NRW Reduction Technology Training and Capacity Building Project in Malaysia

Transcription

1 NRW Reduction Technology Training and Capacity Building Project in Malaysia Nguyen Phan Kieu Dung *, Norikazu Suzuki *, Hajime Horiguchi * *Business Department, TSS Tokyo Water Co., Ltd., 5F Shinjuku Green Tower Building, , Nishishinjuku, Shinjuku-ku, Tokyo , Japan ( nguyen-phan@tssk.jp; suzuki-norikazu@tssk.jp; horiguchi-hajime@tssk.jp) Abstract TSS Tokyo Water Co., Ltd (TSS) executed the Non-Revenue Water (NRW) Reduction Technology Training and Capacity Building Project in Penang, Malaysia for three (3) years from 2014 by utilizes the funds from Japan International Cooperation Agency (JICA). In this project, TSS first setup the Technical Training Field and provided Water Leak Detector to Penang Water Supply Corporation (PBAPP) and utilized them to conduct training practical skills and know-how on NRW Reduction Technology to PBAPP. Next, these trainers will conduct lectures and train nationwide water operators personnel provided by Ministry of Energy, Green Technology and Water (KeTTHA) in developing human resources in NRW Reduction Countermeasures. This project is an attempt to build such mechanism and reduce the NRW throughout Malaysia. This paper introduces the implementation contents of the project Keywords NRW, Capacity building, Training, JICA, TSS EXECUTIVE SUMMARY Tokyo Metropolitan Waterworks Bureau (TMWB) supplies stable, safe and tasty water to 13 million people. The current water capacity is about 6.9 million m 3 per day. The NRW rate is 3% and boasting the unprecedented lowest in the world. TSS Tokyo Water Co., Ltd (TSS) is established as a subsidiary and partner to TMWB. It undertakes contract management services of various facilities ranging from water sources to water supply equipment in Tokyo. In addition, by utilizing the abundant of experience and know-how of water supply business based on the accumulation of technologies cultivated through TMWB, TSS provide and support NRW reduction and human resource development etc. As part of international contribution, TSS under Japan International Cooperation Agency (JICA) partnership program, a NRW Reduction Technology Training and Capacity Building was carried out for three (3) years from In this paper, we introduce the implementation content of this project. 1

2 OUTLINE OF NRW REDUCTION TRAINING SKILLS AND CAPACITY BUILDING PROJECT Objective The national average for NRW rate in Malaysia is high at 36.6% (2013). For this reason, the Malaysian government has set a goal of reducing the NRW rate to 25% by 2020 and is making efforts to reduce it Unfortunately, it has not improved so easily and in order to achieve this goal, it has added new measures to respond. In this project, TSS first established the technical practice field and provided water leak detector to Penang Water Supply Graph 1. Corporation (PBAPP) and utilizes them to Non-Revenue Water Rate (Each state in Malaysia) instruct staff of PBAPP on practical technical skills and know-how on the reduction of NRW. Next, they will become trainers, train the staff of the water operators companies nationwide, and develop human resources that contribute to measures and reduction of NRW. This project is an attempt to build such a mechanism and reduce the NRW throughout Malaysia. Selection of Counterpart We chose PBAPP as the counterpart for technological transfer and below are the reasons. 1. As of 2013, the national average of Malaysia for NRW rate was 36.6%, whereas PBAPP was the lowest 18.2%, which also holds a certain level of technology on the reduction of NRW. 2. There are also a suitable area for the installation of training ground and classroom for lectures. 3. As there are system for technical staff to be trained as lecturer is in place, it is easy to acquire human resources who could become lecturers. From these reasons, we discussed with Ministry of Energy, Green Technology and Water (KeTTHA) and selected PBAPP as a counterpart for this project as a training place for lecturer development to improve capacity for countermeasures against NRW. In addition, PBAPP is a water operator company, which is responsible to supply water for the entire of Penang State which is located in the northwest of the Malaysian Peninsula. As of 2015, PBAPP has a total water distribution pipe length of 4,346 km, 576,000 clients served and water consumption of daily average of 812,800 m 3. Implementation Outline The project implementation period was about 3 years from January 2014 to November In March 2014, an MOM was concluded and signed within 3 parties; JICA, TSS and PBAPP on JICA grass-roots technical cooperation project, which leads to starting of this project. Later, we constructed and upgraded the training ground and distributed leak detector equipment which was use when we started the training for NRW reduction technology to PBAPP staff from September 2

3 2014. Under the instruction and guidance of TSS, PBAPP staff prepared training textbooks / manuals for training and until January 2016, we groomed 15 PBAPP staff as training lectures. In the final year 2016, for the purpose of further improving the skills of PBAPP staff, we conducted an OJT (on-job-training) on an actual DMA (District Metered Area). And the NRW rate in this DMA has been improved greatly. For the training of Malaysia Waterworks Operators (Workshop), we conducted 4 days training in the first session, and increased to 6 days for the second and third session, with a total of 77 trainees / participants attended. Training Ground Outline The size of the ground constructed is 32 m (length) x 22 m (width). An asphalt road and lawn was constructed as residential area. An underground water distribution pipe with a length of 193 meter was laid, a flow meter and a pressure reduction valve (PRV) were installed in the water inflow section. To imitate DMA, a fire hydrant, water control valve, air valve etc. were also installed. And a part of water distribution pipe was installed above ground so that it is easy to conduct the disassembly and assembly of pipe and air valve. The distribution pipe (φ100mm) consisted of various pipes used in Malaysia (mainly, HDPE (high density polyethylene), others DI (ductile iron), MS (mild steel), AC (asbestos cement). 9 water supply pipes (φ20mm) were connected to the water distribution pipe by using HDPE, PVC (polyvinyl chloride pipe), SS (stainless steel), GI (galvanized steel pipe). In order to conduct water leakage detection work training, a total of 14 water leak holes (2 to 4 mm in diameter) were opened in the water distribution pipe and the water supply pipe. At the location of this hole, drainage facilities were installed underground so that underground leakage did not appear on the ground. Training Ground Installation Work With regard to the selection of construction contractors for training grounds, TSS conducted a tender bidding process with top performance record recommended by PBAPP. From this result, TSS signed a project contract with one company which successfully bid for the project. The construction period was 3 months. In principle TSS staff supervised the construction and PBAPP staff supervised the project during the absence of TSS. As this contractor hired a low-wage piping worker from overseas who has poor knowledge, we provide instruction and guidance to them on how to joint the pipeline properly to ensure that there is no unexpected leakage during construction. 3 Photo 2. Training Ground after Completion of Construction

4 In addition, we instructed on-site cleanliness, safety management, construction management, quality control and they gradually become conscious of making good work. With this, TSS awarded the contractor with a letter of appreciation upon the completion of the construction. Implementation of Lecturer s Training Session The lecturer training for PBAPP staff was carried out separately with classroom training mainly conducted by engineers and Photo 3. Training Ground Elevation View practical ground training conducted by technician at the training ground. As the training period was 3 years, the class lectures was not limited to the general subjects such as General Theory on NRW but we also included explanation of water distribution system, pressure adjustment equipment and Japan 5S (Seiri/Set in Order, Seiton/Organizing, Seiso/Cleaning, Seiketsu/Standardize, Shitsuke/Sustain), Quality & Safety Management as training subjects. In addition, practical training at ground, we conducted leak detection exercise using Listening Rods, Noise Correlator, TS Leak Checker, Helium Gas Detector etc. In addition, we conducted STEP TEST (survey selection of areas with area with highest amount of water leakage by measuring amount of water in a selected area in a sequenced manner by controlling valve operation) in a created DMA with content that are useful training for practical work which consist of the fundamental maintenance of water pipes, removal and installation of air valve / water pipe, valve operation. Finally, we conducted OJT for NRW reduction countermeasures on an actual DMA with the aim to skill up PBAPP staff and we verified the results. The main training items are as shown on the Table 1. Photo 4. Class Training Photo 5. Ground Training (Removal & Installation of Distribution Pipe) With regard to the classroom training, the engineers for the instructor made the training materials, examined and refined the content of training materials based on TSS material together with TSS experts. With regard to practical training at the training ground, TSS asked the technician to 4

5 prepare the Equipment Manual Book of Leak Detection Equipments and the Instructor s Manual Book consisting of Daily Task of Roles and Assignments, Explanation Contents, Time Required, Equipment Used etc. by themselves. The photo 4 and 5 shows the trainer conducting classroom and ground training. Table 1. Main Training Contents Subject MAIN TRAINING CONTENTS Lecture Outline on Measures for NRW Water Lecture Introduction of Training Ground Lecture Method to Construct DMA Lecture Equipment Maintenance(PRV, Air Valve, Water Control Valve, Flowmeter) Lecture Explanation of Equipment related to NRW Countermeasures(Listening Rod, TS Leak Checker, Water Leak Detector, Correlation Leak Detector, Helium gas leak detector, Iron Pipe / Cable Detector, Water Quality Measuring Instrument) Lecture Management of flow and water pressure Lecture Comparison of water pipe repair / pipe replacement work(malaysia and Tokyo) Lecture Comparison of various leak sounds Lecture 5S Quality Control Safety Management (Training acquired in Japan) Lecture Discussion on issues related to each trainee s water utility Practical Filling water in Distribution Pipe, Drainage, Operation on Opening / Closing of Water Control Valve, Confirmation of Closing of Water Control Valve Practical Disassembly, Cleaning and Assembling of Air Valves Practical Piping practice on Water Distribution Pipe(Removing and Installation of Fitting) Practical Equipment Maintenance & Control(PRV, Air Valve, Water Control Valve, Flowmeter) Practical Water Leakage Measurement STEP TEST Practical Leak Detection Practice(Use of Listening Rod, TS Leak Checker, Water Leak Detector) Practical Leak Detection using Helium Gas Practical Connection work of Water Service Pipe from Water Distribution Pipe OJT Practical training on NRW countermeasure in actual DMA On-Site OJT Training on NRW Reduction In the final period of the trainer`s training course in July 2016, we conducted OJT to reduce NRW at an actual DMA. We introduce the contents below. At PBAPP, a total of 229 DMA zone has been developed with 145 zone in peninsular Malaysia and 84 zones in Penang Island. Within this DMA, there is DMA [Sungai Gelugor] with a sudden increase in NRW rate. During PBAPP investigation, they were unable to pinpoint the cause, therefore, we conducted an actual survey as OJT. Work Steps in Water Leakage Survey Training As preparatory work, we confirmed the DMA drawing and data on flow rate and pressure and carried out on-site investigation by the following procedure. 1 Analyze data of calculated NRW 2 Investigate water leakage at meter, valve and road surface 3 Replacement of faulty meter, 5

6 Repair Work of water leak 4 Analyze improvement results data, organizing tasks 5 Report results to PBAPP Analysis of DMA Water Inflow volume & Meter Reading Volume In the field survey where the past data was reviewed we can see a big difference in Meter Volume data in February 2016 as compared to December There was no significant change in the amount of water inflow to the DMA and the Graph 7. Analyze of Water Volume History Data amount of water meter reading for housing, but there was a reduction by half in the amount of water at the meter used for construction. Based on this result, abnormality of construction meter was already suspected during the preliminary survey stage. Results of On-Site Survey Discovery of Faulty Meter used for Construction During day time sound listening work, we found a faulty large diameter meter (Not moving: 1 point, Slow moving: 1 point). This meter is a temporary meter with a diameter of φ50, connected to nearest water route with Polyethylene. The water supply pipe was laid and was supplied to the high-rise residential building construction area along the coast. φ50hdpe pipe Leakage Volume 11l/min Discovery of Water Leakage in Water Supply Pipe Photo 8. Leakage Condition We found water leak at 5 points. As shown on photo 8, there is a vertical crack of about 3 cm in length in a φ50mm polyethylene pipe. The leakage volume was 11l/min. We noticed many pavement repair marks on nearby roads and this was telling us that there are many leak incidents along this route. Discovery of Illegal Water Supply Pipe Connection We also found one (1) illegal connection where a meter was not installed at the steps of a house under construction. Since the water supply pipe used was a polyethylene pipe, it is easily to connect illegally as it was only stopped with a bending and tight with a rope. Estimating NRW rate after improvement During the period of this training, 2 faulty meter was replaced, one(1) leak point was repaired out of 5 leak point found. One Photo 9. Water Meter Replacement 6

7 of the possible cause why a meter was not running is due to mud like adhesion found in the Y type strainer. Results calculated after meter replacement and leak repair, the NRW rate as of June 2016 has improved from 26.7% to 15.1%. During this OJT, we have identified that the cause of the increase in NRW were due to faulty φ50 meter and occurrence of water leaks. Base on the result of discussion on the cause of they could not grasp the situation accurately is due to that the weakness in the meter reading department when conducting meter reading plus the lack of information and knowledge sharing between meter department and NRW department. Training for Trainers in Japan In 2015 and 2016, we invited 5 trainee instructors in each year to Japan where they visited Tokyo Metropolitan Waterworks Bureau and learned advanced technology, quality control, strict observation on time and discipline and the actual situation on 5S (Seiri, Seiton, etc). The place visited were, water source and water intake facility, water purification plant, construction site for shielding of large diameter water distribution pipe, construction site for small diameter water distribution pipe replacement, water operation room for water supply/distribution facility, training development center to develop human resource, customer center and water supply history museum. In addition, we also visited a private enterprise manufacturing water supply pipe where they practiced strict 5S and quality control. Photo 10. Distribution Pipe Replacement Work Photo 11. Raw Water Communication Pipe Shield Work Training for Water companies Nationwide(Workshop) TSS and PBAPP cooperated to conduct the workshop with the assistance of KeTTHA in inviting trainees from water operators from each state where the lectures was conducted by PBAPP trainers. To the interested participants, in addition to years of experience in NRW and work attachment, we requested the participants to submit survey answers before the workshop on NRW rate of each operation utilities and issues faced by the organization which will be used for the discussion on the final day. Base on the survey the most frequent reason why NRW did not decrease lies on these 4 elements; Lack of manpower, Lack of necessary knowledge, Lack of water detection equipment and Lack of funds. The duration of the workshop was approximately 6 days. The main training contents are lectures on NRW management and various practical training at the training ground. In practical training, trainees used water leak detectors to determine the presence or absence of leakage from the road and identified the water leak location. At the same time we also carried out Step Test, 7

8 Maintenance Training by disassembling and assembling of pipes and air valves, draining and supplying water in water network, installing water supply pipe branch. Feedback received from the participants is that it was easy to understand for both theory and practical training; and information received was useful for future work. In latter part of the training, participants were asked to share the problem faced in each state and exchanged opinions between trainees and trainee lecturers to help information sharing and problem solving. During the Closing Ceremony, we introduced Japanese manufacturers where they each make presentation on their products (corrugated stainless steel pipe, electromagnetic flow meter, HDPE pipe and hole punching equipment for water service pipe). Below are the photos (Photo 12 to 15) showing the actual situation of the workshop. Photo 12. PBAPP Staff as Trainers (Air Valve) Photo 13. Leak Detection Practical by participants from nationwide Photo 14. Hands On by nationwide trainees on connecting water pipe Photo 15. Introduction of Product Technology by Japanese Water Companies CONCLUSION With this project, we constructed a training ground in PBAPP and prepared various water leak detection equipment. By utilizing them, we trained 15 PBAPP staff as trainers on NRW reduction technology over the period of three (3) years and they in turn trained 77 trainees from all water operators throughout Malaysia. In this training, we incorporated not only the fundamentals and practical skills of NRW management but also Japanese 5S (seiri, seiton, etc.) which are important for the spirit in working. Through the training, we are able to feel the strong desire for work improvement in the staff of Malaysia Water Works operators. In the future, the PBAPP trainers who has acquired the know-how of NRW management will continuously train personnel who can contribute to reduce NRW utilizing the training ground and leak detection equipment provided by JICA. Thus, we anticipate that the entire Malaysia NRW rate will be improved further. 8