Ball Valve Replacement

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 May 2018

01 October 2020

ENA months

£139,329

Energy

South East

Network Innovation Allowance

Project Contact, SGN

Develop a solution to extract two types of ball valves from GD Governors located within the SGN regions. It is proposed to install a mechanical extraction device around the shut Ball Valve by removing the handle. For the next stage it is proposed to utilise the principal of an existing Arctic Driver System, currently used to extract ferrules under pressure in the water sector. This will then be further developed to allow for a full encapsulation of the ball valve and extraction gas free while securing the Ball Valve at all times throughout the process whilst live gas is present.The project will focus on the conceptual design and manufacture of a prototype sealing system. This system is to isolate beyond or around the leaking or corroded ball valve to allow them to be removed.A pre-production phase prototype will be developed and deployed over 3 live field trial sites with the results of the trials being fully assessed. The project will focus on the conceptual design and manufacture of a prototype sealing system. This system is to isolate beyond or around the leaking or corroded ball valve to allow them to be removed.It is proposed, by installing a mechanical extraction device around the shut Ball Valve by removing the handle – based on the existing system that is used to extract ferrules under pressure in the water sector – this will allow for a full encapsulation of the ball valve and extraction gas free while securing the Ball Valve at all times throughout the process.This would be the first time that this methodology would be used on a live UK gas network. Complete and provide a detailed conceptual design to meet the performance criteria for the extraction of ball valves from GD Governors. Complete a risk assessment and gap analysis of the conceptual design against relevant aspects of primary and secondary legislation, SGN and Gas Industry standards. Carry out a detailed design review, addressing design gaps identified. Manufacture prototype for use and carry out offsite testing against criteria specified. Following completion of the off-site testing, incorporate any design revisions as required to allow approval for live field trials or otherwise. Provide training package and training for operatives carrying out the valve replacements. Support the installation and track performance of at least 3 live field trials. Assess the performance from the trials and review the outcomes and provide recommendations Following the live trials, prepare installation and maintenance Work Instructions in SGNs Safety Management Framework (SMF) format. A detailed final report is required on completion of the project.

External corrosion has been identified on auxiliary valves on the impulse rails to the governors. The external corrosion is due to condensation from pressure reduction, and galvanic corrosion due to dissimilar metals. There are a significant number of governors within SGN network operating at 2 to 7 Bar consisting of approximately 1600 Streams. Currently the governors must be bypassed or isolated at the fire valve to enable the valves on the impulse rails to be removed and replaced. This can often lead to a stream replacement or a full governor replacement.

09/11/22