Subterranean Valve Testing, Lubricating, and Sealing Device

Abstract

A sealant gun is inserted into a limited space work area to engage a buttonhead fitting supported by a fitting assembly perpendicular to a valve stem extending from a tapered plug valve. The fitting assembly orients the buttonhead fitting on the valve stem for movement of the sealant gun in a single vertical direction to engage the buttonhead fitting. The sealant gun injects a sealant under pressure through the buttonhead fitting and the valve stem into a tapered bore of the valve body. The tapered bore receives a tapered plug on the end of the valve stem for movement into and out of a closed valve position with the tapered bore. The sealant is injected between the tapered plug and the tapered bore to provide a seal therebetween that prevents the escape of the fluid flowing through the valve from the valve through the valve stem to the atmosphere.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a valve servicing device and, more particularly, to an apparatus and method for testing, lubricating, and sealing a subterranean valve positioned within a keyhole excavation site.

2. Description of the Related Art

Plug valves are widely used in utility and industrial applications. Plug valves include a buttonhead grease fitting mounted on the exposed end of the operating stem of the valve. The buttonhead fitting includes a round, flat top that includes a hole positioned in the middle. The hole includes a spring loaded ball detent. A groove is positioned under the flat top to encircle the buttonhead fitting.

Plug valves are used in above-ground applications and in underground applications. In underground applications, the plug valves are buried either in pits or in valve boxes. Pits are either accessible or inaccessible to people. Valve boxes are pipes or other tubular objects that are placed over a valve. A typical valve box includes a lid that keeps debris from entering the interior of the box.

Plug valves are commonly positioned in limited space work areas, such as at subterranean excavation sites, and other confined spaces. The term “confined space” relates to a space having existing or potential hazards. Under OSHA rules, employers must determine whether a jobsite has a confined space, and if so, determine if the space has existing or potential hazards. OSHA rules classify four potential physical and atmospheric hazards: isolated-hazard confined space, controlled-atmosphere confined space, permit-required confined space, and continuous system-permit-required confined space.

Plug valves have long been known in the prior art as an effective means of controlling the flow of fluid in pipelines. Some plug valves include a closure member that is cylindrical in form and mates with a similarly shaped seat within the body of the valve. Other plug valves include a tapered plug that fits within a similarly tapered bore within the body. Other plug valves include plugs that are in metal-to-metal contact with the tapered bore.

Some plug valves include a film of lubricant or sealant that is interposed between the surface of the plug and a tapered bore. The lubricant or sealant augments the sealing properties of the closure member of the plug and to minimize the amount of torque required to turn the valve between its open and closed position. The terms “lubricant” and “sealant” are used interchangeably with respect to plug valves.

Most, if not all, plug valves include a valve stem that is connected to the plug. The valve stem extends through an opening in the housing to the exterior of the body to provide means for rotating the plug between its open and closed position. This feature provides a possible leakage path from the interior of the body to the exterior.

Plug valves need to be maintained through a maintenance program. The maintenance program must include lubricating the valve with valve sealant. The maintenance program must also include exercising the valve to allow the valve to function properly.

Valve sealant is a specially compounded material that is used to both seal and lubricate plug valves. The term “grease” is commonly used to refer to valve sealant. However, valve sealant differs from conventional grease in that valve sealant typically has properties that more closely resemble solid materials. Typically, valve sealant is provided in cylindrical sticks that have a diameter of 1.5 inches (3.8 cm) and a length of 8 inches (20 cm). The “grease” sticks are stored upright indefinitely.

Valve sealant must be installed with a suitable high pressure sealant gun due to its viscosity. Suitable high pressure sealant guns include hydraulic sealant guns that develop pressures as high as 13000 psi (880 atm). High pressure sealant guns typically include buttonhead couplers because such sealant guns would require 23000 psi (1560 atm) of pressure to push sealant through a sealant gun hose that does not include a buttonhead coupler.

Valve sealant is injected into the plug valve by connecting the buttonhead coupler onto a buttonhead fitting mounted on the end of the valve stem and building pressure in the sealant gun. The typical buttonhead coupler includes a body, a spring loaded plunger, and a spring loaded ball detent. The body includes a slot that fits in a groove on the buttonhead fitting. The plunger includes a hole. The detent is placed over the plunger hole and in the center of the groove.

The plunger has a flat surface that will seal around the spring loaded ball detent. Sealant flows through the plunger hole and pushes open the ball detent. The pressure within the sealant gun opens the buttonhead fitting ball detent to allow sealant to flow onto the valve plug through the valve stem.

The lubrication of plug valves that are located above ground is not difficult when the plug valves are people accessible. Similarly, plug valves that are located in people-accessible can be serviced without much difficulty. However, plug valves that are located underground or in confined spaces must be serviced using techniques that minimize disruption to the surrounding landscape through minimally invasive technology or subterranean “keyhole” excavations.

Subterranean keyhole excavation involves performing work above ground using extension tools to access valves, couplings, and the like on a subterranean natural gas pipeline or water line. The objective of subterranean keyhole excavation is to perform as much work underground with the smallest possible ground opening.

A small opening is cut in the pavement, so that earthen material around the pipe is excavated to provide access to a particular section of the pipeline. The target holes are typically eighteen inches in diameter, but may be as small as twelve inches in diameter. Typically, a valve is replaced or repaired. These operations are performed by using tools that extend through the keyhole to the underground pipeline.

The valves that are located in underground or in confined spaces must be lubricated by using an extension commonly called an injection rod. The injection rod is essentially a pressure rated tube that has a buttonhead fitting on one end and a button head coupler on the other end.

U.S. Patent No. Re. 31,027 discloses a valve having a sealed system of grease-containing channels for preventing any leakage flow of gas. This grease or lubricant is replenished by injecting it into the valve through a buttonhead grease fitting which is mounted on the exposed end of the operating stem of the valve. The grease fitting included an attachment stem that is threaded at its lower end. The grease fitting is received in a correspondingly threaded aperture formed in the end of the valve stem. The grease fitting also includes an enlarged head portion which is hexagonal in shape for tightening the grease fitting in place using a wrench or similar tool. The buttonhead portion on the upper end of the grease fitting has conventional shape for connection of a grease gun when the valve lubricant is to be replenished.

U.S. Pat. No. 4,619,283 discloses a lubricated plug valve having a conventional buttonhead grease fitting projecting vertically from the valve upper surface. The buttonhead fitting includes a cylindrical or disc shaped portion. The buttonhead fitting connects to a grease gun for lubrication.

During keyhole excavation operations, a grease gun or other extension tool must be lowered into a hole that contains the valve to lubricate, test, or service the valve. The grease gun connects to the buttonhead fitting through a conventional coupler. Initially, the coupler must be lowered in a vertical direction relative to the valve. Next, the coupler on the grease gun or an extension thereof must be moved in a horizontal direction relative to the valve, so that the coupler can engage the buttonhead fitting. This combination of vertical and horizontal movements makes it difficult to connect and seat the coupler to the buttonhead fitting, so that an improved method and apparatus for servicing a subterranean valve is needed.

SUMMARY OF THE INVENTION

In accordance with the present invention there is provided a fitting assembly for sealing a stem of a tapered plug valve having a body with a tapered bore for receiving between open and closed positions a tapered plug extending from the end of the stem. A base has a lower surface with a first opening positioned therein and an upper surface having a vertical member projecting therefrom. The first opening has a preselected dimension for receiving a tubular threaded member extending from the valve stem. The vertical member has a second opening with a preselected dimension. The second opening extends perpendicular to the valve stem. A buttonhead fitting extends from the second opening on the vertical member. The buttonhead fitting includes a checkvalve. The buttonhead fitting extends from the second opening in the vertical member in perpendicular alignment with the tubular threaded member extending from the valve stem. The base has an internal passageway connecting the first opening to the second opening to transmit a sealant under pressure from the buttonhead fitting into the valve body between opposing surfaces of the tapered plug and the tapered bore to provide a seal there between to prevent the escape of fluid from the valve through the valve stem.

Further in accordance with the present invention, there is provided an apparatus for servicing a tapered plug valve having a valve stem with a tapered plug extending from the stem and engageable in and out of sealing relating with a tapered bore in the body of the valve. A tubular threaded member projects vertically from the valve stem. The base has means for connecting the base to the tapered plug valve tubular threaded member. A buttonhead fitting includes a checkvalve. The base has means for positioning the buttonhead fitting extending perpendicular to the tubular threaded member. The base has means for transmitting a sealant under pressure from the buttonhead fitting through the valve stem to the body of the valve between the tapered plug and the tapered bore to form a seal therebetween to prevent fluid from escaping from the valve through the valve stem.

In addition, the present invention is directed to a method for servicing a tapered plug valve having a vertically extending valve stem with a tapered plug engageable with a valve seat that includes the steps of providing an elongated buttonhead fitting having a longitudinally extending internal bore with a checkvalve positioned in the internal bore. The buttonhead fitting is positioned in perpendicular relation to the valve stem. A fitting assembly is attached to the valve stem with an internal bore extending through the fitting assembly in fluid communication with the valve stem. The buttonhead fitting is connected to the fitting assembly in fluid communication with the internal passageway and extending perpendicular to the valve stem. A sealant is transmitted under pressure into the buttonhead fitting through the internal passageway and the valve stem to the valve seat to form a pressure seal between the tapered plug and the valve seat to resist the pressure of the fluid in the valve from escaping through the valve stem.

Accordingly, a principal object of the present invention is to provide a buttonhead fitting device that can be serviced by lowering an extension tool along a single axis into a subterranean hole.

Another object of the present invention is to provide a buttonhead fitting that can be visually inspected and cleaned during keyhole excavations.

Another object of the present invention is to provide a buttonhead fitting assembly having an unobstructed flow path from a buttonhead fitting to a valve.

Another object of the present invention is to provide an extension tool for testing a subterranean valve for leakage through a keyhole operation or valve box.

A further object of the present invention is to provide an extension tool for testing a subterranean valve having an improved buttonhead fitting device.

A further object of the present invention is to provide an improved method for testing, lubricating, and servicing a subterranean valve.

These and other objects of the present invention will be more completely described and disclosed in the following specification, accompanying drawings, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial sectional view in side elevation of a lubricated plug valve, illustrating a conventional buttonhead grease fitting.

FIG. 2 is a view similar to FIG. 1 of a lubricated plug valve, illustrating a buttonhead fitting assembly in accordance with the present invention.

FIG. 3 is a sectional view in side elevation of the buttonhead fitting assembly shown in FIG. 2.

FIG. 4 is an end view of the buttonhead fitting assembly shown in FIG. 2.

FIG. 5 is a sectional view in side elevation of another embodiment of a buttonhead fitting assembly in accordance with the present invention.

FIG. 6 is a sectional view similar to FIG. 5 of another embodiment of a buttonhead fitting assembly.

FIG. 7 is an elevational view of a sealant gun.

FIG. 8 is a fragmentary exploded view partially in section of an extension tool lowered into a limited space work area to lubricate a plug valve through the buttonhead fitting assembly shown in FIG. 2.

FIG. 9 is a view similar to FIG. 8 of an extension tool lowered into alignment in a limited space work area with the buttonhead fitting assembly shown in FIG. 2.

FIG. 10 is a further view similar to FIGS. 8 and 9 of an extension tool in position for lubricating a plug valve through the buttonhead fitting assembly shown in FIG. 2.

FIG. 11 is a partial sectional view in side elevation view of a valve key positioned over a plug valve having a novel buttonhead fitting assembly in accordance with the present invention.

FIG. 12 is a sectional view in side elevation of subterranean valve testing device.

FIG. 13 is an exploded view in side elevation of the valve testing device shown in FIG. 12 lowered into a limited space work area to test a plug valve.

FIG. 14 is a view similar to FIG. 13 of the valve testing device shown in FIG. 12 lowered into alignment for engagement with a buttonhead fitting assembly on a plug valve.

FIG. 15 is a further view similar to FIGS. 13 and 14 illustrating the valve testing device in position for testing a plug valve.

FIG. 16 is a sectional view in side elevation of another embodiment of a subterranean valve testing device.

FIG. 17 is an exploded view in side elevation of the valve testing device shown in FIG. 16 lowered into a limited space work area to test a plug valve.

FIG. 18 is a view similar to FIG. 17 of the valve testing device shown in FIG. 16 lowered into alignment for engagement with a buttonhead fitting assembly on a plug valve.

FIG. 19 is a view in side elevation of the valve testing device shown in FIG. 16 connected to a buttonhead fitting assembly on a plug valve.

FIG. 20 is an exploded view similar to FIG. 19 of an extension tool actuating a plunger mechanism on the valve testing device shown in FIG. 16.

FIG. 21 is a fragmentary sectional view in side elevation of an extension tool lowered into a limited space work area to lubricate a plug valve positioned within a valve box through the buttonhead fitting assembly shown in FIG. 2.

FIG. 22 is a view similar to FIG. 21 of the extension tool lowered into alignment with the buttonhead fitting assembly in the limited space work area.

FIG. 23 is a view similar to FIGS. 21 and 22 of the extension tool engaged with the buttonhole fitting assembly for lubricating the plug valve shown FIG. 21.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is employed with a traditional lubricated plug valve, such as the plug valves provided by Nordstrom Audco of Sulphur Springs, Tex. U.S. Pat. Nos. 4,619,283 and RE 31,027 also disclose lubricated plug valves and are incorporated herein by reference.

Referring to the drawings and, particularly, to FIG. 1, there is shown a conventional lubricated valve known in the art generally designated by the numeral 10. The valve 10 includes a valve stem 12 that receives fluids through a conventional buttonhead grease fitting 14 during lubrication or sealing operations. The buttonhead fitting 14 projects vertically from the valve 10 so that it is essentially perpendicular to a valve upper surface 16.

The buttonhead fitting 14 includes a disc shaped upper portion 18 and a cylindrical lower portion 20. The fitting 14 is tubular with an internal passageway (not shown) extending through the upper portion 18 to the lower portion 20 to allow fluids to flow through the fitting 14 to the valve stem 12 during lubrication or sealing operations. The internal passageway is closed by a conventional detent mechanism (not shown) which when depressed allows lubricant to enter the valve stem. The detent prevents the fluid conveyed through the valve from escaping to the atmosphere through the valve stem.

The alignment of disc shaped upper portion 18 relative to the cylindrical lower portion 20 has several disadvantages. The valve 10 must be serviced with an injection rod (not shown) by sliding a coupler (not shown) horizontally over the fitting 14. The orientation of the valve 10 in the subterranean environment makes it difficult to determine visually whether the coupler (not shown) and the fitting 14 are aligned properly, particularly when the valve is located underground in a valve box.

The buttonhead fitting upper portion 18 typically includes old sealant or other debris that is not visible from above the valve 10. The sealant or debris interferes with the connection between the coupler (not shown) and the fitting 14.

Conventional couplers that include a spring loaded plunger can prevent the injection rod from making a good connection with the valve 10. A poor connection is difficult to detect. A poor connection also results in sealant flowing around the outside of the valve top 12, as opposed to being injected into valve 10. In fact, the operator may think that he has lubricated the valve, not knowing that the lubricant was not injected into the valve. The relatively high viscosity of the sealant makes it difficult to determine if the sealant has been injected into the valve 10 under such conditions.

Referring now to FIGS. 2-4, there is illustrated in FIG. 2 a conventional valve 10 having a buttonhead fitting assembly 22 in accordance with the present invention projecting vertically from the valve upper surface 16. The fitting assembly 22, as shown in detail in FIGS. 3 and 4, includes a body 24, a tubular connecting member or nipple 26, and a buttonhead fitting 14. The body 24 includes a base 28 positioned in an overlying relationship with the valve upper surface 16 and a vertical member 30 projecting upwardly from the base 28.

The body 24, the nipple 26, and the buttonhead fitting are formed using any suitable materials from any suitable manufacturing process. Preferably, the body 24, the nipple 26, and the buttonhead fitting 14 are formed separately through a casting process or through a machining process. Alternatively, the combination of the body 24, the nipple 26, and the buttonhead fitting 14 are formed integrally from the same materials or the buttonhead fitting assembly 22 is formed integrally from a unitary structure, and, therefore, is not assembled from individual components. In one example of the present invention, the body 24 including base 28, fitting 14, and nipple 26 are machined from a solid block of material. The elements are formed in a single unit or body. The unitary body is also formed from a casting which is machined. Other processes used to form the unitary body include investment casting or lost wax processing. Therefore, it should be understood in accordance with the present invention that reference herein to a buttonhead fitting assembly includes within the definition of the term a fitting formed of individual component parts as well as formed from a single unit or unitary body and not an assembly of parts.

The embodiment of the buttonhead fitting assembly 22, as shown in FIGS. 2-4, includes an assembly of component parts, as opposed to a unitary body. The base 28 is essentially orthorhombic in shape with an essentially flat lower surface 32 that is parallel to the valve upper surface 16. The base lower surface 32 includes a centrally positioned opening 34 that communicates with connecting member 26. The opening 34 has a preselected dimension to receive the connecting member 26 as it extends from the valve 10. The connecting member 26 and the base are threaded in a corresponding manner to facilitate connection to one another.

The vertical member 30 is essentially orthorhombic in shape with an essentially flat face 36 that is aligned perpendicular to the valve upper surface 16. The face 36 includes an opening 38 having a preselected dimension for receiving the buttonhead fitting 14. The opening 38 is positioned to align the buttonhead fitting 14 essentially perpendicular to the connecting member 26 and parallel to the valve upper surface 16.

As shown in FIG. 3, the body 24 has an internal passageway generally designated by the numeral 40 to facilitate fluid communication between the buttonhead fitting 14 and the connecting member 26. In operation, the passageway 40 allows fluid to flow through the buttonhead fitting 14 from fitting upper portion 18 to the connecting member 26. The fluid exits the base 28 through the opening 34 into the connecting member 26 and the valve stem 12.

The passageway 40 is formed in the body 24 through any suitable conventional manufacturing process. Preferably, the passageway 40 is formed by drilling two vertical holes 42, 44 and two horizontal holes 46, 48 in the body 24. The holes 42, 46 are partially closed with set screws 50, 52. Alternatively, the holes 42, 46 are welded shut.

As shown in FIG. 3, one end of the hole 42 intersects with the hole 48. The opposite end of hole 42 receives a set screw 50. One end of hole 46 intersects with hole 44. A set screw 52 also extends through 24 into hole 46. The holes 42, 46 connect to one another, so the passageway 40 connects the opening 38 to the opening 34.

Referring now to FIG. 5, there is illustrated another embodiment of a buttonhead fitting assembly generally designated by the numeral 54 in which like elements are also identified by numerals shown in FIGS. 1-4. The buttonhead fitting assembly includes a body 56, a tubular connecting member 26, and a buttonhead fitting 14. The body 56 connects the connecting member 26 to the buttonhead fitting 14.

The body 56 includes a base 58 and a vertical member 60. The base 58 is positioned in an overlying relationship with the valve upper surface 16 shown in FIG. 2 and the connecting member 26. The vertical member 60 projects upwardly from the base 58 to connect the buttonhead fitting 14 to the base 58. The vertical member 60 is essentially perpendicular to the base 58, so that the buttonhead fitting 14 projects outwardly from the vertical member 60 in an essentially perpendicular alignment with the connecting member 26.

The vertical member 60 includes a hole 48 that forms an internal chamber therein. The chamber 48 connects to an internal bore 62 positioned within the buttonhead fitting 14 through the opening 38. The chamber 48 is axially aligned with the internal bore 62 to form an essentially horizontal flow path from the buttonhead fitting 14 into the vertical member 60.

The base 58 includes an internal chamber 64 that includes an upper portion 66 and a lower portion 68. The diameter of the lower portion 68 is substantially greater than the diameter of the upper portion 66. The lower portion 68 connects to an internal bore 70 in the connecting member 26 through an opening 34. The base internal chamber 64 is axially aligned with the connecting member internal bore 70, so that the base internal chamber 64 is essentially perpendicular to the vertical member internal chamber 48.

The base internal chamber 64 connects to the vertical member internal chamber 48 to form a continuous passageway 72 to connect the buttonhead fitting 14 to the connecting member 26. The passageway 72 facilitates fluid flow from the valve 10 shown in FIG. 2 to the buttonhead fitting 14. Preferably, the connecting member 26 includes sidewalls 74 that are substantially thinner than the diameter of the base chamber upper portion 66. The relatively thin connecting member sidewalls 74 provide a direct flow path to the vertical member internal chamber 48.

As shown in FIG. 6, there is illustrated a further embodiment of a buttonhead fitting assembly generally designated by the numeral 76 in which like elements are also identified by numerals shown in FIGS. 1-5. In comparison with the embodiment shown in FIG. 5, the assembly 76 includes a buttonhead fitting that has a substantially shorter lower portion 80. The shorter lower portion 80 substantially decreases the overall width of the assembly 76, which facilitates use in combination with a gate key (not shown).

The buttonhead fitting assembly 76 also includes a body 56 and a tubular connecting member 26. The body 56 includes a base 58 includes an internal passageway 72 that provides substantially unobstructed fluid flow from the tubular connecting member 26 to the buttonhead fitting 78.

Referring now to FIG. 7, there is shown a sealant gun generally designated by the numeral 82 that is used to lubricate or seal the valves 10 shown in FIGS. 1-2. The sealant gun 82 includes a supply of sealant. The sealant is injected under pressure into the valve 10 through the buttonhead fitting 14 and into the valve stem 12.

The sealant gun 82 includes a tubular cylindrical housing 84 that includes a reservoir 86 for holding the sealant/lubricant. The housing 84 is connected to a fulcrum assembly 88 that extends outwardly in an essentially perpendicular direction from the center axis of the sealant gun 54. The fulcrum assembly 88 includes an outwardly projecting pivot arm 90. The pivot arm 90 includes a grip 92 to facilitate manipulation of the gun 82.

The reservoir 86 communicates with a sealant nipple 94 through a connection with the housing 84. The reservoir 86 delivers sealant or lubrication to the nipple 94 under pressure. The pressure is measured by a gage 96 that is in fluid communication with the housing 84 and the nipple 94. The gage 96 is positioned adjacent to the nipple 94 to connect the housing 84 to a high pressure hose 98.

The high pressure hose 98 is in fluid communication with the housing 84 to transmit fluid from the housing 84 to a sealed coupler 100. A swivel 102 and a by-pass valve 104 are positioned between the hose 98 and the coupler 100. The swivel 102 enables the coupler 100 to move in any operational position. The by-pass valve 104 reduces pump time for multiple valve lubrication operations.

Referring now to FIGS. 8-10, there is illustrated the sequence of steps for lubricating a valve 10 using the sealant gun 82 shown in FIG. 7. The coupler 100 is lowered into a hole, such as a hole excavated in a keyhole operation, to engage a buttonhead fitting 14 projecting upwardly from the valve stem 12. The buttonhead fitting 14 is connected to the fitting assembly 22 shown in FIG. 2, so that the fitting 14 is essentially parallel to the valve upper surface 16. The sealant gun 82 injects pressurized sealant through coupler 100 into the valve 10 through the buttonhead fitting 14 and into the valve stem 12. In accordance with the present invention, this arrangement facilitates easier and secure attachment of the coupler 100 to the fitting 14. Further, the arrangement permits the valve 10 to be operated with the fitting 14 attached, as shown in FIG. 11. This overcomes the problem encountered with standard plumbing fittings of not permitting operation of the valve without removal of the fitting from the valve.

The disc shaped upper portion 18 of the buttonhead fitting 14 is aligned in a perpendicular direction to the valve upper surface 16. The coupler 100 includes a slot 108 having a preslected configuration to receive the buttonhead fitting upper portion 18. The alignment of the buttonhead fitting upper portion 18 with the coupler slot 108 allows the sealant gun 82 to connect to the buttonhead fitting 14 without moving in a horizontal direction parallel to the valve upper surface 16. After the sealant gun 82 connects to the fitting 14, the sealant gun 82 provides lubrication to the valve 10 under pressure.

The position of the buttonhead fitting 14 on the fitting assembly 22 facilitates visual inspection of the connection of the fitting 14 with the coupler 100. The connection is made by vertically pushing or pulling the sealant gun 82 into the fitting 14, which is substantially easier than sliding the sealant gun 82 horizontally. The fitting 14 provides a positive stop for the sealant gun 82 to allow the operator to determine when a positive connection with the fitting assembly 22 has been made.

Referring now to FIG. 11, there is shown a valve 10 with a valve key generally designated by the numeral 110 positioned over the valve upper surface 16. The valve 110 is conventional. A conventional valve key is disclosed in U.S. Pat. No. 7,117,883. The valve stem 12 is connected to a buttonhead fitting assembly 22 projecting upwardly from the valve upper surface 16. The buttonhead fitting assembly 22 is positioned between the walls 112, 114 of the valve key 110. The fitting assembly base 28 and vertical member 30 are dimensioned so that the buttonhead fitting 14 does not contact the walls 112, 114 when the valve key 110 is positioned in surrounding relation with the valve stem 12.

The valve stem in FIG. 11 has an internal check valve which stops fluid from flowing out of the valve while permitting sealant to flow into the valve. An example check valve for a valve stem is disclosed in U.S. Pat. No. 4,305,567. If the check valve leaks and fluid flows past the check valve, then the detent ball in the sealant fitting prevents the fluid from leaking to the atmosphere. Removal of the fitting, in the case where the check valve is leaking, causes fluid to be released to the atmosphere. The sealant fitting on the top of the valve stem must be changed periodically. If the check valve is leaking, then removal of the sealant fitting will cause leakage of fluid (gas) into the atmosphere. This is not desirable and could be potentially very dangerous.

With the present invention the valve stem is tested to determine if fluid (gas) has leaked past the valve stem internal check valve. This is done by pressing the detent in the top of the sealant fitting. If the check valve is leaking, then gas will escape. If the internal check valve is not leaking, then gas will not leak through the detent hole in the top of the sealant fitting because no gas is present. The test unit attaches to the sealant fitting with an airtight seal. The internal shaft, which is in a sealed housing, depresses the ball detent in the top of the sealant fitting. A gas leak is indicated by a positive reading on the pressure gage.

Referring now to FIG. 12, there is shown a valve testing device generally designated by the numeral 116 for use with the present invention. The testing device 116 is used to determine whether the valve 10 shown in FIG. 1 is adequately sealed/lubricated. The testing device 116 engages the vertically aligned buttonhead fitting 14 extending from the valve 10 to determine whether fluids have leaked from an internal chamber 118 into the valve stem 12 through a check valve (not shown).

The testing device 116 includes an extension tool 120, a coupler 122, and a plunger mechanism 124. The extension tool 120 includes a handle 126, an elongated tubular member 128, a pressure gage 130, and a stuffing box 132. The coupler 122 connects to one end of the extension tool 120. The plunger mechanism 124 extends from the extension tool 120 to the coupler 122.

The handle 126, the stuffing box 132, and the pressure gage 130 are positioned at the opposite end of the extension tool 120 from the coupler 122. The elongated member 128 connects the coupler 122 to the stuffing box 132, the handle 126, and the pressure gage 130. The handle 126 is a tee handle.

The elongated member 128 includes an internal chamber 134. The internal chamber 134 is in fluid communication with the gage 130 and the coupler 122. The elongated member 130 also includes an internal rod 136 that is connected to the handle 126. The internal rod 136 extends through the elongated member internal chamber 134 into the coupler 122.

The plunger mechanism 124 includes the rod 136, a spring 138, and a plurality of spacers 140, 142. The rod 136 is vertically aligned within the elongated member 130. The spacers 140, 142 maintain the rod 136 in a central position within the tool 120. The spring 138 facilitates the reciprocal movement of the rod 136 within the tool 120.

Referring now to FIGS. 13-15, there is illustrated the sequence of steps for testing a valve 10 using the testing device 116 shown in FIG. 12. As shown, the testing device 116 is specially adapted to connect to a valve 10 having a conventional buttonhead fitting 14 vertically aligned and projecting in a perpendicular direction from the valve upper surface 16. The testing device 116 must be manipulated to move in both a vertical direction and a horizontal direction for the coupler 122 to engage the buttonhead fitting 14.

As shown in FIGS. 13-14, the testing device 116 is lowered into a limited space work area to engage the buttonhead fitting 14. The testing device 116 is initially lowered in a vertical direction to align the slot 144 on the coupler 122 with the disc shaped portion 18 of the buttonhead fitting. Once the slot 144 is aligned with the disc shaped portion 18, the testing device 116 is moved in an essentially horizontal direction to insert the fitting upper portion 18 into the slot 144 to connect the testing device 116 to the valve 10, as shown in FIG. 15.

Once the coupler 122 is connected to the valve 10, the rod 136 of the valve testing device 116 shown in FIG. 12 is reciprocated in a vertical direction to open the ball detent in the vertical sealant fitting on the valve stem. If the internal check valve of the valve stem is leaking, then the rod 136 allows fluid to flow from the valve stem 12 into the elongated member internal chamber 134. The pressure gage 130 detects leakage from the valve stem 12 by measuring the pressure in the elongated member internal chamber 134.

The coupler 122 on the end of the valve testing device 116 attaches to the top of the buttonhead fitting 14 to form a seal from the atmosphere. The handle 126 shown in FIG. 12 activates to push the central rod 136 into the ball detent (not shown) on the fitting 14, providing fluid communication between the internal chamber 134 and the interior of the valve stem. Once the fitting 14 communicates with the internal chamber 134, the pressure gage 130 measures any internal pressure in the valve stem, indicating pressure on the testing unit. An increase in pressure after the valve 10 is opened indicates that leakage has occurred.

Referring to FIG. 16, there is illustrated a further embodiment of the testing device generally designated by the numeral 146. The testing device 146 includes an extension tool 148, a coupler 150, and a plunger mechanism 152. The extension tool 148 includes an elongated member 154 and a gage 130. The elongated member 154 includes an internal chamber 156 to allow the gage 130 to communicate with the coupler 150.

In comparison with the embodiment of the valve testing device 116 illustrated in FIGS. 12-15, the plunger mechanism 152 includes a horizontal rod 158 that moves in a reciprocal manner in a direction perpendicular to the elongated member 154. As a result, the plunger mechanism 152 is contained within the coupler 150.

Referring now to FIGS. 17-20, there is shown the sequence of steps for connecting the testing device 146 to a valve 10. The testing device 146 is specially adapted to connect to a valve 10 having the buttonhead fitting assembly 22 shown in FIG. 2. In comparison with the embodiment shown in FIGS. 12-15, the testing device 146 only requires movement in a single direction to engage the buttonhead fitting 22.

The testing device 146 is lowered into a limited space work area to engage the buttonhead fitting 14. The testing device 146 is lowered to align a slot 160 on the coupler 150 with the disc shaped portion 18 of the buttonhead fitting 14. Once the slot 160 is aligned with the disc shaped portion 18, the coupler 150 connects to the buttonhead fitting 14.

As shown in FIG. 20, after the coupler 150 connects to the buttonhead fitting 14, a second extension tool 162 and a socket assembly 164 are lowered into the limited space work area to actuate the plunger mechanism 152 by engaging a member 166 extending therefrom. The extension tool 162 corresponds to the extension tool described in co-pending U.S. patent application Ser. No. 11/403,474, which is incorporated herein by reference. The extension tool 162 rotates a member 168, which is connected to the socket assembly 164. The rotating member 168 and socket assembly 164 engage the member 166 to actuate the plunger mechanism 152.

Referring now to FIGS. 21-23, there is shown the sequence of steps for lubricating a valve 10 positioned within a valve box or a curb box generally designated by the numeral 170. The valve box 170 is buried underground to provide protection for the underground valve 10. The valve box 170 also provides access to the valve 10. The valve box 170 is similar to the valve box that is disclosed in U.S. Pat. No. 4,746,034, which is incorporated herein by reference.

The valve box 170 includes a tubular body portion 172 and an access cover 174. The tubular body portion 172 defines a cavity 176 that encloses the valve 10. The valve 10 is lubricated by lowering a sealant gun 82 into the cavity 176 in the manner shown in FIG. 21. A coupler 100 extends from one end of the sealant gun 82.

As shown in FIG. 22, the sealant gun 82 is positioned in a manner so that the coupler 100 is in overlying relation with the fitting assembly 22. The coupler 100 has a slot 108 for engaging a buttonhead fitting 14 extending from the fitting assembly 22.

As shown in FIGS. 22-23, the sealant gun 82 moves vertically until a top portion of the buttonhead fitting 14 inserts into the slot 108. The insertion of the buttonhead fitting 14 into the slot 108 connects the fitting assembly 22 to the sealant gun 82. After insertion, the sealant gun 82 injects pressurized sealant through the coupler 100 into the valve 10 through the buttonhead fitting 14 and into the valve stem 12.

It should be understood that while the sealant gun 82, valve key 110, and testing device 146 of FIGS. 7-11 and 16-23 are shown in operation with the buttonhead fitting assembly 22 of FIGS. 2-4, alternative embodiments are contemplated in which the sealant gun 82, valve key 110, and testing device 146 are used with the buttonhead fitting assemblies 54, 76 shown in FIGS. 5-6.

According to the provisions of the patent statutes, I have explained the principle, preferred construction and mode of operation of my invention and have illustrated and described what I now consider to represent its best embodiments. However, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.

Claims

1. A fitting assembly for sealing a stem of a tapered plug valve having a body with a tapered bore for receiving between open and closed positions a tapered plug extending from the end of the stem comprising: a base having a lower surface with a first opening positioned therein and an upper surface having a vertical member projecting therefrom,the first opening having a preselected dimension for receiving a tubular threaded member extending from the valve stem,said vertical member having a second opening with a preselected dimension, said second opening extending perpendicular to the valve stem,a buttonhead fitting extending from said second opening on said vertical member, the buttonhead fitting including a check valve,the buttonhead fitting extending from the second opening on the vertical member in perpendicular alignment with the tubular threaded member extending from the valve stem, andthe base having an internal passageway connecting the first opening to the second opening to transmit a sealant under pressure from the buttonhead fitting into the valve body between opposing surfaces of the tapered plug and the tapered bore to provide a seal therebetween to prevent the escape of fluid from the valve through the valve stem.

2. A fitting assembly as set forth in claim 1 which includes: the buttonhead fitting having a cylindrical portion, andthe buttonhead fitting extending in an essentially perpendicular direction from the vertical member so that the cylindrical portion extends over the base.

3. A fitting assembly as set forth in claim 1 which includes: the threaded member connecting the base to the valve.

4. A fitting assembly as set forth in claim 1 which includes: the vertical member being integral with the base.

5. A fitting assembly as set forth in claim 1 which includes: the base having a chamber connecting to the first opening,the vertical member having a chamber connecting to the second opening, andthe base chamber connected to the vertical member chamber to form the internal passageway.

6. A fitting assembly as set forth in claim 5 which includes: the vertical member chamber being axially aligned with the buttonhead fitting,the base chamber being axially aligned with the threaded member, andthe base chamber having a direct flow path to the vertical member chamber.

7. An apparatus for servicing a tapered plug valve having a valve stem with a tapered plug extending from the stem and engageable in and out of sealing relation with a tapered bore in the body of the valve comprising: a tubular threaded member projecting vertically from the valve stem,a base,the base having means for connecting the base to the tapered plug valve tubular threaded member,the base having means for positioning a buttonhead fitting extending perpendicular to the tubular threaded member, andthe base having means for transmitting a sealant from the buttonhead fitting through the valve stem to the body of the valve between the tapered plug and the tapered bore to form a seal therebetween to prevent fluid from escaping from the valve through the valve stem.

8. An apparatus as set forth in claim 7 in which: the base having preselected dimensions to facilitate insertion into a gate key.

9. An apparatus as set forth in claim 7 which includes: the buttonhead fitting having a cylindrical portion, andthe cylindrical portion extending over the base.

10. An apparatus as set forth in claim 7 which includes: an elongated tubular member having an internal chamber,means for connecting said tubular member to the buttonhead fitting extending from said base,a plunger mechanism for inserting a rod into the buttonhead fitting to allow fluid to flow from the subterranean valve to said internal chamber, andmeans for measuring the pressure of said internal chamber to detect fluid leakage from the subterranean valve.

11. An apparatus as set forth in claim 7 which includes: means for actuating the plunger mechanism.

12. An apparatus as set forth in claim 7 which includes: means for injecting the sealant under pressure through the buttonhead fitting into the subterranean valve.

13. A method for servicing a tapered plug valve having a vertically extending valve stem with a tapered plug engageable with a valve seat comprising the steps of: providing an elongated buttonhead fitting having a longitudinally extending internal bore with a checkvalve positioned in the internal bore,positioning the buttonhead fitting in perpendicular relation to the valve stem,attaching a fitting assembly to the valve stem with an internal passageway extending through the fitting assembly in fluid communication with the valve stem,connecting the buttonhead fitting to the fitting assembly in fluid communication with the internal passageway and extending perpendicular to the valve stem, andtransmitting a sealant under pressure into the buttonhead fitting through the internal passageway and the valve stem to the valve seat to form a pressure seal between the tapered plug and the valve seat to resist the pressure of the fluid in the valve from escaping through the valve stem.

14. The method as set forth in claim 13 which includes: connecting the base to the valve with a tubular connector.

15. A method as set forth in claim 14 which includes: threadedly connecting the base to the tubular connector.

16. A method as set forth in claim 13 which includes: connecting a coupler to the buttonhead fitting, andinjecting fluid through the coupler into the buttonhead fitting internal bore to flow through the base internal passageway into the valve.

17. A method as set forth in claim 13 which includes: providing a valve testing device having a coupler extending therefrom,connecting the coupler to the buttonhead fitting to place a chamber within the valve testing device in fluid communication with the valve, andmeasuring the internal pressure of the valve testing device chamber to detect leakage from the valve.

18. A device for testing a subterranean valve comprising: a coupler,an extension tool having a handle, an elongated member, and a pressure gage,the elongated member connecting the handle to the coupler and having an internal chamber communicating with the pressure gage,the handle for manipulating the extension tool to insert the coupler into a limited space work area containing the subterranean valve,a plunger mechanism having a reciprocating internal rod positioned therein,the plunger mechanism adjacent to the coupler to facilitate insertion of the rod into the coupler, andthe rod opening a check valve on a valve stem extending from the subterranean valve to allow fluid to flow from the valve stem into the elongated member internal chamber, so that the pressure gage detects leakage from the valve stem by measuring the elongated member internal chamber pressure.

19. A device as set forth in claim 18 which includes: the plunger mechanism rod extending through the elongated member internal chamber.

20. A device as set forth in claim 18 which includes: the plunger mechanism rod being essentially perpendicular to the elongated member.

21. A device as set forth in claim 18 which includes: the handle being a tee handle.

22. A valve testing apparatus comprising: an elongated tubular member having an internal chamber,means for connecting said tubular member to a fitting extending from a subterranean valve,a plunger mechanism for inserting a rod into the fitting to allow fluid to flow from the valve to the internal chamber, andmeans for measuring the pressure of the internal chamber to detect fluid leakage from the valve.

23. A valve testing apparatus as set forth in claim 22 which includes: means for manipulating the elongated tubular member.

24. A valve testing apparatus as set forth in claim 22 which includes: means for actuating the plunger mechanism.

25. A method for servicing a subterranean valve comprising: inserting a valve testing device into a limited space work area to engage a coupler with a valve stem extending from the subterranean valve,actuating a plunger mechanism to insert a rod into the coupler to open a check valve positioned on the valve stem,allowing fluid to flow from the valve stem into the valve testing device, andmeasuring the valve testing device internal pressure to detect fluid leakage from the subterranean valve into the valve stem.

26. The method as set forth in claim 25 which includes: disengaging the valve testing device coupler from the subterranean valve,inserting an extension tool into the limited space work area to connect another coupler to the subterranean valve, andinjecting fluid through the extension tool coupler into the subterranean valve.

27. A method as set forth in claim 25 which includes: inserting an extension tool into the limited space work area to actuate the plunger mechanism.

28. A method as set forth in claim 25 which includes: disengaging the valve testing device coupler from the subterranean valve,inserting an extension tool into the limited space work area to connect another coupler to the subterranean valve, andinjecting fluid through the extension tool coupler into the subterranean valve.