FIELD OF THE DISCLOSURE

[0001] The present patent relates generally to process control systems and, in particular, to process control systems and associated monoflanges.

BACKGROUND

[0002] 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.

SUMMARY

[0003] 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.

[0004] In accordance with a second example, a process control system includes a fluidic line having a longitudinal axis and including a fluidic connection. The fluidic connection has 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 surface. The monoflange includes an outlet port and a flanged interface surrounding the outlet port of the monoflange. The monoflange includes a bleed port and 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 surface of the male portion being welded to the outlet port of the primary block valve.

[0005] In accordance with a third example, a monoflange for use with a process control system includes a primary block valve 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 to 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 is adapted to threadably engage the primary block valve of the process control system.

[0006] In accordance with a fourth 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.

[0007] In accordance with a fifth example, a monoflange includes a male portion forming an inlet port and including an external surface. The monoflange includes an outlet and a flanged interface surrounding the outlet port of the monoflange. The monoflange includes a bleed port, 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 surface of the male portion is adapted to be welded to the outlet port of the primary block valve.

[0008] In further accordance with the foregoing first, second, third, fourth, and/or fifth examples, an apparatus and/or method may further include any one or more of the following:

[0009] In an example, the primary block valve, the secondary block valve, and the bleed valve enable double block and bleed functionality.

[0010] In another example, the secondary block valve is positioned between the male portion forming the inlet port and the bleed valve.

[0011] In another example, the bleed valve is positioned between the flanged interface surrounding the outlet port and the secondary block valve.

[0012] In another example, the monoflange includes an integral body.

[0013] In another example, the integral body includes a one-piece forged valve body. [0014] In another example, further including a neck flange coupled to the flanged interface of the monoflange.

[0015] In another example, further including a gasket disposed between the neck flange and the flanged interface.

[0016] In another example, further including a diaphragm seal disposed adjacent the flanged interface.

[0017] 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.

[0018] In another example, at least one of the secondary block valve or 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.

[0019] 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.

[0020] In another example, the first portion includes slot and the second portion includes a head that is disposed within the slot.

[0021] In another example, closing the secondary block valve prevents additional process fluid flow through the secondary block valve and toward the bleed valve.

[0022] In another example, the bleed valve and the secondary block valve are positioned in a vertical plane relative to one another.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Fig. 1 illustrates a process control system assembled in accordance with a first disclosed example of the present invention.

[0024] Fig. 2 illustrates a plan view of the monoflange of the process control system of Fig. 1.

[0025] Fig. 3 illustrates a cross-sectional view of an example implementation of at least one of the secondary block valve or the bleed valve that can be used with the monoflange of the process control system of Fig. 1 .

[0026] Fig. 4 illustrates a cross-sectional view of another example implementation of at least one of the secondary block valve or the bleed valve that can be used with the monoflange of the process control system of Fig. 1 .

[0027] Fig. 5 illustrates an isometric partial cut away view of the implementation of at least one of the secondary block valve or the bleed valve of Fig. 4.

DETAILED DESCRIPTION

[0028] Although the following text discloses a detailed description of example methods, apparatus and/or articles of manufacture, it should be understood that the legal scope of the property right is defined by the words of the claims set forth at the end of this patent. Accordingly, the following detailed description is to be construed as examples only and does not describe every possible example, as describing every possible example would be impractical, if not impossible. Numerous alternative examples could be implemented, using either current technology or technology developed after the filing date of this patent. It is envisioned that such alternative examples would still fall within the scope of the claims.

[0029] Referring now to the drawings, Fig. 1 illustrates a process control system 100 assembled in accordance with a first disclosed example of the present invention. The process control system 100 may be used in association with oil production industries, refining industries, power generation industries, and/or chemical industries. Other applications may prove suitable.

[0030] In accordance with the disclosed example, the process control system 100 includes a fluidic line 102, a primary block valve 104, and a monoflange 106. The monoflange 106 may act as a manifold. The primary block valve 104 and the monoflange 106 are adapted to provide double block and bleed functionality to the process control system 100. The primary block valve 104 may be referred to as a primary isolation valve. While the process control system 100 is shown in a vertical orientation, other configurations may prove suitable. For example, the process control system may be oriented in a horizontal orientation.

[0031] In the example shown, the fluidic line 102 has a longitudinal axis 108 and includes a fluidic connection 110. The fluidic connection 110 is a T-connection having external threads 112. The fluidic connection 110 includes an axis 114 that is angled relative to the longitudinal axis 108 of the fluidic line 102. The axes 108, 114 are shown being substantially perpendicular relative to one another. However, the axes 108, 114 may be differently arranged. For example, the axes 108, 114 may be disposed at approximately 45 ^“ relative to one another.

[0032] The primary block valve 104 includes an inlet port 116 and an outlet port 118. The inlet port 116 is coupled to the fluidic connection 110. In the example shown, the inlet port 116 has internal threads 120 that threadably engage the external threads 112 of the fluidic connection 110. However, the primary block valve 104 may be coupled to the fluidic connection 110 in different ways. For example, the inlet port 116 of the primary block valve 104 may be welded to the fluidic connection 110. The outlet port 118 also includes internal threads 121 in the illustrated example.

[0033] The primary block valve 104 is illustrated as a globe valve. However, the primary block valve 104 may be a different type of valve.

[0034] The primary block valve 104 includes an actuator 122 formed as a hand wheel 124. However, the actuator 122 may be differently implemented.

[0035] In the example shown, the monoflange 106 includes a male portion 126 and a flanged interface 1 8. The male portion 1 6 opposes the flanged interface 128. The male portion 126 may be formed as a boss.

[0036] The male portion 126 forms an inlet port 130 (represented by dashed lines) and includes an external threaded surface 132 that threadably engages the outlet port 118 of the primary block valve 104. The threaded connection between the primary block valve 104 and the monoflange 106 couples the components together. As a result of providing the monoflange 106 with the male portion 126 having the external threaded surface, the monoflange 106 can be easily fluidically coupled to the primary block valve 104 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 100 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.

[0037] Referring still to Fig. 1 , the flanged interface 128 surrounds an outlet port 134 of the monoflange 106 (the outlet port 134 is more clearly shown in Fig. 2). The outlet port 134 may be used to flow process fluid to another instrument, a bleed ring, and/or a diaphragm seal.

[0038] In the example shown, the monoflange 106 also includes a bleed port 136 (represented by dashed lines) that may be used to bleed pressure and/or fluid from the process control system 100 during maintenance and/or another procedure. Additionally or alternatively, the outlet port 134 and/or the bleed port 136 may be adapted to be used as an instrument port, a calibration port, and/or to provide bleed ring functionality.

[0039] The monoflange 106 also includes a bleed valve 138 and a secondary block valve 140. The bleed valve 138 and the secondary block valve 140 may be positioned in a vertical plane 141 relative to one another. The secondary block valve 140 may be referred to as a secondary isolation valve.

[0040] In the example shown, the bleed valve 138 and/or the secondary block valve 140 may be outside screw and yoke (OS&Y) needle valves. However, other types of valves may prove suitable.

[0041] The secondary block valve 140 may be referred to as an isolation valve. The secondary block valve 140 may provide for a bubble-tight shut off. The bleed valve 138 may provide for a bubble-tight shut off.

[0042] The bleed valve 138 is adapted to control fluid flow from the bleed port 136 and the secondary block valve 140 is adapted to control fluid flow from the outlet port 134. Thus, the monoflange 106 provides single block and bleed functionality. However, other arrangements may prove suitable. For example, the monoflange 106 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.

[0043] In the example shown, the secondary block valve 140 is positioned between the male portion 126 forming the inlet port 130 and the bleed valve 138. The process control system 100 may be bleed after the secondary block valve 140 is closed. The bleed valve 138 is positioned between the flanged interface 128 surrounding the outlet port 134 and the secondary block valve 140. While the monoflange 106 is shown including two outlet ports (e.g., the outlet port 134 and the bleed port 136), providing the monoflange 106 with a different number of outlet ports may prove suitable. The monoflange 106 may include a number of valves that corresponds to the number of outlet ports.

[0044] The monoflange 106 includes a monoflange body 142. The monoflange body 142 may be integral. For example, the monoflange body 142 may be a one-piece forged valve body. Forming the monoflange body 142 as an integral body and/or a one-pieced forged valve body may allow the monoflange 106 to be field installed without non-destructive testing taking place in the field. Moreover, forming the monoflange body 142 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 100, may reduce an overall height 143 of the monoflange 106, and/or may reduce a weight of the monoflange 106. Because the monoflange 106 is relatively light, support brackets (e.g., additional support brackets) may not be used when installing the monoflange 106. Reducing the overall height of the monoflange 106 may provide the monoflange 106 with a relatively compact design and, thus, a reduced envelope size.

[0045] In the example shown, a neck flange 144 is coupled to the flanged interface 128 of the monoflange 106. The neck flange 144 is coupled to the monoflange 106 using fasteners 146. The fasteners 146 are received in threaded bores 148 (the threaded bores 148 are more clearly shown in Fig. 2) of the monoflange body 142. Other components, such as instrumentation products, may be mounted (e.g., directly mounted) to the flanged interface 128.

[0046] A layer 150 may be disposed between the neck flange 144 and the flanged interface 128. The layer 150 may be a gasket or a diaphragm seal.

[0047] Fig. 2 illustrates a plan view of the monoflange 106 of the process control system 100 of Fig. 1. In the example shown, the bleed port 136 is positioned on a first side 151 of the monoflange body 142 and the secondary block valve 140 is positioned on a second side 152 of the monoflange body 142 opposite the first side 151 . The bleed valve 138 is positioned on a third side 153 of the monoflange body 142. The third side 153 is positioned approximately 90° from the second side 152 on which the secondary block valve 140 is disposed. Other arrangements may prove suitable.

[0048] In the example shown, the bleed valve 138 and the secondary block valve 140 include a bonnet 154. The bonnet 154 includes a hex 155 and the monoflange 106 has an external monoflange surface 156 adjacent the corresponding bonnet 154. The hex 155 may be used to secure the bonnet 154 within the body of the monoflange 106. A seal 157 surrounds the bonnet 154 and is positioned between the hex 155 and the external monoflange surface 156. The seal 157 may be adapted to prevent process fluid from flowing between the external monoflange surface 156 and the bonnet 154. The seal 157 may be an O-ring.

[0049] Fig. 3 illustrates a cross-sectional view of an example implementation of at least one of the secondary block valve 140 or the bleed valve 138 that can be used with the monoflange 106 of the process control system 100 of Fig. 1. In the example shown, the bonnet 154 includes a central bore 158, external threads 160, and a distal portion 162. A stem assembly 164 is disposed within the central bore 158 of the bonnet 154.

[0050] In the example shown, the monoflange body 142 includes a threaded bore 166, a valve seat 168, and a portion 170 surrounding the valve seat 168. The valve seat 168 is formed by the monoflange body 142 and, thus, is integral to the monoflange body 142. The portion 170 may be a step including an inwardly tapered surface 172.

[0051] The external threads 160 of the bonnet 154 threadably engage the threaded bore 166 of the monoflange body 142 and the distal portion 162 of the bonnet 154 sealingly engages the portion 170 surrounding the valve seat 168. An interface 174 between the distal portion 162 of the bonnet 154 and the portion 170 of the monoflange body 142 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 162 of the bonnet 154 and the portion 170 of the monoflange body 142.

[0052] The interface 174 between the distal portion 162 and the portion 170 surrounding the valve seat 168 is spaced from the external threads 160 of the bonnet 154. As a result of the spacing, the external threads 160 may be isolated from the process fluid.

[0053] Fig. 4 illustrates a cross-sectional view of another example implementation of at least one of the secondary block valve 140 or the bleed valve 138 that can be used with the monoflange 106 of the process control system 100 of Fig. 1.

[0054] In the example shown, the bonnet 154 includes the central bore 158 and the external threads 160. A central bore surface 176 defines the central bore 158 that includes internal bonnet threads 178 and defines a packing step 180.

[0055] Packing 182 is disposed within the central bore 158 adjacent the packing step 180.

[0056] A packing nut 184 is disposed within the central bore 158 and extends from the bonnet 154. The packing nut 184 includes external threads 186 that threadably engage the internal bonnet threads 178 of the central bore surface 178. The packing nut 184 includes a packing nut bore surface 188 that includes internal threads 190. The packing nut 184 is adapted to compress the packing 182 against the stem assembly 164. [0057] The stem assembly 164 is disposed within the central bore 158. In contrast to the stem assembly 164 of Fig. 3, the stem assembly 164 of Fig. 4 includes an upper stem portion 192 and a lower stem portion 194. The upper stem portion 192 is rotationally coupled to the lower stem portion 194. In the example shown, rotationally coupling the upper stem portion 192 and the lower stem portion 194 allows rotational movement of the upper stem portion 192 to not correspondingly rotate (or minimally rotate) the lower stem portion 194. Thus, the upper stem portion 192 may both rotationally and linearly move while the lower stem portion 194 linearly moves but the lower stem portion 194 may not rotationally move. Not rotating or minimally rotating the lower stem portion 194 may allow increased sealing engagement between the packing 182 and the lower stem portion 194. In the example shown, rotationally coupling the upper stem portion 192 and the lower stem portion 194 allows linear movement of the upper stem portion 192 to correspondingly move the lower stem portion 194. Thus, when the upper stem portion 192 is rotated and moves in a direction generally indicated by arrow 196, via the threaded engagement with the packing nut 184, the lower stem portion 194 correspondingly moves in the direction generally indicated by arrow 196.

[0058] In the example shown, the upper stem portion 192 includes a distal end 198 having a slot 200 that includes a lateral opening 202 and an end opening 204. The lower stem portion 194 includes a proximal end 206 that includes a head 208 that is adapted to be received within the slot 200 of the upper stem portion 192 to rotationally couple the upper stem portion 192 and the lower stem portion 194.

[0059] The distal end 198 of the upper stem portion 192 may include a pair of space-apart prongs 210 (the prongs 210 are more clearly shown in Fig. 5). The prongs 210 are shown defining the end opening 204. The proximal end 206 of the lower stem portion 194 includes a necked portion 212 that is disposed between the prongs 210. The head 208 of the lower stem portion 194 is passed through the lateral opening 202 to position the prongs 210 about the necked portion 212 of the lower stem portion 194. The head 208 of the lower stem portion 194 engages a surface of the prongs 210 to form the rotational coupling between the upper stem portion 192 and the lower stem portion 194.

[0060] In the example shown, the central bore surface 176 of the bonnet 154 includes a bonnet blowout stop 214. The bonnet blowout stop 214 may be formed as an internal step. The bonnet blowout stop 214 may be internally tapered. Flowever, the bonnet blowout stop 214 may not be internally tapered. The lower stem portion 194 includes a distal end 216 having a blowout shoulder 218 that is adapted to engage the bonnet blow out stop 214. [0061] In the example shown, the packing nut 184 includes a central internal portion 220 and a packing blowout stop 222. The packing blowout stop 222 is disposed adjacent and/or formed by the central internal portion 220. The distal end 198 of the upper step portion 192 includes a blowout shoulder 224 that is adapted to engage the packing blowout stop 222.

[0062] The lower stem portion 194 includes the distal end 216 that includes a plug 228. In the example shown, the plug 228 is a ball 230 carried by the distal end 216 of the lower stem portion 194. Other types of plugs may prove suitable.

[0063] Fig. 5 illustrates an isometric partial cut-away view of the secondary block valve 140 or the bleed valve 138 of Fig. 4. In the example shown, the stem assembly 164 includes the upper and lower stem portions 192, 194 that are coupled in a manner that allow rotational and linear movement of the upper stem portion 192 to correspondingly linearly move the lower stem portion 192. Flowever, the upper stem portion 192 being rotated does not correspondingly move the lower stem portion 192.

[0064] The disclosed examples may be adapted to isolate and vent process media(s) using a single body for valving configurations and piping adaptations. Moreover, the disclosed examples allow weight to be reduced, the envelope size to be , external supports (bracing) may not be used to support the monoflange, and/or the visibility of the actuator handles allow users to visually see the position of the actuator handle and, thus, the valve.

[0065] Further, while several examples have been disclosed herein, any features from any examples may be combined with or replaced by other features from other examples. Moreover, while several examples have been disclosed herein, changes may be made to the disclosed examples within departing from the scope of the claims.