Piping Failure in Water Utilities

Piping Failure in Water Utilities 2011
Piping Failure in Water Utilities

ENB 432 Asset Management and Maintenance Group Report
Group Name Student Name Enji M. Lazuardi Hannibal Nasserie Mohammad Motamedi Wildan Pradana Yulianto Putra
Group 10 Student Number 07622805 07266553 06090613 07622848
Email Contact enji.puapua@connect.qut.edu.au hannibal.nasserie@student.qut.edu.au m.motamedi@student.qut.edu.au
Phone Contact 0420907711 0413535838 0433930025
wildan.yuliantoputra@connect.qut.edu.au 0450882904

Work Plan Certificate
The Work Plan shows the equitable distribution of work that everyone in the group is satisfied with. Students as listed in the table certify that we worked equitably and diligently on the research, preparation and submission of the report as per the Work Plan. This signature also certifies that this is our original work for this course and has not been presented in any other course as part of any workplace task.
Group Name Student Name Enji M. Lazuardi Hannibal Nasserie Mohammad Motamedi Wildan Pradana Yulianto Putra
Group 10 Student Number 07622805
Responsibility (in the Report Part) Executive Summary, Introduction, Conclusion, Recommendation, FMECA Worksheet Description of Loss Production Event, Asset Management Issues Discussion, FMECA Worksheet Literature Review, FMECA and Risk Management Method Discussion, FMECA Worksheet Asset Management Issues Discussion, Loss Prevention and Mitigation Solution, FMECA Worksheet
Signature
07266553
06090613
07622848

Executive Summary
As we all know that the final report is about to manage the productive assets of the water utility. We are concern to understand the faults and how they impact on the production goals of the assets. The other things that concern are how these faults can be prevented and how to maintain the productive assets of water utility. After several discussions, we found out some of the faults in water utility. There are a lot of things that affect the assets of water utility, such as; natural disaster, human error, machinery failure, and failure in infrastructure that can cause a catastrophic damage to the water utility component. Therefore, the project that we are going to do for the final report is The Piping Failure in Water Utilities. The reason we are doing this as our final report is failures that occur in the pipeline needs a very expensive repairing cost, cutting water supply to a large numbers of customers and sometimes producing millions of dollars in damage. Understanding the causes of these failures is essential to preventing a repetition on the same line. We also want to describe briefly about the failure modes in the pipeline system in water utility. We are going to describe the failure on the components of the pipeline system, such as the fittings, valves, tapping, etc.
Last, some preventive measures will also be explained briefly in this report and some action that must be done to maintain the water utility in its best performance.

Table of Contents
Work Plan Certificate ............................................................................................................................ 1 Executive Summary .............................................................................................................................. 2 Table of Contents.................................................................................................................................. 3 List of Table .......................................................................................................................................... 4 1.0 Introduction ..................................................................................................................................... 5 2.0 Literature Review ............................................................................................................................ 6 2.1 Inspection on FMECA Analysis ................................................................................................... 6 2.2 Inspection of Failures in Pipe ...................................................................................................... 7 2.3 The New SAE FMECA ................................................................................................................ 9 3.0 Description of Loss Production Event ........................................................................................... 10 4.0 FMECA and Risk Management Method Discussion ..................................................................... 12 4.1 Selection of Critical Components .............................................................................................. 12 4.2 Failure Mode and Effect Analysis .............................................................................................. 13 4.3 RPN and Corrective Actions ..................................................................................................... 13 4.4 FMECA discussion .................................................................................................................... 15 4.4.1 Fitting ................................................................................................................................. 15 4.4.2 Valves ................................................................................................................................ 15 4.4.3 Pipeline .............................................................................................................................. 16 4.4.4 Hydrants ............................................................................................................................. 16 4.4.5 Tapping Bands ................................................................................................................... 16 4.4.6 Pump .................................................................................................................................. 16 5.0 Asset Management Issues Discussion.......................................................................................... 17 5.1 Treatment of Piping Operation .................................................................................................. 17 5.2 Piping Main Repairs .................................................................................................................. 18 5.3 Source of Water Loss Due to Piping Leakage .......................................................................... 18 5.4 Risk Issues................................................................................................................................ 19 6.0 Maintenance Management Issues Discussion .............................................................................. 20 7.0 Loss Prevention and Mitigation Solution Discussion ..................................................................... 23 7.1 Measurement of Unaccounted Water ........................................................................................ 23 7.2 Searching the Leakage ............................................................................................................. 24 7.3 Repair the leakage .................................................................................................................... 26 7.4 Measurement of Unaccounted Water (Second Measurement) ................................................. 28 8.0 Conclusion .................................................................................................................................... 30 9.0 Recommendation .......................................................................................................................... 31 10.0 Reference List ............................................................................................................................. 32

List of Table
FMECA Worksheet ............................................................................................................................. 34 RPN Format ........................................................................................................................................ 38

1.0 Introduction
Many water treatment companies run their company without knowing how to manage their productive asset in the right way. They are aware that major disruptions to production could be avoided if there was a better understanding of faults and failures and how these could be addressed through better understanding and application of asset management and maintenance practices. They realize that, for triple bottom line reasons, they need to establish a new baseline of asset management protocols within the organization. In this project, we were given task to help the water treatment company to assist the company itself to protect and maintain their valuable assets. Their concern is that they do not understand faults and how they impact on the production goals of their assets. So what we need is to work as a group and identify a major loss of production or other risk that can happened to the company due to poor asset management or maintenance practices. We have to analyse the loss the production and by using the FMECA, we must identify at least 10 reasons for the event. In this task we act as a consultant of water Utilities Company by providing the assistant of managing the company by applying all methods and material that already given on the course, and we also need to advise the client for what they need to do to prevent or mitigate production loss events.

2.0 Literature Review
2.1 Inspection on FEMCA Analysis
In June 1996 in North Korea, the failure mode, effect and critically analysis (FMECA) on mechanical Subsystems of Diesel Generator performed. In their report it is discussed that for the implementation of RCM in nuclear power plant, three steps are required; (1) Functional failure analysis (FFA), (2) Failure mode, effect and criticality analysis (FMECA), (3) Logic tree analysis (LTA). It is stated that the emergency or standby diesel generators in nuclear power plant take an important role in the accident situations. In this report the FMECA results for six mechanical subsystems of the diesel generators of nuclear power plants to improve the reliability is performed. The six mechanical subsystems are (1) Starting air, (2) Lub oil, (3) Governor, (4) Jacket water cooling, (5) Fuel, and (6) Engine subsystems. Generic and plant-specific failure and maintenance records are reviewed to identify critical components/ failure modes. Kim and Singh (1996).
In 2008 Jacques Virasak carried out the (FMECA) Analysis for a typical helicopter main rotor Scissor bearing assembly. As he stated the main rotor scissor rotating bearing assembly has only two functional failure modes: 1. Loss of its ability to allow relative motion between the rotating scissors and the rotating swash plate. 2. Loss of its ability to accommodate various combinations of loads and motions between the rotating scissors and the rotating swash plate.
The loss of relative motion between the rotating scissors and the rotating swash plate will result in loss of the controllability of the main rotor, increase rotor vibration, and decrease response to control input. The loss of load transmission from the rotating scissor to the rotating swash plate will create an unbalanced rotor and increase rotor vibration. Virasak (2008)

2.2 Inspection of Failures in Pipe
Pipe leakage in Australia is perceived to be a major problem by many water authorities, both from an environmental point of view, as well as the associated costs that are incurred due to overdesign of sewerage systems (to cope with wet weather loads) and the treatment of additional potable water that is lost due to leakage. Burn and Desilva (1999) In many water distribution systems, a significant percentage of water is lost while in transit from treatment plants to consumers. According to an inquiry made in 1991 by the International Water Supply Association (IWSA), the amount of lost or unaccounted for water (UFW) is typically in the range of 2030% of production (Cheong 1991). In the case of some systems, mostly older ones, the percentage of lost water could be as high as 50% (AWWA 1987). In Australia and Canada the problem is not quite as severe due to relatively newer systems. For example, water authorities in Australia report UFW levels varying between 8 and 28% with the average being 15% in 1997/98 (WSAA Facts 1998).
UFW is usually attributed to several causes including leakage, metering errors and theft. According to the IWSA survey, however, leakage is the major cause. Water leakage is a costly problem, not only in terms of wasting a precious natural resource but also in economic terms. The primary economic loss due to leakage is the cost of raw water, its treatment and transportation. Leakage inevitably also results in secondary economic loss in the form of damage to the pipe network itself, e.g. erosion of pipe bedding and major pipe breaks, and in the form of damage to foundations of roads and buildings. Diminution of supply security as a result of a reduction in water stored per capita may also represent a cost if such diminution requires augmentation of supply to maintain security. Besides the environmental and economic losses caused by leakage, leaky pipes create a public health risk, as every leak is a potential entry point for contaminants if a pressure drop occurs in the system. Burn and Desilva (1999).
Leakage occurs at both designed overflow points and from joints and cracks in pipelines. The purpose of designed overflow structures is to relieve pressure in pipes

at controlled locations, i.e. adjacent to storm water drains, so that overflows do not occur at private residences or businesses or environmentally sensitive locations. They function when pipe capacity is exceeded due to infiltration or blockage during storms. Except in the most poorly designed systems, they do not function in dry weather when no blockage exists. Cracks, on the other hand, may function at any time, releasing sewerage into local waterways or soils (exfiltration) or allowing stormflow to enter sewers (infiltration), leading to pressure build up and possible overflows during heavy weather. The environmental impacts of leakage include impacts on ecosystems, aesthetic impacts and human health risk. These impacts, however, need to be considered in context. The Sydney Water Corporation has recently completed a series of Environmental Impact Statements (EISs) looking, in part, at the environmental effect of overflows and sewer system leakage (Sydney Water Corporation 1998). These documents listed the potential environmental effects of overflows as being: Eutrophication as a result of nutrient-rich sewage reaching receiving waters. Toxicant impacts (especially chlorpyrifos and dieldren (respectively,
organophosphate and organochlorine pesticides) copper and ammonia). Faecal coliforms; oxygen reduction in receiving waters (which may lead to fish kills and other impacts). Increased turbidity and increased sediment loads (and litter).
Each of these has potentially serious impacts. Their actual environmental effect depends, however, on the volume and concentration discharged and the receiving water environment. So too must the general environmental conditions at the time of discharge be considered (i.e. rain or dry weather). The key point to stress, however, is that quantification of leakage impacts and, by expansion, the degree of corrective action required would depend on the situation and the degree of risk we judge acceptable. That leakage causes environmental impacts on receiving waters, land (e.g. water logging and nutrient enrichment), recreational amenity, flora and fauna, and air quality is, however, undeniable. Burn and Desilva (1999)

2.3 The New SAE FMECA
In regard to avoid some of the mathematical difficulties of the RPN analysis, the new SAE FMECA has accomplished through three major changes. The new standard describes the FMECA procedure as a process to be used throughout the product development cycle, rather than as a task to be done after the design is complete. It emphasizes the role of functional and interfaces FMECAs as well as that of the traditional piece part FMECA. The concept of failure mode equivalence enables failure modes that have equivalent effects to be analyzed together and reduces much of the duplicative work generated by traditional component-by-component fault analyses. This concept allows the analyses of functional failure modes done early in the design process to be carried over to the effects of interface and piece-part failure modes analyzed later in the design. Criticality is assessed using a Pareto ranking procedure based on the probability and the severity of the failure mode. This is more broadly applicable than the use of criticality numbers SAE J1739. Bowles (1998)

3.0 Description of Loss Production Event
FMECA Description of loss production is an estimate of damage inflicted on an industry in terms of quantities of finished products denied the enemy from the moment of attack through the period of reconstruction to the point when full production is resumed. This event can possibly cause by faults or failures due to many reason (mostly poor asset management). Loss production may also occur because of human error (like causing fire or contamination of water supply) or natural disaster (such as volcanoes, flood, etc). There are several reasons of faults or failures that may occur in this water utility. These failures if not being taken seriously will cause greater damage to environment and will cost loss production, even harm human being. 1. Breakdown in the water treatment system 2. Contamination of water supply 3. Clusters of illness potentially due to the former 4. Limitation of water supply due to droughts 5. Piping leakage due to failure of material 6. Disaster such as petrochemical accident 7. Infrastructure damage due to accident like fire 8. Corrosion in pipe, causing contamination to communitys water supply 9. Machinery damage due to poor asset maintenance 10. Infrastructure and machinery damage due to major natural disasters such as volcanoes, flooding, insect plagues, etc
Piping failure in water utilities is chosen as the main topic, therefore this report will mainly discuss about piping failure. The main reason why it is chosen is because piping failure waste both money and a precious natural resource, and they create a public health risk. The primary economic loss is the cost of raw water, its treatment, and its transportation. Piping failure leads to additional economic loss in the form of damage to the pipe network itself, e.g., erosion of pipe bedding and pipe breaks, and to the foundations of roads and buildings (Figure 1). Risk to public health can be
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caused by contaminants entering the pipe through leak openings if water pressure in the distribution system is lost.
Figure 3. Leakage leads to damage to the pipe network, e.g., erosion of pipe bedding and pipe breaks, and to foundations of roads and buildings.
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4.0 FMECA and Risk Management Method Discussion
4.1 Selection of Critical Components
In terms of critical components, a few critical components in pipe are identified by researching through the exits data of failures and maintenance in pipe. Critical components are known as those kinds of components that have a critical failure mode. A component failure mode having significant operational, safety or maintenance effects that warrants the selection of maintenance tasks to prevent the failure mode from occurring. Figure below shows logical diagram for critical component selection.
Consequences of the failure mode

Yes Impact on Safety?
No Yes Impact on Generation? No Yes Impact on Cost of Repairs? No
Critical Component
Non-critical Components
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4.2 Failure Mode and Effect Analysis
Failure modes are the way in which a failure is observed, usually a description of how a failure occurs. General types of failure modes are: I premature operation, II failure to operate at a prescribed time, III failure to cease operation at a prescribed time, IV failure during operations, V intermittent failure, VI and dormant failure. Once the failures are determined they need to be catalogued and analysed in a very systematic and robust way. The three main analysis methods are: qualitative, quantitative and risk priority number. Failure effects are identified and inserted in each row of the FMECA matrix by taking into consideration the criteria identified in the ground rules. Effects are categorized as: I local, II next higher and III end levels. System level effects would then include system failures, degraded operation, system status failure, or no immediate effect.
4.3 RPN and Corrective Actions

Risk Priority Number (RPN) is a measure used when assessing risk to help identify critical failure modes associated with your design or process. It is rated using the probability of the failure occurring, its severity and the unlikelihood of its detection. These variables are rated with a number from 1 to 10 with 10 being the worst case. The RPN values range from 1 (absolute best) to 1000 (absolute worst). The graphic below shows the factors that make up the RPN and how it is calculated for each failure mode. The risk priority number rating is found using the following formula:
Severity (S) - Severity is a numerical subjective estimate of how severe the customer (next user) or end user will perceive the EFFECT of a failure.
Occurrence (O) - Occurrence is a numerical subjective estimate of the likelihood that the cause, if it occurs, will produce the failure mode and its particular effect.
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Detection (D) - Detection is a numerical subjective estimate of the effectiveness of the controls to prevent or detect the cause or failure mode before the failure reaches the customer. The assumption is that the cause has occurred. RPNs have no value or meaning in themselves. Although it is true that larger RPN values normally indicate more critical failure modes, this is not always the case. For example, here we have three cases where the RPNs are identical, but clearly the second case would warrant the most attention.
Figure 4.a. RPN 1
As a general rule, any failure mode that has an effect resulting in a severity 9 or 10 would have top priority. Severity is given the most weight when assessing risk. Next, the Severity and Occurrence (S x O) combination would be considered, since this in effect, represents the criticality. Below, the failure modes with the lowest RPN values are actually the most critical. It shows that the first line is most critical even though it has the lowest RPN value, then the second line, and finally the third line.
Figure 4.b.: RPN 2
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4.4 FMECA discussion
Critical components/ failure modes of pipe subsystem are identified as below:
Leak at seal or gasket on fittings, valves, hydrants and tapping bands. Internal corrosion on fitting and hydrants. Ball valve jammed. Rusty pipeline and pipe leakage on pipelines. Spindle failure on gate valves Over flow and over heat on pump.
4.4.1 Fitting
Fittings are used in pipeline systems in order to connect straight pipe or tubing sections. It has various connections such as threaded pipe, solvent welding, compression fittings, and flared fittings. It also can be made from many materials provided by the nature, but most often it is the same base material as the pipe or tubing being connected, for example copper, steel, brass, or PVC. Fittings have many types, from reducer, elbow, tee, cap, plug, and nipple.
4.4.2 Valves
The most common control failure in the Pipe system is valve failure. Valves fail to operate most frequently by not closing completely or sticking open. Dirt or water in the air starting system may cause this to happen. Water transports dirt and metal particles and creates rust. The valve may stuck because of dirt and/ or water but additionally is susceptible to overheating and coil failure. If, there is no maintenance for valves, then there is no need to find out the cause of failure. Only replacement is the solution. So time should be fixed according to old failure and maintenance records.
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4.4.3 Pipeline
Polluted pipeline and leakage in pipe lines are two failure modes that can be occur due to improper material as well as improper insulation. The effects of these failure modes can be led up to stop the water supply or/and contaminate the water. The severity of these failure modes is high and the RPN number is the highest. Highest RPN number shows that these failure modes are the most critical failures.
4.4.4 Hydrants
Hydrant is an outlet from water main often consisting of an upright pipe with a valve attached from water can be tapped. The most frequent hydrants failure is internal corrosion. Internal corrosion can occur due to aging and improper material. The end failure effect is having no water supply, so it can be classified as a critical failure mode. Acoustic leakage detector method can be used to prevent this failure in hydrant.
4.4.5 Tapping Bands

Tapping bands provide an economical and effective way of tapping into new or existing pipelines. Leak at seal or gasket is the failure modes that can be occur due to improper gasket or sealant. Loss of water can be the most important effect of these failures on the pipeline.
4.4.6 Pump
We could assume that pump is a third-party component in the pipeline system, but it is still an important component thus it pumps the water and distribute the water to the consumer. The two primary failure modes of pumps over flowing and overheating of the pump. Lack of lubrication in the pump can cause the overheating while wrong pump setting can make overflow in the pipeline. Other reason that can make an overflow is the pump breakdown (e.g. due to age) thus gives the wrong pressure to the water. So we have to check the usage time of the pump and check periodically the pressure that produce by the pump.
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5.0 Asset Management Issues Discussion
There are several issues regarding of asset management for water utility system. Infrastructures such as tank storage, source of water and of course piping system to distribute the water need to be taken seriously. We need to do as best as we can to prevent bad things that will happen to provide clean drinking water for the protection of public health against cholera and other water borne diseases for examples. Later challenges included:

Securing sufficient quantities of water often through the building of dams Providing satisfactory water distribution systems Building sewerage systems to protect the environment and public health Responding to the growing expectations of the community and the impact of competition policy
Water authorities were generally invested with strong powers and were, by design, fairly independent from governments. This independence was thought to be necessary to ensure that the building of long-life infrastructure was not compromised by shorter-term considerations. This chapter will mainly discuss about some issues that mainly occur in water utilities regarding to piping failure such as, treatment of piping operation, piping main repairs, the source of water loss due to piping leakage and risk issues that mostly occur from implementing a water loss management.
5.1 Treatment of Piping Operation

A number of factors can contribute to the condition of water pipes and cause them to crack, break or leak, including ground movement, corrosion, and external traffic loading. This will affect the quality of water source. It is important to keep regular maintenance for the piping system to prevent such a failure. Maintenance can also be tricky. It can cost lots of money if we dont do it as the procedure. On the other hand, if we didnt do regular maintenance, we cant be sure whether the piping system is still in good condition or not. We will briefly discuss about maintenance process in the next chapter.
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5.2 Piping Main Repairs
Once we done the maintenance, we can actually found if there is any failure in that pipe. Regarding to the failure, if it doesnt do much damage to the pipe, we can try to repair the pipe instead of replacing it. Replacing pipe can cost the company more so if the failure is not too serious then repair seems to be the best option. Repairing is not as easy as it seems. If it doesnt do right as the procedure, it can cost lots of money from the company. Moreover, bad repairing can cause more failures and eventually producing malfunction to the entire piping system.
5.3 Source of Water Loss Due to Piping Leakage

System water loss can be over 30% in some schemes. Sources of water loss are illustrated below
Figure 5. Schematic diagram of Sources of water loss
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As we can see from the diagram above, leakage can produce real losses. It is something that the company would like to avoid. For example, if the leakage happens it will affect the water source. The water source will be gone fast, causing drought in drain area during dry season, or worse; contamination. If the contaminate water reach the consumer and causing public disease such as cholera and other water borne diseases, surely it would become great disaster for people. That is why real losses have to be taken seriously to prevent such a disaster.
5.4 Risk Issues

Risk is very closely related to reliability and product safety. Risk is defined as an economic aspect of safety as: Risk$ = probability of a failure*exposure*$consequences The probabililty of failure (POF) and exposure elements in the calculation lie between 0 and 1. Consequence $s for costs vary from 1 up to and including X millions of dollars. This statement of risk is the expected monetary value for an event or set of events. For business management, risk could hardly be absolutely eliminated. No matter how hard we try to prevent such a loss, there always risk issues that need to be considered. However, most of the risk can be avoided by the implementation of effective strategies. The top priority of the company is to survive. In considering about how to profit from the business operation, the company must also take account of preventing loss and confronting unexpected risk. Potential risks associated with implementation of piping leakage strategies include:

Quality of raw data; Implementation of sub-optimal water loss reduction strategies; and Sustaining the levels of water loss reduction.
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6.0 Maintenance Management Issues Discussion
Water supply in general is a complex structure of different factors, i.e. .production, transport and distribution. Within this structure, pipe networks represent one of the largest infrastructure assets of industrial society. The management of potable water networks encompasses all activities principally concerned with: the supply of water from the outlet of the water treatment works to the customers taps; and all related functions, including water resources provision, water treatment, customer relations, business planning, human resources and information services. Thus, maintenance planning designed to meet current and future system demands of flow rate and pressure head, and to reduce future maintenance costs, represents an integral part of a network management strategy. Selection of the maintenance strategy for a water distribution system is a difficult problem due to: a large number of system components, e.g. pipes, pumps, valves, meters, etc.; dynamic evolution of the failure mode of deteriorating water pipe; the existence of a certain degree of coupling among the various system components; limited resources available for maintenance activities; and the associated difficulty in quantifying many of the benefits and costs. The problem has often been treated as a complex optimization problem with several possible objectives used in isolation or combined, e.g. maximization of reliability, minimization of downtime and the minimization of total maintenance costs. A few analytic and optimization approaches have been published to assist in making pipe replacement, relining or reinforcement decisions. Shamir and Howard (1979) proposed an analytic model for making pipe replacement decisions based on pipe breakage history and the cost of repairing and replacing pipes. They claim that the optimal time for replacing existing pipes can be obtained using this methodology.
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There are 4 most common issues that come up when maintain the water utilities; 1. On the surface dealing with utility cuts Surveys show that pavement restoration following underground work on utilities is a major challenge facing municipalities and utility providers, with huge cost implications for both. Carelessness and lack of attention will lead to accidents related to water pipes can lead to water stoppage and flooding in large areas, directly affecting civic life (and causing damage).
Figure 6. Excavator Burst a Pipeline in Hong Kong
2. A seal in time road maintenance Preventive maintenance is the key to delaying road reconstruction, and sealing cracks as they occur is an increasingly important way to do this. Effective crack sealing can increase pavement service life by 10-20 percent and save municipalities more than $800 million over the next 20 years. Effective is the key. 3. Going underground managing large sewers The failure of deeply buried large sewer structures (more than 900 mm in diameter) can have enormous consequences, both physically and financially. And maintaining these systems can be equally difficult and expensive. 4. The sound of running water locating leaky pipes Most of water distribution has a lost on its transit between treatment facilities and consumer. The major cause of thing is usually a leakage. Leakages
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usually caused by one of any failure occur on the piping system. In order to do maintenance for this leakage, Water Company could use an acoustic device to locate leaks, but as any other devices, it has a limitation, particularly in the detection of plastic pipe, large diameter, or pipe in clay soils or below the water table. To support this limitation, the use of combined leak detection should be used.
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7.0 Loss Prevention and Mitigation Solution Discussion
As described before, we can assume that all of the failure types lead to the piping leakage that can produce a catastrophic damage to the pipeline system thus can stop the distribution and of water. For this reason we need some preventive measure to reduce the probability of failure. With some good preventive measures we also can reduce the cost of maintenance of the water utility. The main idea to prevent the loss of water is to search for the leakage on the pipeline system and fix it immediately. We can make a very good pipeline system design with a best precision, but in the actual situation there is still some leakages even a small one. This figure shows the steps that can prevent the leakage that can leads to massive loss of water, they are:
Start
Measurement of Unaccounted Water Volume (First Measurement)

Above permissible volume
Searching for Leaking Spot Repair the Leakage Measurement of Unaccounted Water Volume (Second Measurement)
Below permissible volume Below permissible volume
Above permissible volume
Done
7.1 Measurement of Unaccounted Water

There is no current comprehensive national regulatory policy that limits the amount of water loss from a public water supplys distribution system. Most states, however, do have policies and regulations that address excessive distribution system water losses. The policies vary among states, but most set limits that fall within the range
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of 10% to 15% as the maximum acceptable value for the amount of water that is lost or unaccounted-for. Neither the term unaccounted-for-water nor the use of percentages as measures of water loss is sufficient to completely describe the nature and extent of losses in water utility operations. Unaccounted-for-water is a term that has been historically used in the United States to quantify water utility losses. Unaccounted-for-water, expressed as,
We can assume that if the unaccounted-for-water above 10% so we have to continue with the second step that is searching the leakage.
7.2 Searching the Leakage

There are several methods that can be use to find the leakage in pipeline system, they are: Method by residue chlorine Method by electric conductivity Method by pH value Method by water temperature Method by trihalomethane Method by acoustic leakage detector
Nowadays, the most common used method is the acoustic leakage detector. Water leaks in underground, pressurized pipes may make many different sounds: Hiss or Whoosh from pipe vibration and orifice pressure reduction Splashing or Babbling Brook sounds from water flowing around the pipe Rapid beating/thumping sounds from water spray striking the wall of the soil cavity Small clinking sounds of stones and pebbles bouncing off the pipe
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The Hiss or Whoosh sound, which often sounds like constant static noise, is the only one, which is always present for leaks in pipes with 30 psi or higher water pressure. The other sounds may or may not be present, and usually they are not as loud. So we decide whether there is leak or no, by listening the Hiss or Whoosh. The device that used in this method is the acoustic leakage detector. It can receive the sound from the underground where the pipes located.
Figure 7.2.a. Man using the leakage detector
First thing that we have to do in searching for leakage is to survey in every hydrant, valve, and service line is a possible location to hear the sounds of water leaks when there is no obvious evidence like water flowing on the streets. Since the sounds travel on the pipe walls better than through the soil, always listen at the hydrants, valves, and meters first. As you get closer to the leak, the sound gets louder. Finally, decide which two of these locations are the loudest. After this we can start with water leak pinpointing.
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Figure 7.2.b. Listening leak sounds on hydrant
Figure 7.2.c. Listening leak sounds on meter
Water Leak Pinpointing is the term applied to the process of pinpointing the exact leak location. For Acoustic Leak Detection, the exact leak location is usually the spot where the leak sounds are the loudest.
Figure 7.2.d. Pinpointing
This activity can also be done regularly, for example every month check the leaking sound, so we can prevent the loss of water.
7.3 Repair the leakage

After we find the exact spot of leakage we can determine the leaking cause. It can be because of:
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Corrosion o Water and other pollutant can cause the pipe corrosion. Piece blown out o Removal of a piece of pipe wall. This form of failure is brittle in nature. Size can be vary depend on pipe material but generally greater than 100 cm2. Broken back (circumferential break) o A single crack extending part or full way around the pipe circumference. Longitudinal Split o A crack along the pipe axis. The length can vary from a few mm to the full length of the pipe. Pipe rupture or tear o A rupture to the pipe wall where the material tears and creates an opening in the pipe wall. This form of failure is ductile in nature. Leaking joint o Water leakage through the joint. Often a result of a displaced rubber ring joint or debris left in the ring groove during installation of RRJ pipes. Lead jointed steel pipe can also leak. Aging o Due to long period, pipe experience many interference that can reduce the performance itself.
Some of preventives measure can be taken before the leakage bigger and break the pipeline system, such as change the components that leak especially at joints or fittings, we can also use the anti-corrosive material to reduce the probability of rusted, or we can use Split Repair Sleeve like in Osaka, Japan, they used this sleeve
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to cover up the leaking pipe so they can prevent the loss of water.
Figure 7.3.a. Pipe leakage in Osaka pipeline
Figure 7.3.b. The leakage covered with the Sleeve split sleeve
7.4 Measurement of Unaccounted Water (Second Measurement)

We again measure the unaccounted for water like the first one, then the number decides do we have to look for the leakage again or finished up the preventive measure of loss of water. With this method we can prevent the loss of water and reduce the cost. It can be very expensive if the pipeline system damage catastrophically, it can stop the water distribution, the water quality, also the traffic on the ground if the water blows up.
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Figure 7.4. Pipeline damage that have to be prevented
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8.0 Conclusion
In this report, the failure mode effect and critically analysis of the pipeline in common water utilities. It describes of piping failure, especially on leakage on the basis of functional analysis for pipeline itself. This report should be helpful to select the appropriate maintenance step and prevention method to reduce any bigger losses. With the right method of maintenance and prevention, the water distribution will not be disturbed in a big scale. To summarise, we think that although many of the risks that initially faced the system have now been resolved, some risks still exist. However, with the contingency plans (particularly the standalone system) that we have put into action, we feel that these risks can be minimised. We feel that risk management is a useful technique and it would have been useful to have learnt more about it nearer to the beginning of the project rather than at this late stage. Still, we feel that even now it can be useful and we will try to use it to good effect in the remaining six weeks of the project. For further preventive action, we also have some recommendation for you that will be written in another part of this report.
30

9.0 Recommendation
From the report above we understand that every business has it own risk. To reduce the chance on getting a bigger loses from your asset, you need to do some prevention for your assets. In this case, you must protect your asset from piping failure that can cause a catastrophic damage that have a negative impact to your business. So, our recommendation is that you must protect your asset by any means. To prevent the water loses, you can do a periodically maintenance for your asset, for example you can use an acoustic leakage detector to find any leak along the pipeline. The faster you know the leakage location, the more loss can be reduced. You need to calculate the usage time of each of your asset so that you can plan to spend some of your money on renewing your asset. For example, pipe has it owns lifetime, and pipe needs to be replaced by the end of its lifetime. Calculating this renewal cost can reduce your chance from getting trouble from aging. It is also good to prevent unwanted accident during maintenance, like we have mentioned before, you need to pay more attention to heavy machinery that used for maintenance purposes. We also recommending to you to increase the security for the facility, to prevent the illegal usage of your asset. For example, irresponsible people may take out the water without your permission due to low supervision. This kind of illegal usage of this facility can increase in water loses that lead to bigger losses for your assets.
31

10.0 Reference List
seqwater.(2000). seqwater.Available: ttp://www.seqwater.com.au/public/home. Last accessed 13th May 2011.
AWE. (2010). Water loss control. Available: http://www.allianceforwaterefficiency.org/Water_Loss_Control_-_What_Can_Be_Done.aspx. Last accessed 13th May 2011.
NSW government. (2004). NSW health responce protocol. Available: http://www.health.nsw.gov.au/publichealth/environment/water/response.asp. Last accessed 13th May 2011.
Quiggin, John. (2000). Urban water supply in Australia: the option of diverting water from irrigation. School of Economics and School of Political Science and International Studies University of Queensland
Sydney Water Corporation (1998), Licensing Sewerage Overflows, Environmental Impact Statement: Volume 1 Sydney-wide Overview.
AWWA (1990), Water Audits and Leak Detection, Manual of Water Supply Practices No. M36, American Water Works Association, Denver, CO.
Drucker, Professor Peter F. (1999). The End of Distance. Sydney Morning Herald, 18th November, 1999 (reproduced from the Atlantic Monthly).
32

Horvath, B., Leakage Management: Assessing the effect of pressure reduction on losses from water distribution systems, Urban Water Research Association of Australia, Research Report No. 5, December 1989.
33

Asset: WATER UTILITIES' PIPELINE WATER UTILITIES PIPELINE Funct ion Funct ion #: Analy st: c d e f g h Failure Effects Local Next Higher WATER LOSS INCREAS ED End NO WATER COULD SUPPLI ED i j k Operational Indication Normal Abnormal Fail ed NO WA TER SUP PLI ED NO WA TER SUP PLI ED BAD WA TER QU ALIT Y BAD WA TER QU ALIT Y Sev erity Occur rence Dete ction R P N Action l m n o p q SUFFICIENT WATER SUPPLY SUPPLY FRESH WATER Notes: RPN=Severity X Occurrence X Detection
Syste m: Subsyste m: a
Failure Mode R ef Item Functio n CONNE CTING PIPELI NE Let ter Descript ion LEAK AT SEAL OR GASKE T
Failure Cause Nu Descriptio mbe n r IMPROPE R SEALANT
FITTIN GS
WATER DRIPPING FROM LEAKAGE
SUFFICI ENT WATER SUPPLY
LESS WATER SUPPLIED
96
USE THE RIGHT SEALANT FOLLOW THE STANDAR D PROCEDU RE OF INSTALLA TION CHECK THE TIMEUSAGE OF THE COMPONE NT USE ANTICORROSI VE MATERIAL
IMPROPE R INSTALLA TION
WATER LOSS INCREAS ED
NO WATER COULD SUPPLI ED
LESS WATER SUPPLIED
72
INTERN AL CORRO SION
AGING
CONTAMI NATING WATER
CAN CAUSE MAJOR LEAKAGE
NO WATER COULD SUPPLI ED NO WATER COULD SUPPLI ED
WATER SUPPLY CONTAMIN ATED
16 2
IMPROPE R MATERIAL
CAN CAUSE MAJOR LEAKAGE
21 6
34

VALV ES REGUL ATING THE FLOW LEAK AT SEAL OR GASKE T BALL VALVE JAMME D IMPROPE R GASKET OR SEALANT WATER DRIPPING FROM LEAKAGE WATER LOSS INCREAS ED NO WATER COULD SUPPLI ED NO WATER COULD SUPPLI ED SUFFICI ENT WATER SUPPLY VALVE OPERAT E REGULA RLY LESS WATER SUPPLIED NO WA TER SUP PLI ED NO WA TER SUP PLI ED NO WA TER SUP PLI ED NO WA TER SUP PLI ED NO WA TER SUP PLI ED NO WA TER SUP PLI ED USE THE RIGHT SEALANT/ GASKET
96
ACCUMUL ATED POLLUTIO N
VALVE DIFFICULT TO OPERATE
THE VALVE GOT STUCK
NO FLOW THROUGH THE VALVE
96
CLEAN UP THE COMPONE NT FOLLOW THE STANDAR D PROCEDU RE OF INSTALLA TION USE ANTICORROSI VE
MISSALIG NMENT
VALVE DIFFICULT TO OPERATE
THE VALVE GOT STUCK
VALVE OPERAT E REGULA RLY
NO FLOW THROUGH THE VALVE
96
PIPEL INE
WATER DRAIN AGE
PIPELIN E GOT RUSTY
IMPROPE R MATERIAL
IMPROPE R INSULATI ON
CAN CAUSE MAJOR DAMAGE TO THE PIPE CAN CAUSE MAJOR DAMAGE TO THE PIPE CAUSING MAJOR DAMAGE TO PIPELINE
BROKE N PIPE
SUPPLYI NG THE WATER
HALT THE WATER SUPPLY PROCESS
12 0
BROKE N PIPE
37 8
USE THE RIGHT INSULATI ON METHOD FOLLOW THE STANDAR D PROCEDU RE OF INSTALLA TION
1 0
PIPE LEAKA GE
IMPROPE R INSTALLA TION
DECREASI NG WATER FLOW
BROKE N PIPE
37 8
35

1 1
ACCIDENT AL EVENTS DECREASI NG WATER FLOW CAUSING MAJOR DAMAGE TO PIPELINE BROKE N PIPE SUPPLYI NG THE WATER HALT THE WATER SUPPLY PROCESS NO WA TER SUP PLI ED NO WA TER SUP PLI ED INCREASE PROTECTI ON TO PIPELINE
96
1 2
GATE VALV ES
USED IN LOW PRESS PIPE
LEAK AT SEAL OR GASKE T SPINDL E FAILUR E LEAK AT SEAL OR GASKE T INTERN AL CORRO SION
IMPROPE R GASKET OR SEALANT
LESS WATER SUPPLIED
90
USE THE RIGHT SEALANT / GASKET
1 3
SUPPL Y ADEQU ATE WATER
BEARING FAILURE
UNUSUAL NOISE
DEACRE ASE IN TOOL LIFE WATER LOSS INCREAS ED
SCRAP
SPINDLE OPERAT S REGULA RLY SUFFICI ENT WATER SUPPLY LESS WATER SUPPLIED NO WA TER SUP PLI ED BAD WA TER QU ALIT Y STO P THE WA TER SUP PLY
90
CHECK THE TIMEUSAGE OF BEARING USE THE RIGHT SEALANT / GASKET CHECK THE TIMEUSAGE OF THE COMPONE NT USE ANTICORROSI VE MATERIAL
1 4
HYDR ANTS
NO WATER COULD SUPPLI ED NO WATER COULD SUPPLI ED
24
1 5
AGING
MAJURE LEAKAGE
32 4
1 6
TEMPERA TURE
CONTAMI NATING THE WATER
BROKE N HYDRA NTS
GOOD WATER DISTRIB UTION
AFFECT THE WATER QUALITY
63
36

CONTAMI NATING THE WATER BROKE N HYDRA NTS GOOD WATER DISTRIB UTION AFFECT THE WATER QUALITY STO P THE WA TER SUP PLY USE ANTICORROSI VE MATERIAL
1 7
OXIDATIO N
63
1 8
TAPPI NG BAND S
GIRIPPI NG THE PIPE AND PROVI DING THE WATER TIGHT SEAL
LEAK AT SEAL OR GASKE T
LESS WATER SUPPLIED
NO WA TER SUP PLI ED
96
USE THE RIGHT SEALANT AND INSTALL IT CORRECT LY
1 9
PUMP
PUMP THE WATER
OVERF LOW
REGULAT OR FAILURE
STRESS ON PIPE
OVER STRESS ON PIPE
WATER COME OUT FROM THE PIPE
GOOD WATER FLOW
TOO MUCH FLOW INSIDE THE PIPE
WA STE ON WA TER
32 4
CHECK THE TIMEUSAGE OF THE PUMP
2 0
OVER HEAT
LACK OF LUBRICAT ION
COMPON ENTS FAILURE
PUMP STOP WORKI NG
GOOD WATER DISTRIB UTION
REDUCE WATER DISTRIBUTI ON
NO WA TER SUP PLY
32 4
CHECK THE PERFORM ANCE OF THE PUMP REGULAR LY
37
RPN Format
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