Redacted in line with NIC IPR conditions NI Robotics ... · NI Robotics Project Progress Report...

NIC Robotics Project Progress Report Four

19th December 2015

Sam Wilson

NIC Robotics Project Manager

Redacted in line with NIC IPR conditions

Contents

1 Document Control ............................................................................................................................... 1

2 Executive Summary ............................................................................................................................. 2

2.1 Risks to Project Delivery .............................................................................................................................. 4 2.2 Learning Summary ....................................................................................................................................... 5

3 Project Managers Report ..................................................................................................................... 6

3.1 Previous Six Months – 19.06.2015- 19.12.2015 .......................................................................................... 9 3.2 Targets for the next six months – 19.12.2015 – 19.06.2016 ..................................................................... 27

4 Business Case Update ........................................................................................................................ 29

5 Progress against Plan ......................................................................................................................... 29

6 Progress against Budget .................................................................................................................... 30

7 Bank Account .................................................................................................................................... 31

8 Successful Delivery Reward Criteria ................................................................................................... 31

9 Consistency with Full Submission ....................................................................................................... 32

10 Learning Outcomes .......................................................................................................................... 32

11 Intellectual Property Rights ............................................................................................................. 37

12 Risk Management ............................................................................................................................ 37

13 Other .............................................................................................................................................. 38

14 Accuracy Assurance Statement ........................................................................................................ 39

Appendix A - ULC Project Progress Report ............................................................................................. 40

Appendix B - RPS Project Progress Report ............................................................................................. 62

Appendix C - Risk Register – 3.2 – 19.12.2015 ........................................................................................ 85

Appendix D - Bank Account References ................................................................................................. 89

Appendix E - Stakeholder Engagement .................................................................................................. 90


NIC Robotics – Project Progress Report Four

2 4thDecember 2015

2 Executive Summary The purpose of this document is to report on the progress the project has made since the last submission on the 19th June 2015 and the key deliverables over the next six months of the project. The report contains a summary of the progress made from SGN with subsequent reports from ULC Robotics as the principle project partner, and RPS as the technical consultant.

The aim of the Robotics project is to develop robotics system to be used in a live gas main to perform the following functions:

Element 1 – Development of a robotic ‘platform’ and launch system to enable deployment of modular repair and inspection devices for 12” to 48” diameter metallic gas mains

Element 2 – Development of an internal mechanical joint installation module and Weco seal repair method

Element 3 – Robotic visual and non-visual inspection

Element 4 – Automated live asset replacement for distribution services and mains for tier 1 pipes

Since the last PPR (Project progress report) the project has progressed as planned in line with the project plan and budget, successfully delivering each milestone and the targets listed in PPR3. A list of the key deliverables is shown below, a breakdown of each can be found throughout this report.

Elements 1&2

Robotic Platform Launch, Retrieval and Travel Testing

Seal Robot Tool Testing

Procure Spares and Material for Field Testing

Perform 20 Days Field Testing

Submission of SDRC9.6 report - Launch Robot

Element 3

Integrate and Test Tether With Sensor/Data Acquisition System

Sensor Data Validation

Submission of SDRC9.4 report - Configuration Testing with Robotic Platform

Develop Test Plan for the Field

Incorporate Improvements Discovered During Testing

Perform 20 Days Field Testing

Submission of SDRC9.7 report - Launch Robot

Element 4

Delivery of High Level, Preliminary Specification Document By ULC To SGN

Learning Gained through the development of Element 1-3

Submission of SDRC9.2 report - Development of Conceptual Designs

Element 4 Consultation Period

The project has progressed significantly over the past six months from assembly and controlled testing to live gas field trials of Elements 1, 2 and 3 systems (Figure 1 & 2). The sensor validation and testing was a complex challenge to overcome and was achieved as part of the milestone for the Sensor Data Validation and Configuration Testing with Robotic Platform SDRC reports. To ensure the sensors selected could perform in the challenging environment of a live gas main, extensive controlled tests were run in custom built test rigs constructed to replicate the environment will perform in.

Workshop testing was carried in line with the technical assurance spreadsheet constructed by RPS to ensure that all risks identified were mitigated throughout controlled testing prior to the live gas trials. This was used to complement the engineering and SGN/PM/G/23 policy document submitted for approval to SGN’s Engineering Safety Committee and Policy department.

The field trials were successfully held at two locations on SGN’s South London network with both the CIRRIS XI™ inspection and the CIRRIS XR™ repair systems tested in a live gas environment. All of the predetermined test



4 4thDecember 2015

Figure 3: Preliminary concept for remotely connecting service lines proposed by ULC. Robotics platform is inserted into the main to map the location of all features (left). Custom fittings are installed on to a section of PE pipe to be live inserted (centre). Service lines are inserted

using ULC designed adaptor to create connection (right).

As specified in the project direction, once a conceptual design had been selected SGN were required to facilitate a consultation to disseminate the conceptual design proposed by ULC to the GB GDNs and the wider stakeholder group. The consultation was a success, with positive feedback supporting the development of the conceptual design through to the field trial stage. At the time of writing the report to Ofgem summarising the outputs of the consultation is under review prior to an announcement on whether the funding required for the development of the conceptual design in line with the project plan will be granted.

2.1 Risks to Project Delivery A summary of the associated risks highlighted in the guidance document are listed below with a short description of the mitigation methods used. All risks and their associated mitigation methods are listed in detail in the project risk register in Appendix C.

Due to E1, 2 & 3 of the project nearing completion with the CIRRIS platform field trials completed, 15 of the risks identified on the project risk register have been successfully mitigated. The remaining risks on the risk register relate to the development of E4.

Recruitment Risk There is no requirement to recruit customers to take part in the project until the field trial stage of Element 4 scheduled for 2017. This stage presents no risk to project delivery. A customer engagement plan will be drafted and submitted to Ofgem for review in advance of the field trial.

Procurement Risk There are no procurement risks with respect to the development of the CIRRIS XR™ and CIRRIS XI™ systems. The risks highlighted in PPR3 concerning the tether was resolved by ULC using a combination of two separate vendors without any detrimental impact on the project schedule.

For Element 4 of the project there are risks associated with the selection of vendors to supply the supporting technologies identified. Productive initial discussions have been held with the vendors and communication will be maintained throughout the early stages of the project. Once the outcome of the review period by Ofgem has been announced instruction will be issued to the selected vendors to ensure the project schedule is maintained.

Installation Risks From the 6th November 2015 the 20 day field trial for Elements 1-3 was successfully carried out by the project team. Extensive controlled testing took place prior to the live trials to ensure all potential risks had been mitigated, providing the project team with full confidence in its ability to operate in the challenging environment of a live gas main.

Prior to the field trial RPS carried out an independent technical analysis on all aspects of the system including an Electrical Technical Assurance report, weight loading calculations, and a Technical Assurance spreadsheet. All assurance documents were then used as part of the Engineering Safety Committee presentation and



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SGN/PM/G/23 policy submissions prior to the field trials took place. The work that was carried out by the project team has been described in further detail in Section 3 of this report.

Other Risks At this stage there are no other risks to the successful delivery of the project.

2.2 Learning Summary In line with previous PPR’s, the project learning outcomes will be divided into two categories of dissemination; internal and external. The aim of the project dissemination plan is to ensure accessibility to, and dissemination of the project results and methods. The plan details the format and timescales of the internal and external dissemination modes, ensuring transparency and effective communication with all stakeholders. Further detail can be seen in the ‘Learning Disemination’ from Section 3 of this report.

Since the last progress report SGN have used a number of different methods to disseminate information on the project:

1. The LCNI conference was held from the 24th to the 26th November in Liverpool with presentation given in breakout sections and the CIRRIS XI system at the conference.

2. Gas Innovation Governance Group (GIGG) meeting updates 3. Presentations the Health and Safety Executive (HSE) and Ofgem were held in August. 4. All GB GDNs along with other external stakeholders to the field trials in November 5. Both internal and external press releases where issued to provide dissemination to the wider stakeholder

group and general public 6. A comprehensive dissemination plan has been developed with ULC targeting international markets to

promote CIRRIS. A communication plan has been included in the Section 3 of this report 7. Presentations on the project have been provided at key industry events including Asset Infrastructure

Conference, Safe and Efficient Street Works workshop, National Joint utilities group functions and IGEM. 8. The consultation period for the Element 4 conceptual design was carried out with an online questionnaire

sent to 150 of SGN’s key stakeholders and SGN’s social media platforms used to capture feedback on the estimated benefits the system has the potential to deliver.



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3 Project Managers Report Since the submission of PPR3, the project has progressed as planned with no variation to the schedule or the budget. The field trial for Elements 1, 2 & 3 has successfully been completed achieving all the SDRC (9.6 & 9.7) criteria defined in the project direction. The conceptual designs for Element 4 have also been submitted to Ofgem and the consultation period where feedback from SGN’s stakeholder group was collected and submitted has also been completed. At the time of writing the outcome of the consultation is being review by Ofgem with the outcome being announced on or before 4th March 2016.

The last six months of the project has been focused on the preparation and execution of the field trials of the CIRRIS XI & XR systems developed under E1, 2 & 3 of the project. Significant resource, logistical and scheduling challenges had to be overcome to ensure the system was ready for operation in a live gas environment and demonstration to SGN’s stakeholders.

Due to the geographical location of ULC to the site and the wider project team a detailed delivery plan was developed to ensure that the distance between the workshop where the systems have been developed and the main support function is located didn’t impact on the delivery of the trial. 10 days of the 20 day trial were allocated to each of the XI and XR systems, which reduced the amount of people required on each test site whilst maximizing the amount of time that could be spent carrying out controlled testing in ULC’s facilities.

Once each system had been shipped and arrived in the UK, further controlled testing needed to be done to ensure the systems hadn’t been damaged in transit, and to demonstrate to SGN and RPS that the system could pass key functional tests before it could be launched in to a live main. A test rig for preliminary functional tests was developed by SGN and FlowStop Services Limited. SGN provided a 24 inch diameter, approximately 10 feet (3 meter) long spun iron mains cut out. FlowStop tapped and installed a fitting, and manufactured a custom stand to allow it to be safely secured on site. The mains cut out included a bolted joint which also had a Weco seal installed. Thorough testing was performed in the test piece to prove mobility, sensing, and No Power Extraction (NPE).

Fig 4 – 24” test pipe with a tee and 16” sandwich valve installed

The detailed schedule and the ability to continue controlled functional testing with a custom test rig on site significantly reduced the potential impact of relocating the project team to the UK. This maximized the time spent testing the system allowing the team to satisfy all test criteria specified and to demonstrate the systems operation to over 50 visitors throughout the trial.

Another major development for the project since the last PPR submission is the start of Element 4 of the project. Element 4 focuses on the development of a method to reconnect service connections remotely once a tier one



7 4thDecember 2015

metallic main has been inserted with a new PE pipe. The type of environment this type of system needs to operate in is completely different to that of CIRRIS, with a different environment, performance criteria and operating parameters to overcome.

ULC have investigated in detail four different design concepts for the robotic platform and have assessed them against the key form factors identified. The key learning from the research and design of each concept has been recorded in the SDRC9.2 report, with consideration given to the use of the robot in practice, the ease of duplication and the commercialisation of the system. The report clearly highlights the reasons behind the selection of the chosen conceptual design and the benefits it presents as well as the areas where there’s an opportunity to stretch the goals set at the start of the project.

The selection of insertion and connection techniques to be progressed highlights the importance of ULC’s experience in the research and development of robotic solutions for the utility industry. The learning gained through the development of the Elements 1, 2 & 3 provided significant benefits allowing ULC to assess the theory behind the design principles by utilising a number of cutting edge technologies including rapid prototyping, 3D modelling and in house prototype testing. Consideration has been given to key aspects such as deployment, retrieval, surveying, connection operations and repeatability of the operation to ensure the final solution can be practically applied across the GB gas distribution networks.

Prior to continuing the development of Element 4 past the conceptual design phase SGN were required to conduct a consultation period gaining feedback from the GB GDN’s and key stakeholders. A detailed animation was created showing how the system is designed to operate. The animation was used extensively to support presentations on the project and to share with stakeholders to highlight the potential benefits the system can bring to both industry professionals and those with minimal knowledge of how this type of work activity is carried out. To gather written feedback on the proposed method SGN created a webpage containing a questionnaire, further information on the project, a link to the animation and contact details for people to contact the robotics team.

SGN received 72 completed questionnaires with a broad range of responses from the target audiences of gas customers, highways agencies, council, gas industry professionals, and government representatives. The results of the survey and the specific questions asked are shown in the graphs below. As well as the survey feedback SGN received written responses as a result of visits to the CIRRIS field trials, presentations and the animation being made available online.

The key achievements from the last six months and targets for the next six months are listed below with a description for each.



18 4thDecember 2015

deployed, operated and retrieved in a live gas environment. Given the similarities with the operation of the CISBOT™ robotic system a comparable methodology to the ‘CISBOT™ Technical Assurance Report of Electrical Safety’ was used.

RPS completed an Electrical Safety Technical Assurance report for the CIRRIS Project a full copy is available on request. The system’s construction is not intrinsically safe, however, it will be operating in a saturated natural gas environment. For this reason the system does not pose any adverse risk because it won’t be operating in a gases environment. To ensure this is the case for the entire operation, Nitrogen is used throughout the launch and retrieval purging processes. Additional measures are offered as the electrical components are sealed within the robotic systems and the tether is hermetically sealed using both chemical and mechanical means to ensure gas pressure does not permeate through any part of the tether.

Technical Assurance Spreadsheet The Technical Assurance Spreadsheet for Field Trials was initially developed as an efficient method for the project team to assess the requirements of functional testing in relation to the high level performance specifications for Elements 1, 2 & 3. This formed a basis of assessing whether the systems could be safely trialled in live gas conditions.

Prior to the field trial taking place, the Technical Assurance Spreadsheet was regularly reviewed and updated by the project team as per the relevant testing updates and reports provided by ULC Robotics.

An updated version of the spreadsheet with all cells relevant to the CIRRIS XI™ and CIRRIS XR™ field trial recorded as being satisfactorily met was issued to SGN on 12th November 2015, prior to the first launch into a live gas main. The final version of the Technical Assurance Spreadsheet for Field Trials, with all performance specifications at a satisfactory level to progress to field trials was issued to the project team by RPS on 19th November 2015. This is included in Appendix B of this Report.

The final Technical Assurance Spreadsheet will also be issued post-field trials to be included in the final project report.

SGN/PM/G/23 field trial procedure The G/23 procedure document covered the CIRRIS XR™ & XI™ systems for operations in a live gas environment for the purpose of the initial field trials in November 2015 and the subsequent pilot program in 2016. The document was rigorously analysed by SGN’s policy department to ensure that all risks had been identified and the respective mitigations agreed. The G23 procedure was successfully approved and signed off on 2nd November 2015. The content page of the document can be seen below in Figure 20 and the full document is available upon request.



26 4thDecember 2015

Prior to the field trails, the SGN project team successfully submitted G/23 and ESC papers to the respective engineering boards for executive approval. RPS provided a technical assurance document outlining the functional specifications of the CIRRIS XR™ and CIRRIS XI™ system that had to be met prior to live gas operations. RPS and SGN also reviewed the controlled testing outputs, witnessed the testing once the system has been shipped to the UK, and reviewed the site report from ULC and confirmed full compliance with the SDRC9.6 criteria and the original bid document.

Figure 30: The CIRRIS XI™ Inspection Robot at the SGN Kennington Gas Holder site being prepared for launch. The inspection robot was tested over multiple days in a live gas main. All SDRC milestone criteria were successfully completed.

A breakdown of the evidence provided in the full SDRC report can be found below

The full system, including the robot, launch tube, and required support equipment, was shipped to the UK from ULC Robotics New York facilities

SGN selected sites suitable for deployment of the robot and prepare opening notices, traffic management, excavations, mains drilling and valve installation

ULC Robotics team of engineers and robot operators arrived in the UK and prepared the equipment for operations. All of the components were unpacked and tested to ensure they are functioning properly prior to being deployed at SGN sites

All safety procedures, in accordance with SGN’s Safety Management Framework and Safe Control of operations permitry was prepared, registered and authorized by SGN.

The launch tube was mounted and the robot deployed in the main

Robotic inspection and sealing operations took place under live gas conditions

ULC Robotics has made recommendations for further engineering works

Learning Dissemination & Consultation Period As part of the funding for the project, prior to continuing the development of Element 4, SGN was required to conduct a consultation period gaining feedback from the GB GDN operators. As part of field trial for Elements 1-3, both SGN and ULC disseminated information in regards to the direction of the project including information about Element 4.

Following on from the field trial, a short animation created by ULC of the conceptual design and questionnaire was disseminated to key stakeholders. The content of this document detailed the successful development of the robotic solutions for Element 1-3, the learning gained through the development process, and the chosen conceptual design for Element 4. A questionnaire was distributed to allow key stakeholders to provide feedback and evaluate the suitability of the proposed design.



27 4thDecember 2015

The results of the consultation period were extremely positive, with wide support for the conceptual design from a variety of key stakeholders including the GDN’s, Highways Agencies, Local Council’s and industry experts.

Following the success of elements 1, 2 & 3 of the project, the quality of the conceptual design developed by ULC and the support shown by SGN’s stakeholders, SGN recommended element 4 of the project continues in line with the project plan in the project direction. This report submitted contained details of the relevant learning from E1, 2 & 3 and how it will be applied, the conceptual design process and the results of the consultation. An independent appraisal by RPS technical consultants supporting the continuation of the project and the viability of the conceptual design was also submitted as part of the report.

3.2 Targets for the next six months – 19.12.2015 – 19.06.2016 Key deliverables scheduled for delivery over the next six months of the project are listed below.

Final Reports for Elements 1, 2 & 3

Support demonstrations of CIRRIS for other GDN’s

Review of Element 4 Conceptual Designs by OFGEM

Element 4 Initial Electrical Schematic Design

Initial 3D Design of Mechanical Components for Element 4

Final Reports for Elements 1, 2 and 3 The final report for the development of Elements 1, 2 & 3 will be submitted on the 18th January 2016. This will provide SGN and ULC a platform to fully disseminate the development of the project both to Ofgem and the wider stake holder group. Included with the general project narrative, the final report will provide SGN the opportunity to include concepts that were discovered throughout the development and unforeseen projects that of the can be integrated into operations. Further detail can be found later in the report under ‘Future Projects’.

Support demonstrations of CIRRIS for other GDN’s As part of the scope of work under the NIC Robotics project ULC wil provide a FOC (free of charge) demonstration of the CIRRIS platforms for the other GDN’s. As part of the demonstration, the CIRRIS XI™ will perform a multi-point inspection in each straight barrel of 24” cast iron. The CIRRIS XR™ will perform repair operations on mechanical joints and internal Weco seals.

It is expect that the support provide by SGN will include:

Dissemination of the site arrangements to aid demonstration operations. During the field trial technical information was shared to all GDN operator representatives who attended. This included site footprint, layout and operational requirements.

SGN will attend meetings between the respective GDNs and ULC to facilitate further technical support required

Sharing of any supporting documentation

Figure 31: Sam Wilson SGN project manager in discussion with Northern Gas operations managers on CIRRIS field trial

Figure 32: Excavation information provided to GDN operators for CIRRIS demonstration



34 December 2015

To ensure all of the learning from the trial was shared with key stakeholders, a visitors schedule was developed and invitations sent to ensure the number of visitors on site could be managed safely. Notable visitors to site included National Grid, Northern Gas, Ofgem and the NIC expert panel. A full attendance list can be found in Appendix G.

Due to the difference in technology, potential value to the network operators and logistical practicality, it was decided to have the GB GDN stakeholders only attend the CIRRIS XI™ field trial. During this demonstration a presentation describing the full capability for both the CIRRIS XI™ and CIRRIS XR™ systems was given to all attendees. The presentation included the following topics along with one to one discussions to answer any questions raised:

An introduction to the CIRRIS XI™ and CIRRIS XR™ robots and system components

An update on the NIC Robotics project to date

Information to support up to 300m field demonstration for each network

CIRRIS Field Trial Demonstration All stakeholders who attended provided positive feedback with respect to both the project specification and achievements as well as the information that was presented through the day. Photos of the GDN site visitors can be seen in the section below.

Figure 41 - ULC president and CEO Gregory Penza giving an introductory presentation of CIRRIS to all GDN attendees

Figure 42 - GDN representatives include operations managers from National Grid and Northern Gas

Figure 43 - CIRRIS XI™ was operated on a live gas main throughout the demonstration period with the other GB GDN

representatives on site

Figure 44 - One to one discussions with the project team for information dissemination

In 2014 National Grid Transmission also won funding through the Network Innovation Competition to develop a robotic platform for the inspection of unpiggable gas pipelines in pressure reduction stations (PRS) with their



35 December 2015

project GRAID submission2. Although similar in the basic principles, each project faces different challenges including the pressures, flow rates and configurations each system will need to operate in.

It was agreed that the GRAID project team members from both national grid and their primary project partner Synthotech attended site as part of the dissemination process. Following a demonstration of the CIRRIS XI™ system productive discussions were held on key learning points the GRAID team can take from the site trials. Communication between each project team will continue to ensure any further learning is shared.

Figure 45 - Discussions between Gregory Penza and Sam Wilson with SynthoTech project managers of the GRAID project

with National Grid

Figure 46 - Further discussion between the respective project teams

SGN Dissemination Plan SGN and ULC have developed an extensive internal and external communication plan to ensure the project and the CIRRIS field trial is recognised across the gas industry to provide a platform for CIRRIS to become a commercial success in to the future. A summary table from the dissemination plan can be found in the appendices of this report, the full document is available on request. Once the outcome of the E4 consultation has been announced a similar dissemination plan will be developed.

Figure 47 below highlights the primary stakeholders and their relationship with the project. SGN will continue to engage with the parties listed to provide updates on how the CIRRIS system develops throughout the pilot works, and to provide updates on E4 of the project.

2https://www.ofgem.gov.uk/publications-and-updates/gas-networks-innovation-competition-submission-national-grid-gas-transmission-%E2%80%93-line-robotic-inspection-high-pressure-installations


NIC Robotics – Project Progress Report Three

40 December 2015

Appendix A - ULC Project Progress Report


CONFIDENTIAL INFORMATION – NOT FOR PUBLIC RELEASE

1

18 December 2015 | Project Progress Report No. 4

Contents

Revision History .............................................................................................................................................. 2

Referenced Documents .................................................................................................................................. 2

Executive Summary ............................................................................................................................ 3

Project Managers Report ................................................................................................................... 4

2.1 Element 1, 2 & 3 ............................................................................................................................. 4

2.2 Element 4 ....................................................................................................................................... 5

Consistency with Full Submission ....................................................................................................... 6

Risk Management ............................................................................................................................... 6

Learning Outcomes ............................................................................................................................ 7

5.1 Future Work for NIC Platform ........................................................................................................ 7

5.2 Element 1&2 – Repair Robot .......................................................................................................... 8

5.2.1 Robotic Platform Launch, Retrieval and Travel Testing & Seal Robot Tool Testing ................... 8

5.2.2 Procure Spares and Material for Field Testing .........................................................................10

5.2.3 Perform 20 Days Field Testing & Launch Robot .......................................................................11

5.3 Element 1&3 – Inspection Robot .................................................................................................11

5.3.1 Integrate and Test Tether with Sensor/Data Acquisition System ............................................11

5.3.2 Sensor Data Validation .............................................................................................................12

5.3.3 Configuration Testing with Robotic Platform ..........................................................................13

5.3.4 Develop Test Plan for the Field ................................................................................................14

5.3.5 Incorporate Improvements Discovered During Testing ...........................................................14

5.3.6 Perform 20 Days Field Testing & Launch Robot .......................................................................15

5.4 Element 4 .....................................................................................................................................16

5.4.1 Delivery of High Level, Preliminary Specification Document by ULC to SGN ...........................16

5.4.2 Development of Conceptual Designs .......................................................................................17

Progress Against Plan and Budget ....................................................................................................19

Intellectual Property Rights (IPR) .....................................................................................................19


CONFIDENTIAL INFORMATION – NOT FOR PUBLIC RELEASE

3

18 December 2015 | Project Progress Report No. 4

Executive Summary

The objective of the NIC Robotics project is to develop new, cutting edge robotic repair and inspection technologies which can operate inside live gas distribution mains. The project is split up into four elements. Elements 1 through 3, which after twenty-two months have been successfully completed under the NIC Robotics project, provide unprecedented inspection and repair technology to tier 2 and 3 mains. The goal of Element 4 is to develop a system capable of remotely reconnecting service lines to inserted pipe in tier 1 mains without the need to perform excavations over each of the connection points. The success and achievements of the project to date are a direct result of an excellent level of collaboration and attention to detail from all project stakeholders, namely SGN, the project sponsor and RPS, the project technical service provider.

Figure 1 – The field testing of the CIRRIS XI™ (Inspection Robot, Element 1&3) (Left) and the CIRRIS XR™ (Repair Robot, Element 1&2) (Right) was successfully completed on-schedule.

ULC Robotics has been under contract since February 2014. Since the submission of the last project progress report (June 2015) all milestones were achieved on schedule including four (4) SDRC milestones. Since the start of the project, and as of the date of this report, forty (40) deliverables have been completed on schedule which includes six (6) SDRC’s and thirteen (13) Go/No-Go’s. There are two (2) project milestones remaining for Elements 1, 2 & 3. The milestones that were successfully completed since the submission of the previous progress report reflect several significant project accomplishments. The field testing of the CIRRIS XI™ (Element 3) and the CIRRIS XR™ (Element 1 & 2) has been successfully completed, and the conceptual design phase of Element 4 has been completed as well. The project is fully staffed with dedicated engineering and management personnel. All team members are full-time and dedicated to the NIC Robotics project. Additional resources such as sensor consultants have been utilized as well on an as needed basis. A detailed summary of the project’s progress and upcoming objectives are given in this report. What we’ve learned, our development approach and the intricate details of the designs have been detailed in all project milestone reports.


NIC Robotics – Project Progress Report Three

62 December 2015

Appendix B - RPS Project Progress Report


rpsgroup.com/ireland

Document Control Sheet

Copyright RPS Group Limited. All rights reserved. The report has been prepared for the exclusive use of our client and unless otherwise agreed in writing by RPS Group Limited no other party may use, make use of or rely on the contents of this report. The report has been compiled using the resources agreed with the client and in accordance with the scope of work agreed with the client. No liability is accepted by RPS Group Limited for any use of this report, other than the purpose for which it was prepared. RPS Group Limited accepts no responsibility for any documents or information supplied to RPS Group Limited by others and no legal liability arising from the use by others of opinions or data contained in this report. It is expressly stated that no independent verification of any documents or information supplied by others has been made. RPS Group Limited has used reasonable skill, care and diligence in compiling this report and no warranty is provided as to the report’s accuracy. No part of this report may be copied or reproduced, by any means, without the written permission of RPS Group Limited

Client: SGN

Project Title: Network Innovation Competition (NIC) Robotic Solutions

Document Title: Ofgem Project Progress Report Update Four

Document No: MDR1025Rp0032

Text Pages: 24 Appendices: -

Rev. Status Date Author(s) Reviewed By Approved By

F01 Final 17th

December 2015 Ian MacHugh Ciarán Butler Ciarán Butler

Ofgem Project Progress Report Update Four


NIC Robotic Solutions Project Progress Report 4

MDR1025Rp0032 i

TABLE OF CONTENTS

EXECUTIVE SUMMARY ................................................................................................................. 1

1 INTRODUCTION ................................................................................................................ 3

2 RPS PROFILE ..................................................................................................................... 4

2.1 NIC PROJECT TEAM ........................................................................................................................ 4

3 PROGRESS SUMMARY ...................................................................................................... 5

3.1 ELEMENT 1 - DEVELOPMENT OF A ROBOTIC PLATFORM AND LAUNCH SYSTEM TO ENABLE DEPLOYMENT OF

MODULAR REPAIR AND INSPECTION DEVICES FOR TIER 2 AND TIER 3 PIPE ................................................ 14

3.1.1 Project Progress Update .................................................................................................. 14

3.2 ELEMENT 2 - DEVELOPMENT OF AN INTERNAL MECHANICAL JOINT INSTALLATION MODULE AND WECO SEAL

REPAIR METHOD FOR TIER 2 AND TIER 3 PIPE ..................................................................................... 14


3.3 ELEMENT 3 - ROBOTIC VISUAL AND NON-VISUAL INSPECTION ............................................................... 15


3.4 ELEMENT 4 - AUTOMATED LIVE ASSET REPLACEMENT FOR DISTRIBUTION SERVICES AND MAINS .................. 16


3.5 RPS STRUCTURAL ASSESSMENT REPORTS ......................................................................................... 16

3.6 MRPS INTERPRETATION REPORT .................................................................................................... 17

3.7 ELECTRICAL SAFETY REPORT ........................................................................................................... 18

4 KEY LEARNING OUTCOMES ............................................................................................. 19

5 PROGRESS AGAINST TARGET PRICE ................................................................................. 20

6 CONSISTENCY WITH FULL SUBMISSION PRO-FORMA ....................................................... 21

7 TECHNICAL ASSURANCE SPREADSHEET ........................................................................... 22

8 RISK MANAGEMENT ....................................................................................................... 23

9 KEY TARGETS FOR THE NEXT SIX MONTHS ...................................................................... 24

LIST OF TABLES

Table 2.1: RPS Project Team ................................................................................................................... 4 Table 3.1: RPS Deliverables since previous Project Progress Report ...................................................... 5 Table 3.2: Face to Face Project Team Meetings ..................................................................................... 6 Table 3.3: Table of Reports by RPS ......................................................................................................... 7



MDR1025Rp0032 1

EXECUTIVE SUMMARY

The objective of this project is to develop new robotic technologies to operate inside live gas mains. This new technology will have the ability to remotely repair leaking mechanical joints, failed Weco seals and also support pipe fracture risk management processes by providing enhanced inspection capabilities. Element 4 of the project involves developing robotic techniques to integrate the PE pipe insertion method with a method of remotely connecting service pipes without needing to carry out individual excavations.

RPS were appointed to provide technical services to SGN in supporting this industry leading innovation project in developing robotic platforms and solutions for the gas industry in partnership with a robotics manufacturing & utility company – ULC Robotics. This innovation project will potentially allow extensive work to be carried out on the UK’s gas network without the need for disruptive road works, reduce repair costs, reduce third party damage, improve the risk management of metallic mains and reduce leakage from gas distribution mains.

This Project Progress Report - Update Four provides a concise update of work completed since the previous progress report issued to Ofgem on 19th June 2015.

Progress Summary The project is currently progressing well and is within budget; All testing set out to prepare for deployment of the systems in live gas mains was carried out

and documented on the Technical Assurance Spreadsheet for the project; ULC and SGN conducted successful field trials in London between 9th November and 4th

December 2015, which was attended by and reported on by RPS; The project has met all of the Successful Delivery Reward Criteria associated with Elements

1, 2 & 3; Conceptual design of the system to be developed under Element 4 has been completed,

consultation is underway with key stakeholders and the first SDRC Report has been submitted by SGN to Ofgem.

In addition to assessing ULC reports, SDRC reports and field trials, RPS has delivered a number of reports of significance importance to this NIC project during this period.

o Phase 2 Structural Assessment Report on 23rd September 2015 to identify the structural and maximum stress imposed by the launch tube on a range of pipe sizes under different effective remaining wall thicknesses.

o Phase 3 Structural Assessment Report Update on 16th October 2015 outlining the impact of deploying the drilling rig for cutting the coupon from the pipe on various pipe sizes under different effective remaining wall thicknesses.

o Final Issue of the MRPS Interpretation Report on 11th September 2015 outlining how the data garnered from the inspection robot can impact the current risk management system used in the gas distribution industry. This report also proposed a number of scanning configurations which could be used by the inspection robot depending on requirements. Key considerations will be to optimise how the robot system is deployed to gather sufficient information in each scenario to input into decision making in relation to the asset.

o An Electrical Safety Technical Assurance Report on 11th September 2015 which reviewed the detailed design and operational procedures for the systems in the context of confirming the safe operation of both the mechanical and electrical systems being deployed, operated and retrieved in a live natural gas environment and outlining any safety requirements.



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Key Learning Outcomes The robotic systems can be launched, conduct their required activities and be retrieved

safely in a natural gas environment. All SDRC for Elements 1, 2 & 3 have been achieved. The field trials identified a number of areas of improvement for the system which will be

implemented by ULC prior to the commercialisation of the system. The conceptual design for Element 4 provides confidence that the goals for this stage of the

project can also be achieved in the coming 2 years.

Consistency with Full Submission Pro-Forma The project development to date is consistent with the SGN Full Submission Pro-forma to Ofgem.

Risk Management The risk register is discussed and regularly updated with all members of the project team. Key project risks are then identified. Controls are then put in place to mitigate these risks. There were twelve risks over the past six months that were marked as closed out.

Intellectual Property Rights There is very significant value in the IPR developed under this project to GB gas consumers. Techniques used in this project for the launching process, robotic platforms, repair and inspection are at the forefront of robotic technology to inform risk and asset management especially in a live gas main.

This robotics project has the potential to transform the way the UK gas industry maintains its gas distribution pipes. The use of robotic technology to repair and inspect mains may lead to significant benefits, both for customers and our environment.



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1 INTRODUCTION

The aim of the project is to develop robotic techniques that will allow Gas Distribution Networks (GDNs) to repair leaking joints and inspect mains providing sensor outputs of mains condition in a ‘live’ gas environment from a remote location.

RPS were appointed as the technical service provider to SGN in supporting an industry leading innovation project in developing robotic platforms and solutions in partnership with a robotics manufacturing & utility company – ULC Robotics.

This Project Progress Report - Update Four provides an update of work completed between June and December 2015. The key areas to which RPS will discuss in this progress update report are:

RPS Company Profile;

Progress Update and Summary;

Key Learning Outcomes;

Progress against Target Price;

Consistency with Full Submission Pro-Forma;

Technical Assurance Spreadsheet;

Risk Management;

Key Targets for the next Six Months.



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5 PROGRESS AGAINST TARGET PRICE

It is noted in each ULC report that there has been no variation in the progress against the target price.



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6 CONSISTENCY WITH FULL SUBMISSION PRO-FORMA

The Gas Network Innovation Competition Full Submission Pro-Forma covers the entire summary of the project and describes the design process and various milestones in detail. The overall objectives of the project are described in detail throughout the document.

The Pro Forma is broken down into 9 sections:

1. Project Summary

2. Project Description

3. Project Business Case

4. Evaluation Criteria

5. Knowledge Dissemination

6. Project Readiness

7. Regulatory Issues

8. Customer Impacts

9. Successful Delivery Reward Criteria (SDRC)

The final design of the robotic systems developed under Elements 1, 2 & 3 underwent significant changes since the initial and conceptual design stages. At each milestone, the Full Submission Pro-forma was checked for compliance by the RPS Project Team. It has been deemed compliant at each milestone to-date.

The conceptual design provided by ULC for Element 4 has also been deemed compliant with the Full Submission Pro-Forma to-date.



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8 RISK MANAGEMENT

Risk Management has been used by the project team throughout as a tool to identify, monitor and implement measures to reduce risks to various aspects of the project. The project specific Risk Register was formulated using inputs from SGN, ULC and RPS and is discussed regularly on an ongoing basis between all members of the project team. The Risk Register is a dynamic model that has been revised a number of times to account for new risks which are identified as the project progresses or to adjust the likelihood or impact scores of existing risks as the associated constraints develop.

RPS considers the Risk Register as part of the assessment process of ULC reports and identifies any areas of concern which may require attention. This is typically followed by a discussion of any potential risks during a teleconference between the project team to determine the extent of these risks and the best control and mitigation measures to implement.

The control of this document is by SGN. Twelve risks were marked as completed during this period.



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9 KEY TARGETS FOR THE NEXT SIX MONTHS

The following are key deliverables over the next six months from ULC and RPS:

Elements 1 & 2

Final Reports

Element 3

Final Reports

Element 4

Initial Electrical Schematic Design and Parts Selection; Initial 3D Design of Mechanical Components; Circuit Card Layout and Fabrication; Microprocessor Firmware Programming.

RPS will continue to review the design of the systems for Element 4 as they progress through detailed design and offer input during key project stages over the next six months.

The key target for the next six months is to gain Ofgem’s approval to progress with the designs for Element 4. Should acceptance be granted, the progression of the design of the system will be the key target.


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