E&I Installation Archives

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.

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.

West Winch Regulator Skid

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The Project

As part of the Cadent Gas Pre-Heat Replacement project – Phase One at West Winch AGI, a new packaged Boiler House and electrical Pre-heat was to be installed on site including the installation of a new HP-MP Pressure Reduction Skid.

The project included the E&I Design and Build of a new Gas Pressure Reduction Skid Unit. Upon completion of the mechanical fabrication and assembly by others, the skid unit was to be pre-wired within the workshop of our Sunderland premises prior to shipment to site.

Instrument

The Pressure Reduction Skid comprised installation of inlet and outlet gauge pressure transmitters, inlet filter differential pressure monitoring transmitter and outlet temperature resistance thermocouple devices. The skid instrumentation was installed and cabled back to an Exe rated junction to allow connection of end user field cables.

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.

Test and Inspection

All ‘dead tests’ were carried out on the unit including continuity and insulation resistance testing to cabling prior to shipment to site.

Records

Test Records, material certificates and updated as-built drawings were produced and released with delivery of the skid unit for pre-commissioning purposes by the site installer in accordance with Cadent Gas T/SP/RE/9 documentation procedures.

Health & Safety

All works carried out under management supervision in accordance with the workshop safe system of work procedure.

WRENTHORPE

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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 Wrenthorpe 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 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

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

POOLE ROUNDABOUT

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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 Poole Roundabout PRS site was obsolete, approaching end of service life and in need of replacement.

Employed directly for Northern Gas Networks to carry out the E&I Installation works associated with the site re-build, SONAE worked closely with the MWC (RJ Utilities) to ensure key deliverables were achieved to the satisfaction of and the end user (Northern Gas Networks).

Electrical

A new governor kiosk with integrated E&I room was constructed housing an all new electrical distribution system. A new electrical system was 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 delivered in accordance with the clients G17 detailed design documentation and inspected and tested to BS7671.

Instrument

An all new remote telemetered instrument monitoring and control system was installed in the E&I room. The scope included the manufacture and installation of new RTU, I.S barrier, Non-I.S and PSU control panels. Pneumatic hook-up and cabling of Inlet Pressure Transmitter IP1, Outlet Pressure Transmitter LP1 and Filter Differential Pressure FLT-DP1 and FLT-DP2. Installation of switches and cabling associated with Slam Shut and Intruder Alarm equipment. 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

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

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.

MARTON CROSSROADS

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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 Marton Crossroads PRS site was obsolete, approaching end of service life and in need of replacement.

The project comprised a full civil, mechanical, electrical and instrument rebuild to bring the site in line with current Northern Gas Networks standards and compliant with British and European legislation. Due to the compact footprint of the site, its location on a busy crossroads and the requirement to maintain supply through the site at all times the project presented many challenges.

Employed directly for Northern Gas Networks to carry out the E&I Installation works associated with the site re-build, SONAE worked closely with the MWC (Fastflow Group) to ensure key deliverables were achieved to the satisfaction of the end user (Northern Gas Networks).

Electrical

A new E&I kiosk was constructed to house an all new electrical distribution system allowing the existing installation to continue to operate in parallel the new installation. A new electrical system was 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 delivered in accordance with the clients G17 detailed design documentation and inspected and tested to BS7671.

Instrument

A new E&I kiosk was constructed to house an all new remote telemetered instrument monitoring and control system. The scope included the manufacture and installation of new RTU, I.S barrier, Non-I.S and PSU control panels. Pneumatic hook-up and cabling of Inlet Pressure Transmitter IP1, Outlet Pressure Transmitters MP1, LP1 and Filter Differential Pressure FLT-DP1, FLT-DP2, FLT-DP3 and FLT-DP4. Installation of switches and cabling associated with Slam Shut and Intruder Alarm equipment. 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 installations 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 directly by the end user (Northern Gas Networks) to carry out the E&I installation works.

Sonae (UK) undertook the role of a contractor during the construction phase, working in co-ordination with the Principal Contractor (Fasflow Group).

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.

Electrical

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.

CHOPWELL

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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 Chopwell PRS site was obsolete, approaching end of service life and in need of replacement.

The project comprised installation of a new E&I kiosk, replacement governor building, general site civil improvements, electrical and instrument rebuild to bring the site in line with current Northern Gas Networks standards and compliant with British and European legislation. The project posed a challenge as it could not be isolated during the works resulting in an extensive crash deck being installed to protect the live gas equipment prior to the old building being dismantled. A new modular GRP building was constructed in its place meaning the supply of gas was uninterrupted.

Electrical
A new E&I kiosk was constructed to house an all new electrical distribution system allowing the existing installation to continue to operate in parallel the new installation. A new electrical system was 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 delivered in accordance with the clients G17 detailed design documentation and inspected and tested to BS7671.

Instrument
A new E&I kiosk was constructed to house an all new remote telemetered instrument monitoring and control system. The scope included the manufacture and installation of new RTU, I.S barrier, Non-I.S and PSU control panels. 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 Slam Shut and Intruder Alarm equipment. 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
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
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.

ABERFORD

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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 Aberford PRS site was obsolete, approaching end of service life and in need of replacement.

The project comprised full electrical and instrumentation rebuild, relocation of the satellite communications dish, lagging of outlet temperature monitoring pipework, 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.

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, 1:1 isolation transformer, 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

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

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.