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Transcript of Naga Aleki
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1
TSMEGYPT
Compliance Records
for water treatment plants
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Company Name: QUENA Company for water
and waste water .
Plant Name: Naga Eliqy -QUENA
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Inspectors Compliance Summary
Decision and Findings
THE INSPECTION RESULT
We confirm that the management ofNaga Eliqy Water treatment plant
under the lead of Eng. Mohamed Mahmoud Ahmed, within the
inspection of 11/12/2011 and 12/12/2011 has fulfilled the requirements
of TSM (Egypt).
TSM (Egypt) Inspection Team:
Eng. Michael Buckler, Lead Inspector....
Dipl.-Ing.(FH), Holger Gruetzmacher,
Inspector,....Eng. Mohamed Maged,
Inspector
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Inspectors Findings During The Inspection:
H2 - The HR responsibility is not clearly shown in the structure. The
responsibility for HR should preferably be with the plant manager.
H3 - The job descriptions do not state clearly what qualification is needed to fill
the post.
The stated qualification of the OHS manager in the job description does not
comply to the labour law.
H5 - The Assessment is not yet done! The TSM (Egypt) Inspection team
recommends to do the assessment after 9 month plant operation, in December2011 and after that yearly (according to regulations).
H6 - Readings of the raw water flow meter do not comply with the records kept.
(Quaterly report)
H7 - The library should be developed further. O&M documents should be
preferably in arabic (Gas sensor and alarm system).
H10 - Instructions from the daily dosage sheet are not all signed.
OHS4 - The layout is very colorful but does not differentiate between important
information and less important information (landscape)
OHS5 - The emergency plan for power failure is not published. The plant could
not establish if there is an automatic interlock for the grid/generator connection.
OHS10 - The plant could not prove that the gas sensors have been tested and
are in working condition.
The plant failed in the practical exercise of the chlorine leak . (Staff not wearing
the mask properly, staff is unsure of the use of the repair kit, the exercise took
a long time), Training of staff is urgently needed.
OHS11 - To switch the submersible pump on/off, the operator needs to open an
electrical board.
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O3 - The process of informing consumers of interruption of water supply is not
clear. The documents shown did not prove the process explained.
O10 - In close range of the intake are animals and a storage place for construction
debris, what is not acceptable. Signs should be posted to inform the public aboutregulations referring to the intake protection.
M1 - The TSM(Egypt) Inspection Team recognizes the problem of drawings not
been handed to the plants of this type and recognizes as well the effort of the
plant to overcome the problem. Nevertheless the drawing should be completed
in number and improved by using standard signs. (This is a recommendation only)
M4 - The existing asset register in the CMMS should be completed .
M5 - The plant has started applying the maintenance reporting system. The plant
is still under warranty what prevents the staff to apply the system in all details.
The AC should make sure that the implementation of it is done and accompanied
by training.
M7 - The SMPs are only published in one office and need to be distributed to
every workstation. Some stations ( Al2SO4) show signs of lack of Maintenance.
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Contents
HR management
OHS
PART 2
Operations
Maintenance
QA/QC
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TSM Compliance Forms
PART 1 1-1 HR management (W/WWTP)
1-2 OHS (W/WWTP)
PART 2
2-1 Operations (WTP)
2-2 Maintenance (WTP)
2-3 QA/QC (WTP)
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1-1TSM Compliance Forms: HR Management for wtp
H 1
Is there a technical affair responsible of TSM program?
TSM
References:
TSM template H1TSMH1
Guidelines:
A decree for a TSM Technical Affairs Responsible must be issued; he could be
the plant manager or any technical engineer in the plant or outside the plant
as a Technical support manager or O&M sector head he could be responsible
for follow up the program in one plant or more, or planning/construction
supervision
He has the know how to act adequately.
Review decree number and date of approval
Inspectors may discuss the program concept with the TSM responsible.
(TSM(
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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H 2
Is there an organization chart for the plant?
References:
Egyptian code of O&M of wtp/ chapter 8-3 and WWTP chapter7
8-3
.
TSM template Nr. H2
TSMH2
Guidelines:
Organization chart must be developed and approved for the plant according to the
following criteria:
Plant capacity
Plant type(water-wastewater)
Technology
The chart includes name, position and picture of key Positions, (plant manager-
operation managermaintenance managerlaboratory managerHRD manager and
OHS specialist, etc.)
Review the organization chart and its approval date Ensure the matching between key positions and real staff
:
(-)-
-
(
.
Inspectors
Assessment:
The HR responsibility is not clearly shown in the structure. The responsibility for HR
should preferably be with the plant manager.
Compliance
Decision:
Yes
Signature
No
Signature
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H 3
Are there job descriptions comply with the qualification requirements for the
key staffs of the plant?
References:
Egyptian code of O&M of wtp/ chapter 8-3 andwwtp chapter7
8-3
.
TSM template Nr. H3
TSMH3
Guidelines:
Submit job descriptions of key staff which includes plant manager, OHS
specialist, operation manager maintenance manager ,HRD manager and lab
manager, etc. also CVs and the decrees issued to occupy the positions.
Review the job descriptions of the key staff and the decrees issued to occupy
the positions. .
Select on CV and compare to the job requirements as in job description.
Inspector may select one of the job descriptions and discuss the job tasks withthe occupier.
.
.
.
.
Inspectors
Assessment:
The job descriptions do not state clearly what qualification is needed to fill the post.
The stated qualification of the OHS manager in the job description does not comply
to the labour law.
Compliance
Decision:
Yes
Signature
No
Signature
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H 4
Are there instructions showing the levels of authority delegation for key
positions during absence of original occupiers to works staff?
References:
Best practice
Guidelines:
Issue instructions to show the level of authority delegation of the key position
Hold a delegation list including dates, names of actual key staff or the delegates (you
can use a white board and the suitable pens for that purpose).
Review the delegation instructions and delegation approval date.
Inspector may check that delegation instructions match the names appearing in the
delegation board (if applied).
)
)
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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H 5
Is the performance of the plant staff assessed on an annual basis?
References:
Egyptian code of O&M of wtp 8-1 and wwtp chapter7
template Nr H5
8-1
.
Guidelines:
Submit forms of staff assessment (annual or other).
Review the assessment forms and approval date.
(
)
.
Inspectors
Assessment:
The Assessment is not yet done! The TSM (Egypt) Inspection team recommends to
do the assessment after 9 month plant operation, in December 2011 and after that
yearly (according to regulations).
Compliance
Decision:
Yes
Signature
No
Signature
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H 6
Do you develop quarterly plant performance indicators of the plant?
References:
Egyptian O&M WTP Code chapter 10-3 and Requirements of HCWW and EgyptianO&M WWTP Code chapter7
10-3
TSM template Nr. H6
TSMH6
Guidelines:
Submit quarterly performance indicators (HCWW forms), present indicators
graphically for 1 year at least (if possible).
Review the indicators, the inspector may ask interpretation of the indicators
and actions taken.
(
)
( ).
.
Inspectors
Assessment:
Readings of the raw water flow meter do not comply with the records kept.
(Quaterly report)
Compliance
Decision:
Yes
Signature
No
Signature
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H 7
Is there a place where training materials and plant documents are kept?
References:
O&M code of wtp chapter 6-1-10 and Egyptian O&M WWTP Code
chapter4-1-10.
6-1-10
4-1-10.
Guidelines:
The plant have to establish a place to keep all training material, catalogues and
documents as well as codes, standards ,environmental lawsetc. Issue decree
of responsible, borrowing system.
Check the location and responsible decree and the borrow log book.
/
.
.
Inspectors
Assessment:
The library should be developed further. O&M documents should be preferably in
arabic (Gas sensor and alarm system).
Compliance
Decision:
Yes
Signature
No
Signature
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H 8
Do you develop annual training plan for the plant staff and you follow up
implementation centrally?
References:
Egyptian code of O&M of wtp/ chapter 8-1 and Egyptian O&M WWTP Code chapter7-
1-4
8-1
7-1-4
Guidelines:
Submit annual training plan clarifying training needs assessment, training
certificates.
Review training plan.
Review training certificate (internally and externally).
.
.
(
.)
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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H 9
Do you have administration procedures for approving and recording annual
leave, sick leave, and other absences?
References:
Egyptian code of O&M of wtp/wwtp chapter 8-1 and Egyptian O&M WWTP Codechapter7-2
8-1
7-2TSMH9
Guidelines:
Submit a copy of all administrative forms related to work orders and different
vacations and internal orders in addition to vacation request procedures and
other absences with all details in a clear place for all staff.
Check installation of these procedure during site visit.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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H 10
Is there a system in place secured, that staff members have only access to
valid instructions?
References: O&M code of wtp chapter 8-3 and Egyptian O&M WWTP Code chapter4-2 3
2
Guidelines:
Variation of operational instructions due to lab analysis results must be update and
announce for the operators (for wwtp: RAS and WAS rate, DO concentration and
chlorine dose) and for wtp :alum dose, chlorine dose ,frequency of back wash and
sludge drawing off.
Variations also includes the following factors:
Equipments lock-out/tag-out for maintenance and sudden facility upset
Exchanging facility operations
Sudden changes in maintenance plans and facing emergency risks Changes of units operation plan.
In all previous cases, all staff should be notified in written.
Check presented instructions (system).
:
(
)
Inspectors
Assessment:
Instructions from the daily dosage sheet are not all signed.
Compliance
Decision:
Yes
Signature
No
Signature
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1-2TSM Compliance Form: OHS
OHS 1Is the position of OHS specialist / technician in the plant occupied?
/
References:
labour law 12/2003 (ministerial decree of manpower and emigration no 134- article 2):
(If the plant staff exceeds than 50 labour, they have to nominate fulltime specialist
(engineer/chemist) while if it is less than that, they have to nominate fulltime
technician)
12/2003(
)
(
/)
.
Guidelines:
You have to issue internal decree according to the labour number of the plant.
Check the decree and its approval date.
Inspector may discuss the job tasks with the responsible.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 2Is there an OHS committee in the plant?
References: ministerial decree of manpower and emigration no 134- article 3.
3.
Guidelines:
you have to develop a f ile contains the following documents:
Internal decree of OHS committee Establishment.
Monthly meeting logbook, stamped and signed by manpower.
Review the committee organizational decree and date of approval.
Check the monthly record approved from the ministry of manpower and training.
Inspector may discuss the committee decisions and how to follow up and activate its
recommendations.
:
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 3
Do you inform the ministry of manpower about accidents, permanent
disease, occupational diseases and work injures, using their reporting forms?
References:
Ministerial decree of manpower and emigration no 126/2003 article 2. /.
TSM template Nr. OHS 3
TSMOHS 3
Guidelines:
If the staff does not exceed 50 members, the plant has to fill the statistics and
accidents forms and sends it to the man power office of your area every 6 months.
For the bigger plants > 50 members, the 5 forms should be filled in.
Review the forms and ensure its submission to the Man Power office according to the
staff number.
50
.
5
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 4
Do all hazardous areas (confined space, electric switch boards, chlorine
buildingetc have warning signs?
References: Ministerial decree of manpower and emigration no 211/2003
/
TSM template Nr. OHS 4
TSM OHS 4
Guidelines:
Show list of hazardous areas in the plant like:
Sedimentation tanks Aeration tanks Drying beds and thickener - electric switch
boards Chlorine building labs - valves chambers warehouses pump houseetc.
Mark this area with warning signs.
Review the hazardous areas list
Visit to ensure the suitability of warning signs to the hazardous area.
:
- -
-
--
....
Inspectors
Assessment:
The layout is very colorful but does not differentiate between important information
and less important information (landscape)
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 5
Do you have an action plan for all emergency cases (Fire, chlorine leak,
confined space entry for evacuation of injured persons and power cut,
emergency exits
-
)
References:
Ministerial decree of manpower and emigration no 211/2003
/
TSM template no OHS 5..
TSMOHS 5
Guidelines:
You have to develop a plant scenario for emergency cases.
Fire, chlorine leak, confined space entry for evacuation of injured persons, power cut and
emergency exits.
Check the emergency plans to face risks mentioned above.
Make sure that all plans are attached and fixed in the proper areas.
Check emergency exists and routes are located to the plant layout and matching reality. The inspector may discuss one of the staff about his understanding of the plan.
:
1-2-
3- 4-
-5
.
.
.
.
Inspectors
Assessment:
The emergency plan for power failure is not published. The plant could not establish
if there is an automatic interlock for the grid/generator connection.
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 6
Do you have a plan to secure the plant from potential risks approved from the
Civil Protection authorities
References:
Ministerial decree of manpower and emigration no 211 /2003
211/2003
TSMOHS 6
Guidelines:
Submit a plan to face potential risks approved from the Civil Protection authorities
that includes for example:
List number of extinguishers, types, capacity, their locations on
general layout expiry date hazardous areas routine check plan training plan for
25% of the plant staff on civil defense and rescue tasks.
Review the plant security plan approved by civil defense.
Inspector may check the expiry date of the extinguishers and the training plan for 25%of the staff on civil defense tasks
:
-
-
25% -
...
.
25%
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 7
Is there an annually routine medical check up for all of the staff?
References: According to ministerial decree of manpower and emigration no 180 /2003
/
Guidelines:
You have to contact health office of your area for annual medical check up and keep a
file for all staff; you have to record this medical check up in the monthly OHS
committee meeting.
Review the medical check up lists and its frequency.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 8
Are there sanitary utilities for personal in the plant?
References: Ministerial decree of manpower and emigration no 211 /2003
/
Guidelines:
You have to establish WC-Shower room for washing and changing labours clothes.
Show warning signs to prevent food and beverage in places where there is a direct
contact with waste water
Prepare a food court with a WC to wash hands before eating.
Review the availability of WC, showers, space for changing labours clothes and food
court.
.
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 9
Do all plant operating staff have appropriate personal protection equipment
(PPE)?
References:
Ministerial decree of manpower and training no 211 /2003
211/2003
Guidelines:
Gloves, overalls, safety shoes, goggles, safety helmet must be submitted to every
labor based on their personal responsibility to deal with: mechanical, electrical,
chemical, biological, confined space Hazards
Prepare a cabinet for each staff member to keep their PPE after work shifts.
Review the personal protection equipment list and their storage areas
(
)
) (
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 10
Is there safety equipment ( gas detectors, breathing apparatus, safety ropes, floats
. to deal with risk situations )chlorine leak, confined space entry,.) is it regularly
inspected and the labours get a training on using it?
.
References:
Ministerial decree of manpower and training no 211 /2003
211/2003
Guidelines:
Attach and fix the safety equipments in relevant places.
Submit routine check documents
Submit staff training certificates on the equipment use.
Make sure that safety equipments are fixed in relevant places.
Inspector may check staff skills to use any equipment practically.
Review routine check documents
.
.
.
.
.
.
Inspectors
Assessment:
The plant could not prove that the gas sensors have been tested and are in working
condition.
The plant failed in the practical exercise of the chlorine leak . (Staff not wearing the
mask properly, staff is unsure of the use of the repair kit, the exercise took a longtime), Training of staff is urgently needed.
Compliance
Decision:
Yes
Signature
No
Signature
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OHS 11
Is mechanical and electrical equipment properly contained and guarded to
prevent injury to personnel?
References:
Labour law no 12/2003 chapter 5- clause 224
/
Guidelines:
Secure the mechanical and electrical equipment with wire screens,
handrails, coupling guards, etc. to protect the staff against accidents or
injuries.
This includes screens, intake, pumps, water works and ladders.
Check that the labors are secured in doing their works during site visit.
.
:--
-
-.
.
Inspectors
Assessment:
To switch the submersible pump on/off, the operator needs to open an electrical
board.
Compliance
Decision:
Yes
Signature
No
Signature
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2-1 TSM Compliance Form: Operation of water treatment plants (WTP)
:
O 1
Is there a routine program for the visual inspection of the plant units for
checking that is it functioning properly?
References:
O&M Egyptian code of WWTP- chapter 5
TSM template Nr. O 1
TSMO1
Guidelines:
One of the items of routine operation plan is checklists that the equipment and treatment
process are functioning correctly. It is checked by the operators so ,You have to submit check
lists( includes the following min requirement):
Visual inspection of M&EL equipment.
Visual inspection of treatment process of all treatment units
Fix the Visual inspection instructions in certain areas in the plant
Submit the form of reporting an upset or an operation as an outcome of the
inspections program.
Review the visual inspection list
Inspector may make sure that staff understands the program during the visit.
.
:
.
Inspectors
Assessment:
ComplianceDecision:
Yes
Signature
No
Signature
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O 2Are chemical dose rates in the water recorded and the records kept for 1year?
References: Best practices
Guidelines:
All consumable / chemicals (chlorine, polymers) have to be recorded and kept for at
least 1 year (manual /electronic).
Submit a summarized graph to illustrate the amount of treated wastewater against
consumable chlorine for the last 12 months.
Review the records and the data for at least one year
.
12.
12
(
)
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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O 3
Are the consumers informed before planned interruption of water supply?
References: HCWW instructions.
Guidelines:
You have to coordinate with the Costumers service center of your company (hot line
form) and inform them with the planned time for any interruption either because of
emergency maintenance activities or because of the consequences of main power cut
off.
Show forms used in the last interruptions
Inspect presented documents
(
)
.
Inspectors
Assessment:
The process of informing consumers of interruption of water supply is not clear. The
documents shown did not prove the process explained.
Compliance
Decision:
Yes
Signature
No
Signature
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O 4Are there records of the operational data of each of the operation processes?
References: O&M Egyptian code of wtp chapter 10
.
Guidelines:
You have to develop log sheets, records for each operational process.
Operational data include frequency backwash, sludge quantity, operating
hours of pumps, etc.
Check the operation log sheets to make sure of accurate records and manager
signature.
....
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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O 5
Do the activities in each operational process follow the Standard Operational
Procedure?
References:
O&M Egyptian code of wtp chapter 10
TSM template Nr. O 5
5
Guidelines:
You have to develop SOP of all plant operation procedures, displayed in appropriate
place to be guidance for the operators.
Present also work order and fault report as an output of this program.
Review the standard operational process during the visit
Inspector may ask some staff members to measure their understanding.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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O 6
Are the wastes and sludge disposed according to laws and regulations?
References: Egyptian environmental law no 48/1982and law 4/1994 article 2 48/1982
4/19942
Guidelines:
You have to dispose all wastes (sludge-backwash screening solids- etc) out of water
table or to the drying beds or sludge thickener.
Check how wastes (back wash water and sludge) are disposed.
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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O 7
Is a report including calculation of the O&M cost of treatment developed
monthly?
References:
O&M Egyptian code of wtp chapter 6-2-7-6
6-2-7-6
TSMO7
Guidelines:
Develop monthly report including cost of treatment of 1 m3.
Use the plant performance indicators in developing the needed.
Review the monthly report.
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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O 8Are there operation plan for the plant?
References: O&M Egyptian code of water treatment plants chapter 2-2
2-2
Guidelines:
Operational plan includes the following parameters:
Operation schedule of equipment (in service and standby units).
Record of flow for inlet and outlet and measure losses.
Identify daily alum and chlorine dose
Timing of Filters wash according to pressure difference in each filter.
Review the submitted operational plan
Inspector may discuss with any of staff members to make sure they understand the
plan
:
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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O 9Are the lab results communicated to the operation department?
References: O&M Egyptian code of WTPchapter 2
Guidelines:
You have to coordinate with the lab to control the operational process(alum dose -
chlorine dose-frequency of backwash- --etc).
Develop daily sheet (or other system) for at least chemical doses. It must be signed
mutually by shift engineer and shift chemist.
Review the key operational factors list
Inspector might discuss with the operation and labs manager to know the labs role incontrolling operation condition.
.
( )(
)
.
( )
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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O 10
Are all needed precautions realized to protect the raw water at the intake
from contamination?
References: Ministry of Health decree 458/2007 ,301/1995 and 27/1978
458/2007301199527
Guidelines:
Install barrier to protect water intake against any illegal discharge or hazard (oil and grease
spill-raw material or chemical spill).
Develop a routine program for analysis and monitoring of quality of water intake.
Coordinate also with (MOI) to plan dredging of the water body course closer to the intake
to avoid influence of the raw water.
Protect the intake with (e.g.) mesh, fence, and floats.
Monitor application of decree of (MOH) No 301/1995 and 27/1978 and prevent any
building at a deep of 50 m of the intake restricted area and upstream of the water intakewith 500 MT and downstream of the water intake with 200 MT.
Supply the materials and the needed substances (sponge sheets burlap roll) to deal with
emergency pollutants
Check precautions on site visit of the water intake.
( )
.
. 301/1995
50
500
200 .
(
-
...
)
.
Inspectors
Assessment:
In close range of the intake are animals and a storage place for construction debris,
what is not acceptable. Signs should be posted to inform the public about
regulations referring to the intake protection.
Compliance
Decision:
Yes
Signature
No
Signature
-
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2-2 TSM Compliance Form: Maintenance of WTP
M 1Are the basic drawings and documents of the plant available?
References:
O&M Egyptian code of wtp chapter 6-1-10 --
Guidelines:
Min requirement are :
Plant Lay out
single line diagrams
process flow
chemicals delivery system High Voltage/Low Voltage distribution Systems
O&M documents
Check the mentioned documents.
:
.
Inspectors
Assessment:
The TSM(Egypt) Inspection Team recognizes the problem of drawings not
been handed to the plants of this type and recognizes as well the effort of
the plant to overcome the problem. Nevertheless the drawing should be
completed in number and improved by using standard signs. (This is a
recommendation only)
Compliance
Decision:
Yes
Signature
No
Signature
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M2
Is the key process monitoring instruments maintained and/or calibrated on a
regular basis?
References: O&M Egyptian code of WTP chapter 2-2-2, 2-3-1-6 -----
Guidelines:
This question refers to mechanical, electrical equipment or electronic devices showing
water quality, water level, pressure, flow, voltage, current, frequency or chemical
dosing rates .it also include all actions for quality measurements (incl. calibration)
Submit a list of monitoring instruments you have, the actions for calibration,
certificates of approved calibration and calibration methods. Calibration should be
performed in specialized companies
Check the instruments list
Check the process of calibration and the certificates
Check the proper functioning of some instruments
) . .)
.
.
.
InspectorsAssessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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M3
Is there a system for inventory of material and spare parts available, which
shows their quantity, types, and identification cards for each
equipment/spare part considering the correct storage concepts?
/
References:
O&M Egyptian code of wwtp chapter 4 .
Guidelines:
Present documents (register) showing which parts and materials available and in what
quantity?
Computerized or manual.
Attach an identification card to the store components considering the correct storing
criteria; use the recommended code by the Holding company.
Review the inventory system during the visit.
(
)
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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M 4
Do the electro-mechanical maintenance works comply with the maintenance
management process?
References: O&M Egyptian code of wtp chapter 6
TSM template M4
TSMM4
Guidelines:
That includes planned, corrective and overall maintenance, work history and reports
Present (manual or automatic) maintenance system of routine maintenance activities,
and work orders and fault report as an output of system implementation.
Check maintenance schedule (auto/manual) and select one of the work order or fault
report to insure program implementation.
.
( )
.
()
.
Inspectors
Assessment:
The existing asset register in the CMMS should be completed .
Compliance
Decision:
Yes
Signature
No
Signature
-
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M 5
Does the maintenance report include the reasons for failure, proposed
corrective works and the needed budget?
References: O&M Egyptian code of wtp chapter 6
Guidelines:
Present fault report, work order include fault analysis of faults, cost of repair and
repair actions.
Select one of the work orders randomly and make sure that failure reasons are
documented, budget and the needed actions for repair.
Visit one of the buildings and ask for operating one of the stand by equipment.
.
.
.
Inspectors
Assessment:
The plant has started applying the maintenance reporting system. The plant is
still under warranty what prevents the staff to apply the system in all details.
The AC should make sure that the implementation of it is done and
accompanied by training.
Compliance
Decision:
Yes
Signature
No
Signature
-
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M 6
Are there rehabilitation /maintenance plan of civil works of all structures
)process structures, civil works, etc. reported regularly to the companys
management?
/
..
)
References:
O&M Egyptian code of wtp chapter 7
Guidelines:
Rehabilitation needs /maintenance plan of civil works of the above units Includes
tanks, reservoirs, chambers, administration ancillary buildings, landscaped areas,
irrigation, networks, roads, sidewalk and fences etc
Check the rehabilitation/maintenance plan and notification of the company with the
needs.
During site visit, check landscape, fences, leaks from the treatment units and .etc.
/
.
.
...
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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M 7
Do the activities in each maintenance process follow the Standard
Maintenance Procedure?
References:
O&M Egyptian code of wtp chapter 6
TSM template Nr. M7
TSMM7
Guidelines:
Submit the SMP to all the components of the treatment plant.
Instructions to available and visible to relevant staff.
Review the standard maintenance procedures(SMP) are displayed inside every
compartment or treatment unit during the site visit
Inspector might ask one of the staff members to check his understanding.
.
.
Inspectors
Assessment:
The SMPs are only published in one office and need to be distributed to every
workstation. Some stations ( Al2SO4) show signs of lack of Maintenance.
Compliance
Decision:
Yes
Signature
No
Signature
-
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2-3 Compliance Form: QA/QC (Water Treatment Plant)
Q 1
Do treatment chemicals (alum) comply with the requirements of the relevant
Egyptian standard specifications?
References:
(Egyptian standards of alum specification)
(
)
TSM template Nr. Q1
TSMQ1
Guidelines:
Submit the standard specifications for the alum and the results of the samples analysisprovided to the plant
Review the presented documents. Compare results of sample analyses with standard
specifications.
.
.
.
InspectorsAssessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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Q 2
Is the water analyzed regularly at the inlet, outlet and after relevant process
steps complying the Egyptian code?
References: O&M Egyptian code for WTP chapter 5-1-1&5-3 ---Q2 TSM
Guidelines:
Develop sampling program includes the following criteria as a min requirement:
Sampling locations (inside and outside of the plant) and type.
Sampling frequency
Sampling reservation methods.
Number of samples.
Analytical standard.
Locate the sampling points on the plant layout.
Develop a list of the total monthly samples (conforming non-conforming and the reasons)
Attach and fix the plant layout with the above data
Check the plant layout signed with above mentioned data
Check the samples sheet (comply/non comply)
Inspector may discuss the results and sampling system to make sure understanding the program
.
:
(
)
(
-)
.
(
)
.
.
(
)
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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Q 3
Are the lab instruments and glassware are calibrated and maintained
periodically?
References: O&M Egyptian code for WTP chapter 5-2 -
Guidelines:
Prepare a list of instruments to be calibrated.
Calibrate instruments internally by standard solution (or based on manufacturer
instructions)
Keep calibration certification with the instrument logbook
Outside calibration done only for all types of thermometers and other devices in national
institute of calibration or any other specialized companies.
Keep a piece of calibrated glassware and use it to calibrate the whole glassware in annual
base.
Review calibration certificates
Inspector may discuss the process of calibration during lab visit. Check the list of instruments that need routine calibration
.
(
)
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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Q 4Are there identification cart attached to all chemicals and instruments?
(
References: Good practices TSM template Nr. Q4
TSMQ4
Guidelines:
Develop, attach and fix ID card for all chemicals and instruments.
Check IDs.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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Q 5Are raw and produced water analyses results recorded daily and archived?
References:
O&M code of wtp chapter 10
Guidelines:
Keep daily lab data records for at least 1 year.
Check daily data and is kept for one year at least.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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6Q
Are the analyses results, done by other inspectors (Ministry of Health,
Holding Company and Regulator) are kept and used on the plants level?
References:
Instructions of HCWW
Guidelines:
Keep last analyses data of any monitoring entities.
Check analyses reports of other regulators. Compare with plant results.
Inspectors may discuss in case of conflict with plant results to know remedial actions
taken.
.
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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Q 7Do you havea log book for each lab instrument?
References:
O&M Egyptian code of wtp chapter 5-2
-
TSM template Nr. Q7
TSMQ 7
Guidelines:
Prepare a log book for each lab instrument including requested data.
Check log books during lab visit. Check data recorded. Signing of lab manager.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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8QIs there a registered book for all chemicals, standard solutions and glassware?
References: GPL O&M Egyptian code of wtp chapter 5
Guidelines:
Develop an inventory of all chemicals, buffer solutions and glassware Identify at least
size, quantities and expire date.
Check the inventory list (book). Data Recorded. Discuss to prove reliability.
()
.
/
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
-
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Q 9Is the filter media inspected regularly against mud ball
)
References:
O&M Egyptian code of WTP chapter 2-4-5-2
---
TSM template Nr. Q9
TSMQ9
Guidelines:
Test sample of filter media for mud ball content.
Present test results and action in case of detecting mud balls.
Check results of analyses in case of mud balls discovered by lab analyses.
(
.)
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature
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Q 10
Is there a safety plan to protect chemists against lab common incidences?
References: Ministerial decree of manpower and immigration no 234/2003
/
TSM template NO Q10
TSMQ10
Guidelines:
Develop a plan to protect the staff against common incidences
Submit a copy of your plan includes:
Chemical spill
Fires
Chemicals burst.
Protection of the staff from chemicals fumes.
Safety guide lines and warning signs.
Storage of chemicals in a safe way
Fume hood cupboard , air ventilators , eye wash and fire extinguishers, etc Fix the plans in clear places
Fix and hang fire extinguishers
:
- - -
-
- -
...
-
-
.
.
Inspectors
Assessment:
Compliance
Decision:
Yes
Signature
No
Signature