E-05 (Rev1)

Abu Dhabi Distribution Company
Condition Assessment and Energy

Management Survey of ADDC Water
Pumping Stations
Eastern Region PS 05 - Ghanada, Samha
Pumping Station DW-GND-WPS2
February 2010
Contents
1. Introduction 1
1.1 Project Objectives 1
1.2 Project Scope 1
1.3 Purpose of this Report 1
1.4 Related Reports 1
1.5 ADDC Supplied Information 1
2. Pump Station Overview 2

2.1 Description of Pumping Station 2
3. Pump Station Assessments 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
4. Civil and Infrastructure Assessment 6

4.1 Safety Assessment 6
4.2 Building and General Infrastructure 6
4.3 Pump Station Operation 6
5. Mechanical Assets Assessment 7

General Description 7
Vibration 7
Shaft Alignment 8
Noise Levels 8
Thermal Imaging 9
Summary of Action Points 9
6. Electrical Assets Assessment 10

6.1 General Description 10
6.2 Motor Description and Condition 10
6.3 Station Power Supply 11
6.4 Main Switchboard and Control Panels 11
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
Eastern Region PS 05 - Ghanada, Samha Pumping Station DW-GND-WPS2
6.5 Power Cabling 13
6.6 Fire Alarm System 13
6.7 Summary of Action Points 13
7. Recommendations 14
Figure Index
Figure 1 Eastern Region PS 05 - Ghanada, Samha Pumping
Station DW-GND-WPS2 3
Figure 2 Computerised Graphics of Pumps Automation
System 5
Figure 3 Pump Floor Layout 6
Figure 4 Measurement Point Locations 7
Figure 5 Vibration at Location 3 on Pump 1 8
Figure 6 Acoustic Spectrum from Pump 1 9
Figure 7 Surge Tank (8,000 Litre Capacity, 16 Bar Pressure)
- One of 2 Tanks on this Site 9
Figure 8 Packaged Power Supply Substation 11
Figure 9 Station Main Switchboard 12
Figure 10 Controls Displays 12
Figure 11 Floor Chase Detail 13
Figure 12 Access Road to Site 15
Figure 13 Pipes and Connection Setup to Water Pumps 15
Appendices
A Pump Station Schematic
B Site Safety Assessment
C Civil and Infrastructure Assets
D Mechanical Assets
E Electrical Assets
F Pumps and Motors - Vibration, Alignment and Noise
G OEM vs Pump Performance
H Thermographic Images
I 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. Upon ADDC approval, complete condition and performance assessments on the remaining 36
pumping station;
5. Produce a Condition Assessment and Energy Management Report on each of the nominated water
pumping stations; and
6. Produce a final Condition Assessment and Management Strategy Report for the 37 water pumping
stations which:
– summarises the results of the individual pumping station surveys;
– identifies plant and equipment for repair, overhaul or replacement; and
– presents GHD’s recommendations for condition monitoring, maintenance and energy
management improvement and operator training and operations improvement.
1.3 Purpose of this Report

This report presents the following results of GHD’s Condition Assessment and Energy Management
Survey of Eastern Region PS 05 - Ghanada, Samha Pumping Station DW-GND-WPS2 .
1.4 Related Reports

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

Not all information to conduct the full scope of the pumping station survey was available from ADDC or
from GHD’s research of equipment suppliers and their websites.
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations 1
2. Pump Station Overview
2.1 Description of Pumping Station

Pump Station Location Description
Date of Inspection 19 August 2009
Name Ghanada Pump Station, Samha
Location On the coast between Samha and Ghantoot
Access Via Samha, off Abu Dhabi – Dubai Road
Date of Commissioning 2007
Supply Source DN 500 Pipeline from Taweela Desalination Plant
Area of Supply VIP Villas along AL Jurf Coast
Storage Tanks 1 x 2.25 Ml Ground Tank (partitioned into 2 cells)
Pumps 3 x 35 l/s horizontal Centrifugal Pumps (2 duty + 1 standby)
Elevated Storages None (owned by ADDC)
Pump Station Schematic Refer Appendix A
Figure 1 Eastern Region PS 05 - Ghanada, Samha Pumping Station DW-GND-WPS2
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
GHD’s condition assessment schedules for civil and infrastructure assets is 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, 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 Computerised Graphics of Pumps Automation System
4. Civil and Infrastructure Assessment
4.1 Safety Assessment

The following safety matters require attention as noted in Appendix B:
No site lights in the compound except two small ones near the entrance of the control room.
There is no First Aid or Personal Protection Equipment on site for use by the operator.
4.2 Building and General Infrastructure

All new buildings and general infrastructure are in an ‘as new’ condition. This is with the exception to old
and deteriorated accommodation site shed for pump station operators.
4.3 Pump Station Operation

The pumping station was completed in 2007 and a Final Acceptance Certificate (FAC) has not yet
been issued.
The 2 pumps together operate 16 hrs per day.
There is no mimic panel; the station is operated by SCADA readings only.
Storage Tanks
The storage tanks (ground and elevated) are generally in a satisfactory condition; however the following
operational issues are noted.
The painted storage tank walls make it harder for earlier leaks detection.
There is no digital tank level indicator only a manual wire indicator.
The incoming valve to the storage tank does not open at times.
Figure 3 Pump Floor Layout
5. Mechanical Assets Assessment
General Description
This station is a station with 3 small horizontal pump motor sets. Overall the equipment is in good
condition. The control room temperatures were acceptable with the temperatures in the machine room
(non air conditioned) appreciably lower than the outside temperatures.
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 well secured and 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.
Details of pump pipework setup
Figure 5 Vibration at Location 3 on Pump 1
General Condition - External: Good.
Shaft Flexible Couplings Good
Pipe Work - Flexible Connections Good
Shaft Alignment
Alignment was measured on each pump set. Individual results are presented in the appropriate
schedule. The displacement readings for all the pumps were within accepted limits.
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) with pump 1 running. The room noise levels are expected to rise by 3 dB for
every doubling of the number of running pumps. This gives a maximum level in the pump room of 80
dB(A) which is below the recommended limits of 85 dB(A) over an 8 hour period.
Figure 6 Acoustic Spectrum from Pump 1
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.
Summary of Action Points

No action points for noise, vibration and thermal images.
Figure 7 Surge Tank (8,000 Litre Capacity, 16 Bar Pressure) - One of 2 Tanks on this Site
6. Electrical Assets Assessment
6.1 General Description

The station is located in the forestry area and supplies the number of VIP villas along the Al Jurf coast.
The station features a single, partitioned water tank, guard house and a well laid out, tidy site
Adjacent to the entry is an accommodation block.
Power supply for the site is via a packaged substation located immediately inside the entry.
No site area lighting is provided.
The pumps and motors are located approximately 2m below ground level within a larger pumping room.
To one end is a landing area, accessed via a roller door. To the other end is a large control room with a
viewing window onto the pumping floor. Beyond the control room is the amenity area and a battery
room. Access is to the pump level is via a single ladder. Placement of suction and pressure manifolds
along one wall of the pumping level allows for good access to all pumps and motors via individual
ladders to each pump location as the manifold and piping layout precludes access ‘pump to pump’
6.2 Motor Description and Condition

Manufacturer: ABB
Model: M3BP 180 L 4
Rating: 22 kW @ 415 V 50 Hz
Full Load current 38 A
Rated PF: 0.84
Speed: 1475 r/min
Insulation Class F
Rated Ambient/ rise (Not shown)
Serial Numbers
Motor 1 2 3
Serial No. 0542599510014 (Not shown) (Not shown)
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: Good. Cabling to terminals well formed in terminal boxes.
Motor controls: Each motor has an up stand featuring emergency stop, local controls and
pilot indicators.
6.3 Station Power Supply

The station is powered from a 500 kVA packaged substation. The sub station supplies the pumping
station via a 400A fused circuit from the LV distribution panel. The panel also supplies a single phase
circuit, suspected to be a lighting circuit.
The interior of the LV distribution section was very dusty and there was a significant amount of ‘parts’
discarded inside the cabinet.
The station was ineffectively secured. Rust was noted on the external panels.
Figure 8 Packaged Power Supply Substation
6.4 Main Switchboard and Control Panels

The main switchboard features a single supply entering at the lower left hand corner where the main
isolator is located. Metering and 2 ‘spare’ cubicles are located above the isolator cubicle. Three motor
control cubicles (MCC) are provided each featuring an ammeter, a soft starter by Telemacanique, local
controls and a remote/local over-ride. Pilot lamps for supply, run, trip and over temperature are provided.
Each cubicle is protected by door controlled isolator with an effective interlock.
The board also features a spare motor control cabinet fitted as per the main MCC panels but without the
soft starter.
Figure 9 Station Main Switchboard
Power Factor Correction

A 40 kVA automatic power factor correction cabinet was floor mounted behind the Main Switchboard.
The cabinet featured 4 steps of correction; 6, 12.5, 12.5, 19 kVA nominal. Each step was protected by a
reactor and the cabinet was ventilated by a thermostatically controlled fan.
Pump and Tank Control System

The station features a PLC based control system with a computer based display and control interface.
The system is located in the TSF control room.
Figure 10 Controls Displays

All monitored points and indications were correctly displayed. The PLC equipment was mounted in a
separated floor mounted cabinet. Power supply for the PLC cabinet and the computer interface is via a
double conversion / on-line UPS.
PLC System
Station motor controls are via a PLC system. This is housed in a floor mounted cabinet adjacent to the
main switchboard. The system is based on Siemens Simatic components and features redundancy in
CPU and power supply modules. Internal layout and labelling is excellent.
System display is via a computer installed on the operator’s desk. The computer display is a 17 in LCD
panel. Operator control is via mouse and keyboard. Apart from the operating software the computer
appears to be ‘standard’ in nature.
UPS
An AEG Protect Series 3, 5 kVA free standing a double conversion / on-line UPS c/w a 16 AH 304 cell
NiCD battery is provided.
6.5 Power Cabling
Cable Access Trench

Cables are routed from main switchboard to the pump motors via a shallow floor chase. The vertical
section of the cable path from the pumping floor to the chase beneath the main switchboard is fully
enclosed
Cable tray: Cable trays are fully enclosed and in excellent condition. There is no evidence of
water ingress into the chase. Motor supply cables are steel wire armoured (SWA).
Cable layout: The rises to the individual motors are adequately secured and connections to motor
terminals are well laid out.
Access and Covers lifted via key holes. Covers fitted well and were stable under foot. Covers were
function: easily handled.
Cleanliness: There is a small amount of construction debris and dirt on the floor of the chase.
Figure 11 Floor Chase Detail
6.6 Fire Alarm System

The station includes a Kidde Fire Alarm System, incorporating ionisation detectors and beam protection
for the pump floor. The system was not operating as it had been persistently giving fault indications and
no repairs had been carried out.
6.7 Summary of Action Points

Fire Alarm System requires full commissioning (to be undertaken before FAC is issued)
Additional general site lighting should be provided to facilitate operations.
7. Recommendations
Safety
7. First Aid and Personal Protection Equipment needs to be issued to the ADDC operators.
8. Hearing protection should be provided to all operators.
9. Safety signs should be installed at the entrance to the station (and pump room). - Safety Shoes,
Hard Hat, Hearing Protection and Eye Protection).
10. No site lights in the compound except two small ones near the entrance of the control room.
Additional general site lighting should be provided to facilitate night operations.
11. Install lockable storage tank access hatches.
12. Pump room should be equipped with stand by air conditioning. This air conditioning system should
be used for maintenance or repair works performed during summer hot period.
Civil and Infrastructure Assessment

13. Sand and soft dirt station access road should be upgraded to sealed type road.
14. Consideration should be given to provision of proper accommodation which meets UAE standards.
15. Remove and reinstall substandard quality of satellite antennas installation.
16. Repair sticky isolation valve on incoming pipeline to storage tank.
17. Remove debris and rubbish from roofs of all buildings.
Mechanical Assets Assessment

18. Low pumping efficiency caused by pump capacity over-estimation. In order to improve pumps
efficiency and lower power consumption we recommend downsizing of the existing pump impellors.
This can be done by removal of the impellor and cutting it down (machining it) to desired size
equivalent to the original design water flow.
19. All Pumps. Existing water supply pipework (80mm ND) has been grossly undersized. Currently water
from pumps into common header runs at 7.5m/s velocity. This creates high flow turbulence and
pipework vibration and in time will cause pipework, fittings and valves deterioration. Use of short
radius 90o pipe elbows is not acceptable. We recommend:
– Replacement of the existing ND 80mm pipework and valves on supply side of all pumps with new
pipework at ND 125 mm. This will decrease water velocity down to 2.75m/s.
– Use of 45o elbows on pipe entries into pipe common header.
– Use of long radius elbows ONLY.
20. All Pumps. Existing water suction pipework (100 mm ND) has been grossly undersized. Currently
water from header into all pumps runs at 4.5m/s velocity. This creates high flow turbulence and
pipework vibration and in time will cause pipework, fittings and valves deterioration. In time this may
also cause pump cavitation. We recommend the following actions:
– Replacement of the existing ND 100mm pipework and valves on suction side of all pumps with
new pipework at ND 125mm. This will decrease water velocity down to 2.75m/s.
21. Pump No 1 requires shaft alignment to be set to acceptable manufacturer limits.
Electrical Assets Assessment
22. Fire Alarm System requires full commissioning (to be undertaken before FAC is issued)
Figure 12 Access Road to Site
Figure 13 Pipes and Connection Setup to Water Pumps
Appendix A
Pump Station Schematic
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations A1
Appendix B
Site Safety Assessment
SITE SAFETY ASSESSMENT
Pumping Station Name Ghanada Pump Station, Samha

Assessment Date 19 August 2009
HAZARD SATISFACTORY COMMENTS

Site Access and Egress Yes
Site Security Yes
Lighting No - No lights in the compound, except two small ones near the entrance of the control room.
Mechanical Hazards (eg Unguarded Plant) Yes

Electrical Hazards Yes
Housekeeping (General Tidiness) Yes
Fire Hazard and Equipment Yes
Noise Yes
Dust / Fumes Yes
Hazardous Substances Yes
W orking at Heights Yes
Ladders / Scaffolding Yes
Pressurized Equipment Yes
Heat Illness / Stress Yes -No air conditioning inside pump room
Personal Protective Equipment (PPE) Yes -Provide PPE to all ADDC personnel on site
Knowledge of Site Safety Rules No - No first aid kit available on site.
Site Emergency Procedures Yes
Confined Space Entry Yes
Lock Out / Tag Out Yes
OTHER - Water Quality / Health Hazard No -Tank access hatches are not 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.
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations B1
Appendix C
Civil and Infrastructure Assets
Condition Assessment Schedules:

a) Buildings and General Infrastructure
b) Storage Tanks
c) Pipework and Valves
CONDITION ASSESSMENT - Buildings & General Infrastructure
Pum ping Station Name Gh anada Pump Station - Samha LE GEND - Asset Condition Assessment
Assessment Date 19 August 2009 Description Life Remains Rating
Time: IN / OUT 8.30AM / 12.30P M "As New" 100% 1
GPS P osition (E ntry Gate) N 24° 49.537' E 54° 47.846' Good 75% 2
AD DC GIS Object No: 8081 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 Description Asset Condition A ssessment

Com ments
S chedule Parameters Rating
Access Road Sand and dirt road P oor S ealed Pavements A, B 4
Boundary Fence / Walls Concrete & Brick fence "As N ew" Fences / Str uctures A-F 1
Entry G ate No Gate installed NA
Security House Concrete/ block bui lding "As N ew" Structures A -F 1
External W alls Block s "As N ew" Structures A -F 1
Roof Concrete wi th tiles "As N ew" Structures A -F 1
Internal W alls Plastered blocks "As N ew" Structures A -F 1
Internal Am eniti es None NA
Pump House Concrete/ block bui lding "As N ew" Structures A -F 1
External W alls Block s "As N ew" Structures A -F 1
Roof Concrete wi th tiles "As N ew" Structures A -F 1
Internal W alls Plastered blocks "As N ew" Structures A -F 1
Office & Internal Am enities Office within the control room . "As N ew" Misc. Site Assets A 1
Accomm odation Very old, deteriorat ed site shed Un-useable Structures A -F 6
External W alls Un-useable Structures A -F 6
Roof Un-useable Structures A -F 6
Internal W alls Un-useable Structures A -F 6
Internal Am eniti es No amenities provided Un-useable Misc. Site Assets A -F 6
Internal R oads Paved blocks "As N ew" S ealed Pavements A, B 1
Internal Paths Paved blocks "As N ew" S ealed Pavements A, B 1
Landscaping Hardscaped "As N ew" Misc. Site Assets A, B 1
Co mm en ts
NOTE: 'NA' or 'Blank' = Not Applicable or Data N ot Available.
Ac com modation facilities and amenities for pump station operators are generally in neglect and in poor condition. No show ers.
No dedic ated office space available.
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations C1
CONDITION ASSESSMENT - Storage/ Transfer Water Tanks
STORAGE / TRANSFER TANK 01

ADDC GIS Object No: 18369
Width (m)
Length (m)
Diameter (m) LEGEND - Asset Condition Assessment
Roof Height (m) Description Life Remains Rating
Depth (m) "As New" 100% 1
Capacity (m3) 2250 Good 75% 2
Tank Description WATER STORAGE TANK Fair 50% 3
Material CONCRETE Poor 25% 4
TANK HOLD THE WATER SUPPLIED FROM TAWEELA DESALINATION PLANT Failure Imminent 0% 5
Comments
Failed / Derelict Un-useable 6
Asset Condition Assessment

Asset Description Comments
Schedule Parameters Rating
External - Walls Concrete, painted As New Structures A-F 1
External - Roof Concrete with tiles As New Structures A-F 1
External - Roof Access Steel ladder As New Structures A-F 1
External - Roof Hatches Hinged steel covers As New Structures A-F 1
Internal - Walls Concrete No access NA
Internal - Floor Concrete No access NA
Internal - Roof Concrete No access NA
Water Level Indicator Available As New Mechanical A-H 1
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
1) Painted storage tank walls make harder for any leakage detection.
Structural / Material Testing Recommended (Yes / No) No
CONDITION ASSESSMENT - Pipework & Valves (Suction Side)
Suction Header Pipework Pipe 1

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

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

Pipe Material STEEL STEEL STEEL
Pipe Diameter (mm) 100 100 100
Condition Rating (1 to 6) 4 4 4
Suction Side
Flexible Coupling
Flexible Coupling Diameter (mm) 100 100 100
Isolation Valve
ADDC GIS Object No: 312809 312812 312815 Not Assigned Not Assigned Not Assigned
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
Suction Pipework and related valves ND 100mm - CONDITION ASSESSMENT (poor) 4 - this "As New" 100% 1
pipework has been undersized. Current water velocity runs at 4.5m/s. It is recommended at 2.75m/s Good 75% 2
maximum (for ND 125mm pipe). Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
CONDITION ASSESSMENT - Pipework & Valves (Delivery Side)
Delivery Header Pipework Pipe 1
Pipe Material STEEL
Pipe Diameter (mm) 200
Delivery Header Valves Valve 1

ADDC GIS Object No: Not Assigned
Valve Diameter (mm) 200
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
ADDC GIS Object No: 312811 312814 312817
Isolation Valve Type Needle Needle Needle
Isolation Valve
Isolation Valve Type Gate Gate Gate

"As New" 100% 1
Good 75% 2
Pipework and all related valves rated at 4 (poor). Pipe sizes grossly underestimated. Use of short radious 90 deg.
Fair 50% 3
pipe elbows is not acceptable. Current water velocity at 7.5m/s. We recommend pipes to be increased in size to
Poor 25% 4
ND125mm with velocity at 2.75m/s
Appendix D
Mechanical Assets

a) Water Pumps
b) Other Mechanical Equipment & Systems
Pump and Motor Data
Pump Data Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
AD DC GIS Object No: 7213 7214 7215
Year of Installation 2007 2007 2007
Supply to Sheikh's Palace Supply to Sheikh's Palace Supply to Sheikh's Palace
Purpose / Function
and Villas and Villas and Villas
Brand KSB KSB KSB
Horizontal Split Casing Horizontal Split Casing H orizontal Split Casing
Type
Centrifugal Centrifugal Centrifugal
Model No ETANORM C080-315 SP ET ANORM C080-315 SP ETANORM C080-315 SP
Serial No 9970821299 000 100 02 9970821299 000 100 03 9970821299 000 100 01
Impeller Design Size (mm) unknown unknown unknown
Speed (rpm) 1460 1460 1460
Pumping Design Power (kW ) unknown unknown unknown
Pump Design Efficiency (%) unknown unknown unknown
Duty Point Flow (l/s) 35 35 35
NPSHR (kPa) unknown unknown unknown
Duty Point Pressure (kPa) 320 320 320
Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

AD DC GIS Object No: 7213 7214 7215
Year of Installation 2007 2007 2007
Brand ABB ABB ABB
Type M3BP 180L4 M3BP 180L4 M3BP 180L4
Serial No 05425 99510014 05425 23010010 05425 23010009
Voltage (V) 415 415 415
Speed (rpm) 1475 1475 1475
Current (A) 38 38 38
Insulation F F F
IP or Enclosure IP55 IP55 IP55
cos(fee) 1 1 1
Power (kW) 22 22 22
VSD (Yes / No) No No No
OTHER
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D1
CONDITION ASSESSMENT - Water Pumps
Overall Condition Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
Pump Body Satisfactory Satisfactory Satisfactory
Pump Shaft Satisfactory Satisfactory Satisfactory
Pump Shaft Coupling Satisfactory Satisfactory Satisfactory
Pump Base Satisfactory Satisfactory Satisfactory
Springs / Anti Vib. Mat. NA NA NA
Pump Plinth Satisfactory Satisfactory Satisfactory
Pump Motor Satisfactory Satisfactory Satisfactory
Asset Condition Assessment Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
General Condition Satisfactory Satisfactory Satisfactory

Assessment Schedule Pumps Pumps Pumps
Assessment Parameters B-H B -H B-H
Rating (1 to 6) 1 1 1

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

MEASURED - Pump Flow Head (kPa) 225 220 210
PUMP CURVE - Flow Rate (l/s) unknown unknown unknown
MEASURED - Pump Flow Rate (l/s) 42 45 45
MEASURED - Pump Speed (rpm) 1475 1475 1475
CALCULATED - Pump Hydraulic Power (kW) 9 10 9
MEASURED - Pump Motor Power Input (kW) 19.6 19.3 19.5
CALCULATED - Motor-Pump Efficiency (%) 47.3% 50.3% 47.5%
MEASURED - Pump Shut-Off Head (kPa) 390 390 380
PUMP CURVE - Impellor Diameter (mm)
Comments

1) Operating 16 hours daily.
2) Working on SCADA, no mimic panel.
3) Valve on incoming line to the tank does not open sometim es.
4) New pump station - completed in 2007, FAC not yet completed.
5) Pump have very low efficiencies due to design duty overestimation (320kPa design versus 220kPa actual)
PERFORMANCE CURVES - Water Pumps
Pump Test Flow Pressure

Pump P- 01 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 390 450
Head Pressure (kPa)

400
2 25 320
350
3 42 225 300
4 250
P- 01
5 200
6 150
7 100
50
8
0
0 10 20 30 40 50
Water Flow (l/s)

1 0 390 450
Head Pressure (kPa)
400
2 26 320
350
3 45 220 300
4 250
P- 02
5 200
6 150
7 100
50
8
0
0 10 20 30 40 50
Water Flow (l/s)

400
1 0 380
Head Pressure (kPa)
350
2 24 320
300
3 45 210
250
4
P- 03 200
5
150
6
100
7
50
8
0
0 10 20 30 40 50
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 As New Cranes A -C 1
capacity.
Security House Air Conditioning W indow AC As New Mech. Equip. A-H 1
Pump Room Air Conditioning No AC NA Mech. Equip. A-H NA
Control Room Air Conditioning W indow AC As New Mech. Equip. A-H 1
Pump Room Ventilation Forced ventilation As New Mech. Equip. A-H 1
Surge Tank 1 1 x 8,000l capacity, working As New Mech. Equip. A-H 1

pressure 16 bar
Surge Tank 2 1 x 8,000l capacity, working As New Mech. Equip. A-H 1
pressure 16 bar
Other

"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failed/ Derelict Un-Useable 6
Appendix E
Electrical Assets

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

Year of Installation
Brand ABB ABB ABB
Model No. M3BP 180 L 4 M3BP 180 L 4 M3BP 180 L 4
Serial No 542599510014
Speed (rpm)
Average Voltage (V) 414 414 414
Average Current (A) 24 33 34
Total Power (kW) 24 24 24
Overall Power Factor 0.80 0.80 0.81
Electrical Connection 414 413 412
Soft Start
Hours Run (Hrs) 5009 5087 4982
Cables/ Earthing Good Good Good
Thermal Imaging Ok Ok Ok
Asset Condition Assessment Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 M otor 6

Assessment Schedule Elect. Equip. Elect. Equip. Elect. Equip.
Assessment Parameters C D D
Rating (1 to 6) 2 2 2

Motor 1: Motor upstand has ammeter. "As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations E1
PERFORMANCE ASSESSMENT - Pump Motors
Performance Parameters Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

R Y B R Y B R Y B R Y B R Y B R Y B
Voltage (V) 414 415 414 413 416 414 412 415 415
Current (A) 33 34 5 33 33 34 33 33 35
Power Factor 0.47 0.45 0.47 0.47 0.46 0.47 0.48 0.46 0.47
Dielectric Absorption (30/60sec MW ) >4 G >4 G >4 G
Polarisation Index (1min/10min MW )
Insulation at End of PI (M )
Average Voltage (V) 414.3 414.3 414.0
Average Current (A) 24.0 33.3 33.7
Overall Power Factor 0.800 0.800 0.810
Power Measured (kW ) 19.6 19.3 19.5
Total Power (kVA) 24.4 24.0 24.1
Temperature ºC (Hot = 68ºC) 41.0 42.0 50.0
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 Good 75% 2
Main Isolator Fair 50% 3
Manufacturer Cutler Hamer Poor 25% 4
Type Compact Failure Imminent 0% 5
Rating (A) 400A Failed / Derelict Un-useable 6
Switchboard Test Phases & Links R Y B RY YB BR

Use SB Meters? Voltage (V) 240 240 240 415 415 415
No. Pumps Running Current (A) ?50 ?50 ?50
Meters Switched/ Individual? Switch Power Factor 0.83
Thermal Imaging - Switchboard Comments

Termal Imaging? N Board typically used at <20% rating. Too Shuttered.
Max. Temperature Overall Condition is Good
Compact
Asset Condition Assessment Amm eter not in reading range with 1 pump running
Assessment Schedule Elect. Equip.
Assessment Parameters A-I
Rating (1 to 6) 2
Motor Controls Motor Controls Thermal Comments

Image
Manufacturer Telemecanique Motor Control No 1 Yes NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
Type Motor Control No 2 Yes Very clear layout
Soft Start ? Y Motor Control No 3 Yes
Controls Functional ? Yes Motor Control No 4
Internal Layout Good Motor Control No 5
Interlock on Panel ? Yes Motor Control No 6
CONDITION ASSESSMENT - Other Electrical Equipment and Systems
Electrical Equipment Description Comments Asset Condition Assessment
Power Transformer Packaged substation unit, containing HT switch and LV Elect. Equip. A-I
500 distribution board. Not secured. Corrosion on external 3
Rating
panels. Dusty. I x single phase circuit + PS circuit.
Pump Station Earthing Elect. Equip. A-I
Neutral / Earth Link Not visible Good. 1
Resistance (Earth /Neutral) 0.2
Lightning Protection Elect. Equip. A-I
Earthing resistance unknown. 3
Lightning Protection Good
Pump Room Crane Elect. Equip. A-I
Good support for control box. 1
Electrics Good
Pump Control Panel Elect. Equip. A-I
Clear Mimic (Y/N) Yes PLC based control system - LCD display. Siemens
1
Fully Operational (Y/N) Yes PSC7 software Operator's skills marginal.
Thermal Imaging (Y/N) Ok
Power Cabling Elect. Equip. A-I
Condition good. 1
Main SB to Motors Good
Room Lighting Elect. Equip. A-I
Control Room Lighting Good 2
Emergency/ Exit Lighting --
Exterior Site Lighting Elect. Equip. A-I
More required. 4
Exterior Site Lighting Nil
Fire Alarm System Elect. Equip. A-I
System was switched off owing to continual fault
Manufacturer Kidde 6
indication.
Detector Types Ionisation/Beam

"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Appendix F
Pumps and Motors - Vibration, Alignment
and Noise
Condition Assessment Schedules
TEMPERATURE, NOISE & VIBRATION - Pumps & Motors
Temperature Deg C
Pump Room 33.5
Control Room 26.1
Outside (Ambient) 34.6
Ambient Noise [dB(A)] Noise Source

Pump Room 75 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) 75 78 78
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 0.082 100 0.062 100 0.080 147.5
Point No 2 = Motor - Rear Foot 0.100 147.5 0.105 147.5 0.097 100
Point No 3 = Motor - Top of Motor 0.110 147.5 0.181 100 0.266 100
Point No 4 = Pump - Top Front Bearing 0.271 90 0.150 75 0.169 100
Point No 5 = Pump - Top Rear Bearing 0.099 90 0.066 75 0.079 100
Point No 6 = Pump - Rear Foot 0.043 100 0.094 147.5 0.021 147.5
Point No 7 = Pump - Inlet 0.068 147.5 NA NA NA NA
Point No 8 = Pump - Outlet 0.601 50 NA NA NA NA
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations F1
ALIGNMENT - Pumps & Motors
Pump Shaft Alignment (mm) Pump-Motor 1 Pump-Motor 2 Pump-Motor 3 Pump-Motor 4 Pump-Motor 5 Pump-Motor 6
Angular Limit = 0.08mm/100m
mm mm mm mm mm mm
Linear Limit = 0.10mm
Angular Displacement - Horizontal 0.06 0.00 0.04
Linear Displacement - Horizontal 0.06 0.02 0.04
Angular Displacement - Vertical 0.02 0.04 0.06
Linear Displacement - Vertical 0.18 0.09 0.04
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) 1 1 1
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. LEGEND - Asset Condition Assessment
Pumps in good condition. "As New" 100% 1
Pipework flexible connectors in good condition. Good 75% 2
Pump flexible couplings good condition. Fair 50% 3
Poor 25% 4
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations F2
Appendix G
OEM vs Pump Performance
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations G1
Appendix H
Thermographic Images
Ghanada Pumping Station – Thermal Imaging
Visible Light Image

TI 01
Pump Set No. 1
8/19/2009 9:17:49 AM
Visible Light Image

TI 02
Pump Set No. 1 Motor Bearing
8/19/2009 9:18:02 AM
Visible Light Image

TI 03
Pump Set No. 1 Pump Bearing
8/19/2009 9:18:15 AM
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations H1
Visible Light Image
TI 04
Pump Set No. 1 Pump
8/19/2009 9:18:25 AM
Visible Light Image

TI 05
Pump Set No. 1 Motor
8/19/2009 9:18:32 AM
Visible Light Image

TI 06
Pump Set No. 1
8/19/2009 9:18:44 AM
Visible Light Image
TI 07
Pump Set No. 1 Motor Control Panel
8/19/2009 9:19:27 AM
Visible Light Image

TI 08
8/19/2009 9:19:53 AM
Visible Light Image

TI 09
8/19/2009 9:20:36 AM
Visible Light Image

TI 01
Pump Set No. 2
8/19/2009 9:35:45 AM
Visible Light Image

TI 02
8/19/2009 9:35:55 AM
Visible Light Image

TI 03
8/19/2009 9:36:01 AM
Visible Light Image
TI 04
Pump Set No. 2 Pump
8/19/2009 9:36:10 AM
Visible Light Image

TI 05
Pump Set No. 2
8/19/2009 9:36:16 AM
Visible Light Image

TI 06
8/19/2009 9:36:33 AM
Visible Light Image
TI 07
8/19/2009 9:36:42 AM
Visible Light Image

TI 08
8/19/2009 9:36:50 AM
Visible Light Image

TI 01
Pump Set No. 3
8/19/2009 10:00:36 AM
Visible Light Image

TI 02
8/19/2009 10:02:02 AM
Visible Light Image

TI 03
8/19/2009 10:02:08 AM
Visible Light Image
TI 04
Pump Set No. 3 Pump
8/19/2009 10:02:16 AM
Visible Light Image

TI 05
Pump Set No. 3 Motor
8/19/2009 10:02:24 AM
Visible Light Image

TI 06
8/19/2009 10:02:59 AM
Visible Light Image
TI 07
8/19/2009 10:03:09 AM
Visible Light Image

TI 08
8/19/2009 10:03:13 AM
Appendix I
Vibration Spectrum
Ghanada Pumping Station – Pump Set No. 1
76/10239/11981 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations I1

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Abu Dhabi Distribution Company

Condition Assessment and Energy

2. Pump Station Overview 2

3. Pump Station Assessments 4

4. Civil and Infrastructure Assessment 6

5. Mechanical Assets Assessment 7

6. Electrical Assets Assessment 10

1.1 Project Objectives

1.2 Project Scope

1.3 Purpose of this Report

1.4 Related Reports

1.5 ADDC Supplied Information

2.1 Description of Pumping Station

Date of Inspection 19 August 2009

Name Ghanada Pump Station, Samha

Location On the coast between Samha and Ghantoot

Access Via Samha, off Abu Dhabi – Dubai Road

Date of Commissioning 2007

Supply Source DN 500 Pipeline from Taweela Desalination Plant

Area of Supply VIP Villas along AL Jurf Coast

Storage Tanks 1 x 2.25 Ml Ground Tank (partitioned into 2 cells)

Pumps 3 x 35 l/s horizontal Centrifugal Pumps (2 duty + 1 standby)

Elevated Storages None (owned by ADDC)

Pump Station Schematic Refer Appendix A

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 Computerised Graphics of Pumps Automation System

4.1 Safety Assessment

4.2 Building and General Infrastructure

4.3 Pump Station Operation

Figure 3 Pump Floor Layout

Figure 4 Measurement Point Locations

General Condition - External: Good.

Shaft Flexible Couplings Good

Pipe Work - Flexible Connections Good

Summary of Action Points

6.1 General Description

6.2 Motor Description and Condition

Model: M3BP 180 L 4

Full Load current 38 A

Rated PF: 0.84

Speed: 1475 r/min

Rated Ambient/ rise (Not shown)

Serial No. 0542599510014 (Not shown) (Not shown)

General Condition - Good.

Cabling: Good. Cabling to terminals well formed in terminal boxes.

6.3 Station Power Supply

Figure 8 Packaged Power Supply Substation

6.4 Main Switchboard and Control Panels

Power Factor Correction

Pump and Tank Control System

Figure 10 Controls Displays

6.5 Power Cabling

Cable Access Trench

Figure 11 Floor Chase Detail

6.6 Fire Alarm System

6.7 Summary of Action Points

Civil and Infrastructure Assessment

Mechanical Assets Assessment