Case Study
Service Window Cutter
The Challenge
As gas distribution networks (GDNs) modernise their infrastructure, it's common practice for new polyethylene (PE) pipes to be inserted into redundant metallic pipelines. This method simplifies the process of laying new pipework and reduces excavations.
If a customer wishes to move the position of their gas meter (or a new connection is required), there's currently no safe method to access the PE pipework in the old metallic pipes.
To do this, it's necessary to access the PE pipe at the closest point where it isn't encased (usually at the parent main, which are often found near or under main roads). To access these pipes, excavations will inevitably require more resources, materials and time, plus result in increased disruption and cost.
The Solution
Steve Vick International have developed an innovative new Service Window Cutter tool, which has been thoroughly tested at Gas Networks Ireland's training school.
The tool is designed for use on 1"-2" diameter pipes and will remove a section of the outer metal, without damaging the inserted PE pipe. This will enable operatives to modify services to a property quicker, with minimal disruption.
Approach
The project originated from an EIC call for innovation. The EIC supported the development of a project plan before being started in 2021.
Steve Vick have successfully developed functioning prototypes that have been tested by GNI operatives at their training school.
James Pope, Design & Development Manager
Steve Vick International
"Problem solving in design can be challenging, but working closely with GNI throughout the process allowed us to share insights and expertise, leading to an effective and creative solution that should benefit the network and their customers."
Project Partners
This project was delivered by Steve Vick International, with funding from GNI's Gas Innovation Fund. The two-year project has taken an idea from concept to reality, through rigorous testing and refinement to ensure it's fit for purpose.
The outputs of this project will enable GNI staff to work more effectively when performing operations that require a service to be altered.
Impacts
The new solution is an incremental innovation, building Steve Vick's pre-existing patented window cutting machinery. This new tool is designed specifically for smaller service pipes and will deliver significant operations benefits to GNI.
The Project
Beginning at the concept design stage, the Steve Vick team presented several options to GNI for consideration. A shortlist of preferred concepts were 3D printed and assessed, before more refined prototypes were produced for initial testing.
Two preferred designs were selected to progress to field trials, which took place at GNI's innovation centre and training school. Following this, a preferred design was selected and refined before a final trial was conducted. A small number of units of this version are due to be manufactured for GNI, to begin utilising in the field as part of their business as usual operations.
Key Learning
1. The iterative approach to the design process was beneficial, giving plenty of opportunity for stakeholders to provide input
2. The reliance on having access to GNI's training school caused delays due to a lack of availability; this should be considered for future projects.
Benefits
Customers
Reduced impact on process of relaying services
Health & Safety
The tool will enable safer cutting operations
Financial
Reducing the cost of altering/relaying services
The Project
Live field trials demonstrated various benefits for network partners, including reduced operational expenditure (OPEX). One trial conducted on a sample section of the gas distribution network in the north of England demonstrated that LeakVISION reduced the overall time required to locate and repair multiple gas escapes, minimising disruption to customers.
As part of the SIF funded project, a trial was completed in a live hydrogen pipeline to assess the device’s functionality and its capability to safely detect leaks. The trial proved successful, providing confirmation that both the deployment and retrieval approach for the device are secure.
- The successful implementation of a live thermal imaging robotic system within an operational gas distribution network.
- The system potentially could identify specific ‘areas of interest’ that require remediation.
- The system has future capability to guide more agile asset investment decisions.
- A robotic device that uses a heating element to warm-up flowing gas, in a live distribution network, safely and without incident.
- Identification of design improvements for field operations.
The Impact
Customer Service
Minimised disruptions from excavations to assess pipes in difficult to reach places.
Societal
Reductions in the number of excavations and faster repair times.
Environmental
Reductions in the volume of gas vented to the atmosphere during complex-to-locate gas escapes.
Operational
A reduced number of excavations will lead to improved safety and will result in fewer injuries to operatives.
The Project
The aim of StreetScore Phase 2 project was to improve the accessibility and experience of street works for customers in vulnerable situations and the wider public. The focus was on prototyping and validating concepts that could minimise disruptions experienced during street works, before potentially undertaking further developmental and testing activities that facilitates the transition to Business as Usual (BAU) deployment(s).
Workshops were also held to facilitate active engagement between network operators and key stakeholders, such as community groups, charities and advocacy groups. These sessions allowed network operators to develop a greater understanding of the challenges faced by customers in vulnerable situations and provided valuable insights into how customers adapt their behaviours and lifestyle around street works. The feedback gathered has also helped to inform the shortlisting of potential prototypes and concepts for future development.
The Impact
Customers
Improvements in accessibility and safety around street works, particularly for customers in vulnerable situations.
Community engagement
Improved engagement between network operators and third parties like community groups and charities.
Health and safety
Potential to reduce the number of incidents for customers when navigating street works. Learnings from the project have also enabled recommendations for changes or updates to existing regulations.
Financial
Improved guidance in working around street works thus reducing instances of fines for networks.
The Impact
Customers
Improvements in accessibility and safety around street works, particularly for customers in vulnerable situations.
Community engagement
Improved engagement between network operators and third parties like community groups and charities.
Health and safety
Potential to reduce the number of incidents for customers when navigating street works.
Financial
Improved guidance in working around street works thus reducing instances of fines for networks.
Next steps
Steve Vick are currently working to identify a suitable manufacturing partner to produce a small number of the final tool for GNI to deploy. Following the initial deployment, a wider roll out plan will be considered, subject to the number of use cases.
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