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Projects: Projects for Investigator
Reference Number	NIA_SGN0019
Title	Large CISBOT (Cast Iron Joint Sealing Robot)
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 SGN
Award Type	Network Innovation Allowance
Funding Source	Ofgem
Start Date	01 August 2013
End Date	01 August 2014
Duration	12 months
Total Grant Value	£834,600
Industrial Sectors	Technical Consultancy
Region	South East
Programme	Network Innovation Allowance
Investigators	Principal Investigator	Project Contact , SGN (100.000%)
Web Site	http://www.smarternetworks.org/project/NIA_SGN0019
Objectives	The objective of this project is to develop an innovative solution for the repair of leaking lead yarn joints within SGN’s cast iron mains population. The project will evaluate the effectiveness of the repair technique and associated inspection method to determine extension to asset life and to understand the potential cost benefit. The project will be deemed to be successful if the following outcomes are achieved: Practical assessment of the Large CISBOT’s performance when repairing large diameters mains using the trenchless techniqueCommercial appraisal of the most suitable operating modelAssessment of whether repair to Tier 3 Cast Iron Joints under live gas conditions using CISBOT is possibleThe production of a technical, risk and commercial assessment of the operation of CISBOTUnderstanding of the opportunity to reduce excavation requirements in relation to joint repairUnderstanding of the potential reduction in the amount of material sent to landfillUnderstand the potential to prolong the life of the ageing cast iron mains
Abstract	From the 1850’s up until the 1950’s cast iron mains were used extensively across Great Britain (GB) gas distribution network. Since then the gas industry has moved away from this source of material and is using steel and polyethylene. However a significant portion of larger diameter cast iron is still in use today. At present across SGN there are approximately 843 kilometres of metallic mains >12" diameter that are ageing, requiring inspection, repair or replacement. When installed, these sections of mains were connected at the joint by a bell and spigot. To seal the joints, jute - a plant fibre used in making burlap and twine was packed into the back of the joint, and molten lead was poured into the front of the jute packing creating a gas-tight seal, this is know as a ‘lead yarn joint’. Over time, due to ground movement, winter freeze-thaw cycles and the fact that jute is drying out causing it to shrink and/or crack, we are experiencing leaking joints. Through extensive investigation, it is clear that all Tier 3 mains (18-48" diameter) are less likely to fail through cracks and fractures, and more likely to fail due to leaks within the existing joints. In the past Network Licensees would either fully replace these ageing assets, which is a high cost activity, or aim to maintain them to prolong the asset life. To date the options available to repair large diameter joints have been limited to the use of mechanical joint clamps, encapsulation, or injection of anaerobic sealant into the jute packing. While cheaper than full replacement, these repair techniques have a number of disadvantages including the costs incurred due to significant excavations and material requirements. As Tier 3 mains are predominantly found in city locations, any work carried out on them results in a considerable impact on our customers. An effective method of repair requiring less excavation would be a means of addressing this problem. Following the successful completion of SGN’s Synthotrax I-seal Robot feasibility study, the findings confirmed that Robotic technology offers a step change in the methods used to repair and prolong the life of the ageing cast iron network. An assessment of the available technology in the market was carried out, with ULC Robotics identified as the best placed partner to use to develop the technology further due to their utilization of robotic technology in the US on 16", 20" and 24" CI mains. ULC Robotics have developed a cast iron joint sealing robot known as Large CISBOT. This advanced robotic technology can repair cast iron pipe by internally injecting all of the joints in a given block or area with an anaerobic sealant. The robotic joint sealing operation is performed live through one small excavation, from the rear of a single box truck, and greatly reduces inconvenience to the public, makes the work less visible and decreases the amount of excavation required by other joint repair or pipe replacement methods such as encapsulation or lining. This trenchless technology provides potential for significant cost savings by decreasing the expenditure necessary for taking the main out of service, multiple excavations, restoration and required permitting for these activities. The key stages of the project are listed below: Pre-deployment risk and technical assessmentPre-site inspection using VGC Crawler (camera inspection device)Development and provision of large CISBOT for field trial in the UK. Development of the fittings required to facility attachment of the large CISBOT launch mechanism to the gas mainDevelopment of the large CISBOT launch mechanism under gas free conditions in to the gas mainShipping and delivery of the CISBOT. Field trial of CISBOT including operation of unit on site to determine the technologies compatibility with the GB network. Technical assessment of the ATEX (ATmosphere EXplosibles directive) aspects and quantified risk assessment of the operation of CISBOT. Commercial appraisal of the most suitable operating model. Quantification of anticipated cost benefit. Project Management within approved parameters. Project report.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	10/09/18