Plant Operation Quality Assurance

Procedure

Document Revision and Approval

Developer Jahangir Zafar Shift Engineer 23-Feb-2012

Reviewer Rafi Ahmed Operation Manager 23-Feb-2012

Approver Sunil Kumar Vellat Plant Manager 25-Feb-2012

Name Title Date Signature

Revision Date Description

00 23-Feb -2012 SIWEP-Plant Operation Quality Control Procedure

Proc. No: NE/OPR/SP-011
Proc Title: Plant Operational Quality Control Procedure

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 Plant Operation Quality Assurance Procedure

Table of Contents

1. Purpose....................................................................................................................................................3
2. Scope........................................................................................................................................................3
3. Roles and Responsibilities........................................................................................................................3
4. Equipment/Software................................................................................................................................3
5. Terminology.............................................................................................................................................3
6. Procedure.................................................................................................................................................5
7. Records..................................................................................................................................................10
8. Legal Requirements and References......................................................................................................11

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 Plant Operation Quality Assurance Procedure

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 Plant Operation Quality Assurance Procedure

1. Purpose

To carry out and assure operational process and product water quality in order to meet the
customer requirements as agreed in contract and to fulfill the statutory and regulatory
requirements.

2. Scope

The scope of this operational quality assurance procedure includes the implementation of
policies and procedures followed by NOMAC SIWEP. Quality Assurance Procedure covers the
process and environmental monitoring and analysis at various stages of SIWEP operation.

3. Roles and Responsibilities

3.1 The Plant Manager

Responsible for all activities of SIWEP related to operation departments, Responsible for the
implementation of this procedure.

3.2 Operation Manager

Reporting to plant manager to all activities in the operation department and maintain the plant
availability as per the contractual requirements, Responsible for the implementation of this
plan.

3.3 Process Engineer

Responsible for evaluating the performance and optimizing of RO plant.

3.4 Shift Charge Engineer

Responsible for safe operation and shutdown of the plant, take appropriate action in case of
emergency, creation of PTW.

3.5 Senior Chemist

Plan, program, coordinate, direct, and evaluate laboratory activities in order to ensure adequate
administration of material and financial resources.

3.6 Shift Chemist

Reporting to Senior Chemist, SCE and process engineer regarding keeping the water quality of
various stages of process within limits, conducting in-process and final product inspection.

4. Equipment/Software

4.1 SAP / DCS/Toray Trak

5. Terminology

Accuracy
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 Plant Operation Quality Assurance Procedure

The closeness of agreement between the measured value and the accepted, “true”, or
reference value.

Audit

A systematic, independent and documented process for obtaining evidence and

evaluating its objectively to determine the extent to which agreed criteria are fulfilled

Client

An entity (customer, agency, company, person, etc.) who receives a test result obtained
according to specified requirement.

Controlled Document

A document that is subjected to controls to ensure that the same version of the document and
any revisions are held by or available to all personnel to whom the document is applicable

Document:

A written policy, procedure, or work instruction which defines what people do and how to do it.
Documents should be distinguished from records which are data and/or information acquired by
the laboratory.

Inspection

Conformity evaluation by observation and judgment accompanied by measurement, testing or

gauging.

Product

Result of a set of interrelated or interacting activities which transforms inputs into outputs.

Range

The range of an analytical procedure is the interval the upper and lower concentration
(amounts) of analyst in the sample (including these concentrations) for which it has been
demonstrate that the analytical procedure has a suitable level of uncertainty.

Records & Forms

Refer to the document which is a supporting evidence for the effective operation of the IMS.

Sample

Any material brought into the laboratory for analysis.

Specificity

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 Plant Operation Quality Assurance Procedure

The ability of a method to respond exclusively to the target analyst and not to any degrading,
impurity, or other component of the matrix (Official Methods of Analysis of AOAC
INTERNATIONAL)

Work Instruction

Refers to the specific method or activity to be carried out and determine the acceptable
standard for the service.

Abbreviation:

AR : Analytical Reagent grade

CCB : Continuing Calibration Blank
CCV : Continuing Calibration Verification
CA : Corrective Action
DAR : Data Analysis Report
DQO : Data Quality Objectives
IWEP: Independent Water Expansion Project
IWWTP: Industrial Waste water Treatment Plant
OM: Operation Manager
PE: Process Engineer
PT : Proficiency Testing
PM: Plant Manager
PLC: Programmable Logic Control
QA : Quality Assurance
QAPP : Quality Assurance Project Plan
QC : Quality Control
QMP : Quality Management Plan
SC: Shift Chemist
SCE: Shift Charge Engineer
SAP : Sampling and Analysis Plan
SOP : Standard Operating Procedure

6. Procedure

6.1 Process Map

Attached the following diagrams:

I. Process flow diagram (W07005-XG07-GD-464001).

II. Quality Inspection Flow Chart for Pretreatment system (NE/QAC/PN-001/CH-001).
III. Quality Inspection Flow Chart for RO membranes (NE/QAC/PN-001/CH-002).
IV. Quality Inspection Flow Chart for final product water (NE/QAC/PN-001/CH-003).
V. Quality Inspection Flow Chart for IWWT Plant (NE/QAC/PN-001/CH-004).
VI. Quality Inspection Flow Chart for Remineralization Plant (NE/QAC/PN-001/CH-005).
VII. Quality Inspection Flow Chart for Chlorine Dioxide Plant (NE/QAC/PN-001/CH-006).
VIII.Quality Inspection Flow Chart for CO2 Dioxide Plant (NE/QAC/PN-001/CH-007).
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 Plant Operation Quality Assurance Procedure

IX. Quality Inspection Flow Chart for Bio-treatment Plant (NE/QAC/PN-001/CH-008)

6.2 Plant Operational Monitoring:

Shuaiba IWEP Operation Department has developed a system of operational activities that
should be followed for operating the plant in safe manner and with in the design parameters
limitation. The performance of the plant being monitored by process engineer as per attached
operations procedure and work instructions.

6.2.1 List Of Operational Standard Procedure/ Work Instructions

Document No. Procedure/ Work Instruction

NE/OPR/SP-001 Plant Operational Control Procedure

NE/OPF/SP-005 Performance Monitoring Procedure
NE/OPR/SP-001/WI-01 Operational Work Instruction for Trash Rack Auto Operation
NE/OPR/SP-001/WI-02 Operational Instruction for Trash Rack Manual
NE/OPR/SP-001/WI-03 Operational Work Instruction for Travelling Band Screen Auto Operation
NE/OPR/SP-001/WI-04 Operational Work Instruction for Travelling Band Screen Manual Operation
NE/OPR/SP-001/WI-05 Operational Work Instruction for Trash Raking Machine Cyclic Operation
NE/OPR/SP-001/WI-06 Operational Work Instruction for Start Up of Pretreatment System
NE/OPR/SP-001/WI-07 Operational Instruction for Shutdown of Pretreatment System
NE/OPR/SP-001/WI-08 Operational Work Instruction for Backwash of DMF System
NE/OPR/SP-001/WI-09 Operational Work Instruction for Dirty Wash Water System
NE/OPR/SP-001/WI-10 Operational Work Instruction for Neutralization System
NE/OPR/SP-001/WI-11 Operational Work Instruction for Start Up of 1st Pass RO System
NE/OPR/SP-001/WI-12 Operational Work Instruction for Shutdown of 1st Pass System
NE/OPR/SP-001/WI-13 Operational Work Instruction for Flushing Procedure of 1st Pass RO System
NE/OPR/SP-001/WI-14 Operational Work Instruction for Startup of 2nd Pass RO System
NE/OPR/SP-001/WI-15 Operational Work Instruction for Shutdown of 2nd Pass RO System
NE/OPR/SP-001/WI-16 Operational Work Instruction for Emergency Flushing
NE/OPR/SP-001/WI-17 Operational Work Instruction for Cleaning In Place of RO System
NE/OPR/SP-001/WI-18 Operational Work Instruction for Lime Silo Recharging by Truck Loading
Operational Work Instruction for Lime Silo Recharging by Automatic Bag
NE/OPR/SP-001/WI-19
Splitter Pneumatic Loading
NE/OPR/SP-001/WI-20 Operational Work Instruction for Lime Milk Preparation and Dosing
NE/OPR/SP-001/WI-21 Operational Work Instruction for Sludge Removal
NE/OPR/SP-001/WI-22 Operational Work Instruction for Lime Milk Saturator Normal Operation
NE/OPR/SP-001/WI-23 Operational Work Instruction for CO2 Plant Pre Start Checks
NE/OPR/SP-001/WI-24 Operational Work Instruction for CO2 Plant Start Up
NE/OPR/SP-001/WI-25 Operational Work Instruction for CO2 Plant Shut Down
NE/OPR/SP-001/WI-26 Operational Work Instruction for ClO2 Plant Start Up
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 Plant Operation Quality Assurance Procedure

NE/OPR/SP-001/WI-27 Operational Work Instruction for ClO2 Plant Shutdown

NE/OPR/SP-001/WI-28 Operational Work Instruction for Industrial Waste Water Treatment Plant
NE/OPR/SP-001/WI-29 Operational Work Instruction for Shock Dosing Chlorination

6.3 Quality inspection and test planning

Shuaiba IWEP Operations Department developed a system of bringing quality inspection of

paramount importance. The Standard Operational Procedure-Work instructions will be a guiding
tool in implementing quality assurance and quality testing procedures. The list of standards is
attached with the procedure.

6.4 In-process Quality assurance process

The In-process Quality assurance composed of all the materials which are intended for in
process quality checking and testing generally done in the laboratory and monitoring of process
parameters in the field/ DCS. Following analysis are carried out:

6.4.1 Pre-treatment Process Monitoring

 Sea water quality monitoring: sampling from seawater is taken once a month from the
intake area, list of parameters to be inspected and their limits shown in the sea water
analysis sheet (NE/QAC/PN-001/FM-008).

 DMF/CF outlet water quality monitoring: SDI of DMF/CF outlet water is done three
times per day; in case of close monitoring for DMF outlet water quality, sampling will be
done twice a shift, , the results are recorded in Pretreatment water analysis result sheet.
(NE/QAC/PN-001/FM-002).

6.4.2 RO Process Monitoring

 First/Concentrate quality monitoring: Checking of the conductivity, pH for first pass

feed/concentrate water is done once a day, the results are recorded in SWRO feed
water result sheet (NE/QAC/PN-001/FM-003).

 Second pass feed quality monitoring: pH, temperature and conductivity of second pass
feed water is inspected three times a day, the results are recorded in BWRO feed water
result sheet (NE/QAC/PN-001/FM-004).

 First/Second pass Permeate water analysis: The permeate conductivity for first pass will
be checked once a day , if the Conductivity exceeds the limit of 500 us/cm , the
conductivity profile should be carried out for each vessel. The results of Permeate
conductivity will be recorded in (NE/QAC/PN-001/FM-022 and FM-023) and Profile
results should be recorded in (NE/QAC/PN-001/FM-012 and FM-013 )

6.4.3 Final Product Water Quality Monitoring

 Permeate water quality monitoring: permeate water quality is checked once a shift (08
hrs), the results are recorded in daily water analysis reports (NE/QAC/PN-
001/FM-023).

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 Plant Operation Quality Assurance Procedure

 Potable water quality monitoring: Potable water is the final product of RO plant,
is being checked thrice in a day in case of any non conformance the frequency of
monitoring increased as per process requirements, the results are recorded in daily
water analysis report (NE/QAC/PN-001/FM-001).

6.4.4 Auxiliary Plants Monitoring

 In-process inspection and monitoring of Re-mineralization plant, Carbon di oxide

generation plant will be done thrice a day, the results are recorded in Daily Laboratory
report (NE/QAC/PN-001/FM-021 and FM-006).

 In-process and effluent monitoring of Industrial waste water treatment plant:

Analysis of effluent water will be conducted once in a day for pH and TSS. The results are
recorded in Daily IWWT Effluent water analysis sheet (NE/QAC/PN-001/FM-007). The
complete analysis of IWWT effluent water sample should be carried out on monthly
basis.

6.5 Plant Performance Monitoring

 Data normalization for SWRO trains will be carried out weekly and the results are
recorded in (NE/QAC/PN-001/CH-011), the normalization graphs will be recorded
(NE/QAC/PN-001/CH-012).

 Data normalization for BWRO trains will be carried out monthly and the results are
recorded in (NE/QAC/PN-001/CH-013), the normalization graphs will be recorded
(NE/QAC/PN-001/CH-014).

 Performance of membrane is to be carried out when required on membrane test skid

and the results will be recorded on (NE/QAC/SP-010/FM-001).

6.6 Operational Quality Control Tests

NOMAC IWEP will carry out various analyses of water, effluents/waste water, for specific
purposes. Testing and analysis followed the worldwide accredited ASTM Procedures, Hach
Procedures and Standard Test Method for Water and Wastewater.

6.6.1 List Of Laboratory Standard Work Instruction

Document No Document Title

NEQACPN001WI00
1 Work Instruction for the Determination of Alkalinity in Water
NEQACPN001WI00
2 Work Instruction for the determination Of BOD in water
NEQACPN001WI00
3 Work Instruction for the Determination of Boron in Water
NEQACPN001WI00
4 Work Instruction for the Determination of Calcium in Water

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NEQACPN001WI00
5 Work Instruction for the Determination of Chloride in Water
NEQACPN001WI00
6 Work Instruction for the Determination Of Copper In Water
NEQACPN001WI00
7 Work Instruction for the Determination Of Color In Water
NEQACPN001WI00
8 Work Instruction for the Determination of Iron in Water
NEQACPN001WI00
9 Work Instruction for the Determination Of Floatables in Water
NEQACPN001WI01
0 Work Instruction for the Determination of COD in Water
NEQACPN001WI01
1 Work Instruction for the Determination of Conductivity of Water
NEQACPN001WI01
2 Work Instruction for the Determination of Calcium and Magnesium in Water
NEQACPN001WI01
3 Work Instruction for the Determination of Langelier Saturation index (LSI)
NEQACPN001WI01
4 Work Instruction for the Determination of Sulfate in Water
NEQACPN001WI01
5 Work Instruction for the Determination of Chlorine Dioxide in Water
NEQACPN001WI01
6 Work Instruction for the Determination of pH of Water
NEQACPN001WI01
8 Work Instruction for the Determination of SDI of Water
NEQACPN001WI01
9 Work Instruction for the Determination of UV Organics in Water
NEQACPN001WI02
0 Work Instruction for the Determination of Bacteria in Water
NEQACPN001WI02
1 Work Instruction for the Determination of Aluminum in Water
NEQACPN001WI02
4 Work Instruction for the Determination of Zinc in Water
NEQACPN001WI02
5 Work Instruction for the Determination of Chlorine Dioxide in Water
NEQACPN001WI02 Work Instruction for the Determination of Specific gravity of Industrial
6 Chemicals
NEQACPN001WI02
9 Work Instruction for the Determination of Sulfuric Acid Purity
NEQACPN001WI03
0 Work Instruction for the Determination of Sodium Carbonate Purity
NEQACPN001WI03
3 Work Instruction for the Determination of Ferric Chloride Purity
NEQACPN001WI03
4 Work Instruction for the Determination of Hydrated Lime Purity
NEQACPN001WI03
5 Work Instruction for the Determination of Poly Aluminium Chloride Purity
NEQACPN001WI03
9 SIWEP - RO Calibration Work Instructions For Laboratory Instruments

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NEQACPN001WI04
0 Work Instruction for the Calibration of pH Meters
NEQACPN001WI04
1 Work Instruction for the Calibration of Turbidity Meters

6.6.2 List Of Laboratory Standard Procedures

Document Number
Document Title
NEQACSP001 Industrial Chemicals Handling Procedure
NEQACSP002 Chemical Spillage Control Procedure
NEQACSP004 Water Analysis Guideline Procedure
NEQACSP005 Water Sample Digestion Procedure
NEQACSP006 Laboratory Waste Management Procedure
NEQACSP007 Water Sampling Procedure
NEQACSP008 Industrial Chemicals Sampling Procedure
NEQACSP009 Waste Water Sampling Procedure
NEQACSP010 Membrane Testing Skid Procedure

6.7 Release of product

Permeate water is treated in the potabilization plant for production of potable water. SIWEP
Potabilization plant is equipped with on-line analyzers as well as there is a set of on-line
analyzers at the interface point for determining and maintaining potable water within the
specified limits as desired by the customer. These instrument analyzers are to be in good
working conditions, calibration must be done regularly, and analyzers results must match and
correlate with the actual laboratory analysis results.

Any abnormalities and out of range results are immediately informed to Operation Group for
necessary actions, likewise coordinating the concern departments and people for some tasks to
be quickly accomplished. The potable water quality must match to the guaranteed water quality
(Gulf Standard No.149/2000/Standardization and Meteorology Organization for GCC countries /
Appendix-19-Water Quality Specification of Water Purchase Agreement).

6.8 Operational Quality Reports

Any quality reports related to operational chemical department and the laboratory are
compiled in
Hardcopies, either by compilation of log sheets or by logbooks, some are maintained in
soft copies for easy tracking. Reports which have been made by the shift chemists will
be directly forwarded senior chemist and after his review forwarded to operation
department.

Log sheets, logbooks, and some special analysis related to quality monitoring, correlation of
tests are compiled for future references.

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 Plant Operation Quality Assurance Procedure

Some in-Process inspection and final product inspection results are recorded in QM module in
SAP by shift chemist after that it should be released by senior chemist.

7. Records

Retention
Record Number Record Title Responsibility
Period

NEOPRSP001LS001 Field Log sheet of Cartridge Filter System Process Engineer 5 Years

NEOPRSP001LS002 Field Log sheet of ClO2 Plant Process Engineer 5 Years

NEOPRSP001LS003 Field Log sheet of CO2 Plant Process Engineer 5 Years

NEOPRSP001LS004 Field Log sheet of Sea Water Supply System Process Engineer 5 Years

NEOPRSP001LS005 CCR Log sheet for SWRO & BWRO Trains Process Engineer 5 Years

NEOPFSP005FM001 Trip Report Shift Engineer 5 Years

NEOPFSP005FM002 Field Log Sheet of BWRO Permeate Pressure Process Engineer 5 Years

NEOPFSP005FM003 Trip Notification Report Shift Engineer 5 Years

NEOPRSP001LS002 Field Log sheet of ClO2 Plant Process Engineer 5 Years

NEOPRSP001LS003 Field Log sheet of CO2 Plant Process Engineer 5 Years

Senior Chemist/Shift
5 Years
NEQACPN001FM001 Potable Water Analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM002 Pre Traeatment Water Analysis report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM003 SWRO Waterr Analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM004 BWRO Feed Water analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM005 BWRO Permeate Water Analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM006 Carbon Dioxide Plant Analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM007 IWWT Plant Effluent Water Analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM008 Sea Water Analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM009 IWWT Plant Effluent Water Analysis Report Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM010 Shock Dose Chlorination Result Sheett Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM011 Microbiological Analysis Report Chemist
NEQACPN001FM012 SWRO Train Conductivity Profile Result Sheet Senior Chemist/Shift 5 Years
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 Plant Operation Quality Assurance Procedure

Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM013 BWRO Train Conductivity Profile Result Sheet Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM014 ERD Conductivity Profile Result Sheet Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM015 pH Meter Calibration Record Format Chemist
Senior Chemist/Shift
5 Years
NEQACPN001FM016 Conductivity Meter Calibration Record Form Chemist

8. Legal Requirements and References

Quality control Documents of SIWEP.

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