HETEK Solutions Inc

Ontario Water Works Association
2007 Water Efficiency Awards
Water Leakage Reduction at Canadian Forces Base (CFB) Kingston, using District Meter Area (DMA) Methodology

Executive Summary

The Department of National Defence (DND) is performing an energy management program at CFB Kingston.  Direct Energy Business Services is completing the program, which will encompass 170 buildings and the water distribution system, and will include electrical, gas and water/sewage usage.  For the water usage, HETEK Solutions Inc performed a water use assessment at the base, which identified potential areas for water reduction.

During the year, the average water billed is approximately 5,000 m3 per day, which rises to between 5,700 and 7,400 m3 per day in the winter months, probably associated with water main breaks.  The minimum billing period is during October and November, which was when the audit was completed, and the average billed was between 4,000 and 4,200 m3 per day.

In order to make an assessment of the amount of unaccounted for water, the analysis completed in the following three areas were used:
• Historical water use
• Water supplied to the base profile, for November, 2004
• Buildings water balance

The buildings water balance showed a use of approximately 1,640 m3 per day, divided between 826 m3 per day daytime use, and 814 m3 per day 24 hour continuous flow.  This was based on auditing representative buildings, and not a detailed audit of every building.  There was a significant 24 hour flow of water recorded into the base, of approximately 3,400 m3 per day, of which 814 was accounted for as continuous use in the buildings, leaving approximately 2,600 m3 per day not accounted for.

The unaccounted for water, could be a combination of use within the buildings and leakage from the water distribution system.  An assessment was made of the amount of leakage, and of that amount, what was recoverable in a cost effective manner.  The District Meter Area (DMA) method of leak identification and reduction was employed – this method is now recognised as a Best Management Practice.  The DMA method is based on flow measurement, and the volumes of water leaking are quantified before and after repair.   For this first phase, four major leaks were repaired, and a total of 575 m3 per day was recovered.  This translates into over $100,000 saved in one year.  The cost of the DMA leak detection and repairs was approximately $150,000, which included the construction of several chambers for ongoing DMA use.   A second phase is underway, and an additional 600 m3 per day of leakage has been found and repaired.  Furthermore, individual building water audits are now underway to identify cost effective water efficiency measures in those buildings

1.0 Background
Kingston has a strong military history, and Fort Henry dates back to the War of 1812.  Canadian Forces Base (CFB) Kingston was a military centre during the First World War, where troops were stationed.  During the Second World War, the Royal Canadian Ordnance Corps had a training centre.  From 1945 to 1969, it became the home of the Royal Canadian Electrical and Mechanical Engineers School.
 
In April 1966, Canadian Forces Base Kingston was established.  On 30 March 1995, CFB Kingston was transferred to Army command as part of Land Force Central Area.  It is also the home of the Canadian Forces School of Military Communications.  As is the case with municipal systems, new construction is often combined with older infrastructure, which is replaced as needed.  CFB Kingston is effectively a small town, with residences, work buildings, dining facilities, recreation areas and a hospital.  The working population, on a weekday, is over 5,000 employees, comprised of people who live both on and off the base.  The Department of National Defence (DND) is performing an energy management program at CFB Kingston.  Direct Energy Business Services is completing the program, which will encompass 170 buildings and the water distribution system, and will include electrical, gas and water/sewage usage.

For the water usage, HETEK Solutions Inc performed a water use assessment at the base, which identified potential areas for water reduction.  Water is supplied to CFB Kingston by Utilities Kingston, who was very supportive of the project, and the average water use was 5,000 m3 per day.  An overall water balance was completed by HETEK that identified daytime and continuous 24 hour water demand.  One of the main areas for potential water use reduction was leakage from the water distribution system at the base.

The District Meter Area (DMA) method of leak identification and reduction was employed – this method is now recognised as a Best Management Practice.  The DMA method is based on flow measurement, and the volumes of water leaking are quantified before and after repair.  For the first phase of the work, nearly 600 m3 per day of leakage were found and repaired.  The Awards Submission will present the results of the water use assessment and the first phase leakage reduction program.  An update will be given of the subsequent leakage reduction work, and on water use and efficiency in the buildings.

2.0 Project Description
The focus for this project was on water loss management for the underground distribution system, which supplies water to the buildings on the base.  In essence, the objective was to establish the amount of water leaking from the water distribution system, before it reached the buildings, and then assess the amount of that total leakage that could economically be reduced.  Because of the complexity of the base, in terms of the number and variety of buildings; a water metering system was not that simple. More than one investigation phase would be required to quantify the volume of economically recoverable leakage. 
 
A Water System audit commenced on October 22, 2004, with a site inspection and initial identification of CFB Kingston staff that could be of assistance during the audit.  The main site audit took place on November 17, 18, and 23, 2004.  During this time, several key staff were interviewed to obtain an understanding of the water use at the base.  The domestic water using fixtures were inspected at representative buildings, and where possible, non domestic water uses were identified.  In addition, meetings, discussions and site visits to James Street Booster Station (which supplies water to the base) took place with Utilities Kingston staff, throughout the audit period.  Upon the request of HETEK, Utilities Kingston prepared a seven day profile, on an hourly basis, of metered water into the base.

2.1 Water System Audit Report
The approach taken for the audit was to work at the base level as a whole, rather than individual facility and areas of water use level.  This was considered to be the most cost effective way to establish the magnitude of water loss from the underground water distribution system. Water is supplied from Utilities Kingston through a water main under the Greater Cataraqui River, to the James Street booster station.  At James Street, water is pumped to the CFB Kingston main site, and at James Street water is also supplied to Royal Military College (RMC), via a pressure reduction valve (PRV).  This system is part of Utilities Kingston water distribution system to the communities of Rideau (to the north) and St Lawrence (to the east).  The CFB Kingston site has a water tower and there are also water standpipes in the Rideau and St Lawrence systems.  Depending on the demand, and levels of the standpipes in the Rideau and St Lawrence communities, water either flows to the communities, or flows back into the CFB Kingston site.  Both flows in and out, at the Rideau and St Lawrence communities are metered.

Background research was conducted to achieve a comprehensive picture of water use at the base.   Records were obtained and studied for the period of 2002 to 2004.  Discussions were held with Utilities Kingston, who in turn supplied water meter data and booster pump operation for the period November 4 to 10, 2004.

At any point in time, water is either flowing in or out of the elevated water tower at the base, so this volume of water had to be adjusted from the metered volumes, to derive a true hourly profile of water supplied to the base.  Hetek was then able to use the changes in water tower level, supplied by Utilities Kingston, to compute the water supplied on an hourly basis during the seven day period. Discussions with Hetek staff and Utilities Kingston were held with regards to the meters types, sizes, age and calibration history.  After meetings and site inspections, an estimate was made of water use in the buildings on site.  Hetek installed eight pressure loggers for a period of seven day, from November 17 to 23, 2004.  Two loggers were installed at James Street booster station - pump delivery pressure, and RMC PRV outlet pressure; and six across the CFB Kingston site.  A water balance was then completed, which identified unaccounted for water.

During the year, the average water billed is approximately 5,000 m3 per day, which rises to between 5,700 and 7,400 m3 per day in the winter months, probably associated with water main breaks.  The minimum billing period is during October and November, which was when the audit was completed, and the average billed was between 4,000 and 4,200 m3 per day.

In order to make an assessment of the amount of unaccounted for water, the analysis completed in the following three areas were used:
• Historical water use
• Water supplied to the base profile, for November, 2004
• Buildings water balance

The water use and resulting water balance was for a weekday.  The water balance identified daytime and continuous 24 hour uses.  One focus was to identify and account for, as much as possible of the 24 hour continuous water use. The estimate of domestic water use was completed by establishing the number of workers and residents, completing inspections of a representative sample of the water using devices, and estimating the frequency of use. For cooling and process water use, a combination of interviewing maintenance staff, limited inspection of equipment, and some metered data where available, was used to estimate this volume of water. 

The historical water used for the months of November 2002 and 2003 was 3,933 m3 per day, and 4,180 m3 per day respectively.  For the audit period in November, 2004, the average daily flow was 4,234 m3 per day, which confirmed that the water use during the audit period was representative of previous years.

A profile of water supplied to the base over a seven day period was obtained from Utilities Kingston.  Of great interest was the continuous flow in the overnight period, particularly between 1:00 am and 4:00 am.  To obtain this profile, the data from Utilities Kingston had to be adjusted, to account for water flowing into and out of the water tower on the base.

The buildings water balance showed a use of approximately 1,640 m3 per day, divided between 826 m3 per day daytime use, and 814 m3 per day 24 hour continuous flow.  This was based on auditing representative buildings, and not a detailed audit of every building.  There was a significant 24 hour flow of water recorded into the base, of approximately 3,400 m3 per day, of which 814 was accounted for as continuous use in the buildings, leaving approximately 2,600 m3 per day not accounted for.

The unaccounted for water, could be a combination of use within the buildings and leakage from the water distribution system.  An assessment was made of the amount of leakage, and of that amount, what was recoverable in a cost effective manner.  This approach is very much a phased method to home in on the areas of leakage. The first phase was to establish if there is potential for significant water loss reduction.  The next phase measured the flow into discrete zones within the base, to confirm the potential water loss, and the magnitude of that loss.  A program of active leak detection and repair was designed, which resulted in an initial reduction in water loss, and the establishment of an ongoing water loss management program. 

2.2 District Meter Area (DMA) Water Leakage Reduction
The District Meter Area (DMA) approach involves redirection of the flow from an open, uncontrolled state to a selective closure, controlled state.  The closure of predetermined valves allows the flow to be monitored through a single pipe.  An insertion flow meter is used in conjunction with a data logger.  Careful attention is given to the selection of these ‘perimeter’ valves, as the redirection of the flow must not compromise the following:
• Disruption of flow to consumers and fire flow capacity
• Abnormal change in pressure within the DMA; this is monitored to ensure there are no  substantial changes in pressure
• Water quality by unnecessary operation of valves and other system components

Confirming a suspected leak is a complex process.  Initially, a DMA is monitored to determine the night flow volume.  Second, a step test confirms the area, or branch line on which the leak is located.  Next, fire hydrants and valves are listened on, or ‘sounded’, for leak noise.  The valves on which the greatest noise was heard is subjected to correlation, which pinpoints the leak. 

3.0 Innovation / Creativity
The water distribution system at CFB Kingston consists of various pipe materials, of different ages.  The most common is cast iron, followed by ductile iron and PVC, up to 400mm in diameter.  The service connection pipes are generally copper.  All new pipe and repairs are made in PVC.  The history of the area dates back to Fort Henry.  The base has expanded over time, the most recent expansion occurring in the Cold War era 1950’s.  Much of the infrastructure dates back to this time. 

The ground conditions the pipes are laid in also varies, from limestone trenches, to clay and sands.  The depth the pipes are buried varies from 6 ft to 20 ft.  For the main breaks, if a section of pipe has to be replaced, the existing main is cut back, until pipe in good condition is found.  The new pipe used is plastic, regardless of the existing pipe material.  Due to the complexity and entirety of this operation, many stakeholders representing several organizations were involved at different times throughout.  CFB Kingston Fire Services were to be notified every time the DMA’s were to be initiated.  Operations staff conducted all valve and fire hydrant operations.  Military support staff were on hand to supply information and services.  Health and Safety staff, from the base and Hetek, ensured all regulations were met and exceeded. 

Because of the complexity of the physical water system, coupled with the multi stakeholders, both inside the base, and externally at Utilities Kingston, an innovative communication methodology was set up to ensure that all parties were well informed every step of the way, as each had their own areas of interest.

4.0 Goals, Objectives, Timelines
For the initial Water System Audit Report, a conservative approach was be taken, of reducing the estimated level of continuous 24 hour unaccounted for water, by approximately 23%, from 2,600 m3 per day (section 2.1) to 2,000 m3 per day.  This was mainly because the water system audit was completed at a global level, with only representative building being audited.   The cost for water and sewer charges that were used for the project was 0.49 cents per cubic metre.  Based on a rate of 49 cents per cu m, the 2,000 m3 per day of continuous flow, represents $980 per day, and $357,000 per year.  As can be seen from the historical water use at the base, the volume of water increases significantly during the January to March each year, primarily associated with leakage from the water distribution system.  For these three months, the flow rate increases to, on average, 6,500 m3 per day.  This additional 2,500 m3 per day flow is equivalent to $110,000 over the three month winter period.

The initial target for water loss reduction was 30% of the 2,000 m3 per day.  This represents 600 m3 per day, or 219,000 cu m / year, with a value of $107,000 per year, at 49 cents per cu m.

To obtain a sense of what this means in terms of number of breaks, it is equivalent to:
• 3 main breaks at 150 m3 per day (23 gpm) = 450 m3 per day
• 6 service breaks at 26 m3 per day (4 gpm) = 156 m3 per day
The project proceeded with the target reduction of 600 m3 per day, with the understanding that if this were achieved, then reducing this level further, in a cost effective manner, would be investigated.

5.0 Results and Water Savings
The first phase of the DMA leak detection and repair was conducted.  The DMAs were operated and potential leaks identified, by the methods described in section 2.2.  Because a high level of certainty was required in terms of the leaks, and the potential volume of water leaking, each leak was turned off, and the volume of water reduction recorded on the DMA flowmeter.  Only after this process was completed, were the instructions for repair given.  After the repair, the DMA flow was recorded for a period to confirm the water reduction.  For this first phase, four major leaks were repaired, and a total of 575 m3 per day was recovered.  This translates into over $100,000 saved in one year.  The cost of the DMA leak detection and repairs was approximately $150,000, which included the construction of several chambers for ongoing DMA use.

6.0 Staff Education / Knowledge Gained
Throughout the project, numerous staff at the base, from different departments were involved with the HETEK team.  In addition, several staff from Utilities Kingston participated in the project.  Through this process, they were introduced to the water auditing methods, and to the District Meter Area method of leak detection, which they had not been exposed to before.  The success of the project was because of the knowledge of the water distribution systems that local staff brought, coupled with the new DMA methodology introduced by HETEK.

7.0 Technical Detail
The project included an initial water system audit, which included the estimation of water use in the buildings, and potential water losses form the water distribution system.

Standard methods of water auditing were completed at representative buildings, because at this early stage of the project, a detailed audit of every building was not justified, or required.  The objective was to identify, in a cost effective manner, if there was potential for water loss reduction from the water distribution system.  This was completed, and did indeed identify that there was potential to proceed further.  The DMA approach to leak detection is primarily a flow-based technique, to quantify the level of leakage, or real water losses, in a distribution system.  It is effectively a way to prioritize between the areas of high and low leakage, and so focus efforts in a more cost effective manor. Further investigation, to find leaks, is only completed in the DMA’s with high leakage, once the temporary flow monitoring is complete.  This technique has been described earlier in this submission.

8.0 Transferability to Other Ontario Organisations
CFB Kingston is like many medium sized municipal water systems, with a combination of residential and ICI customers, and an underground water distribution system.  The improvement in the efficiency of water use in the residential and commercial buildings (see future activity in the next section), and also the reduction in water loss from the water distribution system, and the methods to achieve that, can be utilised in most municipalities.  As an example in this case, as a result of their involvement in the project at CFB Kingston, Utilities Kingston are now completing the DMA method of leak detection across part of their area.  To date, seven district metered areas have been established, monitored, and sounded.  Several major leaks have been identified and repaired.

Water has always had the reputation of being the ‘cheapest’ of all utilities.  This is proving to be no longer the case, as the cost of implementing new regulations and its associated technologies are passed on to the consumer.  Realizing the hidden costs associated with loss prevention and water efficiency practices has helped to increase the vigilance of water operations staff on the base, at all levels of responsibility.  This translates into new procedures for active leak detection and repair, versus the ‘old way’ of action, such as waiting for the leak to surface, or responding to customer complaints. 

9.0 Future Activity
The District Metered Area approach to leak detection is an accurate and valuable procedure.  A strong leak noise can mask weaker sound propagation through long stretches of pipeline.  A second phase of leak detection is in most cases necessary to ensure complete area coverage.  The second phase began after the repairs were made in July of 2006. 

As part of this second phase five potential leak locations were identified.  A step-test was conducted to estimate the volume of leakage; an estimate of 600 m3 per day was derived by recording the drop in flow rate as each line was isolated.  All five were pinpointed, marked, excavated and repaired.  Currently, individual building water audits are underway, with the emphasis on reducing water use.  Toilets, sinks and urinals that are forty years old or more are extreme users of water, as automatic flushing of urinal banks occur every ten minutes, 24 hours a day.  A second phase of detection and repair is concluding, with the results being similar to the initial phase.  This meets the goal originally set by Direct Energy; to have the cost of this project be repaid through energy and water savings.

The future holds many challenges for the water industry; stiffer regulations increase the standard of living, this coupled with population growth presents challenges for both water providers and consumers.  By conserving what we have now, through efficiency practices, leak detection, and conservation methods, we can extend our current supply to help meet the needs of the future. 

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