HYDRA · under the hood

What is actually in the pipe, and how it finds a leak

Every part of the system cut in half. Move the sliders — the physics reacts. No black boxes: a coil, a diaphragm, a microphone on a pipe, a radio in a manhole, and one rule about 3 a.m.

1 · WHERE IT LIVES

The valve chamber at the district inlet

Every district already has one: a concrete box under a cast-iron lid where the main enters and a valve can shut it. Nothing is dug. The flow meter goes in-line, the pressure sensor screws onto a tapping, the node box hangs on the wall, and the antenna sits just under the lid.

  • Lid: cast iron, 40 kg — a radio problem, solved in section 9
  • Depth: 1–2 m, often flooded → everything IP68
  • Power: none. Battery only. That decides the whole design.
street level cast-iron lid valve flow meterDN100 in-line pressure nodeESP32 · LoRa antenna, 5 cm under the lid standing water — normal cutaway
2 · MEASURING FLOW WITHOUT MOVING PARTS

Electromagnetic flow meter, cut in half

Water conducts electricity a little. Push it through a magnetic field and it behaves like a wire moving through a magnet: a voltage appears across it (Faraday). Two electrodes on the pipe wall read that voltage. Faster water, higher voltage. Nothing turns, nothing wears, nothing clogs.

U = B · D · v   →   Q = v · π D² / 4
Bfield from the coils, ~0.01 TDpipe diameter, 100 mmvwater velocity — the sliderUmicrovolts to millivolts, amplified on the node
coil N coil S B field electrodeelectrode voltmeter0.8 mV28 m³/h water → longitudinal cut
1.00 m/s
3 · MEASURING PRESSURE

Pressure transducer, cut in half

A thin steel diaphragm sits between the water and a sealed chamber. Water pushes, the diaphragm bends by a few microns, and four tiny resistors printed on its back stretch and change resistance — a Wheatstone bridge turns that into a voltage. 4–20 mA or 0–5 V out, read every minute at night.

  • Range 0–10 bar, resolution 0.01 bar — a leak 300 m away shows as 0.3–1.5 bar less
  • Screws onto the existing ½" tapping on the valve body
  • Costs €15. Three per district localise to a segment.
sealed referencechamber diaphragmstrain gauges ×4 bridge out3.9 bar19.5 mV bend ×2000
3.9 bar
4 · THE BOX ON THE WALL

The node, opened

Four things in an IP68 box the size of a paperback: a microcontroller that sleeps, a LoRa radio, a lithium pack, and the connectors to the two sensors. It wakes up, reads the sensors, sends ~20 bytes, and goes back to sleep. The battery life comes from how little it is awake.

statecurrenttime / day
deep sleep15 µA23 h 55 min
measure30 mA96 × 1 s
LoRa transmit (SF9, 14 dBm)120 mA96 × 0.3 s
≈ 2.3 mAh / day → 19 Ah pack lasts > 8 years
ESP32-S3wakes 96×/day sleeping · 15 µA SX1262 LoRa868 MHz · 14 dBmSF7–SF12 Li-SOCl₂ · 3.6 V · 19 AhD-cell ×2 · −55…+85 °C antenna, +2 dBi flowpressure IP68 polycarbonate · 180 × 130 × 60 mm · €45 in parts
5 · THE THING WE ARE LOOKING FOR

What a leak does to a pipe

A crack or a corroded hole. Water at 4 bar is forced through a gap of a few millimetres at 20–30 m/s. Three things happen at once, and each one is a sensor:

  • More water enters the district than leaves through taps — the flow meter sees it at night.
  • Pressure falls downstream of the hole — the transducers see a step.
  • The jet screams: turbulence at the hole makes a hiss at 1–5 kHz that travels hundreds of metres along the metal wall — the loggers hear it.

Bigger hole: louder, more flow, bigger pressure drop. Slide it.

soil hiss travels along the wall, both ways pressure along the pipe leak 0.9 m³/h
4 mm≈ 0.9 m³/h · 22 m³/day
6 · THE RULE ABOUT 3 A.M.

Minimum night flow: the leak has nowhere to hide

By day a leak is buried under thousands of taps. Between 02:00 and 04:00 a district of 1,000 homes uses almost nothing — a few toilets, a bakery. Everything else flowing in is leaking out. The system reads the minimum in that window and compares it with the same district's own history.

leak ≈ MNFtonight − MNFbaseline

It is the IWA standard method, usually done by a technician once a year with a clipboard. Here it happens every night, in every district, and the alarm has a confidence score because the baseline is a distribution, not a number.

02–04h 22h02h06h12h18h22h080160 leak 0 m³/h — constant all day, visible only at night consumption
0 m³/hMNF 28
7 · FROM A DISTRICT TO A STREET

Three pressure points cut the district into segments

Water loses pressure as it moves through pipe — slowly if the pipe is healthy. A leak between two sensors is extra flow through that section, so the pressure drop across it is steeper than across the others. Compare the drops, and the leak segment stands out.

Move the leak. Watch which pair of sensors disagrees.

P-B → P-C−0.3 bar · normalP-C → P-D−0.3 bar · normal
P-BP-CP-D 3.9 bar3.6 bar3.3 bar pressure profile
segment B–C
8 · TO THE METRE

Two loggers, one delay, one distance

The hiss from the hole runs along the pipe wall in both directions at the speed of sound in that pipe — about 1,180 m/s in cast iron, 400 m/s in plastic. It reaches the nearer logger first. The two recordings are slid against each other until they line up; the slide needed is the delay Δt, and the delay is a distance.

dA = ( Lv · Δt ) / 2
Ldistance between loggers along the pipe (known, 320 m)vspeed of sound in the pipe materialΔtpeak of the cross-correlation — the slider moves the leak, Δt follows

Loggers are a piezo accelerometer on a magnet, stuck to a valve or hydrant. The crew moves them; they are not permanent.

A B L = 320 m logger Alogger B cross-correlation Δt = 0 ms 160 m from A
160 m
9 · THE TELECOM PART

Getting 20 bytes out of a manhole, 5 km, on a battery

A cast-iron lid and a metre of wet concrete eat 20–35 dB of signal. LoRa is built for exactly this: it spreads each bit over a long chirp so the receiver can dig it out below the noise floor. Slower chirps (higher spreading factor) go further and through more concrete, but cost airtime and battery. The thesis measures this from real chambers and picks the setting per node.

link budget = 14 dBm + 2 dBi + 8 dBi − (path loss + lid loss) ≥ sensitivity
SFsensitivityairtime, 20 Bopen rangefrom chamber
SF7−123 dBm61 ms3 km0.8 km
SF9−129 dBm206 ms6 km2 km
SF12−137 dBm1,483 ms14 km5 km
node under the lid ADE water tower gateway · +8 dBi received power−118 dBm SF9 · margin +11 dB · 206 ms · OK 5.0 km
5 km · 25 dB
© Toufik Zeraguet · toufikzeraguet@wavedz.com