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Projects: Projects for Investigator
Reference Number	NIA_NGN_295
Title	Bonded Saddle V2
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 March 2021
End Date	01 March 2022
Duration	ENA months
Total Grant Value	£259,150
Industrial Sectors	Energy
Region	Yorkshire & Humberside
Programme	Network Innovation Allowance
Investigators	Principal Investigator	Project Contact , Northern Gas Networks (100.000%)
	Industrial Collaborator	Project Contact , Northern Gas Networks (0.000%)
Web Site	https://smarter.energynetworks.org/projects/NIA_NGN_295
Objectives	In 2014, ALH Systems developed the Bond and Bolt system that requires only the crown of the host pipe to be excavated. Whilst this has clearly defined benefits in reducing the need for excavation and improvements to safety, the process to install a saddle takes a little over 24 hours to install as the resin technology used in the process, requires a full 24-hour cure period. Bond and Bolt was developed to enable operations to drill 3” – 6” openings for camera surveys, flow stopping and STASS robotic surveys. Following on from Bond and Bolt, this evolved in to the Bonded Saddle which is designed to enable access up to a 2” opening but the resin technology developed further to enable a 90-minute cure. It is proposed that further development of the resin technology of the Bonded Saddle can be innovated further to be used on the Bond and Bolt saddles. This will enable the same access capabilities, but with a significant decrease in time required onsite to carry out operations such as STASS and flow stopping. Traditionally, using Bond and Bolt requires mechanical bolting to the host main to further support the adhesive, however developments and advancement of resin technology now enables the opportunity to speed up the curing process whilst also enhancing the resin capabilities. Stage 1 - Completion of Resin testing Clearly defined project scope with anticipated project outputs Calculations of resin and mechanical requirements clearly documented in accordance with the outputs from the FMEA event ALH In-House report on initial findings issued to and approved in principle by Rosen Stage 2 - Completion of mechanical development Non-Tap Plug installation completed with extended NTP carrier ready for trial All saddles for CI / SI and Steel drawn up and ready for manufacture Necessary drafted work procedures updated for review Stage 3 - Rosen Testing Support initial FMEA 8 off saddles (4 at 18 Cast Iron, 2 at 48” Steel and at 48 Cast Iron) delivered to Rosen for testing. As part of testing, the saddle provided may utilise existing bond and bolt saddles, ie will carry 5 off holes. The reduction in surface area for the adhesion is perceived to be minimal however these can be blocked up where necessary Supply of Field Engineer support for testing Support Rosen with test report close out Stage 4 - Completion and Validation All agreed number of field trial completed – perceived requirements. The objectives of the project are: Development of a suite of technical reports to support the in-house manufacturer testing of the resin Carry out physical tests at 3rd party partner to validate in house testing and therefore offer assurance for network approval Carry out live, G23 Field Trials to confirm anticipated reduction in time taken to carry out operations are proven and thereby validate the Cost Benefit Analysis Clearly identify the cost savings against traditional alternatives for using Bonded Saddle technology Utilise existing saddles to remove the need for additional tooling
Abstract	This project is to further develop the ALH bonded saddle to allow it to be used for flow-stopping and STASS robotmains entry as well as challenging the current D/4 drilling regulations.Northern Gas Networks (NGN) have fully implemented the use of Bond and Bolt saddles as part of the STASS operation, which is attached to the metallic main using a resin based adhesive and bolts.The technology allows a number of benefits including increased safety to operatives and general public and cost savings on excavation and reinstatementThe D/4 drilling regulations mean that NGN are only allowed to drill a hole ¼ the size of a main to gain access (a 5 mm hole in a 20 mm pipe for example) as the current train of thought is that anything bigger will undermine the stability of the main. There is no substantial evidence available to accurately dispel thislegacy regulation and as such an investigation and findings need to take place (as a part of this project) to ensure we can change regulation safely.One limitation of the current method, Bond and Bolt, is that the resin used requires a 24-hour cure before any ALH System 3 drilling operations can take place. The resin utilised in the new technique, Bonded Saddle, only requires a 90-minute cure time prior to drilling, albeit the drilling uses an ALH System 1 drillrather than a System 3.The D/4 challenge is that we are unable to access some mains with our robotic technology due to not being ableto drill a hold big enough to launch the robot. A specific example here is that STASS requires a 6” drilling tolaunch the robot, therefore for any main less than 24” diameter we are required to excavate fully around the main and install and encirclement clamp to facilitate drilling. A key example here is that 18” mains is the primary work basket for STASS and is the largest volume of repairs undertaken on Tier 3 pipes.
Publications	(none)
Final Report	(none)
Added to Database	19/10/22