Pipeline Management Solutions

Stop Age Discrimination in Pipe Replacement Strategies Wisconsin Wastewater Operators Association October 10, 2019

Over 240,000 water main breaks per

year in the US

Over 900 billion gallons of sewage

overflows per year in the US

>$250 billion investment needed for

water pipelines within 20 years

>$80 billion investment in wastewater

pipelines within 20 years

Sources: ASCE & EPA

70% to 90% of replaced pipelines have

remaining service life

Buried Infrastructure Challenges

Bridging the Gap

3 THE PURE PRECISION PLAYBOOK

Risk

4

Likelihood of Failure (LoF)

Consequence of Failure (CoF)

Risk = LoF x CoF

Likelihood of Failure

Pipe Condition

• Material quality

• Manufacturing

• Design

• Environmental

• Operational

• 3rd party damage

• Installation

• Age

Consequence of Failure

Social

• Loss of trust

• Traffic disruption

Environmental

• Creeks and rivers

• Sensitive areas

Economic

• Repairs

• Damage

• Loss of product

CoF – What is the Impact of Pipe Failures?

Why do pipes fail?

Mechanical Overload

Operational Pressure

External Loading

Failure

Weakening of Pipe

Why do Pipes Fail?

Cast Iron Pipes

• Cracking from joints (leadite)

• Longitudinal or circumferential cracking

• Graphitization, corrosion and pitting

Ductile Iron Pipe

• Broad areas of corrosion

• Internal or External

Age alone is a poor indicator of condition

9

36-inch Diameter – Pressure Rated for 150 psi

1908 CI - Pit

1952 CI- Spun

1957 CI - Spun

1965 DI 1976

DI 1991

DI

1.58”

1.22”

0.94”

0.58”

0.38” 0.43”

The Good News

10

3% has some

deterioration

We only need to address 4% of our

pipelines!

96% of pipe is in

good condition

Find the Weak Link

Manage individual assets

Prioritize Replace

Approach to Pipeline Condition Assessment

11

• What is the risk?

• Perceived or quantified

Understand

• What is the condition?

• Leak detection & pipe wall assessment

Assess • What do I do

now?

• Repair or replace

Address

• What do I do in the future?

• Remaining useful life and capital planning

Manage

Risk, Operational

Characteristic, History

Gather condition data

Repair/Rehabilitation

Reinspection

Capital Planning

12 THE PURE PRECISION PLAYBOOK

No single technology or technique can identify all of the indicators of pipe deterioration. Therefore, a holistic, risk based approach should be used.

Loading Structural Capacity

Degredation

←—

AV

206

2+1

9

←—

PW

206

9+8

5

←—

AV

207

3+1

8

←—

BO

207

6+7

8

←—

TO 2

094+

36

←—

PW

210

1+3

5

˾__

____

____

____

__/

TO 2

101+

49

←

—A

V 2

105+

63

←—

BO

211

4+8

6

←—

AV

211

7+0

5

←—

MH

212

0+4

3

←—

PW

212

8+5

0

←—

MH

213

9+3

5

←—

AV

214

6+7

5

←—

PW

215

9+1

6

←—

AV

216

5+9

6

←—

PW

217

3+0

5

←—

AV

217

6+1

7

←—

MH

218

0+4

3

←—

MH

218

6+1

0

←—

MH

219

2+2

9

←—

MH

220

4+3

4

←—

PW

221

5+4

5

←—

MH

222

5+8

4 ←

—M

H 2

231+

48

←

—M

H 2

236

+88

←

—A

V 2

241+

37

←—

PW

226

3+4

9

←—

AV

226

5+8

9

←—

BO

226

9+1

0

←—

AV

227

4+6

0

←—

PW

228

2+0

0 ←

—A

V 2

299+

60

˾

____

____

____

__/

TO 2

300+

00

←—

BO

232

6+2

5

←—

AV

233

7+6

8

←—

PW

234

5+5

9

←—

TO 2

357+

30

←—

AV

236

4+6

0

←—

MH

239

3+1

2

←—

MH

239

8+9

0

←—

BO

240

8+2

2

←—

MH

241

2+0

2

←—

MH

241

7+5

5

←—

TO 2

435+

61

←

—A

V 2

440+

65

←—

BO

244

8+7

3

←—

AV

245

5+7

5

←—

BO

246

5+6

6

←—

AV

247

0+3

4

←—

PW

247

3+8

6

←—

AV

247

8+4

5

←—

BO

248

5+1

0

←—

TO 2

502+

50

˾

____

____

____

__/

AV

250

3+5

0

←—

BO

251

4+2

9

←—

AV

252

3+1

0

←—

BO

253

1+8

3

←—

AV

254

4+1

9

←—

BO

256

1+4

7

←—

——

——

——

AV

256

2+8

2

←—

PW

256

8+0

4

←—

——

——

——

AV

256

9+5

6

←—

BO

257

4+5

0

←—

AV

257

8+3

0

←—

BO

260

3+5

0

←—

MH

262

2+5

9

FRS

0001

+00

TO

˾__

____

____

___/

TO

263

6+4

9

0

100

200

300

400

500

600

700

800

900

1,000

1,100

1,200

1,300

1,400

1,500

1,600

1,700

1,800

1,900

2,00040% - 60% 60% - 80%

PWA with Leak & Gas Pocket Detection

• Stress

PureEM -

• Broad areas of corrosion & wall loss

PureMFL

• Detailed pitting & wall loss

Low

Medium

High

Using Risk as a Guide for Condition Assessment

Gas Pocket Detection

EM

MFL Leak

detection

Ultrasonic Thickness

Testing

Pulsed Eddy Current Testing

Pressure Monitoring Soil surveys

Test pits

Correlators

Structural Analysis

Remaining Useful Life

Transient Pressure Monitoring

15 2016 © Pure Technologies

Small Diameter Leak Detection

16

Pinpoint with

Handheld Mic

Leak Survey

with Loggers Localize with

Correlators

Pinpoint with

Handheld Mic

THE PURE PRECISION PLAYBOOK

• Precursor to failure

• SmartBall and Sahara

• Contribute to force main failure

• Operational impact

17

Leak and Gas Pocket Detection

2 or 4 inch

opening

Identifies leaks & air

pockets not found with

correlators

Tethered hydrophones can identify leaks and air pockets

Dallas Water Utilities Award Winning Program • 144 leaks repaired in large diam pipe following

111 miles of inline leak detection

In-line Acoustic Leak & Gas Pocket Detection

Free Swimming/ Non-Tethered Hydrophone Technology

•Locates leaks and gas pockets in transmission or force mains

•Launch and retrieve in live flow through 4” openings

•Average 1 leak per 3 miles in concrete pipe

•Average 1 leak per 2 miles across all pipe materials

Introduction to SmartBall

20

Identifying and locating hidden leaks and gas

pockets with high accuracy

Mapping the pipeline to confirm alignment

Measuring the pressure along the pipeline to identify

partial blockages and confirm pipeline elevations

Identifying and locating potential undocumented

features and pipe type changes

Contributing current inspection data to engineering

analysis used for capital planning

SmartBall is a free-swimming inspection platform

that is used to help pipeline owners better manage

their pipelines by:

Identify pipe wall defects

• Corrosion

• Wall loss

• Broken prestressing wires

• Broken bar-wraps

Pipe Wall Condition

PHASE

AMPLITUDE

Electromagnetic inspection identifies each pipe joint and broken wire wraps

Manned

Diameter: 36”+

Dewatered

Manned system

Allows for visual

and sounding

inspection

3D Mapping

Long Range

Robotics Free-Swimming

Diameter: 18”+

Depressurized pipeline

8,000 foot tether

Robotic with EM,

CCTV, SONAR, laser,

etc.

3D Mapping

Diameter: 16”+

Pipeline In Service

Free swimming

* SONAR

* CCTV recording

External

Diameter: Any

Pipe segments

excavated to

springline

Manned system

Internal and External EM Inspection Tools

• Complements EM Inspection and Structural Analysis

• Identifies problems with joints not addressed by EM

• Finds non-wire break related to problems (i.e., over loading, cracking, spalling, etc.)

• Provides accurate lay schedule and pipe inventory

Internal Visual and Sounding Inspection

Structural Evaluation

• AWWA Design check

• Finite Element Modeling

Engineering & Analytics

Remaining Useful Life Projection

Pipe Performance Curves based on FEA Provide Structural Assessment

0

25

50

75

100

125

150

175

200

225

250

275

300

325

350

0 10 20 30 40 50 60 70 80 90 100

Pre

ssu

re (

psi)

Number of Broken Wire Wraps

Yield Limit

Strength Limit

(Pipe Failure)

20 Wire Breaks at

Current Operating

Pressure 35 psi

180 psi allowable for

pipe with 20 Wire

Breaks

90 allowable wire

breaks at 50 psi

Pipeline condition data and statistical models estimate remaining useful life

27 27

30 to 40 years until

significant number of

failures

Reinspect in 10 years

www.puretechltd.com

Validation

• Pipe 127 chosen for validation

• Large EM anomaly

• Visual indications in video

PipeDiver EM Signal Contour Plot

Pipe 127

PipeDiver Video

EM Data

www.puretechltd.com

Validation of Pipe 127

29

EM Anomaly

Take Aways

Time to move beyond age, failure, and material based replacement strategies

Cost effective pipeline asset management uses risk to guide data collection, not replacement

Data collection technique selection should be life-cycle based

Inspection and repair approach typically 5 to 10% of the cost of most replacement only strategies

Advanced pipeline asset management strategies can provide significant financial benefits

31

Summary

2016 © Pure Technologies

Knowledge based tools empower utilities to make informed decisions to ensure public health, community

sustainability and protect our environment.

Using risk to drive data, information and knowledge development can safely and

cost effectively extend the life of pipeline assets for decades.

Reducing risk through understanding condition Condition assessment is an important part of your asset management program

• Reduce risk

• Manage more effectively

Questions? Steve Bruskiewicz

262-305-5238

steven.bruskiewicz@xyleminc.com