Eastern Region PS 02 11978 Rev3

Abu Dhabi Distribution Company
Condition Assessment and Energy

Management Survey of ADDC Water
Pumping Stations Including Water
Tank & Internal Inspections
Eastern Region PS 02 - Al Khatim
Pumping Station DW-KHT-WPS1
February 2012
Contents
1. Introduction 1
1.1 Project Objectives 1
1.2 Project Scope 1
1.3 Purpose of this Report 1
1.4 Related Reports 1
1.5 ADDC Supplied Information 2
2. Pump Station Overview 3

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

3.1 Site Safety Assessment 4
3.2 Civil and Infrastructure Assets Condition Assessment 4
3.3 Mechanical Assets Condition Assessment 4
3.4 Electrical Assets Condition and Energy Assessment 4
3.5 Pump Performance and Efficiency Assessment 5
3.6 Vibration, Alignment and Noise Assessment 5
3.7 Concrete Water Storage Tanks Condition Assessment 5
4. Civil and Infrastructure Assessment 6

4.1 Safety Assessment 6
4.2 Building and General Infrastructure 7
4.3 Pump Station Operation 7
4.4 Storage Tanks 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
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water
Eastern Region PS 02 - Al Khatim Pumping Station DW-KHT-WPS1
6.3 Station Power Supply 12
6.4 Main Switchboard and Control Panels 12
6.5 Power Cabling 14
6.6 Station Lighting 15
6.7 Fire Alarm System 15
7. Electrical Equipment Alert 16

7.1 Damage to Motor Field Winding Termination 16
7.2 Connection of Operating Computer to UPS 17
8. Concrete Water Storage Tanks Assessment 18

8.2 Ground tank 18
8.3 Elevated tank 18
9. Recommendations 20
Figure Index
Figure 1 Eastern Region PS 02 - Al Khatim Pumping Station
DW-KHT-WPS1 3
Figure 2 Elevated Tower Hatch showing surrounding Avian
Debris 6
Figure 3 Overhead Crane (No End Stops) 7
Figure 4 Measurement Point Locations 8
Figure 5 Vibration at Location 2 on Pump 1] 9
Figure 6 Acoustic Spectrum from Pump 2 10
Figure 7 TFS Main Switchboard 12
Figure 8 Interior of Main Switchboard 12
Figure 9 Controls Displays 13
Figure 10 Pump Control Panel 14
Figure 11 Interior of Control Panel 14
Figure 12 Cable Tray 15
Figure 13 Vertical Cable Tray 15
Figure 14 High Temperature Winding Tail 16
Figure 15 Key to Thermal Image 16
Figure 16 High Temperature Winding Tail 16
Figure 17 Key to Thermal Image 16
Appendices
A Pump Station Schematic
B Site Safety Assessment
C Civil and Infrastructure Assets
D Mechanical Assets
E Electrical Assets
F Pumps and Motors - Vibration, Alignment and Noise
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. Upon ADDC approval, complete condition and performance assessments on the remaining 36
pumping station;
5. Conduct a visual inspection of concrete water storage tanks;
6. Produce a Condition Assessment and Energy Management Report on each of the nominated water
pumping stations;
7. 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; and
8. 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 02 - Al Khatim Pumping Station DW-KHT-WPS1 .
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”.
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water 1
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 17 August 2009
Name Al Khatim Pumping Station
Location Al Khatim
Access Off Al Khatim Overpass - western side of Abu Dhabi – Al Ain Highway
Date of Commissioning Commissioned 1982/83. Refurbished in 2007.
Supply Source Transco DN400/300 Pipeline from Shubassi Pumping Station
Area of Supply Al Khatim Tanker Filling Station (TFS) and Al Khatim Reticulation
Storage Tanks 1 x Partitioned Ground Tank (2 x 0.565 Ml)
Pumps 2 x Pumps Horizontal Centrifugal (both duty pumping) + 1 x Wash-down

pump
Elevated Storages 1 x 450 m3 Concrete Tower Storage
Pump Station Schematic Refer Appendix A
Figure 1 Eastern Region PS 02 - Al Khatim Pumping Station DW-KHT-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
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 earthing 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.
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 as Appendix G.
4. Civil and Infrastructure Assessment
4.1 Safety Assessment

The following safety matters require attention as noted in Appendix B:
Pump motor isolation is only possible by opening the motor Main Control Panel. Locking pins are not
available. Safe operating condition provided by opening the cabinet cover and removing control
handles. The cabinet is visible from motor.
The elevated tower access stairs have no safety railing and personnel can be injured if they fall
between the stairs and the pipe risers.
There is a significant health hazards to water customers as most of the elevated tank roof, as well as
access hatch, is covered with layers of birds droppings, nests, eggs, bones, etc. which can fall into
the water stored in elevated storage when the access hatch is opened.
Figure 2 Elevated Tower Hatch showing surrounding Avian Debris
There are no stop ends on the overhead crane rail to prevent the 1 tonne travelling crane from being
dislodged from its supporting rail.
Elevated tank – roof
No End Stops
Figure 3 Overhead Crane (No End Stops)
4.2 Building and General Infrastructure

Buildings and general infrastructure are generally in a satisfactory condition.
Although an office is set up in the control room (original security room), there is no dedicated office
building available with necessary amenities and facilities for the operator. There is no proper
accommodation for the operator, although 24 hour operator availability is required to attend any
emergency.
4.3 Pump Station Operation

The 2 pumps together operate 10 hrs per day.
There is no emergency lighting in pump room.
4.4 Storage Tanks

The storage tanks are in need of repair due to several visible cracks and leaks along the exterior walls.
Refer to Section 8 for a detailed assessment of the structural condition of the tanks.
5. Mechanical Assets Assessment
5.1 General Description

This station is a station with 2 medium sized, horizontal pump motor sets. Overall, the equipment
appears in good condition. The control room and machine room were the same space with the
temperatures high for a control room but acceptable for a machine room. The installed A/C units served
to reduce the temperatures from outside by around 2 deg C.
5.2 Vibration
Vibration measurements were taken from the points shown 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 2 mm/sec expected for such pumps
and indicate the pumps to be secured well 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.
Figure 5 Vibration at Location 2 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 displacement horizontal readings for all the pumps were just outside accepted limits
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) with Pump 2 running.
Additional measurements were undertaken at 1m from the individual pumps. The reverberant nature of
the pump houses and the difficulties in arranging for the running of individual and pumps in combination
meant that these measurements were inconclusive with respect to a co-relation with vibration and
alignment
Figure 6 Acoustic Spectrum from Pump 2
5.5 Thermal Imaging

Thermal images were taken of the motors during operation and the main switch board. The thermoscan
of Motor 2 showed increased temperature in the field winding connection lead. An Exceptional condition
report was filed to have the matter rectified.
The motor thermo scans showed the front shaft bearing for motor No 2 was running at 73 deg C which is
warmer than many other bearings, but still within operational limits.
5.6 Summary of Action Points

Motor to pump shaft alignment should be adjusted to manufacturer’s limits.
Motor No 2 field winding is overheating and this condition is to be rectified.
6. Electrical Assets Assessment

This station supplies water to the Al Khatim tanker filling station (TFS) via a pressure tower and to the Al
Khatim reticulation. The station houses two pumps and a small wash down pump.
The pump house is located against the end wall of the partitioned storage tank. The pump floor is
located approximately 3m below ground level, accessed by a single stairway from the entry landing. The
entry landing accommodates the motor control panel and a distribution panel.
The station is nominally controlled from the TSF control room, adjacent to the pressure tower, which
accommodates the operators.
Site power is supplied at LT and is controlled by a main switchboard located in the TSF control room.
The layout of the station and the congestion of tank balance, wash-down and filling pipes creates a
situation where access to the pumps is limited.
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 given
Serial Numbers
Motor 1 2
Serial No. 05425178 10030 05425230 10007
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: Poor. Damaged field winding termination. See Exceptional Condition Report
17-08-2009
Motor controls: the motor control panel includes local distribution circuits. Individual motors were
isolated by means of manually tripping the MCB controlling the particular starter
set. The MCB could be locked off via a pin securing the operating level. An
appropriate pin was not available The motor control board is within sight from
each motor.
6.3 Station Power Supply

The station complex is supplied at LT from an unknown location. The supply is taken to a main
switchboard in the TSF control room and via a sub-main from this panel to the pump room control panel.
Both control room and the pumping room feature local distribution panels/main switchboards.
6.4 Main Switchboard and Control Panels
Main Switchboard
The main switchboard features a 150A MCCB main isolator and a 100 MCCB Amp supply to the motor
control board. Additional sub circuits include the supply to the control UPS.
There is no visible link between earth and neutral at the main switchboard. Measurement indicates a
resistance of 0.2 ohm indicating that there is a (remote) link.
Figure 7 TFS Main Switchboard Figure 8 Interior of Main Switchboard
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 9 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.
Additional remote reading/indicating level and flow meters were fitted to the pump house to provide input
for the control system.
Pump Motor Control

A motor control panel is mounted in the landing area of the pump house. The panel features switched
volt and ammeters, simple pump controls, run and trip pilot lights. The panel does not feature a local
isolator interlocked to its cover. The supply terminals of the panel isolator are partially exposed and
should be protected. Thermo graphs show that the panel runs warm, particularly the MCB.
Thermostatically controlled, mechanical ventilation of the cabinet is recommended.
Figure 10 Pump Control Panel Figure 11 Interior of Control Panel
PLC System
Station motor controls are via a PLC system. This is housed in a floor mounted cabinet in the control
room. 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 complete with a 16 A-
Hr 304 cell NiCD battery is provided. The UPS control display indicates that the system is operating at
about 10% load, or an estimated 11 hour back up time.
6.5 Power Cabling
Pumping floor
Power supply cables for the motors are steel wire armoured (SWA). The cables are run in floor mounted
elevated cable trays protected with light weight covers. Cable trays are subject to being stood on as the
access around the pumps/motors is limited. Cables are unsupported as they rise to motor terminal boxes
Landing Level
The cable tray from the pump floor rise directly beneath the control board. Full covers are fitted.
Figure 12 Cable Tray Figure 13 Vertical Cable Tray
6.6 Station Lighting
Pressure Tower
Tower lighting was full operating. Wiring was in good condition apart fro a single partially broken
connection rose at low level and a connection box broken from the tower wall at the level of the final
ladder.
6.7 Fire Alarm System

No Fire Alarm System is fitted.

Undertake actions as outlined in Electrical Equipment Alert (17 Aug 2009) (refer Section 7):
Provide protection for motor control panel supply terminals.
Provide mechanical ventilation for motor control panel.
Provide clear access to control room distribution panel.
7. Electrical Equipment Alert
7.1 Damage to Motor Field Winding Termination

The routine thermoscan of Motor 2 .showed increased temperature in the field winding connection lead
W2. This is indicated in Figures 1 & 2.
Visible Light Image

Pump Set No. 2
17/8/2009 10:26:02 AM
Figure 14 High Temperature Winding Tail Figure 15 Key to Thermal Image
The termination for the blue phase and the W@ tail was undone, revealing that the lower terminal
connection for the tail was loose. This was tightened. The thermoscan was repeated after the pump was
run for a few minutes. The results are presented in Figures 3 and 4.
Pump Set No. 2

17/8/2009 11:02:04 AM
Figure 16 High Temperature Winding Tail Figure 17 Key to Thermal

Image
It is apparent that the re-termination action did not resolve the problem. It is suspected that either:
The actual termination has become high resistance and the it should be replaced; or
There is damage to the winding tail itself.
Immediate Action
Reduce operation of the pump as much as possible. We note that the station requires that two pumps
be run simultaneously for much of the operating period of the station (approximately 10 hrs per day).
Remedial Action
As the pump is relatively new, approximately 2 years and 6,000 hours, the fault may have been present
since manufacture. Accordingly, and in recognition of the specialist nature of any repair to the tail we
recommend that a manufacturer’s representative be asked to investigate the problem.
7.2 Connection of Operating Computer to UPS

The pumping station features a PLC based monitoring and control system complete with computer based
readout and control input. Both parts of the system are powered by a UPS. It was noted that the supply
from the UPS to the computer utilises a multi-way powerboard into which the various computer supply
cords are connected. The 5m flexible connection cord for this board has been permanently connected to
the UPS distribution board and the wire enclosed in power trunking along with other cables.
The connection of the board is unsafe and the use of the box for a critical UPS based system is
inappropriate. The quality of the connections available inside the powerboard is inferior to the reliability of
the UPS, greatly reducing the reliability of the overall system.
Immediate Action
Provide a standard power outlet adjacent to the computer location and connect the powerboard to this
via a standard plug. This will remove the flexible cable from the permanent wiring system.
Remedial Action
Provide an appropriate number of standard outlets adjacent to the computer for the individual connection
of the required powered items.
8. Concrete Water Storage Tanks Assessment

This station has three (3) concrete storage tanks. A single, rectangular structure forms two of the tanks
being divided by an internal wall with each tank having a 0.57 Ml capacity. The third is an elevated
circular structure of 0.675 Ml capacity. The bottom of the ground tanks sit at ground level and the tanks
are nominally 24 metres by 5 metres each with a height of 5.5 metres. The roof level is accessed by two
steel ladders. There are two manholes in the roof for each tank with GRP ladders. The perimeter walls
are covered with a thin plaster coating and the roof is covered with ceramic tiles. The tanks are internally
lined with a plaster coating on the walls and floor with the roof soffit being painted. Discussions with the
site staff confirmed our finding that a significant rehabilitation of the tank had recently occurred to repair
several defects in the tank.
The elevated, circular tank is accessed by a spiral staircase through the central support pedestal.
Internal access is gained through a single manhole. GHD was not granted access into the elevated tank
by the site engineer so an assessment of the internal tank was not completed.
Refer to Appendix G for the detailed inspection record sheets and schedules.
8.2 Ground tank

A visual inspection of the external surfaces of the ground tank revealed several cracks in the concrete
with evidence of newly formed leaks. Evidence of repairs to the tank were observed along the walls and
while the repairs to not appear to be completed in a satisfactory manner, there are no signs of leaks at
these areas. Cracks on the walls were measured at widths of approximately 0.1 – 0.2 mm. Most cracks
did not show signs of leaking but there are a few areas with calcium carbonate deposits and staining that
indicate leaking. The plaster coating was also peeling and bubbling around the leaks. The tank showed
no evidence of ground movement or settlement, abnormal deflection or bulging in areas other than those
repaired. Several leaks were identified around the pipe penetrations.
A visual inspection of the internal surfaces did not allow for an appropriate assessment of the concrete
structure due to the protective plaster coating on the walls and floor that had been applied during the
tank rehabilitation. Hammer tapping on the floor was not possible in tank 1 due to the water remaining in
the tank but tapping the tank 2 floor did not identify any defects. Multiple active leaks were identified
along the dividing wall that separates the two tanks; the adjacent tank was full at the time of inspecting
each tank. The existing coating on the walls is showing signs of deterioration at the leak locations
exhibiting delamination and peeling from the concrete surface. Several cracks with leakage marks were
observed in the roof soffit. Severe concrete spalling was evident around most of the pipe penetrations.
Significant delamination of plaster was observed near the access hatch locations.
8.3 Elevated tank

An external inspection of the elevated tank could only be conducted from the ground level. Signs of
staining and paint peel were visible along the bottom of the elevated tank but a detailed examination was
not possible due to the height. The exterior support columns and pedestal did not show any signs of
cracks or stains but did have areas with paint peel. Paving covers the tank footing so ground settlement
could not be determined.
An internal inspection of the pedestal identified areas of previous repair on the walls. Minor crazing and
delamination was also identified in one section.

Cracks that are leaking or show historic leaks to be repaired,
Internal plaster coating to be removed and replaced in areas that show deterioration and
delamination,
Detailed inspection of internal concrete surfaces to be performed after removal of existing coating and
before application of new coating to identify any further structural defects. Repair of any significant
defects must be completed prior to reapplication of coating,
External plaster to be removed and replaced in areas that show deterioration and delamination,
Pipe penetrations require remedial work to protect the wall and pipe from further deterioration.
9. Recommendations
Safety
9. PPE equipment including hearing protection should be provided to all operators.
10. Safety signs should be installed at the entrance to the station (and pump room). - Safety Shoes,
Hard Hat, Hearing Protection and Eye Protection).
11. Lock out/ tag out facilities are required to safety operate and maintain the pump motors and
associated electrical equipment
12. The elevated tower access stairs require a safety railing.
13. The elevated tower tank access hatchway requires a protective outer cover lid to keep avian debris
away from the opening and the roof area needs to be cleaned prior to opening the hatch to minimise
air borne particulates being carried into the storage tank.
14. End stops need to be added to the pump room overhead crane rail to prevent accidental
dislodgement of the trolley crane.
Civil and Infrastructure Assessment

15. Consideration should be given to provision of an office equipped with amenities for operations staff
and for safe storage of pump station records.
16. Consideration should be given to provision of proper accommodation which meets UAE standards.
17. Pump house roof requires removal of al leftover debris and rubbish.
18. Elevated tank roof requires periodical cleaning set as a maintenance routine.
Mechanical Assets Assessment

19. Low pumping efficiencies due to grossly oversized pumps (both water delivery rates and pipework
system working pressure) compared to duties performed (pump design duty 32 l/s @ 320 kPa, actual
measured duty 51 l/s @ 180 kPa).
20. Install flexible couplings on pump-pipework connection points.
21. Motor to pump shaft alignments should be adjusted to manufacturer’s limits.
22. Pumps are at very low efficiency as result of poorly (oversized) selected pumps for duty. Reviewed
and correct pump selections should be considered in the event of pumps replacement.
Electrical Assets Assessment

23. Pump No 2 termination wiring is faulty. Reduce operation of the pump as much as possible. As the
pump is relatively new, the fault may have been present since manufacture. Accordingly, and in
recognition of the specialist nature of any repair to the tail, we recommend that a manufacturer’s
representative be asked to investigate the problem.
24. Motor No 2 field winding overheating condition is to be rectified.
25. Provide an appropriate number of standard power outlets adjacent to the computer for the individual
connection of the required powered items. Provide a dedicated power supply from the UPS to the
computer to replace the multi-way power board into which the various computer supply cords are
connected. The quality of the connections available inside the power board is inferior to the reliability
of the UPS, greatly reducing the reliability of the overall system.
26. Provide protection for motor control panel supply terminals.
27. Provide mechanical ventilation for motor control panel.
28. Provide clear access to control room distribution panel.
Pump room layout.
Concrete Water Storage Tank Assessment

29. Repair areas of leakage and large cracks with an appropriate method.
30. Reapply plaster in areas of crack repair and where peeling has occurred.
31. External plaster to be replaced after leaks and cracks are repaired.
32. Repair of pipe penetrations.
Appendix A
Pump Station Schematic
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water A1
Appendix B
Site Safety Assessment
SITE SAFETY ASSESSMENT
Pumping Station Name Al Khatim Pump Station, Al Khatim

Assessment Date 17 August 2009
HAZARD SATISFACTORY COMMENTS

Site Access and Egress Yes
Site Security Yes
Lighting Yes - No emergency light in pump room.
Mechanical Hazards (eg Unguarded Plant) No - No Stop Ends on Crane Railing
Electrical Hazards No - Motor isolation required operation of the motor MCB. Locking pins are not available. Safe
operating condition provided by removing cabinet cover and removing handles. Cabinet visible
from motor.
Housekeeping (General Tidiness) Yes Elevated tank roof needs immedaite cleaning, same for pump room roof.
Fire Hazard and Equipment Yes
Noise Yes
Dust / Fumes Yes
Hazardous Substances Yes
Working at Heights Yes
Ladders / Scaffolding No - No railings on the elevated tank stairs , though the pipes are very close to stair well.
Pressurized Equipment Yes
Heat Illness / Stress Yes
Personal Protective Equipment (PPE) Yes PPE equipment should be issued to ADDC personnel
Knowledge of Site Safety Rules Yes
Site Emergency Procedures Yes
Confined Space Entry Yes
Lock Out / Tag Out No (See above - electrical hazard)
OTHER - Water Quality / Health Hazard No - Health hazards as most of the elevated tank roof, as well as access hatch, covered with
layers of birds droppings, nests, eggs, bones, etc.
Comments
It is recommended that proper safety signs should be installed at the entrance to the station (and pump room): Safety Shoes, Hard Hat, Hearing Protection,
Eye Protection.
Health-hazard - water can get contaminated with birds nest, droppings, eggs, bones, etc.
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water 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
Pumping Station Name Al Khatim Pump Station - Al Khatim LEGEND - Asset Condition Assessment
Assessment Date 13 August 2009 Description Life Remains Rating
Time: IN / OUT 8.30AM / 12.30PM "As New" 100% 1
GPS Position (Entry Gate) N 24° 11.190' E 55° 0.117' Good 75% 2
ADDC GIS Object No: 7 Fair 50% 3
Poor 25% 4
Inspection Personnel Failure Imminent 0% 5
John John (GHD) Failed / Derelic t Un-useable 6
Roger Hawkins (Palmer Acoustics )
Padalchai P.
Asset Condition Assessment

Asset Description Comments
Schedule Parameters Rating
Access Road Asphalt Satisfactory Sealed Pavements A, B 2
Boundary Fence / Walls Conc rete fence Satisfactory Fences / Struc tures A-F 2
Entry Gate Steel Gate Satisfactory Structures A -F 2
Security House No accommodation building. NA
External Walls NA
Roof NA
Internal Walls NA
Internal Amenities NA
Pump House Conc rete/block building Fair Structures A -F 3
External Walls Blocks Fair Structures A -F 3
Roof Conc rete Not satis factory Structures A -F 4
Internal Walls Plastered blocks Fair Structures A -F 3
Office & Internal Amenities Office within control room Not satis factory Misc. Site Assets A 6
Accommodation No accommodation building. NA
External Walls NA
Roof NA
Internal Walls NA
Internal Amenities NA
Internal Roads Paved blocks Satisfactory Sealed Pavements A, B 2
Internal Paths Paved blocks Satisfactory Sealed Pavements A, B 2
Landscaping Hardscape & some plants & trees Satisfactory Misc. Site Assets A, B 2
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
- No dedicated offic e space available with nec essary amenities and facilities.
- No proper acc ommodation facility, though 24 hours operator available to attend emergency.
- No security/guard room.
'- Pumphouse roof needs cleaninf (rubbish and debry)
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water C1
CONDITION ASSESSMENT - Storage/ Transfer Water Tanks
STORAGE / TRANSFER TANK 01

ADDC GIS Object No: 129
Width (m) 10.0
Length (m) 24.0
Diameter (m) LEGEND - Asset Condition Assessment
Roof Height (m) Description Life Remains Rating
Depth (m) 4.7 "As New" 100% 1
Capacity (m3) 2 x 565 m³ Good 75% 2
Tank Description WATER STORAGE TANK Fair 50% 3
Material CONCRETE Poor 25% 4
Tank holds water supplied from TRANSCO Shobaisi pump station Failure Imminent 0% 5
Comments
Failed / Derelict Un-useable 6

External - Walls Concrete, painted Satisfactory Structures A-F 2
External - Roof Concrete Satisfactory Structures A-F 2
External - Roof Access Steel ladder Satisfactory Structures A-F 2
External - Roof Hatches Hinged steel covers Satisfactory Structures A-F 2
Internal - Walls Concrete Satisfactory Structures A-F 2
Internal - Floor Concrete Satisfactory Structures A-F 2
Internal - Roof Concrete Satisfactory Structures A-F 2
Water Level Indicator Available Satisfactory Mech Equip. A-H 2
Comments
1) Painted storage tank walls make it harder for earlier leaks detection
Structural / Material Testing Recommended (Yes / No) YES
CONDITION ASSESSMENT - Elevated Water Tanks
ELEVATED TANK 01
ADDC GIS Object No: 142
Width (m)
Length (m)
Diameter (m) Not accessible LEGEND - Asset Condition Assessment
Elevated Height (m) Description Life Remains Rating
Depth (m) Not accessible "As New" 100% 1
Capacity (m3) 450 Good 75% 2
Tank Description Tower Fair 50% 3
Material Concrete Poor 25% 4
Failure Imminent 0% 5
Comments W ater supplying to township

Tank Tower/ Stand Concrete Satisfactory Structures A-F 2
Tank Tower Access Concrete stairs & steel ladder Satisfactory Structures A-F 2
Pipe Risers Steel Satisfactory Pipework A-C 1
Pipe Riser Supports Steel Satisfactory Structures A-F 2
External - Walls Concrete Satisfactory Structures A-F 2
External - Roof Concrete Poor - see note below Structures A-F 4
Internal - Walls Concrete Not accessible NA
Comments
1) No railings on the elevated tank stairs , though the pipes are very close to stair well.
2) Roof covered with birds nest, droppings, eggs, bones, which can contaminate the water through the access hatch.
Structural / M aterial Testing Recommended (Yes / No) No
Suction Side
CONDITION ASSESSMENT - Pipework & Valves (Suction Side)
Suction Header Pipework Pipe 1
Pipe Material STEEL
Pipe Diameter (mm) 200
Condition Rating (1 to 6) 2
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
Pipe Diameter (mm) 125 125
Condition Rating (1 to 6) 2 2
Flexible Coupling
Flexible Coupling Diameter (mm) Nil Nil
Condition Rating (1 to 6) NA NA
Isolation Valve
ADDC GIS Object No: 7182 7194
Isolation Valve Type Gate Gate
Isolation Valve Diameter (mm) 125 125
Comments LEGEND - Asset

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
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
Pipe Diameter (mm) 100 100
Flexible Coupling
Flexible Coupling Diameter (mm) Nil Nil
Delivery Side
Condition Rating (1 to 6) NA NA
Non-Return Valve
Isolation Valve Type Flap Flap
Isolation Valve
Isolation Valve Type Gate Gate
Comments LEGEND - Asset Condition Assessment

"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Appendix D
Mechanical Assets

a) Water Pumps
b) Other Mechanical Equipment & Systems
Pump and Motor Data
Pump Data Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
Year of Installation 2007 2007
Purpose / Function Supply to elevated tank Supply to elevated tank
Brand KSB KSB
Horizontal Split Casing Horizontal Split Casing
Type
Centrifugal Centrifugal
Model No ETANORM-C-080-315-SP ETANORM-C-080-315-SP
Serial No 9970821299 000400 01 9970821299 000400 02
Impeller Design Size (mm) unknown unknown
Speed (rpm) 1460 1460
Pumping Design Power (kW) unknown unknown
Pump Design Efficiency (%) unknown unknown
Duty Point Flow (l/s) 35 35
NPSHR (kPa) unknown unknown
Duty Point Pressure (kPa) 320 320
Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

Year of Installation 2007 2007
Brand ABB ABB
Type M3BP 180L-4 M3BP 180L-4
Serial No 542523010007 542517810030
Voltage (V) 415 415
Speed (rpm) 1460 1460
Current (A) 38 38
Insulation F F
IP or Enclosure IP55 IP55
cos(fee) 1 1
Power (kW) 22 22
VSD (Yes / No) No No
OTHER
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water D1
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) 180 195
PUMP CURVE - Flow Rate (l/s) unknown unknown
MEASURED - Pump Flow Rate (l/s) 51 51
MEASURED - Pump Speed (rpm) 1460 1460
CALCULATED - Pump Hydraulic Power (kW) 9 10
MEASURED - Pump Motor Power Input (kW) 20.0 19.9
CALCULATED - Motor-Pump Efficiency (%) 45.1% 49.0%
MEASURED - Pump Shut-Off Head (kPa) 370 365
PUMP CURVE - Impellor Diameter (mm)
Comments

1) Original year of installation is 1982/83, but refurbished in 2007.
2) Two (2) pumps together in operation for 10 hours daily.
PERFORMANCE CURVES - Water Pumps
Pump Test Flow Pressure

Pump P- 01 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 370 ) 400
a 350
2 38 250 P
k
( 300
3 51 180 e
r
u 250
4 s
P- 01 s 200
5 e
r
P 150
6 d
a 100
7 e
H 50
8
0
0 10 20 30 40 50 60
Water Flow (l/s)
Pump Test Flow Pressure

Pump P- 02 Performance Curve
No. No. Q (l/s) P (kPa)
1 0 365 ) 400
a
2 45 230 P 350
(k 300
3 51 195 e
r
u 250
4 s
P- 02 s 200
5 e
r
P 150
6 d
a 100
7 e
H 50
8
0
0 10 20 30 40 50 60
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 Safety - no stoppers on rails Cranes A- C 5
capacity.
Security House Air Conditioning No security house NA
Pump Room Air Conditioning Window AC Not satisfactory Mechanical A-H 5

Equipment
Control Room Air Conditioning Window AC Fair Mechanical A-H 4
Equipment
Pump Room Ventilation No ventilation, as AC space NA
Other

- No emergency light in the pump room. "As New" 100% 1
- No end stoppers (both ends) in the overhead crane - Refer Assessment Rating = 5. 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 Motor 6

Year of Installation
Brand ABB ABB
Model No. M3BP 180 L4 M3BP 180 L4
Serial No 05425178 10030 05425230 10007
Speed (rpm)
Average Voltage (V) 424 426
Average Current (A) 35 33
Total Power (kW) 25 25
Overall Power Factor .80 .80
Electrical Connection 423 425
Soft Start
Hours Run (Hrs) N/A N/A
Cables/ Earthing Good Good.
Thermal Imaging OK Fault identified
Asset Condition Assessment Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

Assessment Schedule Elect. Equip. Elect. Equip.
Assessment Parameters C D
Rating (1 to 6) 2 5

Motor 1: Motor recently replaced as part of station refurbishment "As New" 100% 1
Motor 2: Good 75% 2
Motor 3: Fair 50% 3
Motor 4: Poor 25% 4
Motor 5: Failure Imminent 0% 5
Motor 6: Failed / Derelict Un-useable 6
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water 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) 423 425 423 425 428 425
Current (A) 35 35 36 33 33 34
Power Factor 0.47 0.45 0.46 0.49 0.46 0.47
Dielectric Absorption (30/60sec MW) >4 >4
Polarisation Index (1min/10min MW)
Insulation at End of PI (M )
Average Voltage (V) 423.7 426.0
Average Current (A) 35.3 33.3
Overall Power Factor 0.80 0.80
Power Measured (kW) 20.0 19.9
Total Power (kVA) 25.0 24.6
Temperature ºC (Hot = 68ºC) 55.0 60.0
CONDITION ASSESSMENT - Main Switchboard & Motor Control Panels
Main Switchboard LEGEND - Asset Condition Assessment

Year of Installation Description Life Remains Rating
Clear Labelling? Poor "As New" 100% 1
Logical Layout? Yes Good 75% 2
Main Isolator Fair 50% 3
Manufacturer Toshiba Poor 25% 4
Type MSB in control office 100 Failure Imminent 0% 5
Rating (A) 100 A Failed / Derelict Un-useable 6
Switchboard Test Phases & Links R Y B RY YB BR

Use SB Meters? Voltage (V) 240 240 240 405 405 405
No. Pumps Running 2 Current (A) 66 82 81
Meters Switched/ Individual? Switch Power Factor NA
Thermal Imaging - Switchboard Comments

Termal Imaging? Y Overall Condition is Poor
Max. Temperature 32 MSB in control office 100 A supply to pump house
Motor control panel in pump house, MCCB isolator and S-D starters
Assessment Schedule Elect. Equip.
Assessment Parameters A-I
Rating (1 to 6) 4
Motor Controls Motor Controls Thermal Comments

Image
Manufacturer Motor Control No 1 Yes NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available.
Type Motor Control No 2 Yes Control pane includes local distribution
Soft Start ? N Motor Control No 3 Motor isolation could be interlocked by a pin through the MCB frame.
Controls Functional ? Yes Motor Control No 4 Pin not available. Panel in sight of pump motors
Internal Layout Simple Motor Control No 5
Interlock on Panel ? No Motor Control No 6
CONDITION ASSESSMENT - Other Electrical Equipment and Systems
Electrical Equipment Description Comments Asset Condition Assessment

Power Transformer From Pillar outside gate. Pumping station is hard Elect. Equip. A-I
4
Rating LT connected to pillar supply Pillar cover not secured.
Pump Station Earthing Elect. Equip. A-I
Neutral / Earth L ink Yes . 2
Resistance (Earth /Neutral) 0.2
Lightning Protection Strap runs straight to ground, no pit, no estimate of Elect. Equip. A-I
3
Lightning Protection Rod and strap protection for pressure tower. condition.
Pump Room Crane No mechanical stop to prevent crane block coming Elect. Equip. A-I
4
Electrics Manual of end of beam.
Pump Control Panel Elect. Equip. A-I
Clear Mimic (Y/N) Nil
Panel OK. 3
Fully Operational (Y/N) NA
Thermal Imaging (Y/N) Yes
Power Cabling Elect. Equip. A-I
Clean. Cable to motor not supported SWA cable. 3
Main SB to Motors Covered chase on floor.
Room Lighting Elect. Equip. A-I
Control Room L ighting Lighting mostly working. Some new lamps & 3
Emergency/ Exit Lighting No emergency lighting. Ceiling and wall fittings.
Exterior Site Lighting 8m poles. Operators report that repairs are done as Elect. Equip. A-I
2
Exterior Site Lighting All working. required Bollard and up-lighting for pressure tower.
Fire Alarm System
Manufacturer Nil NA
Detector Types --

"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Appendix F
Pumps and Motors - Vibration, Alignment
and Noise
Condition Assessment Schedules
TEMPERATURE, NOISE & VIBRATION - Pumps & Motors
Temperature Deg C
Pump Room 34
Control Room 34
Outside (Ambient) 36.6
Ambient Noise [dB(A)] Noise Source

Pump Room 75 Pump 2
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) 73 75
Noise Source 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 0.303 100 0.359 25
Point No 2 = Motor - Rear Foot 0.799 100 0.120 147.5
Point No 3 = Motor - Top of Motor 0.521 100 0.250 147.5
Point No 4 = Pump - Top Front Bearing 0.456 147.5 0.433 25
Point No 5 = Pump - Top Rear Bearing 0.238 147.5 0.145 25
Point No 6 = Pump - Rear Foot 0.190 147.5 0.204 147.5
Point No 7 = Pump - Inlet 0.127 100 NA NA
Point No 8 = Pump - Outlet 0.337 50 NA NA
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water 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 0.00 0.02
Linear Displacement - Horizontal 0.30 0.28
Angular Displacement - Vertical 0.04 0.04
Linear Displacement - Vertical 0.16 0.16
Thermal Images (Hot > 68 Deg C) Cool Hot
Flexible Couplings Pump-Motor 1 Pump-Motor 2 Pump-Motor 3 Pump-Motor 4 Pump-Motor 5 Pump-Motor 6

Assessment Schedule Mech. Equip. Mech. Equip.
Assessment Parameters F F
Rating (1 to 6) 2 2
Comments
NOTE: 'NA' or 'Blank' = Not Applicable or Data Not Available. LEGEND - Asset Condition Assessment
The pump 2 main shaft bearing was running at 73 deg C, which was warmer than many other bearings but still within
"As New" 100% 1
manufacturer limits.
Pumps in good condition Good 75% 2
Fair 50% 3
Pump flexible couplings OK condition Poor 25% 4
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water F2
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.
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water G1
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
Al Khatim – Internal – Tank No. 1
Roof soffit Leaking and plaster delamination
Spalling at pipe penetration Spalling at pipe penetration
Water and sediment on floor Leaking
Al Khatim – Internal – Tank No. 2
Crack Coating bubbling on floor
Coating bubbling and peeling on wall
Air voids on wall without coating Corroded access ladder
Al Khatim – External – Ground Tanks
Access opening and ladder Tiles on roof
Leak at pipe penetration Leak and peeling plaster
Water tank and pump room Cracks around roof access up-stand
Al Khatim – Elevated Tank
Staining under tank

Paint peeling around pedestal
Paint delamination Crazing inside pedestal
Appendix H
OEM vs Pump Performance
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water H1
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water H2
Appendix I
Thermographic Images
Al Khatim Pumping Station – Thermal Imaging
Visible Light Image

TI 01
Pump Set No. 1 Motor Control Panel
8/17/2009 8:29:09 AM
Visible Light Image

TI 02
8/17/2009 8:29:44 AM
Visible Light Image

TI 03
8/17/2009 8:29:52 AM
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water I1
Visible Light Image
TI 04
8/17/2009 8:30:14 AM
Visible Light Image

TI 05
8/17/2009 8:30:32 AM
Visible Light Image

TI 06
8/17/2009 8:30:53 AM
Visible Light Image
TI 07
Pump Set No. 1 Motor Bearing
8/17/2009 9:48:19 AM
Visible Light Image

TI 08
Pump Set No. 1 Pump Bearing
8/17/2009 9:48:25 AM
Visible Light Image

TI 09
Pump Set No. 1 Pump
8/17/2009 9:48:34 AM
Visible Light Image
TI 10
Pump Set No. 1 Motor
8/17/2009 9:48:39 AM
Visible Light Image

TI 11
Pump Set No. 1
8/17/2009 9:48:48 AM
Al Khatim Pumping Station – Thermal Imaging
Visible Light Image

TI 01
Pump Set No. 2
8/17/2009 9:55:59 AM
Visible Light Image

TI 02
Pump Set No. 2 Motor Bearing
8/17/2009 9:56:13 AM
Visible Light Image

TI 03
Pump Set No. 2
8/17/2009 9:56:20 AM
Visible Light Image
TI 04
Pump Set No. 2 Pump Bearing
8/17/2009 9:56:52 AM
Visible Light Image

TI 05
Pump Set No. 2 Motor
8/17/2009 9:57:03 AM
Visible Light Image

TI 06
Pump Set No. 2 Shaft
8/17/2009 9:57:13 AM
Visible Light Image
TI 07
Pump Set No. 2
8/17/2009 10:26:02 AM
Visible Light Image

TI 08
Pump Set No. 2
8/17/2009 11:02:04 AM
Appendix J
Vibration Spectrum
Al Khatim Pumping Station – Pump Set No. 1
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water J1
Al Khatim Pumping Station – Pump Set No. 2
76/10239/11978 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations Including Water J2
GHD Global Pty Ltd CLN 1001592
P.O. Box 45921, Abu Dhabi

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

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

Author
No. Name Signature Name Signature Date
0 C Teske K Skawinski K Skawinski* P Rodda P Rodda* 16 Dec 2009
1 C Teske K Skawinski K Skawinski* P Rodda P Rodda* Feb 2009
2 M Andrews G Shepherd G Shepherd* P Rodda P Rodda* July 2010
3 H Glass G Shepherd G Shepherd* G Shepherd G Shepherd* Feb 2012

Eastern Region PS 02 11978 Rev3

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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 6

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

Date of Inspection 17 August 2009

Name Al Khatim Pumping Station

Date of Commissioning Commissioned 1982/83. Refurbished in 2007.

Supply Source Transco DN400/300 Pipeline from Shubassi Pumping Station

Storage Tanks 1 x Partitioned Ground Tank (2 x 0.565 Ml)

Pumps 2 x Pumps Horizontal Centrifugal (both duty pumping) + 1 x Wash-down

Elevated Storages 1 x 450 m3 Concrete Tower Storage

Pump Station Schematic Refer Appendix A

Figure 1 Eastern Region PS 02 - Al Khatim Pumping Station DW-KHT-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

3.7 Concrete Water Storage Tanks Condition Assessment

The inspection aims to identify and record defects such as:

4.1 Safety Assessment

Figure 2 Elevated Tower Hatch showing surrounding Avian Debris

Elevated tank – roof

Figure 3 Overhead Crane (No End Stops)

4.2 Building and General Infrastructure

4.3 Pump Station Operation

4.4 Storage Tanks

5.1 General Description

Figure 4 Measurement Point Locations

General Condition - External: Good.

Shaft Flexible Couplings: Good

Pipe Work - Flexible Connections: Good

5.3 Shaft Alignment

5.4 Noise Levels

5.5 Thermal Imaging

5.6 Summary of Action Points

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 given

Serial No. 05425178 10030 05425230 10007

General Condition - Good.

6.3 Station Power Supply

6.4 Main Switchboard and Control Panels

Figure 7 TFS Main Switchboard Figure 8 Interior of Main Switchboard

Figure 9 Controls Displays

Pump Motor Control

6.5 Power Cabling

6.6 Station Lighting