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Projects: Projects for Investigator
Reference Number NIA_CAD0004
Title Bonded Saddle for Temporary Mains Access
Status Completed
Energy Categories Fossil Fuels: Oil Gas and Coal(Oil and Gas, Refining, transport and storage of oil and gas) 100%;
Research Types Applied Research and Development 100%
Science and Technology Fields ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering) 100%
UKERC Cross Cutting Characterisation Not Cross-cutting 100%
Principal Investigator Project Contact
No email address given
Cadent Gas
Award Type Network Innovation Allowance
Funding Source Ofgem
Start Date 01 June 2017
End Date 01 June 2018
Duration 12 months
Total Grant Value £238,963
Industrial Sectors Technical Consultancy
Region London
Programme Network Innovation Allowance
Investigators Principal Investigator Project Contact , Cadent Gas (100.000%)
Web Site http://www.smarternetworks.org/project/NIA_CAD0004
Objectives Define product performance criteria - to include: Enable access into the gas network with reduced excavationUse typical tooling available to technician where possible. (i. e. effort made to avoid specialist tools)The bonded saddle must have connection interface for a service valve to enable drill attachmentSaddle size must be sufficient for attaching around existing fittings for removalSafely enable operatives to install a range of fittingsEnable operative to launch devices such as cameras into the mainConsideration to the use within the Core and Vac techniqueAll operations will be performed under no gas conditionLaboratory testing and assessmentTesting will include: Tensile testCombined Tensile and Torsion testCleavage/Peel testFollowing completion of the laboratory tests, a report will be written providing the results, assessments, and recommendations. The G23 field trial procedure will be developed following successful product qualification in the laboratory. G23 Field Trial ProcedureConsideration will be given to: Excavation size requiredMaterials and componentsSurface PreparationBond application and cure timesSaddle, Valve, and drill assembly / disassemblyDrilling and tappingFitting removalFitting insertionQuality AssuranceField Trial Evaluation and reportIt is proposed that ROSEN will attend three field trials which will include steel pipe and cast iron pipe, at least one of which will be part of the valve remediation programme. ROSEN will provide independent witnessing for operational assurance of the bonded saddle technology. The practical application of the G23 procedure will be witnessed, and each process evaluated and feedback provided to Cadent Gas Ltd. Develop Manufacturers SpecificationIt is proposed that ROSEN will develop a manufacturers specification including type testing and batch release testing requirements. Development of the bonded saddle to which will ultimately lead to: Successful product qualification of the product in the laboratorySuccessful product qualification of the product in the field
Abstract Gaining access in to the gas network, for a range of requirements, this could be for new installations, replacement of existing fittings or access for other techniques typically requires full circumferential exposure of the host main to enable chains to hold the equipment in place and access the main under no gas conditions. On smaller diameter mains found in the HSE Tier 1 and 2 range, the excavation size and subsequent costs are not of major significance. However, mains falling in to the Tier 3 range, typically 18 inch and above, can involve large excavation works that are expensive and time consuming. Further advancing the ALH Bond and Bolt technique and adapting the principal to deliver a bond only system for drilling saddle attachment for temporary mains access will speed up the process and enable operations to drill, tap and install new fittings along with the ability to remove an existing fitting where required leading to reduced excavation and increased safety. There is also the potential longer term, for a wider range of uses, however this may require further development. ROSEN UK (ROSEN) will support Cadent with qualification of the bonded drilling saddles for drilling and tapping operations. This would allow threaded fittings to be installed on gas pipelines (for the range of operations described above) as a permanent fixture with only a small excavation. The ‘ bolt and bond’ saddles are currently used to perform flow stop operations. Following the completion of the flow stop operation the ‘ bolt and bond’ saddle is capped and remains as a permanent fitting on the gas pipeline. Cadent Gas Ltd. (Cadent) propose to apply the bonded drilling saddle technique to support additional maintenance activities including: ; Insertion and/or removal of fittings. ; Repair Activities; Small Diameter Connections; Rider bypass during MP valve remediation; Pressure pointsIt is proposed that a drilling machine is fitted to the saddle to enable the gas pipeline to be drilled and tapped so that a threaded fitting to be permanently attached. In this scenario there is no requirement for the saddle to be a permanent fitting and therefore a ‘ bonded drilling saddle’ (i. e. without bolts) development is proposed, thus removing the requirement to tap and insert the bolts.Note : Project Documents may be available via the ENA Smarter Networks Portal using the Website link above
Publications (none)
Final Report (none)
Added to Database 07/06/18