Commercial Applications

Highlighted below are some commercial products developed through NYSEARCH.

NYSEARCH delivers products and solutions to the industry following investment of funding and industry resources towards a complex research and development lifecycle. Both staff and NYSEARCH members strive towards commercialization using a carefully planned process involving numerous partners and collaborators.

Pre-Commercial Release of Energy Harvesting Module for EXP Series of Robotic Inspection Platforms (Pipetel/ an Intero Company)

In May 2021, NYSEARCH officially completed with cofunding from PHMSA/DOT an energy harvesting module to provide self-powering from the gas flow in the pipeline. This module is intended for the full range of robotic inspection platforms offered by Pipetel known as Explorer. However, the size range that was the focus of over (4) years of research, development and demonstration by NYSEARCH members was for pipe diameters ranging from 20” – 26”.

Explorer robots carry on-board batteries that provide all the power needed for operation. As a result, the range of the robots is limited by the on-board power available. To improve Explorer’s operational range by utilizing gas flow available in the pipeline, NYSEARCH sponsored an earlier project to develop a module that would use principles of Energy Harvesting. The goals were to minimize or possibly eliminate power drawn from the robot’s batteries when travelling with the flow, and to charge the robot’s batteries using the available gas flow instead of above ground attached equipment (currently used), which requires expensive excavation and hot tapping.

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Natural Gas Dispersion Study

With Fire & Risk Alliance, LLC from Rockville, MD, NYSEARCH completed a two-phase study that performed experimental and modeling work to study the dispersion of Natural Gas in residential structures. The data from this project has been provided to industry and the National Fire Protection Agency (NFPA) to aid in the development of a detector placement standard and to facilitate the deployment of methane detectors.

The two-phases of work included over 150 physical tests and modeling simulations to gather data to improve understanding of the gas dispersion patterns in a residence. The overall recommendations from that study are based on a wide array of potential gas flow rates (1 SCFH to 150 SCFH) and release conditions, residential structure configurations and ventilation conditions including HVAC...

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Butt Fusion Repair Sleeves and Variable Length Repair Sleeves

In 2020, adding to commercial products already developed through the NYSEARCH program, NUPI Americas commercialized another size in a series of approved permanent repair solutions for butt fused plastic pipe. These ASTM certified permanent repairs for suspect and non-leaking damages come in two configurations; butt fusion repair sleeves (BFRS) and variable length repair sleeves (VLRS) and they apply to both Medium Density (MDPE) and High Density (HDPE) plastic pipe. The 1 ¼” pipe sleeve (pipe diameter size) that was released in 2020, adds to other sizes that include 2”, 4” and 6” for both BFRS and VLRS. Following prior NYSEARCH-funded development and testing, NUPI has also commercialized the 8” and 12” sizes for the BFRS. Both the BFRS and VLRS are high-density fittings using PE4710 (PE100) material that can be applied for plastic pipes up to 124 psig and for up to 50% thru-wall damage without interrupting services or conducting bypass operations...

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Explorer Robot – Pipetel Technologies, Inc.

The Explorer Robot (EXP) revolutionized the natural gas industry by providing an innovative solution for in-line inspection of what was once considered “un-piggable” pipes. The robots are tetherless, modular, remote controlled and self-powered inspection robots that can operate in live pipelines, capture high quality imaging, and measure corrosion anomalies and mechanical damage in pipe sizes ranging from 6” – 8”, 10” – 14”, 16”– 18”, 20” – 26”, and 30” – 36”.

Alongside the years of research and collaboration dedicated to building the Explorer robot itself, NYSEARCH members have developed supporting technologies advancing current sensing and other capabilities. Some of the supporting technologies that are now commercially available include an in-line charging tool to extend range and mechanical damage/ovality sensor to measure pipe defects. Other supporting technologies under development include an Eddy Current crack sensor, hardness tester, and cleaning tool.

NYSEARCH members are also exploring the opportunities of automating various robotic controls to execute autonomous operation during inspections and energy harvesting to harness potential energy within the pipeline system to power the robot and extend range. The continued advancements of the Explorer platforms highlight the dedication and support of revolutionary ideas that NYSEARCH members choose to develop and progress the industry in overcoming the many challenges of safety and integrity.

Polyethylene Repair Sleeves VLRS/BFRS – NUPI Americas and Mulcare Pipeline Solutions

A permanent and approved solution to remediating both suspect butt fusion joints and other non-leaking damages in 4’’ and 6’’ PE services has been developed and realized through NYSEARCH. The Variable Length Repair Sleeve (VLRS) is a high-density PE fitting that allows an operator to safely make a permanent electro-fusion repair on PE pipeline up to 124psig operating pressure without interrupting service or wasting resources on constructing a by-pass. The Butt Fusion Repair Sleeve (BFRS) is also a high-density PE fitting that can be applied to suspect butt-fused joints and electro-fused using standard electrofusion equipment without the need to interrupt gas service and perform a cut-out. The BFRS is considered a full encirclement repair by ASTM. 2’’, 8’’, and 12’’ sizes for the VLRS and BFRS are near commercial.

NYSEARCH RANGE™ Plus Model for Gas Interchangeability Assessment of Residential Appliances

The United States is experiencing a shift in natural gas supply with the discovery of new gas formations and recent strides to incorporate renewable natural gas from biogas suppliers. Changes in fuel composition can pose a public safety challenge when appliance burner tip effects are not thoroughly understood. NYSEARCH members completed a long-term study to address the concern of changing gas supplies with both laboratory and in-situ testing to model how changing gas composition can impact the performance of in-service residential appliances. An online risk-assessment model is available for purchase on the NYSEARCH website or by contacting our office. Click the link below to find out more.

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NYSEARCH Threat ID™ Tool for Interacting Threats Risk Assessment of Natural Gas Transmission Pipelines – NYSEARCH

Another risk-assessment model created in collaboration with Kiefner and NYSEARCH members identifies and quantifies the potential effects of interacting threats and the increased likelihood or risk impact for transmission pipeline systems. An intricate database of algorithms that includes factors for interacting threats was developed and incorporated into Kiefner’s existing risk-assessment model software. The software quantifies the effects of all identified interacting threats based on SME analysis of actual gas transmission incidents from the PHMSA and Kiefner forensic databases. A subscription to the online risk-assessment model can be purchased here. A stand-alone import spreadsheet with associated algorithms also comes with the purchase, which can be used in conjunction with any operator’s established risk model.

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Remote Methane Leak Detector (RMLD™) – Heath Consultants, Inc.

One of the first commercial products successfully developed by NYSEARCH funders is the Remote Methane Leak Detector. The RMLD™ was commercialized in 2006 by Heath Consultants, Inc. The tool became a productivity innovation for walking leak surveys allowing inspection of a service line without requiring the operator to walk the entire length. The RMLD™ also allows inspection of difficult to access areas such as secured buildings/homes and yards with dogs, detecting leaks as low as 5ppm at distances up to 100ft away. Over 3000 units have been sold worldwide to date.