ULC TECHNOLOGIES LLC — Department of Energy SBIR Phase I: 19a

Description

With a vast network of over 400 thousand miles of transmission pipeline and over one million miles of aging distribution pipeline in the U.S., it is a huge endeavor to continuously monitor pipeline integrity, detect leaks, and repair leaks. Conventional methods to repair leaks are labor intensive and could take many hours during which there are chances for leak propagation, excessive release of methane (greenhouse gas) into the surroundings, and potential loss of property and life due to ensuing dangerous conditions. Pipeline operators are subject to significant revenue losses and increased expenses from these leaks and also from intentional attempts to compromise pipe integrity including the theft of natural gas. A resident robot residing in a “smart branch” of transmission pipe will respond to urgent requests to repair pipeline leaks. After entering the pipe and using the natural gas flow to propel itself downstream, the robot will identify the threat location, inspect for leakages, and perform appropriate repairs to prevent further leakage. Minimal design, low power consumption, and the use of energy harvesting techniques will allow the robot to travel long distances while keeping the overall system cost low. By integrating into existing communication and health monitoring systems employed by pipeline operators, and by making minimal changes to physical infrastructure, the resulting rapid adoption of the robotic system will quickly resolve this ubiquitous nationwide problem of repairing pipe leakages. Phase I of this project will focus on testing and evaluating (i) the leak detection sensor in a high pressure, high flow test environment, and (ii) the internal repair methods for fixing various sizes and types of leaks. The robotic system including the launch and retrieval station will be conceptually designed and the business logic involving robotic operations will be refined. The system power budget will be estimated and the feasibility of the robotic system will be evaluated. The robot can be used to repair not only leaks but also incipient leaks. The robotic system will help pipeline operators meet regulations for methane emissions and lower their insurance costs. Reducing methane emissions positively impacts climate change and in turn the public. Climate change has shown to cause an increased intensity of storms and longer droughts. Indirect impacts include increased insurance premiums, food prices, and allergy seasons.