synthotech e brochure

FOR THE GLOBAL UTILITIES MARKET

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Synthotech have supplied us with quality engin“

PIONEERINGVALUES

CONCEPTDESIGN

MANUFACTUREIMPLEMENTATION

SUPPORT

WELCOME TO SYNTHOTECH

At Synthotech we see the sale of a product or service as the beginningof a very important partnership. We believe customer relationships arebuilt on belief, trust, confidence and reward, four values which underpineverything we do at Synthotech. We are designing and manufacturingpractical engineering solutions for problems that face the gas andutilities industries worldwide. Our core product range is based on livelaunch systems for under pressure pipework. Product developmentremains at the forefront of our business strategy and continues to beone of our passions.

Mark TindleyManaging Director

M.Tindley

neering products for more than a decade

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National Grid

INNOVATIONAt Synthotech we pride ourselves on our capabilityto produce value adding products and customersupport for our global market. From concept ourdevelopments are targeted to reduce operatingcosts, improve safety and minimise impact on theenvironment. Each new development is vigorouslytested to ensure gas industry approval. Such is theadvanced nature of some developments that wehave to write the specifications.

At Synthotech we use 3D CAD software that candownload directly to CNC machinery for prototypingcomponents. The components are then manufacturedand assembled in our facility in the UK.

DEVELOPMENT &DESIGN

SERVICESSynthotech's consultancy purpose is to providestrategic management and engineering expertise tocreate value to owners, asset managers and operatorsof gas transportation assets. This is achieved in anumber of ways: -

• Identifying business opportunities with and forclients.

• Assisting clients in the development of identifiedopportunities.

• Project management and implementation onbehalf of clients.

FORWARDTECHNOLOGYNEW PRODUCTSBuilding on our existing portfolio, 2008 will seeseveral new product launches. They will includeour SynthoCam II™ CCTV system that will offerimproved performance and flexibility of our highlyregarded SynthoCam™ system, underpinned byquality training and support.

At Synthotech we do not just develop products weprovide a complete package:

• Production of specifications, standards and workprocedures.

• Total training solutions that develop and improveindividual and organisational capability throughcompetency, skill and underpinning knowledge.

SUPPORTAt Synthotech our philosophy is to work in synergywith our customers from concept to completion.We pride ourselves in our ability to provide strategicwork, implementation and ongoing technical support.

The competence and expertise ofSynthotech is provided by a widerange of internationally recognisedexperts, experienced in managementof gas transportation assets.

Synthotech has delivered first class product innova“

ation in support of our Core Technology Programme

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BGGroup

PRODUCTINNOVATION

SYNTHOCAMCCTV system for gas mains. Procedure completed without the need to isolate thegas supply.

M-CEXGas valve exchange system for service pipes. Procedure completed without theneed to isolate the gas supply.

CAPEXA system that determines if a gas service pipe is carrying gas or not ('live or dead').Capable of removing cap or plug ends. Procedure completed without the need toisolate the gas supply in 'riser' system.

I-SEALGas leakage repair system for threaded pipe joints.Procedure completed without the need to isolate the gas supply.

SEALBACKA pipeline replacement system for metallic gas mains. Replacement with Polyethylenepipe (PE) is carried out remotely by a ‘live mains transfer’ process. Used for replacingsections of mains from side-streets into the main carriageway significantly reducing theneed for excavation and traffic management systems.

STARGLANDA polyethylene (PE) pipe tracing system for gas service and main pipelines.Procedure completed without the need to isolate the gas supply in the main pipeline.

SERVIFLEXA flexible pipe insertion system for the replacement of gas service pipes. It has aunique capability to negotiate 90 degree tight radius bends. Pipe can be carriedfrom the existing gas meter position.

ServiFlex® is a registeredtrademark of Uponor Ltd.

The SynthoCam™ CCTV system is a versatile safe andefficient method of inspecting mains, specifically developedfor the gas market. The system is available in modularcomponents for a range of applications. Entry and exitfrom the main is achieved using under pressure equipmentthat enables the camera to be launched and retrievedunder controlled 'live' gas conditions, without the need toisolate or interrupt the gas supply. Approved to UK gasindustry standards for use up to 2bar operating pressure.

Benefits:

• Significantly improves the rate of pipe replacement.

• Significantly reduced excavation, reinstatementand associated activities.

• Reduces the time consumers are without gas.

• Assists in the identification of poor pressure condi-tions and gas leakage.

• Significantly reduces operational costs.

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INNOVATIVE

ENGINEE

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(0)1423816060

Synthotech Limited: B2b Crimple Court,Hornbeam Square North, Hornbeam Park,Harrogate, North Yorkshire HG2 8PB. UK

[email protected] +44 (0)1423 810 001

©2008 Synthotech Limited. All rights reserved to make changes to design and specification without prior notice or consent. E&OE.

Applications:

• An up front design and planning tool forthe effective replacement of gas pipesystems. Identifies:1. Obstructions - debris, corrosion,

siphons/dip pipes, bends, etc.2. Connections, bends, etc.

• Can assist in identifying poor pressureconditions i.e. water ingress, obstructionsand unknown connections.

• Can assist in identifying gas leakages.

• Can assist in the condition assessmentof metallic and PE pipework systems.

• The system offers: 24mm, 35mm &50mm colour cameras; 30m, 80m or120m coilers incorporating meterage;10'' TFT daylight visible screen; DVDrecorder; QWERTY keyboard; live launchand retrieval assembly for 3'' diameterpipes and above.

After care:

SynthoCam™ is underpinned by acomprehensive support package includingour acclaimed:

• SynthoCam™ training programme.

• *Rapid responsemaintenance programmetargeted to ensure optimum use.

• Mobile technical support units.* Renewable annually.

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The Meter Control Exchange (M-CEX™) system is aversatile safe and efficient method of exchangingleaking valves from gas pipework systems undercontrolled 'live' gas conditions. The system uses arange of rigid and flexible stoppers applicable tometallic and polyethylene (PE) pipes. A range of kitswithin the size range 1⁄2'' to 2'' and 16mm to 32mmare available.

M-CEX™ is an easy to use system that has beenspecifically designed using our unique Stargland™gas seal technology.

Applications:

• Can be used on 1⁄2'' to 2'' pipes.

• Can be used on pipework systems up to75mbar operating pressure.

• Designed to exchange a wide range ofgas valves including emergency controlvalves (ECV).

• Can be used on metallic and PE pipesystems.

• Can be used on 3⁄4'', 1 & 11⁄4'' metallic pipesystems containing long and short radiusbends.

• Contains adaptors for BSP and BS 746threads.

Benefits:

• Designed for use in restricted locations.

• Significantly reduces the time consumersare off gas.

• Avoids the need for planned maintenanceoperations to isolate pipework systems,particularly in multi-occupancy or high risebuildings.

• Reduces operational costs.

M-CEX™ is available with a completeproduct support package including:easy to use installation instructions,a comprehensive training package andafter sales service.

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11⁄2''- 2'' kit

3⁄4''- 11⁄4'' kit

11⁄2''- 2'' kit

3⁄4''- 11⁄4'' kit

©2008 Synthotech Limited. All rights reserved to make changes to design and specification without prior notice or consent. E&OE. D12

06

Pipe stoppers

The Cap and Plug Exchange (CaPEX®) system is a versatilesafe and efficient method of removing caps and plugsfrom gas pipework systems and replacing them with anemergency control valve (ECV). The procedure is completedwithout the need to isolate the riser system. It can also beused to determine if a gas pipe is ‘live’ or ‘dead’.

The system offers two methods of exchange:

• The CaPEX® tool comprises a plastic bodied valve andgland assembly and is approved to UK gas industrystandards for use up to 75mbar.

• The CaPEX® bag system is a transparent laminatedplastic bag system and is approved to UK gas industrystandards for use up to 50mbar.

CaPEX® is an easy to use system that has been specificallydesigned using our unique Stargland™ gas seal technologyand is fully integrated to work with our meter controlvalve exchange system (M-CEX™) for use with all typesof gas valve.

Applications:

• Can be used on 1⁄2'', 3⁄4'' & 1'' pipes.

• Can be used on pipework systems up to75mbar operating pressure.

• Can remove a wide range of cap typesincluding hexagonal, webbed and cylindrical.

• Can remove a wide range of plugs.

• Can be used on pipe systems containingbends.

• Attachments are available for use on cop-per riser and lateral systems.

Benefits:



• Avoids the need for planned maintenanceoperations to isolate pipework systems,particularly in multi-occupancy or highrise buildings.

CaPEX® is available with a complete productsupport package including: easy to useinstallation instructions, a comprehensivetraining package and after sales service.

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CaPEX® bag systemCaPEX® tool system AfterBefore

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09

The I-Seal™ system is a versatile safe and efficient method of repairing leaking threadedjoints on gas pipework systems. The system uses an anaerobic sealant that is injected intothe leak path of the threaded joint. The delivery system comprises of an I-SEAL™ clip andnon-return valve. This assembly is connected onto the leaking joint and drilled to a prescribeddepth. The sealant is injected into the leak path using a high-pressure hand pump.

Applications:

• Can be used on 1⁄2'' to 6'' diameter standardpipe threads.

• Can be used on pipework system up to2bar operating pressure.

Benefits:



• Avoids the need for planned maintenanceoperations to isolate pipework systems.

• Reduces operational costs.

I-SEAL™ is available with a completeproduct support package including:easy to use installation instructions,a comprehensive training packageand after sales service.

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+44

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[email protected] +44 (0)1423 810 001

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04

The Sealback® system is a safe and efficientgas controlled 'live' main replacementmethod for traffic sensitive locations orwhere access onto the main is restricted.Replacement is undertaken from a remotelocation (10m - 13m) to where it intersectsits parent pipeline, usually from a side roadinto the main carriageway.

The principal of the operation is to insert thenew polyethylene (PE) pipe into the old ironmain. All activities associated with the livetransfer process are accessed througha 'glanding box' that enables a gas controlled operation. A two-part nose cone is installedonto the leading end of the PE pipe. The outer part of the nose cone is usedto decommission the iron main as the new PE pipe is inserted to its required location.The primary gas seal is achieved by the introduction of an annular sealant. The new PEpipe is commissioned by the withdrawal of the inner section of the nose cone.

Applications:

• Approved to UK gas industry standardsfor use up to 75mbar operating pressure.

• Replacement diameters: 55mm in 3'',75mm in 4'' and 125mm in 6'' metallicpipes.

• Maximum insertion length 13m.

Benefits:

• Significantly reduces excavation,reinstatement and associated activities.

• Significantly reduces the use of trafficmanagement systems.

• Reduces inconvenience to the road user.

• Reduces working in higher risk locations.

• Reduces the time consumers are without gas.

• Reduces operational cost.

Sealback® is offered with a complete productsupport package including contract service.

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Two part nose cone Inner nose cone Cross section pipe


03

The Stargland™ system is a versatile safe and efficient'live access tool' that enables tracing of polyethylene(PE) gas pipework systems. Tracing of PE pipes isachieved by inserting a tracing wire and sondethrough the 'live access tool'. The tracer wire andsonde is energised by use of a standard aboveground signal generator and located by a cableavoidance tool. The 'live access tool' has beenspecifically designed using our unique Stargland™gas seal technology.

Applications:

• Can be connected onto through wallhouse entry fittings up to 32mm diameter.

• Can be connected onto many types ofemergency control valves (ECV).

• Can be connected directly onto 16mm,20mm, 25mm, 32mm diameter PE pipes.

• Can be connected onto PE top tappingtees for tracing of pipe systems up to180mm diameter.

• Can trace up to 50m for gas service pipesand 100m for mains.

• Approved to UK gas industry standardsfor use up to 75mbar.

Benefits:

• Significantly reduces excavation, rein-statement and associated activities.

• Enables PE pipe systems to be accuratelyidentified.


Stargland™ system is available with acomplete product support package including:easy to use installation instructions,a comprehensive training package andafter sales service.

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Top tee accessTracing wire Sonde

The Serviflex® system is a versatile, safe andefficient gas service pipe replacement system.It is capable of relining aged metallic pipeworkthat contains short radius bends (elbows) from themeter position, inside the property, to a convenientexternal location. Insertion is achieved by use ofa dual wall, gas grade, polyethylene (PE) flexibleliner. Installation of the liner is achieved by the useof Synthotech's specifically designed tooling thatenables the liner to be temporarily stiffened duringthe insertion process. This is achieved withoutcompromise to the long term strength of the pipeor flow capacity.

Applications:

• Approved to UK gas industry standardsfor use up to 75mbar.

• Used for relining 1'' metallic pipes.

• Maximum insertion length 16.5m.

Benefits:

• Avoids the costs associated with gasmeter re-runs, typically £100 - £250.

• Can significantly reduce excavation,reinstatement and associated activities.

• Maximises capacity throughput aroundshort radius bends.

• Can significantly reduce the cost of pipereplacement on registered/listed buildings.

• Reduces the time consumers are withoutgas.


Serviflex® is available with a completeproduct support package including: easy touse installation instructions, a comprehensivetraining package and after sales service.

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(0)1423816060

ServiFlex® is a registeredtrademark of Uponor Ltd.


[email protected] +44 (0)1423 810 001

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“Synthotech have supplied us with qualityengineering products for more than a decade.

National Grid

Synthotech has delivered first class product innovationin support of our core Technology Programme.

BG Group

...with recent Medium pressure approval, the SynthoCamTM

system has become a really flexible tool in the manager’sarsenal, with the ability to enter a small mains with minimalexcavation. Synthotech provides a complete camera package,including a quality training product.

Operations Performance Development Team, National Grid Gas Plc

...following the upgrading of our six live mains insertioncameras, we are now gaining the benefit with a reductionin abortive excavations, increased accuracy and ultimatelyimproved productivity.

AMEC Utilities Limited

...after the success of using their StarGland SystemTM Kitfor tracing PE mains from top tees, we had confidence inthem as an organisation to develop a particular CCTVsolution we had for remote access into our PE mains.

TPI Gas Services Limited

...since changing to the SynthoCamTM system we now havemuch better in-pipe vision and are able to benefit from theSynthotech backup and support.

United Utilities, Northern Gas Network

Testimonials

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INNOVATIVE ENGINEERING+44(0)1423 816 060

synthotech e brochure

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