Western Region PS 24 15817 Rev 3

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Abu Dhabi Distribution Company

Condition Assessment and Energy


Management Survey of ADDC Water
Pumping Stations Including Water
Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh
No. 3 Pumping Station DW-GSH-WPS3
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 6

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


6.1 General Description 11
6.2 Motor Description and Condition 12
6.3 Pump and Tank Control Panel 12
6.4 Station Power Supply 13

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6.5 Main Switchboard and Control Panels 14
6.6 Power Cabling 15
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


7.1 General Description 17
7.2 Ground Tank 17
7.3 Summary of Action Points 17

8. Recommendations 18

Figure Index
Figure 1 Western Region PS 24 - Grain Al Ayesh No. 3
Pumping Station DW-GSH-WPS3 3
Figure 2 Pump Room Building 5
Figure 3 Pump Setup 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 Water Storage Tank 10
Figure 8 Pump Floor Layout 11
Figure 9 Mimic Panel Grain Al Ayeseh 13
Figure 10 Transformer Location 13
Figure 11 MSB - Right Hand End 14
Figure 12 Cable Way beneath MSB 15
Figure 13 Cable Rise to Motor 15
Figure 14 Fire Alarm Panel 16
Figure 15 Mimic Panel 16

Appendices
A Pump Station Schematic
B Site Safety Assessment
C Civil and Infrastructure Assets
D Mechanical Assets

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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

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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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 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3 .
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
11390.

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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.

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2. Pump Station Overview

2.1 Description of Pumping Station


Pump Station Location Description
Date of Inspection 14 July 2009
Name Grain Al Ayesh No. 3 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 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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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;

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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 Room Building

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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.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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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


There is no sealed access road.
The office housed in control room and no dedicated office space available with necessary amenities
and facilities.
Water services to the guard room and control room is not working.
Pump room automatic front door Is not opening

4.3 Pump Station Operation


Clock in mimic is not working and the light at the back door of the mimic not working.

Storage Tank
Round concrete storage tank, 5 Ml capacity.
Tank level indicator is not working on the mimic (does not correspond to the mechanical indicator).

Figure 3 Pump Setup

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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 air 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.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Figure 5 Vibration at Location 2 on Pump 2

General Condition - External: Good.

Shaft Flexible Couplings Good

Pipe Work - Flexible Connections Good

The pumps and motors were well secured using have bases and concrete under the base. This quality
of mounting is reflected in eh low vibration levels.

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

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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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 Water Storage Tank

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6. Electrical Assets Assessment

6.1 General Description


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

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6.2 Motor Description and Condition
Manufacturer: Siemens

Model: ILG4 220 – 4AA90-Z 225S

Rating: 34 kW @ 415V

Full Load current 63 A

Rated PF: 0.82

Speed (rpm): 1480

Insulation Class F

Rated Ambient/rise Not stated

Serial Numbers

Motor 1 2 3 4

Serial No. 0305/043202203 0305/043202204 0306/042398202 0306/042398201


IMB3 IMB3 IMB3 IMB3

Hours run 2008 2004 2000 2000

Motor Condition

General Condition - Ok.


External:

General Condition - Motor winding insulation > 4 G .


Electrical:

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 fro on/off/trip.

6.3 Pump and Tank Control Panel


The station features a comprehensive mimic and monitoring panel, currently fully operational.

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Figure 9 Mimic Panel Grain Al Ayeseh

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.

Figure 10 Transformer Location

Station voltages are above the nominal setting. The transformer tapping should be adjusted to give the
correct voltage. It was noted that the gates to the transformer were not secured.

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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. 380 E-N was measured. A conspicuous link
should be provided at the main switchboard.

Figure 11 MSB - Right Hand End

Power Factor Correction


At either end of the board are 2 x 30 kVA PF corrections cubicles. The controller on the right hand
cabinet was locked and displaying a PF value of 1.0
The unit on right hand end did not respond to changing PF conditions. I suspect that either the panel
controller is faulty or that it is sensing the load conditions on the unused supply and is therefore
inoperative when the board is being operated from a single supply. This could be investigate either by
query to the board designer or study of the main switchboard design documentation.

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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 layers 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.

Figure 12 Cable Way beneath MSB Figure 13 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. Where access had proved inconvenient some covers had been cut (in half ) on site to
reduce the weight and increase ease of use.

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.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Figure 14 Fire Alarm Panel Figure 15 Mimic Panel

Control & Power Rooms


Generally over-lit. Fittings are 2 x 40w 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 and 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.
Replacement of the main switchboard ammeters with units appropriate for the load.
Possible downsizing of the supply transformer to reduce standing losses.
Adjust transformer tapping to give correct station voltage.

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7. Concrete Water Storage Tanks Assessment

7.1 General Description


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 surface of the ground tank revealed some cracks, stain marks and
leakage marks. Crack widths ranges from 0.10 – 0.80 mm. Most of the cracks did not show any signs of
leaking but there are a few areas with calcium carbonate deposits and staining that indicate leaking.
Stain marks were mostly visible in sealant joint areas. Leakage and paint blisters were also identified in
joint locations. Some areas of delaminated concrete were also observed. There was no evidence of
ground movement or settlement. The footing is covered with interlocking tiles.
A visual inspection of the internal surface showed no evidence of a protective coating. Inspection of the
roof soffit did not allow for an appropriate assessment due to multiple droplets present during
inspections. Cracks and leakage marks were identified in some areas of the wall. Deformed and failed
sections of joint sealant were also observed at wall areas. Signs of repair works to cover irregularities in
concrete finish can be observed as per the multiple patches present in surface areas of walls, columns
and beams. Detailed inspections of the wall and columns showed multiple air voids. Some patches in
the wall and column areas exhibit surface crazing but hollow sounding (by hammer tapping) was not
observed. Hammer tapping at floor areas was not possible due to the water and sand sediment
remaining in the tank.

7.3 Summary of Action Points


Cracks that are leaking or show historic leaks to be repaired.
Repair delaminated areas of concrete at external walls.
Remove and replace deformed and failed sections of joint sealant.
Further assessment of crazed surface in patch repair areas.
Future application of protective coating at the internal elements will only proceed once all significant
defects and irregularities are rectified.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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8. Recommendations

Safety
1. PPE including hearing and eye 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 tank access hatches.
4. Install dedicated air conditioning system into pump room. This system should be used by
maintenance personnel for service or repair works carried out during hot summer period.

Civil and Infrastructure Assessment


5. Provide dedicated office space with necessary amenities and facilities.
6. Repair pump room automatic door.

Mechanical Assets Assessment


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

Electrical Assets Assessment


8. Investigate further condensation accoutring inside the main board.
9. Provide a conspicuous Earth - Neutral link at the main switchboard.
10. Alter the sensing for the PF correction units.
11. Replace the main switchboard ammeters with units appropriate for the load.
12. Investigate downsizing of the supply transformer to reduce standing losses.
13. Remove plastic from HID lightning fittings in pump room.
14. Repair or replace water level indicator on mimic panel.
15. Repair or replace clock on mimic panel.
16. Repair lights at the back door of the mimic panel.

Concrete Water Storage Tank Assessment


17. Repair areas of concrete delamination, cracks and leakages with an appropriate method.
18. Replace joint sealant.
19. Further assessment of crazed surfaces in patch areas.
20. Detailed inspection of concrete surfaces prior to future application of protective coating at internal
structural elements.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Appendix A
Pump Station Schematic

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76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Appendix B
Site Safety Assessment

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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
SITE SAFETY ASSESSMENT

Pumping Station Name Grain Al Ayesh-3 Pump Station, Mirfa


Assessment Date 14 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 No Neglected and not maintained fire alarm system
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 should be provided to all ADDC station 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.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Appendix C
Civil and Infrastructure Assets

Condition Assessment Schedules:


a) Buildings and General Infrastructure
b) Storage Tanks
c) Pipework and Valves

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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CONDITION ASSESSMENT - Buildings & General Infrastructure
Pumping Station Name Grain Al Ayesh-3 Pump Station - Mirfa LEGEND - Asset Condition Assessment
Assessment Date 14 July 2009 Description Life Remains Rating
Time: IN / OUT "As New" 100% 1
GPS Position (Entry Gate) N 24° 4.025' E 53° 9.247' Good 75% 2
ADDC GIS Object No: 8453 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 Walls 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 Walls Plastered blocks Satisfactory Structures A -F 2
Office & Internal Amenities Office inside the control room Satisfactory Misc. Site Assets A 2
NA This pump station is for Shiekh Sulthan, no accommodation
Accommodation NA
for personnel to inside the compound.
External Walls NA NA
Roof NA NA
Internal Walls NA NA
Internal Amenities NA 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 amenities 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 very good conditi

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CONDITION ASSESSMENT - Storage/ Transfer Water Tanks

STORAGE / TRANSFER TANK 01


ADDC GIS Object No: 18707
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 WATER STORAGE TANK Fair 50% 3
Material CONCRETE Poor 25% 4
TANK HOLD THE WATER SUPPLIED INTO THE STATION FROM TRANSCO Failure Imminent 0% 5
Comments
DESALINATION PLANT Failed / Derelict Un-useable 6

Asset Condition Assessment


Asset Description Comments
Schedule Parameters Rating
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

Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
1) Painted storage tank walls make harder for earlier leaks detection

Structural / Material Testing Recommended (Yes / No) No

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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
Condition Rating (1 to 6) 2

Pump Suction 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
Condition Rating (1 to 6) 2 2 2 2
Suction Side

Flexible Coupling
Flexible Coupling Diameter (mm) 150 150 150 150
Condition Rating (1 to 6) 2 2 2 2

Isolation Valve
ADDC GIS Object No: 302721 302724 302722 302723
Isolation Valve Type Butterfly Butterfly Butterfly Butterfly
Isolation Valve Diameter (mm) 150 150 150 150
Condition Rating (1 to 6) 2 2 2 2

Comments 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

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CONDITION ASSESSMENT - Pipework & Valves (Delivery Side)
Delivery Header Pipework Pipe 1
Pipe Material STEEL
Pipe Diameter (mm) 400
Condition Rating (1 to 6) 2

Delivery Header Valves Valve 1


ADDC GIS Object No: Not Assigned
Valve Diameter (mm) 300
Condition Rating (1 to 6) 2

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
Condition Rating (1 to 6) 2 2 2 2

Flexible Coupling
Flexible Coupling Diameter (mm) 150 150 150 150
Delivery Side

Condition Rating (1 to 6) 2 2 2 2

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 Diameter (mm) 150 150 150 150
Condition Rating (1 to 6) 2 2 2 2

Isolation Valve
ADDC GIS Object No: 302725 302726 302727 302728
Isolation Valve Type Butterfly Butterfly Butterfly Butterfly
Isolation Valve Diameter (mm) 150 150 150 150
Condition Rating (1 to 6) 2 2 2 2

Comments 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

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Appendix D
Mechanical Assets

Condition Assessment Schedules:


a) Water Pumps
b) Other Mechanical Equipment & Systems

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Pump and Motor Data
Pump Data Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
ADDC GIS Object No: 4841 4842 4843 4844
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-61-732 593/3 5-L-61-732 593/4 5-L-61-732 590/2 5-L-61-732 590/1
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


ADDC GIS Object No: 4841 4842 4843 4844
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-0306/ 042302203 UC-0306/ 042302204 UC-0306/ 042398202 UC-0306/ 042398201
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

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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

Comments LEGEND - Asset Condition Assessment


NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. Description Life Remains Rating
Pumps 01 to 04 (2 duty + 2 standby). "As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
Failed / Derelict Un-useable 6

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PERFORMANCE ASSESSMENT - Water Pump Duty Point

Performance Parameters Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6


ADDC GIS Object No: 4841.0 4842.0 4843.0 4844.0
MEASURED - Pump Flow Head (kPa) 420 420 420 450
PUMP CURVE - Flow Rate (l/s) unknown unknown unknown unknown
MEASURED - Pump Flow Rate (l/s) 48.0 46.0 50.0 50.0
MEASURED - Pump Speed (rpm) 1485 1485 1485 1485
CALCULATED - Pump Hydraulic Power (kW) 19.8 19.0 20.6 22.1
MEASURED - Pump Motor Power Input (kW) 32.2 32.0 32.0 32.0
CALCULATED - Motor-Pump Efficiency (%) 61.4% 59.2% 64.4% 69.0%
MEASURED - Pump Shut-Off Head (kPa) 560 570 580 580
PUMP CURVE - Impellor Diameter (mm)

Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
1) Level indicator is not correct in mimic
2) Clock in mimic is not working
3) Light at the back door of the mimic is not working

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PERFORMANCE CURVES - Water Pumps

Pump Test Flow Pressure


Pump P- 01 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 560 ) 600
a
2 36 460 P
(k 500
3 46 435 e
r 400
4 48 420 u
s
P- 01 s
5 r 300
e
P
6 d 200
a
7 e 100
H
8
0
0 10 20 30 40 50 60
Water Flow (l/s)

Pump Test Flow Pressure


Pump P- 02 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 570 )
600
a
2 37 520 P
(k
500
3 45 480 e
r
400
4 46 420 u
P- 02 s
s
5 300
e
r
6 P
200
d
7 a
e
100
H
8
0
0 10 20 30 40 50
Water Flow (l/s)

Pump Test Flow Pressure


Pump P- 03 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 580 700
)
a
2 40 510 P
600
k
(
3 45 485 e
500
r
4 50 420 u
s
400
P- 03 s
5 re
300
P
6 d
200
a
7 e
H
100
8
0
0 10 20 30 40 50 60
Water Flow (l/s)

Pump Test Flow Pressure


Pump P- 04 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 580 )700
a
2 25 540 P
(k600
3 45 490 e
r500
4 50 450 u
s400
P- 04 s
5 e
r300
P
6 d200
a
7 e
H100
8
0
0 10 20 30 40 50 60
Water Flow (l/s)

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CONDITION ASSESSMENT - Other Mechanical Equipment and Systems

Mechanical Equipment Description Comments Asset Condition Assessment


Schedule Parameters Rating
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
Surge Tank 10,000 l, 16 bar pressure, air or Satisfactory Mechanical
A-H 2
Notrogen Equipment

Comments 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

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Appendix E
Electrical Assets

Condition Assessment Schedules:


a) Pump Motors
b) Switchboards and Motor Controls
c) Other Electrical Equipment and Systems

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CONDITION ASSESSMENT - Pump Motors

Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6


ADDC GIS Object No: 4841 4842 4843 4844
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 0305/ 043202203 UC 0305/ 043202204 UC 0305/ 043202202 UC 0305/ 042398201
1MB3 1MB3 1MB3 1MB3
Speed (rpm)
Average Voltage (V) 430 430 430 429
Average Current (A) 56 58 57 57
Total Power (kW) 43 42 43 43
Overall Power Factor 0.74 0.75 0.74 0.74
Electrical Connection 430 430 430 429
Soft Start/ VSD
Hours Run (Hrs) 2008 2004 2000 2000
Cables/ Earthing Fully bonded, Ok Ok Fully bonded,
terminal insulating terminal insulating
tape discolouring tape discolouring
Thermal Imaging Ok Ok Ok Ok

Asset Condition Assessment Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 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

Comments LEGEND - Asset Condition Assessment


NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. Description Life Remains Rating
Motor 1: Motor in exellent condition / Flow reading 171 m3/hr / All lamps function at local control "As New" 100% 1
Motor 2: Motor in exellent condition / Flow reading 171 m3/hr / All lamps function at local control Good 75% 2
Motor 3: Motor at ambient temperature, run only for test Fair 50% 3
Motor 4: Not measured Poor 25% 4
Motor 5: Failure Imminent 0% 5
Motor 6: Failed / Derelict Un-useable 6

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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) 430 430 430 430 430 429 430 430 429 429 429 428
Current (A) 57 56 55 59 58 57 58 57 56 58 57 56
Power Factor 0.424 0.438 0.429 0.43 0.44 0.43 0.42 0.43 0.4 0.43 0.44 0.43
Average Voltage (V) 430.0 429.7 429.7 428.7
Average Current (A) 56.0 58.0 57.0 57.0
Overall Power Factor 0.750 0.740 0.740
Dielectric Absorption Insulation Insulation Insulation Insulation
(30sec / 60sec) >4G >4G >4G >4G
Polarisation Index (1min/10min) Not measured Not measured Not measured Not measured
Hours Run 2008 2004 2000 2000
Power Measured (kW) 32.2 32.0 32.0 32.0
Total Power (kVAr) 28.4 28.0 28.0 28.0
Total Power (KVA) 43.4 42.0 43.0 43.0
RPM
Temperature ºC (Hot > 68ºC) 59.0 36.0 36.0 34.0

NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.

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CONDITION ASSESSMENT - Main Switchboard & Motor Control Panels
Main Switchboard LEGEND - Asset Condition Assessment
Year of Installation Description Life Remains 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. Failure Imminent 0% 5
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) 249 249 249 415 415 415
No. Pumps Running Current (A) Below meter
range
Power Factor
PF = 1 No
Meters Switched/ Individual? Switched Pumps running

Thermal Imaging - Switchboard Comments


Termal Imaging? N
Max. Temperature Panel fully shuttered & running
below 10% of rating. Overall Condition is Excellent
Mirror Image, dual supply
Asset Condition Assessment 1 supply provisioned and the bus coupler operated
Assessment Schedule Elect. Equip. PF correction units fitted, one not working. One bank apparently connected, 15 kBar Indicated.
Assessment Parameters A-I Condensation problem.
Rating (1 to 6) 3

Motor Controls Motor Controls Thermal Comments


Image
Manufacturer ABB PST 85-600-70 Motor Control No 1 Yes All components within appropriate range of temperature.
Soft Start ? Yes Motor Control No 2 Yes Panels have anti-condensation heaters fitted and permanently operating.
Controls Functional ? Yes Motor Control No 3 Yes
Internal Layout Good Motor Control No 4 Yes
Interlock on Panel ? Yes Motor Control No 5
Motor Control No 6

NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.

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CONDITION ASSESSMENT - Other Electrical Equipment and Systems
Electrical Equipment Description Comments Asset Condition Assessment
Schedule Parameters Rating
Power Transformer Externally accessed room in main building / On trolly base Good Elect. Equip. A-I
2
Rating 500 earthing. Transformer room well lit. Voltage too high.
Pump Station Earthing Elect. Equip. A-I
Neutral / Earth Link No 2
Resistance (Earth /Neutral) 185
Lightning Protection Multi rod earthing system. Apparently joined by earthing strap not Elect. Equip. A-I
Strap and rod system on tank, pump house cable. No test of earth resistance. 2
Lightning Protection
and security hut.
Pump Room Crane Electric cranes in pump house (5 ton) and valve room (1 ton) Elect. Equip. A-I
2
Electrics Operating fully
Pump Control Panel Occasional mis read - up to 50% of meter reading 24 volt DC Elect. Equip. A-I
Clear Mimic (Y/N) Yes supplies cool. ABB PLC Controls - AC 800M. All surfaces dusty.
2
Fully Operational (Y/N) No Internal light not operating - plan pocket on door loose
Thermal Imaging (Y/N) Ok
Power Cabling All pump floor cabling on above floor cable trays, not good Elect. Equip. A-I
2
Main SB to Motors Well supported on trays. protection.
Room Lighting Elect. Equip. A-I
Overlit. One fitting has fallen from ceiling
Control Room Lighting 2
and is hanging by its supply cable.
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. Not maintained well Elect. Equip. A-I
Manufacturer Wormald 4
Detector Types Beam and ionisation

Comments 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

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Appendix F
Pumps and Motors – Temperature, Noise,
Vibration and Alignment

Condition Assessment Schedules

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TEMPERATURE, NOISE & VIBRATION - Pumps & Motors

Temperature Deg C
Pump Room 34.2
Control Room 23.5
Outside (Ambient) 42.2

Ambient Noise [dB(A)] Noise Source


Pump Room 78 Pump 1
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) 78 74 78 72
Noise Source Motor Motor Motor Motor

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 0.165 125 0.142 100 0.124 57.5 0.183 172.5
Point No 2 = Motor - Rear Foot 0.166 100 0.236 125 0.170 125 0.096 125
Point No 3 = Motor - Top of Motor 0.307 125 0.276 100 0.242 100 0.356 122.5
Point No 4 = Pump - Top Front Bearing 0.197 125 0.106 65 0.161 65 0.212 75
Point No 5 = Pump - Top Rear Bearing 0.751 77.5 0.377 125 0.262 125 0.207 65
Point No 6 = Pump - Rear Foot 0.520 125 0.197 125 0.344 125 0.077 75
Point No 7 = Pump - Inlet 0.822 125 N/A N/A N/A N/A N/A N/A
Point No 8 = Pump - Outlet 0.079 125 N/A N/A N/A N/A N/A N/A

NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.

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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 1.15 0.14 0.14 0.10
Linear Displacement - Horizontal 0.04 0.12 0.02 0.00
Angular Displacement - Vertical 0.16 1.12 0.18 0.98
Linear Displacement - Vertical

Thermal Images (Hot > 68 Deg C) Cool Cool Cool Cool

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. Mech. Equip. Mech. Equip.
Assessment Parameters F F F F
Rating (1 to 6) 2 2 2 2

Comments
NOTE: '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 Imminent 0% 5
Failed / Derelict Un-useable 6

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Appendix G
Water Storage Tanks

Condition Assessment Procedure and Schedules


a) Inspection Procedure
b) Defect Schedule
c) Record Sheets
d) Photographic Records

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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.

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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.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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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.

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
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

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 - Internal

Tank Internal Crack in wall

Crazing in patch repair surface in wall Deformed section of joint sealant in wall

Multiple patches in column Leakage mark and patches in wall

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 - External

Crack in wall Leakage mark and stain at joint location


in wall

Delaminated concrete in wall Delaminated concrete in wall

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Leakage marks in wall Crack and staining in wall

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Appendix H
OEM vs Pump Performance

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Appendix I
Thermographic Images

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Thermal Imaging

Visible Light Image


TI 01
Mimic Panel
7/14/2009 3:01:46 PM

Visible Light Image


TI 02
Mimic Panel
7/14/2009 4:41:28 PM

Visible Light Image


TI 03
Mimic Panel
7/14/2009 4:43:13 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 04
Mimic Panel
7/14/2009 4:43:21 PM

Visible Light Image


TI 05
Mimic Panel
7/14/2009 4:43:41 PM

Visible Light Image


TI 06
Mimic Panel
7/14/2009 4:43:53 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Thermal Imaging

Visible Light Image


TI 01
Pump Set No. 1 Motor Control Panel
7/14/2009 2:14:50 PM

Visible Light Image


TI 02
Pump Set No. 1 Motor Control Panel
7/14/2009 2:15:04 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 03
Pump Set No. 1 Motor Control Panel
7/14/2009 2:15:14 PM

Visible Light Image


TI 04
Pump Set No. 1 Motor Control Panel
7/14/2009 2:15:22 PM

Visible Light Image


TI 05
Pump Set No. 1
7/14/2009 2:16:10 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 06
Pump Set No. 1 Motor Bearing
7/14/2009 2:16:43 PM

Visible Light Image


TI 07
Pump Set No. 1 Pump Bearing
7/14/2009 2:17:03 PM

Visible Light Image


TI 08
Pump Set No. 1 Pump Rear Bearing
7/14/2009 2:17:10 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 09
Pump Set No. 1 Motor
7/14/2009 2:17:28 PM

Visible Light Image


TI 10
Pump Set No. 1 Shaft
7/14/2009 2:17:52 PM

Visible Light Image


TI 11
Pump Set No. 1 Pump Rear Bearing
7/14/2009 2:17:58 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Thermal Imaging

Visible Light Image


TI 01
Pump Set No. 2
7/14/2009 2:32:45 PM

Visible Light Image


TI 02
Pump Set No. 2 Motor Bearing
7/14/2009 2:33:02 PM

Visible Light Image


TI 03
Pump Set No. 2 Motor Bearing
7/14/2009 2:33:09 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 04
Pump Set No. 2 Shaft
7/14/2009 2:33:17 PM

Visible Light Image


TI 05
Pump Set No. 2 Pump Rear Bearing
7/14/2009 2:33:24 PM

Visible Light Image


TI 06
Pump Set No. 2 Motor
7/14/2009 2:33:35 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 07
Pump Set No. 2 Shaft
7/14/2009 2:33:42 PM

Visible Light Image


TI 08
Pump Set No. 2 Pump
7/14/2009 2:33:54 PM

Visible Light Image


TI 09
Pump Set No. 2 Motor Control Panel
7/14/2009 2:35:02 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 10
Pump Set No. 2 Motor Control Panel
7/14/2009 2:35:19 PM

Visible Light Image


TI 11
Pump Set No. 2 Motor Control Panel
7/14/2009 2:35:31 PM

Visible Light Image


TI 12
Pump Set No. 2 Motor Control Panel
7/14/2009 2:35:41 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Thermal Imaging

Visible Light Image


TI 01
Pump Set No. 3
7/14/2009 2:59:36 PM

Visible Light Image


TI 02
Pump Set No. 3 Motor Bearing
7/14/2009 2:59:47 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 03
Pump Set No. 3 Pump Bearing
7/14/2009 3:00:17 PM

Visible Light Image


TI 04
Pump Set No. 3 Pump Rear Bearing
7/14/2009 3:00:22 PM

Visible Light Image


TI 05
Pump Set No. 3 Motor
7/14/2009 3:00:32 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 06
Pump Set No. 3 Shaft
7/14/2009 3:00:38 PM

Visible Light Image


TI 07
Pump Set No. 3 Pump
7/14/2009 3:00:48 PM

Visible Light Image


TI 08
Pump Set No. 3 Motor Control Panel
7/14/2009 3:01:07 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 09
Pump Set No. 3 Motor Control Panel
7/14/2009 3:01:24 PM

Visible Light Image


TI 10
Pump Set No. 3 Motor Control Panel
7/14/2009 3:01:32 PM

Visible Light Image


TI 11
Pump Set No. 3 Motor Control Panel
7/14/2009 3:01:39 PM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Thermal Imaging

Visible Light Image


TI 01
Pump Set No. 4 Motor Bearing
7/16/2009 9:33:14 AM

Visible Light Image


TI 02
Pump Set No. 4 Pump Bearing
7/16/2009 9:33:20 AM

Visible Light Image


TI 03
Pump Set No. 4 Pump Rear Bearing
7/16/2009 9:33:28 AM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 04
Pump Set No. 4 Motor
7/16/2009 9:33:39 AM

Visible Light Image


TI 05
Pump Set No. 4 Motor
7/16/2009 9:33:44 AM

Visible Light Image


TI 06
Pump Set No. 4 Motor Control Bearing
7/16/2009 9:35:01 AM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Visible Light Image
TI 07
Pump Set No. 4 Motor Control Bearing
7/16/2009 9:35:14 AM

Visible Light Image


TI 08
Pump Set No. 4 Motor Control Bearing
7/16/2009 9:35:22 AM

Visible Light Image


TI 09
Pump Set No. 4 Motor Control Bearing
7/16/2009 9:35:28 AM

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Appendix J
Vibration Spectrum

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Pump Set No. 1

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Pump Set No. 2

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Pump Set No. 3

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
Grain Al Ayesh 3 Pumping Station – Pump Set No. 4

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11390 Tank Internal Inspection
Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3
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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*

2 M. Aguinaldo G Shepherd G Shepherd* P. Rodda P. Rodda* 20 June 2011*

3 H. Glass G Shepherd G Shepherd* P. Rodda P. Rodda* 18 Jan 2012*

76/10239/15817 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
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Western Region PS 24 - Grain Al Ayesh No. 3 Pumping Station DW-GSH-WPS3

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