Bond and Bolt Saddle System

Completed

Fossil Fuels: Oil Gas and Coal(Oil and Gas, Refining, transport and storage of oil and gas)

Applied Research and Development

ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering)

Not Cross-cutting

Project Contact
SGN

Network Innovation Allowance

Ofgem

01 April 2014

01 June 2018

50 months

£96,977

Technical Consultancy

South East

Network Innovation Allowance

Project Contact, SGN

The objectives of the project are to: Design and develop proof of concept bond and bolt saddle system to be used in conjunction with the existing branch drilling equipment. Develop working prototype and carry out off site testing. Carry out field trials to comprehensively review the new solution in a live gas environment. Carry out a detailed cost benefit analysis for field trials. Provide relevant information to the other Network Licensees. The success criteria for the project are to: Consider a criterion relating to development of the product as well as practices. Develop operational practices to support a bespoke adhesive that will form a long lasting joint to improve a temporary bond and bolt saddle system. Identify the extent to which adhesive solution minimises the size of excavations required when completing branch drilling operations. Produce and disseminate learning around the expected cost and time reductions. Provide Network Licensee with the technical report produced, which will incorporate information on the research, development and field trialling of the new adhesive and saddle. In order to determine whether this project has been successful or not at various stages, the project must progress through a number of stage gate milestones. SGN’s Project Manager will evaluate the performance against the requirements before approving progress to the next stage..

From the 1850’s up until the 1950’s cast iron mains were used extensively across the United Kingdom (UK) gas distribution network. Now the gas industry has moved away from this source of material and is using steel and polyethylene. However a significant portion of cast iron mains is still in use today. At present across Scotia Gas Networks (SGN) there are some 20,647 kilometres of metallic mains When conducting branch drilling operations to connect to or replace sections of mains, the full main must be excavated so that the drilling saddle can be safely secured to the pipe. Over the years many companies have looked to develop and market new products for drilling on the gas distribution networks. In the past SGN have utilised managed services and equipment to perform branch drilling operations, particularly on large diameter mains. The technology already exists to temporarily bond a saddle to the crown of a metallic main without the need to expose the underside of the pipe. This is currently done using a bespoke two part epoxy adhesive that forms a high tensile joint, coupled with mechanical bolts. This process significantly reduces the size of the required excavation hence reducing time and cost. This project will aim to develop a branch saddle joint capable of lasting fifty years. If this solution is achieved it will create substantial savings through a reduction in excavation size and the time taken to carry out a large connection, and significantly reduce the disturbance caused to the public whilst the work is being undertaken. ALH Systems Limited are developing a sealing procedure for cast iron and steel pipes that will reduce excavations to carry out inspections and repairs and a critical aspect of the procedure is the use of adhesively bonded mild steel saddle plate to seal the pipe at the end of the process. The purpose of this project is to provide evidence of the durability of joints prepared in the manner described above through a laboratory based study in which the residual strength of bonded joints is determined after exposure to environmental and load regimes representative of in service conditions. The study will investigate up to 3 different proprietary adhesive systems.Note : Project Documents may be available via the ENA Smarter Networks Portal using the Website link above

10/07/18