Audit

Engineering Audit Report - Site Data

Business Unit Data

Business Unit

Business Unit Address

Business Unit General Manager at time of Audit

Head of Business Unit Engineering Department (HBUED)

Auditor

Environmental

Site Temperature Range

Maximum Annual Temperature in Degrees Centigrade
Minimum Annual Temperature in Degrees Centigrade

Site Wind Conditions

Maximum Sustained Wind m/s
Maximum Gust Speed m/s
Site Maximum Operating Wind Speed m/s

Site Seismic Classifications

Site Rainfall

Business Data

Container Volume (TEU)

TEU YTD

TEU Previous Year

Background
Terminal Location and Background Information

Terminal Location and Background

Terminal Information:

Background

Terminal Equipment, Including Type i.e. QC, RTG, MHC, Reach-stacker and How Many of Each Type

Equipment Type and Amount

Equipment Type:

Equipment

Engineering Structure
M and R Introduction and Personnel Breakdown
Total M and R Personnel.
Maintenance and Repair Organisation Chart

Engineering Personnel Breakdown

Amount and Type of Each Position:

Amount and Designation

Objective:

The Engineering Audit is created to provide an analytical tool to review, understand and evaluate the Engineering Function of ICTSI Business Units and to check compliance with Engineering Corporate Policies. This objective approach identifies key controllable factors affecting safety, performance, productivity and costs.

We anticipate that sound Engineering Maintenance practice guided by the Corporate Policies and local Quality Management systems, will result in:

Improving Key Performance Indicators

Safer Operation

Lower Risk of Accident

Cost Control

Corrective Actions and Recommendations:

At the end of each section, the Auditor shall identify items of non-compliance and categorize priorities for rectification according to the following rules:

Priority 1:

This category is reserved for serious conditions which could affect safety of personnel and equipment. Corrective action to be applied immediately

Priority 2:

This category is reserved for conditions which are important but not serious enough to affect personnel safety and equipment integrity. Corrective action to be applied within three (3) months of the audit visit.

Priority 3:

This category is applied to non-serious item and identified only as a recommendation to be completed before the next audit.

Marking Scheme:

This audit shall include marking scheme to establish percentage compliance with the Corporate Policies. Each Section of this audit is awarded with a starting position of 10 points. Points are deducted for non-compliance in relationship to priority categories as follows:

Priority 1 - 2 deductible points

Priority 2 - 1 deductible point

Priority 3 - 0 deductible points

Asset Inventory

To audit the BU Asset Inventory, check and confirm the following compliance requirements.

Asset Iventory Available Points (max 5)

The following list defines equipment which is currently operated by the business unit:

Confirm all maintenance worthy assets is included

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm Asset List is compliant with corporate standard format

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm Asset List is complete with accurate and appropriate data included for each piece of equipment.

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Review the Asset List with HBUED and confirm items correspond with the financial records for insurance purpose.

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Auditors Comments

Comment

Comment

Asset Inventory Marking Summary

Asset Inventory Score

Add Asset Inventory Score Summary Media

Score summary media
Auditor Signature

Add Additional Auditor Signature

Additional Signatory
Auditor/Authorising Manager Signature
Performance Indicators

A scheme of performance measurement and reporting is for all established ICTSI group business units. All front line container handling equipment, such as Quay Cranes and RTG's are included in the scheme since January 2007.

Results are circulated on a quarterly basis and the following graphics represent the most important KPI's for QC's

The main Key Performance Indicators (KPI's) are defined to be:

Mean Moves Between Failures (MMBF) - A calculation based upon total monthly container moves divided by the number of breakdowns caused by equipment malfunction during the same period.

Mean Time to Repair (MTTR) - A calculation based upon the total repair time the fleet is out of operation caused by breakdown fault divided by number of breakdowns

Checklist for measuring MMBF and MTTR:

Review MMBF and MTTR figures for the Business Unit in comparison with other ICTSI Group Terminals.

To audit the BU Key Performance indicators (KPI) check and confirm the following compliance requirements.

Performance indicators Available Points (max 20)

Confirm that Previous Year and Current Year record of MMBF and MTTR are complete.

Corrective Action

Corrective Action

Priority Level

Explain why records are incomplete?

Corrective Action Media

Compare records upon arrival to confirm that common records are submitted to ICTSI Engineering Corporate and to Business Units Management Committee.

Corrective Action

Corrective Action

Priority Level

Provide mitigating circumstances if any why Performance Indicators are not regularly submitted.

Corrective Action Media

Confirm records are credible by comparing against recorded breakdowns based on maintenance breakdown logs and twist-lock logic on randomly selected equipment.

Corrective Action

Corrective Action

Priority Level

Highlight any discrepancies with data submitted and local data.

Corrective Action Media

MMBF Quay Crane Previous Year

MMBF Quay Crane

BU QC MMBF Comparison Chart Previous Year

Higher or lower than group average?

Explain Reasons and Possible Solutions for Lower than Group Average MMBF

MMBF Quay Crane YTD

MMBF Quay Crane

BU QC MMBF Comparison Chart YTD

Higher or lower than group average?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Lower than Group Average MMBF

Corrective Action Media

MTTR Quay Crane Previous Year

MTTR Quay Crane.

BU QC MTTR Comparison Chart Previous Year

Higher or lower than group average?

Explain Reasons and Possible Solutions for Higher than Group Average MTTR

MTTR Quay Crane YTD

MTTR Quay Crane

BU QC MTTR Comparison Chart YTD

Higher or lower than group average?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Higher than Group Average MTTR

Corrective Action Media

MMBF RTG Crane Previous Year

MMBF RTG Crane

BU RTG MMBF Comparison Chart Previous Year

Higher or lower than group average?

Explain Reasons and Possible Solutions for Lower than Group Average MMBF

MMBF RTG Crane YTD

MMBF RTG Crane

BU RTG MMBF Comparison Chart YTD

Higher or lower than group average?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Lower than Group Average MMBF

Corrective Action Media

MTTR RTG Crane Previous Year

MTTR RTG Crane

BU RTG MTTR Comparison Chart Previous Year

Higher or lower than group average?

Explain Reasons and Possible Solutions for Higher than Group Average MTTR

MTTR RTG Crane YTD

MTTR RTG Crane

BU RTG MTTR Comparison Chart YTD

Higher or lower than group average?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Higher than Group Average MTTR

Corrective Action Media

MMBF MH Crane Previous Year.

MMBF MH Crane

BU MHC MMBF Comparison Chart Previous Year

Higher or lower than group average?

Explain Reasons and Possible Solutions for Lower than Group Average MMBF

MMBF MH Crane YTD

MMBF MH Crane

BU MHC MMBF Comparison Chart YTD

Higher or lower than group average?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Lower than Group Average MMBF

Corrective Action Media

MTTR MH Crane Previous Year.

MTTR MH Crane

BU MHC MTTR Comparison Chart Previous Year

Higher or lower than group average?

Explain Reasons and Possible Solutions for Higher than Group Average MTTR

MTTR MH Crane YTD

MTTR MH Crane

BU MHC MTTR Comparison Chart YTD

Higher or lower than group average?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Higher than Group Average MTTR

Corrective Action Media

Section Support Media

Support media
Support media

Auditors Comments

Comment

Comment

Performance Indicators scoring summary

Performance Indicators Score

Add Performance Indicator Score Summary Media

Score summary media
Auditor Signature

Add Additional Auditor Signature

Additional Signatory
Auditor/Authorising Manager Signature
Power Consumption and Energy Efficiency.

Electrical Power

To audit the BU Electrical power consumption and energy efficiency check and confirm the following compliance requirements.

Power Consumption and Energy Efficiency Available Points (max 20)

Confirm total annual electricity consumption (kWh) YTD

kWh consumption YTD

Support media

Confirm total annual electricity consumption (kWh) Previous Year

kWh consumption Previous Year

Support media

Confirm total annual electricity bill (US$) YTD

US$ YTD

Support media

Confirm total annual electricity bill (US$) Previous Year

US$ Previous Year

Support media

Does the electricity utility provider apply penalties for low power factor, demand or harmonic infringements?

Charges applied for utility provider infringements and corrective actions

Charge

Priority Level

Explain reasons and possible solutions for Utility provider charges

Corrective Action Media

Does the business unit measure average electricity consumption per TEU throughput in the terminal?

Record average kWh/TEU for YTD and previous year.

YTD

Previous Year

Does the business unit measure average electricity consumption per move on each quayside container crane (STS or MHC)?

Record BU average kWh/Move for YTD and previous year and compare with ICTSI group average.

Previous Year

Higher or lower than group average previous year?

Reasons for higher than group average kWh/move

YTD

Higher or lower than group average YTD?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Higher than Group Average kWh/move

Corrective Action Media

Has the BU ever made analysis of the entire electrical system infrastructure from a viewpoint of identifying inefficiencies and reducing cost?

Record details of electrical system analysis.

Support media.

Has the Business Unit installed standby generators?

What is the installed power?

What is primary purpose of installing standby power?

Record reason for installing generators.

Are standby generators used to power quay cranes?

Is quay crane regenerative or pump back power:-

If metering equipment is available record amount of regenerated energy (kWh) dissipated through resistors, this maybe difficult to establish depending on where and how resistors are connected (DC bus, or on HV side local to generators) depending on port network configuration and the location of resistor banks there may be some regenerated energy consumed in the local network.

Does the business unit receive compensation for export kWh to the local utility supply grid?
CR = Compensation received.
NC = No compensation.
MNA = Meters not available.

If metering equipment is available record amount of regenerated energy (kWh) exported to utility supply grid, record exported kWh from QC meter and compare with substation meter the difference will be the energy consumed internally.

Corrective Action

Corrective Action

Priority Level

Explain reasons and possible solutions with regards to not receiving compensation for regenerative power or utilising internally.

Corrective Action Media

Is the Business unit servicing Reefer Containers?

What is the BU annual reefer volume throughput?

How many reefer sockets are installed in the BU
What is average power consumption kWh of each reefer container serviced?

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for high energy consumption

Corrective Action Media
What is the average Power Factor of the reefer container installation?

Corrective Action

Corrective Action

Priority Level

Explain reasons and possible solutions for low power factor

Corrective Action Media

Yard and Container Cane Lighting

What is the average lighting level in the container yard (Lux)?

Corrective Action

Corrective Action

Priority Level

If yard average lighting levels are too high, excessive energy will be consumed

Corrective Action Media

Are there any country laws that define minimum lighting levels?

Minimum lighting level permitted for a container yard in Lux

Is there a system installed in the container yard that automatically reduces lighting intensity levels during periods of non operation?

Provide system details.

Support media

Corrective Action

Corrective Action

Priority Level

If all yard lighting remains on during times of reduced operation or hours of daylight excessive energy will be consumed.

Corrective Action Media

Is there a system installed in the container yard that automatically switches off yard lighting at daybreak?

Provide system details.

Support media

Corrective Action

Corrective Action

Priority Level

If all yard lighting remains on during times of reduced operation or hours of daylight excessive energy will be consumed.

Corrective Action Media

What type of lighting is installed to illuminate container yard ?

Record type

Record type.

Are the quay cranes and yard cranes equipped with photocells that automatically switch off light at daybreak

Provide system details.

Support media

Corrective Action

Corrective Action

Priority Level

If all QC lighting remains on during times of reduced operation or hours of daylight excessive energy will be consumed.

Corrective Action Media

Are the quay cranes and yard cranes fitted with energy efficient lighting systems?

Record type.

Support media

Section Support Media

Support media
Support media

Auditors Comments

Comment

Comment

Power Consumption and Energy Efficiency Scoring Summary

Power Consumption and Energy Efficiency Score

Add Power Consumption and Energy Efficiency Score Summary Media

Score summary media
Auditor Signature

Add Additional Auditor Signature

Additional Signatory
Auditor/Authorising Manager Signature
Fuel Facility and Fuel Management.

To audit the BU Fuel Facility and Fuel Management check and confirm the following compliance requirements.

Fuel Facility and Fuel Management Available Points

Fuel Facility

Does the business unit utilise an on site fuel facility or receive daily visits from fuel tanker

Confirm that BU has formal documented procedure for fuel dispensing

Provide procedure details

Support media

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm responsible personnel are assigned to dispense fuel and maintain the fuel facility.

Provide personnel details

Support media

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm that fuel facility is properly secured against theft and sabotage.

Provide details of security systems to maintain fuel facility and fuel dispensing secure and free from theft and/or sabotage

Security systems

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm that fuel facility is safe from accidental spillage with spill containment unit equivalent to the volume of the tank (if overhead or at ground level).

Provide details of spill containment unit equivalent to the volume of the tank (if overhead or at ground level).

Spillage containment

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm that fuel facility has emergency response procedure and materials for spillage and fire mitigation equipment (fire extinguisher, fire hose)

Provide details of emergency response procedure

Emergency response

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm that fuel dispensing unit (metered dispensing unit) has undergone regular calibration.

Provide details equipment calibration

Metering unit calibration

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Confirm that fuel spillage due to overflow during dispensing is mitigated and recovered.

Provide details equipment calibration

Metering unit calibration

Corrective Action

Corrective Action

Priority Level

Priority Description

Corrective Action Media

Fuel Management.

Confirm total annual diesel consumption (litres) and cost (US$) at the terminal for YTD

Litres consumed

Cost US$

Support media

Confirm total annual diesel consumption (litres) and cost (US$) at the terminal for previous year

Litres consumed

Cost US$

Support media

Does the business unit measure average diesel consumption per TEU throughput in the terminal?

Record average diesel consumption per TEU for YTD and previous year.

Previous Year

YTD

Does the business unit measure average diesel consumption per move on each RTG?

Record BU average diesel consumption per move for YTD and previous year and compare with ICTSI group average.

Previous Year

Higher or lower than group average previous year.

Reasons for higher than group average Lt/move

YTD

Higher or lower than group average YTD

Corrective Action

Corrective Action

Priority Level

Explain Reasons and Possible Solutions for Higher than Group Average Lt/move

Corrective Action Media

Section Support Media

Support media
Support media

Auditors Comments

Comment

Comment

Fuel Facility and Fuel Management Scoring Summary

Fuel Facility and Fuel Management Score

Add Fuel Facility and Fuel Management Score Summary Media

Score summary media
Auditor Signature

Add Additional Auditor Signature

Additional Signatory
Auditor/Authorising Manager Signature
Please note that this checklist is a hypothetical example and provides basic information only. It is not intended to take the place of, among other things, workplace, health and safety advice; medical advice, diagnosis, or treatment; or other applicable laws. You should also seek your own professional advice to determine if the use of such checklist is permissible in your workplace or jurisdiction.