seg 06 -the role of critical control points in controlling ...€¢ fda/usda mandatory for juice and...
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2Role of Critical Control Points
• Systematic preventative approach to Food Safety.
• Common with TQM – focuses on process barriersrather than end of pipe quality.
• FDA/USDA mandatory for juice and meat.
• Applied to drinking water treatment.
• A number of examples for IPR and other recycledwater production
Hazard Analysis and Critical Control Points(HACCP)
Conceived in 1960s by Pillsbury for NASA
Defined in ISO 22000 – Food Safety
3Role of Critical Control Points
The 7 HACCP Principles
Conduct a HazardAnalysis
Determine CriticalControl Points
Establish CriticalLimits
Establish System toMonitor the Control of a
CCP
Establish Corrective Action to beTaken When Monitoring a CCP is
Not Under Control
Establish Procedures forVerification to Confirm that
HACCP System is workingeffectively
Establish DocumentationConcerning All Procedures andRecords Appropriate to These
Principles and Their Application
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4Role of Critical Control Points
HACCP Approach Applied to Recycling
IdentifyHazardousContaminants
IdentifySource ofContaminants
IdentifyHazardousEvents
Determine andRank Risks
Identify CriticalControl Points
Identify WaterQuality Testing
Validation Develop CCPResponseProcedures
Verification OngoingAnalysis andAssessment
Hazard Analysis
Critical Control Points
Monitoring
Procedures &Corrective Actions
Identify CriticalControl Points
Identify WaterQuality Testing
Validation Develop CCPResponseProcedures
Verification OngoingAnalysis andAssessment
Critical Control Points
Monitoring
Procedures &Corrective ActionsIdentify
HazardousContaminants
IdentifySource ofContaminants
IdentifyHazardousEvents
Determine andRank Risks
Hazard Analysis
5Role of Critical Control Points
Select Critical Control Points – Control Hazards
Halliwell et al WRRF 09-03
Clear methodology forCritical Control PointSelection
6Role of Critical Control Points
Example – Western Corridor Recycled Water Plant
CCP 2
Microfiltration(Pressure Decay Integrity Test)
CCP 3
Reverse Osmosis(Permeate conductivity)
CCP 4
Advanced Oxidation(Peroxide Dose and UV Dose)
CCP 1
Activated Sludge Process(On Line Ammonia)
CCP 5
Chlorine Dose(CT)
7Role of Critical Control Points
Establish Critical Limits
The HACCP team establishes critical limits to assess whether aparticular control measure is effective.
If this critical limit is exceeded or not met, it triggers the need for acorrective action.
The critical limit can be either a numerical limit (e.g., chlorine residualconcentration, system pressure) or a yes/no type response on whethera particular control measure was completed .
Example limit – Western Corridor Qld Australia
9Role of Critical Control Points
• Western Corridor Recycled Water Project, Brisbane Australia (ISO 22000Certified).
• PUB, Singapore SS 444:998 (Singapore Standard)
• Orange County Water District – Groundwater Replenishment Scheme, CA
• Melbourne Water – Recycling System
• Gold Coast Seawater Desalination Plant
• Elements in the US, but current concern is additional requirements.
Where have Critical Control Points BeenUsed
10Role of Critical Control Points
Critical Control Point Assessment toQuantify Robustness and Reliability ofMultiple Treatment Barriers of a DPRScheme
WRRF-13-03:Can We Trust the
Technology?
11Role of Critical Control Points
Direct Potable Reuse - The Definition
Indirect Potable ReuseDirect Potable Reuse
12Role of Critical Control Points
DPR- Raising the Stakes
Can We Trust theTechnology?
Can We TrustOperations?
Trust but VerifyWRRF 13-03
Critical Control Point Assessment to Quantify Robustnessand Reliability of Multiple Treatment Barriers of a DPRScheme
WRRF 13-13
Development of Operation and Maintenance Planand Training and Certification Framework forDirect Potable Reuse (DPR) Systems
Convincing a skeptical public Convincing regulators
14Role of Critical Control Points
Conduct a hazard assessment to identify health risks, identifywater quality objectives and identify critical control points for 2treatment trains.
Goals for 13-03
Full Advanced Treatment(FAT)
Non MembraneTreatment
16Role of Critical Control Points
Non FAT - O3 – BAC – GAC – UV – Cl2 – Engineered Storage
UV REACTOR
WASTEWATERTREATMENT PLANT
GAC
BAC
CHLORINE
CHLORINECONTACTOR
OZONE
DRINKING WATER PLANTOR DISTRIBUTION
ENGINEEREDSTORAGE
17Role of Critical Control Points
• Identify hazards and hazardous events.
• Assess and quantify those risks.
• Describe how hazards and hazardous events are to bemanaged and which control measures need to beimplemented.
Conduct a Hazard Analysis
Source Water Analysis
IdentifyHazardousContaminants
IdentifySource ofContaminants
IdentifyHazardousEvents
Determine andRank Risks
Hazard Analysis
18Role of Critical Control Points
Began with a literature review
• Source concentrations inliterature.
• Reviewing data fromparticipating utilities.
Identify Source Water Hazards
19Role of Critical Control Points
Target water quality -EPA primary drinking water regulations andincluded California Drinking Water Regulations.
Used lower of the two values where applicable
Focus on action levels and notification levels.
The team agreed not to include secondary standards unless anargument can be made for specific individual constituents.
Determined our Treated Water QualityObjectives
20Role of Critical Control Points
Identify Hazardous Events
Accidentalcontamination of the
catchment
Disease outbreak –high pathogen load
Failure of biologicalprocesses
High rainfall event –bypassed treatment Catastrophic
membrane integritybreach
Formation of DBPs inthe process train
Overdosing,underdosing or
contamination ofchemicals
21Role of Critical Control Points
Semi Quantitative Risk AssessmentWe established a model source water basedon CA facilities
Contaminant Risk before treatment Risk post treatment
22Role of Critical Control Points
CCPs – FAT TrainNDMA Control
Micro-organisms
Micro-organismsChemicals of Concern
Micro-organismsChemicals of Concern
Lead/copper leaching indistribution system.
Micro-organisms
23Role of Critical Control Points
CCPs – Non FAT TrainCCP and Risk Assessment Highlight Need for Process Modification
Particle Removal
Treat as Combined
TOC, DBP, DBPPrecursors
Micro-organisms Micro-organisms
Micro-organisms
Micro-organismsTOC
24Role of Critical Control Points
How Reliable are these CCPs?
Monte Carlo Simulation from FullScale Operating Data
Quantify Reliability with Statistical Analysis
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quency
0.0
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quency
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quency
27Role of Critical Control Points
TOC Rejection (%) by RO2 4 6 8
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quency
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quency
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quency
28Role of Critical Control Points
RO rejection (%) by Monte Carlo simulation93
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quency
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quency
98.0
98.2
98.4
98.6
98.8
99.0
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99.6
99.8
100.0
Fre
quency
92
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Fre
quency
29Role of Critical Control Points
• Identify gaps following review of full scale plants.
• Planned full scale plant tests (Scottsdale Water Campus)
• Additional bench scale for gaps if required.
Where to From Here..
Conduct Bench/Pilot Level Challenge Test Studies
30Role of Critical Control Points
Develop Standard Design Approachesand Response Strategies
Alert limit is exceeded
Check analyser as perWI-GWA-WCB-2232.
Check SCADA reading isconsistent with analyser reading.Check presence of significant air
bubbles in the associatedde-bubbling column.
Alert limit is still exceeded?
Monitor RO feed turbidityanalysers (1A_AIT 2004-1 or
1B_AIT 1921)
Record
Critical limit is exceeded
Critical limit is stillexceeded?
Check analyser as perWI-GWA-WCB-2232.
Check SCADA reading isconsistent with analyser reading.Check presence of significant air
bubbles in the associatedde-bubbling column.
NO
NOYES
YES
Shut down the MF plant if ROturbidity analyser exceeds 0.2NTU for more than 15 minutes
Manually initiate a PDT
PDT and start pressure areacceptable?
Refer to CCP 5 / PDT
YES
NO
Notify Plant Supervisor
MF plant auto shut down
Check the common header andunit selectable turbidity analysers
trends. Look for failure ofindividual MF units.
Put back online the units that areproducing acceptable filtratequality. Leave others offline.
31Role of Critical Control Points
Summary
Can We Trust theTechnology?
Trust but Verify
CCP – ongoing verification of the technology.
Provides a framework to transparently demonstrate how risks are managed.
Provides reliability and safety of water quality.
Integrates well into operations and is practical.
YES