Western Region PS 25 15819 Rev 3

Abu Dhabi Distribution Company
Condition Assessment and Energy

Management Survey of ADDC Water
Pumping Stations Including Water
Tank Internal Inspections
Western Region PS 25 - Grain Al Ayesh
No. 4 Pumping Station DW-GSH-WPS4
January 2012
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 2
2. Pump Station Overview 3

2.1 Description of Pumping Station 3
3. Pump Station Assessments 4

3.1 Site Safety Assessment 4
3.2 Civil and Infrastructure Assets Condition Assessment 4
3.3 Mechanical Assets Condition Assessment 4
3.4 Electrical Assets Condition and Energy Assessment 4
3.5 Pump Performance and Efficiency Assessment 5
3.6 Vibration, Alignment and Noise Assessment 5
3.7 Concrete Water Storage Tanks Condition Assessment 5
4. Civil and Infrastructure Assessment 7

4.1 Safety Assessment 7
4.2 Building and General Infrastructure 7
4.3 Pump Station Operation 7
5. Mechanical Assets Assessment 8

5.1 General Description 8
5.2 Vibration 8
5.3 Shaft Alignment 9
5.4 Noise Levels 9
5.5 Thermal Imaging 10
5.6 Summary of Action Points 10
6. Electrical Assets Assessment 11

6.2 Motor Description and Condition 12
6.3 Pump and Tank Control Panel 12
76/10239/15819 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11391 Tank Internal Inspections
Western Region PS 25 - Grain Al Ayesh No. 4 Pumping Station DW-GSH-WPS4
6.4 Station Power Supply 12
6.5 Main Switchboard and Control Panels 13
6.6 Power Cabling 14
6.7 Fire Alarm System 15
6.8 Station Lighting 16
6.9 Crane System 16
6.10 Items for Further Investigation 16
7. Concrete Water Storage Tanks Assessment 17

7.2 Ground Tank 17
7.3 Summary of Action Points 17
8. Recommendations 18
Figure Index
Figure 1 Western Region PS 25 - Grain Al Ayesh No. 4
Pumping Station DW-GSH-WPS4 3
Figure 2 Water Storage Tank 5
Figure 3 Surge Tank 7
Figure 4 Measurement Point Locations 8
Figure 5 Vibration at Location 2 on Pump 2 9
Figure 6 Acoustic Spectrum from Pump 1 10
Figure 7 Base of the Pump 10
Figure 8 Pump Floor Layout 11
Figure 9 Transformer Location 13
Figure 10 Main Switchboard 14
Figure 11 Cable Way beneath MSB 15
Figure 12 Cable Rise to Motor 15
Figure 13 Fire Alarm Panel 16
Figure 14 Pump Station Schematic 16
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
G Water Storage Tanks
H OEM vs Pump Performance
I Thermographic Images
J Vibration Spectrum
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. Conduct a visual inspection of concrete water storage tanks;
5. Produce a Condition Assessment and Energy Management Report on each of the nominated water
pumping stations;
6. Produce a Condition Assessment of concrete water storage tanks which:
– Summarises the structural condition of the tanks with respect to defects such as cracks, leaks,
settlement, honey combing, deflection and condition of any linings or protective coatings;
– Identifies and recommends what repairs are required to remediate any defects;
7. 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 25 - Grain Al Ayesh No. 4 Pumping Station DW-GSH-WPS4 .
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”. This report was previously numbered as document
11391.
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.
2. Pump Station Overview
2.1 Description of Pumping Station

Pump Station Location Description
Date of Inspection 16 July 2009
Name Grain Al Ayesh No. 4 Pumping Station
Location Grain Al Ayesh Palace Area, Mirfa
Access Access road through Grain Al Ayesh Palace area
Date of Commissioning 2002
Supply Source Pipeline from DN1600 TRANSCO Water Transfer Pipeline
Area of Supply Sheikh Sulthan’s Grain Al Ayesh Palace Area
Storage Tanks 1 x 5 Ml concrete storage tank
Pumps 4 x 50 l/s horizontal centrifugal pumps (2 duty + 2 standby)
Elevated Storages Nil (at the pumping station)
Pump Station Schematic Refer Appendix A
Figure 1 Western Region PS 25 - Grain Al Ayesh No. 4 Pumping Station DW-GSH-WPS4
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 Water Storage Tank
3.7 Concrete Water Storage Tanks Condition Assessment

GHD’s site team conducted a visual inspection of the concrete storage tank, both internal and external.
The inspection was carried out in accordance with GHD’s “Procedure for Structural Inspection of
Concrete Water Tanks” as attached in Appendix G.
The inspection aims to identify and record defects such as:
Cracks;
Leaks;
Honeycombed or drummy concrete;
Excessive or abnormal deflection;
Ground settlement;
Internal lining failure; and
External protective coating failure (if there is an external coating).
GHD’s condition assessment schedules for concrete water storage tanks are attached in Appendix G.
4. Civil and Infrastructure Assessment
4.1 Safety Assessment

There are no safety matters requiring attention as noted in Appendix B:
4.2 Building and General Infrastructure

Grain Al Ayesh is a restricted area requiring special permission to enter. The pumping station is
relatively new.
There is no sealed access road.
Water services to the guard room and control room is not working.
The office housed in control room and no dedicated office space available with necessary amenities
and facilities.
4.3 Pump Station Operation

Pressure tank solenoid taken out for repair and not replaced.
Storage Tank
Round concrete storage tank, 5 Ml capacity.
Figure 3 Surge Tank
5. Mechanical Assets Assessment
5.1 General Description

This station is a newer station with 4 large horizontal pump motor sets. Overall the equipment looks in
good condition. The control room temperatures were acceptable and the temperatures in the machine
room (non air-conditioned) were found to be well under the outside ambient temperatures.
5.2 Vibration
Vibration measurements were taken from the points shown on Figure 4 below. Individual measured
levels are shown in the enclosed inspection schedule. OEM levels were not available for correlation. All
measured velocity levels were below the accepted maximum level of 2mm/sec expected for such pumps
and indicate the pumps to be in good mechanical condition.
Figure 4 Measurement Point Locations
Vibration velocity levels were recorded as narrow band FFT levels with the data graphed as below with
all the graphs presented in the Appendix to this report.
Figure 5 Vibration at Location 2 on Pump 2
The motor to pump support frames were well supported to the machine room concrete plinths.
General Condition - External: Good.
Shaft Flexible Couplings Good
Pipe Work - Flexible Connections Good
5.3 Shaft Alignment

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

Noise measurements were performed at the start of the visit to assess the risk to hearing from noise
generated in the pump room. These results are presented in the enclosed schedule. Noise levels were
measured at 78 dB(A) with pump 1 running.
Additional measurements were undertaken at 1m from the individual pumps. The reverberant nature of
the pump houses and the difficulties in arranging for the running of individual and pumps in combination
meant that these measurements were inconclusive with respect to a co-relation with vibration and
alignment. Further correlation will be attempted as the data base of motors and alignment information
grows. The acoustic spectrum from pump 1 is illustrated in Figure 6. All other noise levels spectrum data
is contained in the appendix to this report
Figure 6 Acoustic Spectrum from Pump 1
5.5 Thermal Imaging

Thermal images were taken of the motors during operation and the main switch board. These images
showed no over heat conditions for both the pump and motor bearing or the electrical cabinets.
5.6 Summary of Action Points

Motor to pump shaft alignment should be adjusted to manufactures limits.
Figure 7 Base of the Pump
6. Electrical Assets Assessment

The station is one of 4 located within the Grain Al Ayesh palace grounds to supply the needs of the
palace and grounds. All four are less than 5 years old and are, for all intents and purposes identical.
They feature provision for dual power supplies and automatic power factor correction.
Lightning in control, switchboard and pumping rooms is good and supported by a number of fluorescent
fitting being fitted with emergency battery packs.
The perimeter fence and the outer edge of buildings are fitted with copper earthing strap forming a
comprehensive lightning protection system. Lightning rods are fitted to the diagonal corner of the tank
and to the pump house.
Within the station comprehensive earthing bonding is provided.
The station features a separate control room housing a full mimic and control panel.
The pumps and motors are located in a 2m well in the pumping room. Access is via individual ladders to
each pump location as the manifold and piping layout precludes access ‘pump to pump’
Figure 8 Pump Floor Layout
6.2 Motor Description and Condition
Manufacturer: Siemens
Model: ILG4 220 – 4AA90-7 225S
Rating: 34 kW @ 415V
Full Load current 63 A
Rated PF: 0.82
Speed (rpm): 1480
Insulation Class F
Rated Ambient/rise 50°C/not given
Serial Numbers
Motor 1 2 3 4
Serial No. 0305/04320220 0305/04320220 0305/04237890 0305/04237890

2 IMB3 1 IMB3 3 IMB3 4 IMB3
Hours run 1953 1955 1956 1956
Motor Condition
General Condition - Ok.

External:
General Condition - Motor winding insulation > 4 G at 500 V. Insulation value at 1000V given in
Electrical: schedule. Motors are being operated at above their rated power.
Cabling: Good. Cables well supported to motor.
Local Controls An upstand adjacent to the motor provided Start/stop, Valve open/close,
emergency stop controls and pilot indications for on/off/trip.
6.3 Pump and Tank Control Panel

The station features a comprehensive mimic and monitoring panel, currently fully operational.
While testing at a different station of this series a lock out condition was encountered when pumps could
not be started. There was no indication as to what condition was not satisfied or how to overcome the
situation. When available the operator adjusted pressure switch operating points and bled air from the
supply pipe. One of these actions restored function. This control action should be taken up with the
system designer and an indication provided of the lockout condition.
6.4 Station Power Supply

The station is equipped with a single 500 kVA supply transformer linked to a main switchboard that
features dual incoming breakers and a bus coupler. The transformer is housed in a room, accessed
externally but integral to the pump house building. The room is secured with dual opening gates. The
transformer is mounted on a trolley base.
The transformer space is well lit with bulkhead fittings.
It was noted that the gates were secured with a rusted and ineffective padlock.
Figure 9 Transformer Location
6.5 Main Switchboard and Control Panels

The main switchboard features dual incoming supplies with a bus coupler. The board is mirror imaged
about the bus coupler; pump 1 & 2 MCC to the left and 3 &4 to the right. One supply is provisioned and
the unused supply isolated. The bus coupler is operated. The incoming breakers are rated at 1250A
and are marked as being adjusted to 800A. With a maximum load from all four pumps of approximately
250 amp and a typical running load of 125 amp the board is operating at approximately 10% of its rating.
The on board switched current meter does not read reliably below 160A and is therefore ineffective. The
supply transformer is rated at 666A and is therefore unprotected from long tern overload by the incoming
MCCB. However, as stated the connected load can’t provide this overload.
There is no earth – neutral link at the main switchboard. A conspicuous link should be provided at the
main switchboard.
Figure 10 Main Switchboard
Power Factor Correction

At either end of the board are 2 x 30 kVA PF corrections cubicles. The controller on the left hand panel
was displaying the power factor, the right hand unit displaying kVA. Both controllers were locked and
indicating that no capacitor banks were switched into circuit. I suspect that the left hand controller was
faulty. As the right hand controller was locked I have no opinion about whether it was operating.
However it has been noted on the other stations of this type that the controllers are incorrectly
connected.
6.6 Power Cabling
Cable Tray
In good condition, firmly mounted, fully earth bonded. Within the pump room trays are above the floor
level and are two layer beneath the walk way. Cable trays are 3 layer beneath the main switchboard.
Cables are in good order although covered with dirt/dust and mud. Power supply cables for the motors
are steel wire armoured (SWA).
Cable Layout
Pump power cables acceptably laid out. Cables fully secured as they enter the pump room from the
control room with access holes foam filled. The rises to the individual motors are not completely secured
but as these cables are SWA there is not potential risk of major damage. Actual connection to the motor
terminal box is well done with protective boots and clear labels. Minor adjustments were performed on
the layout of the cables to motor 4 to prevent further abrasion to the cable sheath.
Figure 11 Cable Way beneath MSB Figure 12 Cable Rise to Motor
Access and Function

Covers lifted via integral handles. Covers fitted well and were stable under foot. Covers were generally
large and heavy.
Cleanliness
Dried mud on the cables, trays and floor of the trench.
6.7 Fire Alarm System

The station features a Wormald Fire Alarm System providing detection via smoke detecting detector
heads in general areas and via flame detecting beams in the pump room. The system maintenance log
was not sighted, and is assumed not to exist. Alarms are local only. Hand held fire extinguishers are
provided.
The system appears to be fully operational and is in good repair; however some dust/painting covers are
still fitted to detectors.
Figure 13 Fire Alarm Panel Figure 14 Pump Station Schematic
Control & Power Rooms

Generally over-lit. Fittings are 2 x40w Fluorescent with diffusers. One fitting has detached from the roof
and is supported by its power cabling.
Pump Room
4 x Ceiling HID fittings. Fittings still have remains of plastic construction covers. Plastic to be removed.
Fittings are supplemented with wall mounted fluorescent fittings, most of which have emergency packs
fitted.
6.8 Station Lighting

Generous allocation of lighting based on 12m, single luminare masts. Masts are located around the
permitter of the site and to cover internal areas.
6.9 Crane System

The site has two overhead gantry cranes, one 5 ton crane in the pump house one 1 ton crane in the
valve room. Both are provided with local isolators and are operating fully.
6.10 Items for Further Investigation

Provision of a conspicuous Earth - Neutral link at the main switchboard;
Alteration of sensing for the PF correction units and operational check;
Replacement of the main switchboard ammeters with units appropriate for the load;
Possible downsizing of the supply transformer to reduce standing losses;
Removal of dust covers from fire alarm detectors;
7. Concrete Water Storage Tanks Assessment

This station has only one water storage tank. The tank is a circular ground structure with a capacity of
5.0 Ml. The roof is supported by multiple circular columns and a beam located above the baffle wall.
The bottom of the ground tank sits at ground level and the tank has an internal diameter of 31.0 metres
and an internal height of 6.0 metres. The roof level can be accessed by two steel ladders with protective
cages. There are four manholes in the roof with GRP ladders and protective rail cover at each manhole.
The external wall is covered with a protective coating and the roof is covered with concrete tiles. There
is no evidence of applied protective coating at each internal structural element of the tank.
7.2 Ground Tank

A visual inspection of the external wall of the ground tank revealed multiple cracks, stain marks and
leakage marks. Crack widths ranges from 0.10 – 0.15 mm. Most of the cracks did not show any signs of
leaking but there are few areas with calcium carbonate deposits and staining that indicate leaking. Signs
of leaking and paint blisters can also be observed at joint locations. Loose concrete at apparent tie rod
locations have been observed in one wall location. Concrete tiles which cover the roof showed some
cracking. There was no evidence of ground movement or settlement. Footing is covered with
interlocking tiles.
A visual inspection of the internal surface showed no evidence of a protective coating. Multiple cracks
and crazing were observed in roof soffit with few cracks showing evidence of leaking. Signs of leaking
were also observed in some joint areas of the main wall. Some joint locations in the walls and floor also
exhibit deformed and failed sections of joint sealant. Hammer tapping in floor areas was only conducted
in dry areas due to the water and sand sediment remaining in the tank. Signs of repair works to cover
irregularities in concrete finish can be observed as per the multiple patches present in surface areas of
wall, columns and beams. Detailed inspection at wall and column locations showed multiple air voids.
Some patches in the wall and column areas exhibited crazed surface but hollow sounding (by hammer
tapping) was not observed. Rust staining which involves a portion of corroded reinforcement or tie rods
was also observed in the walls.
7.3 Summary of Action Points

Cracks that are leaking or show historic leaks to be repaired.
Repair areas of delaminated concrete at external walls
Remove and replace joint sealant.
Further assessment of crazed surface in patch repair areas.
Further assessment of rust staining especially in apparent areas of corroded reinforcement or tie-
rods.
Future application of protective coating at the internal elements will only proceed once all significant
defects and irregularities are rectified.
8. Recommendations
Safety
1. PPE including hearing protection should be provided to all operators.
2. Safety signs should be installed at the entrance to the station (and pump room). - Safety Shoes,
Hard Hat, Hearing Protection and Eye Protection).
3. Install locks or padlocks on water tank access hatches.
4. Install dedicated air conditioning inside the pump room. This air conditioning should be used by
maintenance personnel for service and repair works performed during hot summer period.
Civil and Infrastructure Assessment

5. Repair water services to the guard room and control room.
6. Provide dedicated office space with necessary amenities and facilities.
Mechanical Assets Assessment

7. Motor to pump shaft alignment should be adjusted to manufactures limits.
Electrical Assets Assessment

8. Provide a conspicuous Earth - Neutral link at the main switchboard.
9. Alter for the PF correction units and conduct an operational check.
10. Replace the main switchboard ammeters with units appropriate for the load.
11. Investigate downsizing of the supply transformer to reduce standing losses.
12. Remove dust covers from fire alarm detectors.
Concrete Water Storage Tank Assessment

13. Repair areas of concrete delamination, cracks and leakages with an appropriate method.
14. Replace joint sealant.
15. Further assessment of crazed surfaces in patch areas.
16. Further assessment of rust staining involving corroded portions of reinforcement or tie rods.
17. Detailed inspection of concrete surfaces prior to future application of protective coating at internal
structural elements.
Appendix A
Pump Station Schematic
Appendix B
Site Safety Assessment
SITE SAFETY ASSESSMENT
Pumping Station Name Grain Al Ayesh Pump Station No. 4

Assessment Date 16 July 2009
HAZARD SATISFACTORY COMMENTS

Site Access and Egress Yes
Site Security Yes
Lighting Yes
Mechanical Hazards (eg Unguarded Plant) Yes
Electrical Hazards Yes
Housekeeping (General Tidiness) Yes
Fire Hazard and Equipment Yes
Noise Yes
Dust / Fumes Yes
Hazardous Substances Yes
Working at Heights Yes
Ladders / Scaffolding Yes
Pressurized Equipment Yes
Heat Illness / Stress Yes No air conditioning inside the pump room
Personal Protective Equipment (PPE) Yes PPE to be issued to all ADDC site personnel
Knowledge of Site Safety Rules Yes
Site Emergency Procedures Yes
Confined Space Entry Yes
Lock Out / Tag Out Yes
OTHER - Water Quality / Health Hazard Yes - tank access hatches are not key lockable
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.
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
Pumping Station Name Grain Al Ayesh Pump Station No. 4 LEGEND - Asset Condition Assessment
Assessm ent Date 16 July 2009 Description Life Remains Rating
Time: IN / OUT "As New" 100% 1
GPS Position (Entry Gate) N 24° 5.288' E 53° 11.676' Good 75% 2
ADDC GIS Object No: 8451 Fair 50% 3
Poor 25% 4
Inspection Personnel Failure Imminent 0% 5
John John (GHD) Failed / Derelict Un-useable 6
Roger Hawkins (Palmer Acoustics)
Padalchai P.
Asset Condition Assessment

Asset Description Comments
Schedule Parameters Rating
Access Road Sandy access No proper access road Sealed Pavements A, B 4
Boundary Fence / Walls Brick wall with barbed wire on top Satisfactory Fences / Structures A-F 2
Entry Gate Steel Gate Satisfactory Structures A -F 2
Security House Concrete/block building Satisfactory Structures A -F 2
External Walls Blocks Satisfactory Structures A -F 2
Roof Concrete Satisfactory Structures A -F 2
Internal W alls Plastered blocks Satisfactory Structures C 2
Internal Amenities Toilet, kitchenette Satisfactory Misc. Site Assets A 2
Pump House Concrete/block building Satisfactory Structures A -F 2
External Walls Blocks Satisfactory Structures A -F 2
Roof Concrete Satisfactory Structures A -F 2
Internal W alls Plastered blocks Satisfactory Structures A -F 2
Office & Internal Amenities Office inside the control room Satisfactory Misc. Site Assets A 2
This pump station is for Shiekh Sulthan, no accommodation for personnel to inside the
Accommodation NA
com pound.
External Walls NA
Roof NA
Internal W alls NA
Internal Amenities NA
Internal Roads Paved blocks Satisfactory Sealed Pavements A, B 2
Internal Paths Paved blocks Satisfactory Sealed Pavements A, B 2
Landscaping Hard Landscape Satisfactory Misc. Site Assets NA 2
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
- No accommodation facilities and am enities for pump station operators within the compound.
- Office housed in control room, no dedicated office space available with necessary amenities and facilities.
- This pump station is otherwise in good condition.
CONDITION ASSESSMENT - Storage/ Transfer Water Tanks
STORAGE / TRANSFER TANK 01

ADDC GIS Object No: 18706
Width (m) N/A
Length (m) N/A
Diameter (m) 31 LEGEND - Asset Condition Assessment
Roof Height (m) N/A Description Life Remains Rating
Depth (m) 6 "As New" 100% 1
Capacity (m3) 4546.1 Good 75% 2
Tank Description W ATER STORAGE TANK Fair 50% 3
Material CONCRETE Poor 25% 4
TANK HOLD THE W ATER SUPPLIED INTO THE STATION FROM TRANSCO Failure Imminent 0% 5
Comm ents
DESALINATION PLANT Failed / Derelict Un-useable 6
Asset Condition Assessment

Asset Description Com ments
External - Walls Concrete, painted Satisfactory Structures A-F 2
Concrete covered with concrete
External - Roof No visible signs of deterioration Structures A-F 2
square shape pavers
External - Roof Access Steel ladder Satisfactory Structures A-F 2
Hinged GI chequered plate cover,
External - Roof Hatches Satisfactory Structures A-F 2
lockable (allen-key)
Internal - Walls Concrete Satisfactory Structures A-F 2
Internal - Floor Concrete Satisfactory Structures A-F 2
Internal - Roof Concrete Satisfactory Structures A-F 2
Mechanical
Water Level Indicator Available Satisfactory A-H 2
equipment
Comm ents
1) Painted storage tank walls make harder for earlier leaks detection
Structural / Material Testing Recommended (Yes / No) No
CONDITION ASSESSMENT - Pipework & Valves (Suction Side)
Suction Header Pipework Pipe 1

Pipe Material STEEL
Pipe Diameter (mm) 400
Condition Rating (1 to 6) 2
Suction Header Valves Valve 1

ADDC GIS Object No: Not Assigned
Valve Diameter (mm) 400
Pum p Suction Pipework Pump 1 Pum p 2 Pump 3 Pump 4 Pump 5 Pum p 6

Pipe Material STEEL STEEL STEEL STEEL
Pipe Diameter (mm) 150 150 150 150
Condition Rating (1 to 6) 2 2 2 2
Suction Side
Flexible Coupling
Flexible Coupling Diameter (mm) 150 150 150 150
Isolation Valve
ADDC GIS Object No: 302696 302699 302697 302698
Isolation Valve Type Butterfly Butterfly Butterfly Butterfly
Isolation Valve Diameter (mm) 150 150 150 150
Comm ents LEGEND - Asset Condition Assessment

NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. 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
CONDITION ASSESSMENT - Pipework & Valves (Delivery Side)
Delivery Header Pipework Pipe 1
Pipe Material STEEL
Pipe Diameter (mm) 400
Delivery Header Valves Valve 1

ADDC GIS Object No: Not Assigned
Valve Diameter (mm) 300
Pump Delivery Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Pipe Material STEEL STEEL STEEL STEEL
Pipe Diameter (mm) 150 150 150 150
Flexible Coupling
Flexible Coupling Diameter (mm) 150 150 150 150
Delivery Side
Non-Return Valve
ADDC GIS Object No: Not shown Not shown Not shown Not shown
Isolation Valve Type Pump flow control Pump flow control Pump flow control Pump flow control
Isolation Valve
Isolation Valve Type Butterfly Butterfly Butterfly Butterfly
Comments LEGEND - Asset Condition Assessment

"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
Year of Installation 2003 2003 2003 2003
Supply to Shiekh Palace Supply to Shiekh Palace Supply to Shiekh Palace Supply to Shiekh Palace
Purpose / Function
& plantations. & plantations. & plantations. & plantations.
Brand KSB KSB KSB KSB
Type Horizontal Split Casing Horizontal Split Casing Horizontal Split Casing Horizontal Split Casing
Model No OMEGA-100-375A OMEGA-100-375A OMEGA-100-375A OMEGA-100-375A
Serial No 5-L-61-732 593/2 5-L-61-732 593/1 5-L-61-732 591/3 5-L-61-732 591/4
Impeller Design Size (mm) unknown unknown unknown unknown
Speed (rpm) 1479 1479 1479 1479
Pumping Design Power (kW) unknown unknown unknown unknown
Pump Design Efficiency (%) unknown unknown unknown unknown
Duty Point Flow (l/s) 50 50 50 50
NPSHR (kPa) unknown unknown unknown unknown
Duty Point Pressure (kPa) 420 420 420 420
Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

Year of Installation 2003 2003 2003 2003
Brand SIEMENS SIEMENS SIEMENS SIEMENS
Type 1 LG4 220-44490-Z 1 LG4 220-44490-Z 1 LG4 220-44490-Z 1 LG4 220-44490-Z
UC-0305/043202202 UC-0306/042302201 UC-0305/042378903 UC-0305/042378904
Serial No
1MB3 1MB3 1MB3 1MB3
Voltage (V) 415 415 415 415
Speed (rpm) 1475 1475 1475 1475
Current (A) 63 63 63 63
Insulation F F F F
IP or Enclosure IP55 IP55 IP55 IP55
cos(fee) 1 1 1 1
Power (kW) 34 34 34 34
VSD (Yes / No) No No No No
OTHER
CONDITION ASSESSMENT - Water Pumps
Overall Condition Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
Pump Body Satisfactory Satisfactory Satisfactory Satisfactory
Pump Shaft Satisfactory Satisfactory Satisfactory Satisfactory
Pump Shaft Coupling Satisfactory Satisfactory Satisfactory Satisfactory
Pump Base Satisfactory Satisfactory Satisfactory Satisfactory
Springs / Anti Vib. Mat. NA NA NA NA
Pump Plinth Satisfactory Satisfactory Satisfactory Satisfactory
Pump Motor Satisfactory Satisfactory Satisfactory Satisfactory
Asset Condition Assessment Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

General Condition Satisfactory Satisfactory Satisfactory Satisfactory
Assessment Schedule Pumps Pumps Pumps Pumps
Assessment Parameters B-H B-H B- H B -H
Rating (1 to 6) 2 2 2 2

Pumps 01 to 04 (2 duty + 2 standby). "As New" 100% 1
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

MEASURED - Pump Flow Head (kPa) 400 380 380 300
PUMP CURVE - Flow Rate (l/s) unknown unknown unknown unknown
MEASURED - Pump Flow Rate (l/s) 60.0 54.0 60.0 66.0
MEASURED - Pump Speed (rpm) 1485 1485 1485 1485
CALCULATED - Pump Hydraulic Power (kW) 23.5 20.1 22.4 19.4
MEASURED - Pump Motor Power Input (kW) 37.0 36.0 33.0 39.0
CALCULATED - Motor-Pump Efficiency (%) 63.6% 55.9% 67.8% 49.8%
MEASURED - Pump Shut-Off Head (kPa) 575 560 590 590
PUMP CURVE - Impellor Diameter (mm)
Comments
1) Pressure tank solenoid taken out for repair and not replaced.
2) Pumping efficiencies figures are very low due to elevated electric power supply to all motoer (@428V not 415V).
PERFORMANCE CURVES - Water Pumps
Pump Test Flow Pressure

Pump P- 01 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 575 ) 700
a
P
2 25 540 ( 600
k
3 44 470 e
r 500
u
4 60 400 s 400
P- 01 s
e
r 300
5 P
6 d 200
a
e
7 H 100
8
0
0 20 40 60 80
Water Flow (l/s)

1 0 560 ) 600
a
P
2 35 500 (k 500
3 45 400 e
r
u 400
4 54 380 s
P- 02 s
5 re 300
P
6 d 200
a
e
7 H 100
8
0
0 10 20 30 40 50 60
Water Flow (l/s)

) 700
1 0 590 a
P 600
2 30 545 k
(
e
r 500
3 50 480 u
s 400
4 60 380 s
P- 03 e
r
5 P 300
6 d
a 200
e
7 H 100
8 0
0 20 40 60 80
Water Flow (l/s)

1 0 590 )a 700
P
2 30 560 (k 600
53 440 e
r 500
3 u
4 55 400 s 400
s
e
P- 04 r
5 66 300 P 300
6 d
a 200
e
7 H 100
8 0
0 20 40 60 80
Water Flow (l/s)
CONDITION ASSESSMENT - Other Mechanical Equipment and Systems
Mechanical Equipment Description Comments Asset Condition Assessment

Overhead Crane Overhead type crane, 1T lifting In as new condition. Regular Cranes A-C 2
capacity. maintenance in place.
Security House Air Conditioning NA Nobody stays there. Used as store NA
Pump Room Air Conditioning NA Non AC space NA
Control Room Air Conditioning Wall , split type with air cooled Satisfactory Mechanical A-H 2
condenser Equipment
Pump Room Ventilation Natural Cross Ventilation with Satisfactory Mechanical A-H 2
sand-trap type louvres Equipment
Other

"As New" 100% 1
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 M otor 6

Year of Installation
Brand Siemens Siemens Siemens Siemens
Model No. 1LG4 220 4AA90-Z 1LG4 220 4AA90-Z 1LG4 220 4AA90-Z 1LG4 220 4AA90-Z
225S 225S 225S 225S
Serial No UC 0306/043202202 UC 0306/043202201 UC 0305/042378903 UC 0305/042378904
IMB3 IMB3 IMB3 IMB3
Speed (rpm)
Average Voltage (V) 428 427 427 426
Average Current (A) 62 62 63 66
Total Power (kW ) 29 45 45 49
Overall Power Factor 0.79 0.76 0.78 0.79
Electrical Connection 428 427 427 427
Soft Start/ VSD
Hours Run (Hrs) 1953 1955 1956 1956
Cables/ Earthing Fully bonded, Fully bonded, Fully bonded, Fully bonded,
term inal insulating terminal insulating term inal insulating terminal insulating
tape discolouring tape discolouring tape discolouring tape discolouring
Therm al Imaging OK OK Ok Ok
Asset Condition Assessm ent Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 M otor 6
Assessment Schedule Elect. Equip. Elect. Equip. Elect. Equip. Elect. Equip.
Assessment Parameters C D D D
Rating (1 to 6) 2 2 2 2
Comm ents LEGEND - Asset Condition Assessment

Motor 1: Motor is at or exceeding ratings. Voltage should be lowered. "As New" 100% 1
Motor 2: Good 75% 2
Motor 3: Fair 50% 3
Motor 4: Not measured Not measured Poor 25% 4
Motor 5: Failure Imm inent 0% 5
Motor 6: Failed / Derelict Un-useable 6
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) 428 428 427 427 427 426 427 427 426 427 426 426
Current (A) 62 62 61 62 62 61 63 63 62 66 66 65
Power Factor 0.45 0.45 0.45 0.43 0.44 0.44 0.45 0.46 0.45 0.46 0.46 0.46
Average Voltage (V) 427.7 426.7 426.7 426.3
Average Current (A) 61.7 61.7 62.7 65.7
Overall Power Factor 0.790 0.760 0.780 0.790
Dielectric Absorption Insulation 188 @ Insulation 173 @ Insulation 188 @ Insulation 204 @
(30sec / 60sec) >4G 1000 V >4G 1000 V >4G 1000 V >4G 1000 V
Not Not Not Not

Polarisation Index (1min/10min)
measured measured measured measured
Hours Run 1953 1955 1956 1956

Power Measured (kW) 37.0 36.0 33.0 39.0
Total Power (kVAr) 46.0 29.0 28.0 29.0
Total Power (KVA) 29.0 45.0 45.0 49.0
RPM
Temperature ºC (Hot > 68ºC) 47.0 39.0 48.0 49.0
CONDITION ASSESSMENT - Main Switchboard & Motor Control Panels
Main Switchboard LEGEND - Asset Condition Assessm ent
Year of Installation Description Life Rem ains Rating
Clear Labelling? Yes "As New" 100% 1
Logical Layout? Yes. Mirror image, dual supply. Good 75% 2
Main Isolator Fair 50% 3
Manufacturer ABB SACE E1 Poor 25% 4
Type Mirror Image, dual supply,1 Failure Imminent 0% 5
supply provisioned with bus
coupler operated.
Rating (A) 1250A set at 800 A Failed / Derelict Un-useable 6
Switchboard Test Phases & Links R Y B RY YB BR

Use SB Meters? Y Voltage (V) 180 180 180 300 300 300
No. Pum ps Running Current (A) Below meter range
Meters Switched/ Individual? Switched Power FactorPower factor correction installed.
Thermal Imaging - Switchboard Comm ents

Term al Imaging? N
Max. Tem perature Panel fully shuttered & running
below 10% of rating. Overall Condition is Excellent.
Mirror Im age, dual supply, 1 supply provisioned with bus coupler operated.
Asset Condition Assessment Voltage meters reading low.
Assessment Schedule Elect. Equip. PF correction units fitted, one not working. Condensation problem.
Assessment Parameters A-I
Rating (1 to 6) 3
Motor Controls Motor Controls Thermal Comments

Im age
Manufacturer ABB PST 85-600-70 Motor Control No 1 yes Panel 4 has a new isolator fitted. Different model to the others.
Soft Start ? Y Motor Control No 2 Yes The replacement lacks aux contacts - an additional relay has been fitted.
Controls Functional ? Yes Motor Control No 3 yes Door needed modification. Capacitor banks have the sam e model switch.
Internal Layout OK Motor Control No 4 yes
Interlock on Panel ? Operative Motor Control No 5
Motor Control No 6
CONDITION ASSESSMENT - Other Electrical Equipment and Systems
Electrical Equipment Description Com ments Asset Condition Assessm ent
Schedule Param eters Rating
Power Transformer Manufactured 2004 3.95% impedance, 666A Externally Elect. Equip. A-I
500 accessed room in main building. On trolley base, Good 2
Rating
earthing. Transform er room well lit. Voltage too high.
Pump Station Earthing Shutters not removed No link apparent Elect. Equip. A-I
Neutral / Earth Link Not tested 2
Resistance (Earth /Neutral) NA
Lightning Protection Multi rod earthing system. Apparently joined by earthing Elect. Equip. A-I
Strap and rod system on tank, strap not cable. No test of earth resistance 2
Lightning Protection
pump house and security hut.
Pump Room Crane Electric cranes in pump house (5 ton) and valve room (1 Elect. Equip. A-I
2
Electrics Operating fully ton)
Pump Control Panel Pump control based on ABB AC800 M PLC controller Elect. Equip. A-I
Clear Mimic (Y/N) Yes
2
Fully Operational (Y/N) Yes
Thermal Imaging (Y/N) Ok
Power Cabling All pump floor cabling on above floor cable trays, not good Elect. Equip. A-I
W ell supported on trays. protection. Cabling adjusted on pump 4 to prevent further 2
Main SB to Motors
cable sheath damage.
Room Lighting Elect. Equip. A-I
Control Room Lighting O verlit, operating 2
Emergency/ Exit Lighting --
Exterior Site Lighting Reported to be fully working. Generous layout, approx 10m Elect. Equip. A-I
2
Exterior Site Lighting Ok masts.
Fire Alarm System 8 Zone configuration. Fireray beam system. No Elect. Equip. A-I
Manufacturer W ormald maintenance log. Dust/paint covers on some detectors. 2
Detector Types Beam and ionisation

"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
Pum p Room 26
Control Room 35
Outside (Am bient) 40.6
Ambient Noise [dB(A)] Noise Source

Pum p Room 75 Pump 3&4
Control Room
Outside (Am bient)
Pump/ Motor Noise Pump-Motor 1 Pump-Motor 2 Pum p-Motor 3 Pump-M otor 4 Pum p-M otor 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) 80 77 79 77
Noise Source Motor Motor Motor Motor
Vibration (mm /s) / Frequency (Hz) Pump-Motor 1 Pump-Motor 2 Pum p-Motor 3 Pump-M otor 4 Pum p-M otor 5 Pump-Motor 6
Vibration Limit = 2mm/sec V (m m/s) w (Hz) V (m m/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 0.438 122.5 0.406 122.5 0.208 100 0.264 50
Point No 2 = Motor - Rear Foot 0.283 122.5 0.170 122.5 0.485 122.5 0.841 122.5
Point No 3 = Motor - Top of Motor 0.359 125 0.341 122.5 0.609 122.5 0.935 122.5
Point No 4 = Pum p - Top Front Bearing 0.340 125 0.402 125 0.449 122.5 0.592 122.5
Point No 5 = Pum p - Top Rear Bearing 0.915 122.5 0.144 122.5 0.292 122.5 0.843 122.5
Point No 6 = Pum p - Rear Foot 0.487 122.5 0.773 122.5 0.955 122.5 1.093 122.5
Point No 7 = Pump - Inlet 0.133 112.5 N/A N/A N/A N/A N/A N/A
Point No 8 = Pump - Outlet 0.163 65 N/A N/A N/A N/A N/A N/A
NO TE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
ALIGNMENT - Pumps & Motors
Pump Shaft Alignment (mm) Pump-Motor 1 Pump-Motor 2 Pum p-Motor 3 Pump-Motor 4 Pum p-Motor 5 Pump-Motor 6
Angular Limit = 0.08mm/100m
mm mm mm mm mm mm
Linear Lim it = 0.10mm
Angular Displacement - Horizontal 0.49 0.10 0.10 0.40
Linear Displacement - Horizontal 0.08 0.00 0.02 0.08
Angular Displacement - Vertical 0.13 0.45 0.90 0.16
Linear Displacement - Vertical 0.00 0.04 0.06 0.08
Thermal Images (Hot > 68 Deg C) Cool Cool Cool Cool
Flexible Couplings Pump-Motor 1 Pump-Motor 2 Pum p-Motor 3 Pump-Motor 4 Pum p-Motor 5 Pump-Motor 6
Assessment Schedule Mech. Equip. Mech. Equip. Mech. Equip. Mech. Equip.
Assessment Parameters F F F F
Rating (1 to 6) 2 2 2 2
Comm ents
NO TE: 'NA' or 'Blank' = Not Applicable or Data Not Available. LEGEND - Asset Condition Assessment
Pumps and motors in reasonable condition "As New" 100% 1
Noise within the station is an issue of concern Good 75% 2
Pipework flexible connectors in good condition Fair 50% 3
Pump flexible couplings OK Poor 25% 4
Failure Im minent 0% 5
Appendix G
Water Storage Tanks
Condition Assessment Procedure and Schedules

a) Inspection Procedure
b) Defect Schedule
c) Record Sheets
d) Photographic Records
Procedure for Structural Inspection of Concrete Water Tanks
The following procedure is to be used when carrying out visual inspections of concrete water tanks for
ADDC.
1. Safety
Read the Safety Plan and be aware of all of the safety issues relating to the inspection procedure.
Consider each tank and site individually and identify the risks that are present for that tank.
Carry out the procedures of the Safety Plan with regard to isolation of water, working at heights,
entering confined spaces, preparations and methodology of rescue etc.
2. Recording
All defects shall be recorded, photographed and given a condition grading in accordance with the
attached matrix.
3. Visual Inspection – Exterior

Inspect the tank exterior surface as far as it is accessible, including the roof and at ground level if the
tank base is below ground.
Record the following:
Exterior dimensions,
Create a map of each wall or surface to record the location of all defects below,
Determine if any section of wall below ground has a waterproofing membrane installed,
Identify cracks and measure their width,
Note and photograph cracks that are actively weeping, damp and/or have staining from leaks,
including efflorescence (lime scale build up). Remove part of the efflorescence with a hand scraper
in order to measure the crack width,
Note and photograph areas of spalling/bursting and areas of rust staining,
Note and photograph areas of ground settlement around the tank base,
Note and photograph areas of honeycombing,
Use a lightweight hammer to tap the surface to detect areas of soft or drummy concrete,
Note and photograph any other defects.
4. Visual Inspection – Interior
Inspect the tank interior surface as far as it is accessible, including at floor and roof soffit.
– Linings
If the tank has a lining then inspect the lining and determine what material is used. Note colour,
hardness, thickness if possible,
Note and photograph the condition of the lining and identify any defects such as holes, tears,
cracks, delamination etc.
Record the extent of the lining around the walls and if the roof soffit is lined.
Inspect all penetrations where pipes pass through the lining, record condition and any defects.
– No lining (bare concrete)

Record the following:
Interior dimensions,
Create a map of each wall or surface (including roof and floor) to record the location of all defects
Identify cracks and measure their width,
Note and photograph areas of spalling/bursting and areas of rust staining,
Note and photograph areas of honeycombing,
Use a lightweight hammer to tap the surface to detect areas of soft or drummy concrete,
Note and photograph any other defects.
5. General
Make sure that all photos have a scale reference clearly visible in them, such as ruler or pen.
Tools required:
– Crack graduation gauge,
– Lightweight hammer,
– Metal hand scraper.
Structures Rating Matrix Includes all tanks, buildings, wells, pits, platforms, access bridges
Distress
Assessment Component Mode Rating Rating Rating Rating Rating
Parameter
1 2 3 4 5
Structural Cracking Structure sound - Some minor Cracking becoming Cracking evident that Significant cracking evident that
Integrity / no cracking cracking evident more evident has impacted on the presents a high probability of
A Function evident. that has little impact however still little assets structural the structures collapse or
on the structures impact on structural integrity or function. failure.
strength or function. integrity or function.
Movement No movement Some minor Asset has moved Movement has Movement has severe impact
evident. movement evident significantly however impacted on the on structural integrity or
B that has little impact structural integrity assets structural function with a high likelihood of
on the structures and function are integrity or function. failure.
strength or function. retained.
Surface Deterioration Surface appears Some minor surface Surface Surface deterioration Severe deterioration of surface
as new with little wear evident that deterioration evident that has presenting a high probability of
or no signs of has little impact on becoming more impacted on the the structures collapse or
C deterioration. the structures evident however still assets structural failure.
strength or function. little impact on integrity or function.
structural integrity or
function.
Operational Loss of Asset able to Some minor Minor operational Significant Asset provides very little of its
Performance Function/Costs perform it elements of the difficulties or costs operational intended function and requires
D intended current assets function are being presented by difficulties or costs enhancement to correct.
function. not able to be the loss of function. presented by the
provided. loss of function.
Foundation Ground No movement/ Some minor Significant ground Movement/ erosion Movement/erosion has severe
Movement/ erosion evident. movement/ erosion movement or has impacted on the impact on structural integrity or
Erosion evident that has erosion, however asset's structural function with a high likelihood of
E
little impact on the asset structural integrity or function. structural failure.
structure's strength integrity and function
or function. are retained.
Fixings Cracking / Fixing sound - no Some minor Cracking/corrosion Cracking/corrosion Significant cracking/corrosion
Corrosion cracking/corrosion cracking/corrosion becoming more evident that has evident that presents a high
evident evident that has evident however still impacted on the probability of the fixings failure.
F
little impact on the little impact on structural integrity. Crane cannot be used.
fixings strength or structural integrity.
function
Grain Al Ayesh 4 - Internal
Tank Internal Crack with evidence of leaking in soffit
Crazed patch repair in column Rust staining in wall
Air voids in wall Deformed section of joint sealant in wall
Grain Al Ayesh 4 - External
Leakage marks in parapet Leakage mark, paint blisters and stain

at joint location in wall
Delaminated / loose concrete in wall Crack in wall
Leakage mark in wall Cracked tile in roof slab
Appendix H
OEM vs Pump Performance
Appendix I
Thermographic Images
Grain Al Ayesh 4 Pumping Station – Thermal Imaging
Visible Light Image

TI 01
Mimic Panel
7/16/2009 1:39:43 PM
Visible Light Image

TI 02
Mimic Panel
7/16/2009 1:40:18 PM
Visible Light Image

TI 03
Mimic Panel
7/16/2009 1:40:28 PM
Visible Light Image
TI 04
Mimic Panel
7/16/2009 1:41:05 PM
Visible Light Image

TI 05
Mimic Panel
7/16/2009 1:41:12 PM
Visible Light Image

TI 06
Mimic Panel
7/16/2009 1:41:33 PM
Visible Light Image
TI 07
Mimic Panel
7/16/2009 1:41:42 PM
Visible Light Image

TI 01
Pump Set No. 1
7/16/2009 12:11:11 PM
Visible Light Image

TI 02
Pump Set No. 1 Motor Bearing
7/16/2009 12:11:21 PM
Visible Light Image

TI 03
Pump Set No. 1 Motor
7/16/2009 12:12:33 PM
Visible Light Image
TI 04
Pump Set No. 1 Shaft
7/16/2009 12:12:40 PM
Visible Light Image

TI 05
Pump Set No. 1 Pump Bearing
7/16/2009 12:12:50 PM
Visible Light Image

TI 06
Pump Set No. 1 Pump Rear Bearing
7/16/2009 12:13:00 PM
Visible Light Image
TI 07
Pump Set No. 1 Pump
7/16/2009 12:13:07 PM
Visible Light Image

TI 08
Pump Set No. 1 Motor Control Panel
7/16/2009 12:14:29 PM
Visible Light Image

TI 09
7/16/2009 12:14:47 PM
Visible Light Image
TI 10
7/16/2009 12:14:57 PM
Visible Light Image

TI 11
7/16/2009 12:15:03 PM
Visible Light Image

TI 12
7/16/2009 12:15:11 PM
Visible Light Image

TI 01
Pump Set No. 2
7/16/2009 12:31:10 PM
Visible Light Image

TI 02
7/16/2009 12:31:30 PM
Visible Light Image

TI 03
7/16/2009 12:31:39 PM
Visible Light Image
TI 04
Pump Set No. 2 Pump
7/16/2009 12:31:45 PM
Visible Light Image

TI 05
7/16/2009 12:31:54 PM
Visible Light Image

TI 06
Pump Set No. 2
7/16/2009 12:32:02 PM
Visible Light Image
TI 07
7/16/2009 12:32:09 PM
Visible Light Image

TI 08
7/16/2009 12:33:29 PM
Visible Light Image

TI 09
7/16/2009 12:33:43 PM
Visible Light Image
TI 10
7/16/2009 12:34:21 PM
Visible Light Image

TI 11
7/16/2009 12:34:31 PM
Visible Light Image

TI 12
7/16/2009 12:34:38 PM
Visible Light Image

TI 01
7/16/2009 10:07:49 AM
Visible Light Image

TI 02
7/16/2009 10:08:18 AM
Visible Light Image

TI 03
7/16/2009 10:08:27 AM
Visible Light Image
TI 04
7/16/2009 10:08:36 AM
Visible Light Image

TI 05
7/16/2009 10:08:45 AM
Visible Light Image

TI 06
Pump Set No. 3
7/16/2009 10:41:38 AM
Visible Light Image
TI 07
7/16/2009 10:41:56 AM
Visible Light Image

TI 08
7/16/2009 10:42:22 AM
Visible Light Image

TI 09
7/16/2009 10:42:41 AM
Visible Light Image
TI 10
7/16/2009 11:10:06 AM
Visible Light Image

TI 11
Pump Set No. 3 Pump
7/16/2009 11:10:13 AM
Visible Light Image

TI 01
7/16/2009 10:09:17 AM
Visible Light Image

TI 02
7/16/2009 10:09:31 AM
Visible Light Image

TI 03
7/16/2009 10:09:40 AM
Visible Light Image
TI 04
7/16/2009 10:09:46 AM
Visible Light Image

TI 05
7/16/2009 10:09:51 AM
Visible Light Image

TI 06
Pump Set No. 4
7/16/2009 10:43:18 AM
Visible Light Image
TI 07
7/16/2009 10:43:58 AM
Visible Light Image

TI 08
Pump Set No. 4 Shaft
7/16/2009 10:44:15 AM
Visible Light Image

TI 09
7/16/2009 10:44:28 AM
Visible Light Image
TI 10
7/16/2009 10:44:40 AM
Visible Light Image

TI 11
Pump Set No. 4 Pump
7/16/2009 10:44:52 AM
Visible Light Image

TI 12
7/16/2009 10:45:16 AM
Appendix J
Vibration Spectrum
Grain Al Ayesh 4 Pumping Station – Pump Set No. 1
Grain Al Ayesh 4 – Pump Set No. 4
GHD Global Pty Ltd CLN 1001592
P.O. Box 45921, Abu Dhabi

United Arab Emirates
T: 971 2 696 8700 F: 971 2 447 2915 E: abumail@ghd.com
© GHD Global 2010

This document is and shall remain the property of GHD Global Pty Ltd. The document may only be used
for the purposes for which it was commissioned and in accordance with the Terms of Engagement for the
commission. Unauthorised use of this document in any form whatsoever is prohibited.
Document Status
Rev Reviewer Approved for Issue

Author
No. Name Signature Name Signature Date
0 C. Teske K. Skawinski K. Skawinski* P. Rodda P. Rodda* 28 Jan 2010*
1 C. Teske K. Skawinski K. Skawinski* P. Rodda P. Rodda* xx Feb 2010*
3 H. Glass G Shepherd G Shepherd* P. Rodda P. Rodda* 18 Jan 2012*

Western Region PS 25 15819 Rev 3

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Abu Dhabi Distribution Company

Condition Assessment and Energy

2. Pump Station Overview 3

3. Pump Station Assessments 4

4. Civil and Infrastructure Assessment 7

5. Mechanical Assets Assessment 8

6. Electrical Assets Assessment 11

7. Concrete Water Storage Tanks Assessment 17

1.1 Project Objectives

1.2 Project Scope

1.3 Purpose of this Report

1.4 Related Reports

2.1 Description of Pumping Station

Figure 1 Western Region PS 25 - Grain Al Ayesh No. 4 Pumping Station DW-GSH-WPS4

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 Water Storage Tank

3.7 Concrete Water Storage Tanks Condition Assessment

4.1 Safety Assessment

4.2 Building and General Infrastructure

4.3 Pump Station Operation

Figure 3 Surge Tank

5.1 General Description

Figure 4 Measurement Point Locations

General Condition - External: Good.

Shaft Flexible Couplings Good

Pipe Work - Flexible Connections Good

5.3 Shaft Alignment

5.4 Noise Levels

5.5 Thermal Imaging

5.6 Summary of Action Points

Figure 7 Base of the Pump

6.1 General Description

Figure 8 Pump Floor Layout

Model: ILG4 220 – 4AA90-7 225S

Full Load current 63 A

Rated PF: 0.82

Speed (rpm): 1480

Rated Ambient/rise 50°C/not given

Serial No. 0305/04320220 0305/04320220 0305/04237890 0305/04237890

Hours run 1953 1955 1956 1956

General Condition - Ok.

Cabling: Good. Cables well supported to motor.

6.3 Pump and Tank Control Panel

6.4 Station Power Supply

Figure 9 Transformer Location

6.5 Main Switchboard and Control Panels

Power Factor Correction

6.6 Power Cabling

Figure 11 Cable Way beneath MSB Figure 12 Cable Rise to Motor

Access and Function

6.7 Fire Alarm System

Control & Power Rooms

6.8 Station Lighting

6.9 Crane System

6.10 Items for Further Investigation

7.1 General Description

7.2 Ground Tank

7.3 Summary of Action Points