Summary Report Feb 2010 (Rev 0)

Abu Dhabi Distribution Company
Condition Assessment and Energy

Management Survey of ADDC Water
Pumping Stations
Summary Report
February 2010
Contents
1. Introduction 1
1.1 Project Objectives 1
1.2 Project Scope 1
1.3 Purpose of Report 1
2. Pumping Station Assessments 2

2.1 Number of Water Pumping Station Assessments 2
2.2 Assessment Methodology 2
2.3 Safety Assessments 2
2.4 Condition Assessments 2
2.5 Performance and Efficiency Assessments 3
2.6 Vibration, Alignment and Noise Assessments 3
2.7 Operations and Maintenance Assessments 3
2.8 Asset Maintenance and Management Strategies 4
2.9 GPS Location of ADDC Pumping Stations 4
2.10 ADDC GIS Object Numbers 4
3. Safety and Compliance 5

3.1 Relevant Laws, Decrees and Regulations 5
3.2 Existing Safety Issues 5
3.3 Safety Improvement 6
4. Civil Asset Maintenance and Management 8

4.1 Asset Lives 8
4.2 Civil Asset Management 8
5. Electrical Asset Maintenance and Management 10

5.1 Overview 10
5.2 Quality of Maintenance 10
5.3 Availability of Maintenance 11
5.4 Requirements of Maintenance Management 11
5.5 Instrumentation Maintenance 11
5.6 Attitudes towards Maintenance 11
5.7 Recommendations 12
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
Summary Report
6. Energy Management 13
6.1 Overview 13
6.2 Constraints 13
6.3 Pump Motors 13
6.4 Control Systems 13
6.5 Electrical Supply Infrastructure 14
6.6 Station Cooling and lighting 15
6.7 Pumping Duty Cycle 16
6.8 Energy Management Recommendations 16
7. Motor Control Systems 17

7.1 Overview 17
7.2 Emergency Power 17
8. Mechanical Asset Maintenance and Management 19

8.1 Overview 19
8.2 Findings and Observations 19
8.3 Recommendations for Existing Pumping Stations 26
9. Technician and Operator Training 31

9.1 Overview 31
9.2 Operation Scenarios 31
9.3 Current Situation 31
9.4 Operator Skills 32
9.5 Effects of Maintenance 32
10. GIS Object Identifiers 33

10.1 Review of GIS Object Identifiers 33
11. Conclusions and Recommendations 34

11.1 Relevant Data and Reports 34
11.2 Conclusions 34
Table Index
Table 1 Number of Pump Stations with Non-Compliant
Safety Assessments 6
Summary Report
Table 2 Asset Condition Assessment Rating 8
Figure Index
Figure 1 Typical Pump-Motor Configuration 3
Figure 2 Broken External Light Fittings 10
Figure 3 Metering Box with Exposed Cables 12
Figure 4 Exposed Manholes (Electrical & Sewer) 12
Figure 5 Flat versus Steep Performance Curves 20
Figure 6 Typical Pump Performance Curve 20
Figure 7 Pump Efficiency versus Flow 21
Figure 8 Pumping Power, Pressure and Flow versus Pump
Speed 21
Figure 9 Pump Best Efficiency Curves 21
Figure 10 Pump Curve - Sila Border Post PS, Western
Region (Pump 1) 22
Figure 11 Pump Curve - Bainounah Palace, Ghayathi,
Western Region (Pump 1) 23
Figure 12 Pump Curve - IPS2 Ghayathi, Western Region 23
Figure 13 HH Sheikh Zayed Palace, Delma 24
Figure 14 Samha East PS - Spring Loaded Check Valve and
Gear Operated Butterfly Valve 25
Figure 15 Samha East PS - Additional Pump Steel Fixings 25
Figure 16 Magnetic Motor-Pump Shaft Coupling 26
Figure 17 Energy Savings with Magnetic Pump-Motor Shaft
Couplings 27
Figure 18 Pump Control Valve in In-Line and Angle
Configuration 28
Appendices
A Pumping Station Codes, Identifiers and GPS Coordinates
B Site Safety Assessment
C Civil Assets Assessment
D Pumps and Motors Assessment
E Other Equipment and Systems
F Maintenance and Management Strategy
G ADDC GIS Object Numbers
Summary Report
1. Introduction
1.1 Project Objectives

The objective of this project is to develop a prioritised maintenance and management strategy that
extends the life and reliability of some 39 water pumping stations managed by the Abu Dhabi Distribution
Company (ADDC).
1.2 Project Scope

The scope of activities for this project includes:
1. Collect and review available technical information to conduct the pumping station condition
assessment of ADDC’s water pumping stations located in Central, Eastern, and Western Regions;
2. Develop a methodology for condition and performance assessment;
3. Conduct a Pilot Test on 3 pumping stations and submit an assessment report for review by ADDC;
4. Upon ADDC approval, complete condition and performance assessments on the remaining pumping
stations;
5. Produce a Condition Assessment and Energy Management Report on each of the nominated water
pumping station; and
6. Produce a final Summary Report on facility maintenance and management strategies for all water
pumping stations.
1.3 Purpose of Report

This Summary Report summarizes all data, findings and recommendations of GHD’s condition
assessment of ADDC’s water pumping stations and includes:
Plant/equipment identified for replacement, overhaul, upgrade, investigate further or no action
required;
Recommendations for further actions including:
– Equipment condition monitoring;
– Energy management;
– Operator training;
– Technicians training;
– Operator management improvement; and
– Maintenance management improvement.
This report should be read in conjunction with the “Assessment Overview Report (GHD, Nov 2009)” and
the individual “Condition Assessment and Energy Management Pumping Station Survey” reports (GHD,
Dec 2009 and Jan 2010) for each of the pumping stations.
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations 1
Summary Report
2. Pumping Station Assessments
2.1 Number of Water Pumping Station Assessments

Initially, 39 water pumping stations were nominated for assessment under this project. However, upon
inspection of each of the sites, GHD’s field team found that only 37 water pumping stations were
operational.
Bida Al Mutawa Pump Station, Western Region was duplicated in the ADDC records.
Mirfa Truck Filling Station (TFS), Western Region exists but was abandoned some 2 years ago.
2.2 Assessment Methodology

The methodology for infrastructure and equipment condition and performance assessment is described
in the “Assessment Overview Report (GHD, November 2009)”.
2.3 Safety Assessments

In accordance with GHD’s Job Safety Plan1, GHD’s site team supervisor conducted a safety assessment
upon entering each pumping station facility. If the safety assessment identified any areas (buildings,
structures) or equipment considered unsafe, this was immediately reported to ADDC staff or contractors.
GHD’s site safety assessments are detailed in the individual Pumping Station Assessment Reports and
summarised for all pumping stations in Appendix B.
2.4 Condition Assessments
2.4.1 Civil Assets

Condition assessments of the following civil assets are detailed in the individual Pumping Station
Assessment Reports and summarised for all pumping stations in Appendix C:
buildings and general infrastructure;
storage and transfer water tanks; and
pipework and valving.
2.4.2 Pumps and Motors

Condition assessments of the pump and sets in each pumping station are detailed in the individual
Pumping Station Assessment Reports and summarised for all pumping stations in Appendix D:
1
Job Safety Plan for Consultancy Services for Condition Assessment and Energy Management Survey of 39 Nos. of Abu Dhabi
Distribution Company (ADDC) Pumping Stations (GHD, 22 June 2009).
Summary Report
2.4.3 Other Mechanical and Electrical Assets
Condition assessments of mechanical, electrical and instrumentation assets (other than the pumps and
motors) are detailed in the individual Pumping Station Assessment Reports and summarised for all
pumping stations in Appendix E.
2.5 Performance and Efficiency Assessments

The hydraulic performance of each of the pump sets against Original Equipment Manufacturer’s (OEM)
specifications are detailed in the Individual Pumping Station Assessment Reports and summarised in
Appendix D.
2.6 Vibration, Alignment and Noise Assessments

Vibration and alignment assessments for each of the pump sets in each of the pumping stations are
detailed in the individual Pumping Station Assessment Reports and summarised in Appendix D.
2.7 Operations and Maintenance Assessments

An assessment of the pump station operational and maintenance practices are detailed in the individual
Pumping Station Assessment Reports together with recommendations for addressing identified issues.
Figure 1 Typical Pump-Motor Configuration
Summary Report
2.8 Asset Maintenance and Management Strategies
Appendix F presents a range of recommended actions and strategies for asset replacement, overhaul,
upgrade, further investigation or no action for each of the assessed pumping stations.
2.9 GPS Location of ADDC Pumping Stations

During the assessment of the condition of ADDC’s water pumping stations, GHD recorded the Latitude
and Longitude of the main entrance gateway to the compound using handheld Geo-Positioning System
(GPS) unit. If a compound fence and gate were not present, GHD recorded the approximate location of
main access point to the pumping station facility and recorded each station’s coordinates in the individual
Pumping Station Assessment Reports.
A summary of all GPS coordinates are provide in
2.10 ADDC GIS Object Numbers

Appendix G provides a summary of the GIS object numbers recorded on ADDC Geo-database as
identified by GHD for each of the assets at each pumping station.
Summary Report
3. Safety and Compliance
3.1 Relevant Laws, Decrees and Regulations
Site safety includes the provision of appropriate accommodation and amenities for operating personnel.
ADDC is a "nominated entity" under the Abu Dhabi Environment, Health and Safety Management
System (EHSMS) Decree. All the requirements listed in the Abu Dhabi EHSMS Code of Practice No. 10
are enforceable, including;
working at heights;
electrical safety;
occupational noise;
living and accommodation conditions (including specific requirements for working in remote
locations);
communications; and
site access, egress and security.
All of the following laws, decrees and regulations have specific requirements in relation to the safety
issues and recommendations presented in the individual Pumping Station Assessment Reports and
summarised in this report:
Federal Law No. 8 (1980) - Regulations of Labour Relations;
Ministerial Order No 32 (1982) - Regarding Determination of the ways and means to Protect
Employees against Occupational Hazards;
Cabinet Decision No. 13 of 2009 - General Standards Labour Accommodation;
Decree No. 42 of 2009 - Regarding the Abu Dhabi EHSMS; and
AD EHSMS CoP 10 - Occupational Health and Safety.
3.2 Existing Safety Issues

GHD’s site safety assessments are detailed in the individual Pumping Station Assessment Reports and
summarised for all pumping stations in Appendix B. The numbers of pumping stations that are non-
compliant with current legislations or unsatisfactory across the range of safety areas assessed during
this project are provided in Table 1 below.
Summary Report
Table 1 Number of Pump Stations with Non-Compliant Safety Assessments
No. Pump Stations where:
HAZARD Immediate Action Some Action
is Required is Required
Electric Hazards 16 1
Lighting 15 5
Noise 12 2
Site Security 8
Lock Out / Tag Out 7 2
Housekeeping (General Tidiness) 6
Mechanical Hazards (e.g. Unguarded Plant) 5 2
Ladders / Scaffolding/ Access Ways 5 1
Fire Hazard and Equipment 4
OTHER - Water Quality / Health Hazard 4
Site Access and Egress 3 2
OTHER - Telephone Communication 2
Knowledge of Site Safety Rules 1
Site Emergency Procedures 1
OTHER - Structural Safety Hazard 1
Dust / Fumes
Hazardous Substances
Working at Heights
Pressurized Equipment
Heat Illness / Stress
Personal Protective Equipment (PPE) 5
Confined Space Entry
3.3 Safety Improvement

All safety issues highlighted in individual Pumping Station Assessment Reports must be individually
addressed and positively resolved. Therefore, it is inappropriate to highlight particular issues. The
recommendations below represent the major and general items found on most of ADDC pumping
stations.
Recommendations
Issue Personal Protective Equipment (PPE) to all ADDC pump station operators and insist that
visitors and guests provide their own PPE, rather than rely on the local pump station staff having
spare PPE available.
Provide planned, periodic first aid and safety training to all ADDC pumping station operators.
Establish and train operators in emergency procedures (call for help, emergency alerts) for all
pumping stations - especially for remote stations.
Develop English literacy of pumping stations operators so they can read and comprehend safety
manuals, equipment instructions, equipment safety bocks, etc. and report findings and operational
data accurately.
Summary Report
Attend to all electrical, mechanical and general hazards as listed in individual reports.
Install, repair or replace and reinstate to full operation:
– all external lights within pumping station compounds; and
– all internal lights in pump rooms, control rooms, elevated towers, technical rooms and access
corridors within all station buildings and structures where personnel access is required.
Provide lockable and locked access hatches to all storage tanks and elevated tanks for protection of
water quality supplied to the public.
Ensure no unauthorised site access is possible.
Provide accommodation of pumping stations operating personnel (as described in current UAE Safety
Laws).
Clean up and perform routine housekeeping on all pumping stations to ensure personnel safety.
Summary Report
4. Civil Asset Maintenance and Management
4.1 Asset Lives

Pumping station asset service lives typically range from around 8 years for electronic assets (e.g.
instrumentation and sensors) to 70 years for ‘long life’ civil assets (e.g. buildings, concrete tanks, roads,
etc). The actual length of service life is determined by the nature and frequency of scheduled
maintenance, programmed rehabilitation or renewal work on these assets.
The higher the ‘criticality’ of individual assets, the more frequent condition assessments should be
undertaken to provide confidence of the asset’s reliability and remaining service life.
The condition assessment and rating score provided in this Summary Report and in the individual
Pumping Station Assessment Reports includes a preliminary assessment of the remaining asset service
life as shown below in Table 2.
Table 2 Asset Condition Assessment Rating
LEGEND - Asset Condition Assessment
Description Life Remains Rating
"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
Failed / Derelict Un-useable 6
4.2 Civil Asset Management

It is important that the assessment criteria used is consistent on all assets throughout their service lives
to ensure comparative analyses can be undertaken between similar assets across the Emirate and over
time. These regular condition assessments provide valuable information on average asset lives for input
to setting appropriate design specifications and undertaking asset revaluations.
Civil assets are generally long-life assets (50-80 year lives) and typically show few visible signs of aging
in the first half of their service lives.
Recommendations - General
Regular, independent, condition assessment against set assessment criteria, such as those in the
Assessment Overview Report (GHD, Nov 2009), should be undertaken every 5 years (max) throughout a
civil asset’s life.
As the asset enters the last 25% of its service life, visual inspections should be undertaken more
regularly (say, every 3 years) and supplemented with materials testing until the asset is disposed of,
rehabilitated or replaced.
Summary Report
Recommendation - Storage Tanks
The individual Pumping Station Assessment Reports and this Summary Report specifies whether
material testing of the water storage and elevated tanks should be undertaken, based on the visual
inspection undertaken in this Project to more accurately assess the remaining service lives of these
critical assets (refer Appendix C).
Recommendation - Buildings, Roads and Fences

The civil assets of Buildings, Roads and Fences are not critical to the primary function of pumping water,
and are considered and managed as supporting assets and services. These assets must be assessed
against, and remain compliant with, Environment, Health and Safety Management requirements
throughout their service lives.
Summary Report
5. Electrical Asset Maintenance and Management
5.1 Overview
Provision of a critical service (e.g. water supply to a community) includes both scheduled, routine and
repair maintenance as an integral part of the provision of service and is accepted and planned for in
operational staffing and budgeting.
However, this scheduled, routine and repair maintenance was not apparent with the majority of the
systems inspected in the pumping stations visited.
An exception appears to be a regular inspection of fire alarm systems. However this inspection does not
fully extend to repairs or to the provision of a maintenance log book, held locally at each station.
Maintenance logs were not evident or available during inspections.
5.2 Quality of Maintenance

Where routine or repair maintenance has been observed, it is inconsistent in quality. Instances of fire
alarm systems having individual circuits taken permanently out of service, rather than repaired, have
been noted. A further example is found in the area of external lighting. The installed mast type fittings
frequently fail (refer Figure 2).
It appears that they are not repaired and that ordinary interior fittings are then fitted to provide essential
lighting, often of mechanical tank level gauges. The fittings and the wiring are not safe, or are
inappropriate. It is not clear if the fittings are installed by the maintenance engineers or the operators (in
desperation) but it does indicate a failure of maintenance practice.
Figure 2 Broken External Light Fittings
Summary Report
5.3 Availability of Maintenance
At many pumping stations, operators state that reported faults are not actioned and that they are not able
to obtain simple spares that they are capable of fitting themselves when required (e.g. lamps for pilot
indicators and spare lamps for interior lights).
5.4 Requirements of Maintenance Management

A maintenance ‘system’ must include:
Regular inspections by competent persons;
Immediate action by the inspecting team on items that pose a safety risk;
Response to faults logged by operating staff, including an estimate of when action will be undertaken
and any remedial or immediate work-around solutions;
Scheduled maintenance of specific plant items (e.g. fire alarm systems, motor lubrication at set hour
intervals etc.); and
A set of procedures that minimises temporary solutions being implemented and ensures that such
solutions are logged with the action taken and an estimate of when permanent action will be
undertaken. It may be that a ‘solution’ can wait for the next scheduled inspection, but the logging will
ensure that appropriate spares and tools are taken to site.
5.5 Instrumentation Maintenance

Most stations have some instrumentation failures ranging from simple lamp or clock failures to most
metering being out of order. Repair or replacement has been noted as taking a long time to occur (if at
all).
The instrumentation failures that were noted by GHD are considered premature, suggesting that simple
replacement of damaged or failed parts will only lead to further early failures. Instrumentation should be
examined at the time of repair to ascertain, as far as possible, the cause of failure and then steps need to
be taken to prevent further premature failure.
We suspect that a majority of faults are caused by fluctuating power supply regulation and by power
supply surges. All stations are at particular risk, due to their location, from electrical surges caused by
lightning. Flow and pressure instrumentation is particularly sensitive to surge damage from this cause.
Further, it was noted that many station operate with individual phase voltages above 230 V AC which is
the general upper limit for mains powered equipment. Motor power supplies voltages need to be
maintained below this level.
5.6 Attitudes towards Maintenance

Maintenance and the standard of maintenance achieved reflect the attitude of senior management. Only
when senior managers demand that maintenance is of a high standard will this be realised as an
improvement in equipment reliability. Examples of the current standard of maintenance are shown below.
Figure 3 shows an external metering box at an ADDC depot. The enclosure is sub standard and the
metering cables are fully exposed. In the background exposed cables may be seen.
Summary Report
Figure 4 indicates significant safety issues as two manholes are left exposed. As the broken covers can
be seen lying nearby, it would appear that the situation has not occurred recently. While this situation
exists in a depot, outlying stations will not be maintained to a higher standard.
Figure 3 Metering Box with Exposed Figure 4 Exposed Manholes (Electrical &
Cables Sewer)
5.7 Recommendations
Maintenance quality and completeness is to be specified and directed as a Management Objective.
Conduct an annual thermo scan on all major switchboards, control panels and motor cable
terminations. This will find most common faults.
During the course of these pumping station assessments, electrical testing did not indicate that motor
resistance testing was going to show anything useful. Load tests showed that some motors were
operating in overload conditions, but this should have been clear apparent at station commissioning
and doesn’t need to be checked annually.
Maintain a log of maintenance actions to be kept on each site and regularly reviewed by Senior
Management staff.
Specific, routine maintenance tasks, able to be performed by operators, should be defined and
appropriate training given to the operators.
A procedure to obtain maintenance spares is to be formulated and implemented.
Instrumentation repairs are to be logged and the cause of fault is to be determined, wherever
possible.
Summary Report
6. Energy Management
6.1 Overview
The Abu Dhabi Distribution Company (ADDC) has a mandate to manage its operations as efficiently as
possible. The sole power source used to distribute water, apart from tanker deliveries, is electricity and
therefore the management of electric power is a principal concern to the ADDC. Power is consumed
within a pumping station by:
Pump motors;
Control systems;
Electrical supply infrastructure;
Station cooling and lighting; and
Various station systems (e.g. fire alarms, exterior lighting)
6.2 Constraints
As water supply is a critical service, energy management must be examined in the context of water
supplied on an ‘as required’ basis rather than on the basis of greatest efficiency. Accordingly, elevated
storage tanks may need to be kept filled to within a narrow range of head rather than filled on, say, the
basis of average daily usage with the consequent pressure variations. Thus, a clear statement of these
operational constrains needs to be formulated for each station before detailed management strategies
can be considered.
During the conduct of the pump station assessment, there was no evidence that the operators have a
clear understanding of the operational constraints and requirements of their stations. Some stations
appear to be run only to change water in the tanks where distribution pressure is sufficient to supply the
needs of the distribution network. Other stations are required to boost pressure for tanker filling to reduce
waiting times. These operations are not energy efficient but are time and cost effective.
6.3 Pump Motors

Pump motors were observed to be as efficient as appropriate for their frame sizes. As a general
observation, motors and pumps are typically oversized for their required duty cycle and therefore the
pursuit of high efficiency for a particular motor may not achieve worthwhile gains. Motors should be
corrected of power factor, as discussed in Section 6.5.1.
Recommendation
When new motors are purchased for new installations, or for replacement, higher efficiency units should
be considered.
6.4 Control Systems

Given the nature of water supply operation, any control system should be operational continually. Control
systems are generally low energy consumers within the context of a whole station. Accordingly, energy
efficiency with respect to controls is not considered further in this report.
Summary Report
6.5 Electrical Supply Infrastructure
Efficiency in power supply is mainly dependent on appropriate selection of components (i.e. cable sizes
and maintenance of a high power factor). Specific comment on the sizing of HT and LT supply cables is
beyond the scope of this report. However, only one instance of significant supply sag with increasing
load was noted during station testing (viz. Liwa Rest House Pumping Station, Western Region).
Generally, where stations are provided with dedicated supply transformers it was noted that these units
were significantly oversized. In many cases units were only loaded to approximately 20% of their
capacity. As few stations are running at near capacity, or requiring more than about 33% of pumping
capacity to be used at any on time, this over capacity represents a significant inefficiency due to standing
‘iron’ losses in the transformer.
If losses are 1- 2 % of full load capacity, a 500 KVA transformer will consume up to 24 x 10 Kw-hr (240
Kw-hr) per day. This may be balanced against a possible pumping requirement of 4 hrs x 30 Kw (120
Kw-hr) per day of productive load. The imbalance is clear.
6.5.1 Power Factor Correction

As the most significant load of each station is inductive, power factors are typically between 0.8 and 0.9.
Improvement in power factor will provide a decrease in the power distribution losses to each station. As
many stations are remote, the savings, while small compared to other possible, efficiency gains are cost
effective to pursue.
A proportion of stations visited were fitted with Power Factor (PF) correction. Installations consisted of:
Automatic correction panels integral to the Main Switchboard (MSB);
Automatic correction panels external to the MSB, typically wall mounted adjacent to the MSB; and
Correction applied to individual motors, fitted internally in the motor control panel.
Where performance could be verified, either by observation of control action or direct measurement only
about 50% of units were working. In some instances controllers appeared to have been connected to the
wrong measuring point, in others the controllers were simply faulty. Where measurement was possible,
only about 50% of capacitors were working and displayed a name plate ‘VAr’. Reasons for the high
failure rate are speculative, but most likely failure is due to over temperature and over voltage/surge
affecting the controller.
Recommendations
To provide surge/spike protection to existing stations, the fitting of an automatic panel represents the
most straight forward option. To circumvent the poor field performance, units should be fitted with surge
protection and thermostatic fans for the capacitor compartments.
For new stations, it is recommended that Power Factor (PF) correction be installed in the motor control
panels and directly switched when motors are operated. As with automatic panels, thermostatically
controlled fan cooling should be provided for the PF panels. As a maintenance aid, a means of testing
operation (e.g. space for clamp meter connection) should be provided.
Summary Report
6.6 Station Cooling and lighting
Consideration of station cooling and lighting needs to be segregated into consideration of the pumping
room and control and amenity rooms. Control and amenity rooms require comfortable air conditioning
and energy management will be achieved in these spaces by the appropriate selection of plant and
placement. Selection of air conditioning plant will be affected by maintenance considerations, however it
was noted that older pumping stations are cooled by packaged, thru-wall systems, which are not energy
efficient.
Recommendation
An air conditioning replacement programme, swapping thru-wall units for more efficient split systems,
would provide significant savings as air conditioners appear to be run continuously. A simple time
control strategy matched to station operating hours could provide additional savings.
6.6.1 Cooling of pumping rooms

Motor life is affected by the ambient temperature of their operation. Therefore, cooling of a pumping
room may have a direct benefit on the life of the installed pump-motor plant. However, cooling comes at
a significant cost in terms of plant and energy required. The situation is made more difficult by the
amount of heat present in the pumped water, which is typically above 40 °C during summer months.
It is considered that the common situation of packaged A/C units mounted to direct chilled air into the
pump room at ground level and up to 2m above the level of the pumps, will not efficiently deliver cooled
air to the pump motors.
In newer stations, the use of ventilation only for the pumping rooms has been observed. Typically, this
takes the form of dust inhibiting air inlet grilles at ground level coupled with high mounted mechanical
extract fans. Only one instance of directed cooling air was observed. In all other situations of this type,
outside air did not directly pass over the motors, serving only to prevent heat build up in the upper levels
of the space. No form of thermostatic control was observed - allowing the situation where outside air
could be warming, rather than cooling an infrequently used or low duty cycle pump room.
Ventilation only cooling also has the effect that the pump room may become uncomfortably hot, making
maintenance in summer months difficult and discouraging regular inspection by operating staff.
Recommendation
Thermostatically controlled, directed air ventilation-only systems should be designed and provided for
pump rooms to deliver the coolest possible air to the pump motors.
6.6.2 Lighting of control and amenity areas

Many station control areas are over lit while generally operated only during the day. However since
lighting does not represent a standing loss, appropriate control by operators is all that is required to
minimise energy losses in this area.
Recommendation
Care should be taken with future stations to ensure that lighting can be controlled such that only the
required level of lighting is used. This could be achieved by reduced general lighting and increased,
locally switched, task lighting.
Summary Report
6.6.3 Lighting of pumping rooms
Pump rooms are all provided with high efficiency lighting fittings, either HID or fluorescent, and these
have been observed to be appropriately controlled, (i.e. used only when necessary).
Recommendation
Simple control by operators, aware of energy saving intentions, will provide an adequate control strategy
in this area.
6.7 Pumping Duty Cycle

While not a direct energy saving item the duty cycle under which pumps are operated has a direct
bearing on the sizing of both pump motors and the supporting power supply infrastructure. Generally
pumps have been observed to operate only a few hours per day. In the extreme, a station may only be
required to operate for 3 hours in the morning. As indicated in Section 6.2, actual operating requirements
are poorly understood, however the energy advantages of operating a smaller pump for 24 hours per day
compared to a larger pump for 3 hours are clear. Power losses will be incurred through:
increased friction losses in the piping system;
power losses in larger motors; and
power losses in large power supply infrastructure.
6.8 Energy Management Recommendations

In a preliminary order of potential energy savings:
Identify, station by station, the actual requirements for operation (i.e. m 3/day, distribution pressure,
etc);
Size pumps to provide a greater duty cycle;
Design thermostatically controlled, directed air, ventilation-only systems for pump rooms to provide
the coolest possible air delivery to motors. This may require input into maintenance and operating
procedures to ensure appropriate comfort for operational and maintenance staff working in the pump
room.
Investigate the possibility of reducing transformer sizing to better match actual load; and
Instruct staff in energy management procedures for such items as station lighting and control room air
conditioning.
Summary Report
7. Motor Control Systems
7.1 Overview
In newer stations, control systems are being configured for possible remote control and monitoring. In
this context, it is important that the control system have a reliable power system that will continue to
function during a power failure, or at least long enough to signal the power fail condition to a central
location. From observation it is also noted that stations with a PLC based control system, most often
featuring a mimic panel display, include redundant power supply systems within their wiring.
At two pumping stations (i.e. Jabbana, Western Region and Jubail Island, Eastern Region), batteries
have been provided to power the control system during a power outage. However in one case (i.e.
Jabbana) the charging system had been removed. Where the control system is based on a computer
screen operator interface, an Uninterrupted Power Supply (UPS) system has been provided to ensure
continuity of power supply.
Although this report does not consider a requirement for control systems to be active to safely shut-down
a station upon loss of power (i.e. to close non-return valves to prevent backflows), it would seem prudent
that every station automatically returns to a safe condition upon complete loss of power.
The actual need for control systems, beyond electrical safety interlocks and motor protection, must be
considered in the context of station staffing, as local staff (if trained) will always out-perform a control and
monitoring system.
7.2 Emergency Power

In only four instances do pumping stations have emergency power derived from diesel generators. The
majority of pumping stations cannot function during a power failure.
It is also noted that when an operator was present, the majority of stations can be operated even though
the control system has failed. This assertion warrants further investigation as it was noted that, for the
four Grain Al Ayesh Pumping Stations (Nos. 1 to 4), the control system is capable of preventing manual
operation of the system.
Smaller pumping stations feature mechanical, fast acting non-return valves in series with each pump.
Such systems are stable under power failure conditions and need no control or operator action to ensure
stability.
The majority of control systems employed in pumping stations are run on 24V DC. Some utilise 230V AC
instrumentation, and one system is apparently 110V AC.
If stations retain local control there in no need for control systems to remain powered during power
failures.
The need for a mimic and control panel is questionable as staff have sufficient time to gather the
monitoring information presented on the panels and can easily be aware of station operation without the
assistance of coloured lights.
Summary Report
7.3 Recommendations
In the absence of a clear policy on automation, it is assumed that station control will remain local.
It would seem prudent, therefore, that station controls allow for full manual override and operation of
pumps under all circumstances.
Summary Report
8. Mechanical Asset Maintenance and Management
8.1 Overview
This section presents a sound, technical approach to selection of pumps, motors, pipework and
associated mechanical equipment.
The ADDC pumping stations discussed in this report contain a total of 126 off “centrifugal water pump
sets” with associated pumps, electric motors, pipework, and flow control valves.
8.2 Findings and Observations
8.2.1 Centrifugal Pump Types

Several different centrifugal pump types (base mounted) have been used on ADDC pumping stations as
follows:
Overhung-Impeller, End Suction, Vertical Split Case - both close and long coupled type. These
pumps most often have been used on low water delivery rate duties starting from 10 l/s.
Double suction, single or two stage with axial (horizontal) or vertical split type case. These pumps
have been used on high water delivery rates up to 300 l/s.
Multistage vertical, centrifugal motor pumps. Typically this type of pump would be installed on system
with low water delivery rate and very high system pressure. This type of pumps has been observed in
the pumping station serving the Sea Palace.
8.2.2 Pump capacity ranges

Pumps set capacity ranges are very wide and as listed below. For individual pump capacity data, refer to
the relevant Pumping Station Condition Assessment reports.
10 l/s to 300 l/s Water flow rates
200 KPa to 1,320 KPa Pump total pressure heads
15 kW to 250 kW Electric motors
8.2.3 Pump Efficiencies

A summary table of all pump efficiency measurements is provided in Appendix D. The key elements of
achieving high pumping efficiency are presented below.
1. Proper selection of type of the centrifugal pump for specified use.
Radial, mixed flow or axial, single flow or multi flow, single stage or multi stage pumps may come with
different impellor shapes and designs specific for different applications (e.g. high pressure – low flow
rate, or low pressure – high flow rate). Figure 5 represents pump performance curves for two different
pump types.
Summary Report
Figure 5 Flat versus Steep Performance Curves
2. Selection of pump design performance point within the highest efficiency area of pump curves.
Figure 6 below illustrates how many different pump types and sizes can be selected for given flow
duty. It is important to select the pump with highest pumping efficiency.
Figure 6 Typical Pump Performance Curve
Summary Report
3. Accurate estimation of piping (network) system dynamic pressure losses and static heads.
Figure 7 below illustrates how inaccurate estimates will result is selection of under or oversized
pumps, hence lower pumping efficiency.
Figure 7 Pump Efficiency versus Flow
4. Accurate estimation and selection of pump flow rate (water delivery rate) is essential. Inaccurate
estimates will result is selection of under or oversized pump, hence lower pumping efficiency.
5. Accurate selection of pump flow duty point – pump duty point should be the same as estimated duty.
A fixed speed pump can perform with high efficiency for one duty point only. In order to achieve high
pumping efficiency for changing delivery rates, variable speed pumps should be used. Figures below
represent pump power and efficiency curves at variable speed condition.
Figure 8 Pumping Power, Pressure and Flow Figure 9 Pump Best Efficiency Curves
versus Pump Speed
Summary Report
6. Accurate selection of electric motor for pump duty.
Electric motors should be sized to pump pumping duty and pump performance within entire
performance range of the impeller. Unnecessarily oversized motors are less efficient and will
contribute to reducing the efficiency of the pump.
8.2.4 Examples of High Efficiency Pump Selection

The following represents two examples of high efficiency pump selections for specified duties on Pump
Stations in Western Region.
Example 1 - Sila Border Post Pumping Station, Western Region
Pump efficiency measured at: 81% (Pump 1), 71% (Pump 2) and 71% (Pump 3)
Figure 10 Pump Curve - Sila Border Post PS, Western Region (Pump 1)
Example 2 - Bainounah Palace, Ghayathi, Western Region

Pump efficiency measured at: 76% (Pump 1), 81% (Pump 2), 77% (Pump 3) and 74% (Pump 4).
Summary Report
Figure 11 Pump Curve - Bainounah Palace, Ghayathi, Western Region (Pump 1)
8.2.5 Example of Low Efficiency Pump Selection

Example – IPS2, Ghayathi, Western Region
Pump efficiency measured at: 25% (Pump 1) and 22% (Pump 2)
Figure 12 Pump Curve - IPS2 Ghayathi, Western Region
Summary Report
8.2.6 Pump – Pipe Connections
All pump stations were observed to have installations divided into two categories:
1. Pumps directly connected to adjoining pipework; and
2. Pumps connected via single bellow rubber couplings.
There was no obvious reason why some pumps have been pipework hard connected and some not.
On number of pumping stations where flexible couplings have been installed on pumps, flexible
couplings have been braced (hard locked in position) with steel brackets (refer Figure 13). This situation
often occurs where pumps are not fixed (bolted) into the plinths. It is suspected these methods have
been applied in order to prevent pump movement during start-up moments.
Figure 13 HH Sheikh Zayed Palace, Delma
8.2.7 Water Flow Control Valves

It has been noticed that many large pumps with high water flow rates and significant system pressures
have been equipped with standard spring loaded check valves and butterfly isolating valves.
As an example, Samha East Pump Station has pump discharge lines equipped with standard check
valves and butterfly valves (refer Figure 14). The pump station is also equipped with 5 large capacity
pumps (pump duty = 126 l/s @ 785 KPa).
During inspections at the Samha East Pumping Station, it was noted that, to shut down a pump,
operators would close the flow isolation valve and then shut down the pump using the local emergency
stop control. This (now) routine procedure was necessitated by the failure of the non-return valves,
which remain ineffective. Using isolation valves to effect pump START/STOP procedures may result in
very damaging effects of water hammers and sudden surges. Samha East is also very good example
where water surging and hammering effect can be seen. The results of this procedure are:
Damaged check valves
Damaged butterfly isolating valves
All pumps have been moving - snapping bolt fixings into the plinths (refer Figure 15).
Pump building shows some serious structural cracks.
Summary Report
Figure 14 Samha East PS - Spring Loaded Check Valve and Gear Operated Butterfly Valve
Figure 15 Samha East PS - Additional Pump Steel Fixings
8.2.8 Pump – Motor Shaft Alignment and Mechanical Shaft Couplings

A total of 94 out of 126 (75%) of long coupled water pumps tested are out of permissible alignment
ranges. For details and recorded measure data refer to Appendix D or to individual Pumping Station
Assessment Reports.
Vibration and shaft alignment measurements are detailed in the individual Pumping Station Assessment
Reports and summarised in Appendix D of which 19 water pumps have shaft couplings in poor or very
poor condition qualifying for immediate replacement.
The affects of pumps running with out-of-alignment shafts are:
Quick deterioration of shaft couplings
Quick deterioration of pump shaft seals
Quick deterioration of pump electric motor bearings
Increased pump vibration and noise.
Increased pump vibration will have longer term destructive effect on surrounding pipework with its
instrumentation (valves, gauges, flow meters etc) and plinth.
Summary Report
8.2.9 Pumps and Mechanical Maintenance and Service
No evidence of service or preventative maintenance has been found at any of the visited pumping
stations. Most (if not all) abnormalities, malfunctions or technical problems found appear to be related to
a complete lack of service and regular maintenance.
8.3 Recommendations for Existing Pumping Stations

Appendix D provides all pumping Station data and statistics related to mechanical condition assessment.
8.3.1 Pump – Motor Mechanical Coupling, Shaft Alignment and Replacement of Damaged
Shaft Couplings
It is recommended the following urgent action to be taken by ADDC:
1. Replace ALL pump-motor shaft couplings, condition rated at 4, 5 or 6, with new couplings; and
2. Conduct shaft alignment on all listed pumps (94 off) assessed as being out of manufacturer’s
allowable limits.
NOTE: Both the above actions should be conducted at the same time. Do not replace damaged coupling
unless it follows with immediate shaft alignment.
Estimated budget cost for pump alignment per pumping station = AED 5,000
8.3.2 OPTION: Magnetic Motor-Pump Shaft Couplings

Considering the knowledge and experience gained during ADDC pumping stations condition assessment
investigations, it is strongly recommended that ADDC consider the application of the “magnetic motor-
pump shaft couplings”. This type of the coupling replaces physical connection between electric motor
and pump and can be applied on the existing pumps, as well as in all new ADDC pumping station
projects.
Figure 16 Magnetic Motor-Pump Shaft Coupling
Summary Report
The principal of the magnetic coupling operation is based on two magnetic discs mounted on both ends
of motor and pump shaft with a tiny air gap between them. Mechanical power and torque is transferred
from motor to pump through the magnetic force existing between two discs.
The advantages of magnetic coupling application include:
Maintenance free coupling with a life expectancy exceeding the pump set;
Pumps with magnetic couplings do not require shaft alignment; and
Energy savings.
Magnetic coupling provide a disconnected “cushioned” start because the motor does not need to
overcome load inertia, the peak demand and duration of current are reduced significantly leading to
energy savings (refer to Figure 17).
Figure 17 Energy Savings with Magnetic Pump-Motor Shaft Couplings
This type of coupling permits “shock” loading.

Elimination of any shaft vibration transfer between motor and pump.
Elimination of any shaft vibration resulting from unaligned pump and motor shafts, leading to:
– Significant increases in life expectancy of pump shaft seals and electric motor bearings.
The coupling air gap can be adjusted to operate the pump at lower speeds. This can be used for fine
pump water flow balance (no valve throttling required leading to energy savings)
Lower and simpler pump maintenance.
Summary Report
As an example of fitting magnetic couplings, a budget sample (per each pump) for the Liwa Hotel Pump
Station is:
Pumps 3 off, each 12 l/s water flow, motor 30 kW, speed 2870 rpm
AED 12,000 - Coupling cost (each)
AED 13,000 - Cost (each): Installation, commissioning
AED 25,000 - Total budget per pump
8.3.3 Pump Check Valve and Flow Control Valve Application

In order to minimize very damaging pump start and stop surges and water hammering effects on ALL
ADDC pumps with connecting pipework sizes of DN 100 mm and bigger, it is recommended that
replacement of standard spring or weight loaded check valves with heavy duty Pump Control Valves
(similar to Ross: Model ECV or similar). Figure 18 illustrates two available valve configurations.
Figure 18 Pump Control Valve in In-Line and Angle Configuration
Surge tanks are recommended to complement and minimise water hammer in pumped pressure mains
due to transient pressures in the distribution network.
8.3.4 Flexible Couplings Connecting to Pumps

It is recommended to:
1. Replace all damaged (rated 5 or 6) flexible couplings with new couplings.
2. On all pumps where steel spacers have been installed on pipe flexible couplings:
– Remove steel spacers allowing couplings to perform intended functions. Ensure correct coupling
installation.
Summary Report
– Ensure that related pumps and pipework surrounding each coupling is secured correctly.
Reminder – many couplings have been braced in order to secure moving and unfixed pump sets
or secure incorrectly supported pipework with valves.
3. In all other pumping stations with pumps hard connected (no couplings) into the pipework – install
appropriate flexible couplings.
8.3.5 Instrumentation Gauges and Flow Meters

It is recommended that:
1. All broken pressure gauges replace with new gauges of reputable brand. Ensure all gauges are oil
filled and supplied with appropriate calibration certificates.
2. All other pressure gauges (working) should be calibrated and supplied with certifications.
3. Repair or replace all damaged flow meters. All repaired or replaced flow meters should be calibrated
and certified.
4. All other operating flow meters should be calibrated and supplied with certifications.
8.3.6 Pump Station Recommissioning

Following the completion of the condition assessment programme and based on the recommendations in
this Summary Report, it is recommended that ADDC to set a programme to recommission each pumping
station. The main reasons and benefits for recommissioning are:
1. Confirm and ensure that all pumping station functions are operational and factual.
2. Set (commission) and record all operational parameters to meet station original or current design
criteria, such as:
– Water flows and system pressures;
– Switching sequences and related pumping times;
– Power supply, controls and automation; and
– Water supply data recording.
3. Provide data base and local knowledge to implement further station operational improvements
(pumping efficiency, water metering, station power use, safety, equipment redundancy, equipment
life, value engineering, and value maintenance).
4. Provide proposals for improvements for station operation.
8.3.7 Recommendations for New Pumping Stations

Pump/equipment selections for new ADDC pumping station projects should consider:
Pump Efficiencies
– Ensure all pumps are selected to achieve working efficiency of 70% and above after
commissioning.
– Do not select pumps to meet the capacity for future demands or expansion. Add additional sized
pumps instead.
Standardize Equipment Sizes
Summary Report
– Based on current pumping stations and future plans and designs, select a few pump types and
sizes for use on all ADDC stations.
Bigger pumping stations can be designed using a greater number of smaller pumps also used in
smaller stations.
Pumping stations with a growing water demand can have additional smaller (standard) size pumps
added on rather than oversized, inefficient pumps installed at commissioning.
– The advantages of standardizing pump sets can also be applied to electric motors, valves, meters,
pipe fittings, instruments, control panels, electrical boards, etc.
Pump availability and stand-by capacity
– Equipment (pumps) availability and stand-by capacity is integral with standardization and use of
multiple smaller pump sets rather than lesser number of larger pumps or a variety of different
pump equipment.
8.3.8 Routine and Preventative Maintenance

It is recommended that implementation of routine servicing and preventative mechanical and electrical
maintenance to be carried out at all of ADDC pumping stations. All maintenance work should be
conducted by qualified, licensed personnel (i.e. licensed electrician, licensed plumber, pump mechanic,
qualified electro-mechanical commissioning technician) by either a specialised company or on sub-
contract to ADDC regional bases.
Maintenance of ADDC’s pumping stations could be arranged with two independently working
maintenance teams. Each team having 4 licensed personnel (Electrician, pump mechanic, plumber and
commissioning technician).
The routine “maintenance” team would travel to all stations over 12 months to provide standard service
and maintenance, while the other team would be attend all emergency calls and undertake planned
repair works. Both teams would be equipped with large size 4-WD truck equipped with all necessary
tools, small spare parts and equipment elements.
The estimated cost for the above operation is AED 3,500,000 to 4,000,000 per Annum.
This cost includes: - labour, transportation, accommodation, tools, safety gear, sundries
This cost excludes: - spares, replacement parts and materials.
Summary Report
9. Technician and Operator Training
9.1 Overview
Any consideration of operator training must be undertaken in the context of future station operation. It
has been suggested that fully automatic operation with remote monitoring is being considered. If this
strategy is to be adopted, this must be clearly defined before decisions are made concerning technician
and operator training.
9.2 Operation Scenarios

The following points are a series of contexts for training requirements based around possible operating
scenarios.
Full Automation
If fully monitored and controlled is being considered then it is assumed to include the following features:
All pump scheduling centrally managed;
All pump and station alarms centrally monitored;
All status information (e.g. flow and cumulative flow) centrally monitored.
Monitoring of this nature requires a significant investment in station and central plant and requires a
(relatively) high capacity data link. With a system of this type, the current number of operators is
unnecessary, and indeed is unwanted. At most, a site security/ guard function is all that is required.
Accordingly, operator training is irrelevant. Regular checks would be undertaken by a maintenance team
who would also provide a rapid response in case of major faults. To date, all stations visited have
significant spare pumping capacity, so the loss of a single pump would not constitute an urgent situation.
Loss of power and fire alarms are more of a concern.
Local Automation
Station operators could use their existing automation (i.e. scheduling and standby selection and
response to flow or level signals) to operate the station. Control would still be centralised but would be
restricted to the monitoring of fault information and key process information (e.g. actual or cumulative
flow). Such a system would require a relatively low capacity data link, possible based on a GSM link
with individual data calls on schedule and in fault situations. As with full automation, this option doesn’t
require operators and therefore training is irrelevant. As before however, there is a need for a competent
maintenance team who are able to monitor the reports and to respond as required.
9.3 Current Situation

Each of the pumping stations visited contained a full operating control panel featuring status and fault
information and a mechanism for duty and standby selection of pumps. While not observed, it is
assumed that the system also features automatic changeover in the event of a fault occurrence.
Currently operators are employed at each station and are present in the control space during all pumping
operations. They are required to complete a log of operation, logging details such as hours run for
pumps and volumes pumped. They also provide a mechanism of fault reporting.
Summary Report
Operators typically appear to ignore the automatic controls and manually control the pumps and their
scheduling. The hours run metering suggests that the principle concern of the operators is to maintain
equal hours run for each pump.
9.4 Operator Skills

The skill level of the operators varies as does their level of initiative. However in each situation, the
operators are largely under utilized as the actual operation of the pumps is straightforward and monitored
overall by level or flow indicators.
Operators displayed varying levels of skill and understanding of the operation of the systems that they
control. Where GHD’s testing schedule caused an unusual situation, operators have displayed equally
unusual methods of correction. Generally, it appears that they have trained “on the job”, have no
understanding of the controls, .but have gleaned information on how to restore service and reset fault
conditions. This extends to altering set points on motor control monitors.
9.5 Effects of Maintenance

As faults occur, maintenance actions appear to be decided based on the need of a particular plant item
to support full manual control of the stations. There does not appear to be any initiative to restore
controls to their “as designed” condition. Further, operators are unable to even obtain simple spare parts
for stations (e.g. lamps for pilot lights).
Lack of control maintenance has also allowed/required operators to develop their own methods of
operating the station. At Samha East Pumping Station, it was noted that, to shut down a pump, operators
would close the flow isolation valve and then shut down the pump using the local emergency stop
control. This (now) routine procedure was necessitated by the failure of the non-return valves, which
remain ineffective. At the same station all main isolator switches on all the motor control panels were
damaged. This can only have been the result of frequent operation of the isolators which should not
have been routine. The reason for why this procedure in still in place is unknown, but the results are
broken isolators, which are an urgent safety concern.
Summary Report
10. GIS Object Identifiers
10.1 Review of GIS Object Identifiers

During the course of this project, ADDC requested GHD to advise on the validity of ADDC’s asset spatial
data recorded on ADDC’s GIS.
GHD took the asset Object Identifiers, asset descriptions and spatial plans, extracted from the ADDC’s
GIS Geo-database, and compared this data with GHD’s field collected data.
Appendix G provides a summary record of where ADDC’s asset Object Identifiers correlated to GHD’s
field collected data for all water pumping stations. Where there was no correlation, these cells are left
‘blank’.
Recommendation
It is recommended that the uncorrelated GIS Objects (‘blank’ cells) be established (or re-established) in
ADDC’s GIS.
Summary Report
11. Conclusions and Recommendations
11.1 Relevant Data and Reports

GHD has completed a condition assessment of some 37 water pumping stations, managed by ADDC, in
all 3 regions. This Summary Report summarizes all data, findings and recommendations of GHD’s
condition assessment of ADDC’s water pumping stations and includes:
Plant/equipment identified for replacement, overhaul, upgrade, investigate further or no action
required; and
Recommendations for further actions including:
– Equipment condition monitoring;
– Energy management;
– Operator training;
– Technicians training;
– Operator management improvement; and
– Maintenance management improvement.
This report should be read in conjunction with the “Assessment Overview Report (GHD, Nov 2009)” and
the individual “Condition Assessment and Energy Management Pumping Station Survey” reports (GHD,
Dec 2009 and Jan 2010) for each of the pumping stations.
GHD’s condition assessments are detailed in the individual Pumping Station Assessment Reports and
summarised for all pumping stations in the appendices of this Summary Report.
11.2 Conclusions
11.2.1 Site Safety

Site Safety has been assessed as being deficient in the following key areas:
– Provision and use of Protective Personal Equipment (PPE) (100% of sites)
– Lighting (46% of sites)
– Electric Hazards (43% of sites)
– Excessive Noise (35% of sites)
– Site Security (22% of sites)
– Lock Out / Tag Out (19% of sites).
It is clear Electrical Hazards and Lock Out / Tag Out hazards together present the largest area of
concern with the greatest potential for operator deaths and injuries.
11.2.2 Operator Accommodation, Amenities and Site office Facilities

In the last 8 months, Government Decrees and Regulations have directed all employers to provide high
standards of Labour accommodation and adherence to Occupational Health and Safety Standards.
Summary Report
Pump Station operator accommodation and amenities in nearly all older sites is non-existent or sub-
standard.
ADDC, as a representative organisation of the Abu Dhabi government, will be expected to meet these
government labour laws and regulations sooner than the general industry.
Nearly all pump stations lack dedicated site office facilities with amenities for operations staff and for safe
storage of pump station records.
11.2.3 Lack of Uniformity in Station Design Philosophy

ADDC’s pumping stations have been constructed over the last 35 years by varying organisations
employing various consultants and contractors. The result is a varied array of pump station layouts,
structures, power and control systems, pumps, connecting pipework and flow control equipment, motors
and instrumentation.
11.2.4 Over Design Issues

Nearly all pumping stations surveyed are operating at a fraction of their design capacities due to the
over-design of their power systems and pumps sets. Pumps & motors are far larger than is necessary to
serve demands and are only operated 2-3 hours a day.
Power transformers are up to 2 times larger the total power demand of the pump station they serve.
Based on preliminary calculations, the energy losses in some transformers is higher than the energy
requirements of the pump station running at full capacity.
11.2.5 Pump Shaft Alignments

All 94 long-coupled pump-motor sets out of a total of 126 pump sets assessed were out of alignment,
leading to:
Worn pump seals;
Worn pump motor bearings, hence overheating motors;
Undue vibration affecting surrounding instrumentation; and
Excessive noise in the Pump Rooms.
11.2.6 Flexible Couples
11.2.7 Lack of Regular Maintenance

Overall, it is evident that there is a lack of regular maintenance on the electrical power and motor control
systems, flow and pressure instrumentation and site lighting as well as on the pump motor sets.
Unqualified Technicians
While evidence of maintenance has been done, it has been of a temporary nature or been carried out by
unqualified persons, resulting in unsafe electrical equipment, unstable pipe to pump connections or poor
quality repairs which will require repair in the near future.
When maintenance is eventually carried out, it is undertaken either by the untrained operators (out of
desperation), or by others who remove components for repair, but in many cases do not reinstalled them.
Summary Report
GHD’s assessment revealed a considerable number of pumps, motors and instruments had been
removed from service for many months, and often, for years.
11.3 Recommendations
11.3.1 Station Specific Recommendations

Detailed recommendations for each of the pumping stations are contained in each of the Condition
Assessment Reports and summarised in the appendices of this Summary Report.
The following recommendations provide a general direction for ADDC in planning, design, construction
operation and maintenance of their current as well as future water pumping stations.
11.3.2 Simple, Robust Design

Many pumping stations contain complex combinations of mechanics, electrics, computerised control and
instrumentation being run by unqualified operators.
It is strongly recommended that ADDC to develop a standardized, but simple, design brief for its future
built pump stations that minimises the issues related to efficiencies, ‘over design’, remote locations,
maintenance/service, reliability and untrained operations staff.
This “standard design brief” should be developed around a performance-based process of “go back to
basics” design and construction focussing on modular, standardised components. The performance
criteria should ensure pumping station components can be combined to produce both small and large
capacity pumping stations, while allowing individual pumping stations to grow to meet local growing
demand. All design consultants and construction contractors should be bound to follow this Standard to
ensure uniform, simple, robust designs are delivered to construct uniform and simple, very efficient, low
maintenance but very well engineered pumping stations. Value engineering should not detract from
adherence to uniform designs and equipment configurations.
11.3.3 New Operating Philosophies

Currently, operators are employed at each station and are present in the control space during all
pumping operations. They are required to complete a log of operation, logging details such as hours run
for pumps and volumes pumped.
The purpose and role of ADDC pumping stations will continue to vary as the Emirate develops.
Therefore, it can be expected that operational philosophies will need to vary according to functional need
of the pumping stations
It is recommended that a range of operational solutions be adopted by ADDC ranging from having:
Unmanned, fully automated, remote monitored and controlled pumping stations; to
Locally managed pumping stations as is currently done.
Summary Report
Fully Automated
Monitoring of this nature requires a significant investment in station and central plant and requires a
(relatively) high capacity data link. With a system of this type, the current number of operators is
unnecessary, and indeed is unwanted.
Local Automation
Station operators could use their existing automation (i.e. scheduling and standby selection and
response to flow or level signals) to operate the station. Control would still be centralised but would be
restricted to the monitoring of fault information and key process information (e.g. actual or cumulative
flow.
11.3.4 Routine and Preventative Maintenance
Personnel Qualifications
It is recommended that implementation of routine servicing and preventative mechanical and electrical
maintenance to be carried out at all of ADDC pumping stations. All maintenance work should be
conducted by qualified, licensed personnel (i.e. licensed electrician, licensed plumber, pump mechanic,
qualified electro-mechanical commissioning technician) by either a specialised company or on sub-
contract to ADDC regional bases.
Mobile Maintenance Teams

Maintenance of ADDC’s pumping stations could be arranged with two independently working
maintenance teams. Each team having 4 licensed personnel (electrician, pump mechanic, plumber and
commissioning technician).
The routine “maintenance” team would travel to all stations over 12 months to provide standard service
and maintenance, while the other team would be attend all emergency calls and undertake planned
repair works. Both teams would be equipped with large size 4-WD truck equipped with all necessary
tools, small spare parts and equipment elements.
11.3.5 Inspection of Standards Pump Station Designs in Australia

It is recommended that ADDC senior Project Planning and Operation and Maintenance Water Managers
undertake a site inspection trip to Australia to visit a range of selected Local Government Water
Authorities to see and learn about the current ‘state of the art’ water pumping and distribution systems
management. GHD would be pleased to assist in organising this tour.
The ‘learnings’ gained from such a study tour would provide the raw models for development of
standardized designs and management models for ADDC.
Summary Report
Appendix A
Pumping Station Codes, Identifiers and
GPS Coordinates
Summary Report
Pumping Station Codes, Identifiers and GPS Coordinates
GPS Field
PS Coordinates
Region Area Pump Station Description ADDC MAXIMO ID
Code
North East
C01 Central Region Abu Dhabi City Sea Palace (new) DW-AUH-E17-WPS1 24° 27.963' 54° 24.379'
C02 Central Region Abu Dhabi City H. H. Shk. Khalifa PS DW-AUH-W30-WPS1 24° 26.726' 54° 20.845'
C03 Central Region Abu Dhabi City H. H. Shk.Hamdan PS DW-AUH-W1902-WPS1 24° 26.875' 54° 21.781'
C04 Central Region Abu Dhabi City Jubail Island PS DW-SAL-WPS1 24° 31.933' 54° 27.628'
E01 Eastern Region Baniyas Military Accommodation DW-WTB-WPS2 23° 55.189' 52° 57.818'
E02 Eastern Region Al Khatim Al Khatim DW-KHT-WPS1 23° 50.698' 52° 41.094'
E03 Eastern Region Samha Samha West DW-SMW-WPS1 24° 39.016' 54° 54.734'
E04 Eastern Region Samha Samha East DW-SME-WPS1 24° 40.767' 54° 46.194'
E05 Eastern Region Samha Ghanada DW-GND-WPS2 24° 46.874' 55° 05.511'
E06 Eastern Region Shahama Zubara DW-AHL-WPS1 24° 39.016' 54° 54.734'
E07 Eastern Region Shahama Shahama DW-SHM-WPS1 24° 23.708' 54° 31.179'
W01 Western Region Sila Sila border post DW-SIL-GWF-WPS1 24° 08.713' 51° 38.782'
W02 Western Region Sila Sila Mena P.S DW-SIL-WPS4 24° 08.269' 51° 38.917'
W03 Western Region Ghayathi IPS 2 DW-RWS-WPS2 24° 09.077' 51° 38.326'
W04 Western Region Ghayathi Ghayathi DW-GHT-WPS1 23° 54.068' 52° 44.364'
W05 Western Region Ghayathi Bida Al Mutawa DW-BMW-WPS1 23° 51.596' 52° 45.030'
W06 (Not Used) (Not Used) (Not Used) (Not Used) (Not Used)
W07 Western Region Ghayathi Bainounah Palace DW-GHT-WPS2 23° 59.681' 52° 37.186'
W08 Western Region Ghayathi Sir Baniyas - PS 1 (Old) DW-SBN-WPS1 24° 18.959' 52° 37.043'
W09 Western Region Ghayathi Sir Baniyas - PS 2 (New) DW-SBN-WPS2 24° 16.800' 52° 47.182'
W10 Western Region Liwa Jabbana Main PS / TFS DW-LWE-JBN-WPS1 25° 03.260' 54° 04.944'
W11 Western Region Liwa HH Shk. Zayed Palace DW-LWA-MUZ-WPS1 23° 07.084' 53° 46.559'
W12 Western Region Liwa Liwa Hotel DW-LWA-SMZ-WPS1 23° 34.558' 53° 16.114'
W13 Western Region Liwa Rest house area DW-LWW-DFR-WPS1 23° 07.023' 53° 45.256'
W14 Western Region Liwa Mougab DW-LWW-MQB-WPS1 23° 11.462' 53° 38.976'
W15 Western Region Liwa Hamrour DW-LWW-HMR-WPS1 23° 07.001' 53° 36.598'
W16 Western Region Liwa Shaya DW-LWW-CHA-WPS1 23° 08.612' 53° 41.361'
W17 Western Region Liwa BuSaddain DW-LWW-SDN-WPS1 23° 09.903' 53° 38.989'
W18 Western Region Mirfa Mirfa TFS DW-MRF-WPS1 24° 05.240' 53° 28.466'
W19 Western Region Mirfa Tarif DW-TRF-WPS1 24° 02.295' 53° 45.871'
W20 Western Region Mirfa Abu Al Abyad Old PS DW-ABL-WPS1 24° 06.909' 53° 52.938'
W21 Western Region Mirfa Abu Al Abyad New PS DW-ABL-WPS2 24° 10.385' 53° 46.368'
W22 Western Region Mirfa Grain Al Ayesh - 1 DW-GSH-WPS1 22° 09.940' 53° 36.057'
W26 Western Region Delma HH Shk. Zayed Palace DW-DLM-WPS1 24° 29.877' 52° 20.003'
W27 Western Region Delma Al Jabal Shabia, PS No. 2 DW-DLM-WPS2 24° 55.032' 52° 21.383'
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations A1
Summary Report
Appendix B
Site Safety Assessment
Summary Report
SITE SAFETY ASSESSMENT
Pum ping Sta tion

HAZARD
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Site Acces s and Egres s Y es No Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es Ye s . Y es
Site Security Y es Y es Y es Y es Y es Y es No No Y es Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es No Y es Y es Y es Y es No No Y es Y es Y es Y es No Y es Y es No Y es
Lighting Y es Y es Y es Y es No Ye s . No Y es No No Y es Ye s . Ye s . Ye s . No No No No No Y es Y es Y es Y es No No No No No Y es Y es No Y es Y es Y es Y es No No
Mechanical Hazards (eg Unguarded Plant) Y es Y es Y es No Y es No No Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Ye s . No Y es Y es Y es Y es Y es No
Electrical Hazards Y es No No Y es Y es No No No Y es Y es No No No Ye s . No Y es Y es Y es No Y es Y es Y es Y es No No No No No Y es No Y es Y es Y es Y es Y es Y es Y es
Hous ekeeping (General Tidines s ) Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es No Y es Y es Y es Y es No No Y es No Y es Y es Y es Y es Y es No Y es
Fire Hazard and Equipm ent No Y es No Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es No No Y es Y es Y es
Nois e Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es No Ye s . Y es Y es No No No No No Y es Y es Y es Y es No Y es No Y es No Y es Y es No Y es No No
Dus t / Fum es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Hazardous Subs tances Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Working at Heights Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Ladders / Scaffolding Y es Y es Y es Y es Y es No No No Y es Y es Y es Ye s . Y es No No Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Pres s urized Equipm ent Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Heat Illnes s / Stres s Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Pers onal Protective Equipm ent (PPE) Y es Y es Y es Y es Y es Y es Y es Ye s . Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Ye s . Y es Ye s . Ye s . Y es Y es Y es Ye s . Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Know ledge of Site Safety Rules Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Site Em ergency Procedures Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Confined Space Entry Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es Y es
Lock Out / Tag Out Y es No Y es Y es Y es No No Y es Y es Y es Y es Ye s . Ye s . Y es Y es Y es Y es Y es No Y es Y es Y es Y es Y es Y es Y es Y es No Y es No No Y es Y es Y es Y es Y es Y es
OTHER - Water Quality / Health Hazard No No No No
OTHER - Structural Safety Hazard No
OTHER - Telephone Com m unication No No
Comments LEGEND - Site Safety Assessment

Note: 'NA' or 'Blank' = Not Applicable or Data Not Available. Yes Satis factory.
Yes . Satis factory, But s om e action is required.
No Not Acceptable, Im m ediate Action Re quired.
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations B1
Summary Report
Appendix C
Civil Assets Assessment
Buildings and General Infrastructure

Storage and Transfer Water Tanks
Pipework and Valving
Summary Report
CONDITION ASSESSMENT - Buildings & General Infrastructure
Pumping Station
Asset
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Access Road 2 2 2 1 2 2 4 4 4 4 3 1 4 4 4 3 2 5 4 4 3 2 1 2 2 3 5 3 4 3 1 4 4 4 4 4 2
Boundary Fence / Walls 2 2 2 NA 2 2 3 4 1 NA 3 1 3 3 4 2 2 NA 2 3 3 2 1 2 2 2 NA 6 2 NA 1 2 2 2 2 6 2
Entry Gate NA 2 2 NA 2 2 3 3 NA NA 3 3 2 5 4 2 2 NA 2 3 3 2 1 2 2 2 NA 3 2 NA 1 2 6 2 2 3 2
Security House NA NA NA NA 2 NA 3 3 1 NA NA 1 NA 5 NA 3 2 NA 2 3 NA NA 1 2 2 2 NA NA 2 NA 1 2 2 2 2 NA NA
External Walls NA NA NA NA 2 NA 3 3 1 NA NA 1 NA 4 NA 3 2 NA 2 3 NA NA 1 2 2 2 NA NA 2 NA 1 2 2 2 2 NA NA
Roof NA NA NA NA 2 NA 3 2 1 NA NA 1 NA 3 NA 3 2 NA 2 3 NA NA 1 2 2 2 NA NA 2 NA 1 2 2 2 2 NA NA
Internal Walls NA NA NA NA 2 NA 3 3 1 NA NA 1 NA 4 NA 3 2 NA 2 4 NA NA 1 2 2 2 NA NA 2 NA 1 2 2 2 2 NA NA
Internal Amenities NA NA NA NA 2 NA 3 NA NA NA NA 1 NA NA NA 3 2 NA 2 5 NA NA 1 3 3 2 NA NA 2 NA 1 2 2 2 2 NA NA
Pump House 2 2 2 1 2 3 3 4 1 3 3 1 2 3 3 3 2 3 2 3 3 2 1 2 2 2 2 4 2 4 1 2 2 2 2 NA 3
External Walls 2 2 2 1 2 3 3 4 1 3 3 1 2 3 3 3 2 3 2 3 3 2 1 4 2 3 2 4 2 4 1 2 2 2 2 3 3
Roof 2 2 2 1 2 4 3 4 1 3 3 1 2 3 3 3 2 3 2 3 3 2 1 3 2 2 3 NA 2 4 1 2 2 2 2 3 3
Internal Walls 2 2 2 1 2 3 3 4 1 3 3 1 2 3 3 3 2 3 2 3 3 2 1 3 2 2 2 4 2 4 1 2 1 2 2 3 3
Office & Internal Amenities NA NA NA 1 NA 6 3 NA 1 3 6 1 2 3 3 NA NA NA NA 3 NA 2 1 3 2 3 2 4 2 NA 1 2 2 2 2 NA NA
Accommodation NA NA NA NA NA NA NA 5 6 NA NA NA NA 3 NA NA 2 NA 6 5 6 NA NA NA NA NA 5 NA 2 NA 1 NA NA NA NA NA NA
External Walls NA NA NA NA NA NA NA 5 6 NA NA NA NA 3 NA NA 2 NA 6 NA 6 NA NA NA NA NA 5 NA 2 NA 1 NA NA NA NA NA NA
Roof NA NA NA NA NA NA NA 5 6 NA NA NA NA 3 NA NA 2 NA 6 NA 6 NA NA NA NA NA 5 NA 2 NA 1 NA NA NA NA NA NA
Internal Walls NA NA NA NA NA NA NA 5 6 NA NA NA NA 3 NA NA 2 NA 6 NA 6 NA NA NA NA NA 5 NA 2 NA 1 NA NA NA NA NA NA
Internal Amenities NA NA NA NA NA NA NA 5 6 NA NA NA NA 3 NA NA 2 NA 6 NA 6 NA NA NA NA NA 5 NA 2 NA 1 NA NA NA NA NA NA
Internal Roads 3 2 2 1 2 2 4 6 1 4 3 1 3 3 3 3 2 5 2 2 3 2 1 3 3 2 NA 4 NA NA 1 2 1 2 2 3 2
Internal Paths NA NA NA NA 3 2 4 2 1 NA 3 1 3 4 NA 3 2 NA 2 2 3 2 1 3 3 2 NA NA NA NA 1 2 1 2 2 3 2
Landscaping NA NA NA NA 2 2 NA 2 1 NA 3 NA NA NA NA NA 2 NA NA NA 3 NA 1 NA NA NA NA NA NA NA NA 2 2 2 2 NA NA

Comments Description Life Remains Rating
Note: 'NA' or 'Blank' = Not Applicable or Data Not Available. "As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations C1
Summary Report
COND ITION ASSESSMENT - Storage/ Transfer Water Tanks
Pumping Sta tion

Asset
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
STORAGE / TRANSFER TANK 01
External - Walls 2 2 2 1 3 2 3 4 1 3 3 1 4 3 3 3 2 3 3 4 3 2 1 4 4 3 4 4 4 4 2 2 2 2 2 4 4
External - Roof 2 2 2 1 2 2 3 3 1 3 3 1 3 3 3 3 2 3 3 3 3 2 1 4 4 2 3 3 3 4 1 2 2 2 2 3 3
Extern al - Roof Acces s 2 2 2 1 2 2 2 4 1 3 3 1 3 3 3 3 2 3 3 3 3 2 1 3 2 2 3 3 4 5 1 2 2 2 2 3 3
External - Roof Hatches 2 2 1 1 3 2 2 3 1 3 3 1 3 3 3 3 2 3 3 4 3 2 1 3 4 2 4 3 4 5 1 2 2 2 2 3 5
Internal - Walls NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Internal - Floor NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Internal - Roof NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Water Level Indicator 2 2 1 1 2 3 NA
6 1 6 5 6 3 2 3 3 NA
2 1 NA3 NA
3 6 6 NA6 3 2 2NA2 2 NA NA NA NA
Material Testing (Yes / No) No YES YES No YES YES YES YES No No YES No YES YES YES YES YES YES YES YES YES No No YES YES YES YES YES YES YES No No No No No YES YES

External - Walls 4 3 3 1 3 3 3 4 2
External - Roof 3 3 3 1 3 3 3 3 1
Extern al - Roof Acces s 4 3 3 1 3 3 3 3 1
External - Roof Hatches 3 3 3 1 3 3 3 4 1
Internal - Walls NA NA NA NA NA NA NA NA NA
Internal - Floor NA NA NA NA NA NA NA NA NA
Internal - Roof NA NA NA NA NA NA NA NA NA
Water Level Indicator 6 6 5 6 NA NA 3 NA 3
Material Testing (Yes / No) YES No YES No YES YES YES YES No

External - Walls 3 2
External - Roof 3 1
Extern al - Roof Acces s 3 1
External - Roof Hatches 3 1
Internal - Walls NA NA
Internal - Floor NA NA
Internal - Roof NA NA
Water Level Indicator 6 3
Material Testing (Yes / No) YES No

External - Walls 2
External - Roof 1
Extern al - Roof Acces s 1
External - Roof Hatches 1
Internal - Walls NA
Summary Report
CONDITION ASSESSMENT - Storage/ Transfer Water Tanks
Pumping Sta tion

Asset
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
ELEVATED TANK 01
Tank Tower/ Stand 2 2 3 1 3 2 3 2 2 2 3
Tank Tower Acces s 2 NA 3 1 4 2 5 2 2 2 3
Pipe Ris ers 1 NA 3 1 3 2 5 2 2 2 3
Pipe R is er Supports 2 2 3 1 3 NA 5 2 2 2 3
External - Walls 2 2 3 1 3 2 3 2 2 4 3
External - Roof 4 2 NA NA NA NA NA 3 4 4 NA
Internal - Walls NA 2 NA NA NA NA NA 2 NA NA NA
Material Testing (Yes / No) No YES YES No YES No YES YES YES YES YES
LEGEND - Asse t Condition

Comm ents De scription Life Ra ting
Note: 'NA' or 'Blank' = Not Applicable or Data N ot Available. "As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failed / Derelic t Un-useable 6
Summary Report
CONDITION ASSESSMENT - Pipework & Valves (Suction Side)
Pumping Station
Pipework & Valves
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
E01
E02
E03
E04
E05
E06
E07
C01
C02
C03
C04
Suction Header Pipework 2 2 2 1 2 2 2 3 1 2 3 NA 3 3 3 3 2 3 3 3 3 2 1 NA NA NA 2 2 1 4 1 2 2 2 2 NA NA
Suction Header Valves 2 2 2 1 2 2 3 3 1 3 3 NA NA 3 NA NA 3 NA NA 3 NA 2 1 2 2 2 2 2 1 5 1 2 2 2 2 NA NA
Pump Suction Pipework

Pum p 1 2 3 2 1 2 2 2 3 4 2 3 1 3 3 3 3 2 3 4 3 3 2 4 2 2 2 2 2 1 4 1 2 2 2 2 3 3
Pum p 2 2 3 2 1 2 2 2 3 4 2 3 1 3 3 3 3 2 3 4 3 3 2 4 2 2 2 2 2 1 4 1 2 2 2 2 3 3
Pum p 3 2 3 2 1 2 2 3 4 2 3 1 3 3 3 2 3 4 3 3 2 4 2 2 2 2 2 1 4 1 2 2 2 2 3 3
Pum p 4 2 3 3 2 3 4 3 2 1 6 1 2 2 2 2
Pum p 5 2 3 3 3
Pum p 6 2 3 3
Flexible Couplings (Suction)

Pum p 1 NA 2 NA 1 NA NA NA 3 1 3 NA 1 3 3 NA 2 3 3 3 3 4 2 5 2 2 2 2 NA 1 NA 4 2 2 2 2 6 6
Pum p 2 NA 2 NA 1 NA NA NA 3 1 3 NA 1 3 3 NA 2 3 3 3 3 4 2 5 2 2 2 2 NA 1 NA 4 2 2 2 2 6 6
Pum p 3 NA 2 NA 1 NA NA 3 1 3 NA 1 3 NA 2 3 3 3 3 4 2 5 2 2 2 2 NA 1 NA 4 2 2 2 2 6 6
Pum p 4 NA 3 3 3 3 3 3 2 1 6 4 2 2 2 2
Pum p 5 NA 5 3 3
Pum p 6 NA 3 3
Isolation Valves (Suction)

Pum p 1 2 3 2 1 3 2 3 3 4 3 3 1 3 3 3 3 3 3 3 3 3 2 4 2 2 2 2 2 1 5 1 2 2 2 2 3 3
Pum p 2 2 3 2 1 3 2 3 3 4 3 3 1 3 3 3 3 3 3 6 3 3 2 4 2 2 2 2 NA 1 5 1 2 2 2 2 3 3
Pum p 3 2 3 2 1 3 3 3 4 3 3 1 3 3 3 3 3 6 3 6 2 4 2 2 2 2 2 1 5 1 2 2 2 2 3 3
Pum p 4 2 3 3 3 3 3 3 2 1 6 1 2 2 2 2
Pum p 5 2 3 3 3
Pum p 6 2 3 3

Comments Description Life Rating
Good 75% 2
Fair 50% 3
Poor 25% 4
Summary Report
CONDITION ASSESSMENT - Pipework & Valves (Delivery Side)
Pumping Station
Pipework & Valves
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Delivery Header Pipew ork 2 2 2 1 2 2 2 3 1 2 3 1 3 3 3 3 2 3 3 3 3 2 1 2 2 2 2 3 1 4 1 2 2 2 2 3 3
Delivery Header Valves 2 2 2 1 2 2 3 3 1 3 3 NA 3 NA 2 NA 3 NA 2 3 NA 2 1 2 2 2 2 NA 1 4 1 2 2 2 2 NA NA
Pump Delivery Pipew ork

Pum p 1 2 3 2 1 2 2 2 3 4 2 3 1 3 3 3 3 2 3 3 3 3 2 4 2 2 2 2 3 1 5 1 2 2 2 2 3 3
Pum p 2 2 3 2 1 2 2 2 3 4 2 3 1 3 3 3 3 2 3 3 3 3 2 4 2 2 2 2 3 1 5 1 2 2 2 2 3 3
Pum p 3 2 3 2 1 2 2 3 4 2 3 1 3 3 3 2 3 3 3 3 2 4 2 2 2 2 3 1 5 1 2 2 2 2 3 3
Pum p 4 2 3 3 2 3 3 3 2 1 6 2 2 2 2 2
Pum p 5 2 3 3 3
Pum p 6 2 3 3
Flexible Couplings
Pum p 1 NA 3 2 1 NA NA NA 4 1 3 NA 2 3 3 NA 3 3 3 2 3 4 2 5 2 2 2 2 NA 1 3 4 2 2 2 2 6 6
Pum p 2 NA 3 2 1 NA NA NA 4 1 3 NA 2 3 3 NA 3 3 3 2 3 4 2 5 2 2 2 2 NA 1 3 4 2 2 2 2 6 6
Pum p 3 NA 3 2 1 NA NA 4 1 3 NA 2 3 NA 3 3 3 2 3 4 2 5 2 2 2 2 NA 1 3 4 2 2 2 2 6 6
Pum p 4 NA 4 3 3 3 2 3 2 1 3 4 2 2 2 2
Pum p 5 NA 4 3 3
Pum p 6 NA 3 3
Non-Return Valve
Pum p 1 2 3 2 1 3 2 3 6 4 6 3 1 3 3 5 3 3 3 3 3 3 2 4 2 2 2 2 3 1 5 1 2 2 2 2 3 3
Pum p 2 2 3 2 1 3 2 3 4 4 3 3 1 3 3 5 3 3 3 3 3 4 2 4 2 2 2 2 NA 1 5 1 2 6 2 2 3 3
Pum p 3 2 3 2 1 6 3 6 4 3 3 1 3 5 3 3 3 3 3 3 2 4 2 2 2 2 3 1 5 1 2 2 2 2 3 3
Pum p 4 2 4 3 3 3 3 3 2 1 NA 1 2 6 2 2
Pum p 5 2 4 3 3
Pum p 6 2 3 3
Isolation Valves
Pum p 1 2 3 2 1 6 2 3 2 4 3 3 1 3 3 3 3 3 3 3 3 3 2 4 2 2 2 2 3 1 5 1 2 2 2 2 3 6
Pum p 2 2 3 2 1 3 2 3 2 4 3 3 1 3 3 3 3 3 3 6 3 3 2 4 2 2 2 2 NA 1 5 1 2 2 2 2 3 3
Pum p 3 2 3 2 1 5 3 2 4 3 3 1 3 5 3 3 3 6 3 6 2 4 2 2 2 2 3 1 5 1 2 2 2 2 3 3
Pum p 4 2 2 3 3 3 3 3 2 1 6 1 2 2 2 2
Pum p 5 2 2 3 3
Pum p 6 2 3 3

Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Im m inent 0% 5
Summary Report
Appendix D
Pumps and Motors Assessment
Condition and Performance Assessment

Vibration and Alignment
Summary Report
CONDITION and PERFORMANCE ASSESSMENT - Pumps and Motors
Pumping Station
Pumps
and Motors
W18
W01
W03
W05
W08
W10
W12
W14
W16
W19
W21
W23
W25
W27
C02
C03
W02
W04
W07
W09
W11
W13
W15
W17
W20
W22
W24
W26
C01
C04
E01
E03
E05
E07
E02
E04
E06
Pump Condition
Pump 1 2 3 2 1 3 2 2 3 1 2 3 1 3 3 3 3 3 4 3 4 4 2 1 3 3 2 2 NA 1 4 1 2 2 2 2 4 3
Pump 2 2 3 2 1 3 2 2 3 1 2 3 1 NA 3 3 3 4 4 3 3 4 2 1 3 3 2 2 NA 1 4 1 2 2 2 2 4 3
Pump 3 2 3 2 1 3 2 3 1 3 3 1 NA 3 3 3 4 6 3 5 2 1 3 3 2 2 NA 1 4 1 2 2 2 2 4 3
Pump 4 2 3 3 4 6 3 3 2 1 6 1 2 2 2 2
Pump 5 2 4 3 3
Pump 6 2 3 3
Motor Condition
Motor 1 2 2 2 1 4 1 5 3 2 3 3 2 5 3 3 3 4 3 3 4 3 3 2 2 2 2 3 NA 1 3 1 2 2 2 2 3 3
Motor 2 2 2 2 1 3 5 4 3 2 3 3 2 NA 4 5 3 3 3 5 4 3 3 2 2 2 2 3 NA 1 3 1 2 2 2 2 4 5
Motor 3 2 2 2 1 5 3 3 2 3 3 2 NA 3 3 3 4 6 4 3 3 2 2 2 2 3 NA 1 3 1 2 2 2 2 3 3
Motor 4 2 6 5 3 5 6 4 3 1 6 6 2 2 2 2
Motor 5 2 5 4 NA
Motor 6 2 5 NA
Coupling Condition
Coupling 1 1 4 2 1 2 2 4 1 2 2 1 3 3 3 3 2 2 3 3 4 2 2 5 5 2 2 3 1 4 1 2 2 2 2 4 3
Coupling 2 1 3 2 1 1 2 4 1 2 2 1 NA 3 3 3 2 2 3 3 4 2 2 5 5 2 2 NA 1 4 1 2 2 2 2 4 3
Coupling 3 1 3 2 1 1 4 1 2 2 1 NA 3 3 2 2 3 3 4 2 2 5 5 2 2 3 1 4 1 2 2 2 2 4 3
Coupling 4 1 3 2 NA NA 3 2 1 NA 1 2 2 2 2
Coupling 5 1 3 3
Coupling 6 1 3 3
Motor-Pump Efficiency (%)

Pump 1 38% 32% NA 68% NA 45% 58% 56% 47% 84% 63% 81% 73% 25% 50% 47% 76% 73% NA 57% 48% 41% 60% 67% 53% 58% 59% NA 21% 59% 81% 63% 62% 61% 64% 69% 59%
Pump 2 43% 32% NA 59% NA 49% 65% 50% 50% 85% 56% 71% NA 22% 52% 40% 81% 67% 80% 56% 46% 45% 61% 66% 56% 53% 70% NA 15% 56% 74% 65% 63% 59% 56% 61% 52%
Pump 3 43% NA NA 69% 74% 59% 54% 48% 83% 65% 71% NA 54% 43% 77% 74% NA 58% NA 34% 60% 60% 60% 56% 68% NA 17% 58% 72% 67% 61% 64% 68% 60% 59%
Pump 4 38% NA 73% 74% NA NA 59% 60% 19% NA NA 63% 63% 69% 50%
Pump 5 40% NA 78% NA
Pump 6 32% 61% NA
LEGEND - Asset Condition Assessment LEGEND - Pump-Motor Efficiency

Comments Description Life Remains Rating Description Range
Note: 'NA' or 'Blank' = Not Applicable or Data Not Available. "As New" 100% 1 Good > 60%
Good 75% 2 Fair 50% - 60%
Fair 50% 3 Poor 40% - 50%
Poor 25% 4 Incompatible <40%
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D1
Summary Report
VIBRATION AND ALIGNMENT - Pumps and Motors
Pumping Station
Pumps and Motors
W05
C03
W01
W02
W03
W04
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C04
E01
E02
E03
E04
E05
E06
E07
Max. Vibration (m m/s)
Pump Set 1 NA 1.58 3.12 1.40 NA NA NA NA NA NA NA 0.66 0.93 1.14 0.30 1.12 0.75 1.91 0.77 0.32 3.82 7.21 0.62 0.46 0.80 1.00 0.34 NA 0.75 2.03 1.07 0.88 1.51 0.82 0.92 0.52 1.62
Pump Set 2 NA 0.70 1.56 1.31 NA NA NA NA NA NA NA 0.63 NA 0.76 0.61 2.41 0.53 1.30 0.92 0.92 7.96 12.18 2.19 0.34 0.34 0.24 0.64 NA 1.85 1.99 0.53 0.32 0.58 0.38 0.77 0.49 1.43
Pump Set 3 NA NA 4.54 2.62 NA NA NA NA NA NA 0.39 NA 0.36 2.91 0.61 1.60 NA 0.76 5.84 12.35 0.91 0.45 0.20 0.36 0.71 NA 0.46 1.88 0.45 0.64 0.63 0.34 0.96 0.23 0.44
Pump Set 4 NA NA 1.21 0.55 NA 0.82 0.39 0.50 0.67 NA NA 0.68 0.87 0.36 1.09
Pump Set 5 NA NA 1.41 0.20
Pump Set 6 NA 0.85 0.12
Pump Shaft Mis-Alignment - ANGULAR (mm/100m)

Pump - Motor Shaft 1 NA 0.34 0.22 NA 0.02 0.04 0.46 0.76 0.06 0.36 0.38 8.40 2.32 0.74 0.86 0.42 0.00 0.12 0.04 1.00 5.40 4.96 NA 0.60 0.26 0.22 NA 12.00 NA 1.80 0.73 0.32 0.24 1.15 0.49 4.64 0.90
Pump - Motor Shaft 2 NA 0.02 0.76 NA 0.06 0.04 0.12 0.96 0.04 0.10 0.36 0.36 NA 1.72 4.52 0.18 0.02 0.08 0.10 2.46 4.75 1.78 NA 1.14 0.10 1.28 NA NA NA 7.94 0.40 0.24 0.56 1.12 0.45 3.47 0.89
Pump - Motor Shaft 3 NA 0.38 0.28 NA 0.14 0.50 1.80 0.06 0.36 0.28 1.56 NA 4.52 0.14 0.04 0.04 0.10 2.46 4.75 5.36 NA 1.14 0.10 1.28 NA 9.46 NA 1.26 0.40 0.62 0.56 0.18 0.90 3.47 3.70
Pump - Motor Shaft 4 NA 0.30 2.82 0.00 NA NA 0.77 NA NA NA 0.24 0.36 0.16 0.98 0.40
Pump - Motor Shaft 5 NA NA 1.64 NA
Pump - Motor Shaft 6 NA 0.62 NA
Pump Shaft Mis-Alignment - LINEAR (mm )

Pump - Motor Shaft 1 NA 0.38 0.12 NA 0.06 0.30 0.56 0.16 0.18 0.44 0.44 0.62 0.14 0.44 0.10 0.10 0.02 0.44 0.46 0.15 0.08 0.38 NA 0.10 0.00 0.12 NA 0.46 NA 0.62 0.09 0.72 0.06 0.04 0.08 0.14 0.04
Pump - Motor Shaft 2 NA 0.40 0.53 NA 0.10 0.28 0.34 0.10 0.09 0.04 0.52 0.08 NA 0.24 0.34 0.10 0.06 1.56 0.16 0.15 0.32 0.06 NA 0.10 0.02 0.08 NA NA NA 0.58 0.08 0.02 0.06 0.12 0.04 0.20 0.12
Pump - Motor Shaft 3 NA 0.26 0.16 NA 0.10 0.50 0.28 0.04 0.18 0.40 0.16 NA 0.20 0.20 0.06 0.32 0.28 0.10 0.24 0.40 NA 0.06 0.00 0.08 NA 0.48 NA 0.62 0.12 0.04 0.10 0.02 0.06 0.18 0.16
Pump - Motor Shaft 4 NA 0.64 0.48 0.04 NA NA 0.14 NA NA NA 0.06 0.04 0.06 0.00 0.08
Pump - Motor Shaft 5 NA NA 0.46 NA
Pump - Motor Shaft 6 NA 0.30 NA
Comm ents
Note: 'NA' or 'Blank' = Not Applicable or Data Not Available. LEGEND - Vibration and Alignment
0.09 Satisfactory.
1.01 Not Acceptable, Shaft realignment required.
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D2
Summary Report
Appendix E
Other Equipment and Systems
Mechanical Equipment and Systems

Electrical Equipment and Systems
Summary Report
CONDITION ASSESSMENT - Other Mechanical Equipment and Systems
Pumping Station
Mechanical Equipment
W02
W12
W22
W03
W04
W05
W07
W08
W09
W10
W13
W14
W15
W16
W17
W18
W19
W23
W24
W25
W26
W27
W01
W11
W20
W21
C04
C01
C02
E01
E02
E03
E04
E05
E06
C03
E07
Overhead Crane NA NA NA 1 2 5 2 3 1 6 3 1 3 3 3 1 2 4 3 2 3 2 1 2 2 2 2 NA 1 3 1 2 1 2 2 6 6
Security House Air Conditioning NA NA NA NA 2 NA 3 4 1 NA NA 1 NA NA NA 3 3 NA NA 5 NA NA 1 3 2 2 NA NA 2 NA 1 NA NA NA NA NA NA
Pump Room Air Conditioning NA 2 2 NA NA 4 4 4 NA 5 6 NA NA NA 5 NA NA NA NA 5 4 3 NA NA NA NA 3 6 4 5 NA NA NA NA NA 5 6
Control Room Air Conditioning 2 2 2 1 2 3 3 4 1 5 5 1 3 5 5 2 3 5 6 5 NA 3 1 3 3 6 2 NA 2 NA 1 2 2 2 2 3 3
Pump Room Ventilation 2 NA NA 1 2 NA NA NA 1 NA NA 1 3 6 NA 3 5 6 6 NA NA NA 1 3 2 2 NA NA NA NA 1 2 2 2 2 NA NA
Surge Tank 1 6 6 1 6 4 3
Surge Tank 2 1 3
Air Compressor 4
Diesel Generator 2 5 4 NA
Fire Protection Equipment 2

Good 75% 2
Fair 50% 3
Poor 25% 4
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations E1
Summary Report
CONDITION ASSESSMENT - Electrical Equipment and Systems
Pumping Station
Electrical Equipment
W12
W18
W23
W01
W02
W03
W04
W05
W08
W09
W10
W11
W15
W16
W17
W21
W22
W24
W25
W26
W27
W07
W13
W14
W19
W20
E04
C01
C02
C03
C04
E01
E02
E03
E06
E07
E05
Switchboards
3 4 4 1 3 4 4 5 2 3 4 1 3 3 4 3 3 3 3 3 3 3 2 2 2 2 5 4 2 4 4 2 3 3 3 4 3
& Motor Controls
Electrical Equipment
Pump Station Earthing 5 3 3 3 4 2 5 NA 1 4 3 NA 4 3 3 3 2 3 3 NA 3 NA 6 NA 2 2 5 4 4 6 1 2 2 2 2 4 3
Lightning Protection NA NA NA 2 NA 3 NA NA 3 NA 3 1 NA 3 4 3 2 NA NA NA 3 NA 2 2 3 2 NA NA NA NA 3 2 2 2 2 3 NA
Pump Room Crane NA NA NA 1 2 4 NA 3 1 NA NA 2 3 3 3 3 2 3 3 2 NA NA 2 2 2 2 2 NA 1 NA 2 2 2 2 2 3 4
Pump Control Panel 2 3 3 1 4 3 4 3 1 4 4 3 3 4 5 3 2 3 4 5 3 3 2 3 4 4 4 6 4 NA 2 2 3 2 2 3 3
Power Cabling 2 2 3 4 2 3 4 4 1 3 4 4 4 4 3 4 2 3 3 4 4 2 2 2 2 2 3 5 2 4 2 2 2 2 2 3 3
Room Lighting 3 4 NA 2 5 3 2 3 2 6 3 6 4 5 4 4 3 3 4 3 2 2 3 2 2 4 3 6 2 NA 1 2 2 2 2 3 3
Exterior Site Lighting 6 NA NA 1 4 2 4 5 4 6 4 5 5 5 6 5 5 6 5 3 4 2 2 3 6 3 4 6 4 5 3 2 2 2 2 3 4
Fire Alarm System NA 1 NA 1 NA NA NA NA 6 NA NA 6 NA NA NA NA 6 NA NA 4 NA NA NA 2 4 2 NA NA 3 NA 6 3 3 4 2 NA NA
LEGEND - Asset Condition

Comments Description Life Rating
Good 75% 2
Fair 50% 3
Poor 25% 4
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations E2
Summary Report
Appendix F
Maintenance and Management Strategy
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations F3
Summary Report
SITE SAFET Y - Recommended Actions
Pum ping Station

Action Safe ty Hazard Addre s s e d
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Personal Protective Equipment and First Aid Kits - Supply
and maintain at all pump stations. Saf ety Signage - Install
Know ledge of Site Saf ety Rules X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
signs at site entrance and Pump Room (Saf ety Boots,
Eye & Ear Protection).
Hearing Protection - Provide to all operators (and visitors
Excessive Noise
to be suitably equiped).
Site A ccess Road - Upgrade ac cess road f or improved
Site Acc ess and Egress X X
site access.
Emergency Procedures f or Remote Sites - Implement f or

Site Emergency Procedures X X X X
emergency vehicle acc ess or personnel evacuation.
Telephone Communication - Install a land line for site Site Emergency Procedures;
X X X X X X
emergencies and reliable communications. Telephone Communication
Security Fence - Install/ repair f encing and gates. Site Security X X X X X X
Exterior Lighting - Install/ repair f or saf e night operations. Lighting X X X X X X X X X X X X X X X X
Internal Lighting - Repair lighting in Pump House and

Lighting X X X X X X X X
Control Room.
Elevated Storage Tow er - Repair internal lighting. Lighting X
A ircraft Clearance Lights - Install/ repair elevated tow er
Lighting X X X X
aircraf t clearance lights.
Pow er Cabling - Provide protection f or cabling and
Electrical Hazards X X X X X X
personnel.
Ladders / Scaf folding; Water
Elevated Tow er - Safety modifications required. X X X
Quality / Health Hazard
Storage Tanks - Repair/ modif y to protect w ater quality Water Quality / Health Hazard;
X X X X X X X X X X X X X X X X X X X
and/or personnel saf ety. Ladders / Scaf folding
Site Acc ess and Egress;
Pump House - Safety modif ications required. Mechanical Hazards (e.g. X X
Unguarded Plant)
Unsaf e Structures - Remove surge tank shelter. Structural Safety Haz ard X
Transf ormer - Modif y to protect personnel. Electrical Hazards X
Pow er Cabling - Repair damaged cabling. Electrical Hazards X
Pow er Cabling, Ducting and Trays - Modif y to make saf e. Electrical Hazards X X
Electrical Hazards; Lock Out / Tag

Main Sw itchboard and Motor Controls - Repair. X X X X X X X X X
Out
Mechanical Hazards (e.g.
Overhead Crane - Repair. X X
Unguarded Plant)
Fire A larm and Fire Fighting Sys tem - Modif y/ repair to
Fire Hazard and Equipment X
ensure reliability.
Mechanical Hazards (e.g.
Pumps - Shaft guards required to protect personnel. X X
Unguarded Plant)
Fire Hazard and Equipment;
Housekeeping - Clean up required to make site safe. X X X X X X X X X X X X
Housekeeping (General Tidiness)
Unused Storage Tank - Decommission tank to make saf e. Structural Safety Haz ard X
Summary Report
CIVIL ASSETS - Recommended Actions
Pum ping Station

Action
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Site Access - Upgrade access road. X X X X X
Security Fencing - Install security fencing to prevent unauthorised entry. X X X
Security Fencing - Modif y height to prevent unauthorised entry. X X X X
Security Fencing - Repair broken fencing/ gates. X X X X
Security Fencing - Repair transf ormer f ence. X
Internal Roads - Repair missing pavers and holes. X
Security House - Repair broken fixtures. X X
Accommodation - Install accommodation facilities. X X X X X X X X X X
Accommodation - Repair broken f ixtures. X X
Accommodation - Upgrade/ Replace accommodation facilities. X X X X X X
Operations Of fice - Provide space or construct operations of fice. X X X X X X X X X X X X X X X X X X X X X X X
Guard House - Repair w ater supply services. X X X X
Control Room - Investigate/ repair structural cracking. X
Control Room - Repair doors. X X
Pump House - Install floor sump and dew atering pump. X
Pump House - Investigate and repair structural cracks. X
Pump House - Repair air conditioning. X
Pump House - Repair doors/ w indow s. X X X X X X
Pump House - Safety modif ications required. X X
Elevated Tow er - Repair doors/ roof hatches. X X X X
Elevated Tow er - Saf ety modif ications required. X X X
Storage Tanks - Decommission old storage tank. X
Storage Tanks - Investigate cracking and leakage. X X X X X X X X X
Storage Tanks - Modify/ repair storage tanks/ fixtures. X X X X X X X X X X X X X X X X X X X X X X
Surge Tanks - Demolish unsaf e shelter. X
Instrumentation - Install f low / pressure metering. X X X
Instrumentation - Install storage level indicators. X X X X X X
Instrumentation - Repair/ replace flow / pressure metering. X X X X X X X X X X X X
Instrumentation - Repair/ replace storage level indicators. X X X X X X X X X X X X
Pipew ork & Valves - Install/ repair f lexible couplings. X X X
Pipew ork & Valves - Modify/ align pipew ork. X X X X X X X X X X
Pipew ork & Valves - Repair/ replace pipew ork. X X X X X
Pipew ork & Valves - Repair/ replace valves. X X X X X X X X X X X X X
Pipew ork & Valves - Upgrade pipe/ valve sizes. X X X X
General Operations - Confirm this pump station is to be retained. X
General Operations - Improve operators communication skills. X
General Operations - Modify duty pump selection. X
General Operations - Record hours run f or all pumps. X
Housekeeping - Clear site of loose debris, clean bird debris from around
X X X X X X X X X X X X X X X
storage hatches and fixtures, remove trip hazards.
Summary Report
MECHANICAL ASSETS - Recommended Actions
Pumping Station
Action
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Accom modation - Repair broken fixtures . X
Control Room - Repair/ replace air conditioning. X X X X X X X X X X X X
Operations Office - Replace air conditioning. X
Overhead Crane - Repair or m odify to make s afe. X X X X X X
Pump House - Ins tall air conditioning in the pump room. X X X
Pump House - Repair air conditioning. X X X
Pump House - Repair ventilation/ lighting. X X X X X X X X
Pump House - Replace/ upgrade air conditioning. X X X X
Pump-Motor Set - Modify/ upgrade m ountings to minimise vibration. X X X X X X X X
Pump-Motor Set - Modify/ upgrade to improve energy efficiency. X X X X X X X X X X X
Pump-Motor Set - Realign shaft. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
Pump-Motor Set - Repair/ modify motor. X
Pump-Motor Set - Repair/ modify pump. X X X X X X X X X X X X
Pump-Motor Set - Replace coupling. X X X X
Pump-Motor Set - Replace/ upgrade. X X X X
Surge Tanks - Repair/ tes t s urge tank. X X X X
Water Treatm ent System - As ses s Condition. X X X X
Summary Report
ELECTRICAL ASSETS - Recommended Actions
Pumping Station
Action
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Control Room - Repair lighting. X X X X X
Elevated Tower - Ins tall/ repair aircraft clearance lights . X X X X
Elevated Tower - Repair internal lighting. X
Em ergency Generator - Ins tall s tandby generator. X
Em ergency Generator - Repair equipm ent. X
External Lighting - Ins tall external lighting. X X X X X
External Lighting - Repair/ replace external lighting. X X X X X X X X X X X X X X X X X X X
Fire Fighting Sys tem - Ins tall/ com m iss ion s ys tem . X X
Fire Fighting Sys tem - Repair/ m odify fire fighting equipm ent. X X X X X
Ins trum entation - Ins tall flow/ pres s ure m etering. X X
Ins trum entation - Repair/ replace flow/ pres s ure m etering. X X
Lighting Protection - Repair connections. X
Power Cabling - Modify earthing arrangem ents . X X X X X X X X X X X X X
Power Cabling - Modify ins tallation to protect cabling and operators . X X X X X X X X X X X X X X X X X X X X X X
Power Cabling - Repair/ clean to protect cabling and operators . X X X X X X X
Power Transform er - Modify/ replace power trans form er. X X X X X X X X X X X X X X X X X X X X X
Power Transform er - Repair trans form er. X
Pum p Control and Mim ic Panel - Repair/ m odify panel. X X X X X X X X X X X X
Pum p Hous e - Repair ventilation/ lighting. X X X X X X X X X
Pum p-Motor Set - Repair pum p m otor. X X
Pum p-Motor Set - Repair/ m odify m otor. X X X X X X
Pum p-Motor Set - Res pecify m otors to higher tem perature rating. X X X
Switchboard and Motor Controls - Repair. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
Summary Report
Appendix G
ADDC GIS Object Numbers
Summary Report
ADDC GIS OBJECT NUMBERS - Correlated to GHD Pumping Station Field Data
Pum ping Station

Civil As s e t
W01
W02
W03
W04
W05
W07
W08
W09
W10
W11
W12
W13
W14
W15
C01
C02
C03
C04
E01
E02
E03
E04
E05
E06
E07
Pump Station Facility 7 8 6141 8081 9 123932 6454 12412 11393 9089 39 8769 45 53 41 12049 81 3521 36 38
Pump House
Storage Tank No 1 129 136137 15498, 15499 18369 139, 140 15810 21665 962961 641 702701 19345 13186 218 207 21330 221 19697 198 200
Storage Tank No 2 15496, 15497 139, 140 15810 642 13185 219 208
Storage Tank No 3 138, 141 226
Storage Tank No 4 138, 141
Elevated Tank No 1 142 143 144 15809 644 235 230
Elevated Tank No 2
Suction Header Valve 1
Suction Header Valve 2
Suction Pump Isolation Valve 1 7182 7195 228270 312809 7211 251145 311349 20181 18905 9760 302991 202101 9842 9832 9898 9862 304028 9734 9777
Suction Pump Isolation Valve 2 7194 7197 228265 312812 7210 251140 311348 20180 18908 9748 302994 202098 9840 9830 9900 9862 304030 9732 9775
Suction Pump Isolation Valve 3 7199 228261 312815 7203 251146 311347 18904 9746 302992 202097 9838 9828 9902 9864 304033 9730 9773
Suction Pump Isolation Valve 4 228267 311346 302993 202102 10078 9826
Suction Pump Isolation Valve 5 228269 9834
Suction Pump Isolation Valve 6 9923
Pump/ Motor 1 10 12 2905 7213 21 28 3537 7156 978 657 44 4849 2578 67 54 83 72 5219 35 41
Pump/ Motor 2 11 13 2904 7214 20 29 3539 7153 979 658 43 4850 2577 66 53 84 73 5221 34 40
Pump/ Motor 3 14 2903 7215 19 27 3538 7154 659 42 4851 2579 61 52 85 74 5222 33 39
Pump/ Motor 4 2902 7155 4852 2580 106 51
Pump/ Motor 5 2900 50
Pump/ Motor 6 55
Non-Return V alve 1 7273 7268 228276 312811 7279 7284 251144 311355 20193 18912 9919 202093 10004 9906 9970 10010 304019 9918 9995
Non-Return V alve 2 7274 7275 228275 312814 7278 7286 251138 311356 20192 18910 9990 202096 10003 9905 9971 10011 304032 9917 9994
Non-Return V alve 3 7276 228274 312817 7277 7283 251142 311354 18911 9991 202095 10002 9904 9972 10018 304035 9916 9993
Non-Return V alve 4 228273 311357 202099 10079 9903
Non-Return V alve 5 228272 9908
Non-Return V alve 6 9909
Delivery Isolation Valve 1 7181 7196 228280 312810 7212 7253 251141 311350 20183 18909 9761 302995 202104 9841 9831 9897 9869 304020 9735 9778
Delivery Isolation Valve 2 7193 7198 228281 312813 7210 7254 251143 311351 20185 18906 9749 302996 202084 9839 9829 9899 9864 304031 9733 9776
Delivery Isolation Valve 3 7200 228279 312816 7204 7248 251139 311352 18907 9747 302997 202100 9837 9822 9901 9866 304034 9731 9774
Delivery Isolation Valve 4 228278 311353 302998 202103 10077 9825
Delivery Isolation Valve 5 228277 9833
Delivery Isolation Valve 6 9924
Delivery Header Valve 1
Delivery Header Valve 2
Surge Tank 1 387163 337
Surge Tank 2
Surge Tank 3
Com m e nts
Note : 'NA' or 'Blank' = Not A ppliable or Data Not Available.
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations G1
Summary Report
ADDC GIS OBJECT NUMBERS - Correlated to GHD Pumping Station Field Data
Pum ping Station

Civil As s e t
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
Pump Station Facility 37 48 50 3841 4177 8449 8417 8453 8451 12401 106
Pump House
Storage Tank No 1 199 222 229 12529 18705 18690 18707 18706 21346 21345
Storage Tank No 2
Storage Tank No 3
Storage Tank No 4
Elevated Tank No 1 23 175
Elevated Tank No 2
Suction Header V alve 1
Suction Header V alve 2
Suction Pump Isolation V alve 1 9759 9871 9895 303359 302671 302212 302721 302696 310961 311009
Suction Pump Isolation V alve 2 9755 9873 9893 303362 302674 302211 302724 302699 310963 311010
Suction Pump Isolation V alve 3 9753 10076 303360 302672 302209 302722 302697 310965 311011
Suction Pump Isolation V alve 4 9875 303361 302673 302210 302723 302698
Suction Pump Isolation V alve 5
Suction Pump Isolation V alve 6
Pump/ Motor 1 38 75 82 2257 5185 4833 4497 4841 4837 6833 6850
Pump/ Motor 2 37 76 81 2258 5186 4834 4498 4842 4838 6834 6849
Pump/ Motor 3 36 105 2259 5187 4835 4499 4843 4839 6835 6848
Pump/ Motor 4 77 2260 5188 4836 4500 4844 4840
Pump/ Motor 5
Pump/ Motor 6
Non-Return V alve 1 9989 10019 9965 303377 310967 311020
Non-Return V alve 2 9922 9959 9964 303376 310968 311017
Non-Return V alve 3 9921 10074 303375 310969 311019
Non-Return V alve 4 9960 303374
Non-Return V alve 5
Non-Return V alve 6
Delivery Isolation V alve 1 9758 9870 9896 303363 302675 302213 302725 302700 310962 311016
Delivery Isolation V alve 2 9756 9872 9894 303364 302676 302214 302726 302701 310964 311015
Delivery Isolation V alve 3 9754 10075 303365 302677 302215 302727 302702 310966 311014
Delivery Isolation V alve 4 9874 303366 302678 302216 302728 302703
Delivery Isolation V alve 5
Delivery Isolation V alve 6
Delivery Header V alve 1
Delivery Header V alve 2
Surge Tank 1
Surge Tank 2
Surge Tank 3
Com m e nts
Note : 'NA' or 'Blank' = Not A ppliable or Data Not A vailable.
76/10239/11871 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations G2
Summary Report

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Abu Dhabi Distribution Company

Condition Assessment and Energy

2. Pumping Station Assessments 2

3. Safety and Compliance 5

4. Civil Asset Maintenance and Management 8

5. Electrical Asset Maintenance and Management 10

7. Motor Control Systems 17

8. Mechanical Asset Maintenance and Management 19

9. Technician and Operator Training 31

10. GIS Object Identifiers 33

11. Conclusions and Recommendations 34

1.1 Project Objectives

1.2 Project Scope

1.3 Purpose of Report

2.1 Number of Water Pumping Station Assessments

2.2 Assessment Methodology

2.3 Safety Assessments

2.4 Condition Assessments

2.4.1 Civil Assets

2.4.2 Pumps and Motors

2.5 Performance and Efficiency Assessments

2.6 Vibration, Alignment and Noise Assessments

2.7 Operations and Maintenance Assessments

Figure 1 Typical Pump-Motor Configuration

2.9 GPS Location of ADDC Pumping Stations

2.10 ADDC GIS Object Numbers

3.1 Relevant Laws, Decrees and Regulations

3.2 Existing Safety Issues

3.3 Safety Improvement

4.1 Asset Lives

Table 2 Asset Condition Assessment Rating

LEGEND - Asset Condition Assessment

Description Life Remains Rating

"As New" 100% 1

Failed / Derelict Un-useable 6

4.2 Civil Asset Management

Recommendation - Buildings, Roads and Fences

5.2 Quality of Maintenance

Figure 2 Broken External Light Fittings

5.4 Requirements of Maintenance Management

5.5 Instrumentation Maintenance

5.6 Attitudes towards Maintenance

6.3 Pump Motors

6.4 Control Systems

6.5.1 Power Factor Correction

6.6.1 Cooling of pumping rooms

6.6.2 Lighting of control and amenity areas

6.7 Pumping Duty Cycle

6.8 Energy Management Recommendations

7.2 Emergency Power

8.2 Findings and Observations

8.2.1 Centrifugal Pump Types

8.2.2 Pump capacity ranges

8.2.3 Pump Efficiencies

Figure 6 Typical Pump Performance Curve

Figure 7 Pump Efficiency versus Flow

8.2.4 Examples of High Efficiency Pump Selection