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Failure Monitoring and Asset Condition Assessment in Water Supply Systems

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 May 22-23, 2008
ENVIRONMENTAL The 7th International Conference
ENGINEERING Faculty of Environmental Engineering
Vilnius Gediminas Technical University
Saulėtekio ave 11, LT-10223 Vilnius, Lithuania
Phone: +370 5 2745090; Fax.: +370 5 2744731; e-mail: [email protected]

FAILURE MONITORING AND ASSET CONDITION ASSSESSMENT IN

WATER SUPPLY SYSTEMS

Dalius Misiunas
Vilnius Gediminas Technical University, Faculty of Environmental Engineering, Sauletekio al. 11, Vilnius,
Lithuania,
E-mail: [email protected]

Abstract. The main focus of this paper is the failure management and pipe condition assessment in water
supply systems. The failure development mechanism, management cycle and associated costs are discussed and a
brief review of existing methods and research results is made. The central focus of the paper is to present the main
results of the PhD project carried out by the author. The aim of the work was to explore the feasibility of using the
available low cost measurements and information to improve the operation, reliability, safety and availability of the
urban water supply system. Continuous pressure monitoring was selected as a source of information. Algorithms for
failure detection and location in both single pipelines and pipe networks were developed and tested in the field, using
real water supply systems. Good results were obtained showing the potential of the proposed methods. A pressure
transient based method for a low-cost non-intrusive pipeline condition assessment was developed and tested with
positive results. Finally, a pressure transient based inline valve testing methodology was introduced allowing for a
quick testing of valve seal quality. All presented methods can serve as tools to increase the reliability, availability,
safety and efficiency of urban water supply systems.
Keywords: failure, monitoring, detection, location, asset condition

1. Introduction systems have different topology, pipe sizes and materials,

hydraulic profiles.
Urban water supply system has been built and To be able to evaluate and discuss different pipe
developed for more than a hundred years now. Ageing of failure management and condition assessment approaches,
the infrastructure imposes a new challenge on water a good understanding of the failure mechanism,
utilities – to maintain and rehabilitate the system in a management cycle and associated costs has to be
most efficient way. Rapid development in other parts of established.
urban infrastructure (telecom, transport, etc.) puts a
pressure on water industry for an improvement of the 2. Pipe failure management
operation in water supply systems by increasing the
reliability, availability, safety and efficiency. A Pipe failure is the part of the infrastructure
continuous improvement of the operational practise is deterioration process. Pipe failure is a multi-step process
necessary. As a result, water industry is forced to search as shown in Fig. 1. The lengths of time intervals and the
for new advanced methods for failure and asset mechanism of the failure are case dependent and
management. extremely difficult to predict. Two main events in the
The water supply system can be divided into two failure process are: (i) partial failure – when the leak or a
major parts – transmission and distribution systems. A burst is developed, but the pipe remains in service; and
transmission system consists of components that are (ii) complete pipe failure – when the hydraulic balance of
designed to convey large amounts of water over great the system is influenced to an extent when a repair or
distances, typically between major facilities within the replacement is necessary.
system. The water transported in transmission pipelines The area of failure and asset management in water
to the residential areas is distributed through the water supply systems has been in the focus of both researchers
distribution systems. Transmission and distribution and practitioners in water industry for the last

648
few management techniques currently practised by the water
Service reliability industry is not large.
Initiation of Depending on the timing of the failure management
corrosion activities with respect to the failure itself, two types of
Crack before pipe failure management strategies can be defined:
100 % leak ƒ proactive failure management, when the pipe
Partial repair/replacement decisions are made prior to the
Installation
failure Complete failure event to prevent the failure;
failure ƒ reactive failure management, when the
repair/replacement is performed only after the failure
0% has occurred.
Time
The failure management cycle is shown in Fig. 2.
Fig. 1. Pipe failure development
The cost of pipe failure management is highly dependent
on the type of techniques and practises that are used. The
decades. Since pipe failure has become a frequent event choice of the pipe failure management technique depends
in the urban water supply systems, failure management is on which stage of the pipe deterioration process it is
a part of the everyday operation of pipelines and pipe applied. Generally, the earlier stage of the pipe
networks. A range of methodologies has been described deterioration is considered, the more complex and
in the literature; however, the number of failure expensive inspection technique has to be applied.

1 – start point proactive failure management

Schedule 2 – start point reactive failure management
repair/replace
2
Condition Probability Decision Failure Failure Failure
1 OR Failure
assessment of failure making detection location isolation

Schedule next
inspection
Failure repair/
OR pipe replacement

Proactive Reactive

Fig. 2. The pipe failure management cycle

Fig. 3 shows the inspection cost as a function of the 3.1. Failure monitoring, detection and location
application time. The actual shape of curves in Fig. 3 and,
consequentially, the minimal pipe failure management A number of techniques and methods were
cost depends on the particular situation. In general, Fig. developed and presented for the detection and location of
3a can be applied for distribution networks and Fig. 3b failure in water systems. Pipe failure has different types
can be used for transmission pipelines. The consequences depending on the size and the character. Due to the fact
of a failure (both partial and complete) in the large that for most of the techniques that are described in the
transmission mains can be quite expensive and therefore literature the type of failure is not specified, a leak will be
the cost of failure increases faster than in the case of the used as a general term here. Depending on the
distribution network. Still, due to the relatively low cost application, leak detection can be associated with two
of water and fairly high cost of currently available different operations. In larger transmission pipelines,
proactive failure management techniques along with where larger failures are common, leak detection is
restrictions on the budget of water utilities, only reactive usually associated with identifying discrete pipe failure
failure management can be justified in water supply events. Subsequent leak location involves the
systems. identification of the actual position of the leak. In
distribution networks, leakage detection is often
3. Current practise and available research integrated with leakage assessment, where the amount of
water that is lost due to leaks present in the system is
The review of existing approaches and research estimated. Leakage is detected collectively and the
results found in the literature is divided into two parts: (1) identification of a particular leak is part of the location
failure monitoring, detection and location methods and process. Generally, two leakage detection and location
(2) asset condition assessment techniques. (sometimes also referred to as leakage control) strategies
can be used for both pipelines and pipe networks.

649
 Passive or manual. The reaction to a leak incident is Active or automatic. Active leakage control
based on visual observations. For example, the includes management policies and processes that are used
appearance of water on the ground surface following pipe to locate and repair unreported leaks from the water
failure is visually detected by the staff or reported by supply system [1]. Active leakage control can involve
customers. Manual location techniques are then used to systematic manual leak inspections or continuous
identify the actual location of the failure. monitoring for automatic detection of leaks.

(a) distribution pipes (b) transmission pipelines

Cost Cost
Total cost Total cost

Cost of failure
Min Cost of failure Min
cost cost
Inspection cost Inspection cost

1 2 Time 1 2 Time

1 - partial failure 2 - complete failure

Fig. 3. Variation of inspection and failure costs during the deterioration process

Manual leak location techniques are normally used, research community. The most developed methods are:
although some leak monitoring systems provide leak reflection methods [9], inverse transient methods
automatic location. [10], impulse response analysis [11], transient damping
Passive leakage detection is straightforward, simple method [12] and frequency domain response analysis
and does not involve any systematic action. Thus, it will [13].
not be discussed here. The main focus of the work Leak monitoring approaches can be divided into
presented here is on active leakage detection and location measurement-based and model-based techniques.
strategies. Active leakage control techniques can further Measurement-based methods are using the analysis of
be divided into two groups: measured parameters to detect leaks. Most common
Inspection (survey). Inspection or survey leak techniques are: acoustic monitoring [14], volume balance
detection is a planned action that is performed at discrete [15], pressure-point analysis [16], negative pressure wave
time instances. The inspection involves checking the [17], statistical pipeline leak detection [18], and district
whole or a part of the system to assess the level of meter areas [19]. Model-based leak monitoring techniques
leakage and find leaks that are already present. combine the modelling of the system with the
Monitoring. Continuous failure monitoring is used measurement analysis. Techniques, presented in
for detection of leak events in real-time. A monitoring literature, are: real time transient model [20], inverse
system is installed on a pipeline or in the network analysis [10, 21] and state estimation [22].
permanently and is continuously checking for new leaks. Some general observations can be made before the
Some monitoring systems can perform application of the reviewed techniques can be discussed.
A large number of leak detection and location Leak inspection techniques. Validation results for
techniques have been applied in real systems or have nine different techniques are analysed, twelve test cases
been described in the literature. Some of the existing were considered. 44% of the techniques (4 out of 9) are
techniques are designed for detecting leaks only and are commercially available, while the rest are still under
not capable of locating them. Other methods are development. All approaches can be applied on single
developed specifically to locate leaks. Finally, there are pipelines. However, only 3 out of the 9 techniques are
methods that allow for both detection and location. suitable for application in networks. It has to be noted that
Commercially available leakage inspection methods the method was not considered to be applicable in the
can generally be divided into two large groups - acoustic network in case when it can only be applied on a single
inspection techniques and non-acoustic inspection branch of the network. Only 2 out of 5 methods that are
techniques. In addition to these two groups, transient- under development were tested in the field and leaks that
based leak inspection methods can also be identified. The were detected using those methods were at least 2 − 3
most developed acoustic inspection techniques are times larger (Dl/D) than the leaks that can be detected
listening [2], acoustic monitoring [3] and cross- using available techniques. All available techniques,
correlation [4]. Examples of non-acoustic inspection except pigging (the only intrusive method), have quite a
methods are tracer gas technique [5], thermography [6], short range, i.e. are labour-intensive. Available inspection
ground penetrating radar [7] and pig-based methods [8]. techniques have mainly been applied in water pipelines
Although not yet available commercially, transient-based and networks.
approaches have been given a lot of attention from the

650
 Leak monitoring techniques. Total of sixteen the water supply systems. With system getting older, the
presented monitoring methods are equally divided frequency of these failures is increasing. The techniques
between pipeline and network applications. However, that are currently used in the water industry are not
only 1 out of 8 network approaches is commercially suitable for quick reaction to pipe bursts. Thus, the
available, whereas 63% of pipeline leak monitoring following directions have been formulated for the work
techniques are applied in the field. This situation can be on failure detection and location in pipelines and pipe
explained by the fact that most of the existing leak networks:
monitoring applications are implemented in oil or gas • medium and large bursts are the primary target;
transmission pipelines. The instrumentation level of oil • continuous monitoring or periodical diagnosis;
and gas pipelines is fairly high and the monitoring • low installation and maintenance costs;
techniques used in these pipelines require more • automatic analysis.
measurements. Due to the high risk associated with Automatic techniques that have been developed for
failure of oil or gas pipelines, monitoring approaches are the pipeline failure monitoring, detection and location and
chosen. Acoustic monitoring is the only available the network failure monitoring, detection and location are
approach for the network case. It requires a large number presented in the next section.
of sensors and therefore is labor intensive.
Application in water supply systems. It is 3.2. Asset condition assessment
extremely difficult to find one leak detection and location
technique that would have the best performance in all There are two main approaches for assessing the
cases. There is a number of aspects that have to be condition of a pipe. The first approach is direct inspection
considered before making conclusions regarding the and monitoring, also called non-destructive testing
performance of a particular method. It is clear that the (NDT). The second condition assessment approach is
main parameter that is used as a performance indicator is based on using indirect indicators, such as soil properties
the cost-benefit ratio. However, evaluation of the cost and and historical pipe breakage rates.
the benefit is not that straightforward. First of all, Nondestructive testing is the type of testing that
limitations may apply to the maximum allowable cost in allows detecting and evaluating of defects in materials
the water industry. On the contrary to the oil and gas without disturbing the specimen’s structural or surface
industries, large investments cannot be made by water integrity. The history of NDT started with studies of
utilities. At the same time, evaluation of the benefit of ultrasonic waves and their application for detecting flaws
using one or another leak detection technique is not a in metal objects [31]. In the 1950s, ultrasonics was
simple process. Very limited practical experiences of applied for manufacturing flaw testing in pipes. Later on,
using different techniques can be found. Some general the benefits of using nondestructive testing to assess the
conclusions can be made from the review of available deterioration of metal structures were identified [32].
techniques: Currently, nondestructive testing is used for in-service
1. Since leak inspection techniques are labour inspection, condition monitoring and measurement of
intensive, leak inspections are not frequently performed. components and their physical properties. NDT
This results in long leak detection and location times. techniques are sometimes called nondestructive
2. To achieve a quick response to a leak, continuous evaluation (NDE) or nondestructive inspection (NDI)
monitoring is necessary. techniques. The term nondestructive evaluation will be
3. Most of available monitoring techniques can only used here. The main benefit of NDE is that the testing has
be applied on single pipelines and, in some cases, single no negative effects on the condition of the materials or
branches of the network. structures that are tested. A wide range of NDE
4. Monitoring of every single branch in a network is techniques are available today with different degrees of
financially infeasible. complexity and operational costs, as well as specific
5. Available pipeline monitoring approaches require application areas and limitations. The techniques can vary
the pipeline to be well instrumented. from simple visual examination of a surface to more
6. Failure location capabilities have to be improved complex radiographic, ultrasonic or magnetic methods
in both pipelines and networks. and finally to new advanced and highly specialised
Considerable differences exist between water approaches. To select the optimal NDT method for a
transmission pipelines and distribution networks in terms particular application, a comprehensive knowledge of
of the topology and hydraulics, the regime of operation as both the method and the tested object is necessary.
well as types and consequences of failure. The A large number of contributions to the development
differences are also reflected in the choice of failure and application of NDT techniques can be found in the
detection and location techniques. The overall conclusion literature. Reviews of different NDE techniques are
is that failure monitoring techniques have to be developed presented in literature [33-35]. In general, all NDE
separately for pipeline and network applications. The techniques can be divided into two main categories: (1)
cost-benefit ratio of failure detection depends on the cost visual NDE methods and (2) non-visual NDE methods.
of failure. Medium and large pipe breaks (bursts) present Most popular visual techniques are: closed-circuit
the highest risk and have the most expensive television inspection, pipe scanner technology and laser-
consequences out of all types of pipe failures observed in based scanning. Examples of non-visual methods are:

651
ultrasonic testing, guided waves, magnetic flux leakage, pipelines. Other available NDE techniques reviewed
remote field eddy current, georadar, ground penetrating earlier in this chapter, have similar drawbacks to those of
radar, linear polarization technique, field signature CCTV inspection. Thus, further development of NDE
method, acoustic emission monitoring, impact echo, methods is required to make their use in water supply
mechanical and free vibration methods. systems more frequent and systematic. New techniques,
Historically, NDE methods have been developed for offering low cost and time-effective inspection, represent
large oil or gas pipelines, where inspection budget and another alternative.
failure risk are considerably larger than in water supply
systems. As already noted earlier in Chapter 2, the main 4. Developed methods
requirements for condition assessment techniques from
the perspective of the water industry would be low cost The work presented in this paper is a summary of the
and a fast inspection, whereas high precision of the doctoral thesis written by the author [23] and was focused
inspection is less crucial. None of the existing NDE on the development of systematic approaches for effective
techniques can satisfy those objectives. Furthermore, the failure management in urban water supply systems. Both
range and the speed of inspection are very small. A proactive and reactive failure management techniques
number of techniques require the inner surface of the pipe have been developed. The results can be divided into two
wall to be clean. Water pipelines often have an parts: (1) failure monitoring, detection and location
accumulation of tuberculation on the inside wall and methods and (2) asset condition assessment techniques.
therefore cleaning would be necessary before inspection.
The cleaning would further increase the cost of inspection 4.1. Failure monitoring, detection and location
and, in many cases, water utilities are reluctant towards
any disturbances due to health and safety concerns, i.e. Reactive failure management techniques that were
intrusion of contaminants due to pressure drop or developed are summarised in Fig. 4. Due to different
disinfection of the pipeline after inspection. Currently topological and hydraulic characteristics, separate failure
CCTV inspection is the main tool for condition monitoring approaches were developed for single pipeline
assessment of water pipes. Recent developments of the and pipe network applications. As knowledge about the
technology allow for good quality of the captured image, burst development (burst opening) process is limited, two
but a number of drawbacks still remain. The analysis of burst opening scenarios were considered. The first
the data from CCTV inspection is usually done manually, scenario assumes a sudden rupture of the pipe wall and
which is extremely time and labour intensive. To be able the second scenario considers a burst, which develops
to insert the camera and the transporter into the pipe, over a longer period of time. Each scenario was applied to
cutting the wall is often required. Since the range of a pipe case and a network case and, as a result, a total of
CCTV inspection is only around 300 m on each side of four approaches for failure monitoring, detection and
the access point, a large number of access points will be location were developed. The first two techniques are
necessary in a long pipeline. Finally, de-watering is applicable for automatic failure monitoring in pipelines
usually required. The combination of all these factors and and the other two methods were derived for automatic
related health and safety issues prevent large-scale failure management in pipe networks.
applications of CCTV inspection in water transmission

Failure monitoring

Pipeline Pipe network

Periodical leakage Unsteady-state Steady-state Unsteady-state

analysis-based analysis-based analysis-based
diagnosis
failure monitoring failure monitoring failure monitoring

Fig. 4. Techniques for failure monitoring

Pipelines. For the pipeline case, two approaches were a system can be applied in water transmission
developed and tested. The first approach involves periodical pipelines or in single branches of a distribution
diagnosis of leaks based on transient response difference network, where immediate reactions to failures are
monitoring [24]. Only one pressure monitoring station is critical.
necessary for the whole length of the pipeline, making the An artificial hydraulic transient is periodically
implementation and maintenance costs reasonably low. The generated and the measured response trace is
proposed system has been successfully validated both in compared to the reference transient response that
laboratory and field conditions. The results indicate that such corresponds to a leak-free situation. It is sufficient to

652
have a single pressure measurement point and a single and magnitudes of the transient wave measured at
transient generation point along the pipeline in order to different monitoring stations are used to derive the
detect and locate a leak. When the approach was validated on location of the failure. The method enables quick and
a full scale transmission pipeline, a relatively small leak was precise location of the failure regardless if it occurs at
detected and located with a precision of 0.3% of the total nodal or non-nodal (along pipes) locations. The
length of the pipeline. In addition, the technique was shown technique has been successfully tested on a real water
to be capable of detecting an air pocket and a partial distribution network. Different aspects, such as the
blockage in the pipeline. optimal placement of pressure monitoring stations,
The second technique is a burst monitoring, detection limits of burst sizes that can be detected, uncertainty
and location system designed for a quick reaction to sudden of results and implementation aspects of the system,
pipeline ruptures [25-27]. A transient-analysis based were investigated. Test results demonstrated that three
approach is capable of issuing an alarm of a burst event and pressure measurement stations were sufficient to
deriving the burst location automatically after the failure has monitor a network supplying around 250 households
occurred. and bursts were located with a precision of 9 m
The two pipeline failure monitoring approaches can be without pre-calibration of the network model.
integrated into a multi-type failure monitoring, detection and Combining the two systems into one would allow
location system. The integrated system would enhance the for a wider range of detectable failures as well as
reliability and precision of failure detection and location. higher reliability of the failure detection and location.
Pipe networks. Two failure detection and location
techniques were developed for application in water 4.2. Asset condition assessment
distribution networks. The first approach is based on steady-
state analysis and can be applied on the level of a district The asset-condition assessment-related
metering area (DMA) [28]. The inflow rate is continuously techniques that were developed are summarised in
monitored and the burst-induced change of flow rate is Fig. 2. Two different assets of the water supply system
automatically detected. The location of the burst is derived were considered -- pipes and valves. Pipe condition
using the distribution of the pressure, which is measured at a assessment is part of the proactive failure management
number of monitoring stations within the network. The strategy, whereas valve condition testing is essential
method was successfully validated using simulated data. The for isolation of the failure, i.e. is part of the reactive
optimal measurement point placement, uncertainty of the failure management exercise. A nondestructive pipe
results, performance limits and implementation aspects of the evaluation (NDE) technique designed for condition
technique were investigated. It was shown that a small DMA assessment of transmission pipelines was presented
(300 properties) can be successfully monitored using one [31, 32]. This technique can be used for two purposes:
flow rate and between 2 and 4 pressure measurement points. (1) as a proactive failure management tool and (2) for
The derived failure locations had an error of less than 30 m. rehabilitation planning. The proposed inspection
The second approach for failure detection and location technique has a longer range and higher inspection
in a network is based on an unsteady-state analysis [29, 30]. speed than currently available NDE methods. A
Continuous monitoring of the pressure is performed at a hydraulic transient wave is generated artificially and
number of locations within the network. In case of a sudden the measured response is analysed for pipe condition
pipe failure, the burst-induced pressure wave is automatically assessment.
detected at two or more monitoring stations. Arrival times

Asset management

Pipelines Valves

Condition Localized damage Seal quality

assessment detection and assessment
location

Fig. 5. Techniques for asset management

A comparative evaluation can be made where using more precise NDE techniques is necessary. The
different sections of a pipeline are ranked depending on approach has been tested on a real transmission pipeline.
their condition. The proposed technique can also be used The last technique that was developed was a
to identify sections of a pipeline where further inspection transient-based inline valve seal testing methodology
[33]. For effective isolation of a failure, it is necessary

653
that inline valves seal properly. Currently, there is no Adelaide, Australia for the access to their systems during
established methodology for testing the seal quality of field testing.
valves. The developed approach is based on analysis of
the transient wave reflection from a closed valve. The References
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