Page 21 - Gi flipbook April 2018

connection between a new PE main
and PE service that would last a
minimum of 50 years.
TORS (Tier One Replacement
System) is a robotic solution for
remote service to main connections.
Five years in development, TORS is a
collaboration project between
Synthotech and Cadent, funded using
Ofgem innovation funding
mechanisms, such as the Network
Innovation Allowance (NIA). The first
few years focused on developing
proofs of concept for the tasks that
traditionally need to be performed
through excavation. These included a
proof of concept for 12in and 4in pipe,
developing the multi-function
capability of the robot, and a detailed TORS Team
feasibility and practicability study and
PE partner selection.
The main issue with operating in 4in The connection The robotic train
metallic mains, chosen due to the
quantity left to be replaced and
because they pose the greatest
technological challenge, is limited
working space. Typically, these 4in
mains are inserted with 75mm/90mm
PE pipe, leaving a maximum operating
envelop of only 53mm diameter, about
the same diameter as a can of cola.
As an original equipment
manufacturer (OEM), Synthotech
decided to apply a manufacturing line The fittings
approach to the required solution.
The team focused on the
development of a robotic assembly
train, developed as interchangeable
individual modules optimised for the
task in hand.
The robotic train of modules
needed to be capable of performing
the following tasks in both 75mm
(SDR17.6) and 90mm (SDR11) PE
mains and be compatible with the
industry-approved service liner ‘best of breed’ principles and are ultimately required to perform to
Serviflex (a Radius Systems product): innovative solutions. The project saw the same industry specifications. Two
1. Drive (forwards, backwards, the generation of a number of novel types of fittings were developed that
corkscrew and rotate on the spot) and unique patents (pending), such as could be carried, deployed and
2. Accurately align to an existing for the fittings. remotely activated from over 100m
metallic service (+/- 0.2mm) What makes TORS a game away by the robot. The TORS robotic
3. Drill PE main and manage swarf changer? The robot is intelligent, but train provided all the tests (continuity,
4. Assist PE service installation the golden egg of the process is the power cycle) and control
5. Connect the new PE service to the micro-electrofusion fitting. The fitting (contamination, scrapping and
new PE main via electrofusion provides a method of connecting the clamping) that are currently standard
6. Perform a verification pressure test new mains pipe to the service pipe practice in the UK gas industry.
on the new connection (350mbar) that can be tested and will pass Development work progressed from
7. Be controlled remotely (up to existing accepted industry standards. the bench top to a simulated site at
110m) and record all the data Synthotech had the support of two the Synthotech Test and Research Site
generated project partners, Fusion UK and (STaRS). A demonstration, on 1
Nupigeco (Italy), in the development December 2015, showed TORS was a
The ambition, passion and drive to of the fittings (non-NIA funded). These step closer to becoming a reality.
overcome the challenges to make this are about 80 per cent smaller than a Over the next 18 months, there
project a reality came from combining conventional 32mm PE top tee, but were further developments needed

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