Patent Description:
The present disclosure generally relates to a diagnostic and performance monitoring system for ball valves, particularly for detecting malfunction and component failures.

Valves regulate the flow of a fluid (gases, fluidized solids, slurries, or liquids) by opening, closing, or partially obstructing various passageways. The valve has two or more ports which allow the flow of the fluid into and out of the valve. It includes a valve body that houses a valve member which interfaces with a valve seat. It is formed along the interior surface of the valve body to form a leak-tight seal when the valve member is fully closed. The valve member is attached to or contacts a valve stem which is used to transmit motion to control the position of the internal valve member with respect to the valve seat. External to the valve body, the stem is attached to a handle or other control device.

Isolation valves are an integral part of many industrial plants. There are four fundamental valve designs: globe valves, ball valves, butterfly valves, and gate valves. Valve performance is important through the system lifespan and to ensure plant efficiency.

<CIT> describes a device that has a sensor module positioned detachably on a carrier that is connected with a fixed part of a wheel bearing. The carrier exhibits a paramagnetic or diamagnetic metallic retaining ring, with which a metallic connecting unit is locked at the sensor module. The retaining ring has a circulating edge area with a cup-shaped cross section, in which the sensor module is lockably held. The retaining ring and a support plate are made of high-grade steel, where the sensor module is attached at an external wall of the ring.

<CIT> describes a position induction device for a valve seat of a hydropower valve. The position induction device comprises a main valve body, a valve element is arranged in the main valve body, a valve rod is arranged on the main valve body, side valve bodies are arranged at the two ends of the main valve body, annular valve seats are arranged on the side valve bodies, annular sealing parts are arranged on the annular valve seats, valve seat bases are further arranged in the side valve bodies, annular hydraulic cavities are formed in the positions, on the two side end faces of the annular valve seats, of the side valve bodies and the valve seat bases, and first hydraulic channels and second hydraulic channels are formed in the side valve bodies. Flanges are arranged on the sides, opposite to the main valve body, of the side valve bodies, detection rods are arranged on the flanges, the ends of the detection rods abut against the end faces of the ends, opposite to valve elements, of the annular valve seats, the flanges are provided with hydraulic tanks, the hydraulic tanks are provided with third hydraulic channels and fourth hydraulic channels, springs used for pushing the hydraulic rods to be close to the detection rods are arranged on the hydraulic rods, and limit switches matched with the hydraulic rods are further arranged on the flanges.

This specification describes valves that include diagnostic and performance monitoring system that can be used, for example, for industrial plant isolation valves. The configuration of these diagnostic and performance monitoring system generally increase ease of maintenance and access for split-body valves. These systems quantitatively detect and measure on-stem valve torque and position, the flowrate of the valve seat, valve stem packing leaks, valve body-closure joint leaks, pipeline pig (scraper) position inside the valve, and valve performance deviations against original specified conditions. The system also monitors performance of preventive maintenance procedures and locates the damaged and misaligned seats of the valve. The system is equipped with a local data-logging device, a logic solver, and remotely readable tags for recording valve design and evaluating performance data and performance deviation. The term "logic solver" is used conventionally to indicate a hardware device or a software system whose inputs and outputs are connected to safety critical devices.

The system comprises sensors connected and inserted into the valve body, a controller for valve seat leak measurement, a communication device, and an interface electrical housing. The interface electrical housing hosts a diagnostic logic solver. The logic solver features a non-volatile memory, an internal power pack connection for external power sources, and communication ports. The system of the present disclosure includes a seat leak flow apparatus which determines the leaking valve seat and computes the leak flow-rate compensated for temperature and pressure.

The system detects valve body leaks for ball valves assembled in one or more body pieces, either soft-seated or metal seated. The monitoring system can be integrated into ball valves, welded body type, split-body, top entry, and three-piece type valves. The system can diagnose, measure and detect problems to assess the overall physical condition of the valve seats, presence of fluids in the valve cavities between the trim and the body, actual position of the valve trim against valve openings and alignment of seats against the valve bore. The system enables locating a pipeline pig device while it travels across the isolation valve. Sometimes during pipeline scraping, a pig passing the valve bore is trapped and causes damages to the valve seat. If the pig is not equipped with signalers, the pig location may remain unknown until an inspection of the valve is performed.

The monitoring system detects and measures stem packing leaks. They are measured by a single built-in apparatus machined into an interface flange between the valve gland and the valve-actuator measuring the leak-flow profile within the packing. The monitoring system detects and locates seat damages in order to assess valve condition prior to installation. The technology has the ability to provide specific assemblies in order to isolate electrical sensors built inside the valve inner parts from the atmosphere.

The monitoring system includes non-intrusive sensors mounted on each piece of the valve closure inside the valve body. The sensors locate the pig passage and send a signal to the logic solver. The logic server estimates the position of the pig to prevent a trapping inside the valve. The logic solver compares the arrival time of the pig at the inlet and at the outlet closure pieces of the valve. When a signal is detected on one closure piece it is also detected on another closure piece.

The monitoring system includes integrated device to detect and locate a j oint-leak and a flange bolting condition for ball valves designed with two or more piece assembly (e.g. split-body, top-entry). This apparatus consists of a voltage-free sensitive fiber optic cable inserted into a groove. The groove is machined on the joint face of the valve body. The fiber detects and locates mechanical stress caused by imbalance in a bolting torque. The fiber is also able to detect presence of the fluid escaping the body. Reflectometry routine operating in the logic solver allows the fiber to detect the specified parameters. In some implementations, one or more fibers are integrated into a mechanical conduit machined in the bottom plate of the valve ball. Some fibers are dedicated to measuring local stress and other fibers are dedicated to detect fluid.

The monitoring system includes an apparatus to detect floating seat alignment with respect to the valve body. This apparatus consists of a voltage-free fiber sensor inserted into a groove into the seat body. Any misalignment of the floating seat element with respect to the body seat part will be detected by the fiber through the reflectometry routine running in the logic solver.

The monitoring system includes a capillary pressure sensor and isolation assemblies for detecting fluid joint leaks at the valve body-closure piece.

The monitoring system includes a seat leak flow-rate apparatus and a controller. The apparatus provides a plurality of calibrated orifices isolated by solenoid valves and governed by the controller. In some implementations, the logic solver runs the controller routine. The controller executes a pre-determined routine to automatically select the orifice used for flow measurement. The execution is performed by switching between a larger or a smaller orifice run when out-of-range conditions are detected. The controller receives the differential pressure reading across the selected orifice in order to compute the leak flow compensated for temperature and pressure.

The monitoring system includes a valve main cable pressure tight assembly. It allows the inner valve sensors to safely connect to the outside environment with three levels of sealing. The three levels include a cable male connector plug which isolates the inside sensor, cables with outside electrical conduit, a back seal of the female connector which provides sealing in full retrieved position, and a pipe-tee packing neck which provides fluid sealing in case of damage of the connector plug during operation. The valve main cable pressure tight assembly further provides an isolation valve to allow full isolation in the case of a plug damage.

In aspects in accordance with the claims, a ball valve for use in industrial pipelines includes: a valve body; an inlet closure piece attached to the valve body; an outlet closure piece attached to the valve body, the valve body, the inlet closure piece, and the outlet closure piece together defining an interior cavity; a ball disposed in the interior cavity, the ball defining a bore extending through the ball; a valve seat adjacent the ball; a first strain sensor mounted on the inlet closure piece; a second strain sensor mounted on the outlet closure piece; a seat misalignment sensor system including a ring sensor incorporated in the closure piece body of the outlet closure piece and a magnetized insert ring disposed in the valve seat; and an electronic controller system in communication with the first strain sensor and the second strain sensor, the electronic control system configured: to estimate the position of a pig passing through the valve by comparing an arrival time of the pig at the inlet closure and the outlet closure of the body based on signals from the first strain sensor and the second strain sensor; and to identify valve seat misalignment based on signals from the ring sensor.

In a related aspect that can be used in combination with the claimed ball valve for use in industrial pipelines, the valve includes a seat misalignment sensor system comprising a ring sensor incorporated in the closure piece body of the outlet closure piece and a magnetized insert ring disposed in the valve seat; and an electronic controller system configured to identify valve seat misalignment based on signals from the ring sensor.

In some aspects in accordance with the claims, a ball valve for use in industrial pipelines, the valve includes: a valve body; an inlet closure piece attached to the valve body; an outlet closure piece attached to the valve body, the valve body, the inlet closure piece, and the outlet closure piece together defining an interior cavity; a ball disposed in the interior cavity, the ball defining a bore extending through the ball; a first strain sensor mounted on the inlet closure piece; a second strain sensor mounted on the outlet closure piece; and an electronic controller system in communication with the first strain sensor and the second strain sensor, the electronic control system configured to estimate the position of a pig passing through the valve by comparing an arrival time of the pig at the inlet closure and the outlet closure of the body based on signals from the first strain sensor and the second strain sensor.

Embodiments of the ball valve for use in industrial pipelines include one or more of the following features.

In some embodiments, the output cables for the ring sensor pass through a first conduit defined in the closure piece body of the outlet closure piece, the conduit extending from the ring sensor to a pressure isolation threaded plug. In some cases, a sensor conditioning electronic board with output terminals that terminate directly in a pressure isolation threaded plug.

In some embodiments, the ball valve also includes a piezoelectric sensor assembly responsive to pressure applied by movement of the valve seat. In some cases, the piezoelectric sensor assembly comprises a fiber optic insert with an embedded fiber is seated in a groove machined on a seat pocket area of the outlet closure piece. In some cases, the piezoelectric sensor assembly also includes a spring attached to the valve seat and extending between the valve seat and the fiber optic insert such that movement of the valve seat translates into a mechanical load on the fiber optic insert. In some cases, the piezoelectric sensor assembly includes a plurality of the fiber optic inserts and associated springs and a piezoelectric sensor output signal cable extends between plurality of the fiber optic inserts through an annular conduit around the valve seat. In some cases, the inlet closure piece and the outlet closure piece each incluide a closure piece body, an inner flange, and an outer flange and the first strain sensor includes a strain gage in direct contact with the closure piece body of the inlet closure piece and a transducer circuit. In some cases, the strain gage is seated in a weld boss inner cavity. In some cases, the strain gage includes strain gage cable connected to the transducer by rotary contact.

In summary, the disclosed technology is a comprehensive valve diagnostic system that provides unique and specific apparatuses and instrumentation to address the various valve problems that can be found in industrial valves in plants worldwide. The apparatuses of this invention can be built inside an existing valve parts. Any existing valve can be adopted to perform a self-diagnostic of its current condition without the need for additional instrumentation. This technology include an embedded diagnostic system for valves that find applications in many industries such as oil and gas, petrochemical, chemical, pharmaceutical, food processing and water transportation.

The details of one or more embodiments of these systems and methods are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of these systems and methods will be apparent from the description and drawings, and from the claims.

The system includes sensors connected and inserted into the valve body, a controller for valve seat leak measurement, a communication device, and an interface electrical housing. The interface electrical housing hosts a diagnostic logic solver. The logic solver features a non-volatile memory, an internal power pack connection for external power sources, and communication ports. The system of the present disclosure includes a seat leak flow apparatus which determines the leaking valve seat and computes the leak flow-rate compensated for temperature and pressure.

The flow measurement is performed at actual flowing conditions, and the flow rates are expressed at standard conditions of pressure and temperature. Theactual flow measurement is recalculated (i.e., compensated) for the specific flowing conditions of pressure and temperature including change in fluid density.

<FIG> and <FIG> are, respectively, a perspective view and a cross-sectional view of an isolation valve <NUM> of a Class <NUM> Div <NUM> installation. The isolation valve <NUM> is a three-piece ball valve with a valve body <NUM> holding a ball <NUM> that defines a central bore <NUM>. The central bore <NUM> through in the ball <NUM> is the same size as a pipeline to which the isolation valve <NUM> is attached. This sizing results in lower friction losses as flow through the valve <NUM> is unrestricted and permits pigging of the pipeline but the valve <NUM> is larger and more expensive than valves with smaller balls.

A valve stem <NUM> extends upwards from the ball <NUM>. A valve actuator <NUM> as attached to the valve stem <NUM> and is operable to rotate the ball <NUM> between its open position and its closed position. The body <NUM> is attached to an upstream closure piece <NUM> and a downstream closure piece <NUM>. The closure pieces include a body <NUM>, an outer flange <NUM>, and an inner flange <NUM>. The closure pieces are sometimes referred to as body flanges. Floating valve seats <NUM> within the valve body <NUM> hold the ball <NUM> in position within the valve body.

The three-piece design allows for the valve body <NUM> containing the ball <NUM>, the valve stem <NUM>, and the valve seats <NUM> to be easily removed from a pipeline. This facilitates efficient maintenance and repair of the valve <NUM>.

The valve <NUM> includes a logic solver <NUM>, which monitors and controls the sensors described in detail with respect to <FIG>. A logic solver enclosure <NUM> is mounted on the valve body <NUM> receives sensor input electrical conduits <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM> from the sensor system. In some embodiments, the cables of the seat misalignment sensor, the pig passage sensor, the body flange load and the fluid fireproof body joint sensors travel into the conduit <NUM> to the logic solver enclosure <NUM>. In some embodiments, the pig sensors <NUM> and <NUM> connect to the logic solver enclosure <NUM> by conduits <NUM> and <NUM>, respectively.

The upstream pressure sensor <NUM>, isolated by the root valve <NUM>, and the downstream pressure sensor <NUM>, isolated by the root valve <NUM>, connect to the logic solver enclosure through conduits <NUM> and <NUM>, respectively. The root valves are valves that isolates the instrument from the process and are generally close to the process line. The pressure sensors can be explosion-proof pressure transmitters that are ATEX or IECEx approved for Class I, Div. <NUM> hazardous areas. These transmitters can provide current or voltage output and are designed for harsh ambient conditions. The conduit <NUM> provides a pathway to connect the logic solver enclosure <NUM> with the valve actuator through the connection coupler <NUM>.

<FIG> is a schematic illustrating the logic solver <NUM> and its connectivity. The logic solver <NUM> connects via a data link <NUM> to a communication module <NUM>. The communication module <NUM> is contained in the logic solver enclosure <NUM> shown in <FIG>. The communication module <NUM> provides hardwired communication through a hardwired link <NUM> or wireless communication by an antenna <NUM> to a handheld device <NUM>. The device <NUM> reads and writes data from and to the logic solver <NUM>. The logic solver <NUM> is externally powered by a power pack <NUM> installed inside the logic solver enclosure <NUM> in order to allow power supply autonomy. In some embodiments, the logic solver is alternatively or additionally provided with other power sources (e.g., hardwired into a plant electrical system).

The logic solver <NUM> provides communication ports <NUM>, <NUM> for programming, for communication with a seat leak flow rate measurement apparatus (e.g., the seat leak flow rate measurement apparatus described with respect to in <FIG>), and for connection with an external display and keyboard module <NUM>, respectively. The logic solver <NUM> also provides a communication port <NUM> for communicating with the valve actuator <NUM>. The logic solver receives a data link <NUM> from a RFID tag <NUM> which stores data of the entire system <NUM>, sensors <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, as well as valve <NUM> and actuator <NUM> data. Regularly at a time frame specified by the user in the logic solver <NUM>, the RFID tag <NUM> is programed to include performance deviations of the valve and the actuator parameters, as well as system <NUM> parameters which all are simultaneously stored in the non-volatile memory block <NUM>. The logic solver <NUM> receives inputs from the pig passage strain sensors <NUM>, <NUM>, the body flange load sensor <NUM>, the fluid fireproof body joint sensor <NUM>, the piezoelectric seat load sensor <NUM>, the stem leak sensor <NUM>, the upstream pressure sensor <NUM> and the downstream pressure sensor <NUM>, seat misalignment sensor <NUM>, the valve torque <NUM> and the valve position <NUM>. These sensors are described in more detail with respect to <FIG>.

<FIG> illustrates the enclosure <NUM> of a logic solver <NUM> of a valve of a Class <NUM> Div <NUM> explosion proof installation in position relative to the valve stem <NUM> and top flange <NUM> of the isolation valve <NUM>. Bolts <NUM> attach the closure piece <NUM> to the body <NUM> of the valve <NUM>. Similar bolts are installed through bores <NUM> defined in the outer flange <NUM> of the closure piece <NUM>. The RFID <NUM> is inserted under the plate <NUM>, mounted on the enclosure cover <NUM>. The plate <NUM> is used to provide written design and installation details of the system for the user to visualize onsite. The enclosure <NUM> is mounted on the valve body <NUM> by support plates <NUM>, <NUM> welded on the main valve body <NUM>. The sealing conduit fittings <NUM>, <NUM> provide protection to the incoming and outgoing cables of the logic solver <NUM>.

<FIG> shows a sectional view of the top of the valve body <NUM>, a joint <NUM> of the body closure piece <NUM>, and an upper portion of the valve flange <NUM>. A main internal conduit channel <NUM> is machined into the body <NUM> of the in order to provide a pathway for the cables of the body flange load, body joint leak and misalignment sensors, which connect to the main channel <NUM> by the machined internal conduits <NUM>, <NUM>, <NUM>, respectively. The body flange load sensor cavity <NUM>, body joint leak cavity <NUM>, and misalignment sensors cavities <NUM>, <NUM> provide bonding to the main closure piece body <NUM> for the sensors. Sensors in the misalignment sensors cavities <NUM>, <NUM> measure forces on the seat.

]<FIG> shows a perspective view of split electrical conduits <NUM>, <NUM> welded as shown on sections <NUM> and <NUM> of the valve body and the double union assembly, <NUM>, <NUM>, nipple <NUM> at the joint <NUM> between the main valve body <NUM>, and the closure piece body <NUM>. The double union assembly, <NUM>, <NUM> and <NUM> facilitates decoupling the electrical conduit pieces <NUM> from <NUM> at the joint <NUM> for maintenance or disassembly purposes. In particular, this specific construction o allows disassembling the main valve body from the flanged pieces and can be used in any other split body design valve. The illustrated joint can be used to disassemble the valve pieces for maintenance purposes and can also host an electrical connector inside the electrical conduit which can be disconnected in order to also spilt the electrical connections at the double-union piece <NUM>.

<FIG> shows a cross-sectional view of a section of the welded conduits bodies attached to the valve body and body closure body. This view shows the conduit body <NUM>, the welding thread <NUM>, and the inner conduit <NUM>.

<FIG> shows a representation of the outer valve body welded conduits <NUM>, <NUM>, <NUM> attached on the main valve body, the conduits <NUM>, <NUM> attached on the valve closure piece bodies of upstream and downstream valve ports. The conduits <NUM>, <NUM> connect to interface pieces <NUM>, <NUM>, which are machined (pass thru holes) to provide the double unions <NUM>, <NUM> with the necessary clearance (gap) from the closure body for rotating the double union nuts by a suitable tool for maintenance. Another union <NUM> allows the conduit system to connect to the valve actuator. The conduits <NUM>, <NUM> connect to the upstream and downstream pressure transmitters <NUM>, <NUM> electrical outputs, respectively. The isolation valves <NUM>, <NUM> isolate the fluid connection of the transmitters. The pipe tees <NUM>, <NUM> allow the connection of pressure gauges for operators to visually monitor upstream and downstream pressure. The conduits <NUM>, <NUM> connects to the man logic solver <NUM> through conduit sealing bodies <NUM>, <NUM> and <NUM>. Additionally the logic solver enclosure allows connecting the logic solver to other devices through a sealing body <NUM>, which is seen in this figure with its plug on. The pressure transmitters <NUM> and <NUM> are used by detecting the direction of the seat leak flow whenever leaks in a sustained manner, which normally takes place after permanent damage of the valve seat. It also shows a representation of the stem packing leak flow-rate apparatus <NUM> and its isolation valve <NUM>, which are described more in details in <FIG>.

<FIG> illustrate several approaches to sensing misalignment of the floating valve seats <NUM> within the valve body <NUM>.

Both the upstream closure piece body <NUM> and the downstream closure piece body <NUM> include a seat misalignment sensor.

<FIG> shows a seat misalignment sensor system 316a that measures the misalignment of the floating seat <NUM> using an assembly of a ring sensor <NUM> incorporated in the closure piece body and a magnetized insert ring <NUM> which is inserted in the floating seat <NUM>. The seat misalignment sensor 316a of the upstream closure piece body <NUM> is illustrated in <FIG>. The floating seat <NUM> is shown between the ball <NUM> and the upstream closure piece body <NUM>.

Output cables <NUM> for the ring sensor <NUM> pass through a threaded sealed plug <NUM>, which ends in a flat finishing surface. This configuration provides further isolation against the O-ring <NUM> seated into a groove machined into the closure piece body. An internal conduit <NUM> is drilled at an angle to allow the sensor output cables <NUM> to reach a sensor conditioning electronic board <NUM>. Output terminals of the sensor conditioning electronic board <NUM> terminate directly in a pressure isolation threaded plug <NUM>. Sensor cables <NUM> for a piezoelectric sensor <NUM> reach thru an internal conduit to the sensor conditioning electronic board <NUM>. Both sensor output cables <NUM> and <NUM> reach the sensor conditioning electronic board <NUM>, which provides power to the sensors and receives readings from the sensors. The sensor conditioning electronic board relays the readings to an external receiving electronic board. One approach to connecting the sensor conditioning electronic board to the external receiving electronic board is described in detail with respect to <FIG>. The sensor output cables <NUM> of the pressure isolation threaded plug <NUM> are further protected by the interface isolation flange <NUM>, which is bolted by bolts <NUM> into the body <NUM> of closure piece and is provided ingress protection by the O-Ring <NUM> and the fire-safe gasket <NUM>.

<FIG> shows a seat misalignment sensor system 316b that uses another approach to sensing misalignment of the floating valve seats <NUM> within the valve body <NUM>. The seat misalignment sensor system 316b gives multiple readings for stem leakage. In the seat misalignment sensor 316b, a seat insert <NUM> is floating between the ball <NUM> and the inner body. The seat insert <NUM> extends into a cavity defined in the floating seat <NUM>. A seat O-ring <NUM> provides a seal between the floating seat <NUM> and the closure piece <NUM>. A fiber optic insert <NUM> with an embedded fiber <NUM> is seated in a groove machined on a seat pocket area of the end closure <NUM>. A spring <NUM> is attached to the floating seat <NUM> and extends between the floating seat <NUM> and the fiber optic insert <NUM>. The floating seat <NUM> pushes the spring <NUM> which seats on the fiber optic insert <NUM>. The mechanical pressure of the floating seat translates into a mechanical load on the fiber optic insert <NUM> received by the fiber optic <NUM> and connects to the logic solver <NUM> to measure the imbalance of loads along circumference of the floating seat <NUM>. The imbalance in the loads is caused by misalignment of the seat against the closure piece. The misalignment is formed as a result of debris, dirt or contaminants that travel within the fluid.

<FIG> shows a seat misalignment sensor system 316c. The seat misalignment sensor 316c is generally similar to the seat misalignment sensor 316b in including a spring <NUM> extending from a valve seat <NUM> into a bore <NUM> drilled into the seat pocket area. The spring <NUM> seats on a spring ring <NUM>. The spring <NUM>, which holds the valve seat <NUM> from its rear side facing the pocket area <NUM> of the closure piece, exerts a force on a piezoelectric sensor <NUM> by pushing a pin <NUM> attached to the piezoelectric sensor <NUM>. A piezoelectric sensor output signal cable <NUM> extends through an annular conduit. In order to determine the orientation of the misalignment towards any of the <NUM> quarters of the ball valve, a minimum of <NUM> piezoelectric misalignment sensors are needed at the <NUM>, <NUM>, <NUM>, <NUM> o'clock positions around the seat ring to detect vertical and horizontal displacements of the floating seat ring against the pocket area. The piezoelectric sensor output signal cable <NUM> collects the signal of the sensors located around the seat ring (e.g., at the <NUM>, <NUM>, <NUM>, <NUM> o'clock positions).

<FIG> shows a seat misalignment sensor system 316d in which a piezoelectric sensor <NUM> is approached by a pusher ring <NUM> inserted in the floating seat <NUM>. In this embodiment, a plurality of piezoelectric sensors <NUM> distributed around a machined groove <NUM> detect the motion of the floating seat <NUM> towards the pocket seat area <NUM>. The output cables <NUM> of the piezoelectric sensor <NUM> enter into the inner conduit ring <NUM> which carries the output cables from the plurality of piezoelectric sensors.

<FIG> shows an isometric representation of the pusher insert <NUM> on the floating seat <NUM>.

<FIG> are schematics showing details of an integrated stem leak flow-rate, torque and position sensing apparatus <NUM>, and design features of an associated valve gland <NUM> and top valve-actuator interface flange <NUM>. In the stem leak flow-rate, torque and position sensing apparatus <NUM>, the torque is measured by the hall-effect sensors <NUM>, <NUM>, which are also used to measure position of the valve stem The sensors <NUM>, <NUM> are mounted inside drilled cavities machined on the top valve-actuator interface flange <NUM> and the actuator flange <NUM>, respectively. The stem leak flow-rate, torque and position sensing apparatus <NUM> includes another hall-effect sensor <NUM> that, like hall-effect sensor <NUM>, is installed in a drilled cavity on the actuator flange <NUM>. This approach enables this system to be implemented on valves that are already in operation without machining the valve-actuator interface flange <NUM>. Some actuator flanges only include a single hall-effect sensor as the second hall-effect sensor on the actuator flange is not necessary for valves with the hall-effect sensor <NUM> on the valve-actuator interface flange <NUM>.

The torque hall-effect sensor <NUM> reads the magnetic induction vector angle generated by magnetic inserts <NUM> mounted on the stem <NUM>. The output signal cable of sensor <NUM> runs inside the inner conduit <NUM> machined in the flange <NUM>. In the integrated stem leak flow-rate, torque and position sensing apparatus <NUM>, the torque is measured by multiple sensors (e.g., the sensors <NUM>, <NUM>, <NUM>) in order to achieve higher resolution and accuracy. For example, higher resolution and accuracy can be provided by comparing measuring the displacement at the sensor <NUM> against the displacement at the position of sensor <NUM>, as a result of the rotation of the stem <NUM> caused by the torque applied from the valve actuator.

The hall-effect sensor <NUM> reads the position by measuring intensity and angle of the magnetic insert <NUM>, which are installed in a cavity drilled on the stem <NUM>. Although FIG. 10A shows only one magnetic insert <NUM>, a plurality of magnetic inserts and hall-effect sensors are required in order to use a single cavity on the actuator flange <NUM> for measuring position. In this approach, the position sensor <NUM> detects a combination of magnetic poles facing an array of sensors for every angle of motion as the stem rotates. The torque is determined by measuring the angle and intensity of magnetic flux at working conditions, being the stem rotated under load conditions, against the measurement at rest for a given known load. The calibration process consists in stroking the valve from open and close position at no load conditions (i.e., no fluid passing) while recording the readings of torque at no load conditions at various opening points, next repeating the stroking exercise while applying various loads and finally determining the deviations from no load and loaded conditions along the open-close curve along with hysteresis. The objective of measuring position is to determine the actual position of the valve stem at fully open or fully closed positions rather than measuring position at the actuator level. In large diameter valves the fully open position read by the actuator does not reflect the actual position of the stem, for example the actuator may indicate <NUM>% open but the actual position is <NUM>%. These events can lead to scraper stuck situations and sever damage of the valve seats. The position measurement determines, under static conditions, the actual position of the valve against a previously recorded value of <NUM>% and <NUM>% actual stem position. Thus, the same hall effect sensor will measure the angle and magnetic intensity at actual <NUM>% and <NUM>% in static conditions, and the logic solver will compare it against working conditions having an actual load to determine whether or not the measured position is considered to be, within acceptable and safety margins, a fully open or fully closed position. Another possible embodiment is that the same technique of sensors is placed around the neck body piece around the valve, thus using a plurality of sensors around that piece to measure position at various points around the circumference.

The output cables of the sensors <NUM>, <NUM>, <NUM> run inside the inner conduits <NUM>, <NUM>, <NUM>, respectively. The threaded connectors <NUM>, <NUM>, <NUM> connect to the conduit nipples <NUM>, <NUM>, <NUM>, respectively. These sensor cables run into the conduit fitting tees <NUM>, <NUM>, <NUM>, respectively. The tees <NUM> and <NUM> are interconnected by the nipples <NUM>, <NUM>. The sensor cables connect to the logic solver <NUM> enclosure through the conduit <NUM>. The torque and position sensing approach allows improved safety, valve seat performance, and system durability at reduced cost.

The illustrated ball valve includes a valve gland <NUM> which supports the stem <NUM>, holds stem bearings (i.e., lower stem bearing <NUM> and upper stem bearing <NUM>) , as well as the packing O-rings <NUM>, <NUM>, <NUM> and the fire proofing gasket ring <NUM>. The flanges <NUM> and <NUM> are held in position by studs <NUM> and nuts <NUM> around the flanges perimeter spaced at regular intervals. The valve-actuator interface flange is attached to the valve gland <NUM> by holding bolts <NUM>, while the gland <NUM> is held to the valve body by bolts <NUM>.

When a leak takes place, fluid passes the O-rings <NUM>, <NUM> and the fireproof ring <NUM>. A holding ring (O-ring <NUM>) provides an additional seal to cause the leaking fluid to enter the cavity <NUM> which connects to the inner drilled conduit <NUM>. The leaking fluid then reaches a threaded connector <NUM> connecting to a pipe nipple <NUM> and solenoid valve <NUM>. The solenoid valve <NUM> is commanded by a cable running inside a conduit fitting tee <NUM>, straight conduit <NUM> and tee <NUM>. The tee <NUM> collects signal cables from an electronic rotameter <NUM> and leads to the conduit <NUM> towards the logic solver <NUM> enclosure. The leak flow-rate measurement starts as soon as the fluid enters the rotameter <NUM>, which can be isolated manually by a manual valve <NUM>. The exhaust of the leak is taken to an exhaust pipe <NUM>. A stem key <NUM> holds the mechanical link to the valve actuator driving coupler, not shown in this figure.

In some integrated stem leak flow-rate, torque and position sensing apparatus, the stem leak flow-rate tapping point <NUM> is placed on the same side where the torque measurement sensors are installed.

<FIG> shows a piping and instrument diagram of the packing leak flow-rate operation. The stem packing leak flow rate is measured by a rotameter <NUM> featured with a flow transducer output and an inner pressure transducer that provides a flow-rate signal which is sent over the signal cable <NUM> to the main logic solver of the system <NUM>. The logic solver <NUM> can isolate the flow measurement by closing a solenoid valve <NUM>. The leak flow can be also isolated manually by the isolation valve <NUM>. The rotameter <NUM> is connected to the pipe tee <NUM> and can be isolated by the valve <NUM> manually. The exhaust of the leak flow-rate can be regulated by the control valve <NUM> by the logic solver <NUM> across the signal cable <NUM>. The valve <NUM> is a calibrated needle control valve used to estimate very low range of leak flow-rate when the rotameter range is exceeded. In this embodiment, the method of flow rate measurement is achieved by having every signal output from the logic solver <NUM> calibrated against a percentage of opening of the valve <NUM> along with the corresponding valve Cv. The flow rate across the valve <NUM> can be estimated using control valve theory equations based on the upstream valve pressure from the inner pressure transducer of the rotameter <NUM>. In some cases, the entire flow rate measurement assembly is built in a manifold block <NUM> which provides a main isolation valve <NUM> to facilitate removal of the entire block <NUM>. The exhaust of the leak is discharged to the atmosphere through the exhaust pipe <NUM>.

<FIG> depicts a pig sensor assembly. The pig sensor <NUM> is a non-intrusive strain measurement sensor comprising a strain gage bonded directly to the valve closure piece body <NUM> and a transducer circuit contained in the sensor <NUM> housing. The strain gage is located inside the weld boss <NUM> inner cavity. The output cables of the strain gage cables connect to the sensor <NUM> transducer by rotary contact. The sensor <NUM> is connected by a thread <NUM> into a weld boss <NUM>, which is directly welded to the valve closure piece body <NUM>. The sensor housing <NUM> provides a threaded connection <NUM> for its output signal cables and incoming power cables which come from the logic solver housing. The cables run inside conduit and conduit fitting, namely threaded nipple <NUM>, elbow <NUM>, conduit <NUM> towards the logic solver housing <NUM>. The pig sensor approach detects localized vibration caused by the passage of the pig as a result of micro-deflections on the pie outer surface caused by the increase of pressure at the rear side of the pig in the direction of the flow and against the pipe wall.

<FIG> depicts the piping and instrument diagram of a valve seat leak measurement apparatus <NUM>. A mechanical piping <NUM> to the valve <NUM> connects to the cavity drain valve <NUM> to allow the leaked fluid to enter the apparatus for measurement. In some cases, the mechanical piping <NUM> is a flexible pressure hose. In some cases, the mechanical piping <NUM> is a rigid pipe. In order to facilitate fast coupling, the quick pipe coupler <NUM> allows a fast coupling and decoupling of the apparatus from the valve <NUM>. The apparatus <NUM> connects electrically by a multicore cable <NUM> to the valve sensor outputs, which are available from the valve sensor retrieval fitting <NUM> (described in more detail with respect to <FIG>). At one end, the cable <NUM> provides an electrically safe connector <NUM> to facilitate removing the entire apparatus <NUM> from the valve <NUM>. The connector <NUM> provides an external grounding cable and connector <NUM> to ground the apparatus <NUM> to a valve body ground terminal for embodiments that do not provide shielded flexible couplers or metallic conduit for the cable <NUM>. This approach provides grounding of the apparatus <NUM> prior coupling and decoupling to the valve sensor retrieval fitting <NUM>. In some cases, the connector <NUM> with its grounding and connector <NUM> can directly connect to the valve sensor retrieval fitting <NUM>. In some cases, the cable <NUM> and connector <NUM> are installed inside an electrical flexible coupling hose. In some cases, the connector <NUM> is an explosion proof connector that avoids ignition of the surrounding gases.

<FIG> is a cross-section of the valve sensor retrieval fitting <NUM>. The electrical connector <NUM> and quick pipe coupler <NUM> allow the apparatus <NUM> to be operated as a portable tool detached from the valve. The electrical connector <NUM> provides a grounding cable <NUM> to ensure a safe connection to the valve to avoid static sparks. The cavity drain valve <NUM> is normally closed and it connects by a pipe <NUM> to the quick pipe coupler <NUM>.

The apparatus <NUM> is isolated from the main valve <NUM> by the isolation valve <NUM>, which is normally closed. The operator opens valve <NUM> to initiate the leak flow-rate measurement process. The apparatus <NUM> provides a drain valve <NUM> to depressurize and drain any fluids before disconnecting it from the main valve <NUM>.

The inlet pressure to the apparatus can be read by the operator on the pressure gauge <NUM>. This facilitates quick reading of the inlet pressure before starting the leak flow-rate measurement process. Valve <NUM> isolates the gauge <NUM> and valve <NUM> allows purging the gauge <NUM> process connection. The inlet pressure signal is transmitted over the signal cable <NUM> by the pressure indicator transmitter <NUM> to the apparatus internal logic solver <NUM>. The transmitter <NUM> is isolated by valve <NUM> and purged by valve <NUM>. The temperature indicator transmitter <NUM> transmits the fluid temperature signal over the signal cable <NUM> to the apparatus internal logic solver <NUM>. The transmitter <NUM> is isolated from the main header <NUM> by valve <NUM>. Downstream the valve <NUM>, which is normally closed, isolates the multiple flow elements manifold <NUM>. In some cases, the flow elements consist of three runs with each run providing one orifice plate, <NUM>, <NUM>, <NUM>, to measure low, medium and high leak flow-rates using differential pressure transmitters <NUM>, <NUM>, <NUM>, respectively. The transmitters <NUM>, <NUM>, <NUM> send their individual signals over cables <NUM>, <NUM>, <NUM>, which bundle into a multicore cable <NUM> to the apparatus internal logic solver <NUM>. In some cases, the manifold <NUM> includes multiple runs to accommodate intermediate levels of leak flow-rate measurements. In some cases, each differential pressure transmitter <NUM>, <NUM>, <NUM>, is isolated by a pair of valves as illustrated, <NUM> / <NUM>, <NUM> / <NUM>, and <NUM> / <NUM>, respectively. The manifold <NUM> is isolated from the outlet pipe header <NUM> by the isolation valve <NUM> in order to facilitate maintenance works on the manifold and prevent manifold <NUM> pressurization in the case of utilizing the flushing/bypass line <NUM>. The entire manifold <NUM> can be removed after closing the valves <NUM> upstream and downstream <NUM>. The pressure on the outlet header <NUM> is monitored by the operator on the pressure gauge <NUM> which is isolated by valve <NUM> and purged by valve <NUM>. The outlet header is connected to the exhaust pipe <NUM> sized to accommodate the outlet pressure for the entire range of flow-rates the apparatus handles. In order to manage dirty gaseous or liquid fluids, the apparatus provides a flushing operation mode that the operator executes when selecting flush/bypass mode on the selector switch <NUM>, which provides three operation modes for the apparatus, flushing/by-pass mode, measurement mode and idle mode. The selector switch is connected to the apparatus internal logic solver <NUM> by the cable <NUM>. The entire apparatus can be shutdown in case of emergency by the emergency push button <NUM>, which is connected to the apparatus internal logic solver <NUM> by the cable <NUM>. Pushing the emergency push button <NUM> causes the normally closed solenoid valve <NUM> to close isolating the entire apparatus from the main valve <NUM>.

At the beginning of the operation of the apparatus, the operator opens valves <NUM>, <NUM> and <NUM> to enable operating modes of the apparatus. In flushing/bypass mode, the valves <NUM> and <NUM> are already open, the logic solver <NUM> closes the solenoid valves <NUM>, <NUM>, <NUM> and <NUM>, then opens the solenoid valves <NUM> and <NUM>. In measurement mode, the logic solver <NUM> closes <NUM>, <NUM> then opens <NUM> and <NUM> to start measuring the flow-rate at the lowest measurement range which is provided by the flow element <NUM>.

The logic solver automatically switches over the next measurement run from <NUM> to <NUM> and then <NUM> depending on the flow rate profile measured during a pre-determined amount of time, preselected by the user. The auto switchover prevents cavitation conditions for liquids, freezing of the manifold for highly pressurized gaseous fluids and potential erosion damage of sonic outlet velocities in gaseous fluids and contaminated fluids. The actual flow-rate conditions and damage on the seats of the main valve <NUM>, namely size and extension of the passages on the seat, which are causing the leak to measure, are unknown. It is due to the fluid phenomena associated to releasing fluids through the openings of the apparatus, such as cavitation, freezing and erosion. The seat leak flow rate measurement apparatus provides an automatic flow-rate range selection to prevent damages caused by said phenomena.

The flow-rate for each run, <NUM>, <NUM> and <NUM> is calculated by the logic solver from the signals received from each differential pressure transmitter <NUM>, <NUM> and <NUM>. If the flow-rate exceeds the flow element <NUM> measurement capacity the logic solver <NUM> closes <NUM> and opens <NUM>. If the flow-element <NUM> capacity is exceeded then the logic solver <NUM> closes <NUM> and opens <NUM>. If the flow element capacity <NUM> is exceeded the logic solver <NUM> closes the solenoid valve <NUM> and <NUM> to safely isolate the apparatus. In order to determine the flow element capacity the logic solver <NUM> compares the differential pressure curve of the measuring run against a pre-determined differential pressure profile. If the cavity of the main valve <NUM> remains pressurized after opening the drain valve <NUM> and initiating measurement mode, which normally takes place due to a sustained leak condition of the seats of valve <NUM>, the differential pressure across the current flow element will follow a predetermined profile that indicates the flow-rate is sustained by the valve <NUM> cavity pressure, which is normally the pipeline operating pressure.

<FIG> also shows various conditions of the calculated flow-rate by the logic solver <NUM>. The upper hashed line shows a large leak flow-rate which is out of range and may cause damage to the seat leak flow rate measurement apparatus. This type of leaks are normally sustained by the pressure in the main valve <NUM>. This occurs when the damage in the seats of valve <NUM> is permanent. The next three solid lines show sustained leak flow-rates of various ranges which can be measured by said apparatus. The dashed line shows a leak flow-rate of a decaying leak flow-rate, which indicates possible normal (not damaged) conditions of the seat of the main valve (valve <NUM>, <FIG>).

Referring to <FIG>, the logic solver <NUM> can determine the actual leak flow-rate condition for decaying leak profiles. After a predetermined period of time set by the user elapses, the logic solver <NUM> closes the solenoid valve <NUM> to cut the flow across the apparatus and then monitors the pressure reading from the pressure transmitter <NUM>. If the pressure on the header <NUM> measured by <NUM> remains zero or constantly very low compared to a preset value after another predetermined period of time set by the user, the logic solver <NUM> writes in its non-volatile memory the valve <NUM> status as: "normal seat condition".

The logic solver <NUM> executes a pre-determined routine to select the flow measurement run based on valve design data and by pre-opening the run of smallest flow-rate, which is shown for illustration purposes as line <NUM> in <FIG>. If the leak flow-rate is exceeded the logic solver <NUM> automatically switchover to a larger flow element. The logic solver <NUM> also determines the direction of the leak flow for each run, from the readings of differential pressure transmitters <NUM>, <NUM> and <NUM>. The logic solver <NUM> also compensates the flow calculations for temperature and pressure by receiving the pressure and temperature measurements from pressure indicator transmitter (PIT) <NUM> and temperature indicator transmitter (TIT) <NUM>, respectively. The logic solver <NUM> determines the direction of seat leak flow, whether coming from the inlet port or outlet port of the valve <NUM>, by comparing output signals of each seat ring, which is sent to the logic solver <NUM> by the main logic solver <NUM> ( <FIG>), with the calculated leak flow rate from the current flow run. The output signals of the seat rings is sent across the cable <NUM>, via the electrical connector <NUM>.

<FIG> shows a mechanical drawing of the valve sensor retrieval fitting showing the assembly of the sensors main cables, insertion and retrieval mechanical parts. The inside sensors cable <NUM> inserts into the sealed threaded plug <NUM> which is sealed to the body by the O-ring <NUM> and the fireproof ring <NUM> that seat inside the groove <NUM> and <NUM>, respectively. The threaded plug <NUM> provides a male pin connector array <NUM> to host the female plug <NUM>. The internal threaded welded boss <NUM> is welded <NUM> to the body <NUM> and hosts the nipple <NUM>, which mechanically connects to the valve <NUM> of inlet and outlet threaded ports. The female connector <NUM> is contained in a tee-pipe threaded to the valve <NUM> on one end and connected by the flange <NUM> to the flanged pusher stem pipe <NUM> by studs <NUM> and nuts <NUM>. The female connector stem <NUM> is internally threaded <NUM> to allow the threaded plug <NUM> to rotate into the internally threaded stem <NUM> which linearly moves up and down pushing the sensor-output female connector <NUM> into the plug <NUM> at the end of its travel. The linear movement of the stem <NUM> is achieved by the rotation of the drive threaded plug by the rotation of the hand wheel <NUM> that transmits the motion to the shaft <NUM>. The shaft is held by the bearing <NUM> which is attached to the plate <NUM> and the bearing <NUM> hosted by the cover plate <NUM>, which is bolted to the body of the pusher stem pipe <NUM>.

The stem <NUM> slides linearly thru the O-ring packing <NUM>, <NUM> and <NUM> which are hosted by the pipe packing neck <NUM> which is machined on the same pipe tee body <NUM>. The cable <NUM> is coiled by the spring loaded cable reel <NUM> which allows the cable to slide out and back along with the female connector <NUM> without suffer damages during the retrieval of the connector <NUM>.

The insertion of the female connector <NUM> into the male plug <NUM> is secured by the socket <NUM>. In order to ensure the right alignment of the <NUM> socket with the plug pins <NUM>, the female connector provides includes a groove <NUM> which extends into the ball valve threaded connection.

<FIG> shows a front view of the female connector <NUM> with the guiding grooves <NUM>, the socket female walls <NUM> and female pins <NUM>.

<FIG> shows a back view of the female connector <NUM> which is linked to the stem head <NUM> and the back seat <NUM> that allows sealing the pipe tee in fully retrieved position of the connector <NUM> against the pipe tee packing neck <NUM> (<FIG>). The cable bushing <NUM> provides protection to the main sensors cable <NUM> (<FIG>).

<FIG> shows the bushing <NUM> which provides protection to the cable <NUM> and guides the cable while moving during both insertion and retrieval of the female connector.

<FIG> shows the cover <NUM> of the pusher stem pipe <NUM>. The cover <NUM> provides mechanical support to the bearing <NUM> and the O-ring <NUM> which provides dust and moisture ingress protection from outside environment. The cover <NUM> is bolted on the pusher stem pipe <NUM> by bolts <NUM>.

<FIG> shows the female connector <NUM> slides as it moves along the guiding key <NUM> of the threaded pipe tee <NUM>. The movement of the female connector <NUM> is further guided by the ball valve guiding key <NUM> attached to the ball valve <NUM> (<FIG>, item <NUM>) on the inside bore. This allows the male plug pins <NUM> to lock into the correct female pin connectors <NUM>.

<FIG> shows the O-rings <NUM>, <NUM> which provide sealing to the sliding stem <NUM>. In some cases, the ring <NUM> provides fireproof sealing of the entire assembly, depicted above in <FIG>. The gasket <NUM> seals the surface contact between the flange <NUM> and the pipe-tee packing neck <NUM>. The flange <NUM>, already indicated as item <NUM> in <FIG>, connects mechanically to the pipe-tee packing neck <NUM> by a series of screws located along an inner perimeter of <NUM>. One of the screws <NUM> is shown in <FIG>. The screw <NUM> seats its head on the cavity <NUM>. The flange <NUM> is bolted through the pass-thru hole <NUM> to the pusher stem pipe flange shown in <FIG> and indicated as item <NUM>. The female connector <NUM> (<FIG>) and the back ring <NUM> seat on the pipe-tee neck <NUM>.

<FIG> shows the cable of the main body load sensor ring <NUM> running inside the conduit <NUM>, which is internally machined in the valve body <NUM>. The end of the conduit <NUM> allows the sensor <NUM> cables to connect the main cable-sealing plug <NUM>, which also seals the cable of the fluid-sensitive pressure sensor <NUM>. The load sensor <NUM> radially measures the mechanical load between the closure <NUM> and the body <NUM>. The internal capillary <NUM> of the sensor <NUM> carries the capillary fluid, which is in mechanical contact with the capillary pressure sensor <NUM>. The pressure signal cable <NUM> of the sensor <NUM> enters in the cable-sealing plug <NUM>. The body-joint O-ring <NUM> seals the closure piece <NUM> and body <NUM>. The fire-safe gasket ring <NUM> provides further protection to the O-ring <NUM>. The ball <NUM> seats on the seat ring <NUM> which is shown in <FIG> without cavities. In some cases, the sensor <NUM> is a fluid-sensitive cable placed on a ring cavity machined on the valve body <NUM> and the end segments of the fluid sensitive sensor cable <NUM> enter into the inner conduit <NUM> to reach the main cable-sealing plug <NUM> without the need of the capillary pressure sensor <NUM>. In some cases, the fluid sensitive cable is a fiber optic capable of detecting the passage of the leaked fluid, which connects to the logic solver of the present invention to determine the location of the leak across any point around the valve body-closure piece joint circumference by having the logic solver to execute a leak location routine based on light pulse bandwidth scattering reflectometry methods.

<FIG> shows one embodiment of the present invention of the sensor <NUM> which is numbered as <NUM> in <FIG>. The sensor diaphragm <NUM> transmits the pressure measured between the body O-ring <NUM> and the fire-safe ring <NUM>. When a leak takes place thru the O-ring <NUM> the pressure built up between the two rings <NUM>, <NUM>, will be measured by the diaphragm <NUM>, which is built to withstand the hydro-test pressure of the valve. The capillary <NUM> contains the fluid <NUM> which transmits finally pressure to the pressure sensor <NUM> (<FIG>).

<FIG> the capillary pressure sensor <NUM> is threaded on the cavity <NUM>, which is found at the end of the capillary <NUM>. The pressure sensor <NUM> is threaded by turning the nut head <NUM>. The sensor <NUM> head is sealed by a composite <NUM> to provide electrical insulation for the sensor output cable <NUM>. The cable <NUM> of the load sensor <NUM> (<FIG>) enters in the cavity <NUM> which contains the output cables towards the sealing plug <NUM> (<FIG>).

<FIG> shows one embodiment of the interface isolation flange <NUM> built in a non-ferromagnetic material and bolted to the closure piece body by the bolts <NUM> and the nut <NUM>. The interface isolation flange <NUM> provides two magnetic coupling interfaces, one for power by a ferromagnetic nucleus <NUM> and one for sensor signal <NUM>. The electromagnetic power is received by the coil <NUM> on the external receiving electronic board <NUM> and generated by the power-signal main board <NUM>. The sensors signal coil <NUM> is electromagnetically coupled by the sensor signal nucleus <NUM> and received by the coil <NUM> on the main board <NUM>. The external receiving electronic board <NUM> is mechanically supported by the stand-offs <NUM> which seat on the ears <NUM> and securely fastened by the screw <NUM>.

<FIG> shows the bottom view of the bore <NUM> of the interface isolation flange <NUM> (<FIG>) and the supporting ears <NUM>, screw <NUM> and nuts <NUM> of the external receiving electronic board <NUM> (<FIG>). The load sensor detects force imbalance inside that body that can produce leaks.

As shown in <FIG>, the logic solver <NUM> receives the signals of the system sensors, specifically, seat misalignment sensor <NUM>. In some cases, logic solver <NUM> also receives signals from the upstream pig sensor <NUM> and the downstream pig sensor <NUM>. In some cases, the pig passage is detected by a single sensor, the upstream pressure sensor <NUM>, the downstream pressure sensor <NUM>, the seat load sensor <NUM>, the body flange load sensor <NUM>, the body joint seal leak sensor <NUM>, the packing stem leak sensor <NUM>, the valve torque sensor <NUM>, and the valve position sensor <NUM>. The logic solver is configured by the user to provide an alarm whenever any of the sensor inputs deviates from predetermined lo-lo, lo , hi- hi-hi settings. The logic solver has a plurality of comparators for every sensor input. The alarms are stored in the local non-volatile memory and transmitted to the communication port. The logic solver <NUM> receives and transmits data in the form of configuration parameters, programming logic and set-points from/to an external human-interface data-entry device <NUM>. Similarly, the logic solver <NUM> communicates with other systems of the same nature as the one disclosed in this specification, through port <NUM> and hand-held devices through port <NUM> or wirelessly via the antenna <NUM>. Programming, parameters, set-points and valve and actuator data are stored in a non-volatile memory block <NUM>. The RFID <NUM> stores relevant data of the valve <NUM> and the actuator <NUM>, the entire system is represented by function block <NUM> and the sensors <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM>.

In a ball valve, the floating seat is placed in the seat pocket area. The floating seat misalignment shown in <FIG> may take place during normal operation of the valve due to entrapment of dirt between the seat pocket area and floating seat. During normal operations, solid particles carried by the fluid passing through the valve are formed behind the seat thus, causing the floating seat to get trapped and to lose its ability to float smoothly against the ball. The seat is not able to seal the ball against the body causing the valve to pass fluid even when is closed. The specification provides method and systems to detect seat misalignment and either to prevent further deterioration of the valve tightness or to manage the seat leak problems that may arise.

<FIG> is a block diagram showing a schematic of a data transfer system <NUM>. The example of the data transfer system <NUM> is used to provide computational functionalities associated with described algorithms, methods, functions, processes, flows, and procedures described in the present disclosure, according to some implementations of the present disclosure. The illustrated computer <NUM> is intended to encompass any computing device such as a server, a desktop computer, a laptop/notebook computer, a wireless data port, a smart phone, a personal data assistant (PDA), a tablet computing device, or one or more processors within these devices, including physical instances, virtual instances, or both. The computer <NUM> can include input devices such as keypads, keyboards, and touch screens that can accept user information. Also, the computer <NUM> can include output devices that can convey information associated with the operation of the computer <NUM>. The information can include digital data, visual data, audio information, or a combination of information. The information can be presented in a graphical user interface (UI) (or GUI).

At a high level, the computer <NUM> is an electronic computing device operable to receive, transmit, process, store, and manage data and information associated with the described subject matter. According to some implementations, the computer <NUM> can also include, or be communicably coupled with, an application server, an email server, a web server, a caching server, a streaming data server, or a combination of servers.

The computer <NUM> can receive requests over network <NUM> from a client application (for example, executing on another computer). The computer <NUM> can respond to the received requests by processing the received requests using software applications. Requests can also be sent to the computer <NUM> from internal users (for example, from a command console), external (or third) parties, automated applications, entities, individuals, systems, and computers.

Each of the components of the computer <NUM> can communicate using a system bus <NUM>. In some implementations, any or all of the components of the computer <NUM>, including hardware or software components, can interface with each other or the interface (or a combination of both), over the system bus <NUM>. Interfaces can use an application programming interface (API) <NUM>, a service layer <NUM>, or a combination of the API <NUM> and service layer <NUM>. The <NUM> can include specifications for routines, data structures, and object classes. The API <NUM> can be either computer-language independent or dependent. The API <NUM> can refer to a complete interface, a single function, or a set of APIs.

The service layer <NUM> can provide software services to the computer <NUM> and other components (whether illustrated or not) that are communicably coupled to the computer <NUM>. The functionality of the computer <NUM> can be accessible for all service consumers using this service layer <NUM>. Software services, such as those provided by the service layer <NUM>, can provide reusable, defined functionalities through a defined interface. For example, the interface can be software written in JAVA, C++, or a language providing data in extensible markup language (XML) format. While illustrated as an integrated component of the computer <NUM>, in alternative implementations, the API <NUM> or the service layer <NUM> can be stand-alone components in relation to other components of the computer <NUM> and other components communicably coupled to the computer <NUM>. Moreover, any or all parts of the API <NUM> or the service layer <NUM> can be implemented as child or sub-modules of another software module, enterprise application, or hardware module without departing from the scope of the present disclosure.

The computer <NUM> includes an interface <NUM>. Although illustrated as a single interface <NUM> in <FIG>, two or more interfaces <NUM> can be used according to particular needs, desires, or particular implementations of the computer <NUM> and the described functionality. The interface <NUM> can be used by the computer <NUM> for communicating with other systems that are connected to the network <NUM> (whether illustrated or not) in a distributed environment. Generally, the interface <NUM> can include, or be implemented using, logic encoded in software or hardware (or a combination of software and hardware) operable to communicate with the network <NUM>. More specifically, the interface <NUM> can include software supporting one or more communication protocols associated with communications. As such, the network <NUM> or the interface's hardware can be operable to communicate physical signals within and outside of the illustrated computer <NUM>.

The computer <NUM> also includes a database <NUM> that can hold data for the computer <NUM> and other components connected to the network <NUM> (whether illustrated or not). For example, database <NUM> can be an in-memory, conventional, or a database storing data consistent with the present disclosure. In some implementations, database <NUM> can be a combination of two or more different database types (for example, hybrid in-memory and conventional databases) according to particular needs, desires, or particular implementations of the computer <NUM> and the described functionality. Although illustrated as a single database <NUM> in <FIG>, two or more databases (of the same, different, or combination of types) can be used according to particular needs, desires, or particular implementations of the computer <NUM> and the described functionality. While database <NUM> is illustrated as an internal component of the computer <NUM>, in alternative implementations, database <NUM> can be external to the computer <NUM>.

The computer <NUM> also includes a memory <NUM> that can hold data for the computer <NUM> or a combination of components connected to the network <NUM> (whether illustrated or not). Memory <NUM> can store any data consistent with the present disclosure. In some implementations, memory <NUM> can be a combination of two or more different types of memory (for example, a combination of semiconductor and magnetic storage) according to particular needs, desires, or particular implementations of the computer <NUM> and the described functionality. Although illustrated as a single memory <NUM> in <FIG>, two or more memories <NUM> (of the same, different, or combination of types) can be used according to particular needs, desires, or particular implementations of the computer <NUM> and the described functionality. While memory <NUM> is illustrated as an internal component of the computer <NUM>, in alternative implementations, memory <NUM> can be external to the computer <NUM>.

There can be any number of computers <NUM> associated with, or external to, a computer system containing computer <NUM>, with each computer <NUM> communicating over network <NUM>. Further, the terms "client," "user," and other appropriate terminology can be used interchangeably, as appropriate, without departing from the scope of the present disclosure. Moreover, the present disclosure contemplates that many users can use one computer <NUM> and one user can use multiple computers.

Implementations of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, in tangibly embodied computer software or firmware, in computer hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Software implementations of the described subject matter can be implemented as one or more computer programs. Each computer program can include one or more modules of computer program instructions encoded on a tangible, non transitory, computer-readable computer-storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively, or additionally, the program instructions can be encoded in/on an artificially generated propagated signal. The example, the signal can be a machine-generated electrical, optical, or electromagnetic signal that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. The computer-storage medium can be a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of computer-storage mediums.

The terms "data processing apparatus," "computer," and "electronic computer device" (or equivalent as understood by one of ordinary skill in the art) refer to data processing hardware. For example, a data processing apparatus can encompass all kinds of apparatus, devices, and machines for processing data, including by way of example, a programmable processor, a computer, or multiple processors or computers. The apparatus can also include special purpose logic circuitry including, for example, a central processing unit (CPU), a field programmable gate array (FPGA), or an application specific integrated circuit (ASIC). In some implementations, the data processing apparatus or special purpose logic circuitry (or a combination of the data processing apparatus or special purpose logic circuitry) can be hardware- or software-based (or a combination of both hardware-and software-based). The apparatus can optionally include code that creates an execution environment for computer programs, for example, code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of execution environments. The present disclosure contemplates the use of data processing apparatuses with or without conventional operating systems, for example LINUX, UNIX, WINDOWS, MAC OS, ANDROID, or IOS.

A computer program, which can also be referred to or described as a program, software, a software application, a module, a software module, a script, or code, can be written in any form of programming language. Programming languages can include, for example, compiled languages, interpreted languages, declarative languages, or procedural languages. Programs can be deployed in any form, including as stand-alone programs, modules, components, subroutines, or units for use in a computing environment. A program can be stored in a portion of a file that holds other programs or data, for example, one or more scripts stored in a markup language document, in a single file dedicated to the program in question, or in multiple coordinated files storing one or more modules, sub programs, or portions of code. A computer program can be deployed for execution on one computer or on multiple computers that are located, for example, at one site or distributed across multiple sites that are interconnected by a communication network. While portions of the programs illustrated in the various figures may be shown as individual modules that implement the various features and functionality through various objects, methods, or processes, the programs can instead include a number of sub-modules, third-party services, components, and libraries. Conversely, the features and functionality of various components can be combined into single components as appropriate. Thresholds used to make computational determinations can be statically, dynamically, or both statically and dynamically determined.

Computers suitable for the execution of a computer program can be based on one or more of general and special purpose microprocessors and other kinds of CPUs. The elements of a computer are a CPU for performing or executing instructions and one or more memory devices for storing instructions and data. Generally, a CPU can receive instructions and data from (and write data to) a memory. A computer can also include, or be operatively coupled to, one or more mass storage devices for storing data. In some implementations, a computer can receive data from, and transfer data to, the mass storage devices including, for example, magnetic, magneto optical disks, or optical disks. Moreover, a computer can be embedded in another device, for example, a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a global positioning system (GPS) receiver, or a portable storage device such as a universal serial bus (USB) flash drive.

Computer readable media (transitory or non-transitory, as appropriate) suitable for storing computer program instructions and data can include all forms of permanent/non-permanent and volatile/non-volatile memory, media, and memory devices. Computer readable media can include, for example, semiconductor memory devices such as random access memory (RAM), read only memory (ROM), phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and flash memory devices. Computer readable media can also include, for example, magnetic devices such as tape, cartridges, cassettes, and internal/removable disks. Computer readable media can also include magneto optical disks and optical memory devices and technologies including, for example, digital video disc (DVD), CD ROM, DVD+/-R, DVD-RAM, DVD-ROM, HD-DVD, and BLURAY. The memory can store various objects or data, including caches, classes, frameworks, applications, modules, backup data, jobs, web pages, web page templates, data structures, database tables, repositories, and dynamic information. Types of objects and data stored in memory can include parameters, variables, algorithms, instructions, rules, constraints, and references. Additionally, the memory can include logs, policies, security or access data, and reporting files.

Implementations of the subject matter described in the present disclosure can be implemented on a computer having a display device for providing interaction with a user, including displaying information to (and receiving input from) the user. Types of display devices can include, for example, a cathode ray tube (CRT), a liquid crystal display (LCD), a light-emitting diode (LED), and a plasma monitor. Display devices can include a keyboard and pointing devices including, for example, a mouse, a trackball, or a trackpad. User input can also be provided to the computer through the use of a touchscreen, such as a tablet computer surface with pressure sensitivity or a multi-touch screen using capacitive or electric sensing. Other kinds of devices can be used to provide for interaction with a user, including to receive user feedback including, for example, sensory feedback including visual feedback, auditory feedback, or tactile feedback. Input from the user can be received in the form of acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to, and receiving documents from, a device that is used by the user. For example, the computer can send web pages to a web browser on a user's client device in response to requests received from the web browser.

The term "graphical user interface," or "GUI," can be used in the singular or the plural to describe one or more graphical user interfaces and each of the displays of a particular graphical user interface. Therefore, a GUI can represent any graphical user interface, including, but not limited to, a web browser, a touch screen, or a command line interface (CLI) that processes information and efficiently presents the information results to the user. In general, a GUI can include a plurality of user interface (UI) elements, some or all associated with a web browser, such as interactive fields, pull-down lists, and buttons. These and other UI elements can be related to or represent the functions of the web browser.

Implementations of the subject matter described in this specification can be implemented in a computing system that includes a back end component, for example, as a data server, or that includes a middleware component, for example, an application server. Moreover, the computing system can include a front-end component, for example, a client computer having one or both of a graphical user interface or a Web browser through which a user can interact with the computer. The components of the system can be interconnected by any form or medium of wireline or wireless digital data communication (or a combination of data communication) in a communication network. Examples of communication networks include a local area network (LAN), a radio access network (RAN), a metropolitan area network (MAN), a wide area network (WAN), Worldwide Interoperability for Microwave Access (WIMAX), a wireless local area network (WLAN) (for example, using <NUM> alb/g/n or <NUM> or a combination of protocols), all or a portion of the Internet, or any other communication system or systems at one or more locations (or a combination of communication networks). The network can communicate with, for example, Internet Protocol (IP) packets, frame relay frames, asynchronous transfer mode (ATM) cells, voice, video, data, or a combination of communication types between network addresses.

Cluster file systems can be any file system type accessible from multiple servers for read and update. Locking or consistency tracking may not be necessary since the locking of exchange file system can be done at application layer. Furthermore, Unicode data files can be different from non-Unicode data files.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any suitable sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Accordingly, the previously described example implementations do not define or constrain the present disclosure. Other changes, substitutions, and alterations are also possible without departing from the scope of the present disclosure as defined by the following claims.

Furthermore, any claimed implementation is considered to be applicable to at least a computer-implemented method; a non-transitory, computer-readable medium storing computer-readable instructions to perform the computer-implemented method; and a computer system comprising a computer memory interoperably coupled with a hardware processor configured to perform the computer-implemented method or the instructions stored on the non-transitory, computer-readable medium.

Claim 1:
A ball valve (<NUM>) for use in industrial pipelines, the valve comprising:
a valve body (<NUM>);
an inlet closure piece (<NUM>) attached to the valve body;
an outlet closure piece (<NUM>) attached to the valve body, the valve body, the inlet closure piece, and the outlet closure piece together defining an interior cavity;
a ball (<NUM>) disposed in the interior cavity, the ball defining a bore extending through the ball;
characterized in that the ball valve (<NUM>) comprises:
a first strain sensor (<NUM>) mounted on the inlet closure piece;
a second strain sensor (<NUM>) mounted on the outlet closure piece; and
an electronic controller system (<NUM>) in communication with the first strain sensor and the second strain sensor, the electronic control system configured to estimate the position of a pig passing through the valve by comparing an arrival time of the pig at the inlet closure and the outlet closure of the body based on signals from the first strain sensor and the second strain sensor.