Patent Description:
<CIT> discloses a polyethylene pipe service system comprising: a valve including: a disk axially translatable between an open and a closed position; a cylindrical-shaped lower end located below the disk and configured for connection to a saddle branch fitting of a polyethylene pipe; a cylindrical-shaped upper end located above the disk; and a cylindrical-shaped lower end; and a collar having a diameter greater than the cylindrical-shaped lower end of the polyethylene pipe service machine and configured for connection to the cylindrical-shaped upper end of the valve.

<CIT> discloses a Bayonet-coupling to speed up the assembly and disassembly of a drilling machine.

<CIT> prevents the reduction of a flowing-water sectional area even in the case of the small bore of a fluid pipe, and to stabilize the state of mounting by equalizing and shortening a distance between the lower-end diameter expanding surface of a corporation cock after diameter expansion and the inner circumferential surface of the fluid pipe.

The invention provides a polyethylene pipe service system comprising: a valve including: a disk moveable in an axial direction between an open and a closed position; a cylindrical lower end configured for connection to a saddle branch fitting of a polyethylene pipe run; and a cylindrical-shaped upper end located above the disk; and a polyethylene pipe service machine including a cylindrical-shaped lower end; the polyethylene pipe service system being characterized in that the cylindrical-shaped upper end includes a first portion of a non-threaded cam profile located on an inner wall of the cylindrical-shaped upper end; the cylindrical-shaped lower end contains a second portion of the non-threaded cam profile located on an outer wall of the cylindrical-shaped lower end; and wherein when the first and second portions of the cam profile engage with one another, rotation of the polyethylene pipe service machine relative to the valve changes a vertical elevation of the polyethylene pipe service machine relative to the valve and connects the machine to the valve.

Embodiments of a polyethylene pipe service system of this disclosure include a valve having a lower end configured for removable connection to, and detachment from, a threaded portion of a polyethylene branch connection and an upper end including an external threaded or flanged portion and a first portion of a cam profile. The first portion of the cam profile may be a male portion and include a pair of tabs. The tabs may be located on an inside wall of the upper end of the valve. A polyethylene pipe service machine - such as a drilling machine including a cutting tool or a plugging machine including a plugging tool or a completion machine including a completion tool - includes a connector at a lower end comprising a second portion of the cam profile shaped complementary to the first portion of the cam profile of the upper end of the valve. The second portion of the cam profile may be a female portion and include a pair of stair-stepped channels sized to accommodate a respective tab of the first portion of the cam profile. The stair-stepped channels may be located on an outside wall of the lower end of the machine. In some embodiments, the first portion of the cam profile includes the stair-stepped channel and the second portion of the cam profile includes the pair of tabs.

Mating of the first and second portion of the cam profile and less than a full rotation or turn connects a respective machine to the valve, the machine rotating from its initial clock position to a final clock position. A collar, which may be threaded and having a diameter greater than the portion of the cam profile of the machine, is configured for connection to the external threaded or flanged portion of the upper end of the valve. The collar further secures the machine to the valve.

The cutting tool may include means to contain chips removed during cutting of a polyethylene pipe. The cutting tool and the plugging tool may each include a circular-shaped handle or operating wheel for ease of use. Additionally, the machines may include appropriate indicators or visual controls to guide operators when in use. For example, the valve may include a line or mark and the wheel may include a corresponding line or mark, alignment of the lines or marks with one another indicating the machine is in its proper clock position for insertion into the valve.

The valve may be configured for use with a first polyethylene pipe size and a second different polyethylene pipe size. The first and second polyethylene pipe sizes may be in a range of DN <NUM> to DN <NUM> (<NUM> to <NUM>, imperial sizes <NUM> inches to <NUM> inches). The valve may include a disk with lock-out means configured to prevent the disk from moving between a closed and an open position until pressure is equalized above and below the disk. The valve may also include a grounding strap.

Throughout the drawings, the same reference character is used for the same part, no single reference character being used for two different parts or for a given part and a modification of such part.

For the purposes of this disclosure, the following definitions apply.

Machine means a device configured for use with a polyethylene ("PE") pipe servicing system of this disclosure and connectable to a valve of the PE pipe that provides access to an interior volume of the pipe for servicing, the device connecting to and passing through the valve when in an open position and providing means to tap into a wall of the PE pipe, means to plug product flow through the PE pipe, or means to plug a tapped opening in the wall.

Stair-stepped channel means a passageway located on an interior wall of the valve or an exterior wall of the machine and including at least two runs at different elevations, the runs being separated by a rise orthogonal to the runs.

Cam profile means a non-threaded body or follower (e.g. a tab) and a non-threaded passageway or channel having discrete changes in elevation (e.g. a stair-stepped channel) by which motion is communicated to the follower, with rotation of the passageway or channel into different clock positions relative to the follower places the follower at a different location and elevation within the passageway or channel. The follower and channel are shaped complementary to one another and one or the other may be located on the valve or on the machine. The follower may be a first portion of the cam profile and the channel may be the second portion (or vice versa).

Terms "including", "comprising" and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers. Where the claims or specification refer to "a" or "an" element, the "a" or "an" should not be construed meaning there is only one of that element. Where the specification states that a component, feature, structure, or characteristic "may", "might", "can" or "could" be included, that particular component, feature, structure, or characteristic is not required to be included.

Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, embodiments of the claimed invention are not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.

The term "method" may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs. Methods of this disclosure may be implemented by performing or completing selected steps or tasks manually, automatically, or a combination thereof. Where reference is made to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where context excludes that possibility), and the method can also include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all of the defined steps (except where context excludes that possibility).

The term "at least" followed by a number is used herein to denote the start of a range beginning with that number (which may be a range having an upper limit or no upper limit, depending on the variable being defined). For example, "at least <NUM>" means <NUM> or more than <NUM>. The term "at most" followed by a number is used herein to denote the end of a range ending with that number (which may be a range having <NUM> or <NUM> as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, "at most <NUM>" means <NUM> or less than <NUM>, and "at most <NUM>%" means <NUM>% or less than <NUM>%.

When a range is given as "(a first number) to (a second number)" or "(a first number) - (a second number)", this means a range whose lower limit is the first number and whose upper limit is the second number. For example, <NUM> to <NUM> should be interpreted to mean a range whose lower limit is <NUM> and whose upper limit is <NUM>. Additionally, it should be noted that where a range is given, every possible subrange or interval within that range is also specifically intended unless the context indicates to the contrary. For example, if the specification indicates a range of <NUM> to <NUM> such range is also intended to include subranges such as <NUM> -<NUM>, <NUM>-<NUM>, etc., <NUM>-<NUM>, <NUM>-<NUM>, etc., as well as any other possible combination of lower and upper values within the stated range, e.g., <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, etc. Note that integer range values have been used in this paragraph for purposes of illustration only and decimal and fractional values (e.g., <NUM> - <NUM>) should also be understood to be intended as possible subrange endpoints unless specifically excluded.

Terms of approximation (e.g., "about", "substantially", "approximately", etc.) are to be interpreted according to their ordinary and customary meanings as used in the associated art unless indicated otherwise herein. Absent a specific definition within this disclosure, and absent ordinary and customary usage in the associated art, such terms should be interpreted to be plus or minus <NUM>% of the base value.

Where an example is provided, the example is intended to be non-limiting. The example may not list elements well known in the art and not every element listed or described in the example is necessarily required in the embodiment of the example (except where context excludes that possibility) or in claimed embodiments.

Embodiments of a polyethylene pipe ("PE") servicing system of this disclosure are configured for use with a fusible polyethylene fitting "F" that provides a branch connection to a PE pipeline section or run "P" to be serviced in situ. The fitting F may be a saddle branch fitting. In embodiments of a system and method of this disclosure, no squeezing is used to service the pipeline run P. The system comprises a valve <NUM> including a first portion <NUM> of a cam profile and a machine <NUM> including a complementary second portion <NUM> of the cam profile. The first portion <NUM> of the cam profile may be a male portion and include a pair of tabs <NUM>. The second portion <NUM> of the cam profile may include a pair of stair-stepped channels <NUM> each sized to receive a corresponding one of the tabs <NUM>. Engaging the first and second portions <NUM>, <NUM> of the cam profile with one another places the machine <NUM> in its correct angular or clock position relative to the valve <NUM>. After initial engagement, turning the machine <NUM> relative to the valve <NUM> connects the machine <NUM> to the valve <NUM> and places the machine in its correct clock position for use. In embodiments, the first and second portions <NUM>, <NUM> of the cam profile extend less than <NUM>° of the circumference. Full engagement of the portions <NUM>, <NUM> occurs in less than a full turn of the machine <NUM>. A threaded collar <NUM> may then be used to further secure the machine <NUM> to the valve <NUM>. The machine <NUM> may include a locking bar <NUM>, further securing it to the valve <NUM> in its correct operating position.

In embodiments, the valve <NUM> includes a threaded lower end <NUM> configured for connection to a corresponding threaded portion "T" of the fitting F; and an upper end <NUM> having an external threaded portion <NUM> and the first portion <NUM> of the cam profile. At least one machine <NUM> configured for use in a PE service system includes a connector <NUM> at its lower end <NUM> comprising the second portion <NUM> of the cam profile shaped complementary to the first portion <NUM> of the cam profile at the upper end <NUM> of the valve <NUM>. An O-ring <NUM> may be located below the first portion <NUM> of the cam profile. A threaded collar <NUM>, having a diameter greater than the second portion <NUM> of cam profile and configured for connection to the external threaded portion <NUM> of the upper end <NUM> of the valve <NUM>, may be used to temporarily secure the connection of the machine <NUM> to the valve <NUM>.

In embodiments, the first portion <NUM> of the cam profile includes a pair of tabs <NUM> located at the cylindrical upper end <NUM> of the valve <NUM>. The tabs <NUM> mate to a second portion <NUM> of the cam profile that includes pair of stair-stepped channels <NUM> at a cylindrical lower end <NUM> of a machine 30T, 30P, 30C configured for tapping, plugging, and completion, respectively, of a kind associated with hot tapping, plugging, and completion operations. The tabs <NUM>, which have a total depth "d" and a total height "h", are located opposite one another on an inner wall <NUM> of the upper end <NUM> and extend less than a full circumference of the cylindrical upper end <NUM> of the valve <NUM>. Similarly, the stair-stepped channels <NUM>, which have a total depth "D" and a total channel height "H", are located opposite one another on an external wall <NUM> of the lower end <NUM> and extend less than a full circumference of the cylindrical lower end <NUM>. The depth D and the height H of the channel <NUM> are each sized to accommodate, respectively, the depth d and height h of the tab <NUM> as the tab <NUM> travels an entire distance of the stair-stepped channel <NUM>. As the machine <NUM> rotates relative to the valve <NUM>, the tabs <NUM> move "up" and along the channel <NUM> and the lower end <NUM> of the machine <NUM> (and therefore the machine <NUM>) moves farther down into the valve <NUM>.

In embodiments, D is about the same depth as d or equal to d and, in no cases, is less than d. The channel height H may differ over the length of the stair-stepped channel <NUM>. For example, in some embodiments, H is greater at a first end <NUM> of the channel <NUM> (e.g. H1) than at a second end <NUM> (e.g. H3), or an intermediate run <NUM> in between the two ends <NUM>, <NUM> (e.g. H2). In embodiments, the channel height H may be in a range of <NUM> to <NUM>. For example, H1 may be greater than h; H3 may be about equal to h (accounting for the clearance needed for tab <NUM> to travel the channel <NUM>).

The stair-stepped channel <NUM> includes a first (open) end <NUM> at its lowermost elevation sized to receive the tab <NUM> and a second (closed) end <NUM> at its highest most elevation arranged to prevent further rotation of the machine 30T, 30P, 30C relative to the valve <NUM>. The first end <NUM> of the channel <NUM> is positioned relative to the second end <NUM> so that when the tab <NUM> enters the first end <NUM>, the machine 30T, 30P, or 30C is located at the correct beginning clock position and, after the machine 30T, 30P, or 30C is rotated relative to the valve <NUM>, an end <NUM> of tab <NUM> contacts the second end <NUM> and further rotation relative to the valve <NUM> is prevented, locating the machine 30T, 30P or 30C at its correct ending clock position for use. For purposes of handing the machine 30T, 30P, or 30C and locating it on, and securing it to, the valve the machine <NUM> may include a circular-shaped handle or operating wheel <NUM>. The wheel <NUM>, as well as the valve <NUM>, may each include a line or mark as a visual control. When the lines or marks are aligned with each other, the machine <NUM> is in its correct clock position for lowering or insertion into the valve <NUM>.

In embodiments, the amount of rotation between the beginning and ending clock positions may be in a range of <NUM>° (a quarter-turn) to <NUM>° (half a turn), there being individual angles and sub-ranges within this broader range. The tab <NUM> extends X degrees of arc, where <NUM>° < X < <NUM>°, the stair-stepped channel extending in a range of 2X to 4X degrees of arc, there being integer and non-integer values and subranges within this broader range, where 2X < <NUM>° and 4X < <NUM>°. By way of a non-limiting example, the tab <NUM> may extend <NUM>° of arc with the stair-stepped channel <NUM> extending <NUM>° of arc. Or, by way of another non-limiting example, the tab <NUM> may extend <NUM>° of arc and the stair-stepped channel <NUM> may extend <NUM>° of arc. In some embodiments, the amount of rotation is in a range of <NUM>° to <NUM>°. The amount of rotation permit the tabs <NUM> to the steps <NUM> of the stair-stepped channel <NUM>. In some embodiments, the rotation permits travel along three stairs <NUM>.

The stair-stepped channel <NUM> is defined by upper and lower walls, <NUM>, <NUM> that define corresponding runs <NUM> and rises <NUM> of the channel <NUM> between the ends <NUM>, <NUM>. The upper and lower walls <NUM>, <NUM> may run parallel to one another over the length of a run <NUM>, with the rises <NUM> perpendicular to the run <NUM>. The walls <NUM>, <NUM> may be arranged to provide an upward sloping run <NUM> from the first end <NUM> to the second end <NUM>. The first end <NUM> of each stepped channel <NUM> includes an opening <NUM> sized to receive a corresponding tab <NUM> of the valve <NUM> and having a height H greater than that of the tab <NUM>. The opposing run portion <NUM> of the upper wall <NUM> functions as a stop and positions the tab <NUM> to enter downstream portion <NUM> of the channel <NUM>, the amount of downward travel of the machine 30T, 30P, 30C relative to the valve <NUM> being the difference between the height h of the tab <NUM> and the height H of the channel <NUM> at the run <NUM>. As the machine 30T, 30P, 30C is rotated relative to the valve <NUM>, the tab <NUM> enters subsequent runs <NUM> of the channel <NUM> as rotation brings the second end <NUM> of the channel <NUM> closer to the tab <NUM>. An end <NUM> of tab <NUM> contacts the second (closed) end <NUM> and further rotation of the machine 30T, 30P, 30C relative to the valve <NUM> is prevented, locating the machine 30T, 30P or 30C at its correct clock position for use.

In embodiments, the stepped channel <NUM> may include three "steps", a first step 61A at the first end <NUM>, a third step 61C located toward the second end <NUM>, and a second step 61B located in between, each step <NUM> including a respective run <NUM> sized for the length of the tab <NUM>. The first step 61A includes the open end <NUM> at its upstream end and an opening <NUM> at its downstream end, the opening <NUM> being the upstream end of the second step 61B. Similarly, the second step 61B includes another opening <NUM> at its downstream end, the opening being the upstream end of the third step 61C. The downstream end of the third step 61C is the second (closed) end <NUM> of the channel <NUM>.

In embodiments of a method of use, the method incudes installing the valve <NUM> on the fitting F, locating the machine <NUM> onto the valve <NUM> in a vertical orientation so the portions <NUM>, <NUM> of the cam profile mate to one another, turning a wheel 69n a clockwise direction so that the portions <NUM>, <NUM> of the cam profile continue their further engagement and the machine <NUM> continues its travel vertically downward, and, once the machine <NUM> has travelled the full distance of the cam profile, securing the ring <NUM> to the valve <NUM>. Additional equipment or tooling may then be installed on the machine <NUM>. In embodiments, wheel <NUM> may be used by an operator to lift the machine <NUM> vertically and locate the machine <NUM> on the valve <NUM>. The full distance of the cam profile may include three steps <NUM>. The machine <NUM> may rotate <NUM>° over the full distance. The valve <NUM> may be configured for use with a first pipe size and a second different pipe size, wherein the first and second pipe sizes are in a range of DN <NUM> to DN <NUM> (imperial sizes <NUM> inch to <NUM> inch). In some embodiments, the valve may weigh no more than about <NUM>,<NUM> (<NUM> lbs. for pipe sizes equal to or below DN <NUM>.

In embodiments, the valve <NUM> includes a locking system to avoid the opening of the valve <NUM> before pressure equalization. The valve <NUM> may further include a disk <NUM> with lock-out means, the lock-out means configured to prevent the disk <NUM> from moving or translating axially between a closed and an open position relative to the central bore or valve opening <NUM> until pressure is equalized (balanced) above and below the disk <NUM>. In embodiments, the valve <NUM> may include a purge valve <NUM>, a bypass valve <NUM> (with an associated bypass tool <NUM>), and pressure equalizing button <NUM>. In embodiments, after machine 30T taps into the pipe P and its cutter is retracted to clear a top of the pipe, product fluid fills the valve housing as the disk <NUM> is being closed. The purge valve <NUM> then purges the product fluid above the closed disk <NUM>. After the plugging machine 30P is secured to the valve <NUM>, the pressure equalizing button <NUM> is pushed, thereby opening a channel that allows fluid below the closed disk <NUM> to enter the valve housing above the disk <NUM>. This fluid on both sides of the disk <NUM> equalizes the pressure and the valve <NUM> may now be easily and safely opened. A same procedure may be used when attaching the completion machine 30C to the valve <NUM>.

The disk <NUM> may be operated by means of a handle between an open and a closed position across the valve opening <NUM> by means configured to translate rotational motion into a transverse motion of the disk across the valve opening <NUM>. The valve <NUM> may also include handles <NUM> having an arcuate lower end configured to rest on the pipe P. The valve <NUM> may also include a grounding strap of a kind known in the art (not shown).

The machine <NUM> may be a drilling or hot tapping machine 30T, a plugging machine 30P, or a completion machine 30C. In embodiments, a DN <NUM> to DN <NUM> (imperial sizes <NUM> inch to <NUM> inch) plugging machine may weigh no more than about <NUM>,<NUM> (<NUM> lbs. ) and a DN <NUM> (imperial size <NUM> inch) plugging machine may weigh no more than about <NUM>,<NUM> (<NUM> lbs.

The machine <NUM> may include, where appropriate, a cutter, a plugger, a completion plug, or some combination thereof. The cutter may include means to contain chips removed during cutting of a polyethylene pipe. Other tools insertable through the valve <NUM> may also be used to perform other operations. By way of a non-limiting example, the tool may include means configured to insert and secure a completion plug.

Claim 1:
A polyethylene pipe service system comprising:
a valve (<NUM>) including:
a disk (<NUM>) moveable in an axial direction between an open and a closed position;
a cylindrical-shaped lower end (<NUM>) located below the disk and configured for connection to a saddle branch fitting (F) of a polyethylene pipe run (P);
a cylindrical-shaped upper end (<NUM>) located above the disk; and
a polyethylene pipe service machine (30T, 30P, or 30C) including
a cylindrical-shaped lower end (<NUM>);
the polyethylene pipe service system being characterized in that the cylindrical-shaped upper end includes a first portion (<NUM> or <NUM>) of a non-threaded cam profile located on an inner wall (<NUM>) of the cylindrical-shaped upper end;
the cylindrical-shaped lower end contains a second portion (<NUM> or <NUM>) of the non-threaded cam profile located on an outer wall (<NUM>) of the cylindrical-shaped lower end; and
wherein when the first and second portions of the cam profile engage with one another, rotation of the polyethylene pipe service machine relative to the valve changes a vertical elevation of the polyethylene pipe service machine relative to the valve and connects the machine to the valve.