Sustainable Pipeline Systems Ltd (SPS), based in Aberdeen, specialises in cutting-edge pipeline solutions designed to support the transition to clean energy. This project focuses on advancing SPS's flagship product, the Mobile Automated Spiral Intelligent Pipeline (MASiP), a next-generation pipeline technology engineered for hydrogen transport. MASiP features an innovative composite structure combined with helically wound fibre optic sensors, enabling real-time digital monitoring of pressure, strain, and temperature. Its unique design reduces construction-related carbon emissions by 70% compared to traditional pipelines, supporting global efforts to achieve Net Zero by 2050\. In collaboration with the ASTUTE Centre of Excellence at Swansea University, this project builds on a successful feasibility study. ASTUTE will provide expertise in advanced machine learning (ML) techniques to enhance MASiP's operational capabilities. Together, the partners aim to develop ML-tools that classify threats, assess defect severity, and provide real-time decision-making support, ensuring pipeline safety and reliability. The project aligns with the UK's hydrogen strategy and Net Zero goals, supporting the development of critical infrastructure for clean hydrogen transport. By improving efficiency, reducing downtime, and enabling cost-effective monitoring, MASiP offers a scalable, sustainable solution to decarbonise energy-intensive sectors such as heavy industry and transport. This collaboration positions MASiP as a key enabler in the global transition to a low-carbon future. The project seeks to develop a key enabling tool for energy pipeline networks by providing and interpreting in real time optical fibre signal patters and quantifying them in terms of severity so that network safety can be improved and maintenance and repair actions can be more efficient and more preventative.

The Mobile Automated Spiral Intelligent Pipeline System (MASiP), developed by SPS, is a pioneering pipeline system designed for net-zero onshore networks. Engineered for sustainability, it operates with high-pressure hydrogen and other fluids while boasting a low carbon footprint. Its composite structure, including embedded optical fibre, enables real-time monitoring for continuous health assessment. MASiP offers a 50% faster construction process and a 70% carbon footprint reduction. Its digital surveillance system provides unparalleled sensitivity and a user-friendly dashboard for operators. In collaboration with A4I partner ASTUTE, SPS aims to enhance MASiP further, by leveraging ASTUTE's expertise in data analysis and machine learning, this partnership seeks proactive threat detection, minimized downtime, and improved reliability for pipeline networks. MASiP Pipe represents a paradigm shift in pipeline technology, offering a comprehensive solution to the challenges of construction, monitoring, and maintenance. Its integration of advanced monitoring technologies and data analysis techniques sets a new standard for pipeline integrity management, positioning MASiP as a leader in the hydrogen pipeline industry and beyond.

MASiP is a new pipeline system pipe developed by Sustainable Pipelines (SPS) for the hydrogen era. It is reshaping the landscape of onshore pipeline networks with its ground-breaking solution tailored for high-pressure hydrogen transport. This innovative technology, combines automated infield pipe manufacture with flexible reinforced polymer installation, and digital monitoring - offering versatility for fluids like hydrogen, CO2, water, oil, and natural gas. MASiP's composite structure, featuring an inner HDPE liner, interlocking steel strips, embedded optical fibre, and environmental coatings, ensures unparalleled flexibility and strength. The inner liner dominates stress resistance, while the polymer coating prevents hydrogen embrittlement and facilitates real-time integrity monitoring. Beyond efficiency, MASiP has potential to accelerate construction by 50%, reduce carbon footprint by 70%, and integrate a digital pipeline integrity management system. Addressing hydrogen embrittlement, MASiP undergoes rigorous testing, proving reliability with high-pressure hydrogen exposure. In collaboration with the National Physical Laboratory (NPL), this A4I project delves into the challenges of cross sensitivity of polymer creep and optical fibre strain under pressure and axial creep. With full-scale on-site testing and materials analysis, MASiP ensures real-world applicability, promising a physics-based model for MASiP pipeline behaviour. MASiP's unique flexible pipeline structure with helically wound optical fibre, forms the basis of its commercial offer---automated mobile infield manufacture with digital pipeline lifetime monitoring. The optical fibre system provides real-time feedback, contributing to safety by reducing the risk of leaks , failures and preventing leaks, enhancing maintenance, and providing a preventative backbone of pipeline integrity monitoring. The project tackles the challenge of time dependent axial extension of reinforced polymer pipes under pressure, vital for applications like hydrogen fuel pipelines for industrial clusters. MASiP's solution, applicable to new and replacement pipelines, aligns with the UK's hydrogen transition goals. Partners, SPS and NPL, demonstrate commitment to real-world validation. The project outlines clear deliverables, reporting, and a configurable model, ensuring lasting impact and scalability aligning with A4I objectives. NPL leading expertise and facilities in materials testing and modelling enables the fundamental basis of pipe behavior to be better understood, analyzed and a physics based model of pipe and optical fibre behavior to be developed. MASiP's unique focus on hydrogen pipeline challenges, interdisciplinary approach, and potential for industry impact make it ideal for the A4I competition. The helical optical fibre system offers a cutting-edge solution for real-time threat assessment, positioning MASiP as a leader in sustainable pipeline construction.

This project will address the digital integrity monitoring of pipelines when there are bending events. There are several types of bending event that can be a threat to pipeline integrity such as ground subsidence or impact bending. The project will address the problem of a physics based model for helically wound optical fibre where signals are obtained from a Rayleigh wave distributed sensing system. The project will include model physics tests and numerical simulation as well as evaluation of full scale pipeline data. The development of an infrastructure for hydrogen as the industrial fuel to satisfy sustainability requirements requires new pipeline construction and monitoring. Real time digital integrity monitoring becomes more important in that context.

SUSTAINABLE PIPELINE SYSTEMS LTD is developing game changing new technology (MASiP) for the installation of pipeline infrastructure that incorporates distributed sensors in a spiral configuration during manufacture of the pipe to provide an intrinsically intelligent pipe. An automated mobile manufacturing system offers to halve total installation time with commensurate positive impacts on installed pipeline cost, more than halve the environmental impact and greatly improve the logistics of pipeline installation. Pipelines constructed in this way have a major role to play to transport (and store) vast quantities of energy (in gas or liquid form) over large distances, delivering the underlying infrastructure for net zero HGV, Train as well as general gas transmission use. By using these at higher pressures with Hydrogen, a lower carbon intensity can be achieved in the energy mix. Our spiral wound optical fibre innovation introduces the prospect of real time continuous monitoring to provide a digital platform for the pipeline network of the future. The project addresses a huge global market for onshore pipelines which market research has estimated to exceed $50bn by 2025. It can be argued that the conventional manual pipeline construction and integrity monitoring processes are no longer sustainable. The availability of sustainable pipeline construction and monitoring technology will be a critical enabling factor in the introduction of hydrogen gas as an energy carrier for heating and industrial power. Without widespread hydrogen fuel then heavy transport and industrial processes as well as domestic heating are all unlikely to be able to meet net zero climate regulations even by 2050. This is recognised in several government targets and industry objectives (including National Grid's recently published Future Energy Scenarios 2020) which aim to develop a number of hydrogen projects over the next few years. This offers to be genuinely disruptive technology that will develop its own supply chain in the UK creating many highly skilled jobs for the future. The project also offers large scale opportunities in the international market place. This project will focus on the integration of existing elements of the system into a mobile field trial to develop and demonstrate the mobile manufacturing process

SUSTAINABLE PIPELINE SYSTEMS LTD is developing game changing new technology for the installation of pipeline infrastructure that incorporates distributed sensors in a spiral configuration during manufacture of the pipe to provide an intrinsically intelligent pipe (iPIPE). An automated mobile manufacturing system (MASIP) offers to halve total installed pipeline cost, more than halve the environmental impact and greatly improve the logistics of pipeline installation. Pipelines constructed in this way have a major role to play to transport (and store) vast quantities of energy (in gas or liquid form) over large distances, delivering the underlying infrastructure for net zero HGV, Train as well as general gas transmission use. By using these at higher pressures with Hydrogen, a lower carbon intensity can be achieved in the energy mix. Our spiral wound optical fibre innovation introduces the prospect of real time continuous monitoring to provide a digital platform for the pipeline network of the future. The project addresses a huge global market for onshore pipelines which market research has estimated to exceed $50bn by 2025\. It can be argued that the conventional manual pipeline construction and integrity monitoring processes are no longer sustainable. The availability of sustainable pipeline construction and monitoring technology will be a critical enabling factor in the introduction of hydrogen gas as an energy carrier for heating and industrial power. Without widespread hydrogen fuel then heavy transport and industrial processes as well as domestic heating are all unlikely to be able to meet net zero climate regulations even by 2050\. This is recognised in a number of government targets and industry objectives (including National Grid's recently published Future Energy Scenarios 2020) which aim to develop a number of hydrogen projects over the next few years. This offers to be genuinely disruptive technology that will develop its own supply chain in the UK creating many highly skilled jobs for the future. The project also offers large scale opportunities in the international market place. This project will focus on the core technical and manufacturing innovations needed to be able to automate and scale up the mobile manufacturing process

Sustainable Pipeline Systems have developed a new mobile manufacturing approach which offers to radically change the way that energy and water pipelines are constructed. This requires the integration of a number of advanced manufacturing technologies , specifically high strength steel forming, winding and resistance welding. This will create an automated laminated process for steel strip allowing the mobile formation of high strength pressure resistant structures for pipelines. The new process offers to halve the total installed cost of pipelines and greatly reduce the environmental impact of ther construction. The number of links in the supply chain is halved by means of this approach. Advanced digital methodologies are used both in numerically modelling the multilayer steel structures and in the control and synchronisation of the steps in the manufacturing process. This also offers enhanced quality control over traditional approaches.

SUSTAINABLE PIPELINE SYSTEMS LTD is developing game changing new technology for the installation of pipeline infrastructure. Automated mobile manufacturing modules offer the potential to halve total installed pipeline cost, more than halve the environmental impact and greatly improve the logistics of pipeline installation. Feasibility work has used advanced 3D finite element modelling techniques to built and successfully evaluate designs for 36inch diameter pipelines. The technology advances develop applications for high strength steel strip and build on manufacturing control technologies developed for the automotive industry

Sustainable Pipeline Systems Ltd is developing advanced technology which will allow onshore pipelines to be manufactured and installed with automated mobile machines, replacing the need to pre-fabricate short pipe sections in a factory, transport them to pipe dumps and then manually weld them together on- site. Accreditation and testing are under way in the UK but in order to access the fast growing market for new pipelines in the Middle East and North Africa, a local demonstration centre is needed. This project will conduct and report on a feasibility study to develop a local demonstration centre with local investment and implementation partners. It aims to develop a global group of pipeline operators who will act as critical friends to this new technology which offers major change to the way pipelines are constructed, with the potential to halve the cost and the environmental impact

This project investigates the feasibility of advanced spiral wound steel strip technology for large diameter pipelines for the transport of energy in gas or liquid form. Advances in steel metallurgy and automated process controls combined with an innovative patented interlock offer a new approach with the potential to halve total pipeline costs and dramatically reduce emissions. PIpeline networks are key enabling infrastructure for energy transport and more cost effective than other methods with less environmental impact. The project will bring together advanced finite element analysis methods , composite engineering concepts, advanced steel roll forming and winding technologies to bear on onshore pipeline engineering - which has not changed radically for 75 years