MULTI-FUNCTIONAL AUDIT REPORT Reference No.

RPP-01
Audit Client : SMFI – IP4 BICOL POLYTRADE
MFA Team Leader: Ronnie L. Calibo
Date(s) of Audit: November 7 – 11, 2016
Coverage: Review of 2014 Audit
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head

Plant Performance Assessment (Mechanical - Utilities) 2016

Non-
Year Closed Pending Percent Completion Observation
Conformity
2014 18 6 12 33.33 0
2016 12 + 12 N/A N/A N/A 1

1.1 Completed Non- Conformities

1.1.1 Station batteries of the generator are placed directly to the ground. In such case, batteries
tend to discharge even not in use.

2014 Audit 2014 Audit Present: 2016 Audit

1.1.2 Replacement of generator from 775 KVA to 625 KVA. No oil leaks are observed during the
time of audit.

2014 Audit 2014 Audit Present: 2016 Audit

MFA Form Rev04 1 of 21

 1.1.3 The lone deepwell pump is provided with fence to prevent entry of unauthorized person.

Deepwell
Deepwell pumps
pumps

2014 Audit 2014 Audit Present: 2016 Audit

1.1.4 Installation of flowmeters for lone deepwell pump.

2014 Audit Present: 2016 Audit

1.1.5 Relocation of overflow line of Evaporative condenser.

2014 Audit
Overflow
Overflow line
line

MFA Form Rev04 2 of 21

 Present: 2016 Audit

Overflow
Overflow line
line

1.1.6 Water ponding below the Ice maker Chilled water tank is already addressed including the
water leaks coming from the flange connection and fittings.

2014 Audit

Clogged

2014 Audit 2014 Audit Present: 2016 Audi

MFA Form Rev04 3 of 21

 1.2 Pending Non-Conformities

1.2.1 Cooling tower with missing protective plastic screens promoting airborne particle pick-up
and water contamination.
2014 Audit
Protective
Protective barrier
barrier Missing
Missing protective
protective barrier
barrier

Present: 2016 Audit

Sample

1.2.2 At the time of the audit inspection, the onset of algae growth was observed floating at the
top of the water sump and adhering at the basin walls.

2014 Audit

MFA Form Rev04 4 of 21

 Present: 2016 Audit

1.2.3 Continuous draining of water in the overflow line from the four units of cooling tower as
shown in the picture. The height setting of the overflow is the same as the sump
operating level. As a recommendation, ball float setting must be observed at all times to
eliminate wastages in water.

Overflow
Overflow pipe
pipe line
line

2014 Audit

Present: 2016 Audit

MFA Form Rev04 5 of 21

 1.2.4 Absence of a sampling port and a regular sounding activity to monitor the general
condition and health of the deep well. Absence of a sampling port and a regular sounding
activity to monitor the general condition and health of the deep well. Deep well sounding
determines the static water level and pumping water level of the deep well. The data
obtained will be beneficial to the plant in determining expected life of the well.

Sampling
Sampling port
port

2014 Audit Present: 2016 Audit Sample

Water Level Meter

1.2.5 Thick dust deposits on the air intake filter of the 10 hp aerator blower at WWTP. The air
blower capacity is reduced with clogged intake filter (2014 Audit). During the 2016 audit,
the air intake assembly is already damaged as shown in the picture.

2014 Audit Present: 2016 Audit Present: 2016 Audit

MFA Form Rev04 6 of 21

 1.2.6 Glycerine inside the pressure gauges of the aerator blower is already contaminated.
Glycerin protects the pressure gauge from the vibration produce by the compressor.
Monitoring of the pressure is not possible.

2014 Audit 2014 Audit Present: 2016 Audit

1.2.7 Feeder cable supplying the deepwell pump is not protected from physical/ mechanical
damage and is not in accordance with Electrical Engineering standard.

Power
Power Cable
Cable

2014 Audit Present: 2016 Audit Sample

1.2.8 Ice formation on the lower portion of the sliding door of Cold Storage 2 is a symptom of
deteriorating gaskets resulting to energy losses of the refrigeration system.

2014 Audit

MFA Form Rev04 7 of 21

 Present: 2016 Audit

1.2.9 Lube oil’s color in the portable air compressor is blackish indicating oil contamination.

2014 Audit Present: 2016 Audit

1.2.10 No level indicator for the diesel storage tank. Level indicator will help the plant monitor
the consumption and level of diesel tank. At present they use dip stick with steel

2014 Audit Sample Present: 2016 Audit

1.2.10 Oil leaks are observed in the air compressor thus affects the compressor and floor
condition in the area. Air compressor is already replaced but oil leak still present.

MFA Form Rev04 8 of 21

 2014 Audit Present: 2016 Audit

1.2.11 The stack temperature for 30 BHP is 400°C for 2014 and 350 °C ( based on temperature
gauge) and 430 °C (based on boiler monitoring sheet dated Oct. 17, 2016) for 2016
which is above the normal temperature of 180 – 240 °C (356 – 428 °F). Stack
temperature is an important Boiler operating parameter to monitor since it indicates the
condition of the boiler tube.

Stack
Stack temp.gauge
temp.gauge

2014 Audit 2014 Audit Present: 2016 Audit

Note: Distance of the stack thermometer gauge is very near to the damper. To attain the actual
stack temperature, relocate the tapping point of damper. The minimum distance of
temperature gauge to the damper is 1 x stack diameter.

1.2.12 Noted that the rear door sight glass is unclear / with soot accumulation. During 2016
audit also noted the presence of crack in the door sight glass.
Boiler
Boiler door
door sight
sight
glass
glass

2014 Audit Present: 2016 Audit

1.3 Addressed Observation

MFA Form Rev04 9 of 21

 1.4 Awards / Recognition / Plant Initiatives

MFA Form Rev04 10 of 21

 MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-02
Coverage: MECHANICAL UTILITIES- STEAM GENERATION
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

2.1 Steam header is properly insulated and provided with warning sign. However, steam leaks
are observed at the 1” diameter pipe. Possible defective valve. This contributes to the power
and steam consumption of the plant.

Recommendation:

2.1 Early symptoms of steam leaks must be addressed immediately to prolonged the life of the
equipment and reduce the fuel consumption of the plant. Prioritized the replacement of ball
valve.

MFA Form Rev04 11 of 21

 MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-03
Coverage: MECHANICAL - UTILITIES
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

3.1 The plant installed two units of magnetic type of boiler water treatment (Theoverm).
However no water analysis conducted after the installation of magnetic type water
treatment. Based on the boiler monitoring sheet stack temperature reached up to 430°C
which is above the normal temperature of 180 – 240 °C (356 – 428 °F). Stack temperature
is an important Boiler operating parameter to monitor since it indicates the condition of the
boiler tubes. As per interview, the plant conducted de-sooting last June 2015.

Boiler monitoring sheet

Recommendation:

3.1 Call the attention of the supplier to asses the condition of the magnetic water treatment
equipment and conduct water analysis to assess the effectiveness of the equipment.

MFA Form Rev04 12 of 21

MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-04
Coverage: MECHANICAL - UTILITIES
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

4.1 A sign of ice formation is noted in the evaporator installed in production area. The possible
cause of ice formation is the refrigerant running low on the evaporator coil or suction line,
refrigerant leak, blocked / dirty evaporator coil or refrigerant leak. When there is too little
refrigerant in the system, part of the coils will be far colder than the other parts. This
inconsistency will cause excessive condensation in one area of the coil, which then
forms ice.

Recommendation:

4.1 Check for possible refrigerant leak that contribute to the low refrigerant pressure in the
system.

MFA Form Rev04 13 of 21

MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-06
Coverage: MECHANICAL - UTILITIES
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

6.1 300 Bohp fired tube boiler is provided with safety relief valves. Exhaust extension pipes
outside the boiler room. However no condensate drains line for the 2” conduit. Condensate
drain can be lodge with condensate which is corrosive causing its premature leakage.

 Section 2.0 Specific Requirement for Fire Tube Boilers - Safety Valve

When a vent-out pipe is used, it shall be sufficiently sized and fitted with an open drain to
prevent water lodging in the upper part of the safety valve or escape pipe. When an
elbow is placed on a safety valve outlet or vent-out pipe shall be securely anchored and
supported. All safety valve discharges shall be so located or piped as to be carried clear
from walkways or platform used

Condensate
Condensate drain
drain

Sample
Audit Finding/s: X Non-Conformity Observation

FINDINGS

6.2 Corroded bolts and nuts that hold the flue gas outlet throat and the boiler shell and heavy
corrosion on the flue gas outlet throat as shown in the picture.

MFA Form Rev04 14 of 21

Audit Finding/s: X Non-Conformity Observation

FINDINGS

6.3 The gasket installed for Boiler no.2 flue gas outlet throat is partially damage. Also noted the
type of gasket used is not intended for boiler.

Sample graphite gasket

Recommendation:

6.1 Install ½ inch condensate drain pipe without isolating valve in accordance with Phil.
Mechanical Code standard as shown in the illustration above.

6.2 It is recommended to remove the rust particles from the steel by means of scraping or by
used of rust removers. After removal of rust particles from steel members application of
protective coating should follow to prevent re-occurrence of rusting and lengthen the
service life of the equipments.

6.3 Replaced the gasket that is intended for boiler used. In other SMC facilities, the type of
gasket use is graphite gasket with wire insertion.

MFA Form Rev04 15 of 21

MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-07
Coverage: GENERATOR
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

7.1 It was observed that rust and corrosion have already started to manifest on the exhaust pipe
line and silencer of the 625 KW OR 500 KVA generators as shown in the picture. Rust and
corrosion is a result to natural elements (e.g. rain water) and/or acid fumes.

Audit Finding/s: Non-Conformity X Observation

FINDINGS

7.2 The Plant’s new stand-by power generator is complete with posters for maintenance and pre
start-up inspection points. However it lacked the posting of start-up and shutdown
procedures for operator’s common reference. Below is the sample start-up and shutdown
procedure.

 Standard operations procedure promotes safety, enhances harmonious relations among

operators and facilitates the shifting of power supply during power interruptions.

MFA Form Rev04 16 of 21

Recommendation:

7.1 It is recommended to remove the rust particles from the steel by means of scraping or by
used of rust removers. After removal of rust particles from steel members application of
protective coating should follow to prevent re-occurrence of rusting and lengthen the
service life of the equipments.

7.2 To prepare operations procedure based from the manufactures operations manual in large
frame, cascade to technicians, and post within the Generator set area.

MFA Form Rev04 17 of 21

MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-08
Coverage: MECHANICAL - UTILITIES
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

8.1 Corrosion starts to manifest on the flange connection, elbow and fittings on the water pipe
lines below the water overhead tank. Corrosion if not addressed will cause water leaks that
may affect the plant production.

Recommendation:

8.1 Repainting of water pipe lines, fittings and flange connection with proper surface preparation is
recommended for preservation of assets and prevent deterioration. It is recommended to remove
the rust particles from the steel by means of scraping or by used of rust removers. After
removal of rust particles from steel members application of protective coating should follow
to prevent re-occurrence of rusting and lengthen the service life of the structure.

MFA Form Rev04 18 of 21

MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-09
Coverage: MECHANICAL - UTILITIES
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

9.1 Noted that the cooling tower blower drive motor already showing signs of deterioration due
to corrosion on the body of the motor. It show no preventive maintenance conducted on the
drive motor.

Recommendation:

9.1 Pull –out the drive motor and conduct preventive maintenance which include replacement of
bearing, varnishing and baking, painting and testing.

MFA Form Rev04 19 of 21

MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-10
Coverage: MECHANICAL - UTILITIES
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding/s: X Non-Conformity Observation

FINDINGS

10.1 Various water leaks are noted in the plant. This contributes to water consumption of the
plant. Leaks render the pump and fittings untidy with presence of slime while it is waste of
energy and water resources. Unaddressed water leaks observed as evidenced by algae
growth.

Defrosting line from blast freezer Chlorine dosing pump

Raw water transfer pump

Recommendation:

10.1 Early symptoms of water leaks must be addressed immediately to prevent damage of the
equipment.

MFA Form Rev04 20 of 21

MULTI-FUNCTIONAL AUDIT REPORT Reference No. RPP-11
Coverage: ELECTRICAL - SAFETY
Names of Key Personnel Interviewed: Job Title:
Calixto Gabutero Jr. PSSI – Engineering Head
Audit Finding(s): X Non-Conformity Observation

FINDINGS

11.1 During the 3rd day of audit, supply line of water softener at ice plant was noted to be tied with
plastic strips to somewhat address the pipe leak that had developed. The water leak that had
developed may have been partially addressed but the prolonging its restoration serves as a
precedent to wrong engineering practices which should not be tolerated. Unaddressed water
leaks observed as evidenced by algae growth.

102___11\MVI_3770.MOV

Recommendation:

11.1 Good engineering practices / good workmanship should always be carried-out for
preservation of assets and prevent unwanted breakdown of equipment which would
eventually entail higher cost to the plant. Addressed the water leaks immediately.

Reynaldo P. Parocha Renato C. Ogilvie

Auditor Business Unit Representative
Note: 1) This audit is based on a limited sample and other nonconformities may exist.
2) This report and its content should be treated as confidential except with prior agreement with the client.

MFA Form Rev04 21 of 21