Patent Description:
Process control systems may include fluidic lines and different fluidic connections. Process control valves may be used to control fluid flow between the fluidic lines. Depending on the industry in which the process control systems are included, non-destructive testing may be performed on welded joints between the fluidic lines and the process control valves. Document <CIT> discloses method and apparatus for unplugging hydrocarbon drains or vents including a fluidic line, a primary valve and several connected valves. Another document discloses: "<NPL>].

According to claim <NUM> of the invention and in accordance with a first example, a process control system includes a fluidic line having a longitudinal axis and including a fluidic connection having an axis angled relative to the longitudinal axis of the fluidic line. The process control system includes a primary block valve having an inlet port and an outlet port. The inlet port is coupled to the fluidic connection. The process control system includes a monoflange including a male portion forming an inlet port and including an external threaded surface. The monoflange includes an outlet and a flanged interface surrounding the outlet port of the monoflange. The monoflange includes a bleed port. The monoflange includes a bleed valve adapted to control fluid flow from the bleed port and a secondary block valve adapted to control fluid flow from the outlet port. The external threaded surface of the male portion threadably engages the outlet port of the primary block valve.

According to claim <NUM> of the invention and in accordance with a second example, a method includes threadably engaging an outlet port of a primary block valve with an external threaded surface of a male portion of a monoflange. The primary block valve has an inlet port coupled to a fluidic connection of a fluidic line. The monoflange includes the male portion forming an inlet port, a flanged interface surrounding an outlet port of the monoflange, and a bleed port. The monoflange further includes a bleed valve and a secondary block valve. The method includes actuating the secondary block valve to control fluid flow from the outlet port and actuating the bleed valve to control fluid flow from the bleed port.

In further accordance with the foregoing first and/or second examples, an apparatus and/or method may further include any one or more of the following:.

In an example, the primary block valve, the secondary block valve, and the bleed valve enable double block and bleed functionality.

In another example, the secondary block valve is positioned between the male portion forming the inlet port and the bleed valve.

In another example, the bleed valve is positioned between the flanged interface surrounding the outlet port and the secondary block valve.

In another example, the monoflange includes an integral body.

In another example, the integral body includes a one-piece forged valve body.

In another example, further including a neck flange coupled to the flanged interface of the monoflange.

In another example, further including a gasket disposed between the neck flange and the flanged interface.

In another example, further including a diaphragm seal disposed adjacent the flanged interface.

In another example, at least one of the secondary block valve or the bleed valve includes a bonnet having a bonnet flange and the monoflange includes an external monoflange surface adjacent the corresponding bonnet. Further including a seal surrounding the bonnet and positioned between the bonnet flange and the external monoflange surface.

According to the invention, the secondary block valve and, optionally, the bleed valve include a bonnet having a central bore, external threads, and a distal portion. A stem assembly is disposed within the central bore. A body of the monoflange includes a threaded bore, a valve seat, and a portion surrounding the valve seat. The external threads of the bonnet threadably engage the threaded bore and the distal portion sealingly engages the portion surrounding the valve seat.

In another example, at least one of the secondary block valve or the bleed valve includes a bonnet, a plug, and a stem assembly including a first portion that threadably engages the bonnet and a second portion that carries the plug and is rotationally coupled to the first portion.

In another example, the first portion includes slot and the second portion includes a head that is disposed within the slot.

In another example, closing the secondary block valve prevents additional process fluid flow through the secondary block valve and toward the bleed valve.

According to the invention, the bleed valve and the secondary block valve are positioned in a vertical plane relative to one another.

Referring now to the drawings, <FIG> illustrates a process control system <NUM> assembled in accordance with a first disclosed example of the present invention. The process control system <NUM> may be used in association with oil production industries, refining industries, power generation industries, and/or chemical industries. Other applications may prove suitable.

In accordance with the disclosed example, the process control system <NUM> includes a fluidic line <NUM>, a primary block valve <NUM>, and a monoflange <NUM>. The monoflange <NUM> may act as a manifold. The primary block valve <NUM> and the monoflange <NUM> are adapted to provide double block and bleed functionality to the process control system <NUM>. The primary block valve <NUM> may be referred to as a primary isolation valve. While the process control system <NUM> is shown in a vertical orientation, other configurations may prove suitable. For example, the process control system may be oriented in a horizontal orientation.

In the example shown, the fluidic line <NUM> has a longitudinal axis <NUM> and includes a fluidic connection <NUM>. The fluidic connection <NUM> is a T-connection having external threads <NUM>. The fluidic connection <NUM> includes an axis <NUM> that is angled relative to the longitudinal axis <NUM> of the fluidic line <NUM>. The axes <NUM>, <NUM> are shown being substantially perpendicular relative to one another. However, the axes <NUM>, <NUM> may be differently arranged. For example, the axes <NUM>, <NUM> may be disposed at approximately <NUM>° relative to one another.

The primary block valve <NUM> includes an inlet port <NUM> and an outlet port <NUM>. The inlet port <NUM> is coupled to the fluidic connection <NUM>. In the example shown, the inlet port <NUM> has internal threads <NUM> that threadably engage the external threads <NUM> of the fluidic connection <NUM>. However, the primary block valve <NUM> may be coupled to the fluidic connection <NUM> in different ways. For example, not according to the invention, the inlet port <NUM> of the primary block valve <NUM> may be welded to the fluidic connection <NUM>. The outlet port <NUM> also includes internal threads <NUM> in the illustrated example.

The primary block valve <NUM> is illustrated as a globe valve. However, the primary block valve <NUM> may be a different type of valve.

The primary block valve <NUM> includes an actuator <NUM> formed as a hand wheel <NUM>. However, the actuator <NUM> may be differently implemented.

In the example shown, the monoflange <NUM> includes a male portion <NUM> and a flanged interface <NUM>. The male portion <NUM> opposes the flanged interface <NUM>. The male portion <NUM> may be formed as a boss.

The male portion <NUM> forms an inlet port <NUM> (represented by dashed lines) and includes an external threaded surface <NUM> that threadably engages the outlet port <NUM> of the primary block valve <NUM>. The threaded connection between the primary block valve <NUM> and the monoflange <NUM> couples the components together. As a result of providing the monoflange <NUM> with the male portion <NUM> having the external threaded surface, the monoflange <NUM> can be easily fluidically coupled to the primary block valve <NUM> without requiring additional fluidic connections (e.g., piping) and/or without requiring a welded fluidic connection. Because a welded connection may not be present (or a number of welded connections may be reduced) in the process control system <NUM> as compared to some known process control systems, the disclosed examples may be field installed with less or no non-destructive testing taking place. While the above discloses threaded connections, one or more of the connections may be welded. However, other types of couplings may prove suitable.

Referring still to <FIG>, the flanged interface <NUM> surrounds an outlet port <NUM> of the monoflange <NUM> (the outlet port <NUM> is more clearly shown in <FIG>). The outlet port <NUM> may be used to flow process fluid to another instrument, a bleed ring, and/or a diaphragm seal.

In the example shown, the monoflange <NUM> also includes a bleed port <NUM> (represented by dashed lines) that may be used to bleed pressure and/or fluid from the process control system <NUM> during maintenance and/or another procedure. Additionally or alternatively, the outlet port <NUM> and/or the bleed port <NUM> may be adapted to be used as an instrument port, a calibration port, and/or to provide bleed ring functionality.

The monoflange <NUM> also includes a bleed valve <NUM> and a secondary block valve <NUM>. The bleed valve <NUM> and the secondary block valve <NUM> may be positioned in a vertical plane <NUM> relative to one another. The secondary block valve <NUM> may be referred to as a secondary isolation valve.

In the example shown, the bleed valve <NUM> and/or the secondary block valve <NUM> may be outside screw and yoke (OS&Y) needle valves. However, other types of valves may prove suitable.

The secondary block valve <NUM> may be referred to as an isolation valve. The secondary block valve <NUM> may provide for a bubble-tight shut off. The bleed valve <NUM> may provide for a bubble-tight shut off.

The bleed valve <NUM> is adapted to control fluid flow from the bleed port <NUM> and the secondary block valve <NUM> is adapted to control fluid flow from the outlet port <NUM>. Thus, the monoflange <NUM> provides single block and bleed functionality. However, other arrangements may prove suitable. For example, the monoflange <NUM> may be adapted to provide single block functionality, double block functionality, double block and bleed functionality, and/or single block and double bleed functionality. A corresponding number of valves and ports may be provided depending on the arrangement.

In the example shown, the secondary block valve <NUM> is positioned between the male portion <NUM> forming the inlet port <NUM> and the bleed valve <NUM>. The process control system <NUM> may be bleed after the secondary block valve <NUM> is closed. The bleed valve <NUM> is positioned between the flanged interface <NUM> surrounding the outlet port <NUM> and the secondary block valve <NUM>. While the monoflange <NUM> is shown including two outlet ports (e.g., the outlet port <NUM> and the bleed port <NUM>), providing the monoflange <NUM> with a different number of outlet ports may prove suitable. The monoflange <NUM> may include a number of valves that corresponds to the number of outlet ports.

The monoflange <NUM> includes a monoflange body <NUM>. The monoflange body <NUM> may be integral. For example, the monoflange body <NUM> may be a one-piece forged valve body. Forming the monoflange body <NUM> as an integral body and/or a one-pieced forged valve body may allow the monoflange <NUM> to be field installed without non-destructive testing taking place in the field. Moreover, forming the monoflange body <NUM> as an integral body and/or a one-pieced forged valve body may reduce leak paths, may reduce the number of joints (e.g., less additional fluidic couplings / lines) within the process control system <NUM>, may reduce an overall height <NUM> of the monoflange <NUM>, and/or may reduce a weight of the monoflange <NUM>. Because the monoflange <NUM> is relatively light, support brackets (e.g., additional support brackets) may not be used when installing the monoflange <NUM>. Reducing the overall height of the monoflange <NUM> may provide the monoflange <NUM> with a relatively compact design and, thus, a reduced envelope size.

In the example shown, a neck flange <NUM> is coupled to the flanged interface <NUM> of the monoflange <NUM>. The neck flange <NUM> is coupled to the monoflange <NUM> using fasteners <NUM>. The fasteners <NUM> are received in threaded bores <NUM> (the threaded bores <NUM> are more clearly shown in <FIG>) of the monoflange body <NUM>. Other components, such as instrumentation products, may be mounted (e.g., directly mounted) to the flanged interface <NUM>.

A layer <NUM> may be disposed between the neck flange <NUM> and the flanged interface <NUM>. The layer <NUM> may be a gasket or a diaphragm seal.

<FIG> illustrates a plan view of the monoflange <NUM> of the process control system <NUM> of <FIG>. In the example shown, the bleed port <NUM> is positioned on a first side <NUM> of the monoflange body <NUM> and the secondary block valve <NUM> is positioned on a second side <NUM> of the monoflange body <NUM> opposite the first side <NUM>. The bleed valve <NUM> is positioned on a third side <NUM> of the monoflange body <NUM>. The third side <NUM> is positioned approximately <NUM>° from the second side <NUM> on which the secondary block valve <NUM> is disposed. Other arrangements may prove suitable.

In the example shown, the bleed valve <NUM> and the secondary block valve <NUM> include a bonnet <NUM>. The bonnet <NUM> includes a hex <NUM> and the monoflange <NUM> has an external monoflange surface <NUM> adjacent the corresponding bonnet <NUM>. The hex <NUM> may be used to secure the bonnet <NUM> within the body of the monoflange <NUM>. A seal <NUM> surrounds the bonnet <NUM> and is positioned between the hex <NUM> and the external monoflange surface <NUM>. The seal <NUM> may be adapted to prevent process fluid from flowing between the external monoflange surface <NUM> and the bonnet <NUM>. The seal <NUM> may be an O-ring.

<FIG> illustrates a cross-sectional view of an example implementation of at least one of the secondary block valve <NUM> or the bleed valve <NUM> that can be used with the monoflange <NUM> of the process control system <NUM> of <FIG>. In the example shown, the bonnet <NUM> includes a central bore <NUM>, external threads <NUM>, and a distal portion <NUM>. A stem assembly <NUM> is disposed within the central bore <NUM> of the bonnet <NUM>.

In the example shown, the monoflange body <NUM> includes a threaded bore <NUM>, a valve seat <NUM>, and a portion <NUM> surrounding the valve seat <NUM>. The valve seat <NUM> is formed by the monoflange body <NUM> and, thus, is integral to the monoflange body <NUM>. The portion <NUM> may be a step including an inwardly tapered surface <NUM>.

The external threads <NUM> of the bonnet <NUM> threadably engage the threaded bore <NUM> of the monoflange body <NUM> and the distal portion <NUM> of the bonnet <NUM> sealingly engages the portion <NUM> surrounding the valve seat <NUM>. An interface <NUM> between the distal portion <NUM> of the bonnet <NUM> and the portion <NUM> of the monoflange body <NUM> is a metal-to-metal seal. However, another type of seal may prove suitable. For example, a gasket may be positioned between the distal portion <NUM> of the bonnet <NUM> and the portion <NUM> of the monoflange body <NUM>.

The interface <NUM> between the distal portion <NUM> and the portion <NUM> surrounding the valve seat <NUM> is spaced from the external threads <NUM> of the bonnet <NUM>. As a result of the spacing, the external threads <NUM> may be isolated from the process fluid.

<FIG> illustrates a cross-sectional view of another example implementation of at least one of the secondary block valve <NUM> or the bleed valve <NUM> that can be used with the monoflange <NUM> of the process control system <NUM> of <FIG>.

In the example shown, the bonnet <NUM> includes the central bore <NUM> and the external threads <NUM>. A central bore surface <NUM> defines the central bore <NUM> that includes internal bonnet threads <NUM> and defines a packing step <NUM>.

Packing <NUM> is disposed within the central bore <NUM> adjacent the packing step <NUM>.

A packing nut <NUM> is disposed within the central bore <NUM> and extends from the bonnet <NUM>. The packing nut <NUM> includes external threads <NUM> that threadably engage the internal bonnet threads <NUM> of the central bore surface <NUM>. The packing nut <NUM> includes a packing nut bore surface <NUM> that includes internal threads <NUM>. The packing nut <NUM> is adapted to compress the packing <NUM> against the stem assembly <NUM>.

The stem assembly <NUM> is disposed within the central bore <NUM>. In contrast to the stem assembly <NUM> of <FIG>, the stem assembly <NUM> of <FIG> includes an upper stem portion <NUM> and a lower stem portion <NUM>. The upper stem portion <NUM> is rotationally coupled to the lower stem portion <NUM>. In the example shown, rotationally coupling the upper stem portion <NUM> and the lower stem portion <NUM> allows rotational movement of the upper stem portion <NUM> to not correspondingly rotate (or minimally rotate) the lower stem portion <NUM>. Thus, the upper stem portion <NUM> may both rotationally and linearly move while the lower stem portion <NUM> linearly moves but the lower stem portion <NUM> may not rotationally move. Not rotating or minimally rotating the lower stem portion <NUM> may allow increased sealing engagement between the packing <NUM> and the lower stem portion <NUM>. In the example shown, rotationally coupling the upper stem portion <NUM> and the lower stem portion <NUM> allows linear movement of the upper stem portion <NUM> to correspondingly move the lower stem portion <NUM>. Thus, when the upper stem portion <NUM> is rotated and moves in a direction generally indicated by arrow <NUM>, via the threaded engagement with the packing nut <NUM>, the lower stem portion <NUM> correspondingly moves in the direction generally indicated by arrow <NUM>.

In the example shown, the upper stem portion <NUM> includes a distal end <NUM> having a slot <NUM> that includes a lateral opening <NUM> and an end opening <NUM>. The lower stem portion <NUM> includes a proximal end <NUM> that includes a head <NUM> that is adapted to be received within the slot <NUM> of the upper stem portion <NUM> to rotationally couple the upper stem portion <NUM> and the lower stem portion <NUM>.

The distal end <NUM> of the upper stem portion <NUM> may include a pair of space-apart prongs <NUM> (the prongs <NUM> are more clearly shown in <FIG>). The prongs <NUM> are shown defining the end opening <NUM>. The proximal end <NUM> of the lower stem portion <NUM> includes a necked portion <NUM> that is disposed between the prongs <NUM>. The head <NUM> of the lower stem portion <NUM> is passed through the lateral opening <NUM> to position the prongs <NUM> about the necked portion <NUM> of the lower stem portion <NUM>. The head <NUM> of the lower stem portion <NUM> engages a surface of the prongs <NUM> to form the rotational coupling between the upper stem portion <NUM> and the lower stem portion <NUM>.

In the example shown, the central bore surface <NUM> of the bonnet <NUM> includes a bonnet blowout stop <NUM>. The bonnet blowout stop <NUM> may be formed as an internal step. The bonnet blowout stop <NUM> may be internally tapered. However, the bonnet blowout stop <NUM> may not be internally tapered. The lower stem portion <NUM> includes a distal end <NUM> having a blowout shoulder <NUM> that is adapted to engage the bonnet blow out stop <NUM>.

In the example shown, the packing nut <NUM> includes a central internal portion <NUM> and a packing blowout stop <NUM>. The packing blowout stop <NUM> is disposed adjacent and/or formed by the central internal portion <NUM>. The distal end <NUM> of the upper step portion <NUM> includes a blowout shoulder <NUM> that is adapted to engage the packing blowout stop <NUM>.

The lower stem portion <NUM> includes the distal end <NUM> that includes a plug <NUM>. In the example shown, the plug <NUM> is a ball <NUM> carried by the distal end <NUM> of the lower stem portion <NUM>. Other types of plugs may prove suitable.

<FIG> illustrates an isometric partial cut-away view of the secondary block valve <NUM> or the bleed valve <NUM> of <FIG>. In the example shown, the stem assembly <NUM> includes the upper and lower stem portions <NUM>, <NUM> that are coupled in a manner that allow rotational and linear movement of the upper stem portion <NUM> to correspondingly linearly move the lower stem portion <NUM>. However, the upper stem portion <NUM> being rotated does not correspondingly move the lower stem portion <NUM>.

Claim 1:
A process control system (<NUM>) comprising:
a fluidic line (<NUM>) having a longitudinal axis (<NUM>) and comprising a fluidic T-connection (<NUM>) having an axis (<NUM>) angled relative to the longitudinal axis (<NUM>) of the fluidic line (<NUM>);
a primary block valve (<NUM>) having an inlet port (<NUM>) and an outlet port (<NUM>), the inlet port (<NUM>) has internal threads (<NUM>) that threadably engage external threads (<NUM>) of the fluidic T-connection (<NUM>); and
a monoflange (<NUM>) comprising:
a male portion (<NUM>) forming an inlet port (<NUM>) in line with the axis (<NUM>) of the fluidic T-connection (<NUM>) and comprising an external threaded surface (<NUM>);
an outlet port (<NUM>) in line with the axis (<NUM>) of the fluidic T-connection (<NUM>);
a flanged interface (<NUM>) surrounding the outlet port (<NUM>) of the monoflange (<NUM>);
a bleed port (<NUM>);
a bleed valve (<NUM>) having a valve seat (<NUM>), wherein the valve seat (<NUM>) is formed by a body (<NUM>) of the monoflange (<NUM>) and, as such, is disposed within and integral with the body (<NUM>) of the monoflange (<NUM>) and adapted to control fluid flow from the bleed port (<NUM>); and
a secondary block valve (<NUM>) having a valve seat, wherein the valve seat is formed by the body (<NUM>) of the monoflange (<NUM>) and, as such, is disposed within and integral with the body (<NUM>) of the monoflange (<NUM>) and adapted to control fluid flow from the outlet port (<NUM>), the secondary block valve (<NUM>) includes a bonnet having a bonnet flange and the monoflange includes an external monoflange surface adjacent the corresponding bonnet, wherein external threads (<NUM>) of the bonnet (<NUM>) threadably engage the threaded bore (<NUM>) of the body (<NUM>) of the monoflange (<NUM>);
wherein the external threaded surface (<NUM>) of the male portion (<NUM>) threadably engages the outlet port (<NUM>) of the primary block valve (<NUM>);
wherein the bleed valve (<NUM>) and the secondary block valve (<NUM>) are positioned on sides of the monoflange body (<NUM>), wherein the sides of the body (<NUM>) of the monoflange (<NUM>) are positioned approximately <NUM>° to each other; and
further wherein the bleed valve (<NUM>) and the secondary block valve (<NUM>) are positioned in a vertical plane (<NUM>) relative to one another.