Control Systems Archives

Drax Power Station

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The Project

As a result of a recent HSE surveillance audit at the Drax Power Station, Blackburn site, the existing Gas Pressure Reducing Station was identified as non-compliant with current IGEM/TD/13 Edition 2 standards due to combined relief ventilation configuration.

The project comprised the installation of redesigned ventilation system to the Gas Pressure Reducing Station to bring the site in line with current standards and compliant with British and European legislation.

Working closely with the end user (Drax Generation Enterprise), Sonae (UK) were appointed as Principal Contractor to carry out the Ventilation Modification works associated with Gas Pressure Reducing Skid relief ventilation upgrade.

Ventilation Modifications
The installation currently comprises one common 2” ventilation header pipework that accepts each of the Gas Reducing skid relief vent lines. The redesign of the ventilation system included a number of individual small bore vents to be installed for system of similar duty.

Individual small bore ventilation lines shall vent to atmosphere at high level via vertical ladder rack support system from the Gas Pressure Reducing skid.

All Swagelok tube and fittings were installed by Instrument Pipefitter competent installer with appropriate Swagelok tube fitting installation training records.

All small bore tube and fittings including isolation valves were supplied and installed in accordance with the design hook up drawings and datasheets. All material certificates were retained and included within the handover documentation.
Ventilation pipework was secured by proprietary tube clamps and evenly spaced to prevent any deflection or sagging.

Pressure Testing
All ventilation pipework installed was subject to hydrostatic pressure testing for strength and leaks upon completion of the installation in order to validate that the equipment will operate under desired conditions once returned to service.

Records
Test Records and material certificates were issued upon completion prior to commissioning by site operations in accordance with Drax standard procedures.

Health & Safety
All works were carried out under a controlled permit to work (PTW) in accordance with Drax Power site safety rules and procedures.
Competent person trained in accordance with Drax Power site rules and registered on Competent Person database was in attendance for the duration of all work activity under the contract scope.

All working at height undertaken via 16m Diesel Articulating Boom. Operator IPAF trained as a minimum requirement.

Programme
The works were delivered to the satisfaction of the Drax Power site management personnel in accordance with the key delivery dates specified within the accepted programme during the shutdown period.

HYDEPLOY 2 Compound Build

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HyDeploy is a demonstration project funded by OFGEM, Cadent Gas and Northern Gas Networks to establish the feasibility of supplementing Natural Gas supplies with hydrogen to reduce the carbon dioxide (CO2) emissions.

To achieve this reduction, a consortium formed of Cadent Gas, Northern Gas Networks, the HSE Science and Research Centre, ITM power, progressive energy and keel university have worked together to study the feasibility of injection of up to 20% mol/mol hydrogen into the natural gas supply and into UK households within the north of England region.
Sonae (UK) were appointed Principal Contractor and were responsible for the EC&I, mechanical and civil works associated with the plant.

Works included the installation of new Hydrogen Buffer Tank, Grid Entry Unit (GEU), new Fire & Gas sxstem, LV distribution, new Telemetry system and GPRS communications, new site lighting and new pressure and tempertaure monitoring instrumentation.

Works were coordinated with other vendor work packages to ensure the delivery of the project to client specified timescales.

H21 COMMISSIONING

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The Project

Northern Gas Networks are leading the H21 project on behalf of the other Gas Distribution Networks within the UK to provide the safety based evidence for a 100% Hydrogen conversion in the below 7 bar GB gas distribution network. The next stage is to address the strategic evidence at a network level. The current H21 (Phase 1a and 1b) is looking at the performance of the existing gas network at asset level and establish the background performance of assets and the behaviour of hydrogen in our natural surroundings. However, there remains the need to research and understand the network performance and operations when converting to 100% hydrogen.

The project is the construction of a new hydrogen test facility to trail gas industry operational and maintenance procedures with 100% hydrogen. This is to further develop an existing hydrogen test facility to be able to simulate the various operations on a distribution network, to ensure they can be performed in a similar manner.

Sonae (UK) were appointed to carry out the commissioning the new hydrogen test facility on behalf of Northern Gas Networks. All pre-commissioning checks to be carried out by the E&I installer.

Commissioning

SONAE were responsible for supplying both the NRO documentation and competent persons to control and execute the changeover in line with the networks SCO 5 requirements.

Provision of SCO 4&5 competent persons to carry out the end to end checks and wet commissioning of the complete E&I installation under a controlled NRO procedure.

The support consisted of conceptual and detailed design review in conjunction with all parties to establish buildability, maintainability and sequencing of the works to minimise or mitigate interruption to live processes while maximising on any synergies with other disciplines or departments including quality assurance checks during the construction phase.

Final walkdown site visits were carried out with the Northern Gas Networks Project Engineer and other interested parties such as NGN ARM and NGN Maintenance to ensure snagging and asset tagging works complete to the satisfaction of NGN, obtain user acceptance of the completed works and carry out a ‘lessons learnt’ exercise to identify possible preferences or improvements for future works.

Records

Project records were produced and submitted at key stages throughout the project including support documentation for G17 part D,E and F sign off such as signed red-line marked up as-built drawings, dead and live test commissioning results, instrument pressure test certificates and vendor FAT and SAT documentation where applicable.

All final handover records were submitted to the Northern Gas Networks in both electronic format via A-site media document control system and hard copy format.

Health & Safety

All works were carried out under a controlled PTW in accordance with Northern Gas Networks SCO (Safe Control of Operations) management procedures.

TR Unit Replacement

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The Project

The switch mode power supply corrosion control systems installed at various remote site locations across the Northern Gas Network region have experienced operational issues since implementation with a more robust solution required for pipeline corrosion protection purposes.

The project comprised the replacement of existing switch mode power supply systems at 17No site locations with new Transformer Rectifier Units and associated switchgear within each of the existing roadside kiosks.

Working closely with the end user (Northern Gas Networks), Sonae (UK) were appointed to carry out the replacement of the existing switch mode power supply units under a scheduled work programme.

Cathodic Protection Equipment Replacement

Upon isolation of the existing equipment by authorised EL6 Electrical and CP Technician, the existing groundbed, drain point and main earth conductor cabling were disconnected and pulled back to accommodate removal of the existing backboard including switch mode power supply and associated switchgear.

The replacement backboard comprising Transformer Rectifier, Abriox monitor and interrupter (including 2-year roaming UK airtime package for monitor), Antenna and associated switchgear was pre-built within the workshop prior to installation to reduce downtime during the changeover period.

Upon removal of the existing equipment, the pre-built Transformer Rectifier backboard was installed within the kiosk and existing groundbed, drain point and main earth conductor re-terminated to the new backboard assembly.

The new equipment was then energised by EL6 authorised personnel prior to commissioning

The existing switch mode power supplies were returned to Northern Gas Networks for future maintenance spares.

Cathodic Protection Testing

Upon energisation, the TRU(s) were configured to obtain adequate values in accordance with NGN standards and the test results recorded.

The Abriox monitors were then configured with a single read completed and the data confirmed as being reported and displayed on the Abriox database.

Close Interval Potential Surveys (CIPS) were carried out before and after commissioning to determine the effect of the system.

After commissioning of the new system and the two week stabilizing period, further readings were obtained to ensure compliance with NGN standards and current British and European legislation.

Health & Safety

All works were carried out under EL6 Electrical Isolation procedure in accordance with Northern Gas Networks SCO (Safe Control of Operations) management procedures.

Programme

The works were delivered to the satisfaction of the Northern Gas Networks project lead during a 3 month programme period in accordance with the key delivery dates specified.

Brenda Road

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The Project

As a result of the Asset Health Survey Programme carried out by Northern Gas Networks under the RIIO price control period, it was identified that the existing plant and equipment at Brenda Road site was obsolete, approaching end of service life and in need of replacement including the installation of a new electric pre-heat system.

The project comprised installation of new Inlet Filters, new Electric Heat Exchangers, new 19 to 2bar regulators, new standby generator, new 3 phase power supply and installation of new E&I building to bring the site in line with current Northern Gas Networks standards and compliant with British and European legislation.

The complete site rebuild works were carried out during a shutdown period with key milestone dates to ensure the site was fully operational prior to the winter period.

Appointed as subcontractor to Darke Engineering, key deliverables were achieved to the satisfaction of the end user (Northern Gas Networks) within the programme key date deadlines.

E&I Kiosk Build

A new E&I kiosk was fitted out and pre-wired within the workshop of our Sunderland premises. The kiosk comprised all new site switchgear and distribution, lighting and small power, new 1:1 Isolation Transformer, Free issue Generator Auto Changeover Panel and Bypass Panels, Free Issue ExHeat Heater Control Panels.

In addition, new lighting control panel and RTU control panels were manufactured within the workshop and installed within the E&I kiosk prior to shipment to site.

Electrical

The site electrical installation included the installation of new site lighting, final circuit cabling to new Electric Heaters, incoming generator supply cabling and sub-main cabling from the E&I kiosk to the containerised Generator Set lighting and small power distribution board.

Instrument

The site instrumentation upgrade involved full decommissioning and demolition of the existing installation. Installation and commissioning of all new remote telemetered and site instrumentation monitoring and control equipment comprising new inlet and outlet and filter differential pressure monitoring equipment, ultrasonic flow meter, inline electric heater monitoring and control equipment, generator alarms, pneumatic actuated slam shut alarms and site intruder alarm system. The installation consisted of safe area, Exd and intrinsically safe instrumentation connected to a Pepperl & Fuchs LB barrier system and propriety PLC telemetry unit.

DSEAR Inspection

All ATEX certified equipment supplied and installed under the contract scope was subject to detailed inspection in accordance with DSEAR Regulations BS EN 60079-17.

Commissioning

SONAE were responsible for supplying both the NRO documentation and competent persons to control and execute the changeover in line with the networks SCO 5 requirements.

Provision of SCO 4&5 competent persons to carry out the end to end checks and wet commissioning of the complete E&I installation under a controlled NRO procedure.

Records

Databook records were compiled in accordance with MPTF-001 Databook Framework document.

All final handover records were submitted to the Northern Gas Networks in both electronic format via A-site media document control system and hard copy format.

Health & Safety

Sonae (UK) carried out the works as sub-contractor to Darke Engineering (MWC). All works co-ordinated with site management and Northern Gas Networks operations personnel on a daily basis.

All works were carried out under a controlled PTW in accordance with Northern Gas Networks SCO (Safe Control of Operations) management procedures.

BRAYTON

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The Project

As a result of the Asset Health Survey Programme carried out by Northern Gas Networks under the RIIO price control period, it was identified that the existing plant and equipment at Brayton PRS site was obsolete, approaching end of service life and in need of replacement.

The project comprised full electrical and instrumentation rebuild, installation of buried ducting and general site civil improvements to bring the site in line with current Northern Gas Networks standards and compliant with British and European legislation.

Employed directly by Northern Gas Networks as MWC, key deliverables were achieved to the satisfaction of and the end user (Northern Gas Networks) utilising the expertise of approved civil framework partners.

Electrical

Redundant, non-essential electrical equipment was isolated and removed maintaining only the essential supply to the telemetry equipment. The new distribution equipment was then installed comprising incoming switchgear, overcurrent and earth leakage protection and small power distribution system servicing new interior and exterior site lighting, E&I room lighting and heating and telemetry power supply unit. The installation was installed to the clients G17 detailed design documentation and inspected and tested to BS7671 and the remainder of the essential services were transferred to the new distribution system.

Instrument

In accordance with the G17 design the existing telemetry RTU panel, I.S. and Non-I.S. junction boxes were retained and re-used. The scope of the installation included pneumatic hook-up and cabling of Inlet Pressure Transmitter HP1, Outlet Pressure Transmitter MP1 and Filter Differential Pressure FLT-DP1 and FLT-DP2. Installation of switches and cabling associated with the Intruder Alarm equipment and replacement of cables and junction boxes to the Slam Shut indication switches. Pneumatic Pressure Testing of new small bore stainless steel impulse pipe and instrument loop checks. Isolation, disconnection and removal of redundant, obsolete equipment following instrument changeover.

DSEAR Inspection

All ATEX certified equipment supplied and installed under the contract scope was subject to detailed inspection in accordance with DSEAR Regulations BS EN 60079-17.

Commissioning

SONAE were responsible for supplying both the NRO documentation and competent persons to control and execute the changeover in line with the networks SCO 5 requirements.

Commissioning was phased to allow the existing and new E&I systems to operate in parallel before isolating and de-commissioning the old equipment ensuring continuity of supply throughout the procedure.

Records

Databook records were compiled in accordance with MPTF-001 Databook Framework document.

All final handover records were submitted to the Northern Gas Networks in both electronic format via A-site media document control system and hard copy format.

Health & Safety

Sonae (UK) were appointed Principal Contractor to manage the health and safety during the construction phase including the coordination and management of all subcontractors.

All works were carried out under a controlled PTW in accordance with Northern Gas Networks SCO (Safe Control of Operations) management procedures.

LOW THORNLEY

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The Project

Further to the recent Asset Health Survey Programme carried out by Northern Gas Networks under the RIIO price control settlement, it was identified that the existing plant and equipment at Low Thornley PRS site was obsolete, approaching end of service life and in need of replacement.
The project comprised the demolition and rebuild of existing plant and equipment including the upgrade of the pre-heating to bring the site in line with current Northern Gas Networks standards and compliant with British and European legislation.
Working closely with the end user (Northern Gas Networks), Sonae (UK) was appointed as sub-contractor to MWC (Stanningley Engineering) to carry out the E&I Installation works associated with the site re-build and pre-heater upgrade.

Electrical

A complete rewire of the electrical installation was required including the isolation, disconnection and removal of redundant electrical equipment in accordance with the G17 design. Rewire and relocation of the site electrical distribution to the existing generator room. Installation of new 300kVA 1:1 Isolation Transformer 400/400v. Installation of new 100kVA standby generator set, Auto Changeover and Bypass panel. Installation of new exterior lighting to the new boiler house, governor house and top store building. Rewire of all interior lighting, heating and small power to boiler house, workshop, mess, top store, WC, office, new instrument room, new electrical room, governor house and store. Inspection and testing of the complete installation to BS7671.

Instrument

A complete rewire and replacement of all redundant instrumentation in accordance with the G17 design documentation including isolation, disconnection and removal of redundant, obsolete equipment. Rewire of existing slam shuts and bursting disks. Installation of new intruder alarm circuits. Manufacture and installation of new RTU, I.S barrier, Non-I.S and PSU control panels. Pneumatic hook-up and cabling of new I/P converter to remote pressure monitoring equipment. Installation of new outlet temperature surface mounted RTDs. Pneumatic hook-up and cabling of Inlet Pressure Transmitters IP1, HP2, HP3 and
Outlet Pressure Transmitters HP1 and ODP1. Installation of Boiler Interface and Boiler Control Panels. Pressure Testing of new small bore st.st impulse pipe and instrument loop checks to BS6739:2009

DSEAR Inspection

All ATEX certified equipment supplied and installed under the contract scope was subject to detailed inspection in accordance with DSEAR Regulations BS EN 60079-17.

Commissioning

Preparation and submission of Non-Routine Operation (NRO) document for Authorising Engineer approval prior to pre-commissioning checks.
Provision of SCO 4&5 competent persons to carry out the end to end checks and wet commissioning of the complete E&I installation under a controlled NRO procedure.

Records

Test Records and red-line marked as-built drawings were produced and submitted at key stages as identified by Northern Gas Networks for pre-commissioning purposes in accordance with management procedure NGN/PM/RE/18.
Databook records were compiled in accordance with MPTF-001 Databook Framework document.
All final handover records were submitted to the Northern Gas Networks in both electronic format via A-site media document control system and hard copy format.

Health & Safety

All works were carried out under a controlled PTW in accordance with Northern Gas Networks SCO (Safe Control of Operations) management procedures.

Environmental

The site was located adjacent to an SSSI (Site of Special Scientific Interest) with reports of Great Crested Newts in the area.

All site operatives received environmental awareness training provided by the MWC prior to the commencement of works on site informing them of the content of the environmental management plan and the response procedure to adopt in the event of newts being discovered in the work area.
Programme

The works were delivered to the satisfaction of both the MWC (Stanningley Engineering) and the end user (Northern Gas Networks) in accordance with the key delivery dates specified within the accepted programme.