Gas pipeline infrastructure

Feeder 5 – innovation in gas pipeline construction

  • CLIENT NAME: National Gas
  • LOCATION: UK
  • COMPLETION: 2024

Fit for the future

National transmission system (NTS)

National Gas owns and operates the high-pressure National Transmission System (NTS) that transports gas safely to wherever it’s needed in Britain, they have a key role in the UK’s transition to a clean energy future.

A crucial part of the management of the NTS pipelines is ongoing construction work to ensure that the transmission system is sustained as a safe gas delivery system and fugitive methane emissions are minimised to reduce any environmental harm. This is the ongoing and essential process of maintaining the NTS; whilst in planning and development are the significant, ambitious decarbonisation projects that seek to help us enable the transition to cleaner energy and achieve net zero by 2050.

 

National Gas' biggest single feeder outage to date

Feeder 5 focus

Feeder 5 is a key pipeline that runs from Bacton, the Norfolk North Sea Terminal for National Gas, through East Anglia into the south of London, and through to Kent. A significant section of pipeline that serves a huge area with power generation, industry and homes and businesses dependent on its supply for power and heat. During 2024, National Gas scheduled the largest body of work the region had ever experienced, and possibly the largest in the company’s recent history for pipeline improvement works and they had a target of getting it completed before the end of 2024.

The works involved an exceptionally detailed NRO (Non-Routine Operation) outlining how to safely isolate Feeder 5, which spans over 132 kilometres or roughly 82 miles of pipeline. The safe isolation of this pipeline and the resulting outage was successfully delivered by United Infrastructure working collaboratively with National Gas. There were long days, weekends, and night shifts to deliver key milestones such 24-hour operation at Chelmsford compressor station to ensure a safe and timely network isolation.

The Feeder 5 project was vast, and it is National Gas’ biggest single feeder outage to date and the core construction works were completed within a six-week period with significant work either side to safely isolate the system, well ahead of schedule. This meant that the gas system could be restored by mid November 2024, before the cold weather arrived.

A longstanding, collaborative relationship

Working in partnership to deliver critical infrastructure

United Infrastructure has a longstanding, collaborative relationship with National Gas. Its engineer-led expertise spans the full spectrum of asset lifecycle management, from maintenance and refurbishment to design and construction, delivering complex projects successfully and safely across the UK and ensuring the reliability and safety of the National Transmission System (NTS) and supporting the transition towards a low-carbon gas network.

Working in close partnership with National Gas, UI played a central role in delivering this project, managing various complex construction activities across multiple locations. Its expertise in complex engineering, project management, and operational execution was instrumental in overcoming major challenges and ensuring the project’s success.

UI also delivered two additional opportunity projects, involving isolation joint replacements, corrosion inspections, and rapid mobilisation within a week. These were successfully facilitated by the central hub at Roxwell, ensuring efficient delivery.

 

A project delivered safely and successfully

Achievements and best practices

Despite the original nine-week outage being reduced to just five weeks, UI successfully achieved programme sign-off on 25th October 2024. Several key factors contributed to this success:

  • Strategic planning: Establishing Roxwell as a central hub enabled efficient logistics management and minimised downtime.
  • Collaborative success: Strong collaboration between UI, National Gas, and subcontractors ensured timely completion of works.
  • Flexible resource mobilisation: The ability to rapidly mobilise teams and adjust resources as needed played a critical role in meeting the project deadlines.
  • Positive client feedback: National Gas recognised the team’s professionalism and resource management as essential to the smooth execution of works.

Providing engineer-led expertise

Overcoming challenges

Executing a project of this scale within such a condensed timeframe came with significant challenges. At Braintree, substantial movement in one of the isolation joints required immediate response, leading to a continuous 26-hour shift to resolve the issue. Similarly, at Abridge and Luxborough Lane, design adaptations were required to address future ground settlement risks, which UI successfully implemented in collaboration with National Gas.

At Horndon, managing the interface between Cadent and National Gas operations on a shared site required proactive planning and clear work area segregation to ensure efficient progress. Chignal St James presented difficulties due to below-ground pipework encased in concrete, necessitating a revised sequencing plan to mitigate potential delays.

Delivering world-class infrastructure

Lessons learnt and future applications

The successful execution of this project demonstrates National Gas’ evolving approach to large-scale pipeline improvements, where maximising outages to complete multiple projects at once is becoming the new standard. UI’s experience in delivering complex mechanical outages within tight deadlines highlights the importance of detailed planning, collaborative execution, and adaptability in overcoming challenges.

With over 85 UI personnel working alongside National Gas teams and subcontractors, the collective effort ensured the successful delivery of these outage works. The lessons learnt from this project will shape future large-scale improvement initiatives, helping to further refine processes, reduce risks, and enhance efficiency across the NTS.

The Feeder 5 project stands as a significant milestone in National Gas’ ongoing efforts to maintain and enhance the NTS. Through meticulous planning, expert execution, and a strong commitment to collaboration, this project not only achieved its immediate objectives but also set a benchmark for future infrastructure improvements.

Testimonal

It’s fantastic to see this collaborative and extensive project come to completion. I am immensely proud that our teams have worked together to make these massive pipeline improvement works possible. This project is a step change in how we work by maximising outages to deliver more. As we move into delivering bigger and more ambitious pipeline projects, Feeder 5 is a great example of how we will deliver a bigger workbook, which in the future will see the addition of hydrogen and CCUS projects.

Jonny Thorns, Construction Project Director, National Gas

Contact

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