Mains and Service Replacement through Keyhole

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 July 2014

01 January 2019

56 months

£2,765,417

Technical Consultancy

South East

Network Innovation Allowance

Project Contact, SGN

The objective of this project is to develop an innovative solution to be utilised in conjunction with SGNs keyhole excavation techniques, to allow the trenchless replacement of PE mains and services by both live and dead insertion methods. In order to address the scope, the work has been divided into two specific Elements, which represents sub-projects under the Project scope. The objectives of each Element are as follows: Element 1: Design, develop and manufacture a keyhole located and operated pipe installation system that will install PE pipes in the size range of 25mm through to 90mm, but specifically will be provided with a range of Long Handle Tooling (LHT) designed and manufactured to install and remove a service connection as required. Element 2: Design, develop and manufacture a mains replacement insertion system for live or dead insertion of pipes (63mm through to 180mm diameter) inside existing metallic pipes from a 600mm diameter cored keyhole excavation. The Project will evaluate the effectiveness of both Elements against current replacement methods to determine the potential cost benefit. The project will be deemed to be successful if the following outcomes are achieved: Carry out design, development and manufacture of mains and service technology and keyhole tooling to meet industry and SGN standards and specifications. Produce operator guidelines detailing the correct operating procedure of the equipment for the trials. Development of an associated training packages for field trial Assess the potential benefits of this technology solution against current mains and service replacement activities. Produce and disseminate learning based on final project report.

From the 1850s up until the 1950s metallic 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 replacing those mains with polyethylene pipe, in order to reduce and eliminate risk of fracture, corrosion, and/or leakages. At present across Scotia Gas Network (SGN) there are approximately 5,000 kilometres of small diameter (Tier 1) metallic mains (Throughout RIIO-GD1 Network Licensees are focussing attentions towards Tier 1 replacement activities as part of their total operating expenditure (TOTEX) targets. From 2013 and beyond, SGN have planned to undertake a large number of replacement projects per annum. Such activities are strategically planned with live/dead insertion accounting for a large proportion of these works. Due to the high density of Tier 1 distribution mains in areas of domestic dwellings, inevitably any works carried out will result in a considerable impact on our customers. SGN are now looking to develop a more advanced innovative solution to improve replacement activities of Tier 1 mains through the use of keyhole technology. The new method has the potential to allow mains and service replacement activities (up to 8") to be carried out in an effective way to minimise excavation footprints on replacement projects and reduce the disruption to our customers. The Project is split into two key Elements. Element 1 will provide a keyhole located and operated pipe installation system designated Grundopit KHD 1000/50. It will install PE pipes in the size range of 25mm through to 90mm but specifically will be provided with tooling for pipe sizes 63mm, 75mm and 90mm diameter. Combined with this a range of Long Handle Tooling (LHT) will be designed and manufactured to install and remove a service connection as required, all within the SGN designated keyhole and operated by hand from the carriage way or ground surface. Element 2 is to design, develop and manufacture a mains replacement insertion system. The system will be designed for the live or dead insertion of pipes 63mm through to 180mm diameter in size inside existing metallic pipes from a 600mm diameter cored keyhole excavation. This Project is designated to greatly reduce inconvenience to customers, makes the work less visible and decreases the amount of excavation required by other mains and service replacement methods. 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.

Note : Project Documents may be available via the ENA Smarter Networks Portal using the Website link above

31/08/18