For several years, the members of NYSEARCH and several industry and government partners including DOT/PHMSA have sought to make a quantum leap in inspection technology for un-piggable pipelines. Starting in November 2010, many successful stages of research, technology and product development as well as live field demonstrations have resulted in the commercialization of Explorer II; the first in a series of robots offered by PipeTel Technology Inc.

Explorer II is an un-tethered, modular, remotely controllable, self-powered inspection robot for the visual and non-destructive inspection of 6" and 8" natural gas un-piggable transmission pipelines.  The most prominent reasons that render a pipeline un-piggable are flow rates that are lower than needed to propel an in-line inspection tool (pig); the presence of obstacles such as valves, mitered bends, back-to-back in and out-of-plane bends; and the cost and operational complications associated with installation of launching and receiving equipment. Explorer II can also be used for distribution pipelines as a pre-inspection technology for other rehabilitation and repair techniques.

The Explorer II platform uses a Remote Field Eddy Current Sensor (RFEC) which is a non-destructive inspection sensor that uses low frequency alternating current to measure wall thickness for the entire pipe circumference. Explorer II also incorporates two fisheye cameras at each end of the robot that provide high quality visual inspection for locating joints, tees and other pipeline appurtenances. As an in-line inspection tool, Explorer II is launced operated and retrieved under live conditions and can negotiate diameter changes, bends and tees up to 90° as well as inclined and vertical sections of the pipeline network.

In addition to the Explorer II sizes mentioned above, starting in 2011 PipeTel Technologies Inc. is also offering inspection services for the robotic platform applied to larger pipe diameters such as 12", 16" and larger.

NYSEARCH developed a quantitative risk model that analyzes both the Probability of Failure and the Consequence of Failure for cased pipe systems using corrosion theory that is specific to the annular space environment (with the expertise of DNV Columbus Inc.). Lead by expert modeler, Kent Muhlbauer of WKM Consulting, a user-driven, flexible approach was developed and tested by experts originally in a spreadsheet format. NYSEARCH then licensed the extensive model to New Century Software for distribution under a robust user-friendly platform known as Spatial Risk Analyst.

This model helps operators improve pipeline safety and meet the requirements of 49 CFR 192 Subpart O by providing the ability to prioritize pipeline integrity management actions for cased pipelines. The result is better assessment of actual risk and cost savings that allows improved prioritization of excavations and inspections for cased pipe systems (that can also be compared to traditional transmission pipe). The Cased Pipeline Integrity Assurance Model uses information stored in a variety of formats to provide an assessment of risk for cased pipe.

Gas pipeline operators have the ability to purchase the NYSEARCH Cased Pipe Integrity Assurance Model through New Century Software's Spatial Risk Analyst application. The resulting software product uses industry-leading risk principles to evaluate and categorize the threat level for cased pipe in the operator's system. Using the assessment results, remediation efforts can be focused on the cased pipes that are most at risk, while pipe found to be susceptible but not at risk can be addressed using specific efforts to identify the contributing factor or factors.

Working closely with Physical Sciences Inc. (PSI) and Heath Consultants, NYSEARCH developed the RMLD to improve the walking survey process. As a result, the portable Remote Methane Leak Detector (RMLD™) changes the way distribution natural gas surveys are conducted. Instead of having to walk the entire length of service lines to check for leaks, the RMLD efficiently and quickly detects leaks down to 5 ppm-m at distances up to one hundred feet away. Remote detection allows the user to effectively survey difficult to reach areas, such as busy roadways, yards with large dogs, locked gates, pipe in bridge/overpasses compressor stations, offshore platforms, etc.

RMLD, a lightweight portable detection instrument, uses an eye-safe laser technology for the detection of methane only. For utilities and their employees, this timesaving leak detection method can improve walking survey productivity up to 40% and reduce operating and maintenance costs.

RMLD has proven to be a reliable, trouble-free instrument and available in an intrinsically safe model. RMLD can be purchased from Heath Consultants.

NYSEARCH and its member companies are taking an overall review of sources of natural gas leakage and improvements in operating practices and evaluating ways to better address blowing or lost-and-unaccounted-for gas. NYSEARCH and ULC Robotics have developed a variety of fittings and adapters to convert routine distribution work activities to a "no-blow" process. Many tasks typically performed by gas operators in low pressure and some medium pressure situations allow natural gas to be vented to atmosphere. The No-Blow Tool application directly addresses these work tasks in as effort to reduce Greenhouse Gas (GHG) emissions for natural gas distribution companies.

The No-Blow Tools concept not only addresses GHG concerns, but improves the overall safety for gas operators, by eliminating the need to work in a controlled gaseous environment and, in some cases, reduces the labor needed to perform these functions.

The No-Blow Tools Kit includes specialized adapters and fittings for 4"-12" cast iron and steel mains that convert routine operations like making tapholes, inserting stoppers and service tee repairs into a no-blow process.

The commercially available kit is ruggedized for daily field use with all necessary fittings and adapters enclosed in a storage container and includes installation/operating procedures. ULC will is also prepared to provide demonstrations and training as needed.

There is an ever growing need in the gas industry to repair, replace or rehabilitate aging infrastructure. Prior to repairing or rehabilitating a large diameter pipeline that is 20" and greater, a critical step in the process is a visual inspection.  The ability to perform a reliable and quick internal visual inspection under live-gas conditions helps to avoid costly pipeline shutdowns and customer service interruptions. This will provide gas companies with an efficient and safe, cost effective solution, thereby, allowing them to select the best repair/rehabilitation option.

Working with ULC Robotics, NYSEARCH has developed a unique internal video inspection system for large diameter pipelines known as Large VGC. Large VGC is a tethered pipe crawler equipped with high resolution video inspection and lighting system. The VGC system includes the pipe crawler, launch tube system and remote control system/monitor which is located outside the excavation near the pipe entry point. Large VGC’s unique design enables the pipe crawler to be quickly inserted through a 4” pipe opening using its specially designed launch system. Using a single taphole, VGC is capable of inspecting 20” through 48” pipelines operating up to 100 psi and inspects over 500 feet of pipe in each direction. It is designed to navigate over pipe debris and through a number of pipe bends/fittings.

Initially, large VGC was developed for NYSEARCH member companies and ULC Robotics.  Now, it is available for purchase or as a service for pipeline inspection through ULC Robotics.

Prior to repairing or rehabilitating a pipeline, a visual inspection is critical step in the process, especially when considering diameter pipelines 12" through 18". The ability to perform a quick and reliable internal visual inspection under live-gas conditions is a requirement to avoid costly pipeline shutdowns and customer service interruptions and Video inspection also needs to be simple and reliable in order to be an effective aid in selection of the best repair/rehabilitation option.

Working with ULC Robotics, NYSEARCH has developed a unique internal video inspection system for smaller diameter pipelines know as small VGC. Small VGC is a tethered pipe crawler equipped with high resolution video inspection and lighting systems. The VGC system includes the pipe crawler, a launch tube system and a remote control system/monitor located outside the excavation near the pipe entry point. Small VGC's unique design enables the crawler system to be quickly inserted through a 3" pipe opening through an innovative launch system. It is capable of inspecting 12" through 18" pipelines operating up to 100 psi and has the ability to inspect over 300 feet of pipe in each direction through a single tap. It is designed to navigate over pipe debris and through a number of pipe bends/fittings.

ULC Robotics is prepared to build and sell VGC systems or provide VGC pipeline inspections as a service.

The natural gas industry has an excellent pipeline safety record and has been installing polyethylene pipeline systems for many years. Plastic piping systems have performed over and above safety standards. In the occasional case where maintenance or repair of PE butt fusion joints is required, the repair can be costly and may require service disruption to customers in many cases. Typically, this means shutting down the pipeline to replace the joint(s) in question.

Working closely with GECO, a subsidiary located in Italy, developed a repair fitting for two applications identified by the NYSEARCH member companies. The first application, the Butt Fusion Repair Sleeve (BFRS) provides utilities with a repair option that can be applied directly to the suspect butt-fused pipe joint(s) while maintaining service to surrounding customers. The BFRS fitting eliminates the need for customer interruptions, reduces repair costs and further enhances overall safety to the public and the utility. BFRS is an electrofusion fitting made of high density polyethylene that meets ASTM F 1055 and ISO testing requirements. The BFRS fitting is a split sleeve that gets installed over the suspect PE pipe joint and electrofused to the pipe with standard electrofusion equipment. The end result is a full encirclement repair fused directly to the PE pipe.

BFRS fittings can be purchased directly from NUPI Americas or Mulcare who is the Northeast distributor for the product.

The natural gas industry has an excellent pipeline safety record and has been installing polyethylene pipeline systems for many years. Plastic piping systems have performed over and above safety standards. In the occasional case where maintenance or repair of PE butt fusion joints is required, the repair can be costly and may require service disruption to customers in many cases. Typically, this means shutting down the pipeline to replace the joint(s) in question.

Working closely with GECO (a NUPI Americas subsidiary) located in Italy developed a repair fitting for PE pipe surface damages caused by third party excavators. The newly developed Variable Length Repair Sleeve (VLRS) provides utilities with a repair option that can be applied directly to the damaged section without interrupting gas flow. The VLRS design allows for a multiple sleeve repair that can be applied to any length gouge or scratch. The VLRS fitting eliminates the need for customer interruptions, reduces repair costs and improves overall safety to the public and utility personnel.

VLRS is an electrofusion fitting made of high density polyethylene that meets ASTM F 1055 and ISO testing requirements. The VLRS fitting is a split sleeve that gets installed directly over the damaged pipe section and electrofused to the pipe with standard electrofusion equipment. The end result is a full encirclement repair fused directly to the PE pipe. In the event of long length damage VLRS fittings are designed to be electrofused together creating a long length repair to cover the pipe damage in question.

The VLRS fitting is installed using the standard electrofusion process, thereby providing a full encirclement repair that is fused directly to the PE pipe.

VLRS repair fittings can be purchased directly from NUPI Americas or Mulcare-the Northeast distributor for the product.

Laboratory testing and research studies have concluded that today’s modern PE pipe materials (medium and high density), are highly resistant to slow crack growth (SCG) and can withstand external stresses creating extreme rock-impingement point-loads in buried soil conditions. Through its R & D project and resulting position paper, NYSEARCH and its contractors have generated the information based on the latest test methods and practices, to revise existing standards to eliminate the need for clean/sand backfill materials for PE pipe installations in many situations. Gas companies can obtain significant cost savings for buried PE pipe installations.

Technical evaluation and proof were accomplished by simulating worst case rock impingement point-loads on a variety of 2”and 4” pipe specimens. The specimens were subjected to accelerated long-term tests and established formulas using Popelar Shift Functions (PSF) to determine projected service life. Results from these tests have shown that the modern materials are so resilient that sustained pressure testing over 3,000 hours with extreme and severe impingement point-loads could not generate failures. This is equivalent to over 100 years of service life based on standard piping calculations. All lab testing and studies to date have concluded that rock impingement for modern PE materials are not a concern based on inherent material properties. Therefore, in PE installations where clean/sand backfill materials were previously required, existing backfill soils can be used.

The position paper can be obtained from NYSEARCH by contacting NYSEARCH.

The members of NYSEARCH have watched and supported Enbridge efforts to design, build and operate this first of its kind ultraclean power generating plant. Enbridge has taken typical power generating equipment and adapted them into a highly efficient plant, revealing the potential for reliable locally produced natural gas derived electricity.

The relatively small foot print of the plant provides a platform for producing electricity at an existing natural gas gate station or large district regulator. This design converts the energy of the normally accepted practice of regulator pressure let-down and instead transforms the pressure reduction into rotational energy to generate electricity. The operating plant is extremely quiet, affording locations in an urban or semi-suburban environment. Carbon emissions and "green" impact are also minimal.

This Enbridge 2.2 MW facility obtains extremely high efficiencies, greater than 60%, by balancing thermal requirements of turbine heating demands with fuel cell cooling demands. This thermal balance ensures avoidance of expenses for energy consumed for the sole purpose of routine power plant heating or cooling. The inherent heat generated within the fuel cell activities provides thermal advantage and exceptional efficiencies.

Enbridge is interested in sharing and expanding this technology with other interested organizations. They have made available preliminary considerations for design and citing. They will also share lessons learned through their experiences in design, equipment sizing, layout, and construction. Furthermore, operating the facility for over two (2) years provides insights to unique operational and maintenance requirements.

Working with ULC Robotics, NYSEARCH has developed a unique application that enables distribution operators to visually inspect service lines and main section without an excavation. Diagnosing system related problems on service lines and mains using traditional inspection techniques may require multiple excavations that can be quite costly. Distribution companies now have a method to quickly investigate, isolate and repair system related problems using a special video inspection technology, known as SlimKit.

The Service Line Inspection Maintenance KIT (SlimKIT) is a remote visual inspection system designed to provide "no-blow" access to low pressure service lines and mains using existing customer meter sets. SlimKIT is a no-hole technology, meaning that no excavation is required. It enables utility personnel to obtain live video inspection of pipelines for leaks, water intrusion, corrosion, etc. SlimKIT can be applied to 1/4" to 2" in diameter service lines through most meter piping configurations.

The SlimKit system includes a miniature camera/lighting head on a cable that can navigate through service lines, typical service plug valves and a variety of street-service tee configurations. The cable is a 150 feet long and is connected to a video control/monitor system located at the entry point.

Non-Interruptible Service Transfer PE fittings developed for NYSEARCH by Perfection Corp. were designed to easily and safely transfer 1" polyethylene gas service lines from an existing to be retired main to a new main without interrupting the flow of natural gas to customers. It is accomplished by using a special PermaLock mechanical tapping fitting to complete the non-interrupt service transfer (NIST).

The new application eliminates temporary interruption to a customer's gas service, as well as the need to gain entry into a house for relight service. NIST reduces overall operating costs and improves customer satisfaction. The special PermaLock mechanical tapping tee is bolted onto the existing service line prior to activating the replacement pipeline. This allows for a by-pass service feed prior to disconnecting the existing service from the main to the NIST fitting.

NIST fittings were tested and approved to ASTM F 1055 standards and are available from Perfection Corp. in both medium and high density polyethylene.