( 66 ,  166 ,  266 ) of the fitting with the central axis CA running parallel to the inner wall of the opening. As shown in  FIG. 3 , the central opening has a circular shape when the fitting is viewed from its proximal end (in this embodiment the distal end also has a circular shape; not shown). 
         [0037]    In one embodiment, and with reference to  FIGS. 1 and 6 , the inner surface of the fitting includes an inner threaded surface. For example, the central opening ( 30 ,  230 ) has an inner wall with inner threaded surface ( 34 ,  234 ) capable of receiving a threaded plug. The inner threaded surface ( 34 ,  234 ) can be formed between inner non-threaded surface ( 36 ,  236 ) and inner non-threaded surface ( 38 ,  238 ), which meet the proximal and distal ends, respectively. The inner threaded surface ( 34 ,  234 ) can also be closer to the proximal end ( 12 ,  212 ) of the fitting. For example, the inner threaded surface ( 34 ,  234 ) can be present at a location in the central opening at a distance from the proximal end ( 12 ,  212 ) that is between about 5% to about 35%, or about 10% to about 30% of the overall length of the fitting (i.e., the distance from the proximal to distal end of the fitting). In embodiments, the length of the inner threaded surface ( 38 ,  238 ) is in the range of about 0.75 inches to about 1.25 inches, such as about 1 inch. 
         [0038]    In other embodiments (e.g., as reflected in  FIG. 5 ), an inner threaded surface is not required. For example, the central opening  130  can have a continuous non-threaded surface  136  from the proximal end  112  to the distal end  166 . 
         [0039]    The inner surface of the central opening ( 30 ,  130 ,  230 ) can be parallel to the central axis over most or all of its length. The inner diameter of the central opening ( 30 ,  130 ,  230 ) will be constant over lengths where the inner wall is parallel to the central axis. The inner diameter of the central opening ( 30 ,  130 ,  230 ) can be sized to accommodate a desired object (e.g., one that is introduced into a pipeline through the central opening of the fitting), such as a plug, pig, or other article used in a hot tapping process. The inner diameter can be sized to provide a desired flow of material through the fitting. The inner diameter can be similar, or the same, over most or all of the length of the central opening. In exemplary embodiments, the inner diameter in the range of about 1.5 inches to about 2.0 inches, such as about 1.74 inches. In some embodiments the inner diameter slightly decreases in step wise manner from the proximal to distal end. For example, with reference to  FIGS. 1 and 5 , the inner non-threaded surface ( 36 ,  236 ) has a greater inner diameter than inner non-threaded surface ( 38 ,  238 ). 
         [0040]    In some embodiments, the inner wall is at an angle to the central axis in raised portion ( 22 ,  122 ,  222 ) causing an increase in the inner diameter of the central opening ( 30 ,  130 ,  230 ) near the proximal end of the fitting (not shown). 
         [0041]    Adjacent and distal to the distal surface ( 18 ,  118 ,  218 ) of flange portion ( 10 ,  110 ,  210 ) is outer vertical surface ( 35 ,  135 ,  235 ). A curved transition surface can be between distal surface ( 18 ,  118 ,  218 ) and (outer) vertical surface ( 35 ,  135 ,  235 ). 
         [0042]    In some embodiments, with reference to  FIGS. 1 and 5 , adjacent and distal to the vertical surface ( 35 ,  135 ) is angled outer surface ( 42 ,  142 ), which is at an angle relative to the central axis. As shown in the side cross-sectional views of  FIGS. 1 and 5  of the flanged fitting, the angled outer surface ( 42 ,  142 ) is seen as a straight line. Angled outer surface ( 42 ,  142 ) defines a first section of fitting wall ( 44 ,  144 ) between the inner surface that decreases in thickness in a proximal to distal direction in the fitting. 
         [0043]    In some embodiments of the fitting, with reference to  FIG. 6 , there is a curved surface  246  of substantial length between outer vertical surface  235  and vertical surface  248 . For example, the curved surface can begin at a distal point of vertical surface  236  and can continue to the proximal point of vertical surface  248 . The curve of the curved surface  246  can follow a portion of a curved object, such as an arc of a circle or oval. For example, the curved surface  246  can follow the arc of a circle having a certain radius, such as in the range of about 0.5 to about 3 inches, about 1 to about 3 inches, about 1.5 to about 2.5 inches, or more specifically 1.75 to about 2.25 inches. An exemplary radius of curved surface  246  is about 2.0 inches. Curved surface  246  can also defines a first section of fitting wall  244  between the inner surface that decreases in thickness in a proximal to distal direction in the fitting. 
         [0044]    Referring back to  FIGS. 1 and 5 , adjacent and distal to the angled outer surface ( 42 ,  142 ) is vertical surface ( 48 ,  148 ). Referring to  FIG. 6 , adjacent and distal to curved surface  246  is vertical surface  248 . Vertical surface ( 48 ,  148 ,  248 ) is parallel to the central axis and defines a second section of fitting wall ( 50 ,  150 ,  250 ) between the inner surface that is constant in thickness. This section of fitting wall represents the thinnest section of fitting wall along the length of the fitting, and in some embodiments has a thickness in the range of about 0.3 inches to about 0.4 inches, such as about 0.35 inch, and a length of about 1.5 inches to about 3 inches, such as about 2.2 inches. 
         [0045]    The length of the vertical surface ( 48 ,  148 ,  248 ) (as measured along the central axis) can vary in embodiments of the inventive fitting. In some embodiments the length of the vertical surface can be in the range of about 0.25 inches to about 2.5 inches, or about 0.8 inches to about 2.5 inches. In exemplary embodiments, with reference to  FIG. 5 , the length of the vertical surface  148  is about 1.0 inches, and with reference to  FIG. 5 , the length of the vertical surface  48  is about 2.2 inches. In other exemplary embodiments, with reference to  FIG. 6 , the length of the vertical surface  248  is about 0.35 inches. 
         [0046]    The thickness of section of fitting wall ( 50 ,  150 ,  250 ) can optionally be described in relation to the inner diameter of the central opening ( 30 ,  130 ,  230 ). For example, in some embodiments, the section of fitting wall ( 50 ,  150 ,  250 ) has a thickness that is in the range of about 15-25% of the inner diameter of the central opening, such as about 20% of the inner diameter. 
         [0047]    In some embodiments, with reference to  FIGS. 1 and 5 , adjacent and distal to vertical surface ( 48 ,  148 ) is angled outer surface ( 54 ,  154 ), which is at an angle relative to the central axis. As shown in the side cross-sectional views of  FIGS. 1 and 5  of the flanged fitting, like angled outer surface ( 42 ,  142 ), angled outer surface ( 54 ,  154 ) is also seen as a straight line. Angled outer surface ( 54 ,  154 ) defines a third section of fitting wall ( 56 ,  156 ) between the inner surface that increases in thickness in a proximal to distal direction in the fitting. 
         [0048]    Optionally, the angled outer surface ( 54 ,  154 ) may be described by its angle relative to the central axis. For example, in some embodiments, angled outer surface ( 54 ,  154 ) is at an angle in range of about 28° to about 38° to the central axis, such as about 32°, 33°, or 34° to the central axis. 
         [0049]    In some embodiments of the fitting, with reference to  FIG. 6 , there is a curved surface  252  of substantial length between outer vertical surface  248  and vertical surface  262 . Like curved surface  246 , the curve of the curved surface  252  can follow a portion of a curved object, such as an arc of a circle or oval and can follow the arc of a circle having a certain radius, such as in the range of about 0.5 to about 3 inches, about 1 to about 3 inches, about 1.5 to about 2.5 inches, or more specifically 1.75 to about 2.25 inches. An exemplary radius of curved surface  252  is about 2.0 inches. In some arrangements, curved surface  252  has the same radius as curved surface  246 . However, in other arrangements, curved surface  252  may have a radius that is greater, or less, than the radius of curved surface  246 . If different, this would result in a length of the corresponding section  256  that is greater or less, respectively than the length of the section  244 , as measured along the central axis. Curved surface  252  defines a third section of fitting wall  256  between the inner surface that increases in thickness in a proximal to distal direction in the fitting. 
         [0050]    In some embodiments, with reference to  FIGS. 1 and 5 , between the angled outer surface ( 42 ,  142 ) and the outer vertical surface ( 48 ,  148 ), and between the outer vertical surface ( 48 ,  148 ) and the angled outer surface ( 54 ,  154 ), are curved transition surface ( 46 ,  146 ) and curved transition surface ( 52 ,  152 ), respectively. The curved transition surface ( 52 ,  152 ) is shown in greater detail in  FIG. 4 . Curved transition surface ( 46 ,  146 ) is not shown in  FIG. 4 , but can be similar or the same as the second transition surface ( 52 ,  152 ). The curved transition surfaces can be formed by having the vertical surface ( 48 ,  148 ) curve into the angled surfaces ( 42 ,  142 ) and ( 54 ,  154 ), and this results in more fitting material present at the transition surface locations. The increase in fitting material can be seen between the curved transition surface ( 52 ,  152 ) and the dashes lines (otherwise representing this portion of the fitting without a curved transition surface). The presence of the curved transition surfaces ( 46 ,  146 ) and ( 52 ,  152 ) enhances the structural integrity of the fitting. In turn, this can allow a fitting to be formed with a bulkier distal portion ( 60 ,  160 ) such as according to those embodiments described here. The bulkier portion (distal section) of the fitting can be present without risking fracture of the fitting in the central portion ( 40 ,  140 ). 
         [0051]    The curve of the curved transition surfaces ( 46 ,  146 ) and ( 52 ,  152 ) can follow a portion of a curved object, such as an arc of a circle or oval. For example, of the curved transition surfaces ( 46 ,  146 ) and ( 52 ,  152 ) can follow the arc of a circle having a certain radius, such as in the range of about 0.1 to about 0.15 inch. 
         [0052]    Similar to the benefits that the curved transition surfaces ( 46 ,  146 ) and ( 52 ,  152 ) of the fitting embodiments show in  FIGS. 1 and 5  provide, curved surfaces  246  and  252  of the fitting embodiment show in  FIG. 6  enhances the structural integrity of the fitting. In turn, this can allow a fitting to be formed with a bulkier distal portion  260 , without risking fracture of the fitting in the central portion  240 . 
         [0053]    As a general matter, the distal section ( 60 ,  160 ,  260 ) of the fitting, when viewed relative to the central section, can have a bulging or bulbous shape. For example, at least a part of the distal section can have a greater outer diameter and greater wall thickness relative to the central section ( 40 ,  140 ,  240 ). The distal section ( 60 ,  160 ,  260 ) can include one or more surfaces angled relative to the central axis, a vertical surface (parallel to the central axis), and combinations thereof. 
         [0054]    In one embodiment, the distal section ( 60 ,  160 ,  260 ) comprises a vertical surface ( 62 ,  162 ,  262 ) parallel to the central axis defining a section of fitting wall ( 64 ,  164 ,  264 ) between the inner surface that is constant in thickness. The section of fitting wall ( 64 ,  164 ,  264 ) of the distal section ( 60 ,  160 ,  260 ) has a thickness that is greater than a thickness of the section of fitting wall ( 50 ,  150 ,  250 ) in the central section ( 40 ,  140 ,  240 ). Also, the outer diameter of the section of fitting wall ( 64 ,  164 ,  264 ) is greater than the outer diameter of the section of fitting wall ( 50 ,  150 ,  250 ). In some embodiments, the section of fitting wall ( 64 ,  164 ,  264 ) in the distal section ( 60 ,  160 ,  260 ) has a thickness that is about 1.8 to about 2.0 times (e.g., about 1.9 times) the thickness of fitting wall ( 50 ,  150 ,  250 ). 
         [0055]    The length of the vertical surface ( 62 ,  162 ,  262 ) (as measured along the central axis) can vary in embodiments of the inventive fitting. In some embodiments the length of the vertical surface can be in the range of about 0.5 inches to about 1.25 inches. In exemplary embodiments, and with reference to  FIG. 5 , the length of the vertical surface ( 162 ) is about 0.67 inches, or, with reference to  FIGS. 1 and 6 , about 1.05 inches ( 62 ,  262 ). 
         [0056]    The thickness of section of fitting wall ( 64 ,  164 ,  264 ) can optionally be described in relation to the inner diameter of the central opening ( 30 ,  130 ,  230 ). For example, in some embodiments, the section of fitting wall ( 64 ,  164 ,  264 ) is in the range of about 35-45% of the inner diameter of the central opening, such as about 40% of the inner diameter. 
         [0057]    The fitting is preferably prepared by a method such as casting, forging, or machining, or a combination of such methods, and most preferably is formed by machining. Portions of, or all of the fitting may be described as “non-welded,” meaning that a welding process is not performed in making the fitting. In preferred embodiments the fitting is made from a single piece of stock material. The fitting can be made from any suitable stock material, such as stainless steel, carbon steel, alloy steel, or other suitable material. In preferred embodiments, the fitting is made from the same material. 
         [0058]    Embodiments of the invention include the flanged fitting along with a threaded plug (e.g., completion plug) capable of being screwed into an inner threaded surface  34  or  234 , with reference to  FIGS. 1 and 6 , respectively. The threaded plug can include a central opening through the plug, and the central opening can be square or rectangular in shape. 
         [0059]    Embodiments of the invention also include the flanged fitting along with a cover plate attachable to the proximal end of the fitting and having bolt holes in alignment with the bolt holes of the fitting. 
         [0060]    In some modes of operation, the flanged fitting may be used in a line stop assembly to seal an opening tapped into a pipeline. The line stop assembly can include the flanged fitting, a pipeline sleeve, and a cover plate. The pipeline sleeve can be formed from two sleeve portions that can be welded, or otherwise coupled, to the pipeline. The flanged fitting can be coupled (e.g., by welding) to a sleeve portion. The fitting can be positioned on the pipeline so a bore in the flange is aligned and in fluid communication with a tapped opening in the pipeline. 
         [0061]    In some modes of operation, the distal end of the fitting can be welded onto a pipeline to surround an opening therein. In some uses, the distal end of the fitting is welded onto a pipeline and then a hot tap is made in the pipeline through the opening. In use, the flanged fitting can be connected to a tapping valve, and further connected to various mechanisms such as hot tapping machines, plugging machines, etc. Through the central opening of the fitting can be passed cutting tools, plugs, and the like, an optionally into the pipeline. 
         [0062]    The completion plug can be inserted into the central opening of the fitting to provide a primary seal of the tapped opening, thereby inhibiting release of any pressurized fluid in the pipeline from the central opening of the fitting. The cover plate can also be is coupled to the flange portion using a set of bolts. The cover plate can prevent contact (e.g., of debris or other object) with the completion plug.