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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?


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?


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:


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:


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

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