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Projects: Projects for Investigator
Reference Number NIA_NGN_153
Title Traceability
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 SOCIAL SCIENCES (Business and Management Studies) 100%
UKERC Cross Cutting Characterisation Not Cross-cutting 100%
Principal Investigator Project Contact
No email address given
Northern Gas Networks
Award Type Network Innovation Allowance
Funding Source Ofgem
Start Date 01 May 2017
End Date 01 April 2018
Duration 11 months
Total Grant Value £20,000
Industrial Sectors Energy
Region Yorkshire & Humberside
Programme Network Innovation Allowance
Investigators Principal Investigator Project Contact , Northern Gas Networks (100.000%)
Web Site http://www.smarternetworks.org/project/NIA_NGN_153
Objectives Stage 1Complete workshop with up to 4 potential supplierDevelop principle agreement on adoption of designed process Stage 2 Modify Existing System to meet requirements of suppliersDevelop technology to meet business requirementsDevelop system integration processDesign data transfer systemDevelop bespoke system for trial Stage 3 Install developed system to integrateAVK App3rd Party Processes/SystemsNGN - Receive, Store and Retrieve DataTest system on purchase made from 3rd Parties Outputs: Development of data transfer system that stores information supplied directly from the fittings manufacturer/supplier,Allowing NGN to book items into stock locations/sites,Creates an inventory management,Assigns a unique QR label to the product,Uses a bespoke application to scan and add those items to database enabling an upload to current NGN Asset Management System. (SAP and Data books) The project will be deemed a success if the following criteria are met: - End to end traceability of key high value material. Reduced waste through loss of fittings being reduced. Reduced likelihood of human error in recording or missing data. Increased likelihood of supply of required certification from manufacturers and suppliers. Reduced need to deviate from NGN specifications and detailed design. Reduced reliance of 3rd party FFP assessment and Quality Assurance. Reduced cost of 3rd party FFP assessment and Quality Assurance. Improved data integrity. Reduced workload for MP Site managers in collating materials and Deviations.
Abstract Networks have encountered a number of incidents whereby products installed onto the network require recalling due to manufacturing or installation issues. The process of identifying products, covered by the recall, and locating those products on the network can take significant resources. Suppliers of key products do have robust Quality Management Systems (QMs) in place; however GDNs do not currently take advantage of these to manage traceability following receipt and installation of assets. Products such as Emergency Control Valves (ECVs), buried valves and PE pipe fittings are all delivered from the suppliers with individual serial numbers, batch numbers and manufacture dates, line number and operator which, if captured correctly, would allow for relatively straight-forward recall in the event of a batch issue. Such assets can often be installed on the network in large volumes which can exacerbate the issue if they are difficult to locate. As an example the GDN currently install 60,000 Emergency Control Valves to domestic and commercial gas services annually, which is undertaken by approximately 200 engineers. There is a requirement for key assets to be able to be identified to allow for targeting of replacement or recall to assist quality management. NGN is experiencing difficulty in recording and capturing details for steel fittings used to construct the >7bar network (bends, tees, flanges etc. ). This information includes1. Manufacturing and heat treatment records. 2. Despatch and delivery information3. Installation information4. Records system update information. This has resulted in a great deal of extra work and cost in verifying; Material suitability and fitness for purpose (FFP). (3rd party assistance in demonstrating FFP). ; Lost and misplaced materials (Duplication of orders and increased downtime). ; Difficulty in determining the final installation location of the item(s). ; Record systems are paper based, (Easily lost, misplaced costly to store and manage)This problem is found throughout the UK gas distribution networks. This purpose of the project is to overcome the problem by means of proof of concept trial which will be undertaken to determine how QR coding can be used for metallic pipeline systems to capture, track and record electronically used involving a technology solution to address points 1 to 4 of the problem. This project will be undertaken on one capital build project with up to 3 manufacturer/suppliers. End to end traceability of these products is currently undertaken manually and stored in hardcopy. This innovative solution will improve reliability of data capture and eliminate the possibility of human error whilst increase efficiency of data capture and storage.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 17/12/18