Abu Dhabi Distribution Company

Condition Assessment and Energy

Management Survey of ADDC Water
Pumping Stations
Assessment Overview Report
November 2009
 Contents
1. Introduction 1
1.1 Project Objectives 1
1.2 Project Scope 1
1.3 Purpose of Report 1
1.4 Number of Water Pumping Station Assessments 1

2. Methodology 2
2.1 Introduction 2
2.2 Technical Review of Pumping Station Data 2
2.3 Condition Assessment Procedures 3
2.4 Job Safety Plan 3
2.5 Pilot Study 3

3. Assessment Personnel 5

4. Safety Assessment 6
4.1 Facility Assessment Checklist 6

5. Condition Assessment 7
5.1 Condition Assessment Criteria 7
5.2 Testing Equipment and Instruments 8
5.3 Calibration Certificates 9
5.4 Civil Infrastructure Assets 9
5.5 Mechanical Assets 10
5.6 Electrical Assets 10

6. Performance and Efficiency Assessment 11

6.1 Pump Hydraulic Performance 11
6.2 Test Preparation 11
6.3 Tests Conducted on Water Pumps 11
6.4 Flow Measurement 12
6.5 Pressure Measurement 13
6.6 Operating Temperature Assessment 14
6.7 Motor to Pump Shaft Alignment 15
6.8 Motor, Pump and Pipework Vibration Spectrum Analysis 16
6.9 Energy Management Assessment 18
6.10 Electrical Assets 18

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 7. Pumping Station Operations Assessment 20
7.1 Assessment Criteria 20

8. References 22

Table Index
Table 1 Pumping Station Data Collected 2
Table 2 Condition Assessment Criteria for Electrical
Equipment (Typical) 7
Table 3 Condition Assessment Criteria for Pump Equipment
(Typical) 7
Table 4 Asset Condition Criteria 8
Table 5 Testing Equipment 8

Figure Index
Figure 1 Ultrasonic Flow Meter 12
Figure 2 HM 650 Hydronic Manometer 13
Figure 3 Thermo Hydro meter for Temperature
Measurement 14
Figure 4 Fluke Ti 10 Thermal Imaging Camera 15
Figure 5 Dick Smith Infrared Thermometer 15
Figure 6 Fixturlaser Dirigo Shaft Alignment Tool 15
Figure 7 B&K Vibro 60 Vibration Analyser 16
Figure 8 Digitech Tachometer 17
Figure 9 Rion NA27 Sound Level Meter 17

Appendices
A Available Technical Data
B Site Safety Assessment Checklist
C Condition Assessment Criteria
D Testing Equipment and Instruments
E Civil Assets Assessment Schedules
F Mechanical Assets Assessment Schedules
G Electrical Assets Assessment Schedules
H Pump Performance and Efficiency Assessment
I Vibration, Alignment & Noise Assessment

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1. Introduction

1.1 Project Objectives

The objective for this project is to develop a prioritised maintenance and management strategy that
extends the life and reliability of 39 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 final Condition Assessment and Energy Management Report on each of the nominated
water pumping station; and
6. Produce a facility maintenance and management strategy report, for the 39 water pumping stations.

1.3 Purpose of Report

This report:
 Presents the methodology employed by GHD to: -
– Collect and review available technical information on ADDC’s water pumping stations and
associated assets;
– Conduct the asset condition and performance assessment on the initial 3 pilot and 34 remaining
water pumping stations; and
 Introduces and appends the individual, investigation reports which present the results of GHD’s asset
condition and performance assessment of ADDC’s 39 water pumping stations.
This report should be read in conjunction with the “Condition Assessment and Energy Management
Pumping Station Survey” reports and the final “Condition Assessment and Management Strategy
Report”.

1.4 Number of Water Pumping Station Assessments

Initially, 39 water pumping stations were nominated for assessment under this project. However, upon
inspection of each of the sites, GHD field team found that only 37 water pumping stations existed.

 Western Region PS No. 18 - Mirfa Truck Filling Station (TFS) was abandoned some 2 years ago.
 Western Region PS Nos. 6 & 5 – Bida Al Mutawa were duplicates.

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2. Methodology

2.1 Introduction
GHD has implemented the following methodology to achieve all project objectives:

 Collect all available pumping station technical data and knowledge in regard to pumping equipment
and related infrastructure of the 37 ADDC water pumping stations.
 Attend each pumping station to collect operational and condition data.
 Review operational and condition data.
 Produce individual pumping station condition and performance assessment reports.

2.2 Technical Review of Pumping Station Data

GHD developed an “existing knowledge” for each of ADDC’s 37 water pumping stations by collecting the
following information in Table 1. GHD has made every effort to obtain the technical data required for this
project (as listed in Table 1) from ADSSC office and operations staff, equipment suppliers and from the
World Wide Web. All available data obtained and used by GHD for this project is listed in Appendix A.

Table 1 Pumping Station Data Collected

Data Obtained Source

Location of the pumping stations, access arrangements, ADDC - Assets and O&M Department
ADDC personnel in charge, communication details and
contact data;

Copies of site location plans from ADDC’s GIS (electronic ADDC – GIS1.
‘as built’ plans were not always available);

Physical and functional data ADDC - MAXIMO

Pump performance curves Supplier Internet Web Pages

Operation and maintenance manuals Refer to Appendix A for information about

available (from ADDC) existing tech. data

Technical data (operational details, performance setup and Refer to Appendix A for information about
commissioning results); available (from ADDC) existing tech. data

Any information related to possible upgrades and changes Not Available

done during the life of the pumping stations;

Records of maintenance, services, calibrations and any Not Available

repair works performed; and

Records of operating parameters (pumps flow settings, Not Available

controls sequencing, electrical data).

Notes: 1. GHD was advised to confirm GIS source data on site as ADDC’s level of confidence in the GIS
data was low.

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2.3 Condition Assessment Procedures
GHD developed procedures to be used by site team to survey and assess each pumping stations assets,
including:-
 facilities architectural and structural assessment;
 mechanical equipment - pumps, valves and paperwork;
 pumping equipment vibration assessment and noise;
 electrical components and power supply - motors, cables, conduits, electric distribution boards,
controls and switching gear; and
 electronic components – monitoring panels and instrumentation.

2.4 Job Safety Plan

GHD developed a Job Safety Plan 1 in accordance with GHD Health and Safety Policy which incorporates
the following matters for the purposes of site assessment of ADDC‘s 37 pumping stations:-

 incorporates ADDC’s HSEQ Procedures;

 procedures for ‘confined spaces’; and
 procedures for ‘at-height’ access.

2.5 Pilot Study

Following an initial pumping stations data review, GHD together with ADDC’s Project Team selected
three pumping stations, varying in size, location and age for a pilot assessment. Subsequently, three
stations were selected and visited to conduct a condition and performance assessment using GHD’s
proposed methodology and procedures.
The three pumping stations selected and assessed in this pilot stage were: -
1. Eastern Region WPS No. 4 - Samha East, Samha;
2. Western Region WPS No. 13 - Liwa PS near Liwa Rest House; and
3. Western Region WPS No. 10 - Jabbana Main PS & TFS, Liwa.
As a result of the pilot investigation GHD produced a “Pilot Investigation Report” for feedback by ADDC.
Following ADDC’s assessment of this pilot work, GHD proceeded to assess the remaining pumping
stations assisted by ADDC project staff. GHD’s assessment of the 3 pilot and 34 remaining water
pumping stations is presented in the 37 Water Pumping Station Assessment Reports appended to, and
referenced by, this Assessment Overview Report.
The individual water pumping station assessment reports present: -

 a description of pumping stations;

 identification and condition of buildings, plant and equipment;
 condition assessment results of all visible pumping station assets;

1
Job Safety Plan for Consultancy Services for Condition Assessment and Energy Management Survey of 39 Nos. of Abu Dhabi
Distribution Company (ADDC) Pumping Stations (GHD, 22 June 2009).

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 performance assessment of the mechanical and electrical pumping equipment; and
 maintenance and management recommendations ranging from immediate action to longer term
strategies.

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3. Assessment Personnel

GHD’s Project team comprises the following staff:

Assessor Qualifications Role

Kristof Skawinski (GHD) – Master of Science Project Manager and first point
Project Manager (Mechanical Engineering) of contact for ADDC.
Assessment of civil and
mechanical assets.

John John (GHD) – Senior Master of Science (Agricultural Site supervision. Condition
Irrigation Engineer Engineering) assessment of pumps and pipe
equipment.

Craig Teske (GHD) – Principal Master of Engineering Science Project Coordinator in Asset
Engineer Asset Management (Civil Engineering) Management related aspects

Andrew Jukes (GHD) – Manager – Environmental Project Safety Manager and

Environmental Manager Management Systems and Coordinator
Audits

Sunit Dhar (GHD) – Senior Bachelor of Science Technical project support.

Mechanical Engineer (Mechanical Engineering)

Ross Palmer (Palmer Bachelor of Engineering Management of acoustic and

Acoustics) - Acoustic Engineer (Mechanical Engineering) electrical assessment.

Roger Hawkins (Palmer Bachelor of Engineering Site assessment of electrical

Acoustics) – Electrical (Electrical Engineering) and control equipment.
Engineer

Patanadomrongit Padolchai Bachelor of Engineering Site assessment of noise,

(Palmer Acoustics) – Engineer (Computer Engineering) vibration, temperature and
shaft alignment of pump
Master of Engineering
equipment.
(Information Technology)

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4. Safety Assessment

4.1 Facility Assessment Checklist

As outlined in GHD’s Job Safety Plan1, 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 check is attached as Appendix B.

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5. Condition Assessment

5.1 Condition Assessment Criteria

Condition assessment of all pumping station assets was undertaken based on its conformance and
performance against a set of condition assessment criteria which varies depending on the type of asset
being assessed. For example, condition assessment of electrical equipment (e.g. motors) could include
the assessment criteria shown in Table 2 and, for mechanical equipment (e.g. pumps), the assessment
criteria shown in Table 3.

Table 2 Condition Assessment Criteria for Electrical Equipment (Typical)

Component Assessment Distress Mode
Parameter
Protective Enclosure A External Condition / Cooling / Sealing
B Deterioration / Overheating/ Layout
Internal Components C Age
D Availability
E Colour and brittleness
Cabling F Insulation resistance
G Thermographic Survey
Spare Parts H Availability
Safety Interlocks (Switchboards) I Operation

Table 3 Condition Assessment Criteria for Pump Equipment (Typical)

Component Assessment Distress Mode
Parameter
Unplanned Outages A Average No. Outages per Year
Efficiency B Flow Output
Operation C Vibration
D Temperature
E Noise
Structural Appearance F Leakage
G Shaft, Supports, Bearing Deterioration
Spare Parts H Availability
A condition rating of from 1 to 6 was recorded against each asset based on its overall condition and
performance against the condition assessment criteria as illustrated below in Table 3. GHD’s detailed
condition assessment criteria for assessment of all asset types are attached as Appendix C.

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Table 4 Asset Condition Criteria

Condition Condition Description Approximate Performance

Rating Remaining
Service Life (%)

Very Good (‘As New’) 100 % Asset able to perform its intended current
1 function.

Good Condition 75% Some minor elements of the asset’s function are
2 not able to be provided.

Fair Condition 50% Minor operational difficulties or costs being

3 presented by the loss of function.

Poor Condition 25% Significant operational difficulties or costs

4 presented by the loss of function.

Very Poor Condition < 5% Asset provides very little of its intended function
5 (Failure imminent) and requires enhancement to correct.

Failed, Broken, Derelict 0% Not Functioning.

6

5.2 Testing Equipment and Instruments

The following testing equipment and instruments were employed for this project. Details of testing
equipment used for site assessments are attached in Appendix D.

Table 5 Testing Equipment

Instrument Make/ Model

Ultrasonic Flow Meter Endress + Hausen
Model: - 91W
Hydronic Manometer ALNOR
Model: - HM-650
Pressure Gauges (Set) DWYER (various gauges, oil filled)
Vibration Meter B&K
Model: - Vibro 60
S/N 00000370
Model: - AS 065 Accelerometer
Calibrator B&K
Model: - 4231
S/N 2095146
Vibration Meter B&K
Model: - 2260
S/N 2001772
Sound Level Meter - Real Time Analyser Rion
Model: - NA27
S/N 00311535
Thermal Imaging Camera Fluke Measure Tronic
Model: - Ti10
S/N Ti10-009050021

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Instrument Make/ Model
Infrared Thermometer Dick Smith
Model: - Q1379
S/N 08071614
Temperature Measurement Themo Hydro Meter
Power Quality Analyser Hioki
Model: - 3197
S/N 080920816
Insulation tester Uni-T
Model: - UT511
S/N 1090121689
Non Contact Voltage Sensor Generic
(Indicative/Safety Use Only)
Rotational Speed Digital Tachometer Digitech
Model: - QM1448 S/N 08043906

5.3 Calibration Certificates

Instrument calibration as required on all testing equipment as per manufacturer’s recommendations to
maintain accuracy of the instruments. The latest calibration or testing certificates for all relevant testing
equipment is attached as Appendix D.

5.4 Civil Infrastructure Assets

GHD site staff documented all buildings and visible infrastructure assets and assessed the type, material,
general condition and functionality of each asset (against GHD’s condition assessment criteria) in a
series of inspection schedules as attached in Appendix E. In addition, the Geographical Position (by
GPS) of the main entrance gate and an overall comment on the condition and functionality of pumping
station was recorded.
Condition assessments for all civil and infrastructure assets were recorded

Civil infrastructure assets generally include the following items: -

 Access (external) 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

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5.5 Mechanical Assets
GHD site staff documented mechanical assets and assessed the type, material, general condition and
functionality of each asset (against GHD’s condition assessment criteria) in a series of inspection
schedules as attached in Appendix F.
Mechanical assets assessed include: -

 main water pumps and associated fittings;

 motor and pump support base;
 motor to pump flexible couplings;
 motor to pump shaft alignment;
 pipework flexible connections;
 valves, including motorised (automated operation);
 flow meters and pressure gauges;
 backup power generators (where present);
 overhead cranes;
 building ventilation and air conditioning;
 air compressors; and
 mechanical water level indicators.

5.6 Electrical Assets

GHD site staff documented electrical assets and assessed the type, material, general condition and
functionality of each asset (against GHD’s condition assessment criteria) in a series of inspection
schedules as attached in Appendix G.
Electrical assets assessed included: -
 power supply and distribution cabling;
 backup power supply systems (where present);
 earthing systems;
 lightning protection systems;
 site and interior lighting;
 main switchboard and motor control panels;
 station control and mimic panels;
 pump motors.

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6. Performance and Efficiency Assessment

6.1 Pump Hydraulic Performance

GHD site staff assessed the hydraulic performance of each of the main pump sets against Original
Equipment Manufacturer’s (OEM) specifications and presented the results in the performance
assessment schedules as attached in Appendix H.
The following details the mechanical efficiency assessment methods undertaken on the pump sets on a
pump by pump basis.

6.2 Test Preparation

 Set all equipment into SAFE OFF position (refer to relevant job safety procedures).
 Set and connect Hydronic Manometer into pressure test points on both sides (suction and supply) of
the pump body.
 Prepare and set the manometer into testing mode using manufacturer’s manual procedures.
 Install Ultrasonic Flow Mater onto relevant water supply pipe.
 Prepare and set the flow meter into testing mode using step-by-step procedure as described in
manufacturer’s Operation and Maintenance Manuals.
 Ensure all valves are set to “open” position for pump nominal duty performance.
 Start relevant water pump.
 Begin testing and recording separately for each individual pump.

Testing Equipment Used

 Hydronic Manometer.
 Ultrasonic Flow Meter.
 Individual pressure gauges.

6.3 Tests Conducted on Water Pumps

 (Hydronic Manometer) - Pressure differential reading across each pump at different settings on
isolation valves on supply side.
 (Ultrasonic Flow Meter) - Water flow readings for each recorded pressure differential (as above) and
valve setting.

Web Search and Data Collection for OEM Specifications

 Pump specific performance curves.
 Technical pump data (impeller sizes, mechanical and electrical power consumptions, pump
efficiencies at design points).
 Pumps technical brochures and Operation and Maintenance Manuals.

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Plotting Performance on OEM Pump Curves
 Each pump has been presented with its original performance curve and design selection point. The
same performance curves have been used to plot current pump performance readings (as described
above in “Tests Conducted on Water Pumps”.
 Current pump performance points were plotted against OEM specifications to assess accuracy and
relation between originally designed pump duties and actual pump and system performance (current
water delivery rates and system pressure).

6.4 Flow Measurement

Ultrasonic Flow Measuring System Application: Flow measurement for standard applications with
drinking water, wastewater and process water. The sensors are perfectly suited for bidirectional
measurement of pure or slightly contaminated liquids, regardless of the pressure, temperature,
conductivity and viscosity.
Measuring Principle: Prosonic Flow operates on the principle of transit time difference. An acoustic
(ultrasonic) signal is sent in both directions from one measuring sensor to another. A transit time
difference arises because the signal propagation velocity of the sound waves is greater in the direction of
flow than against the direction of flow. This difference is directly proportional to the flow velocity. Prosonic
Flow calculates the flow from the pipe cross-sectional area and the measured transit time difference.

Figure 1 Ultrasonic Flow Meter

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6.5 Pressure Measurement

Digital Manometer ALNOR HM-650

General Description: The HM 650 Hydronic Manometer is an easy-to-use instrument designed to
measure differential or gauge fluid pressure of non-potable water in hydronic systems and air pressure in
high-pressure air systems (refer Figure 2. It measures pressures from 0 - 300 psi and displays results on
a large LCD. Measurements can also be stored in memory for later downloading to a printer or personal
computer.

HM 650 Key Features:

 Measures gauge and differential pressure.
 User-selectable units of measure.
 English: psi, feet H2O, inches H2O, inches Hg.
 Metric: kPa, meters H2O, mm H2O, mm Hg, Bar.
 Manual or Time Log measurements.
 User-selectable Time Constant (Manual mode).
 User-selectable sampling interval and number of samples (Time Log mode).
 Stores up to 999 measurements.
 RS 232 output.

Figure 2 HM 650 Hydronic Manometer

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Operation:
The HM 650 Hydronic Manometer utilizes a sensitive pressure transducer in a bridge circuit to measure
gauge and differential pressure. The pressure transducer detects differences in pressure between the
two sides of the bridge circuit and generates a corresponding electrical signal. This electrical signal is
converted into a pressure measurement by the instrument’s built-in microprocessor and displayed on the
digital readout in the selected unit of measure. When making gauge pressure measurements, this circuit
measures the pressure difference between the high-pressure line and atmospheric pressure. In
differential pressure readings, the pressure difference between the high-pressure line and the low-
pressure line is measured.

6.6 Operating Temperature Assessment

Temperature measurements were taken using both the Thermo-Hygro meter and the Thermal Imaging
camera.

6.6.1 Ambient Temperature

The Thermo-Hygro meter was used to record machine room operational temperatures and the outside
ambient temperature in the shade (refer Figure 3). For both internal and external measurements the
meter was given a minimum 5 minutes to stabilise prior to recording the temperature. This data gave an
indication of the levels of thermal radiant heat occurring from the surface or object be assessed.

Figure 3 Thermo Hydro meter for Temperature Measurement

6.6.2 Equipment Operating Temperature

To assess the temperature of various major system components, a Fluke Ti 10 thermal imaging camera
was used (refer Figure 4). This is a non-contact device that provides quick and accurate details on the
levels of thermal radiation from various surfaces. This is a proven technology use as a preventative
maintenance tool to determine: -
 if bearings were overheating and likely to fail;
 if air conditioning equipment was operational; and
 if any electrical connection or component (including switch boards) was overheating relative to
adjacent similar components.
In particular, the main motor power connections and the inside components of the control panels were
checked. As a cross check of the temperatures a Dick Smith Q 1379 Infrared thermometer was used
(refer Figure 5).

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 Figure 4 Fluke Ti 10 Thermal Imaging Figure 5 Dick Smith Infrared
Camera Thermometer

6.7 Motor to Pump Shaft Alignment

Shaft alignment was measured with a Fixturlaser Dirigo shaft alignment tool (refer Figure 6). This tool is
quick and accurate device to provide measures of the shaft misalignment in both angular and vertical
and horizontal displacement (to a resolution of 0.01 mm). The instrument operates in conditions up to 40
deg C over shaft sizes 40 to 500 mm and provides accuracy better than 2 %. Alignment was measured
from each side of the motor to pump shaft coupling.

Figure 6 Fixturlaser Dirigo Shaft Alignment Tool

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6.8 Motor, Pump and Pipework Vibration Spectrum Analysis
To assess vibration from the motor, pump and pipe work, a real time Fast Fourier Transform analyser
(FFT) was employed to measure vibration from 2 to 1000 Hz and 0 to 10 mm/m2. A hand held
accelerometer probe with magnetic head was used with the analysis conducted using a B&K V60
portable vibration analyser with a magnetic base vibration head (refer Figure 7).

Figure 7 B&K Vibro 60 Vibration Analyser

Measurements were taken over 30 second intervals in each location under normal operational conditions
with the average levels stored for later download. The maximum vibration velocities were recorded
against frequency. This data was later compared to typical industry standard maximum acceptable
operational levels.
Vibration levels were measured on 3 locations around each pump and motor and 2 locations on one set
of pipe work. Vibration velocity measurements were taken to assess the overall levels of balance of the
motors and pumps, alignment of the motor and pump shafts, and to give an indication of the rigidity of
the motor and pump support bases. Assessments of the equipment showed that pipe work vibration was
not a concern and always lower than the vibration levels on both the pumps and motors.
As a back up instrument to cross check the Vibro 60 meter a B&K 2260 Investigator meter set in FFT
mode was used with a PCB 353 B33 accelerometer.

Motor Rotational Speed

The motor speed (RPM) was measured using a Digital Tachometer – Digitech Model QM1448. This
combined with a reflective foil tape secured to the shaft enables an accurate determination of the
rotational speed of the shaft.

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Figure 8 Digitech Tachometer

Noise Assessment
Sound levels were measured using a precision grade 1/3 octave band real time analyser (refer Figure 9).
The meter was positioned in a central location (close to 1.2m above the floor) in the machine room to
determine the average (LAeq) 1/3 octave band and dB(A) noise levels. These tests were taken under
typical operating conditions for the pump room. Further to this when there was value in doing so, noise
levels were measured at close to 1m from each pump/motor set. Samples were taken over 30 second
intervals.

Figure 9 Rion NA27 Sound Level Meter

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6.9 Energy Management Assessment
Energy use was assessed at each station and any significant potential for reduction noted. As
information regarding the required daily pumping performance of the station was not available, specific
assessment of station performance was not possible. From observation made of all pumping stations, a
single report highlighting generic procedures has been prepared 2.

6.10 Electrical Assets

Where OEM information is available for electrical characteristics of main switchboard and motors, this
was checked against current readings

Power Supply Configuration

Station power supply arrangements were reported with site transformer ratings or low voltage supply
capacity included where this information was available in the field. Physical security of the supply and
safety of cabling methods were documented. Wherever possible the safety linkage of the supply earth
and neutral connections was assessed and link resistance measured.

Earth Systems
The earth systems were visually inspected and comments made on the degree of earth bonding within
the station.

Safety Assessment Criteria

General electrical safety over the pumping station was assessed. Particular note was made of the
bonding of the supply system to earth and the operation of safety interlocks was assessed.

Main Switchboard / Motor Control Centre

Main switchboards were described from a functional and safety perspective. The ratings of major
components were recorded and, where access was available, thermal images were taken. Any items
under thermal stress were recorded. Motor control panels were described as for the main switchboard
and access obtained for thermal imaging. Thermal imaging was used to identify thermally stressed or
failing components by measurement of absolute temperature and comparison with other components
carrying similar electrical loads.

Site / Interior Lighting

Visual assessment of physical condition of all lighting equipment was undertaken with the current
operational status reported.

Station Control System

The station control systems (if present) were inspected for operation and for adequacy for the task.
Where individual items were found to be non-operational instrument power supply and sensor
connections were checked if access was available. Pump level controls were checked against physical
measurement devices (e.g. manometer), where these were operating.

2
ADDC Water Pumping Stations - Condition Assessment and Energy Management Report, (GHD 2009)

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Motors
Motors were inspected and terminations checked where isolation was available. Inspections included
measurement of Dielectric Absorption, Polarization Index and operating temperature via thermal imaging.
It was expected that insulation indices will be in excess of 2 (i.e. the expected minimum for a healthy
motor). Where winding insulation exceeded 4 GΩ the winding was assessed as healthy.
Appendix G presented the performance assessment schedules use for assessment of electrical assets.

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7. Pumping Station Operations Assessment

7.1 Assessment Criteria

The following matters and issues were considered in the overall assessment of each of the pumping
stations.

Equipment Suitability

Pump Manufacturers (Brand Names) and Pump Types

This information will be used to give a better understanding on issues such as:

 Equipment (pumps) uniformity across all pumping stations used by ADDC. This has direct impact on
pumping equipment and spare parts availability (from UAE manufacturers, available service,
maintenance and spare parts, operator’s knowledge and technical training).
 Interchangeability of pumps, pump components and directly coupled pipe components (bearings,
seals, impellors, shafts, motors, flexible couplings, valves and pipe fittings, pipe sizes).
 Industry recognition, quality of brand and equipment, available brand technical support and training.

Valve (Isolating and Non-Return) Types and Sizes

 Similarly to pumping equipment, data collected for valves and fittings can be used in assessment of
parts uniformity, market availability, quality and management of service and maintenance.

Equipment Capacities
 Original design water flow rates and pumping pressures
 Installed electrical power supply capacity.
 Current water demands and system working pressures.
 Current use (capacity) of electric power supply to pumping station.

Redundancy / Standby Capacity

 Number of duty and stand by pumps in each station.
 Actual pump water flow rates versus existing water demands.

Duty Hours
 Actual pumping station hours of operation.
 Running hours of each duty pump

Automation and Controls

 Role and purpose of the originally installed automation or control systems.
 Existing state and utilisation of the originally installed controls and automatic systems.
 Suitability of the existing controls for revival upgrades, recommissioning or repair.

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Station Operating Personnel
 English language skills.
– Basic ability to communicate in English language (in speech and in writing)
– Ability to understand work orders etc.
– Ability to read and understand equipment operation and maintenance manuals, drawings, safety
manuals.
– Ability to write basic reports or situational descriptions.
– Ability to participate in personal technical development and training (general technical knowledge,
understanding basics of related engineering disciplines (electrical – motors, power supply and
distribution, controls and automation, pumps and fluid flow/pressure, vibration and noise etc).
 Technical knowledge of the mechanical and electrical equipment installed in each station
 Understanding existing automation systems
 Understanding service and maintenance procedures (pumps, motors, valves and piping, building
structures and other existing assets).
 Understanding and performing safety procedures, first aid, fire response, etc.

Other Systems

Outside lighting:  Do all units operate?

 If a unit fails is it fixed quickly?
 Are the lights needed?
 Are they in the right place?

Fire Alarm System:  Is it serviced regularly?

 What happens, if an alarm sounds?
 Do operators report the alarm every time?

Pump Scheduling  Are the pumps left on automatic scheduling?

 Are pumps manually controlled to have equal running hours?

Maintenance  Are operators expected to replace bulbs on pilot and status lights?
 Can they easily get the replacement bulbs?

Mimic panel  Do all the needed indicators work?

 If something breaks can the operators get maintenance done?
 How do they report faults?

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Assessment Overview Report
8. References

1. Job Safety Plan for Consultancy Services for Condition Assessment and Energy Management Survey
of 39 Nos. of Abu Dhabi Distribution Company (ADDC) Pumping Stations (GHD, 22 June 2009).
2. ADDC Water Pumping Stations - Condition Assessment and Energy Management Report, (GHD
2009)

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 Appendix A
Available Technical Data

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
Assessment Overview Report
 Available Existing Technical Documentation

Controls Equipment Service and

Design Equipment Test
No. Unit office Pump Station Drawings O & M Manuals and Control Maintenance Remarks
Parameters Technical Data Certificates
Alarms Logic Records

Pump Station

Storage Tank
Plant Layout

Equipment

Mechanical

Mechanical
Buildings

Electrical

Electrical
Electrical

Electrical
Pumps

Pumps

Pumps
Pump

Other
Central Region
1.1 Sea Palace         Chlorination manual
1.2 Abu Dhabi H.H. Sh.Khalifa Palace          Chlorination system
1.3 City H.H Sh. Suroor Palace (Hamdan?)         Chlorination system
1.4 Jubail Island
Eastern Region
1.1 Samha East  
1.2 Samha Ghanada       
1.3 Samha West
2.1 Baniyas Military Accomodation
3.1 Al Khatim Al Khatim
4.1 Zubara
Shahama
4.2 Shahma
Western Region
1.1 Jabana Main PS + TFS         Chlorination systems
1.2 H.H Sh.Zayed Palace 
1.3 LIWA Hotel   
1.4 Bu Saddain     
Liwa
1.5 Rest House    ` 
1.6 Mougab   
1.7 Hamrour
1.8 Shaya
2.1 Grain Al Ayesh 1PS         
2.2 Grain Al Ayesh 2 PS         
2.3 Grain Al Ayesh 3 PS         
2.4 Grain Al Ayesh 4 PS         
Mirfa
2.5 Tarif       
2.6 Abu Al Abyad New PS      
2.7 Abu Al Abyad Old PS
2.8 Mirfa TFS
3.1 Sir Baniyas PS2 (new)   
3.2 Bida Al Mutawa      Chlorination Syst. manual
3.3 IPS2
Ghayathi
3.4 Ghayathi
3.5 Bainounah Palace
3.6 Sir Baniyas PS1 (old)
4.1 Sila Border Post   
Sila
4.2 Sila Mena PS
5.1 H.H Shk Zayed Palace
Delma
5.2 New Shabiya
% of information & data supplied by ADDC 16.2 0.0 2.7 29.7 0.0 0.0 37.8 27.0 40.5 35.1 32.4 48.6 29.7 10.8 2.7 5.4 0.0

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 Appendix B
Site Safety Assessment Checklist

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
Assessment Overview Report
 SITE SAFETY ASSESSMENT

Assessment Date
Pumping Station Name

HAZARD SATISFACTORY COMMENTS

Site Access and Egress
Site Security
Lighting
Mechanical Hazards (eg Unguarded Plant)
Electric Hazards
Housekeeping (General Tidiness)
Fire Hazard and Equipment
Noise
Dust / Fumes
Hazardous Substances
Working at Heights
Ladders / Scaffolding
Pressurized Equipment
Heat Illness / Stress
Personal Protective Equipment (PPE)
Knowledge of Site Safety Rules
Site Emergency Procedures
Confined Space Entry
Lock Out / Tag Out

Comments

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 Appendix C
Condition Assessment Criteria

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 Asset Condition Assessment Schedules

Table of Contents

1 Cabling
2 Cranes
3 Electrical Equipment
4 Fences
5 Mechanical Equipment
6 Miscellaneous Site Assets
7 Pipework (including Minor Valves & Fittings)
8 Pumps - Dry Well & Line Shaft
9 Roof Structures
10 Sealed Pavements
11 Structures
12 Valves

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 Cabling
Includes Flow meters, Telemetry, SCADA, PCs, PLCs, Housing, Switchboards & Control Panels.

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Cabling Colour and No visible signs of Coating pliable and Coating pliable Coating becoming Coating brittle and
brittleness colour deterioration. providing good however significant brittle. Discolouration beginning to crack.
Coating still pliable insulation protection discolouration may or may not be Infrequent operational
A however some minor occurring present. interruptions resulting.
signs of
discolouration.
Insulation Insulation protection Insulation protection Insulation protection
B Resistance as per original approximately 20 close to minimum
(Mega Test) commissioning test. MegaOhms acceptable limit

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 Cranes
Includes gantry cranes, hoists and winches.

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Fixings Cracking / Fixing sound - no Some minor Cracking/corrosion Cracking/corrosion Significant
Corrosion cracking/corrosion cracking/corrosion becoming more evident that has cracking/corrosion
evident evident that has little evident however still impacted on the evident that presents
A impact on the fixings little impact on a high probability of
structural integrity.
strength or function structural integrity. the fixings failure.
Crane cannot be
used.
Steel Structure Coating / Steel Coating / Steel sound - Coating cracked / Coating cracked / Coating / undercoat Coating / undercoat
- Cracking, no cracking or flaking exposing flaking exposing cracked / flaking cracked / flaking
Flaking corrosion. undercoat. metal. exposing metal. exposing metal.
B Corrosion Corrosion/pitting of Corrosion/pitting of
metal surface at any metal surface at
one location. several locations.
Trolley and Coating / Coating / Steel sound - Coating cracked / Coating cracked / Coating / undercoat Coating / undercoat
Crane Function no cracking or flaking exposing flaking exposing cracked / flaking cracked / flaking
corrosion. Functions undercoat. Functions metal. Maintenance of exposing metal. exposing metal.
as new. Ok. function required. Corrosion/pitting of Corrosion/pitting of
C metal surface at any metal surface at
one location. several locations.
Extensive Crane/trolley does not
maintenance required. operate.

Controls Age/Function Operates Most of control Controls not

Operates as new. Age Some loss of function.
D satisfactorily. Age > 5 function lost. Age > 15 functioning. Age > 20
< 5 Years Age > 10 Years
Years Years Years

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 Electrical Equipment
Includes Flow meters, Telemetry, SCADA, PCs, PLCs, Housing, Switchboards & Control Panels.

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Protective External Condition / Protective enclosure / coating Coating cracked / flaking Coating cracked / flaking Coating cracked / flaking Coating cracked / flaking
Enclosure Cooling / Sealing sound, no deterioration. Sealing exposing undercoat < 20% of exposing undercoat > 20% of exposing metal > 20% of area, exposing metal > 40% of area.
and ventilation / cooling good. area, evidence of corrosion. area, panels corroding. Seal areas of panel heavily corroded. Areas of panel nearly corroded
Some seal wear but no dirt allowing some dirt ingress. Seal allowing dirt ingress, through. Seal allowing dirt
A ingress. Ventilation and cooling Ventilation and cooling contaminating components. ingress, contaminating
adequate. adequate. Ventilation and cooling components causing premature
marginal. failure. Ventilation and cooling
inadequate.

Internal Deterioration / No visible deterioration. Some components showing Majority of components Components showing Components overheating
Components Overheating minor signs of deterioration showing signs of deterioration. advanced signs of deterioration (smell) / malfunctioning and / or
that will contribute to elevated not operational.
B
temperatures and malfunction.

C Age < 2 Years < 5 Years < 10 Years < 15 Years > 15 Years
Availability Components available locally of Components available inter Components available inter Components available inter Components no longer
D the shelf. state of the shelf. nationally off the shelf. Spares nationally to order. available. Can be manufactured
stocked locally. as specials.
Cabling Colour and brittleness No visible signs of colour Coating pliable and providing Coating pliable however Coating becoming brittle. Coating brittle and beginning to
deterioration. Coating still good insulation protection significant discolouration Discolouration may or may not crack. Infrequent operational
E pliable however some minor signs of occurring be present. interruptions resulting.
discolouration.
Insulation Resistance Insulation protection as per Insulation protection Insulation protection close to
F (Mega Test) original commissioning test. approximately 20 MegaOhms minimum acceptable limit
Thermographic Survey No areas with raised < 10% of components have < 30% of components have > 30% of components have > 50% of components have
temperature elevated operating temperature elevated operating temperature. elevated operating temperature. elevated operating temperature.
and / or no single component One component has operating One or more components have Several components have
G
has temperature exceeding temperature exceeding design operating temperature operating temperature
design limits. limits. exceeding design limits. exceeding design limits.

Spare Parts Availability Components available locally of Components available inter Components available inter Components available Components no longer
H the shelf. state of the shelf. nationally off the shelf. Spares internationally to order. available. Can be manufactured
stocked locally. as specials.
Safety Interlocks Operating Fully functional Not operational
I (Switchboards)
Fire Safety Fire Risk Design safety separation in Some components displaced Noteable fire risk (e.g.Non Significant fire risk (e.g.
J (Switchboards) place flamable materials stored in or Flamable components stored in
against board) or against board)

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 Fences

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Fence Post & Security / Recently constructed, Some wear and tear Minor deterioration of Significant Severe deterioration
Wire Deterioration replaced or but still provides good post and wire however deterioration of post of post and wire.
rehabilitated. security. security function still and wire through rust, Collapse likely in high
A maintained. damage and loss of winds or multiple
tension. Some locations of security
breaches of security. breaches.
(openings).

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 Mechanical Equipment
Includes Aerators, Clarifiers, Filters, Screens, Belt Press.

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Unplanned
A Avg No./Year 0 / Year < 2 / Year < 5 / Year < 10 / Year > 10 / Year
Outages
Efficiency Flow within 5% of Flow within 10% of Flow within 20% of Flow within 40% of Flow > 40% of duty
B Flow Output
duty point. duty point. duty point. duty point. point.
Operation Considerable
No unusual vibration Minor vibration
C Vibration Moderate vibration vibration (wristwatch Major vibration
detectable detected
shakes)
No unusual Minimal heat from Heat detected by Heat detected by Heat too high to
D Temperature
temperature detected casing using hand hand hand is uncomfortable assess by hand
No unusual noises Slight whine/rattle Moderate whine/rattle Loud whine/rattle. Disturbingly loud
detected. detected. detected, easily heard operation/vibrations.
E Noise over pump noise.

Structure Surface Surface appears as Some minor surface Surface deterioration Surface deterioration Severe deterioration
Appearance Deterioration new with little or no wear evident that has becoming more evident that has of surface presenting
signs of deterioration. little impact on the evident however still impacted on the a high probability of
F structures strength orlittle impact on assets structural the structures collapse
function. structural integrity or integrity or function. or failure.
function.
Shaft, Shaft & supports Minor shaft/ support Shaft distortion or Shaft distortion or
Significant shaft
Supports, sound - no shaft deterioration evident, bearing/housing wear bearing/housing wear
distortion or
Bearing distortion or no impact on the evident, little impact evident and has bearing/housing wear
G Deterioration deterioration evident. structural strength or on structural integrity impacted on asset
evident, high
function. or function. integrity or function.
probability of fracture
or failure.
Spare Parts Availability Components available Components available Components available Components available Components no
locally off the shelf. inter state off the inter nationally off the inter nationally to longer available. Can
H shelf. shelf. Spares stocked order. be manufactured as
locally. specials.

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 Ferrous Pipework (including Minor Valves (< DN 300mm) & Fittings)
Includes pressure and non-pressure pipes above and below ground.
Includes MS, CI, DICL, MSCL
Assessment Component Distress Mode Rating Rating Rating Rating Rating
Parameter 1 2 3 4 5
Pipe Wall Steel Thickness Still has full wall Still has full wall Loss of < 20% of Loss of > 20% of Loss of design wall
A thickness including thickness but no design wall thickness. design wall thickness. thickness > 50%.
corrosion allowance. corrosion allowance. Note 2 Note 2 Note 2

Pipe Wall / Leak Repair

B Joint / Fittings Frequency / 0 1 - 2 / Year > 2 / Year > 5 / Year > 10 / Year
10K
Fluid Loss Loss / Impact / No visible evidence of Some minor signs of Leakage moderate Significant Fluid loss Fluid loss affecting
Efficiency leakage. Efficiency of leakage having no but no impact on affecting neighbouring neighbouring
distribution > 90%. impact on neighbouring property, potential for property, claim for
neighbouring property. Minor affect claim for damages damages and / or
properties / on environment. and / or causing causing significant
C environment. Efficiency of environmental environmental
Efficiency of distribution > 70%. damage. Efficiency of damage. Efficiency of
distribution > 80%. distribution > 50%. distribution < 50%.

External Cracking / Coating as new, no Coating showing signs Coating loss / Coating loss / Steel heavily corroded
Coating / Flaking / defects. of aging, no visible deterioration exposing deterioration exposing / rusting with large
Surface / Bolts Corrosion defects. steel. Steel surface steel. Steel corroding areas of surface
D corroding / rusting. / rusting with surface delamination / flaking.
delamination / flaking.

Soil / Corrosion Coating as new. Soils Evidence of coating Coating visibly Coating visibly Coating visibly
Environment non-corrosive. aging. Soils non- delaminating / delaminating / delaminating /
corrosive. exposing pipe steel at exposing pipe steel at exposing pipe steel
one or two points in several places in over majority of
E section. Soils mildly section. Pipe steel section. Pipe steel
corrosive. corroding. Soils heavily corroded.
promoting corrosion. Soils highly corrosive.

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 Pumps
Includes Conventional, Dry Well and Line Shaft Pumps

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Unplanned
A Avg No./Year 0 / Year < 2 / Year < 5 / Year < 10 / Year > 10 / Year
Outages
Efficiency Flow within 5% of Flow within 10% of Flow within 20% of Flow within 40% of Flow > 40% of duty
B Flow Output
duty point. duty point. duty point. duty point. point.
Operation Considerable
No unusual vibration Minor vibration
C Vibration Moderate vibration vibration (wristwatch Major vibration
detectable detected
shakes)
No unusual Minimal heat from Heat detected by Heat detected by Heat too high to
D Temperature
temperature detected casing using hand hand hand is uncomfortable assess by hand
No unusual noises Slight whine/rattle Moderate whine/rattle Loud whine/rattle. Disturbingly loud
detected. detected. detected, easily heard operation/vibrations.
E Noise over pump noise.

Structure Leakage Appears as new. Minimal moisture on Water dripping from Water pooling on floor Water squirting/
F Appearance seals/joints. seals/joints. running onto floor.
Shaft, Shaft & supports Minor shaft/ support Shaft distortion or Shaft distortion or Significant shaft
Supports, sound - no shaft deterioration evident, bearing/housing wear bearing/housing wear distortion or
Bearing distortion or no impact on the evident, little impact evident and has bearing/housing wear
G Deterioration deterioration evident. structural strength or on structural integrity impacted on asset evident, high
function. or function. integrity or function. probability of fracture
or failure.
Spare Parts Availability Components available Components available Components available Components available Components no
locally of the shelf. inter state of the shelf. inter nationally off the inter nationally to longer available. Can
H shelf. Spares stocked order. be manufactured as
locally. specials.

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 Roof Structures
Includes steel and masonary roofs

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Roof/Support Deterioration / Appears in excellent Minor deterioration Moderate Significant Major deterioration of
Structure Leakage or as new condition evident <10% of deterioration. < 30% deterioration. < 50% assets performance.
with no visible signs asset value required of asset value of asset value Failure likely within
A of deterioration. to restore asset to required to restore required to restore near future .
near new condition. asset to near new asset to near new
condition. condition.

Sealed Pavements
Includes all roads, car parks, hardstands, concrete paths & drains.

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Surface Material Cracking / Pot Recently constructed, Some signs of surface Some obvious Cracking evident Severe deterioration
Holes / remodelled, replaced, ageing however no cracking, minor through majority of of surface through
Depressions rehabilitated. deformation or surface loss or area. Some potholing cracking, potholes,
A cracking evident. potholes. Pavement and depressions etc. Pavement
underneath exhibiting occurring. underneath shows
no depressions. significant
depressions.
Drainage Ponding / Drainage quickly and Water effectively Some ponding on Significant ponding of Significant ponding of
Drainage Rate effectively removes removed from pavement and water over pavement water over pavement
all water from pavement however drainage channels following rains for periods exceeding
B pavement area with some ponding occurs slow to dissipate however water 24 hours following
no ponding within within drainage water collected. drained away with a rainfall
drainage channels channels few hours.

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 Structures
Includes all tanks, buildings, wells, pits, platforms, access bridges
Includes concrete, timber and steel structures
Assessment Component Distress Mode Rating Rating Rating Rating Rating
Parameter 1 2 3 4 5
Structural Cracking Structure sound - no Some minor cracking Cracking becoming Cracking evident that Significant cracking
Integrity / cracking evident. evident that has little more evident however has impacted on the evident that presents
A Function impact on the still little impact on assets structural a high probability of
structures strength or structural integrity or integrity or function. the structures collapse
function. function. or failure.
Movement No movement Some minor Asset has moved Movement has Movement has severe
evident. movement evident significantly however impacted on the impact on structural
B that has little impact structural integrity and assets structural integrity or function
on the structures function are retained. integrity or function. with a high likelihood
strength or function. of failure.
Surface Deterioration Surface appears as Some minor surface Surface deterioration Surface deterioration Severe deterioration
new with little or no wear evident that has becoming more evident that has of surface presenting
signs of deterioration. little impact on the evident however still impacted on the a high probability of
C structures strength or little impact on assets structural the structures collapse
function. structural integrity or integrity or function. or failure.
function.
Operational Loss of Asset able to perform Some minor elements Minor operational Significant operational Asset provides very
Performance Function/Costs it intended current of the assets function difficulties or costs difficulties or costs little of its intended
D function. are not able to be being presented by presented by the loss function and requires
provided. the loss of function. of function. enhancement to
correct.
Foundation Ground No movement/ Some minor Significant ground Movement/ erosion Movement/erosion
Movement/ erosion evident. movement/ erosion movement or erosion, has impacted on the has severe impact on
Erosion evident that has little however asset asset's structural structural integrity or
E impact on the structural integrity and integrity or function. function with a high
structure's strength or function are retained. likelihood of structural
function. failure.
Fixings Cracking / Fixing sound - no Some minor Cracking/corrosion Cracking/corrosion Significant
Corrosion cracking/corrosion cracking/corrosion becoming more evident that has cracking/corrosion
evident evident that has little evident however still impacted on the evident that presents
F impact on the fixings little impact on structural integrity. a high probability of
strength or function structural integrity. the fixings failure.
Crane cannot be
used.

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 Valves
All Valve Types & Sizes

Assessment Component Distress Mode Rating Rating Rating Rating Rating

Parameter 1 2 3 4 5
Operation Ease of Operates as new Operates satisfactory Operation becoming Requires mechanical Does not operate over
A Operation difficult or internal assistance to fully full travel
build-up close
Sealing Wear / Leakage No observable Some minor wear or Minor leakage is Leakage occurring Excessive leakage.
deterioration. Valve corrosion on sealing likely. Maintenance although not Significant
sealing in good elements works will restore seal excessive. Significant maintenance works
B condition maintenance works required to restore
required to restore seal
seal

Supports / Cracking / Coating as new, no Coating showing signs Coating loss / Coating loss / Steel heavily corroded
Bolts - Coating Flaking / defects. of aging, no visible deterioration exposing deterioration exposing / rusting with large
Corrosion defects. steel. Steel surface steel. Steel corroding areas of surface
C corroding / rusting. / rusting with surface delamination / flaking.
delamination / flaking.

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Assessment Overview Report
 Appendix D
Testing Equipment and Instruments

a) Equipment Manufacturer, Model and Specifications

b) Calibration Certificates

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
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Testing Instruments and Equipment - Specifications
Instrument Make/ Model Specifications / Operation Limits
Mechanical Testing Equipment
Ultrasonic Flow Meter Endress + Pipe range: - DN 50 to DN 4,000
-
Hausen Temp. Range: - 20 to +80oC
Model: - 91W Protection: - IP 67
Applicable liquids: - water, sea water, distilled water, ammonia,
alcohol, benzene, bromide, ethanol, glycol, kerosene, milk,
methanol, toluene, lubricating oil, fuel oil, petrol
Applicable pipe materials: - stainless steel, SS ANSI 304, SS ANSI
316, SS ANSI 347, SS ANSI 410, SS ANSI 430, alloy C, PVC, PE,
LDPE, HDPE, GRP, PVDF, PA, PP, PTFE, glass pyrex, asbestos
cement, carbon steel, ductile iron
Applicable pipe linings: - cement, rubber, tar epoxy
Hydronic Manometer ALNOR Range: - 0 to 2068 kPa
Model: - HM-650 Resolution: - 0.25 kPa
Operating Temperature: - -10° to 60°C
Media Temperature: - 0° to 100°C
Accuracy: - ±2% of reading (plus two times the
resolution) throughout operating temperature range).
Pressure Limits: - Burst pressures = 2,758 kPa each
port.
(Calibration Certificate Supplied)
Pressure Gauges (Set) DWYER (various Set range: - -100 to 1,000 kPa
gauges, oil filled) Resolution: - 5 kPa
Vibration Meter B&K Temperature Range: - 0º to 50º C (ambient)
Model: - Vibro 60 Frequency Range: - 2 to 1000 Hz
S/N 00000370 Amplitude: - 0 to 10 mm/s
Model: - AS 065
Accelerometer
Calibrator B&K
Model: - 4231
S/N 2095146
Vibration Meter B&K Frequency Range: - 2 to 500 Hz
Model: - 2260 Amplitude: - 0 to 10 mm/s
S/N 2001772 (Calibration Certificate Supplied)
Sound Level Meter - Rion Sound Range: - 10 to 120 dB (in 1/3 octave bands)
Real Time Analyser Model: - NA27 (Calibration Certificates Supplied)
S/N 00311535
-
Thermal Imaging Fluke Measure Measurement Range: - 20º to +250º C
Camera Tronic Operating Temperature: - -
10º to 50º C (± 5%)
Model: - Ti10 Resolution: - 640 x 480 pixel
S/N Ti10-
009050021
-
Infrared Thermometer Dick Smith Operating Temperature: - 20º to 250º C
Model: - Q1379
S/N 08071614
Temperature Thermo Hydro Range: - 0º - 50º C
Measurement Meter Relative Humidity: - 2 to 98%
Electrical Testing Equipment
Power Quality Analyser Hioki Operating Temperature: - 0º to 45º Dec C
Model: - 3197
S/N 080920816

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Instrument Make/ Model Specifications / Operation Limits
Insulation tester Uni-T Operating Temperature: - 0º to 50º C
Model: - UT511
S/N 1090121689
Non Contact Voltage Generic (Not Applicable)
Sensor (Indicative/Safety
Use Only)
Rotational Speed Digital Digitech Operating Range: - 2.5 to 99,999 (± 0.05%) RPM
Tachometer Model: - QM1448 Operating Temperature: - 0º to 50º C
S/N 08043906

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CALIBRATION CERTIFICATE – Sound Level Meter: Rion NA-27

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CALIBRATION CERTIFICATE STANDARDS– Sound Level Meter: Rion NA-27

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D4
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CALIBRATION CERTIFICATE – Sound Level Meter: B & K Model 2260

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D5
Assessment Overview Report
CALIBRATION CERTIFICATE – Sound Level Calibrator: Rion NC-73

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D6
Assessment Overview Report
CALIBRATION CERTIFICATE STANDARDS– Sound Level Meter: B & K Model 2260 and Sound
Level Calibrator: Rion NC-73

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D7
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CALIBRATION CERTIFICATE – Accelerometer: PCB Piezotronics Type 353 B33

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations D8
Assessment Overview Report
CALIBRATION CERTIFICATE – Hydronic Manometer: Alnor – HM650

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Assessment Overview Report
 Appendix E
Civil Assets Assessment Schedules

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 CONDITION ASSESSMENT - Buildings & General Infrastructure
Assessment Date LEGEND - Asset Condition Assessment
Pumping Station Name Description Life Remains Rating
Time: IN / OUT "As New" 100% 1
GPS Position (Entry Gate) N E Good 75% 2
ADDC GIS Object No: Fair 50% 3
Poor 25% 4
Inspection Personnel Failure Imminent 0% 5
Failed / Derelict Un-useable 6

ADDC GIS Asset Condition Assessment

Asset Description Comments
Object No: Schedule Parameters Rating
Access Road Not Assigned Sealed Pavements A-B
Boundary Fence / Walls Not Assigned Fences / Structures A-F
Entry Gate - Structures A -F
Security House Not Assigned Structures A -F
External Walls - Structures A -F
Roof - Structures A -F
Internal Walls - Structures A -F
Internal Amenities - Misc. Site Assets A
Pump House Not Assigned Structures A -F
External Walls - Structures A -F
Roof - Structures A -F
Internal Walls - Structures A -F
Office & Internal Amenities - Misc. Site Assets A
Accommodation Not Assigned Structures A -F
External Walls Structures A -F
Roof Structures A -F
Internal Walls Structures A -F
Internal Amenities Misc. Site Assets A
Internal Roads Not Assigned Sealed Pavements A-B
Internal Paths Not Assigned Sealed Pavements A-B
Landscaping Not Assigned Misc. Site Assets A

Comments

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Assessment Overview Report
 CONDITION ASSESSMENT - Water Tanks
STORAGE / TRANSFER TANK 01
ADDC GIS Object No:
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) Good 75% 2
Tank Description Fair 50% 3
Material Poor 25% 4
Failure Imminent 0% 5
COMMENTS
Failed / Derelict Un-useable 6

Asset Condition Assessment

Asset Description Comments
Schedule Parameters Rating
External - Walls
External - Roof
External - Roof Access
External - Roof Hatches
Internal - Walls
Internal - Floor
Internal - Roof
Water Level Indicator

Comments

Structural / Material Testing Recommended (Yes / No)

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 CONDITION ASSESSMENT - Water Tanks

ELEVATED TANK 01
ADDC GIS Object No:
Width (m)
Length (m)
Diameter (m) LEGEND - Asset Condition Assessment
Elevated Height (m) Description Life Remains Rating
Depth (m) "As New" 100% 1
Capacity (m3) Good 75% 2
Tank Description Fair 50% 3
Material Poor 25% 4
Failure Imminent 0% 5
COMMENTS
Failed / Derelict Un-useable 6

Asset Condition Assessment

Asset Description Comments
Schedule Parameters Rating
Tank Tower/ Stand Structures
Tank Tower Access Structures
Pipe Risers Pipework
Pipe Riser Supports Structures
External - Walls Structures
External - Roof Structures
Internal - Walls Structures

Comments

Structural / Material Testing Recommended (Yes / No)

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 CONDITION ASSESSMENT - Pipework & Valves (Suction Side)
Suction Header Pipework Pipe 1
ADDC GIS Object No:
Pipe Material
Pipe Diameter (mm)
Condition Rating (1 to 6)

Suction Header Valves Valve 1

ADDC GIS Object No:
Valve Type
Valve Diameter (mm)
Condition Rating (1 to 6)

Pump Suction Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

ADDC GIS Object No:
Pipe Material
Suction Side

Pipe Diameter (mm)

Condition Rating (1 to 6)
Flexible Coupling
ADDC GIS Object No:
Flexible Coupling Diameter (mm)
Condition Rating (1 to 6)
Isolation Valve
ADDC GIS Object No:
Isolation Valve Type
Isolation Valve Diameter (mm)
Condition Rating (1 to 6)

Comments LEGEND - Asset Condition Assessment

Description Life Remains Rating
"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
Failed / Derelict Un-useable 6

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Assessment Overview Report
 CONDITION ASSESSMENT - Pipework & Valves (Delivery Side)
Delivery Header Pipework Pipe 1
ADDC GIS Object No:
Pipe Material
Pipe Diameter (mm)
Condition Rating (1 to 6)

Delivery Header Valves Valve 1

ADDC GIS Object No:
Valve Type
Valve Diameter (mm)
Condition Rating (1 to 6)

Pump Delivery Pipework Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

ADDC GIS Object No:
Pipe Material
Pipe Diameter (mm)
Condition Rating (1 to 6)
Flexible Coupling
Delivery Side

ADDC GIS Object No:

Flexible Coupling Diameter (mm)
Condition Rating (1 to 6)
Non-Return Valve
ADDC GIS Object No:
Isolation Valve Type
Isolation Valve Diameter (mm)
Condition Rating (1 to 6)
Isolation Valve
ADDC GIS Object No:
Isolation Valve Type
Isolation Valve Diameter (mm)
Condition Rating (1 to 6)

Comments LEGEND - Asset Condition Assessment

Description Life Remains Rating
"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
Failed / Derelict Un-useable 6

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 Appendix F
Mechanical Assets Assessment Schedules

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 CONDITION ASSESSMENT - Water Pumps
Pump Data Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6
ADDC GIS Object No:
Year of Installation
Purpose / Function
Brand
Type
Model No
Serial No
Impeller Design Size (mm)
Speed (rpm)
Pumping Design Power (kW)
Pump Design Efficiency (%)
Duty Point Flow (l/s)
NPSHR (kPa)
Duty Point Pressure (kPa)

Overall Condition Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

Pump Body
Pump Shaft
Pump Shaft Coupling
Pump Base
Springs / Anti Vib. Mat.
Pump Plinth
Pump Motor

Asset Condition Assessment Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

General Condition
Assessment Schedule
Assessment Parameters
Rating (1 to 6)

Comments LEGEND - Asset Condition Assessment

Description Life Remains Rating
"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
Failed / Derelict Un-useable 6

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations F1
Assessment Overview Report
 CONDITION ASSESSMENT - Other Mechanical Equipment and Systems

Mechanical Equipment Description Comments Asset Condition Assessment

Schedule Parameters Rating
Overhead Crane

Security House Air Conditioning

Pump Room Air Conditioning

Control Room Air Conditioning

Pump Room Ventilation

Other

Comments LEGEND - Asset Condition Assessment

Description Life Remains Rating
"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
Failed/ Derelict Un-Useable 6

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 Appendix G
Electrical Assets Assessment Schedules

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 CONDITION ASSESSMENT - Pump Motors
Motor Data Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6
ADDC GIS Object No:
Year of Installation
Brand
Model No.
Serial No
Speed (rpm)
Average Voltage (V)
Average Current (A)
Total Power (kW)
Overall Power Factor
Insulation at end of PI (MΩ)
IP or Enclosure
Electrical Connection
Soft Start
Hours Run (Hrs)
Cables/ Earthing
Thermal Imaging

Asset Condition Assessment Motor 1 Motor 2 Motor 3 Motor 4 Motor 5 Motor 6

Assessment Schedule
Assessment Parameters
Rating (1 to 6)

Comments LEGEND - Asset Condition Assessment

Motor 1: Description Life Remains Rating
Motor 2: "As New" 100% 1
Motor 3: Good 75% 2
Motor 4: Fair 50% 3
Motor 5: Poor 25% 4
Motor 6: Failure Imminent 0% 5
Failed / Derelict Un-useable 6

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations G1
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 CONDITION ASSESSMENT - Main Switchboard & Motor Control Panels
Main Switchboard LEGEND - Asset Condition Assessment
ADDC GIS Object No: Description Life Rating
Remains
Year of Installation "As New" 100% 1
Clear Labeling? Good 75% 2
Logical Layout? Fair 50% 3
Main Isolator Poor 25% 4
Manufacturer Failure Imminent 0% 5
Type Failed / Derelict Un-useable 6
Rating (A)

Switchboard Test Phases & Links R Y B RY YB BR

Use SB Meters? Voltage (V)
No. Pumps Running Current (A)
Meters Switched/ Individual? Power Factor
Thermal Imaging - Switchboard Comments
Max. Temperature Overall Condition is

Asset Condition Assessment

Assessment Schedule Elect. Equip.
Assessment Parameters A-I
Rating (1 to 6)
Motor Controls Motor Controls Thermal Asset Condition Assessment
Image Schedule Parameters Rating
Manufacturer Motor Control No 1 Elect. Equip. A-I
Type Motor Control No 2 Elect. Equip. A-I
Soft Start ? Motor Control No 3 Elect. Equip. A-I
Controls Functional ? Motor Control No 4 Elect. Equip. A-I
Internal Layout Motor Control No 5 Elect. Equip. A-I
Interlock on Panel ? Motor Control No 6 Elect. Equip. A-I

Comments

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 CONDITION ASSESSMENT - Other Electrical Equipment and Systems
Electrical Equipment Description Comments Asset Condition Assessment
Schedule Parameters Rating
Power Transformer Elect. Equip. A-I
Rating
Pump Station Earthing Elect. Equip. A-I
Neutral / Earth Link --
Resistance (Earth /Neutral) --
Lightning Protection Elect. Equip. A-I
Lightning Protection --
Pump Room Crane Elect. Equip. A-I
Electrics --
Pump Control Panel Elect. Equip. A-I
Clear Mimic (Y/N) --
Fully Operational (Y/N) --
Thermal Imaging (Y/N) --
Power Cabling Elect. Equip. A-I
Main SB to Motors --
Room Lighting Elect. Equip. A-I
Control Room Lighting --
Emergency/ Exit Lighting --
Exterior Site Lighting Elect. Equip. A-I
Exterior Site Lighting --
Fire Alarm System Elect. Equip. A-I
Manufacturer --
Detector Types --

Comments LEGEND - Asset Condition Assessment

Description Life Remains Rating
"As New" 100% 1
Good 75% 2
Fair 50% 3
Poor 25% 4
Failure Imminent 0% 5
Failed / Derelict Un-useable 6

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 Appendix H
Pump Performance and Efficiency
Assessment

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
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 PERFORMANCE ASSESSMENT - Water Pump Duty Point

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

ADDC GIS Object No:
MEASURED - Pump Flow Head (kPa)
PUMP CURVE - Flow Rate (l/s)
MEASURED - Pump Flow Rate (l/s)
MEASURED - Pump Speed (rpm)
CALCULATED - Pump Hydraulic Power (kW)
MEASURED - Pump Motor Power Input (kW)
CALCULATED - Motor-Pump Efficiency (%)
MEASURED - Pump Shut-Off Head (kPa)
PUMP CURVE - Impellor Diameter (mm)

COMMENTS

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations H1
Assessment Overview Report
PERFORMANCE CURVES - Water Pumps

Pump
No. Test Flow Pressure
No. Q (l/s) P (kPa)
1 0 0
2
3
4
P- 01
5
6
7
8

Pump
No. Test Flow Pressure
No. Q (l/s) P (kPa)
1 0 0
2
3
4
P- 02
5
6
7
8

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PERFORMANCE ASSESSMENT - Pump Motors

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

R Y B R Y B R Y B R Y B R Y B R Y B
Voltage (V)
Current (A)
Power Factor
Dielectric Absorption (30/60sec MW)
Polarisation Index (1min/10min MW)
Insulation at End of PI (MΩ)
Average Voltage (V)
Average Current (A)
Overall Power Factor
Power Measured (kW)
Total Power (kVA)
Temperature ºC (Hot = 68ºC)

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 Appendix I
Vibration, Alignment & Noise Assessment

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 TEMPERATURE, NOISE, VIBRATION & ALIGNMENT - Pumps & Motors
Temperature Deg C
Pump Room LEGEND - Asset Condition Assessment
Control Room Description Life Remains Rating
Outside (Ambient) "As New" 100% 1
Good 75% 2
Ambient Noise [dB(A)] Noise Source Fair 50% 3
Pump Room Poor 25% 4
Control Room Failure Imminent 0% 5
Outside (Ambient) Failed / Derelict Un-useable 6

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)
Noise Source

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)  (Hz) V (mm/s)  (Hz) V (mm/s)  (Hz) V (mm/s)  (Hz) V (mm/s)  (Hz) V (mm/s)  (Hz)
Point No 1 = Motor - Top Front Bearing
Point No 2 = Motor - Rear Foot
Point No 3 = Motor - Top of Motor
Point No 4 = Pump - Top Front Bearing
Point No 5 = Pump - Top Rear Bearing
Point No 6 = Pump - Rear Foot
Point No 7 = Pump - Inlet
Point No 8 = Pump - Outlet

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
Linear Displacement - Horizontal
Angular Displacement - Vertical
Linear Displacement - Vertical

Thermal Images

Flexible Couplings Pump-Motor 1 Pump-Motor 2 Pump-Motor 3 Pump-Motor 4 Pump-Motor 5 Pump-Motor 6

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

COMMENTS

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations I1
Assessment Overview Report
VIBRATION SPECTRUM ANALYSIS (Example: – Bida Al Mutawa, Ghayathi)

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations I2
Assessment Overview Report
NOISE SPECTRUM ANALYSIS (Example: – Bida Al Mutawa, Ghayathi)

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Assessment Overview Report
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© GHD Global 2009

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Document Status

Rev Reviewer Approved for Issue

Author
No. Name Signature Name Signature Date

0 C Teske K Skawinski xxxxxxxxxxxxxxxxxx P Rodda xxxxxxxxxxxxxxxxxxx 17 Nov 2009

76/10239/11326 Condition Assessment and Energy Management Survey of ADDC Water Pumping Stations
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