A new generation of pipeline robotics that can extend the life of large diameter cast iron pipeline infrastructure could help save time and money for utility companies. After an intensive two year research and development effort, ULC Robotics and SGN introduced the breakthrough CIRRIS XI and CIRRIS XR Robotic System.
The system is comprised of two separate robots that work in tandem — the CIRRIS XI Inspection Robot and CIRRIS XR Repair Robot — to address all three risk factors. With the development of these robots gas distribution networks are able to take on the challenges of internally assessing cast iron pipelines for wall thickness and stress, and sealing multiple joint types to stop and prevent gas leaks in large diameter cast iron mains.
Cast iron pipelines are utilised around the world, but due to their size, weight and inaccessibility can be very costly to replace. However, the thick pipe walls of large diameter cast iron gas mains are capable of providing safe and reliable service for hundreds of years.
By entering the main through a very small excavation in the street and travelling hundreds of meters in either direction to assess and renew these gas mains, the Cirris robots will deliver reduced public disruption and lower costs while fixing and preventing harmful gas leaks.
The CIRRIS XI Inspection Robot internally（ first-of-its-kind robotic system that internally assesses the condition of cast iron pipelines） assesses the condition of cast iron pipelines and collects critical pipeline integrity data using two specialized sensors. The measurement data from these sensors provide key indicators of pipeline integrity and allow network operators to proactively manage their assets.
The first sensor technology which was specialized for this application is electro-magnetic acoustic transducers (EMAT) and is used for measuring pipe wall thickness and graphitic corrosion. The second specialized sensor technology deployed for the CIRRIS XI Inspection Robot is Barkhausen Noise sensors which are used to measure stress in the pipe wall. Before now, network operators were unable to obtain this type of data from inside live gas mains, changing the way gas utilities make decisions about their large diameter cast iron assets.
The second robotic system, the CIRRIS XR Repair Robot was designed specifically to repair mechanical joints, bell and spigot joints and failed Weco seals. The repair robot is capable of injecting up to two different sealants or other materials to repair a leaking joint. To access the aging joint seals, the robot uses a redundant set of highly specialized servo controlled drills and injection mechanisms. A trained operator can efficiently and reliably position the robot to precisely inject prescribed amounts of sealant into each pipe joint. The result is a highly repeatable and practical means for gas utilities to eliminate and prevent gas leaks.
“ULC’s team of mechanical and electrical engineers, sensor scientists and precision machinists worked collaboratively with SGN’s innovation team to integrate the needs of the gas utilities with cutting-edge technologies to develop the CIRRIS XI and the CIRRIS XR Robotic Systems,” said, president of ULC Robotics.
The successful field trials of the CIRRIS XI and CIRRIS XR Robotic Systems in November and December of 2015 will pave the way for commercialized services. As partners in the development of this technology, SGN will be the first to use the CIRRIS XI and CIRRIS XR to effectively and efficiently inspect and renew cast iron pipeline infrastructure.
“We’re thrilled with the development of CIRRIS XI and CIRRIS XR Robotic System,” said Gus McIntosh, manager of innovation and new technology for SGN. “It’s all part of how SGN is transforming the way they work in the street. SGN wants to develop innovative solutions to repair pipes that are causing issues now and identify others before they cause issues in the future.”
By improving upon the success of CISBOT and working closely with gas utility SGN to develop the CIRRIS XI and CIRRIS XR Robotic System, ULC is building the next generation of live gas pipeline robotics. As the robotic technology continues to develop and address the issues of aging large diameter cast iron pipelines, the gas utility industry will see the long-term benefits.
Some of these benefits include:
•Significantly reduces the cost when compared to pipeline replacement and less than other methods of pipeline rehabilitation；
•Reduction and prevention of leakage and gas emissions from multiple types of pipeline joints including mechanical, bell and spigot, and internal mechanical seals — reducing costly and repetitive maintenance；
•Data gathered from the CIRRIS XI Inspection Robot can be fed directly into risk models so pipe risk can be measured using direct inspection data；
•The CIRRIS XI and CIRRIS XR Robots feature faster driving speeds, improved maneuverability and the ability to traverse over obstacles and bends in the cast iron pipe；
•Trenchless technology greatly reduces permit, engineering and reinstatement costs associated with direct burial replacement；
•Robotic inspection and rehabilitation is performed in live gas mains, so there is no need to disrupt gas service to residential and commercial customers；
•Less demanding on limited utility personnel and resources；
•Decreases public disruption, noise, road closures and traffic backups；
The CIRRIS XI™ and CIRRIS XR™ robots give gas network operators an alternative to direct burial replacement by reducing pipeline risk and extending the usable life of large diameter (12″-48″) cast iron gas distribution mains. From one small excavation in the street, the CIRRIS XR™ Repair Robot renews up to 100 mechanical and lead/jute joints, as well as internal mechanical seals to stop and prevent leakage at a lower cost and with less disruption than pipe replacement or other rehabilitation methods.
UTILIZING CIRRIS XI™ INSPECTION DATA
•First-of-its-Kind Inspection Data: The CIRRIS XI™ is the first robot that makes wall thickness and stress data available to gas network operators. This important data allows them to make well-informed decisions and improve the safety and reliability of the gas network’s assets.
•Detect and Measure Wall Loss Due to Corrosion: Specialized Electro Magnetic Acoustic Transducers (EMAT) measure the cast iron pipe wall to identify wall loss caused by corrosion and other factors.
•Detect and Measure Stress on the Pipe Wall: The CIRRIS XI™ also has specialized Barkhausen Noise Sensors which measure stress on the pipe wall. These measurements help to identify adverse loading conditions and pressure points which may lead to pipe fracture.
CIRRIS XR™ Repair Robot
•Internally Drill and Inject From Any Clock Position: Circumferential rotation within the main allows the CIRRIS XR™ Repair Robot to drill and inject from any clock position around the joint.
•Improved Maneuverability: The CIRRIS XR™ and CIRRIS XI™ robots can navigate around 90 degree radial bends, past common obstacles and over most types of debris found in large diameter cast iron mains.
•Redundant Drilling and Injection Mechanisms: The CIRRIS XR™ Repair Robot is equipped with two drilling mechanisms to allows for the injection of two different sealants or for the repair of two different joint types in the same section of pipe.
About ULC Robotics
ULC Robotics is a leader in product development and engineering services for the natural gas, energy, industrial and electric distribution markets. We are committed to solving operations and maintenance problems while reducing costs, increasing efficiency and improving safety.
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