Forged Carbon Fiber Products (FCFP) - Stage 1

Completed

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

Applied Research and Development

PHYSICAL SCIENCES AND MATHEMATICS (Metallurgy and Materials)
ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering)

Not Cross-cutting

Project Contact
SGN

Network Innovation Allowance

Ofgem

01 March 2017

01 September 2018

18 months

£330,247

Technical Consultancy

South East

Network Innovation Allowance

Project Contact, SGN

The objective of this project is to give assurance that Forged Carbon Fibre can be used to manufacture a range of complex products that are used on the gas distribution network. To do this, the project will redesign and manufacture 5 products maximising the material properties and then test those products against the existing metal based product standards and specifications. Assurance gained through testing will be used to support an ongoing Stage 2 which will incorporate field trials of the products. The success criteria for the project are: Technical review of product conceptual design of the products to relevant industry standards and legislationGap analysis and risk assessment against industry standards and specificationsReview and appraisal of design, development, engineering and testing reportsLaboratory testing to simulate the environment the products will be required to operate inCreation of an offsite testing report which details the performance of the products in a non-gas environment and makes an assessment on suitability for field trialRecommendation for Stage 2 field trials

Until the early 1970’s, metals were the default material when creating new, and adding to the gas distribution networks. Due to their corrosive nature of metals and risk that poses, over the last 35 years various iron mains replacement programmes have been in place. The favoured replacement pipe material is Polyethylene or ‘PE’ which is light weight, non-corrosive and offers an up to 80 year life. Until now, the intermediary fittings between differing pipe materials along with any complex parts like valves and the repair fittings for existing pipes have continued to be made of metals to fulfil strength and pressure requirements. This makes them heavy, prone to the same corrosion mechanisms and leaves potential weak spots in otherwise remediated networks. Making these products from metals also has a large carbon footprint due to smelting and working methods. SGN are now looking to develop an initial selection of 5 complex products made from Forged Carbon Fibre (FCF) which is light weight, non-corrosive and is as strong if not stronger than the metals used. Their production can also incorporate recycled carbon materials and is a much less energy intensive process. Under this project the following research and development tasks will be undertaken in collaboration with the manufacture and the appointed technical consultant: Task 1: Design & Engineering of the ProductsCAD design along with basic finite element analysis of the systemsDesign of all vacuum and compression moulding toolsTechnical review of conceptual design of the products to relevant industry standards and legislationGap analysis and risk assessment again GB an EU standardsTask 2: Tooling and Fixtures ManufactureMachining, finishing and assembly of aluminium compression/vacuum mouldsPrinting and finishing of DMLS compression moulding toolConstruction of machining fixtures to be used for manufacturingTask 3: Manufacturing of the ProductsCompression moulding of 3 products along with assemblyVacuum and compression moulding and water cutting of 1 product along with assemblyVacuum moulding of 1 products along with assemblyTask 4: TestingBasic In-house testing following manufactureLaboratory testing to simulate the environment the products will be required to operate inTask 5: ReviewReview and appraisal of design, development, engineering and testing reportsCreation of an offsite testing report which details the performance of the products in a non-gas environment and makes an assessment on suitability for field trialRecommendation for Stage 2 field trialsNote : Project Documents may be available via the ENA Smarter Networks Portal using the Website link above

15/08/18