Project Summary
The project looks to strengthen the UK's energy system robustness by supportingthe integration, adoption and deployment of Internet-of-things (IoT) technology
within the gas network supply chain by addressing specific challengesexperienced during network upgrades and new network construction.
The level of digitisation is extremely low in the gas sector, and the construction ofnetwork assets is still largely paper-based. To enable the efficient construction ofmajor capital projects such as HyNet in the north-west, critical path activities, suchas welding and its associated activities, need to be digitised and intelligentlylinked.
Whilst this program will provide immediate safety and quality improvements, whichinevitably lower costs, it also lowers construction costs by providing real-time 'costof delivery' metrics enabling project teams to laser focus on escalating expensesas they happen and mitigate immediately rather than retrospectively, which onlarge capital projects is often the case.
Partner 1
-- Triton electronics is a leader in the development, manufacture andsupply of welding monitors and software, with deployments in APAC, EMEA andThe Americas in Aerospace, Oil & Gas, Nuclear, Research and other demandingengineering sectors. They are providing the hardware expertise and overall designarchitecture for the solution.
Partner 2
--TWI is a technology and research organisation that is a leadingengineering institution supporting welding and joining professionals with welding,joining and allied technologies. They are providing access to their weldingsoftware platform and assisting in its integration with the hardware.
Partner 3
- United Living is a supply chain partner within the gas network and firstidentified the need for such a technology to enable the efficient build of largenetwork assets such as HyNet. Fully conversant in the construction of high-pressure gas networks, they will test and integrate the solution into theiroperations and provide the welding equipment and staff.
Partner 4
-- Cadent Gas are supporting this initiative looking to develop thetechnology for use by its supply chain network. If successful, they will allow theenvironmental test phase of the project to take place on several sites ensuringoutput is accurate and as described.
Innovation Justification
Digital Inspector YouTube Video
Project Benefits
Digital Inspector will improve fabrication productivity and quality.
Digital Inspector will collect, aggregate and process all welding data from initiation,through procedure qualification and welder qualification and finally to theproduction welds. Previous site-side software deployment in vehicle tracking, fuelusage and temporary works control for example has shown an increase of over66% in efficiency and precision. Similar improvements in documentation.
Poor documentation is a source of weld defects, an unqualified welder or use ofincorrect consumables for instance. Having welder sign ins and consumablescanning, using a welder and consumable credential system will guard againstthese. Providing these assurances automatically and in real time means noproduction hold ups that are caused by staff looking for paperwork or an inspectormanually corresponding procedure documentation to welder qualifications.
Production defects can be introduced by welders using incorrect weldingparameters. Heat input affects weld pool solidification and the weld properties.Automatic data recording not only reduces out of tolerance occurrence by givingwelders instant feedback, but also flags anomalies so defects can be removedearly in the procedure.
Weld values are recorded accurately in real time so productivity rates can becompared within a site, and to greater benefit across multiple applications,simplifying the adoption of best practices. Further, new processes and practicescan be documented and systematically compared, inherent defect ratesestablished. Once the base lines are determined, problem areas and bottle necksare spotted early and alleviated.
Automatically storing weld fabrication data in TWI management software will allowthe easy reuse of welding procedures. New projects can use historicalprocedures, only running new procedure trials when necessary. Similarly storingwelder credentials and their qualification history seamlessly in TWIs managementsoftware means welders only need to requalify when necessary. Even allowingwelders to "carry" qualifications from one site to another, one job to another. Thisis a novel idea that could easily revolutionise the industry, allowing welders tomove between contractors without the need to be re-qualified.
A reduction in "cost of poor quality" is a big benefit for Cadent Gas. This is clearfrom recent incidents in North America and Asia, the issues that can arise frompoor weld quality, so prevention of construction incidents is a significant benefit.
Significant project costs are associated with countering fabrication risks, DigitalInspector will reduce both production overrun and quality risks. Reducing riskreduces project cost and delivery time.
