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Project GRAIDProgress Report 2Gas Robotic Agile Inspection Device

December 2015

Gas Network Innovation Competition

Synthotech Ltd Premtech Ltd Pipeline Integrity Engineers Ltd

Synthotech Ltd specialises in providing innovative engineering and technical services to the utility and infrastructure sectors. They are designing and building the robotic platform comprising of the visual, sensory and non-destructive testing (NDT) systems as well as developing the user interface and control systems.

Premtech Ltd provides engineering, consultancy and design management services for on-shore pipeline and associated installation projects of various sizes. Premtech are designing the robot’s launch and receive vessel, the off-line test facility and providing design consultancy services.

Pipeline Integrity Engineers (PIE) Ltd offers consultancy services relating to the integrity management of high pressure gas pipelines and associated installations. PIE are providing third party assurance, supporting the technical team in developing and implementing the technical strategy, and providing integrity consultancy support in translating inspection results into asset management strategies and operational procedures.

Project GRAID Progress Report - December 2015

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Project GRAID is developing innovative technology to inspect complex gas transmission underground pipework at high pressure installations.

National Grid Gas Transmission (NGGT) and its partner organisations are engaged in an exciting project that is addressing the issue of how to inspect complex, below-ground pipework found at High Pressure Installations. The project is developing ground-breaking robotic technology that will be able to provide real-time data on the condition of high pressure underground assets.

National Grid is collaborating with three British Small Medium Enterprises (SMEs) to develop ways to accurately assess the condition of its pipework assets that cannot currently be inspected via conventional Pipeline Inspection Gauges (PIGs). The complexity of pipework at High Pressure Installations (up to 94 Barg) presents a significant challenge for any robotic solution.

The solution being developed will enable NGGT to look inside their High Pressure Installations for the first time since their construction, in some cases dating back nearly 50 years. The current asset management strategy for this pipework relies on above ground survey techniques, and is based on good design and

construction practices having been applied to these assets. If corrosion is suspected the only way to confirm this presently is through excavation, which is both financially expensive and detrimental to the environment. This project will enable a proactive, risk based approach to the management, maintenance and replacement of these ageing assets.

The project highlights NGGT’s commitment to delivering innovation that provides a more reliable and environmentally friendly approach to managing its assets and building value for gas consumers.

There are 350 kilometers of ‘un-piggable’ pipework in the National

Transmission System

Introduction1

Since the last project progress report Project GRAID has progressed on schedule and within budget. The project team has moved from early conceptual work to the production of a 3D printed space model that represents the preferred robot design that will be taken forward to development testing in stage 2. The project has also produced a ‘backup’ design which has been 3D printed but will not be developed further unless the preferred design proves to be unworkable at a later stage in the project, mitigating the risk of a terminal issue with the primary design. The project has also submitted its first patent application (GB1520462.1) to protect intellectual property created during Solution Development.

This reporting period has also witnessed the successful completion of stage 1 and following a stage review by the project executive, stage 2 is now underway. The project sponsor signed off stage 1 and authorised stage 2 to commence, evidence of which is available at annex A.

Key Deliverables

During this reporting period the following notable deliverables have been completed:

1. Alpha Development. Alpha development represented Synthotech’s design methodology for stage 1 of the project. It encompassed all of the activities contributing to the eventual production of the preferred design in 3D printed models. Since the last progress report Alpha development has focused on drive systems, vision and sensor packages, control software, the umbilical/tether and computational fluid dynamics (CFD). CFD has grown in importance as the team has developed its understanding of the environmental conditions found inside high pressure pipework. Synthotech have produced two 3D printed prototypes of the preferred design and the backup design for bench testing. They have also conducted experiments with wireless technology, investigating the range and integrity of wireless signals inside buried pipework, the results of which will be included in dissemination activity.

Executive Summary2

This is the second progress report for Project GRAID following the successful Gas Network

Innovation Competition award in November 2014. This report documents the progress made

since the last project progress report submitted on the 19th June 2015, and the key activities that

will take place over the next six months. This period has seen the project progress from stage 1

to stage 2 and the end stage report is included as an annex to this document.


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Preferred Robot Design

The aerodynamic, bio-inspired shape form has been designed to withstand the extreme conditions found within high pressure pipework.

2. Trial Site Modelling. The closure of stage 1 saw the completion of the 3D models for the project’s three trial sites. This has been one of Premtech’s main work packages and resulted in three highly accurate 3D models of the Bacton, Tirley and Wormington Above Ground Installations (AGIs). The data contained within the models has provided the project with the means to identify potential launch locations as well as identify routes that the robot can take in order to meet the project’s scope definition. This is crucial as access to the pipework at high pressure installations is limited due to the fact that they were never designed to be in-line inspected. Site access will determine robot routes, which in turn determines what percentage of each AGI can be inspected. The 3D models have also proven useful to other parts of the business with various Bacton projects realising savings of £63k as a result of using data from the models.

3. Test Facility Conceptual Design. The offline test facility has been the subject of much analysis, particularly concerning its construction and location. Following a tender process and subsequent cost-benefit analysis, it was decided that outsourcing the test rig to a third party represented the lowest risk option and best value for money. Stage 1 saw Premtech complete the conceptual design for the test facility, which will now be transferred to the third party contractor for detailed design and construction (subject to contractual confirmation). The conceptual design has enabled Synthotech to produce a draft test strategy for offline

trials and better understand the characteristics the robot must be able to demonstrate before the project team is allowed to conduct online trials.

4. Launch Vessel Design. This reporting period saw the completion of the conceptual design of the launch and receive vessel. The vessel’s final design is dependent on confirmation of the robot’s dimensions and the end-closure that will be used, which is subject to an NGGT safety approval process. The key features are the through-wall connection providing power and connectivity to the robot, and external hand wheel and through-wall stem for manual retraction of the robot in the event of a power failure.

5. CFD Study. An important element identified during this reporting period has been the requirement to understand the drag forces that will be applied to the robot while it conducts an inspection of the buried pipework in a live gas environment. A preliminary numerical analysis has been conducted and formally reported by Newcastle University which included the development of a theoretical model for the calculation of the drag force on an object subject to high gas pressure and flows in a pipework system.

The next stage in the study is to conduct Computational Fluid Dynamics (CFD) simulations in order to be able to relax some of the assumptions made in this study, and specifically to improve on the one dimensionality of the flow and include the effects of fluid compressibility.

Key Risks

All risks and mitigating actions are described in the project risk register, a copy of which is enclosed at annex B. A summary of the key risks facing the project is available at paragraph 11. By way of an introduction:

1. Risk to Budget. As the project has progressed a number of additional challenges have arisen. In trying to gain a better understanding of the gas flow conditions

inside high pressure pipework, complex CFD studies are required. These studies are potentially expensive and a cost benefit analysis will be conducted to determine whether they will de-risk online trials sufficiently to warrant the extra cost. The CFD studies will be valuable to the wider gas industry and there is currently no specific research into this area.

The cost of field trials (stage 3) is currently forecast to be greater than the current stage allocation. The testing strategy is being refined following learning from stage 1 which will then clarify the exact variance predicted for stage 3. A change request will then be submitted to re-allocate labour underspend from stage 1 to stage 3.

Executive Summary

Computational Fluid Dynamics (CFD)

CFD will help the team to understand the drag forces that the robot will be exposed to in a simulated en-vironment. The data will influence the shape of the robot’s shell to produce a shape that maximises down-force whilst minimising disruption to the flow.


3D models of the trial sites will help identify potential launch points

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Executive Summary

2. Website Traffic. The project’s website has received 570 visitors during this reporting period and has experienced spikes in traffic following events where GRAID was present, demonstrating the value of conferences as part of project dissemination. The project has also received international interest with website traffic being recorded from Norway, the United States and the Netherlands in particular.

3. Newsletter Distribution List. Individuals are added to the project’s newsletter distribution list on request and it now numbers 173 people from 18 countries.

2. Risk to Online Trials. Above Ground Installations (AGIs) were never designed to be in-line inspected. As a result, gaining access to the pipework is a challenge due to the lack of connection points and the congested nature of the sites. There are a variety of connection methods available at varying degrees of cost. A study into connection methods is a key part of stage 2 activity; however there is a risk that the most suitable connection method/location does not allow for a large percentage of inspection coverage. The requirement for in-line inspection access points will be fed back to future AGI design teams to assist in creating more cost effective inspections runs.

Key Dissemination Activities

There have been a number of internal and external dissemination activities conducted during this reporting

period. The project communications plan identifies project stakeholders and the communication methods that will ensure stakeholders have access to theproject’s results, methods and learning outcomes. The project communications plan was updated at the end of stage 1 to reflect additional stakeholders identified and review the effectiveness of dissemination activities conducted so far. Since the last project progress report the team have conducted the following activities:

1. Presentations. Since June 2015 the project team has presented GRAID at the following external events:

• Low Carbon Networks & Innovation Conference.• Energy Utilities Alliance (EUA) Network Engineering & Equipment Group.• UK Onshore Pipeline Operators’ Association Annual Conference.• Institute of Engineering Technology (IET) Seminar: Robotics in Extreme Environments.• Ageing Pipelines Conference.• Institute of Gas Engineers and Managers (IGEM) South West Event.• Gas 2015.


LCNI Conference 2015

The Low Carbon Networks & Innovation Conference 2015 took place in Liverpool, UK in November 2015. Project GRAID featured as part of NGGT’s exhibition stand as well as presenting a project update with Q&A to conference delegates.

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Project Manager’s Report3


The key activities over the past six months have been the identification of a preferred robot

design and backup design, the completion of accurate 3D models of the online trial sites,

completion of the conceptual design of the launch and receive vessel and completion of the

conceptual design of the offline test facility.

Since the last progress report the project has progressed on schedule and within budget. This reporting period has seen the successful completion of stage 1 (Solution Development) and stage 2 (Development Testing) is now underway. A preferred robot design has now been identified and 3D printed along with a backup design that will be held in reserve to mitigate the risk of problems with the preferred design later in the development process. The 3D printed model of the preferred design has been fitted with mechanical components to test drive, communication, vision and sensor systems that will be further developed during stage 2 (Development Testing). This will culminate in the construction of the robot into a metallic prototype that will move forward to stage 3 (Field Trials).

The robot’s control station, the Operator Control System (OCS) has been developed and a prototype manufactured. The OCS will continue to be refined during stage 2 in line with the robot’s development and is interchangeable with the backup design should it be required. As project GRAID is adopting a tethered approach, the robot will have an umbilical cable physically connecting it to the Umbilical Management System (UMS) located inside the launch and receive vessel. The umbilical will serve a dual purpose of providing power, control and communication data as well as acting as an emergency retrieval system should the robot malfunction inside the pipework.

The 3D modelling of the online trial sites has been completed and route planning and connection analyses have begun as part of stage 2’s activity. The 3D models are a highly accurate representation of the above and below ground pipework at the Bacton, Wormington and Tirley AGIs. The models not only show accurate pipework layout, but also contain data on the pipework and components which can be mined for other information such as gas volumes. The Bacton 3D model has already been used by other projects within NGGT to locate buried features without having to refer to manual methods, saving approximately £63k of labour costs.

The launch and receive vessel conceptual design has been completed and a potential supplier selected. The design of the launch and receive vessel will be refined during the early part of stage 2 as the robot and UMS dimensions influence the final launch vessel design. Once the design is finalised and approved by NGGT the vessel will be procured in time for the start of offline field trials.

The test facility has represented a challenge during this reporting period. In the previous progress report it was stated that the team’s intention was to locate the test facility at Pipelines Maintenance Centre’s (PMC) site in Ambergate.

Part of the project’s activity during the second half of stage 1 was to conduct a cost benefit analysis of several options for the procurement of the test rig.

As a result of this process it was decided that the option that offered the most comprehensive testing capability and safe environment was an outsourced solution for offline trials to a 3rd party instead of building a test rig at PMC Ambergate.

The offline trials are now expected to take place at DNVGL’s test range at RAF Spadeadam (subject to confirmation of contractual arrangements). The test rig will be moved to PMC Ambergate following offline trials for use as a potential robot training facility for the wider gas industry.

Robot concept development during stage 1

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Wez Little, Innovations Director at Synthotech explains some of the key features of the preferred robot design to Pauline Walsh, Director of Gas Transmission Asset Management, National Grid during the stage 1 review meeting.

Project Manager’s Report

Stage 1 Completion

Stage 1 was completed on 30th October 2015. The stage report is available at annex F. The stage was divided into 9 work streams with 3 being completed at the time of the previous project progress report (PPR) and all 9 completed at the end of the stage. The stage remained on schedule through its duration and helped to refine the plan for stage 2. Stage 1 was reviewed by the project sponsor on the 9th November 2015 after which the sponsor confirmed that stage 1 deliverables and Successful Delivery Reward Criteria had been met, and approved stage 2 to begin.

Project partner stage reports are available at annexes C and D. The work streams completed during this reporting period are as follows:

1. Site Modelling. The 3D modelling of the three trial sites, the robot test facility and the launch and receive vessel were fully completed during stage one, all issues encountered where fully addressed. For the trial sites, Kubit PointSense component recognition software was used and proved a very effective tool to accurately and efficiently position above ground pipework, components and features. To obtain the full benefit of the component recognition software, an extensive and detailed catalogue or database of components should be developed. This will speed up the development of future site models by creating a more automated process.

Stage 1 Review

2. Launch & Receive Vessel Design. The detailed design of the vessel is still subject to further refinement of the robot itself, but the vessel’s conceptual design has been developed to enough detail that the procurement process can be started and the order made following a final design update. RMA have been chosen as the supplier due to their established position as a world leader in through-wall gland seal technologies, a crucial and safety critical component of the launch vessel.

3. Replacement Asset Carbon Footprint. The objectives of the replacement asset carbon footprint work stream were to use the 3D models of trial sites to estimate the carbon cost to replace the existing pipework systems at the GRAID trial sites. The work would also allow the team to estimate the carbon footprint to inspect buried pipework by traditional excavation of the buried pipework, allowing for a comparison of new vs old inspection techniques. The team used the 3D models to create a catalogue of components with carbon values attached. This will result in a more automated and cost effective process for any future site modelling that might take place.

4. Formal Process Safety Assessments (FPSA). The FPSA process was conducted for the test facility that was originally intended to be at PMC Ambergate. From the HAZID, HAZOP and HAZCON studies, a number of potential planning and environmental issues were identified with the PMC Ambergate location. It was also highlighted that during offline trials, noise and nitrogen venting (dispersion) may

have a detrimental effect on the local environment at the PMC Ambergate site. The project risk register had identified these factors from an early stage and the mitigating action of using an alternative location was enacted. Further FPSAs will be conducted during stage 2 for online trials.

5. Test Facility Conceptual Design. The conceptual design of the test facility was completed allowing the robot development team to better understand which features were most commonly found at AGIs and could present the biggest challenges to the robot. The conceptual design was also used to obtain quotes for its construction from potential suppliers. The conceptual design was used to benchmark the four supplier options and following a study into the suitability of each supplier option a preferred supplier was selected.

Launch and Receive Vessel development render

Test facility concept design

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6. Robot Alpha Design. Alpha Development was the term given to the first stage of the robot’s development and forms part of Synthotech’s design methodology. During the previous reporting period the robotic concept and methodology study was completed, the specification defined and Alpha design phase started. As a result of the Alpha design work stream three robotic concepts have been produced and form the basis of the project’s patent application. More detail on the Alpha design phase is available at annex C.

Concept 1 – Streamlined Magnetic Robot

1. Streamlined low profile body 2. Modular NDT scanning module 3. NDT articulation system 4. Forward camera 5. Rear facing camera 6. Drive tracks and suspension system 7. Magnetic free rolling wheels 8. Umbilical connector

• Aerodynamic shape and form of the outer body based on a bio-inspired dolphin shape. A dolphin’s shape form is c.130 times more drag efficient than a sphere.

• Track suspension and tensioning for debris negotiation.• Integration of potential NDT and other secondary sensors.• Front and rear camera integration.• Chosen as preferred design to progress to stage 2 development testing.

Concept 2 – Wall Press Robot

Preferred design that will be taken forward to stage 2 (Development Testing)

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Stage 2 Progress

Stage 2 is now underway and is on schedule and within budget. The first six weeks of the stage have seen the following work streams performed:

1. Update of Stage 1 Documents. A thorough review has been conducted for all stage 1 documents including all project management documentation, basis of design documents (BoDD), registers, work flows and process maps.

2. Standard Connections Study. Premtech are producing drawings and reports for the standard connection options available for the robot to gain access to the pipework. A connections working group has been established and a separate global study has been commissioned to investigate new and innovative

methods of connection in use around the world. The aim of the connections study is to find the most cost effective and safe method of getting the robot into buried pipework at HPIs.

3. Beta Development. Synthotech’s robotic design methodology for stage 2 is known as Beta development and involves the production of a laboratory ready system that can undergo simple bench testing.

This phase is split down into ‘development sprints’ and there is a sprint for each of the main elements of the robotic system: the robot, the UMS and the OCS. Development sprint 1 has been completed on time and development sprint 2 is underway.

4. Continuous Activity. There are several work streams that are continuous throughout the whole project. These include a global tech watch, a patent watch and stakeholder engagement activity.

Future Focus

The next six months of activity will see the continuation of stage 2 development testing as well as the procurement of the launch and receive vessel and the start of construction of the test facility.

Synthotech’s focus will be on the development of the three main elements of the robot system. Firstly the robot itself which comprises the drive and track systems, camera systems, NDT sensors and control systems. They will also be undertaking a CFD study in association with PIE to better understand the drag forces that the robot will be subjected to inside the pipework. Secondly, Synthotech will be further developing the OCS, in particular the hardware and software systems, layout and ‘ruggedisation’ for field use. Thirdly, they will be working on the UMS. This will include the design of the cable management system, the reel control system and the input of the UMS into the final detailed design of the launch vessel.

Premtech will be focusing on the development of the connection methods and processes. The connections work stream is one of the most critical of the project as getting access to buried pipework at HPIs is a significant challenge and potentially expensive as they are likely to require modifications. Connection points and methods will be designed for all three trial sites and will be subjected to a cost benefit analysis to determine the most cost effective method.

The NGGT project team will continue to manage the overall project and all stakeholder engagement activity, but it will also focus on the approvals process required to connect to the National Transmission System (NTS). There are a number of policies and procedures that the equipment must adhere to in order for NGGT to consider the system safe to use on the NTS. Additionally, there will need to be development of new procedures for the use of the robotic platform. The project must also integrate with the activity forecast at the trial sites during online trials to deconflict with other pre-planned activity. Early engagement has already taken place and the project team will work closely with these key internal stakeholders.


Cross section of the UMS inside the launch vessel

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Executive Summary1

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At present the project is progressing on schedule and as per the project plan. As part of the end stage review process for stage 1, a review of the stage 2 plan was conducted and some of the stage 2 work packages were refined as a result. The stage 2 plan was presented to the project sponsor during the end stage review and approved.

All project deliverables were completed on time; a report detailing stage 1’s deliverables is available at annex E. Synthotech and Premtech’s stage reports are available at annexes C and D respectively.

Summary of schedule performance during stage 1:


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Business Case Update4 5 Progress Against Plan

The overall business case for carrying out the project remains unchanged and will potentially strengthen as interest builds from across the industry. There are significant benefits to having in-line (internal) inspection to complement existing external inspection methods. It will ensure that understanding of asset condition is enhanced and maintenance managed effectively. It is currently not possible to use PIG methods on pipework

at High Pressure Installations due to the varying pipe geometry and high pressure. The project is developing a solution that will bridge a current capability gap, which if addressed, could reduce the likelihood of an asset failure and the consequential financial, environmental and reputational damage. There are no changes to the expected financial and environmental benefits highlighted in the original NIC submission.

Rich Waine and Ian Butt from the project team discuss Project GRAID’s development with Darren Elsom, Head of NetworkEngineering, NGGT.

Stage 1 Review

Executive Summary1

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Equipment - The equipment budget is being preserved in order to procure the launch and receive vessel which will take place in stage 2. Whilst there is no change to the overall equipment budget, there is a re-ordering of activity in the plan which will lead to an increased spend on equipment in stage 2, correcting the variance.

PIE - The demand on PIE’s time during stage 1 was greater than anticipated.

The technical assurance PIE has provided throughout stage 1 has been invaluable to the project, providing confidence that the project is delivering an optimal solution and value for money. PIE had identified an increase in their costs early and informed the project lead. An over-spend on PIE’s services during stage 1 was authorised due to the value of their work and was offset against a reduction in another partner’s stage 2 costs following the refinement of the stage 2 plan.


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Progress Against Budget6

The project is currently 7% under budget. This was caused by minor changes to the project team during the initial stages of the project. Project GRAID’s budget for stage 1, as set out in Ofgem’s project direction, was £1,671,218.19, based on estimates in the NIC submission bid; however an internal re-ordering of labour requirements meant that a recalculation of project labour costs was required. The updated stage budget was £1,437,839.24 and the actual spend during stage 1 was £1,340,910.46. A change request is to be submitted requesting amendment of the remaining project stage budgets. This will reflect the increase in estimated labour costs during field trials that will be soaked up by the labour underspend carried from stage 1. All supporting documentation will be provided.

1. Variance. The variance of £96,928.78 is explained as follows:

NG Labour - Changes to the project team in the early part of the stage resulted in less chargeable time recorded than was allocated in the budget. Additionally NGGT operational staff costs were initially planned as a straight line over the duration of the project however this cost has now been assessed as being lower at the start of the project, surging during the field trials before reducing again as the project nears completion, following an S curve trend. It is anticipated that this labour variance will be eliminated half way through stage 3 (field trials).

Expenses - This underspend is due to the limited amount of travel undertaken by the team in the early stages of the project. The expenses budget had initially been set at a constant value spread across the life of the project. As the project matures the communications plan will identify more events to attend as part of the Gas NIC ‘knowledge dissemination’ obligation. This will increase travel and expenses expenditure and correct the variance by the end of stage 3.

University of Leeds student Lloyd Taziker worked on Project GRAID as part of a Summer placement

The successful completion of stage 1 also saw the completion of SDRC 9.1. A review of the SDRC criteria was conducted by the project sponsor during the end stage review. The final element of SDRC 9.1 is evidence of internal senior sign off of confirming SDRC 9.1 has been met and this can be found at annex A.

SDRC Criteria Evidence Status Date

9.1 A concept design study of robotic platform completed and scope clearly defined.

A report will be submit-ted by 30 October 2015 demonstrating that these measurable activities have taken place.

Documentation for SDRC 9.1 uploaded to the inter-nal SharePoint site and project file, external ver-sion uploaded to website.

Publish evidence of inter-nal senior sign-off confirm-ing successful completion of SDRC 9.1 no later than 19 December 2015.

Complete 30 October 2015

Created and validated 3D models for each trial site accurately representing pipework configuration.

Complete

Design of a launch and retrieval device to allow robot insertion into high pressure.

Complete

Robotic platform concep-tual design(s) completed, computer models and 3D prints produced, conceptu-al design(s) demonstrates potential to achieve objec-tives of travelling 100m around 2 bends taking visual readings and wall thickness measurements in buried pipework of up to 100 Bar(G) pressure.

Complete

Evidence submitted with PPR 2 on Friday 18th December 2015.

Executive Summary1

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Bank Account

Project Bank Statements

Bank statements have been provided to Ofgem. Due to the confidential nature of the project’s bank statements they have not been included in this report.

7 4 Successful Delivery Reward Criteria8

Executive Summary1

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Intellectual Property Rights9 4 Learning Outcomes10

A register is maintained to identify and track patents that may impact on the project. This will be reviewed and updated as part of the quarterly patent review process. The next review is planned for the end of February 2016. Yeadon IP is leading the searches and the information is being logged and reviewed.

The project has submitted a patent application to the UK Patent Office (reference GB1520462.1) on behalf of NGGT. The filing covers all technology that the project team feels is unique and enforceable. The single filing covers the three concept designs mentioned earlier in this report. The present invention relates to a mobile robot for internally inspecting pipelines, a robotic system comprising two or more such robots and to a method for pipeline inspection as defined in the present independent claims.

During this reporting period the team have closed out stage 1 and disseminated learning through a number of internal and external stakeholder engagement events. Following the filing of the project’s first patent application the team will be able to add detail without jeopardising intellectual property.

The technology being developed by Project GRAID has wide reaching applications across the gas industry and therefore the project has a responsibility to share learning and experience to help the industry improve asset management strategy.

The project has taken steps to share findings through the events organised by UKOPA, IGEM, the IET and the EUA. Internationally the project has presented to a global audience at the Ageing Pipelines Conference 2015. The project has also established links to academia through partnerships with Leeds, Newcastle and Aston Universities. Newcastle University will be publishing a paper in Q1 2016 following learning gained

through a drag force study conducted on behalf of Project GRAID.

Over the next six months the project will continue to conduct stakeholder engagement activity in line with the project communications plan. The team will disseminate learning through industry associations and conferences. The project is planning on presenting internationally at the Pipelines Technology Conference in May 2016.

The project has established links with several academic institutions to assist with solving challenges and sharing research.

Newcastle University have studied the effects of drag forces on objects inside high pressure pipelines.

The University of Leeds Robotics Department have shared research with Synthotech and supplied students to assist with the development of key robotic systems.

Aston University have conducted research into machine vision applications for the robotic platform.

Links To Academia

Project learning is actively recorded via a ‘lessons learnt’ log that is reviewed by the project team each month. Many of the learning points are internal to NGGT and will help to improve the way the organisation implements innovation. The internal learning points are not included in this report. Technical learning is recorded by the project partners and included in their individual stage reports as well as dissemination at events. Over the last six months the following key learning points have been identified:

1. Closer Team Integration. The nature of the project means the team is geographically dispersed. The value

of face to face contact was highlighted in the previous PPR but since then, the core project from NGGT have taken a more proactive approach to integrating with the partner teams. NGGT personnel now regularly work from partner locations on a ‘hot desk’ basis. This has further developed close relationships and understanding between project partners and reduced the length of the decision making cycle, improving agility within the team. This learning point has been fed into NGGT as a recommended approach for other innovation projects.

Executive Summary1

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Learning Outcomes

Dissemination events conducted during this reporting period:

October 2015:

- Energy Utilities Alliance (EUA) Network Engineering & Equipment Group Annual Conference.- UK Onshore Pipeline Operators’ Association Annual Conference.- Institute of Engineering Technology (IET) Seminar: Robotics in Extreme Environments.- Ageing Pipelines Conference 2015.- Institute of Gas Engineers and Managers (IGEM) South West Event.- Gas 2015.

November 2015:

- Low Carbon Networks & Innovation Conference.- SGN NIC Robotics Demonstration Event

December 2015:

- IGEM North East Robotics Demonstration

On the 17th November the project team visited SGN’s demonstration of the CIRRUS XI robot, another Gas NIC funded project that is developing a robotic platform for in-line inspection and repair. The event presented an opportunity for two NIC projects to collaborate and share information for the benefit of both projects.

NGGT and SGN’s NIC robotics project teams meet to discuss potential shared learning

2. Site Modelling. As well as using Kubit software to position all above ground pipework it can be used to position below ground valves. Where a valve stem extension is above ground, Kubit can be used to position a cylinder over the stem extension. From this cylinder,

the valve will be directly below giving you the exact X & Y coordinates of the valve. The only uncertainty remaining is the depth of valve which can be established from as-built drawings.

Learning Outcomes

3. Basis of Design Documents. Detailed Basis of Design Documents may not be appropriate to elements of a project where there is a large element of research and development. The project tried to establish a basis of design early, however for innovation projects where there is a large amount of research and development it may be better to establish a less detailed basis of design document early. This can then be developed into a full basis of the design document as the rationale and assumptions made at the start of the project become clear and parallel design studies develop further.

4. 3D Printing. The process of ‘rapid prototyping’ using 3D printed models has proved extremely useful in generating early design concepts for the robotic platform. The project has produced some large, complex models and 3D printing on such a large scale has raised tolerance issues that were not expected due to heat shrinkage of high volume components.

Newsletters

Monthly project progress newsletters are distributed to a mailing list that now numbers 173 individuals from 18 countries. Additions to the mailing list are by request only and through a combination of direct website enquiries and following conferences. Twitter and Yammer are also used to access social media channels.

Individual technical lessons are described in detail within annexes C and D. It is anticipated that there will be significant learning around the CFD studies that are currently being undertaken between PIE, Synthotech and Newcastle University. The learning gained from this study is due to be published separately and will form part of the next PPR in June 2016.

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Risk Management11

A comprehensive and live risk register has been established and is regularly reviewed in order to identify and monitor technical and project management risks.

The project’s risk management strategy revolves around the maintenance of a live risk register which lists the significant threats that may have an impact on the successful delivery of the project, as well as identifying threat mitigation control measures. The risk register is updated when required, reviewed informally at each monthly project meeting and reviewed formally at each quarterly project meeting.

Each risk identified is given a score determined by likelihood of occurrence multiplied by severity, which helps to prioritise response measures. Mitigation actions are created for each risk and a risk owner is identified who will be responsible for monitoring the risk and implementing the mitigating actions.

The latest version of the risk register can be found at annex B. A summary of the top risks and their mitigating actions is described below.

1. Budget Insufficient. As the project has progressed a number of additional challenges have arisen. In trying to gain a better understanding of the gas flow conditions inside high pressure pipework, complex CFD studies are required. These studies are potentially expensive and a cost benefit analysis will be conducted to determine whether they will de-risk online trials sufficiently to warrant the extra cost. The CFD studies will be valuable to the wider gas industry and there is currently no existing research into this area.

The cost of field trials (stage 3) is currently forecast to be greater than the current stage allocation. To mitigate this the testing strategy is being refined following learning from stage 1, which will then clarify the exact variance predicted for stage 3. A change request will then be submitted to re-allocate the underspend from stage 1 to stage 3.

2. Risk to Online Trials. AGIs were never designed to be in-line inspected. As a result, gaining access to the pipework is a challenge due to the lack of connection points and the congested nature of the sites. There are a variety of connection methods available at varying degrees of cost and a study into connection methods forms a key part of stage 2 activity. However there is a risk that, whilst the project scope can still be met, the most suitable connection method/location does not allow for a large percentage of inspection coverage at an AGI.

To mitigate this risk a global tech watch specifically for connection methods of being conducted to ensure the team have investigated all potential solutions for a cost effective connection. A cost benefit analysis will be conducted for all connection methods that are feasible at the trial sites to find the solution that represents the best compromise between site coverage and value for money.

Whilst assessing the various methods of communication between the robot and the OCS, the team conducted a series of tests at the AGI at The National Grid Academy, Eakring.

Using a Synthotrax robot as a vehicle, the team attached a wireless communications module and using high power directional antennas they managed to receive a live video feed from the robot at a distance of nearly 200m inside buried pipework. This important test will help shape the design of the robot’s communication systems.

Wireless Signal Strength Tests


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Accuracy Assurance Statement

We hereby confirm that this report represents a true, complete and accurate statement on the progress of Project GRAID in the six month period from 20th June – 18th December 2015 and an accurate understanding of our activities for the next reporting period.

Executive Summary1

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Risk Management Accuracy Assurance Statement12

3. Robot Design Proves Unworkable. There is a risk that the robot design taken forward beyond stage 1 is unsuitable for use in live trial sites following the development and testing phase. The conditions that are expected inside the high pressure pipework could potentially be harsh in terms of flow velocity. As a result, securing the robot to the pipe wall is a key aspect of the robot’s development. CFD studies on the effects of high flow velocities on the drag forces the robot will experience are still underway; as such the risk remains that the magnetic stabilisation system will not be sufficient to secure the robot in the pipe. As mitigation a backup design has been developed that uses a more traditional wall press system to secure the robot in the pipe.

4. Unknown Flow Conditions. There is a risk that high flow velocities and a limited understanding (across the gas industry) of the flow conditions inside high pressure buried pipework could lead to the robot not performing as intended. Not much is understood about how gas flow behaves inside high pressure, complex pipe work. This information is crucial for Synthotech to design a platform that is capable of operating in live gas conditions in a safe and effective manner.

As mitigation PIE and Synthotech, in cooperation with Newcastle University, are conducting drag studies and CFD analyses on the behaviour of high pressure gas at high flow velocity. The results of these studies will enable Synthotech to design the shape form and stabilisation systems to withstand high flow conditions.

This learning will be of significant interest to the wider gas industry.

5. Potential Robot Failure on a Live Site. There is a risk while undertaking online trials that the platform might not perform to the required brief or gets stuck in the pipe causing a significant blockage in the network.

To mitigate this, a comprehensive testing strategy is being developed for offline trials. The offline trials will take place in a safe environment as part of a staged process that will validate the design of the robotic platform. NGGT safety and integrity personnel will provide input into the test strategy to give them the confidence the system will perform as intended on the NTS. The offline trials will prove the technology is safe to use on the live network prior to online trials.

This risk also drove the decision to use a tethered system as opposed to a wireless remote system. The tether will act as an umbilical providing power and communication data to the robot. In the event of a robot power failure, the umbilical will also be used to manually retrieve the robot back to the launch vessel.

http://www.projectgraid.com

[email protected]

@NGGRAID

Annexes:

A - Stage 1 Senior Sign Off LetterB - Risk RegisterC - Synthotech Stage ReportD - Premtech Stage ReportE - SDRC ReportF - Stage 1 Report