Leakage and condition assessment technologies
Capabilities and case studies
WRc is renowned for its innovative and proactive approach to pipeline condition assessment and leak detection, having successfully executed some of the largest, trunk main leak detection projects in the UK and internationally for clients that include global water utilities and industrial stakeholders. Collaborating closely with utilities and industry partners, our assessment and detection methodologies not only save time and money but also contribute to water conservation by minimising unaccounted-for losses.
The comprehensive data gathered during inspections enables prompt prioritisation of leak repairs immediately following the survey. Our innovative technologies are capable of accurately detecting even the smallest leaks and air pockets within pipelines. By leveraging existing access points whenever feasible, our methods ensure that leaks can be swiftly identified, assessed and quantified without causing disruption to service.
Employing a variety of condition assessment techniques across different platforms, including Sahara®, robotic pipe crawlers, SmartBall®, PipeDiver®, acoustic fibre optic (AFO) systems and drone technology, we assist utilities and industries in gaining insights into an underground infrastructure's condition. This proactive approach allows for timely maintenance interventions, mitigating the need for extensive replacement or rehabilitation. Our assessments furnish valuable data to support the development of efficient mains replacement strategies aimed at minimising disruptions and reducing overall costs.
Our suite of technologies, including Sahara®, robotic pipe crawlers, SmartBall®, PipeDiver®, AFO systems and drone technology, are all introduced with their case studies on the following pages.
WRc Infrastructure Geolocation
Sahara®, SmartBall®, Drone Surveys, AFO & Pipe Crawler
UK & Ireland
Sahara®
Europe*
Sahara®
Morocco*
Sahara® USA*
Drone Crawler
Sahara® Europe*
Pipe Crawler Saudi Arabia
Sahara® Yemen*
Sahara® Hong Kong*
Sahara® Australia*
* Sahara®: pre-2014 projects
Sahara® Pipe Inspection System
Sahara® is a highly accurate, tethered inspection tool used for pin-pointing leaks and carrying out pipeline condition assessment in real time while the pipeline is in service. This tool can be used in potable water trunk mains, raw water mains, waste water rising mains and sewers.
In over 20 years’ use of the Sahara® leak detection technology, WRc has found more than 5000 leaks over 5000 km of surveyed water mains. This equates to one leak in every surveyed kilometre. However, we are often asked to carry out annual repeat surveys on the same mains, detecting new leaks for repair each year, e.g. the Thames Water Invasive Leak Framework (see right). Closer analysis of the data shows that on average one leak is detected for every 500 metres of pipeline being surveyed for the first time.
Our previous experience with the Sahara® system had shown that the precise location can be identified - performance that is not possible with any other existing technique on this type of pipe. The only alternative method for locating the leak would have been successive sectioning and testing of the line followed by excavation of individual areas.
- Mike Davey - Project Manager, J Murphy & Sons
Sahara® Case Studies
Sahara® Pipeline inspection surveys
Thames Water Invasive Leak Detection Framework
WRc has worked closely with Thames Water since 1998 when they started investigating methods capable of identifying and accurately marking leakage for repair on their trunk mains network. The primary purpose of the Thames Water ‘Invasive Leakage Detection Framework’ is to meet annual leakage and annual leakage repair targets set by the regulator.
WRc has held the Framework for this service from 1998 up to the present day. In addition, the contract has evolved to cover monitoring of strategic water mains for proactive leakage control and burst prevention. The surveys are undertaken annually on an estate of insertion points that is expanded each year, increasing the annual network coverage.
Newly laid pipework within the Thames Water network is now designed with Sahara® survey access points included. This proactive approach helps to future-proof the network and reduces the cost of expanding Sahara® coverage by designing it in rather than installing access retrospectively.
Starting with a single survey team in 1998, the contract has since expanded to six survey teams operating day and
We use Sahara® to inspect our trunk mains as part of a programme to reduce leakage in the London network. Based on our early findings with the system, and its ability to detect even very small leaks, we have used Sahara® for a number of years to inspect critical mains.
- Trunk Mains Manager, Thames Water
night, all year round within the Thames Water Network. Over 1,300 surveys are undertaken annually.
Sahara®: Commissioning New Pipelines
Farmoor to Blunsdon Duplication Main
Sahara inspected a 900 mm GRP pipeline to identify a leak causing a 1.4 km section to fail a pressure test. The leak location was identified during the survey ensuring remedial action could get underway immediately. Once the identified leak had been repaired the pipe successfully passed the pressure test.
The leaks that cause pipelines to fail an initial pressure test are often extremely small and hence difficult to locate using conventional techniques. The Sahara® system allows leaks to be found without the need to split the pipeline into short sections and pressure test each one.
Sahara® Case Studies
Rising Main Inspection & Location M4 Crossing
During upgrade works to the UK’s M4 motorway, the route of a rising main passing under the motorway needed to be established to avoid damaging it during installation of a new gantry support.
The construction company had spent many months digging trial holes in an effort to locate the precise location. A trench approximately 25 m long, 5 m wide and 3 m deep had been opened, but no evidence of the pipe had been found.
WRc Infrastructure was asked to survey the pipeline using the Sahara® system. Within a few hours of being on site, the location had been established - a short distance beyond the end of the trench. Having confirmed the location, construction of the gantry was able to proceed. The survey was completed with no impact on the operation of the pump station.
Rising Main Profile Trapped gas
Following installation of a rising main to serve a new housing development, its performance was found to be below expectations; specifically, the required flow rate was not being achieved. Investigations by the water company identified that there was a trapped pocket of gas within the rising main, which was partially removed by opening a drain. While this helped in the short term, the problem kept returning and the water company’s operators had to regularly open the drain valve to improve performance. What was needed was an air valve, installed at the highest point along the section of main to allow the air to escape automatically.
WRc Infrastructure was asked to survey the main and map the vertical profile using the Sahara® system.
Our unique tracking device can pinpoint leaks to within 30 cm accuracy in any pipe material, in contrast to other tools that only track distance deployed.
- Dr Dominic Cook, Head of Business Development WRc Infrastructure
During the survey, a sensor was deployed along the pipeline and the pressure mapped with the pumps running and with the pumps off. The data was processed and used to generate a vertical profile and to identify the highest point on the line. An acoustic sensor, incorporated with the system, also identified a large pocket of trapped gas, which coincided with the
high point. Further analysis of the data also showed that there was a significant restriction to flow at a specific point along the pipeline. The survey team pin-pointed the location and found a partially closed valve on the pipeline. This was opened and immediately improved the flow conditions and reduced pumping costs.
Following the survey, an air valve was installed. The required rising main performance was achieved without the need for frequent intervention.
Sewer Condition and Location
A developer was planning redevelopment of an area of waste ground that had a trunk sewer running through the middle of it. Over time, several of the access manholes had become buried under rubble and other debris. In addition, the water company responsible for the sewer required a condition assessment survey of the sewer prior to the works and a further one on completion to confirm no damage had occurred during the construction work.
WRc Infrastructure was engaged to survey the sewer - identifying the route, locating the buried manholes and carrying out a
condition assessment survey. An inspection tool, incorporating a live video feed, HD CCTV camera and locating system, was deployed along the sewer and used to locate the buried manholes and plot the route of the sewer. Images from the live video feed were used to control the deployment over the full 800-m-long survey, and the HD CCTV images were used following the survey to carry out a detailed condition assessment.
The locations of each manhole were subsequently exposed and the recorded route used to ensure the planned new buildings did not encroach on the sewer. The condition assessment showed that the original brick-built sewer was still in excellent condition.
Sahara® Case Study
St Sampson’s Harbour, Guernsey
Client: The States of Guernsey Committee for Home Affairs (Guernsey Fire and Rescue Service)
The Challenge
In March 2024, WRc Infrastructure was asked to undertake a condition assessment of the St Sampson’s Harbour cross-harbour fire main link to ascertain the location and size of a known leak. The fire main crosses the harbour foreshore, so the survey programme had to be carefully timed to correspond with a neap tide to enable on-foot access to the pipeline route.
WRc are a great team to work with, they provide the perfect solution for the brief and timescale. I would highly recommend WRc to anyone in the industry that needed this type of specialist survey.
- Martin Lucas - Head of Operations Guernsey Fire & Rescue Service 26 March 2024
The Solution
WRc used the Sahara® pipeline inspection system with an acoustic survey head. Using an induced flow from a fire hydrant, the team surveyed from a chamber on the south side of the harbour across the harbour foreshore to the ‘Tee’ and into a fire main ring on the north side.
A plan was provided, with timings, to ensure the team hit deadlines for low-tide foreshore access and recommissioning of the fire main for the arrival of the fuel tanker. During an eight-hour window the schedule included the following steps:
1. Isolate the fire main from the pumps and depressurise
2. Sahara® pipeline inspection system with acoustic survey head inserted
3. Fire main re-pressurised
4. Flow induced
5. Survey undertaken to coincide with low tide at 14:23 to allow tracking
6. Leak identified and marked up
7. Survey equipment retrieved and extracted
8. Fire main put back in service.
The Results
The survey achieved the full distance between the two chambers either side of the harbour.
Two leaks were identified: a medium leak close to the harbour wall and another very small leak close to a location where the main was known to have been pieced together during its construction. Both were located and their positions recorded.
All the timelines in the schedule were achieved and the fire main was back in service ready for the arrival of the next fuel delivery.
Sahara® was developed by WRc over 20 years ago and is still one of the most reliable and accurate leak-detection systems on the market.
Pipe Location Services
The ability to accurately locate underground pipes offers numerous benefits across various industries and applications.
Accurately locating underground pipes helps prevent accidental damage during excavation, construction or maintenance activities. This reduces the risk of costly repairs, service interruptions and potential safety hazards for workers and the public.
Knowing the exact location of underground pipes enables utilities and infrastructure operators to conduct routine maintenance, inspections and repairs more efficiently. This minimises downtime, reduces service disruptions and extends the lifespan of critical infrastructure assets.
Accurate pipe location data facilitates urban planning, infrastructure development and construction projects. By understanding the layout of underground utilities, town planners, engineers and developers can avoid conflicts, minimise rework and streamline project timelines. This is of particular benefit to housing developers who can often build several more houses on a plot if the accurate location of pipes on the site is known.
HS2 Crossing Case Study
To minimise the risk of damaging assets buried under the route of the HS2 train line, only vacuum excavation is permitted to confirm the asset’s location. Having an accurate indication of the location and depth of the asset will significantly reduce the time taken to uncover it.
Due to its greater than expected depth, vacuum excavation had failed to find the route of a small diameter rising main where it crossed the main train route. Excavation of trial holes had been carried out for several weeks before WRc Infrastructure was asked to survey the pipe line and establish the route and depth.
The survey was completed in a single shift and accurately identified the route and, importantly, the depth: a trench that had been previously dug across the route had not been dug deep enough to reach the pipe.
With the route found and subsequently confirmed, earthworks in the area were able to proceed.
Sewer Condition and Location
A developer was planning redevelopment of an area of waste ground that had a trunk sewer running through the middle of it. Over time, several of the access manholes had become buried under rubble and other debris. In addition, the water company responsible for the sewer required a condition assessment survey of the sewer prior to the works and a further one on completion to confirm no damage had occurred during the construction work.
WRc Infrastructure was engaged to survey the sewer to identify the route, locate the buried manholes and carry out a condition assessment survey. An inspection tool, incorporating a live video feed, HD CCTV camera and locating system, was deployed along the sewer and used to locate the buried manholes and plot the route of the sewer. Images from the live video feed were used to control the deployment over the full 800-m-long survey, and the HD CCTV images were used following the survey to carry out detailed condition assessment.
The locations of each manhole were subsequently exposed and the recorded route used to ensure the planned new buildings did not encroach on the sewer. The condition assessment showed that the original brick-built sewer was still in excellent condition.
Pipe Location Services Case Study
Client (confidential): Line and depth tracing of three major potable water transfer mains
The Challenge
In November 2023, WRc Infrastructure undertook a line and level survey to trace the line and depth of three major potable water transfer pipelines that crossed a development site in London. The pipelines ran across the development site for approximately 60 metres and included a 60” steel main and 48” and 42” cast iron mains.
Thames Water Developer Services asked the developer to seek WRc’s support to trace the exact location of the three mains
because part of the new building was closer than 15 metres from the face of the pipe, and construction traffic would be traversing the pipes.
The plan below shows the buildings under development and the area (in yellow) of the pipe track affected by the proximity of the build and the construction traffic.
The Solution
WRc has a Framework with Thames Water to conduct leakage and condition assessment surveys on their potable water trunk main infrastructure, which has been in place for over 20 years. In that time, an estate of insertion points has been built up on this infrastructure, which WRc proactively surveys on an annual basis.
Of the three large trunk mains in question, two already had Sahara® insertion points within the yellow area shown on the plan. However, this would not allow coverage of the whole area highlighted. So, two chambers 1100 metres upstream were utilised to cover these two mains, and a chamber approximately 400 metres upstream was used for the third main.
This was on the limits of the distances that could be achieved on the 60” and 48” trunk mains, and, as water velocities in these pipelines can vary depending on demands within the network, plans were made so that more than one attempt on each pipeline could be made if the first failed to cover the required distance.
The Outcome
The surveys were conducted on three separate days during November 2023, with all of them managing to cover the full distance at the first attempt thanks to some perseverance on the part of the survey teams.
The line and depth readings were taken using a high accuracy GNSS device, which kept the variance to within 300 mm. The coordinates were output to the client in a number of formats including the .kml format seen below.
Robotic Pipe Crawlers
Robotic pipe crawlers are mechanised devices designed for inspecting and maintaining water pipelines in source water and potable water environments. These crawlers are equipped with advanced sensors and cameras to detect leaks, corrosion, and other defects within the pipes. They navigate through the pipeline infrastructure, often in challenging environments such as narrow passages or underwater, providing crucial data to utilities for proactive maintenance and prevention of infrastructure failures. By enabling efficient and thorough inspections, play a vital role in safeguarding the integrity of water networks.
WRc Infrastructure uses two types of pipe crawlers:
1. Large/long-range pipe crawler (Versatrax 320™ supplied by Eddyfi Technologies)
This market-leading pipe crawler - one of the only ones of its kind in the UK and Europe - has a range of up to 1000 meters and a depth capability of 60 metres, with survey options for both CCTV (tailored inspection) and NDT (remote sensing and tooling). It is a low maintenance, tethered crawler that is simple to deploy for both underwater and dry applications.
The performance of the Versatrax 320™ can be enhanced by the addition of WRc’s renowned Sahara® tracking system, so the end point of a survey can be marked, providing the option to accurately mark on the surface features found during a survey for later mediation.
2. Small pipe crawler (AM Industrial SP150)
This pipe crawler is deployed where pipeline openings are too small for the large crawler - between 150 mm and 320 mm diameter. It has a range of up to 240 metres, with CCTV survey.
Large Robotic Crawler Case Study
Condition assessment of source water transfer main
Client: semi-rural water company
The Challenge
A water company client, in a semi-rural area of the UK, required a full condition assessment of an existing 7.5-km-long, 900mm-wide, spun iron, source water transfer main. The water company needed to understand the main’s condition prior to works to extend it another four kilometres to an additional extraction source, which would increase the pressure in the main when in use.
The Solution
Following detailed planning by the WRc Infrastructure team, the client and their Tier 1 contractor, a robust inspection plan was developed that centred on the utilisation of WRc’s large, Versatrax 320™ pipe crawler, while leveraging our partnership with NDT Group and utilising services from our sister company RSK Geosciences, to provide a full end-to-end condition assessment solution. The pipe crawler completed all but 35 metres of the full length of the pipeline. Nondestructive testing (NDT) and soil resistivity testing was undertaken at each location during the installation of the under pressure tappings used for entry points.
The Outcome
The pipe crawler’s CCTV surveys found a number of a small piles of rock deposits, silt build-up near a wash out and an intrusion into the invert of the pipe from below. The NDT surveys found no signs of corrosion at any of the seven sites and the soil resistivity confirmed the pipe was laid in an aggressive soil environment. WRc Infrastructure’s final report concluded that the pipeline was still in excellent condition, that it could accommodate the additional pressure and would meet the manufacturer’s quoted lifespan.
Following the replacement of the damaged pipe section and the implementation of a flushing regime to remove the deposits and silt, the pipeline was ready to extend and resume service.
Our pipe crawlers are reserved for use in source water and potable water only. A suite of sterilisation and maintenance checks are completed before a project commences to ensure optimum hygiene is observed between projects.
Small Robotic Crawler Case Study
CCTV condition survey
Client: A UK-based university
The Challenge
A civil engineering and construction firm engaged WRc to provide a suitable potable water solution to obtain CCTV footage from inside polyethylene (PE) potable water main with an internal diameter of 155 mm. The pipe had failed on numerous occasions due to cracks in the invert of the pipe wall. The client needed to understand whether there were further cracks that could lead to future failure and how widespread the problem was.
The Solution
WRc’s Infrastructure team used our small potable water crawler (AMI SP150). This crawler was chosen as it can be used in pipelines with internal diameters of as little as 150 mm. It also has a range of up to 240 metres, which was more than enough for this survey.
The Outcome
The crawler fitted inside the extremely small pipe and travelled a very good distance before encountering an un-reamed butt fusion pipe weld, which decreased the main
diameter to less than 150 mm and therefore prevented further inspection.
CCTV footage was obtained that clearly showed there were splits in the pipe wall at the invert where the pipe material had failed and that these were at regular intervals along the 51-metre section that was surveyed. This footage provided the client with the evidence required to action an informed solution.
As well as the pipeline being flushed and disinfected, the client was given the necessary assurance that WRc Infrastructure had followed a best hygiene practice solution for the provision of CCTV in a potable water pipeline.
Leak Detection
Leak detection in pressurised pipe systems is important in equal measure to the water industry and industrial plants. Even small leaks can result in significant water loss over time. By detecting and fixing leaks, operators can reduce their overall water consumption and ensure efficient use of resources.
Industrial processes consume significant quantities of water, energy and raw materials. Leaks in process equipment, pipelines, or storage tanks can result in the wastage of these valuable resources. By detecting and repairing leaks promptly, industrial facilities can minimise resource losses, improve operational efficiency and reduce operating costs.
WRc Infrastructure employs a range of leak detection techniques, which are tailored to a client’s needs.
Leak Detection Case Study
Leak detection assessment
Client: High-risk COMAH chemical plant (confidential)
The Challenge
The client had detected flow and pressure anomalies in a fire main, which, being a high-risk asset and particularly important for safety compliance at a Control of Major Accident Hazards (COMAH) establishment, needed to be assessed as quickly as possible.
The Solution
WRc Infrastructure’s leak detection team visited the site and carried out a full, twoday leakage detection location service on all available fitting, valves and hydrants on the 200 mm ductile iron, fire pipeline to determine the flow and pressure anomalies. (The fire main system in this instance did not have a flow meter installed; therefore, minimum and maximum flow could not be logged.)
The Outcome
Using ground microphones and leak noise correlators, our leakage detection team located and identified four leaks on the fire main. Due to other anomalies being noted by the team, a return visit will be required once the existing leaks have been repaired.
WRc Infrastructure team recommended a number of options to improve operability of the network along with a routine maintenance and inspection schedule.
Non-Destructive Testing (NDT)
Non-Destructive Testing (NDT) includes a suite of invaluable investigation tools that allow the assessment of the structural integrity of pipes without causing damage to the pipes themselves. This is crucial for identifying potential defects, corrosion, or other issues that could compromise the safety and reliability of the pressurised pipeline system.
By regularly performing NDT on pressure pipeline pipes, engineers can identify early signs of deterioration or damage. This enables them to schedule preventative maintenance activities, such as repairs or replacements before serious problems occur, minimising disruptions to service and reducing the risk of costly emergency repairs.
Return On Investment (ROI) studies indicate that a properly conducted assessment and repair programme can be implemented for a very low percentage of the capital replacement cost, maximising the value of a client's budget.
WRc Infrastructure provides a number of NDT inspection techniques including:
• Visual Inspection
• Ultrasonic Testing (UT)
• Radiographic Testing (RT)
• Magnetic Particle Testing (MT)
• Liquid Penetrant Testing (PT)
• Eddy Current Testing (ET)
• Acoustic Emission Testing (AE)
Each NDT method has its advantages and limitations, and the choice of technique depends on factors such as the material being inspected, the type of defect expected and the desired level of sensitivity. Overall, NDT plays a critical role in quality assurance, maintenance and safety across various industries.
NDT Case Study
Cast
iron pipe condition assessment
Client: Water utility company (confidential)
The Challenge
A Victorian-era, 18-inch, cast-iron trunk main - managed by a water utility company in the west of the UK - had catastrophically burst in the recent past. The water company wanted to ensure the integrity of the main by carrying out a thorough assessment of the pipe on either side of the burst location to confirm the condition and likelihood of further bursts.
The Solution
WRc’s Infrastructure team was asked to inspect the trunk main using non-destructive testing services to carry out the condition assessment. We responded quickly to the request and were able to send a team to the site at short notice.
As the asset was over a hundred years old, we decided to try a range of inspection techniques to determine which could give the best outcome for the client as quickly as possible.
The Infrastructure team used rapid motion scanner (RMS) corrosion mapping and phased array, using a wheel probe (supplied for the assessment by one of our suppliers, Sonatest).
The
Outcome
The combination of the two tests produced a high-quality report on the condition of the pipe, providing insight that will reduce potential future disruption and costs for the client.
Asset Inspection Services
WRc Infrastructure’s Asset Inspection service plays a critical role in maintaining the health and efficiency of water networks.
We review system hydraulics and valve positioning, and by conducting detailed risk assessments (to pinpoint likely points of failure and contamination), we ensure that any potential weaknesses are addressed proactively. Moreover, understanding the hydraulics and valve dynamics aids in optimising energy efficiency for pumping, ensures that the system operates smoothly without unnecessary energy expenditure.
Proper inspection for operational efficiency is vital for asset protection, particularly in managing surge pressures within the pipelines. By regularly inspecting and verifying that all components are functioning correctly, we help prevent issues that could lead to pipeline bursts or malfunctions. This not only extends the lifespan of the infrastructure, but also safeguards against costly repairs and downtime. Ensuring the system operates within designed parameters is crucial for maintaining energy efficiency, reducing wear and tear, and ultimately protecting the infrastructure from surge-related damage.
When it comes to new installations, our design expertise ensures that systems are installed and positioned correctly from the outset, which is critical for the safety of both the pipelines and the public. Proper installation reduces the risk of failure and contamination, contributing to a reliable and safe water supply. Additionally, our physical inspection work, as part of water safety planning, verifies compliance with safety standards and operational requirements. This comprehensive approach ensures that both existing and new infrastructure operate efficiently and safely, protecting public health and ensuring the long-term sustainability of water networks.
Pressure Transient Logging
Pressure transients, also known as water hammer or hydraulic shock, are sudden changes in pressure within a water distribution network. These transients can occur due to various reasons such as sudden valve closures, pump starts or stops, rapid changes in demand, or pipe bursts.
Pressure transients produce high positive and negative pressures that travel through the network at great speed and are generally only detectable with high-speed loggers that record at 25 Hz or faster.
Pressure transients can have damaging effects on the infrastructure of the water distribution network, leading to leaks, breaks and costly repairs. They can also cause water quality issues by stirring up sediment or causing contaminant ingress through leaks.
Understanding the cause of pressure transients is essential, as the problem can often be dealt with at source or mitigation measures can be put in place such as surge tanks, pressure relief valves and pressure reducing valves.
WRc Infrastructure provides a full pressure transient logging service to identify the problem and suggest the most cost-effective solution.
SmartBall®
Partnering with Pure Technologies (Xylem), WRc Infrastructure is able to increase our client offerings to include a free-flowing, in-pipe inspection tool that can cover tens of kilometres without interrupting service.
SmartBall® is one of the world’s most trusted inspection technologies, having already been used on over 7000 kilometers of pipelines globally. It is a free-flowing (rolling) inspection tool that can be deployed for tens of kilometres while the pipeline remains in service, thereby avoiding disruption to customers. The device is inserted and extracted under pressure through 100 mm tappings, and can be used in any pipe over 250 mm diameter.
SmartBall® Case Study
Trunk mains condition assessment
Client: Scottish Water
The Challenge
Many water utilities are faced with the challenge of minimising the risk to their strategic asset base while maximising the performance from it. Scottish Water is one such water company that needs to meet this goal and support an on-going programme of pipeline management. To do this Scottish Water engaged WRc Infrastructure to provide a means of gathering valuable asset condition information on a 15 km strategic section of 30” pre-stressed concrete trunk main. Central to the delivery of this project was the need to overcome the challenge of gathering the required condition information whilst maintaining full operability of the pipeline.
The Solution
Following detailed planning by the WRc team, Pure Technologies and Scottish Water, a robust inspection plan was developed that centred on the utilisation of the in-line free swimming SmartBall® and PipeDiver® inspection systems. The first phase of inspection was conducted using the leakage detection capabilities of SmartBall®.
The survey marked the first European deployment of PipeDiver® and served to establish the benefits of this pioneering approach to asset management.
Secondly, the PipeDiver® platform provided pipe wall condition assessment via detection of wire breaks in the pre-stressed concrete main.
The Outcome
WRc Infrastructure helped Scottish Water to better target investment by combining the technological benefits of SmartBall® and PipeDiver® to inspect the asset condition of 15 km of strategic trunk mains without disturbing operations.
PipeDiver®
from Pure Technologies (Xylem)
PipeDiver® is a free-swimming, high-resolution pipe inspection tool for largediameter pipe inspections. Not only does it operate while the pipeline remains in service, but it is also capable of inspecting the condition of 40 kilometres or more in a single deployment. Inserted and extracted under pressure through a 300 mm tapping, PipeDiver® can be used in pipe diameters from 300 mm to 3000 mm.
This inspection technology provides high resolution pipe wall analysis, and enables remaining-life assessment for metallic and pre-stressed concrete cylinder pipe (PCCP) mains, as well as wire break detection for PCCP.
The SoundPrint® acoustic fibre optic system we have installed, in conjunction with the condition information from previous PipeDiver® surveys, allows us to accurately monitor the condition of our trunk main and plan interventions to ensure the most resilient and reliable water supply to our customers. We made the decision as a company to create intervention points based on the Finite Element Analysis, allowing us to create work packs to manage sections of pipework that are highlighted in the tool. A secondary benefit of this work means that we have more generic intervention work packs prepared for the functional sections of the pipe that can be accessed by our Intelligent Control Centre in the event of an incident, allowing them to action any required intervention faster meaning less disruption to our customers.
- Ian Dunsmore, Team Leader Strategic Water Infrastructure, Scottish Water
Acoustic Fiber Optic (AFO) System
For acoustic fibre optic (AFO) analysis of pipelines, WRc Infrastructure deploys Xylem’s SoundPrint® AFO system, which is an industry-leading technology consisting of a fibre optic cable installed inside the length of a pipeline. Used in conjunction with a data acquisition (DAQ) system, this sophisticated AFO system allows detection and identification of the precise location of any breaks in the pre-stressing wires as they occur. As the wires break, the structural integrity of the main is reduced. Once a critical number of wires have broken in an individual pipe section, the main is at risk of catastrophic failure, with potentially devastating impacts.
AFO Case Study
Xylem’s SoundPrint® System with SmartBall® and PipeDiver®
Client: Scottish Water
The Challenge
The Blairlinnans water main, owned and operated by Scottish Water, is a 42-inch, prestressed concrete pipeline that runs over 16 kilometres from the Blairlinnans water treatment works to a service reservoir in West Dunbartonshire, Scotland. The pipeline was installed in 1974 and is a critical asset in Scottish Water’s water network. Due to the high consequence of failure, SW required a complete engineering assessment to understand the true condition of the pipeline and to then actively manage its integrity.
The Solution – Part 1
In 2022, Scottish Water partnered with WRc Infrastructure and Xylem to inspect the Blairlinnans water main using SmartBall® and PipeDiver® in combination with detailed engineering analysis.
The Outcome – Part 1
The inspection showed most of the pipeline to be in good condition, though some pipe sections (around 2%) were found to have broken, pre-stressed wires that were critical to support the pipeline’s integrity. The low percentage of damaged pipes was not enough to warrant a complete replacement.
The Solution – Part 2
To actively manage the Blairlinnans water main and extend the life of the asset, Scottish Water opted to install Xylem’s SoundPrint® AFO system – a first of its kind within Europe. Fibre optic cable was installed inside the length of the pipeline, in conjunction with the DAQ system, allowing detection and identification of the precise location of any breaks in the pre-stressing wires as they occur. (Once a critical number
of wires break in an individual pipe section, intervention is required to avoid catastrophic failure that could have potentially devastating impacts.)
The continuous monitoring enables evidence-based decisions to be made about which sections of pipe need immediate repair and which sections can be deferred.
The Outcome - Part 2
The inspections and continuous monitoring have allowed Scottish Water to:
• Reduce the risk of failure by preemptively maintaining areas known to be in poor condition.
• Achieve cost savings by extending the life of remaining pipe sections that show either no damage or low-medium deterioration.
• Minimise water supply disruptions to customers.
• Maintain the utility’s public reputation as a forward-thinking, reliable service provider.
• Reduce their CO2 footprint by offsetting emissions associated with pipeline renewal.
WRc delivered the first Acoustic Fibre Optic (AFO) in-pipe monitoring system to inform UK water companies in real-time of wire breaks in prestressed concrete pipes, helping avoid many catastrophic pipe bursts.
Drone Surveys
In partnership with our sister company Scan Station (RSK Orbital), WRc can deliver technical drone inspection services using high resolution camera systems that are capable of delivering everything from total asset mapping to close inspection work.
The powerful drone technology deployed by WRc uses computer vision and laser scanning to produce 3D live mapping of assets, such as internal pipelines, sewer lines and confined spaces. The drones’ SLAM-based stabilisation makes them collision-resistant and steady, even in harsh flying conditions.
Each drone can be equipped with a 10,000-lumen lighting system, 4K video camera system, thermal, and a LiDAR unit, allowing them to take measurements as they fly and produce high-density pipe profiles, which can be fed back live to the operator. On-site engineers can immediately diagnose where maintenance and repairs are needed, and all stakeholders are able to clearly visualise inspection outputs.
Drone Case Study
Drone - Pipe and leak location in a rising main located in an estuarine riverbed
Client: Confidential
The Challenge
A 400 mm rising main was thought to run along the course of an estuarine river, but the exact course of the pipe was unknown. In addition, a small sink hole had appeared along the river bank, and the client needed to know if this was near the pipe and could be the result of leakage from the pipe. As much of the pipe ran in the river, this posed a significant access and health and safety issue and could not be mapped by traditional means.
The Solution
As the river was tidal, a day and time was chosen when the river was very low and the temperature was very cold. Where the pipe could be accessed by land, the Sahara® system was deployed in the pipe, which enabled the use of a Cable Avoidance Tool (CAT) and Signal Generator (Genny) to accurately locate the pipe’s line and depth.
A drone was then deployed to visually locate the line of the main in the riverbed. The drone also provided thermal imagery to identify any potential leaks in the pipe, which may appear
foot.
Infrastructure Investigation Consultation Process
WRc Infrastructure prides itself on delivering bespoke inspection surveys designed to meet a client’s needs.
Right at the beginning of the process, WRc Infrastructure develops an effective communication and collaboration system between the team and the client - an essential step to ascertain a best-fit investigative solution tailored to the client’s specific needs. Through constant dialogue and a clear line of communication we listen carefully to the client’s requirements, concerns and expectations. This provides valuable insights into the client's objectives, operational constraints and desired outcomes. Active listening from our team ensures that all client inputs are thoroughly understood and considered during the solution-development process.
We won’t just deliver a survey, we make sure it’s the right survey!
We work alongside the client at every step of the way, from choosing the appropriate technology to assisting with the design of enabling works (if required), discussing operational requirements through to the analysis and explanation of their results.
Our collaborative approach not only enhances the understanding of a project’s requirements but also fosters a sense of ownership and partnership between WRc Infrastructure and the client. This ultimately leads to a successful project outcome and strengthened client relationships.
WRc Infrastructure’s team reviewing project plans with a client
Programme Delivery Service
WRc Infrastructure can provide both programme and project support, either on a project-by-project or portfolio basis. With access to a range of programme management tools, we can provide strategic controls to manage a range of surveys and their associated activities. This could extend into forward work planning for 12 months and beyond.
The programme can provide key milestones and dependencies, and we have developed business intelligence reporting to give a wider insight into performance. At delivery level, WRc has an end-to-end scheduling tool that manages work progression and status, and gives daily updates on survey performance; a clear example of this is the Thames Water Invasive Leak Detection Framework.
The WRc Infrastructure Team
WRc Infrastructure includes experienced office staff - a project manager, quantity surveyor and planner - and highly trained field-based staff, with 16 Sahara®-trained technicians varying in development from trainees through to team leaders.
Team Leader Kevin Whittaker has been a member of WRc Infrastructure for 17 years. He works on global projects and specialises in waste water Sahara® and sonar systems. Kevin says, “Every day with the infrastructure team presents a new and interesting opportunity.”
Team Leader Jack Westman has been with WRc Infrastructure for 14 years, specialising in Sahara®, crawlers and drone systems. “I enjoy the variety of work and the technical challenges that we tackle every day,” says Jack.
WRc Infrastructure’s fleet of vehicles:
• 20 low-emission vans
• 2- and 4-wheel drive vehicles
• Tracked vehicles
• AI cameras fitted in cabs for driver safety
• Driver performance monitoring
WRc Infrastructure works closely with our asset resilience and leakage strategy and reduction teams. To review their complementary and unique services, please visit the links below: Asset Resilience
Site Planning Through to Reporting
Planning
WRc Infrastructure offers a complete scheduling service, which is completed via a bespoke planning tool developed in house. Dates are secured in conjunction with the client’s need. However, should the need arise, we have a rapid response team on hand.
Real Time Site Data
A bespoke data collection platform has been developed in house, enabling real-time data collection. Point of Works risk assessments are included, while bespoke templates for different survey technologies can also be provided.
We provide the following types of reporting for our clients:
• PowerBI – comprehensive databases for project performance tracking
• Our reports are issued in industry-standard WINCAN format
• GIS mapping to ensure accurate client records
• Online video transfers
• Online reporting with full imagery and line trace
Traffic Management
Traffic management (TM) can be provided. However, this is usually the responsibility of our clients to arrange.
No other pipeline management or inspection company is better placed to understand and improve the performance of your underground assets. Once a customer, you will benefit from the collective expertise of the extended team within WRc. Together, we bring unparalleled experience, advice, solutions and world-class research legacy to the challenges faced by utilities and industry.
For non-specific enquiries please contact us at: solutions@wrcgroup.com
+44 (0) 1793 865000
For specific enquiries with our Infrastructure team please contact them at:
Dr Dominic Cook Head of Business Development
WRc Infrastructure
+44 (0) 7503 683759 dominic.cook@wrcgroup.com
Find out more
Hamish Ridley
Business Development Manager
WRc Infrastructure
+44 (0) 7917 128619 hamish.ridley@wrcgroup.com
Find out more
Anthony Bond Senior Consultant
WRc Infrastructure
+44 (0) 7932 113 628 anthony.bond@wrcgroup.com
Find out more
Pat Boyle
Non-Destructive Testing & Inspection
Business Lead
+44 (0) 7393 464645 pat.boyle@wrcgroup.com
Find out more
