USAC9RL Special Report F[,:-94/02

October 1993

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Guidelines for Quality Assurance Inspection

of Commercial Activities Contracts for

Real Property Maintenance Activities

Guide #2: Wastewater Systems

by

James H. Johnson

Paul C. Bresnahan DTIC

ELECTE

A Quality Assurance (QA) Program allows the JAN 0 5 1994 ,1

Army to evaluate and document a contractor's S; work performance. It depends on a QA Surveillance Plan (QASP). The QASP, which is based

on the contract Performance Work Statement, lists

contractor activities and the surveillance approach,

number of items to be inspected, and an Acceptable Quality Level (AQL) for each activity. This

series of 12 guides will help the Contracting Officer's Representative/Quality Assurance Evaluator

by defining and clarifying the inspection tasks

required by the QASP, which will facilitate inspec- tion uniformity and effectiveness.

This guide discusses OA monitoring of wastewater

collection and wastewater treatment systems.

94-00077

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Approved for public release; distribution is unlimited.

94 3 (093
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REFERENCE: USACERL Special Report FF-94/02, Guidelines for Quality Assurance Inspection of

Commercial Activities Contracts for Real Property Maintenance Activities, Guide #2:

Wastewater Systems

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REPORT DOCUMENTATION PAGE

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1. AGENCY USE ONLY (Leave ls2k) 12. RV DATE 3. REPORT TYPE AND DATES COVERED

October 1993 Final

4. TITLE AND SUBTITLE & FUNDIN NUMBER

Guidelines for Quality Assurance Inspection of Commercial Activities Contracts 4A !62784

for Real Property Maintenance Activities, Guide #2: Wastewater Systems AT41

SB-A5 i

6. AUTHOR(S)

James H. Johnson and Paul C. Bresnahan

7. PERFORMING ORGANIZATION NAME(S) AND ADORESS(ES) . PERFORING ORGANIZATION

U.S. Army Construction Engineering Research Laboratories (USACERL) REPORT NUMBER

P.O. Box 9005 SR FF-94/02

Champaign. IL 61826-9005

9. SPONSORING•tONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. N

U.S Army Center for Public Wcrks (USACPW) AGENCY REPO NUMBER

ATrN: CECPW-FM-S

Bldg 358

Fort Belvoir, VA 22060-5516

11. SUPPLEMENTARY NOTES

Copies are available from the National Technical Information Service, 5285 Port Royal Road, Springfield, VA

22161.

12a% DISTRISUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE

Approved for public release; distribution is unlimited.

13. ABSTRACT (MUxmm 200 waord)

A Quality Assurance (QA) Program allows the Army to evaluate and document a contractor's work performance.

It depends on a QA Surveillance Plan (QASP). The QASP, which is based on the contract Performance Work

Statement, lists contractor activities and the surveillance approach, number of items to be inspected, and an

Acceptable Quality Level (AQL) for each activity. This series of 12 guides will help the Contracting Officer's

Representative/Quality Assurance Evaluator by defining and clarifying the inspection tasks required by the

QASP, which will facilitate inspection uniformity and effectiveness.

This guide discusses QA monitoring of wastewater collection and wastewater treatment systems.

14. SUBJECT TERMS 15. NUMBER OF PAGES

quality assurance 30

real property maintenance activities I& _PRICECODE

wastewater treatment systems

17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT

OF REPORT OF THIS PAGE OF ABSTRACT

Unclassified Unclassified Unclassified SAR

NSN 7540-01-2W0-5500 _qw1dard Frm 216 (Rev. 2-49)

Pumsaeeihb AmSp sod 2ins
FOREWORD

This research was performed for the U.S. Army Center for Public Works (USACPW). under project

4A 1 62784AT4 1, "Military Facilities Engineering Technology," Work Unit SB-A5 1, "QA Inspections Via

Condition Monitoring." The technical monitors were Robert Hohenberg and George Cromwell,

CECPW-FM-S.

The work was performed by the Facility Management Division (FF) of the Infrastructure Laboratory

(FL), U.S. Army Construction Engineering Research Laboratories (USACERL). Alan W. Moore is Acting

Chief, CECER-FF, and Dr. Michael J. O'Connor is Chief, CECER-FL. Special appreciation is expressed

to Robert D. Neathammer of CECER-FF and John H. Williamson, formerly of CECER-FF, for their

contributions. The USACERL technical editor was Gloria J. Wienke, Information Management Office.

LTC David J. Rehbein is Commander of USACERL and Dr. L.R. Shaffer is Director.

2
CONTENTS

pare

SF 298 1

FOREWORD 2

INTRODUCTION ................................................... 5

Background

Objective

Guide Series Organization

2 GENERAL QA INSPECTION INFORMATION ............................. 7

Inspection Organization and Planning

Quality Assurance Surveillance Methods

Increased Surveillance

Decreased Surveillance

3 WASTEWATER SYSTEM QA INSPECTIONS ............................ 10

Wastewater Colection

Wastewater Treatment

METRIC CONVERSION TABLE 15

ACRONYMS 16

REFERENCES 16

APPENDIX A: Inspection Sampling Tables 17

APPENDIX B: QAE Inspection Worksheets

Wastewater Collection 19

Wastewater Treatment 24

DTIC QUALITY INSPECTD 3

DISTRIBUTION

NTIS R&

ODC TAB

U•,announlced

Jostification

......................... ................

By tiof i

Dist ASj~ aidi

3
GUIDELINES FOR QUALITY ASSURANCE INSPECTION OF COMMERCIAL ACTIVITIES

CONTRACTS FOR REAL PROPERTY MAINTENANCE ACTIVITIES

GUIDE #2: WASTEWATER SYSTEMS

1 INTRODUCTION

Background

A Quality Assurance (QA) program allows the Army to evaluate and document a contractor's

performance. The Quality Assurance Evaluator (QAE) conducts skilled and carefully planned inspections

aimed at verifying the satisfactory completion of contractor work. The inspections evaluate the quality,

quantity, and timeliness of the services provided, not the contractor's methods used in performing the

work. A good QA program promotes the best possible product within the terms of the standing contract.

A well organized QA program depends on a QA Surveillance Plan (QASP), which is prepared by

the Government and contains the purpose and methods of the QA program. Although the QASP is not

a part of the contract, it is based on the contract Performance Work Statement. which is part of the

contract. The QASP lists contractor activities and the surveillance approach, approximate number of items

to be surveyed. and an Acceptable Quality Level (AQL) for each activity.

The installation Director of Public Works (DPW), the Contracting Officer (KO), or the Contracting

Officer's Representative (COR) often oversees the QASP. The COR/QAE needs an inspection guide to

help define and clarify the inspection tasks required by the QASP, and to facilitate inspection uniformity

and effectiveness. To meet this need, the U.S. Army Construction Engineering Research Laboratories

(USACERL) developed this series of 12 inspection guides.

Objective

This guide series is intended to supplement any existing QASP and to provide QA guidance for

evaluating Operations and Maintenance (O&M) work as performed by contractors on Army property. This

wastewater system guide contains recommended surveillance methods that can be amended by direction

of the KO or QA management to fit the needs of a specific installation.

Guide Series Organization

This series includes the following guides by USACERL published in October 1993:

#1: Water Systems (Special Report [SR] FF-94/01)

#2: Wastewater Systems

#3: Natural Gas Distribution Systems (SR FF-94/03)

#4: Electrical Systems (SR FF-94/04)

#5: Heating Systems (SR FF-94/05)

#6: Ventilation, Air Conditioning, and Refrigeration Systems (SR FF-94/06)

#7: Building Services (SR FF-94/07)

#8: Grounds Maintenance (SR FF-94/08)

#9: Surfaced Areas (SR FF-94/09)

5
#10: Refuse and Recyclable Handling (SR FF-94/10)

#11: Pest Control Services (SR FF-94/1 1)

#12: Custodial Services (SR FF-94/12).

The QAE is expected to evaluate a contractor's performance by applying appropriate visual and

instrumentation procedures along with necessary technical and interpretive skills. This guide covers QAE

inspection of wastewater systems, and is divided into sections that take the inspector through a step-bystep process of recommended performance indicators, inspection tasks, and surveillance methods.

Wastewater systems are divided into two subsystems in this guide:

1. Wastewater Collection

2. Wastewater Treatment.

General QA information, including detailed explanations of the available surveillance methods, is

given in Chapter 2.

Chapter 3 provides performance indicators, inspection tasks, and recommended surveillance

approaches for each subsystem.

Appendix A contains sampling inspection tables. Appendix B contains QAE Worksheets for each

subsystem; they may be reproduced for field use.

6
2 GENERAL QA INSPECTION INFORMATION

Inspection Organization and Planning

According to custom and standard practice, the contractor submits copies of the previous month's

O&M activities and regulatory agency reports to the COR and the QAE. The due dates of these reports

control the start of inspection scheduling. If possible, the QAE's inspection should be conducted within

3 days after receiving the reports. Effective coordination will allow more efficient inspection of services.

The COR/QAE should look for specific indicators of the contractor's performance and should evaluate

that performance based on Detailed Inspection Tasks. The following chapter lists the Performance

Indicators and Detailed Inspection Tasks for wastewater systems.

Quality Assurance Surveillance Methods

The QAE can use the following five surveillance methods to determine contractor performance:

1. Random Sampling

2. Planned Sampling

3. 100 Percent Inspection

4. Unscheduled Inspection

5. Customer Complaints.

Random Sampling

The methods are based on statistical criteria provided in Military Standard (MIL-STD)-105E,

Sampling Procedures and Tables for Inspection by Attributes (10 May 1989) and are presented as

recommendations. The methods used should be based on the unique needs of an individual system.

Generally, all five methods are not used to evaluate an individual system.

Random sampling is recommended for situations where many work items are candidates for

inspection. For instance, because it is impractical to inspect every roof on an installation with

500 buildings, only a select number of the buildings should be inspected. Likewise, in random sampling,

only a portion of the total performed work is inspected. Acceptance of the work is based on the

assumption that the inspected items are representative of the quality of the contractor's work. The random

sampling technique spreads the selected samples evenly throughout the evaluation period. The following

are steps to be used by the QAE in random sampling.

Tables Al and A2 in Appendix A should be used to determine the number of samples to be

inspected and the number of rejects allowed as a function of the number of inspected work items for

AQLs of 4 and 10 percent, and the level of surveillance. The three levels of surveillance are: normal,

increased (tightened), and reduced. Initially, this guide recommends normal surveillance for random

sampling. However, under the direction of the KO, the level of surveillance can be changed depending

on the contractor's performance.

As an example, assume that the contractor's total scheduled output (i.e., population size) for a

particular work item is 125 units and that the normal surveillance level with an AQL of 4 percent has been

selected. According to Table Al, 20 of the 125 units of work should be inspected, and the entire output

of 125 units should be rejected if 3 or more of the 20 sample units are not acceptable.

7
The QA Worksheets in Appendix B provide room to record the population size, the number of

samples, the maximum number of rejects, and the interval for each Performance Indicator.

The work planned by the contractor for each maintenance task should be listed by date to make it

easier to predict the time when the work samples will be ready for inspection.

Planned Sampling

Evaluation by planned sampling inspects some, but not all, of the work activities and is appropriate

when the number of work items is large. Some items are evaluated before scheduled completion because

they are inaccessible after the work is completed. The COR/QAE subjectively selects key work items for

inspection; the sample size is determined arbitrarily.

The COR/QAE will normally use planned sampling when the contractor's performance at selected

locations or tasks is poor. With this type of evaluation, the contractor knows that work performed in these

areas is more likely to be monitored. Planned sampling provides a systematic way of focing on specific

output and forming conclusions about the contractor's performance level.

100 Percent Inspection

Inspection at 100 percent requires total inspection of all items in a contract requirement. It is

normally used to monitor infrequent work or critical contract work when the number of work items is

small and in cases where nonperformance could seriously damage Army-furnished equipment or processes.

It may also be used in areas where a contractor has had prior performance difficulties.

Unscheduled Inspection

Unscheduled inspections can be used for areas of poor past contractor performance, noncritical areas,

areas of infrequent repairs, or as a follow-up check of previous inspections. If the QAE notices such an

area, an unscheduled inspection can be conducted to evaluate contractor performance.

Customer Complaints

The customer complaint method is based on an informed and cooperative customer population, that

is generally aware of local contract requirements. Customers are expected to monitor contractor services

and, when performance is poor or nonexistent, to notify the COR/QAE. If investigation reveals that the

complaint is valid, the COR/QAE documents the deficiency. Since this is a reactive QA inspection

approach, this method of surveillance normally supplements planned inspection methods.

Increased Surveillance

For areas of poor past contractor performance, the QAE should consult with the KO to intensify the

surveillance method. More than one option is usually available, and selection should be based on the

initial method and the amount of work performed.

1. Random Sampling (Normal Surveillance) can be replaced by:

* Random Sampling (Increased Surveillance)

* Planned Sampling (for a large population size)

8
* 100 Percent Inspection (for a small population size)

* Unscheduled Inspection (for any population size).

2. Planned Sampling can be replaced by:

* Random Sampling (Normal Surveillance)

* 100 Percent Inspection (for a small population size)

* Unscheduled Inspection (for any population size).

3. Unscheduled Inspections can be replaced by:

• 100 Percent Inspection (for a small population size)

• Random Sampling (Normal Surveillance)

* Planned Sampling.

Decreased Surveillance

For work areas in which the contractor maintains a consistently satisfactory performance for 3 to

6 months, the QAE should consult with the KO to decrease the intensity of the surveillance. More than

one option is usually available and selection should be based on the initial method and the amount of work

performed.

1. Random Sampling (Normal Surveillance) can be replaced by:

* Random Sampling (Reduced Surveillance)

* Planned Sampling

* Unscheduled Inspection (for any population size)

* Customer Complaints.

2. Planned Sampling can be replaced by:

* Unscheduled Inspection (for any population size)

* Customer Complaints.

3. 100 Percent Inspection can be replaced by:

* Random Sampling (Normal Surveillance)

* Random Sampling (ReLtced Surveillance)

* Planned Sampling

• Unscheduled Inspection (for any population size)

* Customer Complaints.

9
3 WASTEWATER SYSTEM QA INSPECTIONS

Wastewater Collection

Performance Indicators and Detailed Inspection Tasks

The following numeric items are performed by the contractor. The related detailed inspection tasks

are used by the QAE to verify the contractor's performance.

I. The Preventive Maintenance (PM) checklists and logs are complete, legible, and timely.

Verify that the contractor's PM checklists and logs are complete, legible, and timely. All tasks

must be listed, dated, designated as completed, and initialed by the person(s) who performed

or accepted the work. Check the reports and logs for completeness in the following areas:

a. Description of normal inspection and maintenance of the sewer mains, service lines, and

lift stations.

b. Reports of corrective actions taken if stoppages, failures, or overloading occur.

c. Records indicating leaks, new service lines, and locations of potential cross-connections.

d. Records cf the flushing, rooting, and cleaning of sewer mains.

e. Records of annual hydrocleaning of wastewater collection lines and sludge removal from

septic tanks.

2. An adequate spare parts inventory is being maintained in case of emergency repairs.

Verify that the contractor is maintaining an adequate inventory of wastewater collection spare

parts (i.e., piping, fittings, etc.) for emergency repairs. The number and types of spare parts

should be determined locally based on installed equipment records and appropriate

recommendations/advice found in TM 5-660, TM 5-661, and TM 5-813-5. All sewer main

sizes should be represented.

3. The manhole maintenance is satisfactory.

Verify the effectiveness of manhole maintenance using the following indicators:

a. The manhole frame is tightly sealed to the masonry structure, and masonry joints in the

manhole structure are properly sealed with mortar or bituminous material.

b. The flow channel in the bottom of the manhole is free of accumulated material, allowing

smooth flow from all incoming lines into the receiving main.

Note: Safety precautions require that all personnel be accompanied when inspecting underground facilities.

Use two lift bars when opening manhole covers. Exercise care when handling the cover

because it is heavy and tends to flip over.

10
4. The lift station and sewage-handling equipment maintenance is satisfactory.

Verify the effectiveness of lift station and sewage-handling equipment maintenance in areas

where:

a. Recent inspections have shown deficiencies,

b. No inspections have been conducted in the past 90 days, and/or

c. Sewage backups or overflows have been reported.

Note: Safety precautions require that all personnel be accompanied when inspecting underground facilities.

Lift Stations

a. Pumping Chamber Inspections. When inspecting lift stations, one member of the

inspection team should remain aboveground in case of an accident. Ventilating fans, if

present, should operate for at least 1 minute before entering the pump chamber. Verify

that:

(1) The pump chamber is well lighted, and steps, handrails, and gratings are solidly in

place.

(2) Litter or discarded repair parts have not accumulated.

(3) All exposed metal surfaces are free of rust or peeling paint.

(4) If the wet well is part of the pump chamber, check that the water level is normal and

look for high-water marks that might indicate recent flooding.

b. Wet Well Inspections. Wet wells are holding chambers for wastewater coming into a

pumping station; they provide a collection point for grit and heavy solids that could

damage lift pumps. Check that:

(1) The water level is normal and there are no high-water marks that might indicate

recent flooding.

(2) The top of the sludge accumulation is always a minimum of 18 in. below the pump

suction line. Each lift station should have a probe to measure the depth of sludge

accumulated in the bottom of the wet well.

Sewage-Handling Equipment. Compare the frequency and cost of required repairs for sewagehandling equipment with historical records as a measure of the contractor's effectiveness. If

the interval between repairs has decreased significantly, notify the KO. If historical data is

unavailable, begin a repair file on each major component for future reference.

5. Sanitary sewer line and sewage-handling equipment problems are promptly identified, the

equipment is efficiently repaired, and the system is restored to service.

11
Verify that sanitary sewer line and sewage-handling equipment problems are promptly identified, the equipment is efficiently repaired, and the system is restored to service. Repair work

performed under a work order should be evaluated by unscheduled inspections of the individual

work orders. Visit the repair site to verify that the work is being performed diligently with

minimal service interruption. When the repair work is finished, check that the construction

area is clear of debris and excavated areas are graded to match the surrounding area. Recheck

the site later to see that excavated areas that have settled have been reshaped.

6. Cathodic protection for wastewater tanks and underground conductive piping is adequate.

Check all wastewater tank and underground conductive piping cathodic protection equipment

to ensure that adequate protection against corrosion still exists.

7. "As-built" drawings are updated with changes and corrections.

Verify that the contractor maintains current "as-built" drawings of wastewater collection

facilities and equipmenL Check to see that the drawings are updated annually with all changes

and corrections. The draftperson's initials and the date should accompany each change.

8. An adequate library of equipment manufacturers' manuals is being maintained.

Verify that the contractor maintains an adequate library of manufacturers' manuals for

equipment and facilities. Manuals should be obtained for newly installed equipment, and

obsolete manuals should be discarded.

Recommended Surveillance Approach

* Evaluate performance indicators #1 and #2 monthly using the 100 percent inspection method.

* Evaluate performance indicator #3 monthly using random sampling (normal surveillance,

10 percent AQL).

" Evaluate performance indicators #4 and #5 periodically using the unscheduled inspection

method.

" Evaluate performance indicators #6 through #8 annually using the 100 percent inspection

method.

Wastewater Treatment

Performance Indicators and Detailed Inspection Tasks

The following numeric items are performed by the contractor. The related detailed inspection tasks

are used by the QAE to verify the contractor's performance.

1. The PM logs and checklists are complete, acceptable, and timely.

Verify that the contractor's PM logs and checklists are complete, legible, and timely. All tasks

must be listed, dated, designated as completed, and initialed by the person(s) who performed

or accepted the work. Check for the following documentation:

a. Descriptions of normal inspections and O&M activities of the wastewater treatment plant,

including copies of laboratory analyses of effluent samples.

12
b. Reports of corrective actions taken in the event of equipment failure, overloading, or

failure to meet National Pollutant Discharge Elimination System (NPDES) permit

requirements for effluent quality.

c. Recommended improvements to the treatment plant which will increase its performance,

or repairs to damaged or deteriorated components.

2. The plant equipment repair frequency is satisfactory.

Evaluate the contractor's repair effectiveness by comparing the frequency and cost of required

repairs with historical records of the wastewater treatment plants. If the interval between

repairs has decreased significantly, notify the KO. If historical data is unavailable, start a

repair file on each major component for future reference.

3. The operation and maintenance of wastewater treatment facilities is satisfactory.

Visit all wastewater treatment facilities monthly and evaluate the effectiveness of the

contractor's O&M for each plant based on the following:

a. General. Check that the buildings and grounds look neat and are free of litter:

(1) Grassed areas around the buildings and plant components are mowed and trimmed.

(2) Buildings and exposed pipes are free of rust and peeling, deteriorated paint.

(3) Cleaning equipment and debris from repairs are removed from the site.

b. Bar Screens. Verify that material screened from the incoming wastewater was removed

from the bar screens and placed in a container for disposal.

c. Grit Removal. Check that the amount of sediment collected in the grit removal channel

since the last cleaning is less than 1/4 in.

d. Comminutor. Verify that:

(1) Lubrication fittings are clean and bright, indicating frequent use, and their surfaces

show a film of lubricant.

(2) The comminutor is operating smoothly and quietly, and the cutters are clear of debris.

e. Primary Clarifiers. Check that:

(1) The water surface in the clarifiers is reasonably clear of floating solids.

(2) Material removed from the surface is placed in containers for disposal.

(3) Gas bubbles are rising from the sludge digestion process in the bottom of the tanks

to the water surface.

(4) Accumulated sludge is at least 12 in. below the bottom of the baffles.

13
f. Filters. Verify that:

(I) The distribution system spreads the wastewater evenly across the filter bed.

(2) The movement of the distribution equipment is smooth and quiet.

(3) Lubrication points are clean and bright, indicating frequent use.

(4) Large numbers of flies are not present.

(5) The filter's surface does not contain ponded water.

g. Secondary Clarifiers. Check to see that:

(1) The water surface in the secondary clarifiers is reasonably clear of floating solids.

(2) Material removed from the surface is placed in containers for disposal.

(3) Gas bubbles are not rising from the bottom of the clarifier tanks to the water surface,

which indicates an excess of settled sludge.

h. Pumping Equipment. Verify that:

(1) Pumps, piping, brackets, handrails, and other metal surfaces are painted and free of

rust.

(2) The pump room is free of accumulated debris and is washed clean.

(3) Pumps and motors am running smoothly and quietly without unusual grinding,

scraping, or squealing noises. Noise or excessive vibration during operation might

indicate a bearing or shaft alignment problem. QA instrumentation is especially

recommended to measure lift station pump operation:

(a) Motor vibration by attached sensors or portable probes

(b) Motor heating by thermocouple or infrared (IR) measures

(c) Shaft vibration (misalignment) by forked probe vibration meter

(d) Bearing condition by shock & frequency measures.

(4) Lubrication reservoirs are more than half full, and lubricant flow is visible when the

pumps are running. Grease fittings are clean and bright, indicating frequent use, and

have a slight film of residual lubricant on the surface.

(5) Pump air inlets, air impellers, and heat exchange surfaces are clean of dust and dirt

that may impede the pump from functioning efficiently.

(6) Pipe networks and tanks within the wastewater plants show no signs of leakage.

14
4. Effluent quality reports show that National Pollutant Discharge Elimination System (NPDES)

permit requirements are met.

Verify that effluent samples meet NPDES permit requirements. Besides checking the documentation for compliance with effluent standards, collect an effluent sample monthly and deliver

it to a licensed testing laboratory for analysis.

5. Plant equipment problems are promptly identified, the equipment is efficiently repaired, and

the system is restored to service.

Verify that plant equipment problems are promptly identified, the equipment is efficiently

repaired, and the system is restored to service. Evaluate the contractor's repair performance

using unscheduled inspections of individual work orders. Visit the site of the selected repair

to verify that the work is being performed diligently with minimal service interruption. After

completion of the repair work, verify that the construction area is clear of debris and that any

excavated areas are graded to match the surrounding area. Recheck the site later to see that

excavated areas that have settled are reshaped.

6. "As-built" drawings are updated with changes and corrections.

Verify that the contractor maintains current "as-built" drawings of wastewater treatment

facilities and equipment. See that the drawings are updated annually with all changes and

corrections. The draftperson's initials and the date should accompany each change.

7. An adequate library of equipment manufacturer's manuals is being maintained.

Verify that the contractor maintains an adequate library of manufacturer's manuals for

equipment and facilities. Manuals should be obtained for newly installed equipment, and

obsolete manuals should be discarded.

Recommended Surveillance Approach

Evaluate performance indicators #1 through #4 monthly using the 100 percent inspection

method.

* Evaluate performance indicator #5 periodically using the unscheduled inspection method.

* Evaluate performance indicators #6 and #7 annually using the 100 percent inspection method.

METRIC CONVERSION TABLE

tin. = 254cm

Igul = 3.78L

Ipsi = 6.89kPa

OF = (OC + 17.38) X 1.4

15
ACRONYMS

AQL Acceptable Quality Level

COR Contracting Officer's Representative

DEH Director of Engineering and Housing

KO Contracting Officer

MIL-STD Military Standard

O&M Operations and Maintenance

QA Quality Assurance

QAE Quality Assurance Evaluator

QASP QA Surveillance Plan

REFERENCES

Johnson, James, Special Report FF-93/DRAFT, Catalog of Industrial Instrumentation for Army Real

Property Quality Assurance Applications (U.S. Army Construction Engineering Research Laboratory, 1993).

Military Standard 105E, Sampling Procedures and Tables for Inspection by Attributes (Department of

Defense, 10 May 1989).

Technical Manual (TM) 5-660, Maintenance and Operation of Water Supply, Treatment, and Distribution

Systems (Headquarters, U.S. Army Corps of Engineers [HQUSACE], 30 August 1984).

TM 5-661, Inspection and Preventive Maintenance Services for Water Supply Systems at Fixed

Installations (HQUSACE, 21 September 1945).

TM 5-813-5, Watcr Supply: Water Distribution (HQUSACE, 3 November 1986).

16
APPENDIX A: Inqsction Samplin Tables

Talb Al

Samw im and Rec LaIs (4% AQL)

(As dsveloped hrum TAW=e I A 1 in MIL STD 105E)

Necuid Swwemce Molkoi) SamiBMN bimie Surd~w

pblaion Clue 1 Reject c'a il Reject Cls I Raj"

Size Sample Sim Lvel Sample Sim Level Sample Sam Level

09 toSO * 25% 1 * 40% 1 -

51to90 B 13 2 F 20 2 * 3% 1

91 to 150 F 20 3 G 32 3 * 3% 1

151 io 280 G 32 4 H 50 4 E 5 2

281 to 500 H 50 6 J O0 6 P 8 3

501 to 1200 J OD a K 125 9 0 13 4

1201 to3200 K 125 11 L 200 13 H 20 5

The Reject Level is the number of failed ispectios requiring rejection of the Lot (population).

An mtrisk (*) indicates that the sample level is outside the rang of a 4% AQL for the selected clam.

Table A2

Sample Sims and Reject Levek (10% AQL)

(As developed from Tables I & U in MIL STD 105E)

Normsd Survelbme TOtamed S ewidUme Reduced Surveihmc

Popilation ClM U Rejeat Clau H Reject Clm I Rje

size Sample size Level Sample Sims Level Sample size Level

06 to 15* 33% 1 * 50% 1 - -

16 to 25 C 5 2 D 8 2 8% 1

26 to 50 D a 3 E 13 3 C 2 2

51 to 90 E 13 4 F 20 4 C 2 2

91 to 150 F 20 6 G 32 6 D 3 3

151to280 G 32 8 H 50 9 E 5 4

231 to 500 H 50 11 1 s0 13 P a 5

501 to 1200 J I0 15 K 125 19 G 13 6

1201 to 3200 K 125 22 L 200 19 H 20 8

The Reject Level is the number of failed imspection that require rejectiou of the Lot (populion).

An meisk (0) indicas that the sample level is oubtide the ngp of a 10l AQL for the @eced clmu.

17
Tabb A3

Ramdow Nmbenr

261693551131255178756684494628935

181459272254919294929363514311161

423684632668854911328619871243413

272488835332639327718359681593246

841374461696375621432857824777426

264815497173372174477827576566258

198696837541361133287541914971848

143756559946462345899983232775998

836386389619398398564958743782384

152583752379444483126729978423414

157294256486135451922159757675563

692719775436636344668381479147277

255866785826243276617432848931777

611919299912864737547181342159257

995114899826933259579628311933162

961887783225263664522813323369394

228773817828833985717362765968277

396711473692748832584229148465364

364296446978847355179598467113258

765631978981768893583194674274798

547289272135619683789965964875955

226511337617444952591725499499882

466864615463968456242418384359596

457418823563532182925651994844445

999119589989834791257536542318835

227468225944237957788131431161258

857398792219798611985364339638151

794238617675343521476918924437481

137868789933163384334818634998454

547493731923873892515942491998179

767627325793444261524517992866885

846592135517861798366917922967153

236279562972427477546975199129675

622458294956263626621396846142574 63 549112 127115911723 2 1173 9 5 53 87 891

247679322228134298769578658536862

691714647658549488455817959321376

484198647441592433674892154372512

216868361457968723862991347544398 985456143 62 9619818899 9517492 19 166

532756133354124623325791838461116

227725726112161866812148528411739

289499684323994732419654185377369

234975324644686311896477631578977

679558544561494531732186224781459

537866411442511489428997247841811

723217286469739334471448867419951

843492726379831995871299668887848

18
APPENDIX B: QAE Inspection Worksheets

Wastewater Collection Worksheet Page 1 of 5

Performance Indicator #1: The PM checklists and logs ame complete, legible, and timely.

a. All performed tasks are dated and initialed by the operator(s).

S, U N

b. The documentation includes descriptions of normal inspection and maintenance of the sewer

mains, service lines, and lift stations.

S U N

c. The documentation includes reports of corrective actions taken if stoppages, failures, or

overloading occur.

S U N

d. The documentation includes records of leaks, new service lines, and locations of potential

cross-connections.

S U N

e. The documentation includes records of the flushing, rooting, and cleaning of sewer mains.

S U N

f The documentation includes records of annual hydro-cleaning of wastewater collection lines

and sludge removal from septic tanks.

S U N

Remarks:

Performance Indicator #2: An adequate spare parts inventory is being maintained in case of

emergency repairs.

S U N

Remarks:

"S = Satisfacry, U = Unaaisfiactoy, N = Not aWlicable. Cirle one rating for eah item.

19
Wastewater Collection Worksheet Page 2 of 5

Performance Indicator #3: The manhole maintenance is satisfactory.

a. The manhole frame is tightly sealed to the masonry structure, and masonry joints in the

manhole structure are properly sealed with mortar or bituminous material.

b. The flow channel in the bottom of the manhole is free of accumulated material, and it

allows smooth flow from all incoming lines into the receiving main.

Using the population size , and referring to normal surveillance in Tables Al and A2

gives number of samples and number of allowable rejects.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

20
Wastewater Collection Worksheet Page 3 of 5

Performance Indicator #4: The lift station and sewage-handling equipment maintenance is

satisfactory.

a. Lift Station Pumping Chamber

(I) The pump chamber is well lighted, and steps. handrails, and gratings are solidly in

place.

(2) Litter or discarded repair parts have not accumulated.

(3) All exposed metal surfaces are free of rust or peeling paint

b. Lift Station Wet Well:

(1) The water is normal and there are no high-water marks that might indicate recent

flooding.

(2) The top of the sludge is sufficiently below the pump suction line.

c. Sewage-Handling Equipment: The frequency and cost of required repairs is satisfactory.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

21
Wastewater Collection Worksheet Page 4 of 5

Performance Indicator #5: Sanitary sewer line and sewage-handling equipment repairs are promptly

identified, efficiently repaired, and restored to service.

a. Repair work is being performed diligently with minimal service interruption.

b. The construction area is clear of debris.

c. Excavated areas that have settled are reshaped.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

Performance Indicator #6: Cathodic protection for wastewater tanks and underground conductive

piping is adequate.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

22
Wastewater Colection Worksheet Page 5 of 5

Performance Indicator #7: "As-built" drawings are updated with changes and corrections.

a. The draftperson's initials accompany each change.

S U N

b. The date of change accompanies each correction.

S U N

Remarks:

Performance Indicator #8: An adequate library of equipment manufacturers' manuals is being

maintained.

a. Manuals for new equipment are obtained.

S U N

b. Obsolete manuals are properly discarded.

S U N

Remarks:

Quality Assurance Evaluator

Date

23
Wastewater Treatment Worksheet Page I of 4

Performance Indicator #1: The PM logs and checklists are complete, legible, and timely.

a. All performed tasks are dated and initialed by the operator(s).

S U N

b. Documentation includes descriptions of normal inspections and activities, including copies

of laboratory analyses of effluent samples.

S U N

c. Documentation includes reports of corrective actions taken in the event of equipment

failure, overloading, or failure to meet NPDES permit requirements.

S U N

d. Documentation includes recommended improvements to the treatment plant.

S U N

Remarks:

Performance Indicator #2: The plant equipment repair frequency is satisfactory.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

24
Wastewater Treatment Worksheet Page 2 of 4

Performance Indicator #3: The operation and maintenance of the wastewater treatment facilities is

satisfactory.

a. General areas are satisfactory.

b. The bar screens are satisfactory.

c. Grit removal is satisfactory.

d. The comminutor is satisfactory.

e. The primary clarifiers are satisfactory.

f. The filters are satisfactory.

g. The secondary clarifiers are satisfactory.

h. The pumping equipment is satisfactory.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

25
Wastewater Treatment Worksheet Page 3 of 4

Performance Indicator #4: Effluent quality reports show that NPDES permit requirements are met.

a. The testing reports are complete.

b. The effluent sample collected meets NPDES standards.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

Performance Indicator #5: Plant equipment problems are promptly identified, efficiently repaired,

and the system is restored to service.

a. Repair work is being performed diligently with minimal service interruption.

b. The construction area is clear of debris.

c. Excavated areas that have settled are reshaped.

LOCATION

S U N

S U N

S U N

S U N

S U N

S U N

S U N

S U N

Remarks:

26
Wastewater Treatment Worksheet Page 4 of 4

Performance Indicator #6: "As-built" drawings are updated with changes and corrections.

a. The draftperson's initials accompany each change.

S U N

b. The date of change accompanies each correction.

S U N

Remarks:

Performance Indicator #7: An adequate library of equipment manufacturers' manuals is being

maintained.

a. Manuals for new equipment have been obtained.

S U N

b. Obsolete manuals are properly discarded.

S U N

Remarks:

Quality Assurance Evaluator

Date

27
USACERL DISTRIBUTION

Chief of Engineers USARPAC 96858 Naval Facilities Engr Command

ATIN: CEHEC-IM-LH (2) ATTN: DEH ATTN: Facilities Engr Command (8)

AMFN: CEHEC-IM-LP (2) ATrN: APEN-A ATTN: Division Offices (01)

ATTN: CERD-L ATTN: Public Works Center (8)

HQ USEUCOM 09128 ATT`N: Naval Conm Batlalion Or

CECPW 22060 ATTN: ECJ4-LIE 93043

ATTN: CECPW-FM-S ATITN: Naval Civil Engr Service

ATTN: CECPW-FM AMMRC 02172 Center (3) 93043

ATFN: CECPW-FB ATrN: DRXMR-AF

ATTN: CECPW-FU ATTN: DRXMR-WE Tyndall APB 32403

ATTN: CECPW-F-DPN ATTN: HQAFCESA Program Ofc

CEWES 39180 ATTN: Engrg & Srvc Lab

US Army Engr District AT'N: Library

ATT'N: Library (40) US Gov't Printing Office 20401

CECRL 03755 ATTN: Rec Sec/Deposit Sec (2)

US Army Engr Division ATTN: Library

ATN:Defense 

Tech Info Cent 22304

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INSCOM ATTN: Facilities Engr 21719

ATrN: IALOG-I 22060 ATTN: AMSMC-IR 61299 197

ATIN: IAV-DEH 22186 ATIN: Facilities Engr (3) 85613 10/93

HQ XVIII Airborne Corps 28307 USAARMC 40121

ATTN: AFZA-DEH-EE ATTN: ATZIC-EHA

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Alexandria, VA 22333-0001 ATnN: MTEA-GB-EHP 07002

ATTN: AMCEN-F ATTN: MT-LOF 20315

Installations: ATrN: MTE-SU-FE 28461

ATTN: DEH (19) ATrN: MTW-IE 94626

Rocky Mountain Arsenal 8002

ATTN: AMCPM-RM Military Dist of WASH

Pine Bluff Arsenal 71602 Fort McNair

ATTN: SMCPB-EH ATTN: ANEN 20319

FORSCOM Norton AFB 92409

Forts Gillemn & McPherson 30330 A'fN: Library

ATiN: FCEN

Installations: Engr Societies Library

ATrN: DEH (23) ATTN: Acquisitions 10017

National Guard Bureau 20310 Defense Nuclear Agency

ATTN: Installations Div ATrN: NADS 20305

Fort Belvoir 22060 Defense Logistics Agency

ATTN: CECC-R 22060 ATTN: DLA-WI 22304

TRADOC US Military Academy 10996

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ATTN: ATBO-G ATTN: Facilities Engineer

Installations: ATTN: Geography & Envr Engrg

AMN: DEH (20)

ThWe pubhcai w- reprduhced on nqdyced paper. * U.S. GOVERNMEW PFSnT OFPFC 1993-4-W1-•84o