ICTSI Audit Template 1C

• Document No.

• Audit Title

• Client Site

• Conducted on

  Date

• Conducted by

• Location
  Address

• Assisted by the following BU Personnel

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

  Media

• 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

  Yes

  No
Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

• Confirm Asset List is compliant with corporate standard format

  Yes

  No

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

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

  Yes

  No

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

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

  Yes

  No

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

• Auditors Comments

Comment

• Comment

• Asset Inventory Marking Summary

• Asset Inventory Score

• Add Asset Inventory Score Summary Media

• Score summary media

  Media

• Auditor Signature

  Sign

• Add Additional Auditor Signature

Additional Signatory

• Auditor/Authorising Manager Signature

  Sign

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.

  Yes

  No

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain why records are incomplete?

• Corrective Action Media

  Media

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

  Yes

  No

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  Media

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

  Yes

  No

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Highlight any discrepancies with data submitted and local data.

• Corrective Action Media

  Media

• MMBF Quay Crane Previous Year

• MMBF Quay Crane

• BU QC MMBF Comparison Chart Previous Year

  Media

• Higher or lower than group average?

  Higher

  Lower

• Explain Reasons and Possible Solutions for Lower than Group Average MMBF

• MMBF Quay Crane YTD

• MMBF Quay Crane

• BU QC MMBF Comparison Chart YTD

  Media

• Higher or lower than group average?

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain Reasons and Possible Solutions for Lower than Group Average MMBF

• Corrective Action Media

  Media

• MTTR Quay Crane Previous Year

• MTTR Quay Crane.

• BU QC MTTR Comparison Chart Previous Year

  Media

• Higher or lower than group average?

  Higher

  Lower

• Explain Reasons and Possible Solutions for Higher than Group Average MTTR

• MTTR Quay Crane YTD

• MTTR Quay Crane

• BU QC MTTR Comparison Chart YTD

  Media

• Higher or lower than group average?

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain Reasons and Possible Solutions for Higher than Group Average MTTR

• Corrective Action Media

  Media

• MMBF RTG Crane Previous Year

• MMBF RTG Crane

• BU RTG MMBF Comparison Chart Previous Year

  Media

• Higher or lower than group average?

  Higher

  Lower

• Explain Reasons and Possible Solutions for Lower than Group Average MMBF

• MMBF RTG Crane YTD

• MMBF RTG Crane

• BU RTG MMBF Comparison Chart YTD

  Media

• Higher or lower than group average?

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain Reasons and Possible Solutions for Lower than Group Average MMBF

• Corrective Action Media

  Media

• MTTR RTG Crane Previous Year

• MTTR RTG Crane

• BU RTG MTTR Comparison Chart Previous Year

  Media

• Higher or lower than group average?

  Higher

  Lower

• Explain Reasons and Possible Solutions for Higher than Group Average MTTR

• MTTR RTG Crane YTD

• MTTR RTG Crane

• BU RTG MTTR Comparison Chart YTD

  Media

• Higher or lower than group average?

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain Reasons and Possible Solutions for Higher than Group Average MTTR

• Corrective Action Media

  Media

• MMBF MH Crane Previous Year.

• MMBF MH Crane

• BU MHC MMBF Comparison Chart Previous Year

  Media

• Higher or lower than group average?

  Higher

  Lower

• Explain Reasons and Possible Solutions for Lower than Group Average MMBF

• MMBF MH Crane YTD

• MMBF MH Crane

• BU MHC MMBF Comparison Chart YTD

  Media

• Higher or lower than group average?

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain Reasons and Possible Solutions for Lower than Group Average MMBF

• Corrective Action Media

  Media

• MTTR MH Crane Previous Year.

• MTTR MH Crane

• BU MHC MTTR Comparison Chart Previous Year

  Media

• Higher or lower than group average?

  Higher

  Lower

• Explain Reasons and Possible Solutions for Higher than Group Average MTTR

• MTTR MH Crane YTD

• MTTR MH Crane

• BU MHC MTTR Comparison Chart YTD

  Media

• Higher or lower than group average?

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain Reasons and Possible Solutions for Higher than Group Average MTTR

• Corrective Action Media

  Media

• Section Support Media

Support media

• Support media

  Media

• Auditors Comments

Comment

• Comment

• Performance Indicators scoring summary

• Performance Indicators Score

• Add Performance Indicator Score Summary Media

• Score summary media

  Media

• Auditor Signature

  Sign

• Add Additional Auditor Signature

Additional Signatory

• Auditor/Authorising Manager Signature

  Sign

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

  Media

• Confirm total annual electricity consumption (kWh) Previous Year

• kWh consumption Previous Year

• Support media

  Media

• Confirm total annual electricity bill (US$) YTD

• US$ YTD

• Support media

  Media

• Confirm total annual electricity bill (US$) Previous Year

• US$ Previous Year

• Support media

  Media

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

  Yes

  No

• Charges applied for utility provider infringements and corrective actions

Charge

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain reasons and possible solutions for Utility provider charges

• Corrective Action Media

  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?

  Higher

  Lower

• Reasons for higher than group average kWh/move

• YTD

• Higher or lower than group average YTD?

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  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.

  Media

• Has the Business Unit installed standby generators?

  Yes

  No

• What is the installed power?

• What is primary purpose of installing standby power?

  High tariffs during peak periods

  Unstable or unreliable grid supply

  Back up in the event of grid failure

  Other

• Record reason for installing generators.

• Are standby generators used to power quay cranes?

  Yes

  No

• Is quay crane regenerative or pump back power:-

  Dissipated through resistors

  Returned to grid

  Consumed within local port network

• 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? <br>CR = Compensation received. <br>NC = No compensation. <br>MNA = Meters not available.

  Compensation Recieved

  No Compensation

  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

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  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

  Priority One

  Priority Two

  Priority Three

• Explain Reasons and Possible Solutions for high energy consumption

• Corrective Action Media

  Media

• What is the average Power Factor of the reefer container installation?

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Explain reasons and possible solutions for low power factor

• Corrective Action Media

  Media

• Yard and Container Cane Lighting

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

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  Media

• Are there any country laws that define minimum lighting levels?

  Yes

  No

• 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?

  Yes

  No

• Provide system details.

• Support media

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  Media

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

  Yes

  No

• Provide system details.

• Support media

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  Media

• What type of lighting is installed to illuminate container yard ?

  High Pressure Sodium

  Metal Halide

  HID

  Energy Efficient

  Other

• Record type

• Record type.

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

  Yes

  No

• Provide system details.

• Support media

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  Media

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

  Yes

  No

• Record type.

• Support media

  Media

• Section Support Media

Support media

• Support media

  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

  Media

• Auditor Signature

  Sign

• Add Additional Auditor Signature

Additional Signatory

• Auditor/Authorising Manager Signature

  Sign

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

  Yes

  No

• Provide procedure details

• Support media

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

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

  Yes

  No

• Provide personnel details

• Support media

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

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

  Yes

  No

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

• Security systems

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  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).

  Yes

  No

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

• Spillage containment

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

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

  Yes

  No

• Provide details of emergency response procedure

• Emergency response

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

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

  Yes

  No

• Provide details equipment calibration

• Metering unit calibration

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

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

  Yes

  No

• Provide details equipment calibration

• Metering unit calibration

  Media

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

• Priority Description

• Corrective Action Media

  Media

• Fuel Management.
  

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

• Litres consumed

• Cost US$

• Support media

  Media

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

• Litres consumed

• Cost US$

• Support media

  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.

  Higher

  Lower

• Reasons for higher than group average Lt/move

• YTD

• Higher or lower than group average YTD

  Higher

  Lower

• Corrective Action

Corrective Action

• Priority Level

  Priority One

  Priority Two

  Priority Three

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

• Corrective Action Media

  Media

• Section Support Media

Support media

• Support media

  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

  Media

• Auditor Signature

  Sign

• Add Additional Auditor Signature

Additional Signatory

• Auditor/Authorising Manager Signature

  Sign