A new lease of life for ERS modules; the backbone of gas distribution networks
A new lease of life for ERS modules; the backbone of gas distribution networks
Authors: Faris Churcher, Business Lead for Gas & Energy Transition at Oxford Flow and John Costin, Gas Transmission & Distribution Consultant at Oxford Flow
The safe and reliable operation of gas distribution networks is vital for ensuring we keep the lights on and houses warm, and so gas networks are, and will continue to be, critical infrastructure in the UK. Although the pace of innovation has picked up in recent years through a combination of technological advancements, strategic planning and the strong focus on decarbonisation, traditionally gas networks have not been subjected to radical change since the conversion to natural gas in the 1960s and 1970s.
But, one advancement that was radical at the time, was the development and installation of the British Gas Engineering Research Station (ERS) modules. These compact underground pressure regulator modules became established as part of the backbone of the gas network infrastructure, particularly in urban areas where space constraints make above-ground installations impractical. But, fifty years on, these workhorses are coming to the end of their life, resulting in high costs to maintain and replace them.
Gas networks need a solution, and they needed it yesterday.
Nearing time for retirement
ERS modules were introduced in the 80s by British Gas as a response to the need for efficient pressure regulation, particularly in densely populated areas. They were designed to control gas pressure while being installed underground, saving valuable above-ground space and reducing installation and maintenance costs.
The ERS module features a cartridge system that allows for easy maintenance, with components that can be swiftly replaced to minimise downtime. Despite their innovative design and longevity, they now face several challenges.
Many ERS modules have been in operation for over 40 years, surpassing their expected design life. With British Gas ERS no longer in existence, sourcing replacement parts for these modules has become increasingly difficult. This scarcity of components adds just one layer of complexity to maintaining these systems. Additionally, there is now a heavy reliance on a single specialist in the UK to overhaul and maintain them, which is resulting in lead times of up to six months per unit. This bottleneck ultimately creates a risk for network operators and increases operational costs.
Reduce, reuse, recycle
The most common failure point on the ERS module is the gas regulator, specifically the diaphragms, which are prone to wear and tear over time, leading to performance issues and a need for regular service and maintenance.
Oxford Flow – in partnership with Cadent – looked to identify a long-term solution to a significantly growing problem. With its innovative, diaphragm-free IM-S gas regulator readily available, it was clear that they could solve the common issues that ERS modules today now face. But, unsatisfied with simply fixing one problem, Oxford Flow set about developing a refurbishment programme for these dated modules.
The ERS modules refurbishment programme – PRISM (Pressure Reducing Integrated Subterranean Module) – focuses on reducing the ecological impact by enhancing the efficiency and extending the lifespan of existing infrastructure. Instead of completely overhauling the system, Oxford Flow upgrades critical components, which lowers the frequency and costs of future maintenance and reduces the demand for new raw materials.
Furthermore, by reusing the existing underground setups, Oxford Flow not only preserves the built environment but also minimises the disruption typically associated with major infrastructure projects – and at a fraction of the cost of replacing the equipment and the underground stations.
The existing modules are retrofitted with advanced materials and technologies that are designed to handle both current and future demands, including compatibility with hydrogen, thus maximising the utility of the original installation.
There’s life in the old dog yet
While committed to upgrading and refurbishing as many existing ERS modules as possible, there is one critical component that must be replaced: the gas regulator.
Oxford Flow was chosen by Cadent, not only because of its expert engineering team, but also because it was ahead of the curve when it came to reimagining gas regulator design. The company’s IM-S gas regulator – a smaller, more compact gas regulator that is proven to be suitable for use with up to 100% hydrogen and has a service interval life of 10 years – is used alongside its low pressure gas pilot, PRX2L, offering unparallel levels of performance for process gases.
The installation and maintenance of ERS modules installed in the 1980s have been pivotal in the development of modern gas distribution networks. However, as these systems age and the industry shifts towards new energy sources like hydrogen, innovative solutions are required.
Oxford Flow’s advanced regulators offer a promising alternative, addressing key challenges and ensuring that gas networks remain efficient, safe and future-ready. This commitment to innovation and quality positions the company as a crucial player in the ongoing evolution of the gas distribution industry.
READ the latest news shaping the hydrogen market at Hydrogen Central
A new lease of life for ERS modules; the backbone of gas distribution networks, source
