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Projects: Projects for Investigator
Reference Number	NIA_NGN_205
Title	System Two Assess and Seal System (STASS)
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 Northern Gas Networks
Award Type	Network Innovation Allowance
Funding Source	Ofgem
Start Date	01 April 2017
End Date	01 January 2019
Duration	21 months
Total Grant Value	£866,666
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_205
Objectives	The primary objectives will be to provide the necessary products and process to allow innovative and alternative method for to allow the sealing of joints in Tier 2 and Tier 3 mains. This will include the following defined outputs: Stage 1: Laboratory testing of the complete system - TRL6 - 4 MonthsDevelopment of existing Synthotrax platform to allow the deployment of sealant up to 130m from access pointDemonstration in as bench top / laboratory system (non-gas)Stage 2: Field trial testing of the complete system - TRL7 - 4 MonthsDevelopment of the Stage 1 system for use in a simulated operational environmentDemonstration in a simulated environmentGeneration of Risk Assessments and Method Statements for progression to Stage 3Stage 3a: Mobilisation - TRL8 - 4-6 monthsField Trials in working environmentTraining and Skills assessmentSupport of standards and approvalsTechnical ApprovalsSupport of G23 Field Trial documentationAssess drilling sizes for T2 and T3 mains e. g D/4 vs D/3. 33Stage 3b: Feasibility Study for potential future developmentIdentify and assess the potential for ‘bolt on technology’ e. g. Leak DetectionOptions for Key hole 12" to 18"Review potential Bond for permanent access fittings to allow future periodic inspections at lower costsUnderstand statistical information to inform GD2Stage 4: Technical & NIA closure report (2 Months)Generation of data foldersCollation of trials dataReview of data management protocols for embedding in existing IT infrastructure The project is deemed successful if, the products and end to end processes are developed that;Meets the requirements of the project objectivesAchieves technology readiness level as detailed in the project scope
Abstract	Northern Gas Networks (NGN) are required under Rep 2 Appendix C required to manage their Tier 2 (a&b) and Tier 3 networks. NGN have 1,700 km of Tier 2 and 3 assets and as such interaction such as repair or assessment is expensive. There are three key drivers for intervention in relation to these assets; leakage, proactive risk management, confirmation of as laid data. During 2015 NGN carried out in excess of 1100 repairs to their large diameter mains with the majority of repairs for leaking joints. THe largest population within the Tier 2 to 3 range was 12", 18" and 24" with associated repair costs being circa £5m. This project will look to address the stated size range of 10" to 48". NGN are looking to address the above three drivers to improve how they can proactively manage their Tier 2b and Tier 3 assets. This is as part of risk management, the treatment of joints and connections will not lower the risk model but will provide NGN with greater management information, with the added benefit of being able to treat the joints and connection buy utilising and enhancing three existing tools and techniques (i) Leakage - the largest proportion of network leakage occurs from joints on metallic gas mains. This is the gas transporters’ biggest impact on the environment and is reflected in the networks’ shrinkage declarations. Methane, the primary component of natural gas, is around 21 times more harmful than carbon dioxide (CO2) and lost gas per annum across all the distribution networks has a carbon equivalent of 4. 56Mtonnes of carbon dioxide equivalent (CO2e). The current method of repairing gas main joints requires a separate excavation on each joint which is both costly and causes considerable disruption to the public, particularly road users. The proposed evolution of three key pieces of technology will offer significant reductions even based on an initial approach to seal all joints and connections. The reason for sealing all joints and connections initially is based on maximising the opportunity from the excavation with up to 64 joints or connections sealed from a point of entry (256m). (ii) Proactive Risk Management - NGN are already using technology to proactively manage risks on their larger diameter mains, at present the repairs to the Tier 2b & Tier 3 assets are reactive, dealing with leaks or issues as they are identified. There is a desire to more proactive, this proposed development would be the first step in combining other leak detection technologies to only treat joints and connections based on either confirmation there is a leak or if statistical data generated identifies other areas for proactive repair. The is a distinct driver to understand the potential costs of managing the larger assets during GD2, this project will help inform the models as these should provide up to 2 years of operational data. (iii) Validation of as laid data - NGN want to increase the information that have on their GIS data base on the as laid mains. There is a desire have a balance of visual data and location data to better inform the models looking for trends that relate to the number of joints / connections per pipe length (Short and Long), the location of joints (accuracy of 10cm) and also depth of mains. The above problem definition is one that all GDNs are seeking to address as a result there are a number of other methods that either have been or are being developed to supportthe above. With this NIA project NGN are looking to approach their problems in a different method to these other technologies with key focus being using three existing and well established technologies - (1) Synthotrax Intelligent Robotic Vehicle (2) ALH Bond and Bolt Technique and (3) ALH Main / Flex-spray LC12 sealants. There are a number of other key technological differences in this project which are covered in this submission. NGN will be working with a UK SME (Synthotech Ltd), based within in their operational network with a proven track record of delivering innovation and collaborating with other companies from within their technology hub. This project will aim to bring together ‘best of breed’ to provide a cost effective solution that allows the technology to be used on a significant scale due to a primary benefit of a proactive treatment of all joints and services of Tier 2b and Tier 3 pipes, and secondary benefit of providing valuable assets information and data collection on the internal condition and geometric data. The project will look at enhancing / utilising four existing TRL8/9 solutions;Synthotrax Intelligent Robotic Vehicle - Suitable for vertical live launch through key hole technologyALH Bond and Bolt - Method of accessing larger diameter mains without the need to fully excavate the large diameter mainALH Main Spray system and sealant - Currently used but with limitation on length up to 40-50m max from one point of entry, allowing joints to be sealed. This technology has very limited push distances in mains beyond 18" less than 25m. Location technology - Use of off the shelf technology such as WinCam, Sonde and Location devices to interact with the Synthotrax system As stated the project differs from other NIA / NICs or known developments the key technical differences are; (a) Disturbance and movement of joint debris(b) Spraying of In-pipe features - e. g. Plugs(c) Access Hole Size - Keyhole (20" and Above - Vertical 6" Mains drilling)(d) Non-drilled application of sealant and low pressure delivery system(e) Development of system that can be operated by NGN direct labour teams to maximise cost benefit - e. g. Non-contracted(f) Low pressure only - ≤75 mbar(g) Understand the challenges with rehabilitating previously anaerobically sealed joints or connections NGN want to be able to upskill their operational teams to undertake the works in a planned approach this means that the technology that is developed will need to consider the operational challenges and end user interfaces. This is significantly different from a solution that was to be only offered as a specialist service, and Synthotech have in recent years focused heavily on providing products rather than services. The project will also look to share in the learning from other NGN NIA projects (186, 202 and 171), there is also driver in the project for other GDNs to share their learning from other projects that could compliment this development in future. This will be a key output from the project which is very much seen as a series of developments to prove, embed, monitor and develop the tools that can be carried by the Synthotrax IRV e. g. leak detection technology and automatic component detection. The project will not be looking at providing savings only this will look at the benefits this brings to the toolbox of techniques which NGN has and can use in their asset management approach. There is clear focus on maximizing technology to better inform and manage the assets in the current regulatory period and beyond into GD2. This approach should provide valuable qualitative and quantitative data for use in better understanding the management of the Tier 2b / 3 asset that are not currently planned to be replaced.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