Water Safety Plan Manual For

WATER SAFETY PLAN MANUAL FOR
AQUACLEAN WATER REFILLING STATION
CONTROL MEASURE DETERMINATION &

HAZARD INDENTIFICATION
PRIOTAZATION OF RISKS
Hazardous Events Priority
Process Hazard Justification for
(Source of Control Measure Step (Yes
Step Category Critical Step
Hazard) or No)
Product water after
using orthotolidine
test)
Note: if the water is
chlorinated the test
reveals change in
color (yellow)
Ultrafiltration Contamination and Microbiological Backwashing flushing No
clogging of filter as and cleaning when
a result of possible there is low
dumping from production. Replace
previous process as needed.
due to poor
equipment
maintenance
Fouling of filters
resulting to dumping
to the next state if
processing and
finished product due
to poor equipment
maintenance.
14 layers Fouling of filter Microbiological Backwashing once No
main resulting to pressure drop
filtration “dumpling” (release between 5 – 10 psi is
with of trapped evident in pressure
activated contaminants” to gauge. Replace/clean
carbon the next stage of sediment filter media
water processing once filter media is
due to clogged.
18

Hazard) or No)
Poor equipment
maintenance
Growth and Microbiological Backwashing once

proliferation of Chemical pressure drop
bacteria in carbon between 5-10psi
material
Replace GAC
granulated activated
carbon once
exhausted
(exhausted GAC
activated carbon
shows yellow color in
product water after
using orthotolidine
test)
(GAC can removed
chlorine)
Note: if the water is
chlorinated the test
reveals change in
color (Yellow)
UV light Survival of Microbiological Use appropriate size Yes The last
Sterilization microorganism due of UV bulb and set disinfectant
to insufficient UV water flow rate to method in the
fluence (dose) ensure appropriate process (low risk)
fluence (dose) is met
19

Hazardous
Priority
Process Events Hazard Justification for
Control Measure Step (Yes
Step (Source of Category Critical Step
or No)
Hazard)
Survival of Daily monitoring of UV
microorganisms due light condition (light is
to faulty UV bulb on/no alarm emitted –
(off/unplugged, depending on the type
busted, damaged of equipment) and
ballast) replacing as necessary
Daily monitoring is UV
is plugged prior to
start of operation
Survival of Cleaning of quartz

microorganisms due sleeves based on
to adhering scales required/recommended
on quartz sleeves schedule
blocking UV
radiation
Container, Survival of Microbiological Implement stringent Yes Can directly

caps microorganisms produce on containers, contaminate the
washing & from used container caps washing and product (HIGH
sanitizing and cap due to sanitizing RISK)
insufficient and
ineffective cleaning
Use of non-food Chemical Use food grade or DOH
grade cleaning and approved cleaning and
sanitizing agents sanitizing agents
20

Hazard) or No)
Excessive amount of Train staff to follow
cleaning and proper chemical
sanitizing agents dilution and monitor
compliance (follow
manufacturer’s
instruction on
dilution: not to
exceed 100 ppm
chlorine)
Filling, Contamination of Microbiological Implementing No
capping and water and container stringent health and
sealing from personnel hygiene policy
(finished
product) Train personnel to
prevent
contamination
Implementation strict
hand washing policy
Leaching toxic Chemical Use food grade
chemicals from containers and caps
containers, caps
Delivery Fouling of filter Microbiological Train staff on

resulting to procedure to prevent
“dumpling” (release contamination
of trapped Provision of handle or
contaminants” to ears in bottles for
the next stage of proper handling and
water processing storage practices
due to Maintain delivery
vehicles clean and
sanitary
Use delivery vehicles
with sanitary
clearance from the
LHO
21

Hazard) or No)
Intentional Microbiological Use tamper-free No
tampering of seal/packaging
product during
delivery
Eg. Intentional Chemical Screening and
placing of supervision of
insecticides or personnel
pesticides
Water Improper storage Microbiological Consumer education Yes Can directly
storage and and handling of and product labeling contaminate the
consumption consumers product (low risk)
22
IMPROVEMENT/UPGRADE PLAN
Significant risks that are not fully controlled or in case of absence of control, and improvement/upgrade
plans are established. The WSP focal Person is mostly the person responsible for carrying out these plans. Target
dates to accomplish these plans are also set.
Table 2. Improvement/Upgrade Plan and Accountabilities
Specific Improvement Accountabilitie

Action Arising from Due Status
Plan s
Develop a Unsafe acts of Develop and provide simple Focal person May Not yet
consumer handling and storage instruction guild line for Ma. Theresa 2015 started
education practices at consumer consumers on proper
program level were identified handling and storage of
as uncontrolled risk water and maintenance of
water dispensers (if any)
Or;
Develop & print sticker
label pertaining to proper
handling and storage of
water at consumer level
Provision of Hazard and risk Allocate budget for a WRS Operator July Not yet
tamper-free sea assessment have tamper-free seal. Jove jonti 2015 started
identified intentional
contamination Look for tamper free seal
(tampering) during supplier.
delivery as potential &
uncontrolled risk. Implement consumer
Current design of seal education and marketing
commonly used by strategies so pricing of
WRS Operators is not water can be adjusted to
tamper-free. This is compensate for the
due to the perceived increased cost of seal.
high cost of the
material
23
Specific
Action Arising from Accountabilities Due Status
Improvement Plan
Develop Absence of Develop Focal person Octobe Not yet
emergency/disaster procedures/contingency emergency/disaster Ma. Theresa r started
response plans that will address contingency plan after 2015
procedure in case continuation of consultation and
of natural operation in case of management council
calamities that disasters and still
would lead to ensure sufficient and
destruction of safe water supply
facilities (e.g.
earthquake) and
contamination of
water supply (e.g.
strong typhoon
leading to flooding
such as in the case
of typhoon
Yolanda)
24
MONITORING REQUIREMENT AND CORRECTIVE ACTION
Proper monitoring procedure determine conformance of critical steps to its critical limits. The
procedure are established to detect process deviations and to intervence in the critical limits have
been exceeded or not met. The system of monitoring shall include the area to be monitored, the
person to perform the monitoring,a and the frequency of monitoring and method of monitoring.
Product specification to e checked are defined, persons with appropriate knowledge to perform the
monitoring procedure are assigned, and montoring intervals are establish.
The pre-determined corrective actions are set to eliminate the hazard, to ensure that critical
steps are under control, and to guarantedd that the indentified procedure or conditions that pose
hazards are corrected. The system ensures that each corrective action taken is properly documented.
Table 3. Monitoring Requirements and Corrective Action (Safe Drinking Water)
Process Critical Corrective

What Where When How Who
Step Limit Action
Activated Presence Chlorine Product Once a Use chlorine Staff If chlorine is
carbon of concentrat water month test solution present in
filtration Chlorine ion (orthotolodi product
ne) water,
replace
activated
carbon filter
10-15lbs Pressure Pressure Once a Check Staff If pressure
pressure drop gauges day pressure drop has
drop gauges for reach 10-
pressure 15lbs psi,
drop backwash
U.V. light 9,000 Lamp UB Once a Checking Owner If lamp hours
sterilizatio lamp Hours Quartz year label has reached
n hours Sleeves attached to or exceeded
(refer to U.V. 9,000 hours,
manufac replace bulb
turer’s immediately
recomm
e
25
Process Critical Corrective
What Where When How Who
Step Limit Action
Ndation
on lamp
hours)
Indicator Indicator UV light Before Visual Staff If indicator
light is light equipme start of checking light
on nt operati off/chech if
on plugged and
indicator light
is still off,
replace bulb
or ballast.
Container, 50 ppm Chlorine Chlorine Once a Use chlorine Staff
caps chlorine concentrat solution day test strips
washing solution ion with color
and chart
sanitizing
26
VERIFY THE EFFECTIVENESS OF WSP

Verification measures confirm that the support programs are implemented, the
hazard analysis is updated, the sanitation standard operation procedure and critical limits
are implemented and effective, the hazard levels are within the identified acceptable levels
and that the other procedures required by the company are implemented and effective.
Verification results are recorded and communicated to the WSP team through meetings,
memorandums and electronics mails. Any non-conformity based from testing of end product
is handled as potentially unsafe.
Table 4. Verification Monitoring (Safe Drinking Water)
VERIFICATION
PROCESS STEP
WHAT WHEN WHO
14-layer final Water analysis Every 6 months DOH accredited lab
filtration w/ physical/chemical test Environmental
activated carbon Health Laboratory
Test chlorine residual Every week Ma. THeresa
Review pressure gauge Every week Ma. THeresa

monitoring sheet
UV light Water analysis Once a month Environmental

microbiological Health Laboratory
Review preventive Every year Ma. THeresa

maintenance record
(cleaning lamp hours)
Review flow rate monitoring Every week Ma. THeresa

sheet
Delivery Customer feedback report Every week Ma. THeresa
logbook
27

Other Verification activities perform include:
Internal Audit
Implementation of the WSP is continuously monitored through internal audit on a
yearly basis by the WSP focal person. The audit includes all areas in the production,
including bit not limited to, equipment, raw and product water, containers, records, process
and control. In case a non-conformance is sighted during an audit, corrective action is
implemented by the operator and / or the employee within acceptable timeframe.
Audits may also conduct:
 As part of the investigation of a water safety related incident/costumer

complaint
 To monitor action items from audit findings, as necessary
Water Testing
The most common verification activity used is the laboratory water testing for
microbiological parameters once a month; physical/chemical parameters once every year six
(6) months.
28
MANAGEMENT PROCEDURES
Standard Operating Procedures

Standard Operating Procedures for a WRS are necessary to provide enough detail and guide
employees in performing their task correctly and ensure proper and sanitary operation.
BEFORE OPERATION:
1) Clean and sanitize inside an outside the area
2) Change shoes and wear appropriate uniform and personal protective equipment (PPE)
3) Turn on all equipment
4) Do the usual maintenance needed
5) Check chlorinator/Chemical feeder
6) Flush finish product for 5 minutes
OPERATION:
1) Wash and sanitize the containers including caps
2) Rinse well all container, cap with product water
3) Immediately cover the container after filling with product water
4) Seal after capping
DELIVERY:
1) Clean and sanitize all vehicles
2) Properly arrange products for delivery
3) All products should be delivered within 24 hours
4) Delivery personnel should practice proper hygiene (eg. Hand washing, use hand
sanitizing gel before delivery)
5) Use bottle handles to minimize hand contact
6) Inform customer’s proper handling and storage. Implementing first in out (FIFO)
7) Clean and sanitize dispensers
29

AFTER OPERATION:
1) Clean and sanitize area
2) Turn off all equipment
Incident/Crisis Management
Table 5. Incident/Crisis Management
PROBLEM THAT MAY ARISE ACTION PLAN
EQUIPENT
Leaks Repair immediately
Stop operation and provide a service
technician
Ball valve Repair immediately
Low pressure and low production for
Ultrafiltration membrane Backwash, flush, and clean immediately
Damage on Booster pumps Replace booster pump
HANDLING/GMP
Bottle with algae Discard contaminated water
Clean and sanitize bottles and refill with
finish product water
Protect and store in a well-ventilated
area and away from sunlight
Failed in microbiological and HPC Clean and sanitize pipe line from source
to dispensing. (Bypass resin, RO and
polishing carbon)
Failed in microbiological test Bottle should be well cleaned and
sanitized
Personnel should practice good hygiene
Sealed bottles with mosquito larvae Clean, sanitize, and rinse bottles
DELIVERD PRODUCTS
Product w/Bad taste Protect and store it in a well-ventilated
area and away from sunlight
Particulate matter/mosquito larvae Clean and sanitize bottles
30

PROBLEM THAT MAY ARISE ACTION PLAN

In the hot and cold dispenser Clean and sanitize dispenser
Cover hot and cold dispenser when
replacing empty bottles.
DEVELOPMENT SUPPORT PROGRAMS

Supporting programs provide the basic environmental and operating conditions
essential for the safe production of water. These programs help control the
conditions in the refilling station which contribute to the over-all safety of the water
being produced.
Refer to Amex for Support Programs
CONDUCT WATER SAFETY PLAN REVIEW
4.1 Review
WSP will be periodically reviewed based on the following schedules:
a. Standard of every 2 years
b. When there is change on the equipment or product water
c. After an occurrence of any untoward incidents
31
REVISION FOLLOWING AN INCIDENT

WSP shall be reviewed following an emergency, confirmed incident near
missies or unforeseen events to ensure that the incident will not recur; or whether
the incident could have been handled better. A post – incident review or the incident
investigated will identify opportunities for improvement; therefore, the WSP Focal
Point shall establish new procedures or revise existing ones based one the result of
WSP review and incident investigation. The review will be based on certain guide
questions.
Refer to Annex for the guide questions
The following are considered during the revision of WSP:

 Accountabilities and contact details of WSP and key Personnel are updated
and available
 Clear definition of trigger levels for incidents including a scale of alert level
(e.g. when an incident is elevated to boil water alert)
 Review whether the management procedures were appropriate for the
incident and if not, revise accordingly
 Standard operating procedures and required equipment are readily available
and relevant
 Does the risk assessment need revising?
 Do procedures/training/communication need improving?
 Has the problem shown the need for an improvement of program?
32

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WATER SAFETY PLAN MANUAL FOR

AQUACLEAN WATER REFILLING STATION

CONTROL MEASURE DETERMINATION &

CONTROL MEASURE DETERMINATION &

Growth and Microbiological Backwashing once

CONTROL MEASURE DETERMINATION &

Survival of Cleaning of quartz

Container, Survival of Microbiological Implement stringent Yes Can directly

CONTROL MEASURE DETERMINATION &

Delivery Fouling of filter Microbiological Train staff on

CONTROL MEASURE DETERMINATION &

Table 2. Improvement/Upgrade Plan and Accountabilities

Specific Improvement Accountabilitie

MONITORING REQUIREMENT AND CORRECTIVE ACTION

Table 3. Monitoring Requirements and Corrective Action (Safe Drinking Water)

Process Critical Corrective

VERIFY THE EFFECTIVENESS OF WSP

Table 4. Verification Monitoring (Safe Drinking Water)

Test chlorine residual Every week Ma. THeresa

Review pressure gauge Every week Ma. THeresa

UV light Water analysis Once a month Environmental

Review preventive Every year Ma. THeresa

Review flow rate monitoring Every week Ma. THeresa