Patent Description:
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., <NUM> 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 to <FIG>, a conventional gas-over-oil actuator <NUM> includes an open side gas hydraulic tank <NUM>, and a closed side gas hydraulic tank <NUM>. A mounting bracket <NUM> may be used to install the gas-over-oil actuator <NUM> on a valve disposed in a natural gas pipeline (not shown).

As depicted in <FIG>, the gas-over-oil actuator <NUM> further includes an opening solenoid valve <NUM> and a closing solenoid valve <NUM>, 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 <NUM> VDC, are sent to the opening solenoid valve <NUM> and the closing solenoid valve <NUM> to control and operate the valve. In addition, a limit switch <NUM> (<FIG>) is installed on top of the gas-over oil-actuator <NUM> and 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 actuator <NUM>. 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 actuator <NUM> can 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.

<CIT> discloses a valve system that employs a piezo-electric element to activate a fluid flow valve. The piezo-electric element activates a pilot pressure valve, which allows a control fluid to pass to a main control valve. The control fluid causes the main control valve to activate a working element, which in turn operates the fluid flow valve. A switching assembly is employed to activate the piezo-electric element. In particular, the first embodiment of this document discloses a valve system that includes a valve activation assembly, a transmitter, a working element and a fluid valve. The transmitter transmits a signal from an antenna that is received by an antenna associated with the valve assembly. When the valve assembly receives the signal, it activates the working element, which opens or closes the fluid valve depending on its normal state. The receiver, through non-contacting switch, outputs an electrical signal to a pilot valve. The pilot valve includes a piezo-electric switch assembly attached to a valve body of the valve. The valve is a two position valve which supplies input air at a pilot pressure to a pilot line. The main valve controls application of input air and exhaust to the working element.

<CIT> discloses a valve remote control apparatus is configured to mechanically connect, to a manual operating portion of an existing manual valve, an output shaft of an air motor using an air pressure as a drive source, and to remotely control the manual valve. The valve remote control apparatus includes a solenoid valve operated by an operation signal transmitted and received wirelessly between a contact information terminal portion and a contact information operating portion.

<CIT> discloses a valve positioner system with zero bleed at steady state. The system has a pilot valve, the operation of which is controlled by an electronic circuit powered from a signaling and power connection of a positioner device. A plurality of pneumatic valves are activated and deactivated by the pilot valve to control a valve actuator. With varying configurations and arrangements of normally open or normally closed pilot valves and pneumatic valves, fail freeze and fail safe operations are contemplated. The activation and deactivation of the pilot valve is controlled by an electronic circuit that monitors a valve position signal
<CIT> discloses a pipeline fitting comprising: a process fitting with an actuator for opening and closing a transport pipeline; a drive device for power-operating the actuator of the process fitting; at least one control valve for opening and closing a supply line provided for supplying the drive device with drive power; at least one chargeable buffer for providing the drive power; a communications unit for receiving control signals for carrying out the remote operation of the at least one control valve, and; at least one buffer which can be charged, which provides drive power to the at least one control valve and, optionally, operates the communications unit.

<CIT> discloses the use of a solenoid-type electromagnetic valve in a valve driving device that performs wireless communication. A contact signal converter converts an on-off contact signal to a control signal for operating a solenoid-type electromagnetic valve.

<CIT> discloses an actuating arrangement for valves comprising a gas-hydraulic system, in which solenoid valves are connected to a gas pipeline via lines. The electromagnets of the valves are energized or de-energized in order to conduct the gas flowing through the gas pipeline directly to the corresponding cylinder chambers of the valve actuating arrangement or to supply the gas to pressure vessels in order to pressurize a hydraulic flow medium contained in the pressure vessels and to supply this to the corresponding cylinder chambers. As a result, the valve shaft of a valve built into the gas pipeline is driven.

<CIT> discloses a wireless position transducer for a valve in a process control system that converts a motion or a position of an actuator of the valve into a wireless signal including a value indicative of the position of the actuator. It further discloses a method comprising the steps of: a) converting by a wireless position transducer a motion of an actuator of a valve into a value indicative of a position of the actuator; b) populating by the wireless position transducer a field of a signal with the value indicative of the position of the actuator; c) causing the signal to be wirelessly transmitted by the wireless position transmitter to an electro-pneumatic controller of the valve, the electro-pneumatic controller of the valve determining a position of the actuator exclusively based on the populated value included in the signal, and the electro-pneumatic controller of the valve controlling the valve based on the determined position of the actuator.

In accordance with a first exemplary aspect of the invention, a gas-over-oil actuator system for use with a valve in a natural gas pipeline according to claim <NUM> is provided.

In yet another exemplary aspect of the present invention, a method of operating a valve disposed within a natural gas pipeline according to claim <NUM> is provided.

The dependent claims depict advantageous embodiments of the present invention.

The Figures described below depict various aspects of the system and methods disclosed therein. It should be understood that each figure depicts an example of a particular aspect of the disclosed system and methods, and that each of the figures is intended to accord with a possible example thereof. Further, wherever possible, the following description refers to the reference numerals included in the following figures, in which features depicted in multiple figures are designated with consistent reference numerals.

There are shown in the drawings arrangements which are presently discussed, it being understood, however, that the present examples are not limited to the precise arrangements and instrumentalities shown, wherein:.

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 pneumatic pilot spool valve in the form of an opened center 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 to <FIG>, a process control system <NUM> includes a gas-over-oil actuator system <NUM> operatively coupled to a valve <NUM> installed or disposed in a natural gas pipeline <NUM>. The gas-over-oil system <NUM> includes a gas-over-oil actuator <NUM> and a wireless position monitor <NUM> operatively coupled to the gas-over-oil actuator <NUM>. The wireless position monitor <NUM> replaces the limit switches of conventional systems and monitors the valve <NUM> position using a magnetic linkage system. In one example, and as depicted in <FIG>, the gas-over-oil actuator <NUM> includes first gas/oil tank <NUM>, and a second gas/oil tank <NUM>, and the wireless position monitor <NUM> is disposed between the first and second gas/oil tanks <NUM>, <NUM>. This position of the wireless position monitor <NUM> helps the wireless position monitor <NUM> measure differential pressure across the gas-over-oil actuator <NUM>, such as a piston of the gas-over-oil actuator <NUM>.

In one example, the wireless position monitor <NUM> is a Fisher <NUM>/TopWorx <NUM> Wireless Position Monitor with on/off control option. The integrated diagnostic capability of the Fisher <NUM>/TopWorx <NUM> Wireless Position Monitor, such as feedback in percentage of travel, close time, open time, and alerts, allows acquisition and feedback of both the valve <NUM> and the gas-over-oil actuator <NUM> travel position and stroking time. In addition, the Fisher <NUM>/TopWorx <NUM> Wireless Position Monitor can raise alarms and/or warnings according to customer requirements. While the Fisher <NUM>/TopWorx <NUM> Wireless Position Monitor is the wireless position monitor <NUM> of the process control system <NUM> in 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 invention.

The wireless position monitor <NUM> includes an integral pneumatic pilot valve <NUM> (<FIG>), such as an opened center spool valve, and one or more of an antenna <NUM> or a network interface (not shown) for receiving signals from a remote source via a wireless network, as explained in more detail below. At least one switching relay <NUM> (<FIG>) is operatively coupled to the gas-over-oil actuator <NUM> and the wireless position monitor <NUM>. The at least one switching relay <NUM> receives a signal from the pneumatic pilot valve <NUM>, such as an opened center spool valve <NUM>, to manage pressure supply to the gas-over-oil actuator <NUM>, as also explained more below relative to <FIG>.

The gas-over-oil actuator system <NUM> may further include a bleed valve <NUM> for maintaining the at least one switching relay <NUM> (<FIG>) in a desired position, such as an open position or a closed position, for a time required by the valve <NUM> to complete a desired travel distance, for example. The bleed valve <NUM> may include a locking nut <NUM> to prevent tampering and is disposed within a lockable cabinet <NUM>. In one example, the lockable cabinet <NUM> having the bleed valve <NUM> is disposed adjacent to the second gas/oil tank <NUM> of the gas-over-oil actuator <NUM>.

When the valve <NUM> does not complete the desired travel distance and a value of torque is acceptable, the wireless position monitor <NUM> may again send the pressure signal to the at least one switching relay <NUM> to 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 system <NUM> further includes a workstation <NUM> having at least one wireless gateway <NUM>, such as a Fisher Smart Wireless Gateway <NUM>/<NUM>. The Fisher Smart Wireless Gateway <NUM> connects 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 in <FIG>, a second or redundant "hot" backup gateway <NUM> is further provided in the event the first gateway <NUM> is compromised or fails. A controller <NUM> is operatively connected to the wireless gateway <NUM> via Modbus communications, in one example, and is further communicatively coupled to the wireless position monitor <NUM> via a wireless network <NUM>. More specifically, the wireless gateway <NUM> may include one or more of at least one antenna <NUM>, at least one transmitter, and at least one receiver for one or more of transmitting signals to and receiving signals from the wireless position monitor <NUM> via the wireless network <NUM>. In one example, the controller <NUM> is a FloBoss FB <NUM> controller and includes a processor <NUM>, a memory <NUM> executable by the processor <NUM>, and a transmitter <NUM>. One of skill in the art will appreciate that the controller <NUM> may alternatively be various other controllers and may further be connected to the wireless gateway <NUM> via other communications and still fall within the scope of the present invention.

The workstation <NUM> of the process control system <NUM> may further include a laptop <NUM> coupled to the wireless gateway <NUM> via an Ethernet LAN, for example. In addition, and in some examples, a local control panel <NUM> may be operatively coupled to the controller <NUM> and a LCD screen <NUM>, which may include a touch screen, and may also be operatively coupled to the controller <NUM> of the remote workstation <NUM>. An operator may actuate one or more of a button or key on the laptop <NUM> or the local control panel <NUM>, or a touchscreen of the LCD screen <NUM> to initiate a wireless open/close command from the controller <NUM> to the wireless position monitor <NUM> to operate the valve <NUM>. In addition, the LCD screen may display diagnostic information and alarms for the operators. Further, and in one example, the remote workstation <NUM> may be disposed within one of a local control room <NUM> or a main dispatching center <NUM> and still fall within the scope of the present invention.

In addition, the workstation <NUM> further includes a central control system <NUM>. As depicted in <FIG>, for example, the control system <NUM> is operatively coupled to one or more of the wireless gateway <NUM>, the controller <NUM>, and the laptop <NUM>. A user may initiate certain commands through the control system <NUM>, for example, to remotely operate the gas-over-oil actuator system <NUM>.

More specifically, upon receiving the command, such as an open/close command, from the controller <NUM> and/or the control system <NUM> via the wireless gateway <NUM> and the wireless network <NUM>, the wireless position monitor <NUM> drives a pressure signal from the pneumatic pilot valve <NUM> (<FIG>) to the at least one switching relay <NUM>. In one example, the signal is a low pressure signal, such as a low pressure signal of <NUM> bar. This allows the at least one switching relay <NUM> to manage the pressure supply to the gas-over-oil actuator <NUM> to move the valve <NUM> to a desired position and monitor the position of the valve <NUM>. In addition, the pressure supply to the gas-over-oil actuator <NUM> is a high pressure supply, such as a high pressure supply of up to <NUM> bar.

In addition, to minimize battery drainage, the control command from the controller <NUM> may be maintained for only a few seconds, in one example. The bleed valve <NUM> is then set to maintain the at least one switching relay <NUM> in a desired position for a desired time.

As further depicted in <FIG>, the process control system <NUM> may further include a differential pressure transmitter <NUM>. The differential pressure transmitter <NUM> is operatively coupled to the gas-over-oil actuator <NUM> and may measure one or more of a differential pressure across the gas-over-oil actuator <NUM> or an opening torque of the valve <NUM>, for example. The differential pressure transmitter <NUM> is further communicatively coupled to the workstation <NUM> via the wireless network <NUM> and the wireless gateway <NUM>. This allows data acquisition and feedback relative to the differential pressure across the gas-over-oil actuator <NUM> and the operating torque of the valve <NUM>, for example. In one example, a memory of the laptop <NUM> saves such data relative to the differential pressure of the gas-over-oil actuator <NUM> and the operating torque of the valve <NUM> and displays the data on a screen of the laptop <NUM> for further analysis.

In yet another example, the process control system <NUM> may further include a first pressure transmitter <NUM> disposed within the natural gas pipeline <NUM> upstream the valve <NUM> to measure pressure upstream the valve <NUM>. In addition, a second pressure transmitter <NUM> may be disposed within the natural gas pipeline <NUM> downstream the valve <NUM> to measure pressure within the natural gas pipeline <NUM> downstream the valve <NUM>. The first and second pressure transmitters <NUM>, <NUM> are each communicatively coupled to the wireless gateway <NUM> of the workstation <NUM> via the wireless network <NUM>. This allows data acquisition and feedback relative to the pressure in the natural gas pipeline <NUM> both upstream and downstream the valve <NUM>, for example.

Referring now to <FIG>, not covered by the claims, a schematic view of the gas-over-oil actuator system <NUM> of <FIG> is depicted. As also depicted in <FIG>, the gas-over-oil actuator system <NUM> includes the gas-over-oil actuator <NUM> having the first gas/oil tank <NUM> and the second gas/oil tank <NUM>. Each of the first and second gas/oil tanks <NUM>, <NUM> are in fluid communication with a high pressure supply, such as a high pressure supply of up to <NUM> bar. A manual override system <NUM> is disposed adjacent to the first and second gas/oil tanks <NUM>, <NUM>.

The at least one switching relay <NUM> may include a closed switching relay 124a, which is in fluid communication with the first gas/oil tank <NUM>, and an open switching relay 124b, which is in fluid communication with the second gas/oil tank <NUM>. Each of the switching relays 124a, 124b includes a vent <NUM> and a manual override (not depicted) in the event the switching relays 124a, 124b fail.

The wireless position monitor <NUM> includes a first piezo valve <NUM>, a second piezo valve <NUM>, and a pneumatic pilot valve <NUM>. In one example, the pneumatic pilot valve <NUM> is the opened center spool valve <NUM>, a close up of which is depicted in <FIG>.

The opened center spool valve <NUM> of the wireless position monitor <NUM> is operatively coupled to a pressure regulator <NUM> that includes a relief valve <NUM>. The pressure regulator <NUM> limits an inlet pressure from the pipeline <NUM> (<FIG>) to the opened center spool valve <NUM> of the wireless position monitor <NUM>. The opened center spool valve <NUM> allows low pressure gas, e.g., <NUM> bar, taken from the high pressure natural gas pipeline <NUM> by the pressure regulator <NUM> to flow through the spool valve <NUM> and into the switching relays 124a, 124b.

As depicted in <FIG>, and in one example, the opened center spool valve <NUM> of the wireless position monitor <NUM> is a <NUM>/<NUM> 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 regulator <NUM> to flow through the spool valve <NUM> of the wireless position monitor <NUM> and into the first and second switching relays 124a, 124b. This allows the switching relays 124a, 124b to manage the high pressure supply to the gas-over-oil actuator <NUM> to ultimately operate and control the valve <NUM>. Having a closed center spool valve, for example, would prevent the low pressure gas from the pressure regulator <NUM> to flow through the spool valve <NUM> and into the switching relays 124a, 124b and effective management of the high pressure gas supply to the gas-over-oil actuator <NUM>.

In addition, because the power media of natural gas is taken directly from the pipeline <NUM>, a filter <NUM> has been disposed adjacent to and in fluid communication with the pressure regulator <NUM> to protect downstream devices, for example. In yet another example, a pressure gauge <NUM> is disposed adjacent to the relief valve <NUM> to measure and display the low pressure supply, e.g., <NUM> bar, flowing from the pressure regulator <NUM> to the wireless position monitor <NUM> and the switching relays 124a, 124b.

In yet another example, according to the invention, the gas-over-oil actuator system <NUM> further includes at least one torque limiting device <NUM>, as depicted in <FIG>. More specifically, and for clarity, the gas-over-oil actuator system <NUM> of <FIG> is the gas-over-oil actuator system <NUM> of <FIG>, further including the at least one torque limiting device <NUM>. For example, a first torque limiting device <NUM> is disposed between the wireless position monitor <NUM> and the first switching device 124a. In addition, a second torque limiting device <NUM> is disposed between the wireless position monitor <NUM> and the second switching device 124b. In this manner, each of the first and second torque limiting devices <NUM>, <NUM> prevents excess torque that may be developed by the gas-over-oil actuator <NUM>.

Referring now to <FIG>, not covered by the claims, another process control system <NUM> is depicted with another example wireless actuator system <NUM> operatively coupled to a valve <NUM> installed or disposed in a natural gas pipeline <NUM>. The wireless actuator system <NUM> includes an actuator <NUM> and the wireless position monitor <NUM> operatively coupled to the actuator <NUM>. In one example, the actuator <NUM> includes a housing <NUM>, and the wireless position monitor <NUM> is disposed on the housing <NUM>.

As described relative to the gas-over-oil actuator system <NUM> of <FIG>, <FIG>, the wireless position monitor <NUM> of the wireless actuator system <NUM> also includes the integral pneumatic pilot valve <NUM> (<FIG>), such as an opened center spool valve, and one or more of an antenna <NUM> or a network interface (not shown) for receiving signals from a remote source via a wireless network <NUM> , as explained in more detail below. At least one switching relay <NUM> (<FIG>) is operatively coupled to the actuator <NUM> and the wireless position monitor <NUM>. The at least one switching relay <NUM> receives a signal from the pneumatic pilot valve <NUM>, such as the opened center spool valve <NUM> in one example, to manage pressure supply to the actuator <NUM>, as also explained more below.

Like the process control system <NUM> of <FIG>, the process control system <NUM> also includes a workstation <NUM> having a wireless gateway <NUM>, such as a Smart Wireless Gateway <NUM>/<NUM>. A controller <NUM> is operatively coupled to the wireless gateway <NUM> and communicatively coupled to the wireless position monitor <NUM>. More specifically, the wireless gateway <NUM> may include one or more of at least one antenna <NUM>, at least one transmitter, and at least one receiver for one or more of transmitting signals to and receiving signals from the wireless position monitor <NUM> via a wireless network <NUM>, such as a WirelessHART network. In one example, the controller <NUM> includes a processor <NUM>, a memory <NUM> executable by the processor <NUM>, and a transmitter <NUM>. One of skill in the art will appreciate that the controller <NUM> may alternatively be various other controllers and still fall within the scope of the present invention.

The workstation <NUM> of the process control system <NUM> may further include a laptop <NUM> coupled to the wireless gateway <NUM>. An operator may actuate one or more of a button or key on the laptop <NUM> or the controller <NUM> to initiate a wireless open/close command from the controller <NUM> to the wireless position monitor <NUM> to the actuator <NUM> to operate the valve <NUM>. In addition, the remote workstation <NUM> may be disposed within one of a local control room <NUM> or a main dispatching center <NUM> and still fall within the scope of the present invention.

In addition, the workstation <NUM> may further include a central control system <NUM>. As depicted in <FIG>, for example, the control system <NUM> is operatively coupled to one or more of the wireless gateway <NUM>, the controller <NUM>, and the laptop <NUM>. A user may initiate certain commands through the control system <NUM>, for example, to remotely operate the gas-over-oil actuator system <NUM>.

More specifically, and similar to the gas-over-oil actuator system <NUM> of <FIG>, the wireless position monitor <NUM> drives a signal from the pneumatic pilot valve <NUM> (<FIG>) to the at least one switching relay <NUM> upon receiving the command from the controller <NUM> and/or the control system <NUM> via the wireless gateway <NUM> and the wireless network <NUM>. In one example, the signal is a low pressure signal, such as a low pressure signal of <NUM> bar. This allows the at least one switching relay <NUM> to manage the pressure supply and the actuator <NUM> to move the valve <NUM> to a desired position and monitor the position of the valve <NUM>. In another example, the actuator <NUM> is a high pressure supply, such as a high pressure supply in the range of 1bar-<NUM> bar.

Like the process control system <NUM> of <FIG>, the process control system <NUM> depicted in <FIG> may also further include a first pressure transmitter <NUM> disposed within the natural gas pipeline <NUM> upstream the valve <NUM> to measure pressure upstream the valve <NUM>. In addition, a second pressure transmitter <NUM> may be disposed within the natural gas pipeline <NUM> downstream the valve <NUM> to measure pressure within the natural gas pipeline <NUM> downstream the valve <NUM>. The first and second pressure transmitters <NUM>, <NUM> are each communicatively coupled to the wireless gateway <NUM> of the workstation <NUM> via the wireless network <NUM>. This allows data acquisition and feedback relative to the pressure in the natural gas pipeline <NUM> upstream and downstream the valve <NUM>, for example.

In still another example, and referring now to <FIG>, not covered by the claims, a schematic view of the another exemplary gas-over-oil actuator system <NUM> according to the present disclosure is depicted. The gas-over-oil actuator system <NUM> may be operatively coupled to a valve <NUM>, which may be installed or disposed in the natural gas pipelines <NUM>, <NUM> depicted in <FIG> and <FIG>, respectively, for example. In addition, the gas-over-oil actuator system <NUM> may be operatively coupled to the workstation <NUM> via the wireless network <NUM> of the process control system <NUM> (<FIG>), replacing the gas-over-oil actuator system <NUM> of <FIG>. In another example, the gas-over-oil actuator system <NUM> may be operatively coupled to the workstation <NUM> of the process control system <NUM> (<FIG>) via the wireless network <NUM>, replacing the wireless actuator system <NUM> of <FIG>, for example. In either case, the workstations <NUM>, <NUM> operate relative to the gas-over-oil actuator system <NUM> in the same manner explained above relative to the gas-over-oil actuator system <NUM> or the wireless actuator system <NUM>, respectively.

More specifically, and as depicted in <FIG>, the gas-over-oil actuator system <NUM> includes the gas-over-oil actuator <NUM> having the first gas/oil tank <NUM> and the second gas/oil tank <NUM>. Each of the first and second gas/oil tanks <NUM>, <NUM> are in fluid communication with a high pressure supply, such as a high pressure supply of up to <NUM> bar. A manual override system <NUM> is disposed adjacent to the first and second gas/oil tanks <NUM>, <NUM>.

The gas-over-oil actuator system <NUM> further includes at least one switching relay <NUM> having a closed switching relay 324a, which is in fluid communication with the first gas/oil tank <NUM>, and an open switching relay 324b, which is in fluid communication with the second gas/oil tank <NUM>. Each of the switching relays 324a, 324b includes a vent <NUM> and a manual override (not depicted) in the event the switching relays 324a, 324b fail.

The system <NUM> further includes a wireless position monitor <NUM> having a pneumatic pilot valve <NUM>. In one example, the pneumatic pilot valve <NUM> is an opened center spool valve <NUM>, a close up of which is depicted in <FIG>. As further depicted in <FIG>, and in this example, a solenoid valve system <NUM> is disposed external to the wireless position monitor <NUM> and is electrically wired to the wireless position monitor <NUM>. Said another way, the solenoid valve system <NUM> is operatively coupled to the wireless position monitor <NUM> via physical wires. More specifically, the solenoid valve system <NUM> includes at least one solenoid valve, such as a first piezo valve <NUM> and a second piezo valve <NUM>, both of which are directly wired to the wireless position monitor <NUM>. In addition, the solenoid valve system <NUM> may also include an manual override system <NUM>, as further depicted in <FIG>, which may be operated in the event the solenoid system <NUM> fails.

Unlike the opened center spool valve <NUM> of the wireless position monitor <NUM> depicted in <FIG>, the opened center spool valve <NUM> of the wireless position monitor <NUM> is not operatively coupled to any pressure regulator that limits an inlet pressure from the pipeline <NUM>, <NUM> (<FIG> and <FIG>) to the opened center spool valve <NUM>. Rather, upon receiving a command from the controller <NUM>, <NUM> via the wireless network <NUM>, <NUM>, the wireless position monitor <NUM> drives the at least one solenoid valve of the solenoid valve system <NUM>, such as the first and second piezo valves <NUM>, <NUM>, with a high pressure supply from the natural gas pipeline <NUM>, <NUM>. This high pressure supply from the at least one solenoid valve system <NUM> is driven through the open ended center spool valve <NUM> and into the at least one switching relay 324a, 324b. As a result, only one pressure level, which is the same pressure level as the gas pressure in the natural gas pipeline <NUM>, for example, is used in the system <NUM>. Said another way, the signal from the opened center spool valve <NUM> driven to the at least one switching relay 324a, 324b is a high pressure signal, and the pressure supply to the gas-over-oil actuator <NUM> is 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 valve <NUM>, for example.

As depicted in <FIG>, and in one example, the opened center spool valve <NUM> of the wireless position monitor <NUM> is a <NUM>/<NUM> 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 valves <NUM>, <NUM> and/or the at least one solenoid valve, to flow through the spool valve <NUM> of the wireless position monitor <NUM> and into the first and second switching relays 324a, 324b. This allows the switching relays 324a, 324b to manage the high pressure supply to the gas-over-oil actuator <NUM> to ultimately operate and control the valve <NUM>. Having a closed center spool valve, for example, would prevent the pressure gas from flowing through the spool valve <NUM> and into the switching relays 324a, 324b and effective management of the high pressure gas supply to the gas-over-oil actuator <NUM>.

In view of the foregoing, one of ordinary skill in the art will appreciate the following example method of operating the valve <NUM>, <NUM>, <NUM> within the natural gas pipeline <NUM>, <NUM>. More specifically, the method for operating the valve <NUM>, <NUM>, <NUM> within the natural gas pipeline <NUM>, <NUM> includes integrating the wireless position monitor <NUM>, <NUM> into the actuator <NUM>, <NUM>, <NUM> operatively coupled to the valve <NUM>, <NUM>, <NUM> the wireless position monitor <NUM>, <NUM> communicatively coupled to the workstation <NUM>, <NUM> via the wireless network <NUM>, <NUM>. The method further includes transmitting, via one or more transmitters <NUM>, <NUM>, a command from the controller <NUM>, <NUM>, such as an open/close command, to the wireless position monitor <NUM>, <NUM> via the wireless gateway <NUM>, <NUM> and the wireless network <NUM>, <NUM>.

The method still further comprises sending a pressure signal from the pneumatic pilot valve <NUM>, <NUM> of the wireless position monitor <NUM>, <NUM> to at least one switching relay <NUM>, 124a, 124b, 324a, 324b upon receiving the command. The method further includes managing high pressure supply, e.g., up to <NUM> bar, to the actuator <NUM>, <NUM>, <NUM> via the at least one switching relay 124a, 124b, 324a, 324b to move the valve <NUM>, <NUM>, <NUM> to a desired position, e.g., an open position, a closed position, in response to the pressure signal received from the pneumatic pilot valve <NUM>.

In addition, in one example, the method further comprises monitoring the position of one or more of the valve <NUM>, <NUM>, <NUM> or actuator <NUM>, <NUM>, <NUM> via the wireless position monitor <NUM>, <NUM>. In another example, monitoring the position of one or more of the valve <NUM>, <NUM>, <NUM> or actuator <NUM>, <NUM>, <NUM> via the wireless position monitor <NUM>, <NUM> may comprise acquiring data relative to one of the valve <NUM>, <NUM>, <NUM> or the actuator <NUM>, <NUM>, <NUM> including data relative to a travel position or a stroke time, via the wireless position monitor <NUM>, <NUM> the wireless network <NUM>, <NUM>, and the workstation <NUM>, <NUM>.

In yet another example, the method may further comprise maintaining the at least one switching relay <NUM>, <NUM> in an open position for a time required by the valve <NUM>, <NUM>, <NUM> to complete a desired travel distance via the bleed valve <NUM> (<FIG>). In addition, the method may further comprise limiting the inlet pressure from the natural gas pipeline <NUM>, <NUM> to the pneumatic pilot valve <NUM> via the pressure regulator <NUM> operatively coupled to the wireless position monitor <NUM>.

In still yet another example, the method may further comprise measuring one or more of the differential pressure across the actuator <NUM>, <NUM>, <NUM> or an operating torque of the valve <NUM>, <NUM>, <NUM> via the differential pressure transmitter <NUM> operatively coupled to the actuator <NUM>. Still further, the method comprises preventing excess torque from the actuator <NUM> via the at least one torque limiting device <NUM> (<FIG>) disposed between and operatively coupled to the wireless position monitor <NUM> and the at least one switching relay <NUM>. In addition, the method may also comprise measuring pressure upstream and downstream the valve <NUM>, <NUM> via the first pressure transmitter <NUM>, <NUM> disposed upstream the valve <NUM>, <NUM> and the second pressure transmitter <NUM>, <NUM> disposed downstream the valve <NUM>, <NUM>, respectively.

Overall, one of ordinary skill in the art will appreciate the various advantages of the new wireless actuator system <NUM>, <NUM>, <NUM> and method. For example, the new system and method allows an on/off valve with an actuator, such as a gas-over-oil actuator <NUM>, <NUM> to be moved using the wireless pneumatic position monitor <NUM>, <NUM> that is powered by natural gas from the natural gas pipeline <NUM>, <NUM>. 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 actuator <NUM>, <NUM>, <NUM> and receive feedback about the open and/or closed position of the valve <NUM>, <NUM>, <NUM> without cables or air supply. The communication with the actuator <NUM>, <NUM>, <NUM> and all the relevant equipment in the process control system <NUM>, <NUM> described 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 <NUM>/TopWorx <NUM> Wireless Position Monitor, with an on/off option, into the actuator system <NUM>, <NUM>, <NUM> allows remote operation of the valve <NUM>, <NUM>, <NUM> without 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 system <NUM>, <NUM>.

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.

Some examples may be described using the expression "coupled" and "connected" along with their derivatives. For example, some examples may be described using the term "coupled" to indicate that two or more elements are in direct physical or electrical contact. The term "coupled," however, may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other. The examples are not limited in this context.

In addition, use of the "a" or "an" are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of the description. This description, and the claims that follow, should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Claim 1:
A gas-over-oil actuator system (<NUM>) for use with a valve (<NUM>) in a natural gas pipeline (<NUM>), the system comprising:
a gas-over-oil actuator (<NUM>) for actuating the valve (<NUM>) in the natural gas pipeline (<NUM>);
a wireless position monitor (<NUM>) operatively coupled to the gas-over-oil actuator (<NUM>), the wireless position monitor (<NUM>) having an integral pneumatic pilot spool valve (<NUM>) in the form of an opened center spool valve and configured to be communicatively wirelessly coupled to a remote workstation (<NUM>);
at least one switching relay (<NUM>, 124a, 124b) operatively coupled to the gas-over-oil actuator (<NUM>) and the wireless position monitor (<NUM>), the at least one switching relay (<NUM>, 124a, 124b) configured to receive a pilot signal from the pneumatic pilot spool valve (<NUM>) of the wireless position monitor (<NUM>); and
at least one torque limiting device (<NUM>) disposed between the pneumatic pilot spool valve (<NUM>) of the wireless position monitor (<NUM>) and the at least one switching relay (<NUM>, 124a, 124b) configured to prevent excess torque from the gas-over-oil actuator;
wherein, upon wirelessly receiving a command from the remote workstation (<NUM>, <NUM>), the wireless position monitor (<NUM>, <NUM>) drives a pilot signal from the pneumatic pilot spool valve (<NUM>) to the at least one switching relay (<NUM>, 124a, 124b) to manage a pressure supply to the gas-over-oil actuator (<NUM>) for moving the valve (<NUM>) in the natural gas pipeline (<NUM>) to a desired position.