Western Region PS 05 15686 Rev 3

Abu Dhabi Distribution Company
Condition Assessment and Energy

Management Survey of ADDC Water
Pumping Stations Including Water
Tank Internal Inspection
Western Region PS 05 - Bida Al Mutawa,
Ghayathi Pumping Station DW-BMW-
WPS1
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

6.2 Motor Description and Condition 11
6.3 Pump and Tank Control Panel 12
76/10239/15686 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Prev 11371 Tank Internal Inspection
Western Region PS 05 - Bida Al Mutawa, Ghayathi Pumping Station DW -BMW-WPS1
6.4 Station Power Supply 12
6.5 The Main Switchboard 13
6.6 Motor Control Panels 14
6.7 Power Factor Correction 14
6.8 Power Cabling 14
6.9 Fire Alarm System 15
6.10 Station Lighting 15
6.11 Items for Further Investigation 15
7. Electrical Equipment Alert 16

7.1 Damage to Motor Supply Cable Termination 16
7.2 Automatic Power Factor Correction Cabinet 17
8. Concrete Water Storage Tanks Assessment 18

8.2 Ground Tanks 18
8.3 Elevated Tank 18
8.4 Summary of Action Points 18
9. Recommendations 20
Figure Index
Figure 1 Western Region PS 05 - Bida Al Mutawa, Ghayathi
Pumping Station DW-BMW-WPS1 3
Figure 2 Pump Floor Layout 5
Figure 3 Measurement Point Locations 8
Figure 4 Vibration at Location 3 on Pump 1 9
Figure 5 Acoustic Spectrum from Pump 2 and 3 10
Figure 6 Water Storage Tank 10
Figure 7 Pump Layout 11
Figure 8 Depth of Lowered Floor 11
Figure 9 Mimic Panel Layout 12
Figure 10 Internal Layout 12
Figure 11 View towards Transformer Location behind Wall 13
Figure 12 Main Switchboard 13
Figure 13 MC Panel 14
Figure 14 MCP Interior 14
Figure 15 Rear of MCP 14
Figure 16 Cabling Floor Chase 15
Figure 17 Vertical Section and Stairway 15
Figure 18 High Temperature Cable 16
Figure 19 Key to Thermal Image 16
Figure 20 PF Control Plate 17
Figure 21 Capacitor name plate from equivalent PF panel 17
Figure 22 Security House used as Site Accommodation for
Station Operator 21
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 05 - Bida Al Mutawa, Ghayathi Pumping Station DW-BMW-WPS1 .
This report should be read in conjunction with the “Assessment Overview Report” and the final “Condition
Assessment and Management Strategy Report”.
1.4 Related Reports

This report should be read in conjunction with the “Assessment Overview Report” and the final “Condition
Assessment and Management Strategy Report”. This report was previously numbered as document
11371.
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 13 August 2009
Name Bida Al Mutawa Pumping Station
Location In Bida Al Mutawa reticulation area
Access Via Ghayathi
Date of Commissioning New (2009)
Supply Source DN 200/300 pipeline from Pump Station IPS 2.
Area of Supply Bida Al Mutawa reticulation area
Storage Tanks 1 x 6 Ml Concrete Ground Tank (Partitioned into 2 cells)
Pumps 3 x 30 l/s horizontal centrifugal pumps (excluding new pumps in annex)
Elevated Storages 1 x 450 m3 concrete elevated tank
Pump Station Schematic Refer Appendix A (excluding new pump facility annex)
NOTE: New pump annex is not included in this report. New annex had not been handed over to
ADDC during the time of inspection.
Figure 1 Western Region PS 05 - Bida Al Mutawa, Ghayathi Pumping Station DW-BMW-WPS1
3. Pump Station Assessments
3.1 Site Safety Assessment

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

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

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

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

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

GHD’s site team assessed ambient and motor-pump noise, vibration, and temperature and shaft
alignment of all main pump equipment.
GHD’s vibration, alignment and noise assessment schedules for pump performance assessment are
attached as Appendix F.
Figure 2 Pump Floor Layout
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

The following safety matters requiring attention as noted in Appendix B.
15 out of 17 compound lights not working.
No lights inside in the Elevated Tank tower.
4.2 Building and General Infrastructure

Only 2 out of the 17 compound lights are working.
A/C in control room not cooling.
All door locks are ineffective and main door automatic closer is not working.
Control Room - crack on corner of the building.
Guard Room - window glass broken.
There is no dedicated office or accommodation building available with necessary amenities and
facilities for the operator. The Operator sleeps in the guard room and (as there is no kitchen in guard
room) cooks in a room beside the Control Room.
4.3 Pump Station Operation

Incoming flow indicator on the mimic panel and incoming flow meter (outside) are not working.
Cannot record incoming flow rates.
Outflow accumulated flow totalizer not working.
All pump pressure gauges need calibration.
Storage Tanks
The ground tank level indicator is not working.
The elevated tank lights broken and, hence, the site assessment team could not safely conduct its
inspection.
When the elevated tank level goes below 5.00 m, the mimic panel reading becomes erratic and
unreadable.
5. Mechanical Assets Assessment
5.1 General Description

This station is a station with 3 horizontal pump motor sets. Overall, the equipment looks in reasonable
condition. The control room temperatures were marginally acceptable with the temperatures in the
machine room (a moderate level of air conditioned provided) lower than the outside temperatures.
5.2 Vibration
Vibration measurements were taken from the points shown on Figure 3 below. Individual measured
levels are shown in the enclosed inspection schedule. OEM levels were not available for correlation. All
of the measured velocity levels were below the accepted maximum level of 2mm/sec expected for such
pumps and indicate the pumps to be well supported and in good mechanical condition.
Figure 3 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 4 Vibration at Location 3 on Pump 1
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 marginally 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 75 dB(A).
Additional measurements were undertaken at 1m from the individual pumps. The acoustic spectrum
from Pumps 2 and 3 is illustrated in Figure 5.
Figure 5 Acoustic Spectrum from Pump 2 and 3
5.5 Thermal Imaging

Thermal images were taken of the motors during operation and the main switch board. These images
showed an overheat condition for the motor No 1 power terminals. The fault was rectified by securing
the terminal connection. Motor bearings and electrical cabinets showed no overheat conditions.
5.6 Summary of Action Points

Motor to pump shaft alignment should be adjusted to manufactures limits.
Figure 6 Water Storage Tank
6. Electrical Assets Assessment

The station is located in Bida Al Mutawa and supplies local distribution via an elevated tower tank. The
station includes two ground level storage tanks. The station features 3 pumps arranged perpendicularly
to the suction and pressure manifolds. The pumping floor is located approximately 1.8 m below ground
level. The arrangement of the pumps allows easy maintenance access to all pumps. Motor electrical
supply and signalling cables are on cable trays inside floor chases. The layout of the pump room is
illustrated in Figure 7 and Figure 8.
Figure 7 Pump Layout Figure 8 Depth of Lowered Floor
A separate control room is provided, housing the main switchboard (main switchboard) and mimic panel.
The station also houses a 2 pump arrangement that duplicates the function of the existing pumps. This
arrangement has been commissioned but has not yet been handed over by the contractors to ADDC.
This arrangement and the supporting equipment are discussed separately below.
6.2 Motor Description and Condition

Manufacturer: Leroy Somer
Model: LS 180LKR –T
Rating: 18.5 kW @ 380, 400, 415 V
Full Load current 38, 37, 37 A @ 380, 400, 415 V
Rated PF: 0.83, 0.80, 0.77 @ 380, 400, 415 V
Speed (rpm): 1455, 1460, 1465 @ 380, 400, 415 V
Insulation Class F
Rated Ambient/rise Not given
Serial Numbers
Motor 1 2 3
Serial No. 130655GL003 130655GL001 130655GL002 *
Hours run 14562 14559 14552
*Number is assumed as the name plate had been removed
Motor Condition
General Condition - Good.

External:
General Condition - Motor insulation >4 G . Insulation indexes could not be measured at 500V.
Electrical: Insulation resistance at 1000 V are included in the summary.
Cabling: Generally good. Faulty cable termination on motor 3. See Exceptional

Condition Report 13-08-2009
Motor controls: Each motor has an emergency stop control on an up stand adjacent to the
motor.
6.3 Pump and Tank Control Panel

The station features a comprehensive mimic and monitoring panel, currently approximately 50%
operational. On the inflow side of the panel flow meters were powered but not operating. One of the two
tank pressure/level gauges worked and output flow meters were working. All electrical pilot indicators
were working. The mechanical level gauges on the two ground level tanks were working but were not
visible from the pumping station control room.
Figure 9 Mimic Panel Layout Figure 10 Internal Layout
6.4 Station Power Supply

The station is supplied from a 1500kVA transformer located unenclosed approximately 80m from the
station. The 4 paralleled LT cables run across the sand to a destroyed substation building and then
(apparently) underground to the station. The HT supply to the transformer is also unenclosed on the
surface for some of its length. The transformer is showing signs of oil leakage from the tips of the
ventilation blades on one side.
Figure 11 View towards Transformer Location behind Wall
The physical and electrical security of the supply must be considered unacceptable. It is also inefficient
to have such a large transformer supplying a total station load of less than 100 kVA.
6.5 The Main Switchboard

The main switchboard features a single supply, entering at the lower left with a metering panel
immediately above. The main isolator, a MCCB unit, is rated at 400 Amp and features electrical remote
control. The board contains four motor control cubicles (including a spare panel) for the main pumps,
panels for the sump pump and ventilation fans. Further panels control supply to lighting and local
distribution panels. Generous spare distribution panels are provided.
Figure 12 Main Switchboard
6.6 Motor Control Panels
The motor control panels feature a remote indication panel for the soft starter, hours run meter, switched
ammeter, local pump controls and pilot lamps. The internal layout is tidy but unusual in that the soft
starter and associated contactors are mounted on the rear of the panel and accessed from the rear of the
board.
Figure 13 MC Panel Figure 14 MCP Interior Figure 15 Rear of MCP
6.7 Power Factor Correction

Integral to the main switchboard is a PF correction cubicle. The cubicle features a controller by
Circulator and is rated at 15 kVA. The panel was indicating a power factor of 0.88 at the time of
inspection. A total of 5 out of 6 fuses were blown at time of inspection (See Electrical Equipment Alert,
Section 7).
6.8 Power Cabling
Pumping floor
Power supply cables for the motors are steel wire armoured (SWA). The cables are run on an almost full
width tray in a floor chase protected by checker plate covers. Cables are fully supported as they rise to
motor terminal boxes. Floor chase are wet with water level just below level of cable trays. Some
mountings are showing signs of corrosion. The floor chase needs a sump and drain pump. It is
expected that wash down actions are the cause of the water ingress.
To Motor Control Panels

The vertical section from pump floor to entry to the floor chase in the control room is fully supported. The
vertical section is adjacent to an access stairway and should be protected by a cover.
Water visible
Figure 16 Cabling Floor Chase Figure 17 Vertical Section and Stairway
6.9 Fire Alarm System

No system installed
6.10 Station Lighting

The lighting system is largely faulty.
6.11 Items for Further Investigation

Perform actions as outlined in Electrical Safety Alert (refer Section 7).
Refurbish PF correction cabinet.
Provide sump and pump for electrical floor chase.
Repair site lighting.
Replacement of the main switchboard ammeters with units appropriate for the load.
Possible downsizing of the supply transformer to reduce standing losses.
7. Electrical Equipment Alert
7.1 Damage to Motor Supply Cable Termination

The Thermoscan of the motor, undertaken for each motor inspected, revealed abnormally high
temperature in the blue phase of the motor supply cables at the motor termination point. Subsequent
inspection revealed that the termination was a loose fit inside the crimp connect termination. The cable
insulation showed minimal damage or sign of the problem.
The damaged termination and the thermo scan are presented in Figures 1 & 2.
Visible Light Image

TI 06
Pump Set No. 3
8/13/2009 10:59:34 AM
Figure 19 Key to Thermal Image
Figure 18 High Temperature Cable
The fault was indicated by an abnormally high temperature reading from the Thermoscan of the panel
after the motor had been operating for a short period, approximately 10 minutes, indicating the severe
nature of the fault.
Immediate Action
At the time of discovery of the fault the operator and the Ghayathi Senior Operator were informed. The
motor was left isolated at the MCP. The pump station features 3 pumps and is require to operate only
one pump at any one time.
Remedial Action
The cable termination to be removed and a new termination crimped on if the copper conductors are not
discoloured. If they are then the cable is to be cut back to a point where bright copper is available. After
repair the motor to be run for an extended time, >30 minutes, and all terminations checked for
temperature rise. This is possible with a non contact thermometer.
In the intervening period the pump set should be used only as a last resort.
7.2 Automatic Power Factor Correction Cabinet
The MSB for the station includes a 15 kVAr power factor correction cabinet with a Circuator Brand
controller. The cabinet includes two banks of 3 capacitors recognised to be Merlin Gerin brand units.
Individual ratings could not be read on but it is assumed that they are 7.5 kVA Varplus M capacitors
previously sighted at other stations.
Each bank is connected to the supply via a contactor and individual phase fuses. Of the 6 fuses in total
5 were blown.
Figure 20 PF Control Plate Figure 21 Capacitor name plate from

equivalent PF panel
The application notes for the MG capacitors required that, for units of temperature class (25/D):
Maximum temperature: 55°C;
Maximum average temperature over 24hrs: 45°C; and
Maximum average annual temperature: 35°C.
In the absence of specific temperature modelling the note suggests that, for units of this rating, these
limits will be complied with if cabinets are naturally ventilated with inlet and outlet grill areas 200 cm 2 and
room temperatures are controlled to:
Maximum room temperature 40°C (1 hour);
Average maximum room temperature over 24 hrs: 35°C; and
Average maximum room temperature over 1 year: 25°C.
The cabinet housing the PF capacitors was not ventilated. Further, from observation, the room
temperature limits are unlikely to be met, particularly the average maximum limit.
Immediate Action
As the fuses are blown, the capacitors are isolated and therefore no immediate action is required.
Remedial Action
All capacitors and fuses to be replaced.
Ventilation grilles and forced ventilation to be fitted to the cabinet. Note that in this case the
capacitors are housed in the rear of the cubicle.
8. Concrete Water Storage Tanks Assessment

This station has three (3) concrete water storage tanks. One elevated circular structure of 0.45Ml
capacity and a rectangular ground structure divided into two sub tanks with each having a capacity of
3Ml.
The elevated, circular tank is accessed by a spiral concrete staircase through the central support
pedestal. Access inside the tank is gained through a single manhole with a GRP ladder. The internal
soffit and walls are lined with protective paint coating. Determination of the floor lining was not possible
due to the remaining water inside the tank during the inspection.
The roof level of ground tank is accessed by one GRP ladder wherein part of the top handle was already
broken. The top slab is covered with concrete tiles and the perimeter walls are lined with an external
protective coating. GHD was not granted access inside the ground tanks by the site engineer as these
tanks could not be isolated. Inspections were limited to the external part of the tank.
8.2 Ground Tanks

An external inspection of the ground tank shows multiple cracks and leakage marks at the walls. Cracks
were measured at widths from 0.1mm to 0.5mm. Some cracks did not show signs of leaking, however
many cracks show calcium carbonate deposits and staining that indicate leaking. Multiple paint blisters
and peeling of the plaster coating was also observed.
8.3 Elevated Tank

An external inspection of the elevated tank could only be conducted from the ground level. Multiple
leakage marks were observed on the external face of the tank wall but a detailed examination was not
possible due to height. The exterior support columns and pedestal did not show any signs of cracks or
stains. Determination of ground settlement was not possible due to sand and aggregates covering the
tank footing.
The pedestal that supports the elevated tank consists of an internal spiral staircase to the top of the tank
with vertical pipe work running up the centre. Cracks and leakage marks were observed at the external
face of the centre wall of the tank which exhibits the same evident defects at the internal face of the
centre wall.
A visual inspection of the internal concrete surface shows a lining on the soffit and walls. The lining is
peeling at the soffit. No other concrete defects were identified as a close examination was not possible.
Minor cracks and rust stains were observed at the main wall. Deformed sections of joint sealant were
also observed. Evidence of sealant repairs to the main tank wall was observed and the workmanship
appears to be of a low standard. Determination of lining and hammer tapping of floor surface was not
possible due to presence of remaining water at the tank.
8.4 Summary of Action Points

Cracks that are leaking or show historic leaks to be repaired.
Deformed and previously repaired sections of joint sealant need to be removed and re-applied.
Internal coating at soffit of elevated tank needs to be removed and replaced in areas that show
deterioration.
Peeled coating areas at the external wall of ground tank need to be removed and replaced.
9. Recommendations
Safety
1. Safety signs should be installed at the entrance to the station (and pump room). - Safety Shoes,
Hard Hat, Hearing Protection and Eye Protection).
2. PPE including hearing protection should be provided to all operators.
3. Repair all non working outside lights (2 out of 17 not working).
4. No lights in elevated tank. Install lights to elevated tank.
5. Rubbish and debris should be cleaned and removed from site.
6. Substandard accommodation facility for personnel in charge of the station. Provide (build) dedicated
facility to accommodate station operators and provide onsite amenities.
7. Provide lockable water storage tanks access hatches.
8. Clean site and remove old materials, debris and rubbish scatted around.
Civil and Infrastructure Assessment

9. Investigate pumped water return when pump is off indicating the Non-Return Valve is not functioning.
10. Replace all broken windows in security house.
11. Replace broken window glass in the entry door into the pump room.
12. All doors: locks not working – repair or replace all door locks.
13. Investigate and repair major wall crack in the corner of the building adjacent to the Control Room.
Mechanical Assets Assessment

14. Pump flow analysis indicates that the existing water pumps have been undersized compared to
nominated design duty. This results in:
– Low water flows on each pump (design = 30 l/s, actual 17 to 20 l/s).
– Lower pumping efficiency.
We recommend the following:
– Replacement of the pump impellors with bigger size impellors (if applicable to this particular pump
selection), OR
– Replacement of the existing pumps with bigger capacity to match design duty, OR
– Use all three existing pumps as “duty” pumps.
15. Calibrate or replace all pressure gauges.
16. All pumps – shaft alignment need to be done.
17. Correct leaking air valve on the suction line.
18. Investigate and correct motorized inlet butterfly valve in the pump room which is not opening at low
levels in the tank.
19. Correct leaking washout flange on tank.
20. Repair or replace storage tank water level indicators.
21. Repair or replace air conditioning system serving the Control Room.
Electrical Assets Assessment

22. Repair the termination of the blue phase of the motor supply cables at the motor termination point
23. All capacitors and fuses to be replaced in the Automatic Power Factor Correction Cabinet. Also
ventilation grilles and forced ventilation are to be fitted to the cabinet (refer Electrical Equipment Alert
– Section 7.2).
24. Provide sump and dewatering pump for electrical floor chase.
25. Replace the main switchboard and MCC amp meters with units appropriate for the load.
26. Investigate downsizing of the supply transformer to reduce standing losses.
27. Repair or replace (on mimic panel) elevated tank level reading indicator.
28. Repair or replce external flow meter.
29. Mimic panel – repair or replace station incoming flow meter indication.
30. Repair or replace outflow accumulated water flow totalizer (not working).
Figure 22 Security House used as Site Accommodation for Station Operator
Concrete Water Storage Tank Assessment
31. Repair areas of cracks and leakages with an appropriate method.
32. Deformed joint sealant sections to be removed and re-applied in a satisfactory manner.
33. Internal coating of soffit to be removed and replaced in deteriorated areas.
34. Peeled coating at external wall of ground tank to be reinstated.
Appendix A
Pump Station Schematic
Appendix B
Site Safety Assessment
SITE SAFETY ASSESSMENT
Pumping Station Name Bida Al Mutawa Pump Station, Ghayathi

Assessment Date 13 August 2009
HAZARD SATISFACTORY COMMENTS

Site Access and Egress Yes
Site Security Yes
Lighting No - 15 out of 17 compound lights not working.
- No light inside in the elevated tank.
Mechanical Hazards (eg Unguarded Plant) Yes
Electrical Hazards Yes
Housekeeping (General Tidiness) No Rubbish and debris should be cleaned up and removed from site.
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 pump room
Personal Protective Equipment (PPE) Yes Issue PPE 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 No All water tanks access hatches should be locked.
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 Bida Al Mutawa Pump Station - Ghayathi LEGEND - Asset Condition Assessment
Assessment Date 13 August 2009 Description Life Remains Rating
Time: IN / OUT 8.45AM / 12.00Noon "As New" 100% 1
GPS Position (Entry Gate) N 23° 47.166' E 52° 34.717' Good 75% 2
ADDC GIS Object No: 39 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 Asphalt Fair Sealed Pavements A, B 3
Boundary Fence / Walls Barbed fence Good Fences / Structures A-F 2
Entry Gate Steel Gate Good Structures A -F 2
Security House Concrete/block building Fair Structures A -F 3
External Walls Blocks Fair Structures A -F 3
Roof Concrete Fair Structures A -F 3
Internal Walls Plastered bloc ks Fair Structures A -F 3
Internal Amenities Toilet, kitchenette Fair Misc. Site Assets A 3
Pump House Concrete/block building Fair Structures A -F 3
External Walls Blocks Fair Structures A -F 3
Roof Concrete Fair Structures A -F 3
Internal Walls Plastered bloc ks Fair Structures A -F 3
Office & Internal Amenities No office NA
Accommodation No accommodation building. NA
External Walls NA
Roof NA
Internal Walls NA
Internal Amenities NA
Internal Roads Paved blocks Fair Sealed Pavements A, B 3
Internal Paths Paved blocks Fair Sealed Pavements A, B 3
Landscaping Nil NA
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Av ailable.
- No offic e space available with necessary amenities and facilities.
- No proper accommodation facility. Operator staying in the Guard Room.
- No kitchen in the guard room. Cooking in a room beside the Control Room.
- Guard Room windows are broken - covered with plywood.
CONDITION ASSESSMENT - Storage/ Transfer Water Tanks
STORAGE / TRANSFER TANK 01

ADDC GIS Object No: 702, 701
Width (m) N/A
Length (m) N/A
Diameter (m) N/A LEGEND - Asset Condition Assessment
Roof Height (m) N/A Description Life Remains Rating
Depth (m) N/A "As New" 100% 1
Capacity (m3) 6000 Good 75% 2
Tank Description WATER STORAGE TANK Fair 50% 3
Material CONCRETE Poor 25% 4
TANK HOLD THE WATER SUPPLIED FROM IPS2 Ghayathi Failure Imminent 0% 5
Comments
Failed / Derelict Un-useable 6

External - Walls Concrete, painted Fair Structures A-F 3
External - Roof Concrete Fair Structures A-F 3
External - Roof Access GRP ladder Fair Structures A-F 3
External - Roof Hatches Hinged steel covers Fair Structures A-F 3
Internal - W alls Concrete, lined Fair Structures A-F 3
Internal - Floor Concrete, lined Fair Structures A-F 3
Internal - Roof Concrete, lined Fair Structures A-F 3
Water Level Indicator Available Fair Mech Equip A-H 3
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) YES
CONDITION ASSESSMENT - Elevated Water Tanks
ELEVATED TANK 01
ADDC GIS Object No: Not Assigned
Width (m) N/A
Length (m) N/A
Diameter (m) 9.7 LEGEND - Asset Condition Assessment
Elevated Height (m) N/A Description Life Remains Rating
Depth (m) 8.7 "As New" 100% 1
Capacity (m3) 568.3 Good 75% 2
Tank Description Tower Fair 50% 3
Material Concrete Poor 25% 4
Failure Imminent 0% 5
Comments Water supplying to township

Tank Tower/ Stand Concrete Satisfactory Structures A-F 2
Tank Tower Access Concrete steps Satisfactory Structures A-F 2
Pipe Risers Steel Satisfactory Pipework A-C 2
Pipe Riser Supports Steel Not accessible NA
External - Walls Concrete Satisfactory Structures A-F 2
External - Roof Concrete Not accessible NA
Internal - W alls Concrete, lined Satisfactory Structures A-F 2
Comments
1) No light inside the elevated tank, therefore, cannot conduct inspection.
Structural / Material Testing Recommended (Yes / No) No
CONDITION ASSESSMENT - Pipework & Valves (Suction Side)
Suction Header Pipework Pipe 1

Pipe Material STEEL
Pipe Diameter (mm) 250
Condition Rating (1 to 6) 3
Suction Header Valves Valve 1

Not visible as is
Valve Diameter (mm)
underground
Condition Rating (1 to 6) NA
Pump Suction Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Pipe Material STEEL STEEL STEEL
Pipe Diameter (mm) 100 100 100
Condition Rating (1 to 6) 3 3 3
Suction Side
Flexible Coupling
Flexible Coupling Diameter (mm) 100 100 100
Isolation Valve
ADDC GIS Object No: 9760 9748 9746
Isolation Valve Type Gate Gate Gate
Isolation Valve Diameter (mm) 100 100 100
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
CONDITION ASSESSMENT - Pipework & Valves (Delivery Side)
Delivery Header Pipework Pipe 1
Pipe Material STEEL
Pipe Diameter (mm) 200
Condition Rating (1 to 6) 3
Delivery Header Valves Valve 1

Not visible as is
Valve Diameter (mm)
underground
Condition Rating (1 to 6) NA
Pump Delivery Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Pipe Material STEEL STEEL STEEL
Pipe Diameter (mm) 80 80 80
Flexible Coupling
Flexible Coupling Diameter (mm) 80 80 80
Delivery Side
Non-Return Valve
Isolation Valve Type Flap Flap Flap
Isolation Valve
Isolation Valve Type Gate Gate Gate

"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
CONDITION ASSESSMENT - Water Pumps
Overall Condition Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
Pump Body Fair Fair Fair
Pump Shaft Fair Fair Fair
Pump Shaft Coupling Fair Fair Fair
Pump Base Fair Fair Fair
Springs / Anti Vib. Mat. NA NA NA
Pump Plinth Fair Fair Fair
Pump Motor Fair Fair Fair
Asset Condition Assessment Pump 1 Pump 1 Pump 1 Pump 4 Pump 5 Pump 6

General Condition Fair Fair Fair
Assessment Schedule Pumps Pumps Pumps
Assessment Parameters B -H B-H B-H
Rating (1 to 6) 3 3 3

Pumps 01 to 03 (2 duty + 1 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

ADDC GIS Object No: 44.0 43.0 42.0
MEASURED - Pump Flow Head (kPa) 315 320 325
PUMP CURVE - Flow Rate (l/s) unknown unknown unknown
MEASURED - Pump Flow Rate (l/s) 20.0 17.0 18.0
MEASURED - Pump Speed (rpm) 1465 1465 1465
CALCULATED - Pump Hydraulic Power (kW) 6.2 5.3 5.7
MEASURED - Pump Motor Power Input (kW) 13.1 13.4 13.4
CALCULATED - Motor-Pump Efficiency (%) 47.2% 39.9% 42.8%
MEASURED - Pump Shut-Off Head (kPa) 360 355 365
PUMP CURVE - Impellor Diameter (mm)
Comments
1) In mimic panel level indicator jumps up and down when the elevated tank level goes below 5.00m.
2) Incoming flow indicator on panel and external flow meter outside not working.
3) Outflow accumulated flow totalizer not working.
4) Pressure gauges need calibration.
PERFORMANCE CURVES - Water Pumps
Pump Test Flow Pressure

Pump P- 01 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 360 ) 400
a
P 350
2 15 330 (k
20 315 e
r 300
3 u
s 250
4 s
P- 01 e
r 200
5 P 150
6 d
a 100
7 e
H 50
8 0
0 5 10 15 20 25
Water Flow (l/s)

1 0 355 ) 400
a
P 350
2 13 330 (k
3 17 320 e
r 300
u 250
4 s
P- 02 s
e
r 200
5 P 150
6 d
a 100
7 e
H 50
8 0
0 5 10 15 20
Water Flow (l/s)

) 400
1 0 365 a
P 350
2 12 340 k
(
e 300
3 18 325 r
u 250
s
4 s
P- 03
5 re 200
P 150
6 d
a 100
e
7 H 50
8 0
0 5 10 15 20
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 1
capacity. maintenance in place.
Security House Air Conditioning Split AC Fair Mech Equip A-H 3
Pump Room Air Conditioning No AC NA
Control Room Air Conditioning Split AC Not in good condition Mech Equip A-H 2
Pump Room Ventilation Forced ventilation Fair Mech Equip A-H 3
Other

- AC in control room not cooling. "As New" 100% 1
- All the door locks are not working. Good 75% 2
- Main automatic door not working. Fair 50% 3
- Control room - Crack on corner of the building. Poor 25% 4
Failed/ Derelict Un-Useable 6
Appendix E
Electrical Assets

a) Pump Motors
b) Switchboards and Motor Controls
c) Other Electrical Equipment and Systems
CONDITION ASSESSMENT - Pump Motors
Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

Year of Installation
Brand Leroy Somer Leroy Somer Leroy Somer
Model No. LS 180 LR-T LS 180 LR-T LS 180 LR-T
Serial No 130655GL003 130655GL001 130655GL002
Speed (rpm)
Average Voltage (V) 399 403 402
Average Current (A) 29 29 29
Total Power (kW) 20 20 20
Overall Power Factor 0.67 0.66 0.67
Electrical Connection 402 405 405
Soft Start/ VSD
Hours Run (Hrs) 14562 14559 14562
Cables/ Earthing Good OK OK
Thermal Imaging Good 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.
Assessment Parameters C D D
Rating (1 to 6) 3 3 3

Motor 1: Good Panel meter reads 25/26/26 "As New" 100% 1
Motor 2: OK On the basis of hours run, the motors are near end of life. Good 75% 2
Motor 3: Motor number assumed as ID plate missing Fair 50% 3
Poor 25% 4
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) 402 395 399 405 402 402 405 401 401
Current (A) 30 29 27 30 30 27 30 30 27
Power Factor 0.4 0.36 0.39 0.4 0.37 0.39 0.41 0.36 0.38
Average Voltage (V) 398.7 403.0 402.3
Average Current (A) 28.7 28.8 29.0
Overall Power Factor 0.670 0.660 0.670
Dielectric Absorption 180 @ 150 @
>4 G >4 G >4 G
(30sec / 60sec) 1000v 1000V
Polarisation Index (1min/10min)
Hours Run 14562 14559 14562
Power Measured (kW) 13.1 13.4 13.4
Total Power (kVAr) 14.7 14.9 15.0
Total Power (KVA) 19.7 20.1 20.2
RPM
Temperature ºC (Hot > 68ºC) 40.0 60.0 58.0
CONDITION ASSESSMENT - Main Switchboard & Motor Control Panels
Main Switchboard LEGEND - Asset Condition Assessment
Year of Installation Description Life Rating
Clear Labelling? Yes "As New" 100% 1
Logical Layout? Yes Good 75% 2
Main Isolator Fair 50% 3
Manufacturer Merlin Gerin Poor 25% 4
Type Simple board. Good condition. Failure Imminent 0% 5
ACB for main isolator, remote
control only.
Rating (A) 400 Failed / Derelict Un-useable 6
Switchboard Test Phases & Links R Y B RY YB BR

Use SB Meters? y Voltage (V) 225 225 225 390 390 390
No. Pumps Running 1 Current (A) 50 60 40
Meters Switched/ Individual? switch Power Factor 0.8
Thermal Imaging - Switchboard Comments

Termal Imaging? N
Max. Temperature Inaccessible Overall Condition is Clean
Simple board. Good condition. ACB for main isolator, remote control only.
Asset Condition Assessment PF correction cabinet at RH end of board. Fuses blown and panel not operating.
Assessment Schedule Elect. Equip. With one motor running ampmeter just within scaled range - replace meter.
Assessment Parameters A-I
Rating (1 to 6) 3
Motor Controls Motor Controls Thermal Comments

Image
Manufacturer Leroy Somer Digistart STV 2313 Motor Control No 1 Ok
Soft Start ? Yes Motor Control No 2 Ok
Controls Functional ? Yes Motor Control No 3 OK Fast soft start 1 sec
Internal Layout Simple Motor Control No 4 -
Interlock on Panel ? Yes Motor Control No 5 -
Motor Control No 6 -
CONDITION ASSESSMENT - Other Electrical Equipment and Systems
Electrical Equipment Description Comments Asset Condition Assessment
Power Transformer Approximately 80m from station. No enclosure. LT cables run on surface via Elect. Equip. A-I
1500 A destroyed substation building then disappears into sand. 4
Rating
Pump Station Earthing Earth points adjacent to building supply points and around perimeter of site. Elect. Equip. A-I
Neutral / Earth Link Yes 3
Resistance (Earth /Neutral) 0.4
Lightning Protection Rod and strap protection on tanks, pump building and security hut. Earths may Elect. Equip. A-I
Rod and strap protection on tanks, pump run to pits adjacent to strap down building. 3
Lightning Protection
building and security hut.
Pump Room Crane Operating Elect. Equip. A-I
3
Electrics OK
Pump Control Panel Clear Mimic. Inflow meters not working, all powered. Pilot indications working Elect. Equip. A-I
Clear Mimic (Y/N) Yes 1 of 2 pressure meters working, output flow meters working. Tank mechanical
3
Fully Operational (Y/N) No gauges out of site of control room.
Thermal Imaging (Y/N) Yes
Power Cabling Combination of above and floor chase systems. Good condition above floor Elect. Equip. A-I
SWA Standing water in chase. Cable tray supports immersed and beginning to 4
Main SB to Motors corrode.
Room Lighting Fittings didn't fully strike. New lamps may correct. Elect. Equip. A-I
Control Room Lighting Over lit. 4
Emergency/ Exit Lighting 25% fittings with battery packs.
Exterior Site Lighting Not working. Operators report that the lighting is needed to discourage snakes Elect. Equip. A-I
5
Exterior Site Lighting Extensive and scorpions entering site through wire fence.
Fire Alarm System Elect. Equip. A-I
Manufacturer Nil NA
Detector Types --
New Pumping Annex New pumping annex commissioned but UPS & battery supply in externally accessed room. 2 x 10 kVA, 2 x 145 cell Elect. Equip. A-I
1
not yet handed over to ADDC NiCad

"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Appendix F
Pumps and Motors – Temperature, Noise,
Vibration and Alignment
Condition Assessment Schedules
TEMPERATURE, NOISE & VIBRATION - Pumps & Motors
Temperature Deg C
Pump Room 34.7
Control Room 29.7
Outside (Ambient) 39
Ambient Noise [dB(A)] Noise Source

Pump Room 75 Pump 2 & 3
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) 74 72 71
Noise Source 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 0.949 25 2.319 25 2.813 25
Point No 2 = Motor - Rear Foot 0.700 100 0.299 25 0.951 25
Point No 3 = Motor - Top of Motor 1.122 100 0.237 100 0.631 25
Point No 4 = Pump - Top Front Bearing 0.752 25 2.410 25 2.910 25
Point No 5 = Pump - Top Rear Bearing 0.188 25 0.729 25 1.011 25
Point No 6 = Pump - Rear Foot 0.031 100 0.269 25 1.080 25
Point No 7 = Pump - Inlet 0.051 147.5 N/A N/A N/A N/A
Point No 8 = Pump - Outlet 0.811 25 N/A N/A N/A N/A

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 0.42 0.14 0.14
Linear Displacement - Horizontal 0.10 0.10 0.00
Angular Displacement - Vertical 0.02 0.18 0.14
Linear Displacement - Vertical 0.00 0.02 0.20
Thermal Images (Hot > 68 Deg C) 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.
Assessment Parameters F F F
Rating (1 to 6) 3 3 3
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. LEGEND - Asset Condition Assessment
Shaft Alignment required on ALL pumps "As New" 100% 1
Noise within the station is an issue of concern Good 75% 2
Pipework flexible connectors in OK condition Fair 50% 3
Pump flexible couplings OK condition Poor 25% 4
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
Bida Al Mutawa – Internal – Elevated Tank
Internal main wall Crack mark at main wall
Repaired joint sealant at main wall Evidence of leakage at centre wall
Soffit lining Evidence of leakage at centre wall
Bida Al Mutawa – External – Elevated Tank
Leakage marks at external of main wall Leakage marks at external of main wall
Crack and leakage marks at external Crack and leakage marks at external
face of centre wall face of centre wall
GRP ladder leading to top slab Vertical pipe work
Bida Al Mutawa – External – Ground Tank
Loose lining at wall Vertical wall crack
Crack and leakage mark at wall Paint blisters at wall
Access ladder showing broken handle Leakage marks at wall
Appendix H
OEM vs Pump Performance
Appendix I
Thermographic Images
Bida Al Mutawa Pumping Station – Thermal Imaging
Visible Light Image

TI 01
Pump Set No. 1
8/13/2009 9:45:49 AM
Visible Light Image

TI 02
Pump Set No. 1 Motor Bearing
8/13/2009 9:46:04 AM
Visible Light Image

TI 03
Pump Set No. 1 Pump Bearing
8/13/2009 9:46:12 AM
Visible Light Image
TI 04
Pump Set No. 1 Motor
8/13/2009 9:46:21 AM
Visible Light Image

TI 05
Pump Set No. 1 Pump
8/13/2009 9:46:29 AM
Visible Light Image

TI 06
Pump Set No. 1 Motor Control Panel
8/13/2009 9:47:48 AM
Visible Light Image
TI 07
8/13/2009 9:48:33 AM
Visible Light Image

TI 08
8/13/2009 9:48:42 AM
Visible Light Image

TI 09
8/13/2009 9:48:50 AM
Visible Light Image
TI 10
8/13/2009 9:48:54 AM
Visible Light Image

TI 01
Pump Set No. 2
8/13/2009 9:21:37 AM
Visible Light Image

TI 02
8/13/2009 9:21:51 AM
Visible Light Image
TI 03
8/13/2009 9:22:01 AM
Visible Light Image

TI 04
8/13/2009 9:22:11 AM
Visible Light Image

TI 05
Pump Set No. 2 Pump
8/13/2009 9:22:31 AM
Visible Light Image
TI 06
8/13/2009 10:15:46 AM
Visible Light Image

TI 07
8/13/2009 10:16:13 AM
Visible Light Image

TI 08
8/13/2009 10:16:18 AM
Visible Light Image
TI 09
8/13/2009 10:16:23 AM
Visible Light Image

TI 10
8/13/2009 10:16:54 AM
Visible Light Image

TI 11
8/13/2009 10:16:59 AM
Visible Light Image
TI 12
8/13/2009 10:17:35 AM
Visible Light Image

TI 13
Pump Set No. 2
8/13/2009 10:19:18 AM
Visible Light Image

TI 01
Pump Set No. 3
8/13/2009 9:22:47 AM
Visible Light Image
TI 02
8/13/2009 9:22:58 AM
Visible Light Image

TI 03
8/13/2009 9:23:06 AM
Visible Light Image

TI 04
8/13/2009 9:23:15 AM
Visible Light Image
TI 05
Pump Set No. 3 Pump
8/13/2009 9:23:26 AM
Visible Light Image

TI 06
Pump Set No. 3
8/13/2009 10:59:34 AM
Visible Light Image

TI 07
8/13/2009 11:01:36 AM
Visible Light Image
TI 08
8/13/2009 11:01:57 AM
Visible Light Image

TI 09
8/13/2009 11:02:01 AM
Visible Light Image

TI 10
8/13/2009 11:02:06 AM
Visible Light Image
TI 11
8/13/2009 11:02:10 AM
Appendix J
Vibration Spectrum
Ghanada Pumping Station – Pump Set No. 1
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. K. Skawinski* P. Rodda P. Rodda* 04 Jan 2010*

Skawinski
1 C. Teske K. K. Skawinski* P. Rodda P. Rodda* Feb 2010*

Skawinski
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*

Western Region PS 05 15686 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. Electrical Equipment Alert 16

8. Concrete Water Storage Tanks Assessment 18

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 05 - Bida Al Mutawa, Ghayathi Pumping Station DW-BMW-WPS1

3.1 Site Safety Assessment

3.2 Civil and Infrastructure Assets Condition Assessment

3.3 Mechanical Assets Condition Assessment

3.4 Electrical Assets Condition and Energy Assessment

3.5 Pump Performance and Efficiency Assessment

3.6 Vibration, Alignment and Noise Assessment

Figure 2 Pump Floor Layout

4.1 Safety Assessment

4.2 Building and General Infrastructure

4.3 Pump Station Operation

5.1 General Description

Figure 3 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 6 Water Storage Tank

6.1 General Description

Figure 7 Pump Layout Figure 8 Depth of Lowered Floor

6.2 Motor Description and Condition

Rating: 18.5 kW @ 380, 400, 415 V

Full Load current 38, 37, 37 A @ 380, 400, 415 V

Rated PF: 0.83, 0.80, 0.77 @ 380, 400, 415 V

Speed (rpm): 1455, 1460, 1465 @ 380, 400, 415 V

Rated Ambient/rise Not given

Serial No. 130655GL003 130655GL001 130655GL002 *

Hours run 14562 14559 14552

*Number is assumed as the name plate had been removed

General Condition - Good.

Cabling: Generally good. Faulty cable termination on motor 3. See Exceptional

6.3 Pump and Tank Control Panel

Figure 9 Mimic Panel Layout Figure 10 Internal Layout

6.4 Station Power Supply

Figure 11 View towards Transformer Location behind Wall

6.5 The Main Switchboard

Figure 12 Main Switchboard

Figure 13 MC Panel Figure 14 MCP Interior Figure 15 Rear of MCP

6.7 Power Factor Correction

6.8 Power Cabling

To Motor Control Panels

Figure 16 Cabling Floor Chase Figure 17 Vertical Section and Stairway

6.9 Fire Alarm System

6.10 Station Lighting

6.11 Items for Further Investigation

7.1 Damage to Motor Supply Cable Termination

Visible Light Image