W-18 (Rev1)

Abu Dhabi Distribution Company
Condition Assessment and Energy

Management Survey of ADDC Water
Pumping Stations
Western Region PS 18 - Mirfa Truck
Filling Station
Pumping Station DW-MRF-WPS1
February 2010
Contents
1. Introduction 1
1.1 Project Objectives 1
1.2 Project Scope 1
1.3 Purpose of this Report 1
1.4 Related Reports 1
1.5 ADDC Supplied Information 1
2. Pump Station Overview 2

2.1 Description of Pumping Station 2
3. Pump Station Assessments 3

3.1 Site Safety Assessment 3
3.2 Civil and Infrastructure Assets Condition Assessment 3
3.3 Mechanical Assets Condition Assessment 3
3.4 Electrical Assets Condition and Energy Assessment 3
3.5 Pump Performance and Efficiency Assessment 4
3.6 Vibration, Alignment and Noise Assessment 4
4. Civil and Infrastructure Assessment 5

4.1 Safety Assessment 5
4.2 Building and General Infrastructure 5
4.3 Pump Station Operation 5
5. Mechanical Assets Assessment 7

5.1 General Description 7
5.2 Shaft Alignment 7
5.3 Noise Levels 7
5.4 Thermal Imaging 7
5.5 Summary of Action Points 7
6. Electrical Assets Assessment 8

6.1 General Description 8
6.2 Motor Description and Condition 9
6.3 Pump and Tank Control Panel 9
6.4 Station Power Supply 9
6.5 Station Lighting 10
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
Western Region PS 18 - Mirfa Truck Filling Station Pumping Station DW-MRF-WPS1
6.6 Items for Further Investigation – only if this station is to maintain
future operation 10
7. Recommendations 11
Figure Index
Figure 1 Western Region PS 18 - Mirfa Truck Filling Station
Pumping Station DW-MRF-WPS1 2
Figure 2 Pump Building 4
Figure 3 Damaged Boundary Fence 5
Figure 4 Exposed Pump Cables 5
Figure 5 Grasses against Office Wall 6
Figure 6 Storage Tank Wall Cracking 6
Figure 7 Pump Room 7
Figure 8 Pump Floor layout 8
Figure 9 Station Supply Isolator 9
Figure 10 Interior showing exposed cable 9
Figure 11 Cables to Motor Isolator 10
Figure 12 Interior Showing Exposed Cable 10
Figure 13 General view – Pumps and Storage Tank Buildings 12
Appendices
A Pump Station Schematic
B Site Safety Assessment
C Civil and Infrastructure Assets
D Mechanical Assets
E Electrical Assets
F Pumps and Motors – Temperature, Noise, Vibration and Alignment
1. Introduction
1.1 Project Objectives

The objective for this project is to develop a prioritised maintenance and management strategy that
extends the life and reliability of 37 water pumping stations managed by the Abu Dhabi Distribution
Company (ADDC).
1.2 Project Scope

The scope for this project includes:
1. Collect and review available technical information to conduct the pumping station condition
assessment;
2. Develop a methodology for condition and performance assessment of ADDC’s water pumping station
located in Central, Eastern, and Western Regions;
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 36
pumping station;
5. Produce a Condition Assessment and Energy Management Report on each of the nominated water
pumping stations; and
6. Produce a final Condition Assessment and Management Strategy Report for the 37 water pumping
stations which:
– summarises the results of the individual pumping station surveys;
– identifies plant and equipment for repair, overhaul or replacement; and
– presents GHD’s recommendations for condition monitoring, maintenance and energy management
improvement and operator training and operations improvement.
1.3 Purpose of this Report

This report presents the following results of GHD’s Condition Assessment and Energy Management
Survey of Western Region PS 18 - Mirfa Truck Filling Station Pumping Station DW-MRF-WPS1 .
This report should be read in conjunction with the “Assessment Overview Report” and the final “Condition
Assessment and Management Strategy Report”.
1.4 Related Reports

This report should be read in conjunction with the “Assessment Overview Report” and the final “Condition
Assessment and Management Strategy Report”.
1.5 ADDC Supplied Information

Not all information to conduct the full scope of the pumping station survey was available from ADDC or
from GHD’s research of equipment suppliers and their websites.
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations 1
2. Pump Station Overview
2.1 Description of Pumping Station

Pump Station Location Description
Date of Inspection 20 July 2009
Name Mirfa Truck Filling Station Pumping Station, Mirfa
Location Mirfa
Access Viz Mirfa shabiya
Date of Commissioning (Not Provided)
Supply Source DN 300 Pipeline from Mirfa Summit Tanks
Area of Supply The Mirfa Truck Filling Station on site.
Storage Tanks 1 x 2.25 Ml concrete ground tank divided into 2 cells
Pumps 2 x horizontal centrifugal pumps (1 duty + 1 standby) – Not Operational
Elevated Storages Nil
Pump Station Schematic Refer Appendix A
Figure 1 Western Region PS 18 - Mirfa Truck Filling Station Pumping Station DW-MRF-WPS1
NOTE: This pumping station has been out of pumping operation for approx. 2 years.
3. Pump Station Assessments
3.1 Site Safety Assessment

GHD’s site team supervisor conducted a safety assessment upon entering each pumping station facility.
The safety assessment identified any areas, buildings, structures or equipment considered unsafe and
reported this to ADDC staff or contractors.
GHD’s site safety assessment of this pumping station is attached as Appendix B.
3.2 Civil and Infrastructure Assets Condition Assessment

Civil and infrastructure assets generally include the following items: -
Access and Internal Roads & Paths
Boundary Fence & Gates
Buildings
Site Services (e.g. Water Supply, Sewerage, Lighting, Waste Management, Landscaping, etc.)
Ground and Elevated Reservoirs
Reservoir Water Level Indicators
Exposed pipework, Valve Pits and Chambers
Surge / Pressure Tanks
A schematic plan of the pumps, pipework, and valving and storage tanks is attached as Appendix A.
GHD’s condition assessment schedules for civil and infrastructure assets are attached as Appendix C
3.3 Mechanical Assets Condition Assessment

Mechanical assets generally include the following items: -
Water Pumps;
Pump Room Overhead Cranes;
Pump Room, Switchboard and Control Room Air Conditioning; and
Pump Room Ventilation.
GHD’s condition assessment schedules for mechanical assets is attached as Appendix D
3.4 Electrical Assets Condition and Energy Assessment

Electrical assets generally include the following items: -
pump motors;
power transformers;
pump station earthling and lightning protection;
pump room crane electrics;
main switchboard and pump control panels;
power cabling;
room and exterior lighting; and
fire alarm systems.
GHD’s condition assessment schedules for electrical assets are attached as Appendix E
3.5 Pump Performance and Efficiency Assessment

GHD’s site team assessed the hydraulic performance of each of the main pump sets against Original
Equipment Manufacturer’s (OEM) specifications
GHD’s condition assessment schedules for pump performance assessment are attached as Appendix D.
3.6 Vibration, Alignment and Noise Assessment

GHD’s site team assessed ambient and motor-pump noise, vibration, and temperature and shaft
alignment of all main pump equipment.
GHD’s vibration, alignment and noise assessment schedules for pump performance assessment are
attached as Appendix F.
Figure 2 Pump Building
4. Civil and Infrastructure Assessment
4.1 Safety Assessment

The following safety matters require attention as noted in Appendix B:
The station is supplied at LV from an unknown source via a 400 Amp Dorman Smith isolator on the
Pump Station wall. The insulation on the supply cables is cracked and bare wires are exposed (refer
Section 6.4, Figure 10).
Site boundary fence has had extensive truck impact damage and is collapsing (refer Figure 3).
Power cables are exposed on the floor of Pump Room (refer Figure 4).
Figure 3 Damaged Boundary Fence Figure 4 Exposed Pump Cables
4.2 Building and General Infrastructure

The station comprises a pump room and a connected office and amenity area. The Pump Room houses
the pump controls and an office used to manage the water truck log books. The original office is used for
accommodation and amenities for the station operators.
Pump Room lights are not working.

Pump Room air conditioning is not working.
Site housekeeping is generally poor with high grasses growing in water leakage against the Office/
Accommodation Building wall (refer Figure 5).
4.3 Pump Station Operation

The station features an older single pump and a newer two pump package. The two pump package has
only one pump installed but is equipped with controls and frame accommodation for 2 pumps.
The pump station was originally designed to boost flows to 6 filling points for water trucks, however the
pumps have been out of operation for nearly 2 years and only 4 filling points can be used based on the
pressure and flow in the mains.
Pump No. 2 was taken out for repair some time ago but not returned for installation.
The control panel trips when the pumps are started (reason unknown).
The pump delivery pipe leaks.
Figure 5 Grasses against Office Wall
Storage Tank
The storage tank is fair condition with some wall cracking at the foundation level (refer Figure 6), but is
not filled and is not used since the pump station was turned off.
Figure 6 Storage Tank Wall Cracking
5. Mechanical Assets Assessment
5.1 General Description

This station is an old non-operational station with 2 horizontal pump motor sets. Third pump set has
been removed. The equipment looks in poor condition, although we were unable to carry out tests to
confirm this.
General Condition - External: Very poor.
Shaft Flexible Couplings Fair
Pipe Work - Flexible Connections Fair
5.2 Shaft Alignment

Alignment was measured on each pump set. Individual results are presented in the appropriate
schedule. Alignment was measured on cold pumps. The angular displacement horizontal readings for all
the pumps are well outside generally accepted limits.
5.3 Noise Levels

Unable to test. Pumps are not operational.
5.4 Thermal Imaging

Unable to test. Pumps are not operational.
5.5 Summary of Action Points

No action points – this pumping station has been out of action for 1.5 years.
Figure 7 Pump Room
6. Electrical Assets Assessment
6.1 General Description

The station in its original design have been used to boost pressure to a filling manifold. Without the
pumps operating there is only enough pressure to operate four out of the six nozzles.
The station has a large storage tank to provide for high instantaneous out flows required for tanker filling.
The station is reported to have failed through small issues that were never fixed. The pressure/flow
accumulator tank leaks. Several of the valves leak. The reason that it is unused is that the motors will
only run for a short while before they trip, cause unknown. It appears that there is a status indication
supplied to the manifold control hut and possibly the ability to start and stop pumps remotely.
The station features an older single pump and a newer two pump package. The two pump package has
only one pump installed but is equipped with controls and frame accommodation for 2. There is no
mimic or tank level status. Controls are adequate to run and monitor pumps. There is a motor control
MCCBs with overloads and level trip safety interlocks.
Figure 8 Pump Floor layout
Station layout
The station comprises a pump room and a connected office and amenity area. Both are equipped with
packaged air conditioning units but only those for the office/amenity area are working. It is entirely
possible that the office area has been kept going at the expense of the other area as it is being used as
sleeping accommodation.
6.2 Motor Description and Condition
General Condition - Fair.
External:
General Condition - Motor winding insulation > 4 G at 500 V. Motor cable terminals were in
Electrical: poor condition, dirty and corroded.
Cabling: Unacceptable. Cables loose laid on pumping floor.
Local Controls Motors and control panel are adjacent.
6.3 Pump and Tank Control Panel

The station has an appropriate number and layout of local distribution boards. These boards are in
serviceable condition.
6.4 Station Power Supply

The station is supplied at LV from an unknown source.
The supply is controlled via a 400 Amp Dorman Smith isolator. The insulation on the supply cables is
cracked and bare wires are exposed.
Figure 9 Station Supply Isolator Figure 10 Interior showing exposed cable
Cable Layout
No cable trays are employed. Cables are loose laid from controllers to pumps.
Figure 11 Cables to Motor Isolator Figure 12 Interior Showing Exposed Cable
6.5 Station Lighting

No permanent lighting. A street lighting fitting has been secured to the fence and powered via a long
flexible connection. It is not known if the light is working. The installation is unsafe.
Control Room
Twin fluorescent fittings, not working and with cracked diffusers.
6.6 Items for Further Investigation – only if this station is to maintain future
operation
There are a number of serious shortcomings in the current state of the station. This list is restricted to
electrical matters.
Level control cables to/from the tank are run effectively unprotected over ground to the tank. These
must be properly protected and supported above ground. It is recommended that they be simply
replaced as a matter of course.
Tank level control inputs and control actions are to be recommissioned. It is expected that this action
will remove the “trip” fault in the control system
Power and status cables from control panels to motors and distribution boards to control panels are
loose laid on the station floor. These cables are to be mounted on protective cable trays.
Lighting to be fitted with lamps and diffusers and checked for insulation safety
Panel covers are to be restored to fully working condition. This work to include exterior distribution
board.
7. Recommendations
General
1. A decision is needed as to whether to reinstate this pumping station to its full operational status or
decommission and secure the pump station.
Safety
Whether decommissioned or reinstated the following safety matters are to be attended to urgently:
2. Repair the insulation on the supply cables and secure the bare wires exposed in the power supply
exterior distribution board/ isolation box for the pump station.
3. Safety signs should be installed at the entrance to the station pump room). - Safety Shoes, Hard Hat,
Hearing Protection and Eye Protection).
4. The damaged site boundary fence should be either removed or reinstated with ‘fenders’ to prevent
further damage by trucks.
5. Mount the exposed power cables in the Pump Room on protective cable trays.
6. Permanent site lighting to be installed and temporary light (with flexible cord) removed
Civil and Infrastructure Assessment

Assuming the station is to be reinstated the following recommendations are presented:
7. Repair Pump Room lights and air conditioning.

8. Leaking pipework to be repaired and site housekeeping improved to maintain a safe working
environment.
9. Investigate the cause of concrete spalling near the ground surface around the tank.
Mechanical Assets Assessment

10. All pumps have been decommissioned and are out of action.
11. If station no longer required – consider to recover off pumping, valves and piping equipment for uoue
on other existing sites.
12. Pumps – for future operation – alignment on both shafts will be required.
13. Pump name plates are missing. Investigate and mark all pumps for design duties and operational
parameters.
Electrical Assets Assessment

14. Level control cables to and from the storage tank are run effectively unprotected over ground to the
tank. These must be properly protected and supported above ground. It is recommended that they
be replaced as a matter of course.
15. Tank level control inputs and control actions are to be recommissioned. It is expected that this action
will remove the “trip” fault in the control system
16. Power and status cables from control panels to motors and distribution boards to control panels are
loose laid on the station floor. These cables are to be mounted on protective cable trays.
17. Pump room lighting is be reinstated - fitted with lamps and diffusers and checked for insulation
safety.
18. Panel covers are to be restored to fully working condition. This work will include the exterior
distribution board.
Figure 13 General view – Pumps and Storage Tank Buildings
Appendix A
Pump Station Schematic
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations A1
Appendix B
Site Safety Assessment
SITE SAFETY ASSESSMENT
Pumping Station Name T anker Filling Station (TFS) Pump Station, Mirfa
Assessment Date 20 July 2009
HAZARD SATISFACTORY COMMENTS

Site Access and Egress Yes
Site Security No Boundary fence collapsing
Lighting No Site lighting is provided by a temporary street light with flexible cable.
Mechanical Hazards (eg Unguarded Plant) Yes
Electrical Hazards No Cables exposed on floor of pump room. Exposed wires in external power supply/
distribution box.
Housekeeping (General Tidiness) No General mess
Fire Hazard and Equipment Yes
Noise Yes Not assessed
Dust / Fumes Yes
Hazardous Substances Yes
W orking at Heights Yes
Ladders / Scaffolding Yes
Pressurized Equipment Yes
Heat Illness / Stress Yes
Personal Protective Equipment (PPE) Yes PPE should be issed to all ADDC station personnel
Knowledge of Site Safety Rules Yes
Site Emergency Procedures Yes Not assessed
Confined Space Entry Yes
Lock Out / Tag Out No Station out of pumping operation - no equipment tags etc
Comments
It is recommended that proper safety signs should be installed at the entrance to the station (and pump room): Safety Shoes, Hard Hat, Hearing Protection,
Eye Protection.
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations B1
Appendix C
Civil and Infrastructure Assets
Condition Assessment Schedules:

a) Buildings and General Infrastructure
b) Storage Tanks
c) Pipework and Valves
CONDITION ASSESSMENT - Buildings & General Infrastructure
Pum ping Station Name Tanker Filling Station (TFS) Pum p S tation - Mirfa LE GEND - Asset Condition Assessment
Assessment D ate 20 July 2009 Description Life Remains Ratin g
Time: IN / OUT 9.00AM / 11.00A M "As New" 100% 1
GPS P osition (E ntry Gate) N 24° 5.353' E 53° 28.512' Good 75% 2
ADDC GIS Object No: 50 Fair 50% 3
Poor 25% 4
Inspection Personnel Failure Imminent 0% 5
John John (GH D) Failed / Derelict Un-useable 6
Roger Hawkins (Palmer Acoustics )
Padalchai P.
Asset Condition Assessm ent

Asset Description Com ments
S chedule Parameters Ratin g
Access Road Asphalt Fair S ealed Pavements A, B 3
Bou ndary Fen ce / Walls Barbed fence Collapsed Fences / Structures A-F 6
Entry G ate Steel Gate Fair Structures A -F 3
Security House N o Security house NA
External W alls NA
Roof NA
Internal W alls NA
Internal Am enities NA
Pum p House C oncrete/ bl ock building Not s atisfactory Structures A -F 4
External W alls Blocks Not s atisfactory Structures A -F 4
Roof C oncrete Not accessible NA
Internal W alls Plastered blocks Not s atisfactory Structures A -F 4
Office & Internal Am enities Office inside the pump/ control room Not s atisfactory Misc. Site Assets A 4
Accomm odation N o accommodation building. NA
External W alls NA
Roof NA
Internal W alls NA
Internal Am enities NA
Internal Roads C ompacted sand. S ealed Pavements A, B 4
Internal Paths N il NA
Lan dscaping N il NA
Comm ents
NOT E: 'NA' or 'Blank' = Not Applic able or Data Not Available.
- No separate c ontrol room - controls housed in t he pump room .
- O ffice housed in pump/c ontrol room, no dedicated office space available w ith necessary amenities and facilities.
- This pump station not in operation for last 1½ years.
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations C1
CONDITION ASSESSMENT - Storage/ Transfer Water Tanks
STORAGE / TRANSFER TANK 01

ADDC GIS Object No: 229
Width (m)
Length (m)
Diameter (m) LEGEND - Asset Condition Assessment
Roof Height (m) Description Life Remains Rating
Depth (m) "As New" 100% 1
Capacity (m3) 2250 Good 75% 2
Tank Description WATER STORAGE TANK Fair 50% 3
Material CONCRETE Poor 25% 4
DN 300 gravity line from summit tanks Failure Imminent 0% 5
Comments
Failed / Derelict Un-useable 6
Asset Condition Assessment

Asset Description Comments
Schedule Parameters Rating
External - Walls Concrete, sand blasted Many signs of wall cracks evident Structures A-F 4
External - Roof Concrete covered with tiles Fair Structures A-F 3
External - Roof Access Steel ladder Fair Structures A-F 3
External - Roof Hatches Lockable hinged steel covers Fair Structures A-F 3
Internal - Walls Concrete No access NA
Internal - Floor Concrete No access NA
Internal - Roof Concrete No access NA
Water Level Indicator Available Unreadable NA
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
1) No water storing in the tank. Not in use for the last 1½ years.
Structural / Material Testing Recommended (Yes / No) YES
CONDITION ASSESSMENT - Pipework & Valves (Suction Side)
Suction Header Pipework Pipe 1

Pipe Material steel
Pipe Diameter (mm) 200
Condition Rating (1 to 6) 3
Suction Header Valves Valve 1

ADDC GIS Object No: Not Assigned
Valve Diameter (mm) 200
Pump Suction Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Pipe Material steel steel steel
Pipe Diameter (mm) 150 150 150
Condition Rating (1 to 6) 3 3 3
Suction Side
Flexible Coupling
Flexible Coupling Diameter (mm) NA NA NA
Condition Rating (1 to 6) NA NA NA
Isolation Valve
ADDC GIS Object No: 9895 Not Assigned 9893
Isolation Valve Type gate NA gate
Isolation Valve Diameter (mm) 150 NA 150
Condition Rating (1 to 6) 3 NA 3
Comments LEGEND - Asset Condition Assessment

NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. Description Life Remains Rating
Pipes and valves are leaking and have been abandoned since two years ago. "As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
CONDITION ASSESSMENT - Pipework & Valves (Delivery Side)
Delivery Header Pipework Pipe 1
Pipe Material steel
Pipe Diameter (mm) 200
Delivery Header Valves Valve 1

ADDC GIS Object No: Not Assigned
Valve Diameter (mm) NA
Condition Rating (1 to 6) NA
Pump Delivery Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Pipe Material steel steel steel
Pipe Diameter (mm) 100 100 100
Condition Rating (1 to 6) 3 3 3
Flexible Coupling
Flexible Coupling Diameter (mm) NA NA NA
Delivery Side
Condition Rating (1 to 6) NA NA NA
Non-Return Valve
Isolation Valve Type spring/flap NA spring/flap
Isolation Valve
Isolation Valve Type gate NA gate

Pipes and valves are leaking and have been abandoned since two years ago. "As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Appendix D
Mechanical Assets

a) Water Pumps
b) Other Mechanical Equipment & Systems
Pump and Motor Data
Pump Data Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
ADDC GIS Object No: 82 Removed 81
Year of Installation
Purpose / Function
Brand
Type
Model No
Serial No
Impeller Design Size (mm) Pumps not operational
Speed (rpm)
Pumping Design Power (kW )
Pump Design Efficiency (%)
Duty Point Flow (l/s)
NPSHR (kPa)
Duty Point Pressure (kPa)
Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

ADDC GIS Object No: 82 Removed 81
Brand
Type
Serial No
Voltage (V)
Speed (rpm)
Current (A) Pumps not operational
Insulation
IP or Enclosure
cos(fee)
Power (kW)
VSD (Yes / No)
OTHER
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D1
CONDITION ASSESSMENT - Water Pumps
Overall Condition Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
Pump Body
Pump Shaft
Pump Shaft Coupling
Pump Base Pumps not opeaational
Springs / Anti Vib. Mat.
Pump Plinth
Pump Motor
Asset Condition Assessment Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

General Condition
Assessment Schedule Pumps not operational
Assessment Parameters
Rating (1 to 6) NA NA NA

"As New" 100% 1
This Pump Station has not been operational for 2 years. Good 75% 2
Fair 50% 3
Poor 25% 4
PERFORMANCE ASSESSMENT - Water Pump Duty Point
Performance Parameters Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

ADDC GIS Object No: 82 Rem oved 81
MEASURED - Pump Flow Head (kPa)
PUMP CURVE - Flow Rate (l/s)
MEASURED - Pump Flow Rate (l/s)
Pum ps not operational
MEASURED - Pump Speed (rpm)
CALCULATED - Pump Hydraulic Power (kW)
MEASURED - Pump Motor Power Input (kW)
CALCULATED - Motor-Pump Efficiency (%) NA NA NA
MEASURED - Pump Shut-Off Head (kPa)
PUMP CURVE - Impellor Diameter (mm)
Comments
This Pump Station has not been operational for 2 years.
PERFORMANCE CURVES - Water Pumps
Pump Test Flow Pressure

Pump P- 01 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 0 1
Head Pressure (kPa)

2 0.8
3
4 0.6
P- 01
5 0.4
6
7 0.2
8
0
0 0 0 1 1 1
Water Flow (l/s)

1 0 0 1
Head Pressure (kPa)
2 0.8
3
4 0.6
P- 02
5
0.4
6
7 0.2
8
0
0 0 0 1 1 1
Water Flow (l/s)

1
1 0 0
Head Pressure (kPa)
2 0.8
3
0.6
4
P- 03
5 0.4
6
7 0.2
8
0
0 0 0 1 1 1
Water Flow (l/s)
CONDITION ASSESSMENT - Other Mechanical Equipment and Systems
Mechanical Equipment Description Comments Asset Condition Assessment

Overhead Crane No overhead crane NA
Security House Air Conditioning No security house NA
Pump Room Air Conditioning W indow AC Not working Mechanical A-H 6

Equipment
Control Room Air Conditioning No control room NA
Pump Room Ventilation No Ventilation NA
Other

NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. Description Life Remains Ra ting
1) Lights not working. "As New" 100% 1
2) AC units not working. Good 75% 2
Fair 50% 3
Poor 25% 4
Failed/ Derelict Un-Useable 6
Appendix E
Electrical Assets

a) Pump Motors
b) Switchboards and Motor Controls
c) Other Electrical Equipment and Systems
CONDITION ASSESSMENT - Pump Motors
Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6
Brand
Model No.
Serial No
Speed (rpm)
Average Voltage (V)
Pumps have been decomissionned and not working
Average Current (A)
Total Power (kW)
Overall Power Factor
Electrical Connection
Soft Start/ VSD
Hours Run (Hrs)
Cables/ Earthing Loose laid on floor. Loose laid on floor.
Unsatisfactory Unsatisfactory
Thermal Imaging
Asset Condition Assessment Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

Assessment Schedule Elect. Equip.
Assessment Parameters
Rating (1 to 6) NA NA NA

Motor 1: Motor could not be run "As New" 100% 1
Motor 2: Pump & Motor Removed Good 75% 2
Motor 3: Motor could not be run Fair 50% 3
Motor 4: Poor 25% 4
Motor 5: Failure Imminent 0% 5
Motor 6: Failed / Derelict Un-useable 6
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations E1
PERFORMANCE ASSESSMENT - Pump Motors
Performance Parameters Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6
R Y B R Y B R Y B R Y B R Y B R Y B
Voltage (V)
Current (A)
Power Factor
Average Voltage (V)
Average Current (A)
Overall Power Factor
Dielectric Absorption Insulation 400 @ Insulation 3600 @
(30sec / 60sec) >4G 1000 V >4G 1000 V
Polarisation Index (1min/10min) Not measured
Hours Run 1955
Power Measured (kW)
Total Power (kVAr)
Total Power (KVA)
RPM
Temperature ºC (Hot > 68ºC) 39.0
CONDITION ASSESSMENT - Main Switchboard & Motor Control Panels
Main Switchboard LEGEND - Asset Condition Assessment
Year of Installation Description Life Remains Rating
Clear Labelling? No local metering "As New" 100% 1
Logical Layout? Good 75% 2
Main Isolator Fair 50% 3
Manufacturer Poor 25% 4
Type Failure Imminent 0% 5
Rating (A) Failed / Derelict Un-useable 6
Switchboard Test Phases & Links R Y B RY YB BR

Use SB Meters? Voltage (V)
No. Pumps Running Current (A)
Meters Switched/ Individual? Power Factor
Thermal Imaging - Switchboard Comments

Termal Imaging?
Max. Temperature Overall Condition is for Distribution panel only.
Asset Condition Assessment

Assessment Schedule Elect. Equip.
Assessment Parameters A-I
Rating (1 to 6) 4
Motor Controls Motor Controls Thermal Comments

Image
Manufacturer NA Motor Control No 1 N/A LH motor panel has loose components and requires refurbishment.
Soft Start ? N Motor Control No 2 RH motor panels is a dual control panel in good condition.
Controls Functional ? Yes Motor Control No 3 N/A Ineffective interlocks
Internal Layout Poor Motor Control No 4
Interlock on Panel ? No Motor Control No 5
Motor Control No 6
CONDITION ASSESSMENT - Other Electrical Equipment and Systems
Electrical Equipment Description Comments Asset Condition Assessment

Power Transformer LV supply Bare conductors on supply cable in external Elect. Equip. A-I
6
Rating metering board
Pump Station Earthing Assumed part of LV supply No local E-N link Elect. Equip. A-I
Neutral / Earth Link Not tested 4
Resistance (Earth /Neutral) NA
Lightning Protection
NA
Lightning Protection Nil
Pump Room Crane
NA
Electrics Nil
Pump Control Panel Pumps and controls were not live and could not be Elect. Equip. A-I
Clear Mimic (Y/N) None operated. Cabling to tank sensors laid across ground
6
Fully Operational (Y/N) No and suspected to be faulty
Thermal Imaging (Y/N) N/A
Power Cabling Unsatisfactory Elect. Equip. A-I
5
Main SB to Motors Loose laid on floor
Room Lighting Elect. Equip. A-I
Control Room Lighting Broken fittings 6
Emergency/ Exit Lighting N/.A
Exterior Site Lighting Fittings connected to fence and connected via flexible Elect. Equip. A-I
6
Exterior Site Lighting Nil cable.
Fire Alarm System
Manufacturer Nil NA
Detector Types --

"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Appendix F
Pumps and Motors – Temperature, Noise,
Vibration and Alignment
Condition Assessment Schedules
TEMPERATURE, NOISE & VIBRATION - Pumps & Motors
Temperature Deg C
Pump Room 36.1
Control Room N/A
Outside (Ambient) 36.5
Ambient Noise [dB(A)] Noise Source

Pump Room N/A Non operational
Control Room
Outside (Ambient)
Pump/ Motor Noise Pump-Motor 1 Pump-Motor 2 Pump-Motor 3 Pump-Motor 4 Pump-Motor 5 Pump-Motor 6

dB(A) at 1 m dB(A) at 1 m dB(A) at 1 m dB(A) at 1 m dB(A) at 1 m dB(A) at 1 m
Noise Level (1m Distance) N/A N/A
Noise Source N/A N/A
Vibration (mm/s) / Frequency (Hz) Pump-Motor 1 Pump-Motor 2 Pump-Motor 3 Pump-Motor 4 Pump-Motor 5 Pump-Motor 6
Vibration Limit = 2mm/sec V (mm/s) w (Hz) V (mm/s) w (Hz) V (mm/s) w (Hz) V (mm/s) w (Hz) V (mm/s) w (Hz) V (mm/s) w (Hz)
Point No 1 = Motor - Top Front Bearing N/A N/A N/A N/A
Point No 2 = Motor - Rear Foot N/A N/A N/A N/A
Point No 3 = Motor - Top of Motor N/A N/A N/A N/A
Pumps have been
Point No 4 = Pump - Top Front Bearing N/A N/A N/A N/A
decomissionned
Point No 5 = Pump - Top Rear Bearing N/A N/A and not working N/A N/A
Point No 6 = Pump - Rear Foot N/A N/A N/A N/A
Point No 7 = Pump - Inlet N/A N/A N/A N/A
Point No 8 = Pump - Outlet N/A N/A N/A N/A
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations F1
ALIGNMENT - Pumps & Motors
Pump Shaft Alignment (mm) Pump-Motor 1 Pump-Motor 2 Pump-Motor 3 Pump-Motor 4 Pump-Motor 5 Pump-Motor 6
Angular Limit = 0.08mm/100m
mm mm mm mm mm mm
Linear Limit = 0.10mm
Angular Displacement - Horizontal 12.00 9.46
0.46 Pumps have been 0.48
Linear Displacement - Horizontal
decomissionned
Angular Displacement - Vertical 7.13 8.38
and not working
Linear Displacement - Vertical 0.24 0.48
Thermal Images (Hot > 68 Deg C) N/A N/A
Flexible Couplings Pump-Motor 1 Pump-Motor 2 Pump-Motor 3 Pump-Motor 4 Pump-Motor 5 Pump-Motor 6

Assessment Schedule Mech. Equip. Mech. Equip.
Assessment Parameters F F
Rating (1 to 6) 3 NA 3
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. LEGEND - Asset Condition Assessment
Pumps and motors in reasonable external condition "As New" 100% 1
Could not start pumps, no noise or vibration could be measured Good 75% 2
Pipework flexible connectors in good condition Fair 50% 3
Pump flexible couplings OK Poor 25% 4
Failure Imm inent 0% 5
76/10239/12054 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations F2

W-18 (Rev1)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

W-18 (Rev1)

Uploaded by

Copyright:

Available Formats

Abu Dhabi Distribution Company

Condition Assessment and Energy

2. Pump Station Overview 2

3. Pump Station Assessments 3

4. Civil and Infrastructure Assessment 5

5. Mechanical Assets Assessment 7

6. Electrical Assets Assessment 8

1.1 Project Objectives

1.2 Project Scope

1.3 Purpose of this Report

1.4 Related Reports

1.5 ADDC Supplied Information

2.1 Description of Pumping Station

3.1 Site Safety Assessment

3.2 Civil and Infrastructure Assets Condition Assessment

3.3 Mechanical Assets Condition Assessment

3.4 Electrical Assets Condition and Energy Assessment

3.5 Pump Performance and Efficiency Assessment

3.6 Vibration, Alignment and Noise Assessment

Figure 2 Pump Building

4.1 Safety Assessment

Figure 3 Damaged Boundary Fence Figure 4 Exposed Pump Cables

4.2 Building and General Infrastructure

Pump Room lights are not working.

4.3 Pump Station Operation

Figure 5 Grasses against Office Wall

Figure 6 Storage Tank Wall Cracking

5.1 General Description

General Condition - External: Very poor.

Shaft Flexible Couplings Fair

Pipe Work - Flexible Connections Fair

5.2 Shaft Alignment

5.3 Noise Levels

5.4 Thermal Imaging

5.5 Summary of Action Points

Figure 7 Pump Room

6.1 General Description

Figure 8 Pump Floor layout

Cabling: Unacceptable. Cables loose laid on pumping floor.

Local Controls Motors and control panel are adjacent.

6.3 Pump and Tank Control Panel

6.4 Station Power Supply

Figure 9 Station Supply Isolator Figure 10 Interior showing exposed cable

6.5 Station Lighting

Civil and Infrastructure Assessment

7. Repair Pump Room lights and air conditioning.

Mechanical Assets Assessment

Electrical Assets Assessment

Figure 13 General view – Pumps and Storage Tank Buildings

HAZARD SATISFACTORY COMMENTS

Condition Assessment Schedules:

Asset Condition Assessm ent

STORAGE / TRANSFER TANK 01

Asset Condition Assessment

Structural / Material Testing Recommended (Yes / No) YES

Suction Header Pipework Pipe 1

Suction Header Valves Valve 1

Pump Suction Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Comments LEGEND - Asset Condition Assessment

Delivery Header Valves Valve 1

Pump Delivery Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Comments LEGEND - Asset Condition Assessment

Condition Assessment Schedules: