In collaboration with NGN, and as part of a recent NIA project [NGN_NIA_239], Renda Systems Limited has successfully developed (to TRL 4) a highly cost-effective pressure sensor system, designed to be incorporated at low cost into the PE Purge Tee assembly.
Next steps and this project proposal
This next phase of work seeks to take the learning and PoC pressure sensor system developed to roll out the developed technology in live field trials, to establish the long-term credibility and capability of this new technology approach to information gathering in the real-world setting.
Benefits
The benefits for this technology have been measured against incumbent datalogger technology to gauge advantage. The datalogger technology in use across NGN has a known base cost to install and operate [noting this varies depending on datalogger vendor].
A number of assumptions have been made to determine any benefit such as:
1. The installation cost remains the same for either the datalogger or new innovative pressure sensor [noting the project aims to gain further benefit by reducing install costs further].
2. The new technology battery life will be twice that of existing datalogger capability [and therefore recuing the opex costs to visit to replace batteries]
3. The unit cost for the new technology will be better than half that of existing technologies
4. The data costs for an IoT solution are lower than standard 2G / 3G based datalogger systems
Further benefits are anticipated due to the simplified design making the installation opportunities for this technology more adaptable and agile than exists currently This unlocks further opportunities to support unplanned and planned network operations to provide greater insight into network conditions than would ordinarily be the case.
This project is aiming to create sensor technology sub £200 per unit and to identify the more effective deployment model.
Learnings
Outcomes
The trial was considered a success and concluded that the RENDA SmartCap Sensor System delivered all agreed success factors and objectives within the G23 trial scope. The technology demonstrated that low-cost, easily deployable pressure monitoring on the low-pressure gas network is achievable. With successful installation, data collection, telemetry, alarming and remote management capabilities. The principal remaining challenges relate to environmental ruggedisation, chamber design optimisation, water ingress enhancements and communication resilience ahead of further product development.
1. Successful Installation on a Live Gas Network:
SmartCap installations were successfully deployed on newly installed purge tees at NeRV. The installations were completed by NGN engineers using existing working practices and required minimal additional training. The SmartCap installation was reported to be no more difficult than fitting a standard purge tee cap, and the complete post-purge tee installation process took approximately 10 minutes.
2. Successful Real-Time Pressure Monitoring and Data Transmission:
The trial confirmed that the SmartCap sensor could accurately measure live gas pressure and transmit data to the RENDA cloud platform. In addition to pressure measurements, the system also captured ambient temperature and humidity data. Data could be collected every minute and transmitted at configurable intervals, with a six-minute transmission frequency demonstrated during the trial.
3. Demonstration of Remote Device Management:
The project demonstrated the ability to remotely manage deployed devices. Firmware updates, threshold changes and system configuration changes were undertaken over the air during the trial period. Several software issues identified during testing were resolved remotely without requiring full device replacement.
4. Successful Demonstration of Pressure Alarms:
The project successfully tested pressure threshold alert functionality. The system immediately generated notifications when configured pressure limits were exceeded, independent of the normal transmission schedule. This demonstrated the potential for enhanced operational awareness and faster response to network events.
5. Validation of Core Hardware Design:
The SmartCap, pressure sensor and cable assembly performed particularly well throughout the trial. Even during severe weather conditions and chamber failures, the SmartCap and cable maintained integrity and remained operational. The "Smart Ready" installation also remained fully functional throughout the evaluation period.
Lessons Learnt
The field trial successfully demonstrated that the RENDA SmartCap Sensor System can be installed quickly, integrated into existing gas network workflows, and provide real-time pressure monitoring. This was the first trial installing anything onto the live network at the NeRV site which helped inform future processes. However, the trial also identified several important lessons that should inform future phases of development and deployment.
- The trial highlighted that actual network conditions can differ significantly from planned installation scenarios. As example the gas mains were located deeper than expected, requiring larger excavations and highlighting the need for adaptable chamber designs. Future deployments should ensure equipment and installation methods are suitable for varying pipe depths, ground conditions and chamber environments.
- NGN engineers reported that installation of the SmartCap was straightforward and very similar to fitting a conventional purge tee cap. This is a significant success factor because technologies that require minimal additional training or process changes are more likely to be adopted operationally. Try to maintain alignment with existing operational practices wherever possible and continually refine designs to reduce installation friction.
- The trial revealed that compliance with IP67 standards alone may not be sufficient for gas network environments. One datalogger experienced water ingress after remaining submerged for several days, despite meeting IP67 requirements. The gas network environment can expose equipment to prolonged flooding rather than short-duration immersion tests used in certification standards.
- Although the system successfully buffered data during connectivity outages, one location experienced intermittent NB-IoT signal strength due to local buildings and vegetation. The device continued recording data and uploaded it when connectivity returned, demonstrating system resilience. Pre-installation connectivity assessments should become a standard deployment activity. Development of signal-strength testing tools and consideration of alternative communications technologies will reduce deployment risks.
