Integration of fluid paths into the valve superstructure

Abstract

The superstructures are configured for use with flow control devices, such as control valves. These configurations can have internal piping for transporting fluid between valve components. In one implementation, the piping connects a controller to an actuator, allowing a pneumatic signal from the controller to pressurize the actuator. The internal piping eliminates the need for external pipes or tubing. This feature can simplify assembly and reduce the overall package size of the valve, avoiding potential fit or interference issues at its location on the process line.

Description

[Technical Field]

[0001] Flow control devices play a major role in many industrial facilities. For example, power plants and industrial processing facilities use different types of flow control devices to manage the flow of materials, typically fluids, throughout vast networks of pipes, tanks, generators, and other equipment. Valves, some known as "control valves," are a type of flow control device that actively controls the flow of materials within a process line. These devices often embody an assembly of several parts on a main "superstructure." On the one hand, this multi-part design is useful because it provides operators with a precise and steady flow of material across the process line. However, on the other hand, the specific geometry or physical attributes of the parts can complicate manufacturing or assembly, increase cost of ownership, or in some cases, hinder line layout due to fit or interference issues found in the field. Summary of the Invention

[0002] The subject matter of this disclosure relates to improvements to address accuracy issues in control valves. Of particular interest are embodiments having a superstructure with certain features integrated therein. Using this superstructure design allows for the assembly of a flow control device with fewer parts. This feature results in a more compact design with a smaller footprint, and therefore a less obtrusive package, more adaptable to smaller installation spaces or "envelopes" on process lines. [Brief explanation of the drawings]

[0003] Reference will now be made briefly to the accompanying drawings, in which: [Figure 1] 1 depicts a schematic diagram of an exemplary embodiment of a superstructure; [Figure 2] 2 illustrates a perspective view of an exemplary structure of the superstructure of FIG. 1; [Figure 3] 3 illustrates a cross-sectional elevation view of the superstructure of FIG. 2 from the side. [Figure 4] 1 depicts a perspective view of an example flow control device in a partially assembled configuration. [Figure 5] 5 depicts a cross-sectional side elevation view of the flow control device of FIG. 4.

[0004] Where applicable, like reference characters designate identical or corresponding components and units throughout the several figures, which are not to scale unless otherwise indicated. Embodiments disclosed herein may include elements that appear in more than one of the several figures or in combinations of multiple figures. Moreover, the methods are merely illustrative and may be modified, for example, by reordering, adding, removing, and / or altering individual steps.

[0005] The drawings and any descriptions herein use examples to disclose the invention. These examples, including the best mode, enable any person skilled in the art to practice the invention, including making and using any device or system and performing any incorporated methods. Elements or features described in the singular and preceded by the words "a" or "an" should be understood as not excluding a plurality of such elements or features, unless such exclusion is expressly stated. References to "one embodiment" or "one implementation" should not be interpreted as excluding the existence of additional embodiments or implementations that also incorporate the recited features. DETAILED DESCRIPTION OF THE INVENTION

[0006] Features of the embodiments shown in the above figures will now be described. These features may rely on advanced manufacturing techniques, such as additive or "3-D" manufacturing techniques. The use of these techniques allows for complex geometries that may not easily fit into more standard subtractive (or machining) operations. The designs herein may, for example, provide piping or passageways in the superstructure that can carry fluid flow under sustained pressure. This feature, in turn, may eliminate the need for external pipes or conduits that may extend the operating range of the flow control device beyond operator specifications. Other embodiments are contemplated within the scope and spirit of the present disclosure.

[0007] FIG. 1 depicts a schematic diagram of an example superstructure 100. This embodiment is typically found in a distribution network 102 designed to convey material 104 throughout a network of conduits 106. The superstructure 100 may be part of a flow control device 108 having a valve subassembly 110 connected in series with the conduits 106. The valve subassembly 110 may contain a seat 112 and a closure member 114 that may be moved to various positions relative to the seat 112 to regulate the flow of material 104. A valve stem 116 may connect the closure member 114 to an actuator 118 that includes a piston assembly 120. A controller 122 may have operating hardware 124 that interfaces with a plant instrument air supply (or "instrument air") and is capable of converting an input electronic control signal S1 (e.g., a 4-20 mA signal) into an actuator control signal S2 that pressurizes the actuator 118. In one implementation, the upper structure 100 can include a yoke 126 having features that direct an actuator control signal S2 to energize the actuator 118.

[0008] Generally, the superstructure 100 may be configured to support other components of the valve assembly below. These configurations can provide a stable platform for both the flow control device (e.g., valve) and the actuation mechanism (e.g., pneumatic actuator). This platform typically requires a robust design with sufficient strength to withstand forces, moments, torques, or vibrations compatible with industrial applications. As mentioned herein, the platform design can include integral features such as flow channels that allow air or fluid to pass from or between different parts of the assembly. Advantageously, this feature can reduce the size of the device, eliminating the need for piping external to the superstructure. The smaller size can fit into "tighter" spaces compared to conventional devices that use external pipe networks.

[0009] Distribution systems 102 may be configured to deliver or move resources. These configurations may embody vast infrastructures. Materials 104 may include gases, liquids, solids, or even mixtures. Conduits 106 may include pipes or pipelines that often connect to pumps, boilers, etc. Pipes may also connect to tanks or reservoirs. In many facilities, this equipment forms a complex network.

[0010] Flow control devices 108 can be configured to regulate the flow of material 104 through the conduits 106 in this complex network. These configurations can include control valves and similar devices. The valve assemblies 110 in such devices are often made from cast or machined forgings. The structures can form flanges at openings I and O. Adjacent pipes 106 can connect to these flanges to allow material 104 to flow through the device, for example, through openings in the seat 112. The closure member 114 can embody a metal disk or metal "plug." The valve stem 116 can embody an elongated cylinder or rod that connects to the plug at one end. The other end of the rod can be coupled to an actuator 118. Often, a piston assembly 120 within the actuator 118 can include a piston and spring that together generate a load on the valve stem 116. This load adjusts the position of the plug 114, which in turn manages the flow of material 104 through the seat 112 and into the pipe 106 downstream of the device.

[0011] The controller 122 can be configured to process and generate signals. These configurations can be connected to a control network (or “distributed control system” or “DCS”), which maintains the operation of all devices on the process line to ensure that material flows according to the process. The DCS can generate control signals having operating parameters, including “set points,” that describe or define the operation of the control valve 108 for this purpose. The operating hardware 124 can use electrical and computing components (e.g., processors, memory, executable instructions, etc.). These components can also include electro-pneumatic devices that operate on the input pneumatic supply signal S1. These components ensure that the output actuator control signal S2 to the actuator 118 is appropriate for the control valve 108 to deliver material 104 downstream according to the process parameters.

[0012] The yoke 126 may be configured to carry the control signal S2. These configurations may incorporate internal or integral flow paths that may be present within the material structure of the device. These internal flow paths may connect the actuator 118 and the controller 122. In this manner, flow between these devices may occur without the need for external tubing that may interfere with the use or operation of the flow control device 108 at its location on the process line.

[0013] FIG. 2 depicts a perspective view of an example of a yoke 126. This example can optionally include a stiffened structure 128 made of a material such as a metal or composite. The material can exhibit properties robust enough to withstand corrosive or harsh environments synonymous with the hydrocarbon industry. These materials may also benefit designs compatible with additive manufacturing techniques, as these techniques are useful for providing certain features of this design that occur in a single, integrated form. As shown, the stiffened structure 128 can have an end 130 configured and arranged to receive different portions of the flow control device 108 for final assembly of the device. The end 130 can include a valve mount 132 featuring a generally planar interface plate 134 having a central aperture 136. The plate 134 can receive a portion of the valve subassembly 110. This portion, sometimes referred to as a "bonnet," can provide threaded regions for receiving fasteners (e.g., bolts) that pass through the plate 134. Tightening these fasteners secures the valve subassembly 110 to the yoke 126. A central aperture 136 may allow the valve stem 116 to extend through the plate 134. A pair of uprights 138 may be present on either side of the valve stem 116. The uprights 138 may have a first end that mates with the interface plate 134. A second end may be secured to an actuator mount 140. In one implementation, the actuator mount 140 may form a first portion of the actuator 118. This first portion may embody a lower casing 142 that mates with the second end of the uprights 138. The lower casing 142 may have a peripheral wall 146 that circumscribes the central axis A. The wall 146 may terminate in a flanged outer edge 148 with an opening 150 disposed therein. The peripheral wall 146 may form a rounded, bowl-shaped member. However, other geometries may prevail as well. The openings 150 may be present in the flanged outer edge 148 and are preferably evenly spaced from one another around the circumference thereof.As also shown, the yoke 126 may include a control mount 152 having an arm 154 extending generally horizontally outward from the upright 138. The arm 154 may terminate in an interface plate 156 having a large opening 158. A mounting hole 160 may be present adjacent to the opening 158. The hole 160 may be used to receive a fastener that attaches the controller 122 to the interface plate 156. A port 162 may also extend through the plate 156. The port 162 may align with a corresponding outlet on the controller 122.

[0014] FIG. 3 depicts a cross-sectional elevation view of a side of the yoke 126 of FIG. 2. The port 162 can form an inlet to the flow passage 164. In one implementation, the flow passage 164 can form a bore 166 inside the yoke 126, including the upright 138 or the arm 152. The bore 166 acts as a conduit to transport a fluid, such as air. This conduit can have a substantially continuous interior surface that prevents leakage. Additive manufacturing techniques can prove important to establishing this type of integrated geometry. Also as shown, the bore 166 can terminate in a port 168, shown here as residing within the confines of the peripheral wall 146. The port 168 can form an outlet to the flow passage 164. This feature allows air to enter the interior of the bowl-shaped member.

[0015] FIG. 4 depicts a perspective view of the yoke 126 as part of an example of a flow control device 108. This example has an upper casing 144 attached to a lower casing 142. The upper casing 144 may employ the bowl-shaped member shape described above, with a peripheral wall 146 having a flange 148 with an opening 150. The openings 150 in both members 142, 144 may accept fasteners. For example, nuts and bolts may be used to fasten the flange 148 of the bowl-shaped member 146 together to form a sealed, airtight enclosure. The controller 122 may be secured to its mount 152 so that its "outlet" is aligned with the inlet 162 to the flow passage 164. This feature allows the output actuator control signal S2 to pass through the flow passage 166 to the outlet 168 of the lower member 142. This signal pressurizes the sealed enclosure of the actuator 118.

[0016] 5 shows an elevational view of a cross section of the example of FIG. 4. The sealed enclosure may house the piston assembly 120 described above. The piston assembly 120 may include a piston 172. The valve stem 116 may be attached to the piston 172 using, for example, a threaded end and nut arrangement 174. The device may also include one or more springs 176. Deflection of the spring 176, together with internal pressure due to the actuator control signal S2, may generate a spring load that adjusts the position of the closure member 114 relative to the seat 112.

[0017] In light of the above, integral flow paths within the yoke can be beneficial to the design. These features can transport pressurized air that would normally require external conduits. The result is a more compact assembly with a smaller design envelope. This assembly can alleviate some of the fitment issues that may arise in the field as part of facility construction. These issues can prevent the use of certain devices or, in some cases, costly redesign or retrofit.

[0018] To illustrate embodiments contemplated within the scope and spirit of the present disclosure, the following examples include particular elements or items, one or more of which may be combined with other elements and items. This scope includes and is contemplated by those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they have equivalent structural elements that differ insignificantly from the literal language of the claims.

Claims

1. A flow control device, a yoke having a first end and a second end, the yoke having a mount and a bore extending from an inlet in the mount to an outlet in the second end; a controller secured to the mount, the controller configured to deliver a pressurized signal into the opening.

2. The flow control device of claim 1 , wherein the bore defines a non-linear passage through the material of the yoke.

3. The flow control device of claim 1 , wherein the bore has a continuous interior surface.

4. The flow control device of claim 1 , wherein the pressurized signal is discharged from the outlet.

5. The flow control device of claim 1 further comprising an actuator secured to the second end, the pressurized signal being discharged from the outlet into the actuator.

6. further comprising an actuator disposed at the second end of the yoke; The flow control device of claim 1 , wherein at least a portion of the actuator is integrally formed with the yoke.

7. further comprising an actuator disposed at the second end of the yoke; The flow control device of claim 1 , wherein the actuator comprises a bowl-shaped member integrally formed with the yoke.

8. a sealed enclosure disposed at the second end, the sealed enclosure comprising a pair of separable members, at least one of which is integrally formed with the yoke; The flow control device of claim 1 , wherein the pressurized signal from the controller is discharged from the outlet into the sealed enclosure.

9. 2. The flow control device of claim 1, further comprising a first casing integrally formed with the yoke at the second end, the first casing having a peripheral wall surrounding the outlet.

10. a first casing integrally formed with the yoke at the second end, the first casing having a peripheral wall surrounding the outlet; The flow control device of claim 1 , further comprising: a second casing coupled to the first casing to form a sealed enclosure.

11. A flow control device, A pneumatic actuator; a controller coupled to the pneumatic actuator, the controller generating a pneumatic signal that pressurizes the pneumatic actuator; a superstructure supporting both the pneumatic actuator and the controller, the superstructure defining a bore through which the pneumatic signal passes between the controller and the pneumatic actuator.

12. The flow control device of claim 11 , wherein the superstructure integrally forms a portion of the pneumatic actuator.

13. The flow control device of claim 11 , wherein the pneumatic actuator comprises a sealed enclosure at least a portion of which is integrally formed with the superstructure.

14. The flow control device of claim 11 further comprising a valve coupled to the upper structure and the pneumatic actuator.

15. The flow control device of claim 11 , wherein the bore defines a non-linear passage.

16. The flow control device of claim 11 , wherein the superstructure comprises a 3D printed yoke.

17. 1. An apparatus comprising: a valve having a movable closure member; an actuator coupled to the movable closure member; a controller coupled to the actuator, the controller having operating hardware for converting an electrical signal into a pneumatic signal; and an upper structure that internally directs the pneumatic signal from the controller to the actuator.

18. 18. The apparatus of claim 17, wherein the air pressure signal enters the bottom of the actuator.

19. 18. The apparatus of claim 17, wherein the air pressure signal enters an upper portion of the actuator.

20. 18. The apparatus of claim 17, wherein the upper structure has a bore extending from the controller to the pneumatic actuator for receiving and discharging the pneumatic signal.

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