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ANNUAL ENVIRONMENTAL REPORT
(AER) 2008
For
P. Carney Ltd.,
Crossakiel, Kells, Co. Meath
IPPC Licence Number: P0402-02
(EEC Ltd. Document Number 1123-01 v2.00)
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 2
Document no. 1123-01 v2.00
QF 1. v2 Document Lead Sheet
Document Title Annual Environmental Review (AER) 2008 (IPPC Licence Ref. P0402-2)
Project No. 1123-00 Document No. 1123-00 v2.00 Client P. Carney Ltd. Address Crossakiel, Kells, Co. Meath
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
2.00 Approved 18/05/2009 RnD
Where it is a requirement that this report be issued to a regulatory or other authority, then the client should sign the appropriate place in the above table and, unless specifically agreed in writing to the contrary, forward copies to the appropriate authority (e.g. EPA).
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: Róisín Ní Dhubhda B.Sc., M.Sc., AIEMA
Conditions relating to the issue of this report:
1. No alteration to this report by third parties is permitted
2. Where this report is reproduced, it shall only be reproduced in full.
3. Reports remain the property of Environmental & Efficiency Consultants
(Ireland) Limited until paid for in full.
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 3
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TABLE OF CONTENTS
1 Introduction ......................................................................................................... 5 2 Company Information ........................................................................................ 6 3 Copy of the Company Environmental Policy ................................................... 7 4 Site Description.................................................................................................... 8 4.1 Company Profile ............................................................................................8 4.2 Description of Equipment ..............................................................................8 4.3 Manufacturing Process ...................................................................................9
5 Summary of Emissions...................................................................................... 10 5.1 Emissions from Storm Water .......................................................................10 5.2 Emissions to Atmosphere.............................................................................14
6 Waste Management........................................................................................... 17 7 Resource Consumption ..................................................................................... 18 7.1 Water Consumption......................................................................................18 7.2 Energy Consumption....................................................................................19 7.3 Environmental Incidents and Complaints ....................................................19
8 Environmental Management of Activity......................................................... 20 8.1 Report on Environmental Objectives and targets for 2008 ..........................20
9 Licence Specific Reports (IPPC licence PO402-02) ....................................... 30 9.1 Pollution Emissions Register (PER) 2008 ...................................................30 9.2 Determine PERL for site ..............................................................................30 9.3 PER Proposal 2008.......................................................................................32 9.4 Noise Monitoring Report 2008 ....................................................................32 9.5 Bund Integrity ..............................................................................................32 9.6 Tank and pipeline testing report...................................................................32 9.7 Energy Efficiency Audit Report...................................................................33 9.8 Raw Materials Assessment...........................................................................33 9.9 Water minimisation study ............................................................................33 9.10 Environmental Liabilities and financial provisions .....................................34
Figure 5-1: pH Storm Water Results (2005-2008).......................................................11 Figure 5-2: COD Surface Water Results (2005-2008).................................................12 Figure 5-3: Aluminium Storm Water Results (2005-2008) .........................................12 Figure 5-4: Copper Surface Water Results (2005-2008) Note 1 .....................................13 Figure 5-5: Lead Surface Water Results (2004-2008) Note 2 .........................................13
Table 2-1: AER Content.................................................................................................5 Table 2-1 Company details ............................................................................................6 Table 2-2 Summary of IPC licence ................................................................................6 Table 5-1 Parameters and Monitoring Schedule (licence number: P0402-02) ............10 Table 5-2 Emissions to Storm Water – Monitoring results (2005-2008) ...............11 Table 5-3 Air Monitoring Programme A2-1 (IPPC licence PO402-02) ......................15 Table 5-4 Monitoring Results 2008 from Emission Stack A2-1 .............................16 Table 6-1 Waste Generation during 2008 ................................................................17 Table 6-2 Summary of wastes generated in 2008 ....................................................18
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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Table 7-0-1 Energy Consumption for 2007-2008:.......................................................19 Table 8-1 Report on Objectives and targets for 2008 ..................................................21 Table 8-2 Objectives and Targets for 2009 ..............................................................23 Table 9-1 PER 2008 .....................................................................................................31 Table 9-2 Environmental liabilities..............................................................................34
Appendix 1 Copy of Certificates of Analysis – Storm water 2008 .........................36 Appendix 2 Copy of Certificates of Analysis – Air Monitoring 2008.....................39 Appendix 3 Copy of Dioxin Monitoring Report – May 2008 .................................44 Appendix 4 Copy of Dioxin Monitoring Report – September 2008........................50 Appendix 5 Tank and pipeline inspection report .....................................................56 Appendix 6 Noise Monitoring Report 2008 ............................................................58 Appendix 7 Energy Audit Report Summary............................................................59 Appendix 8 Emergency Response Plan ...................................................................60 Appendix 9 Accident Prevention Policy..................................................................61
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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1 Introduction
P. Carney Ltd was originally licensed by the Agency in April 1999 (Licence No. 402).
However, to accommodate changes in regulations and the installation of an abatement
system, the EPA required the company to request a review. A new licence was
granted by the Agency in August 2006 (P0402-02).
As laid out in Schedule D of IPPC Licence P0402-02, Table 2-1 shows the content
that has to be included in P. Carney Ltd. Annual Environmental Report (AER).
Table 2-1: AER Content
AER Content
• Emissions from the installation.
• Waste management record.
• Resource consumption summary.
• Complaints summary.
• Schedule of Environmental Objectives and Targets.
• Environmental Management Programme – report for previous year.
• Environmental Management Programme – proposal for current year.
• Pollution Emission Register – report for previous year.
• Pollution Emission Register – proposal for current year.
• Noise monitoring report summary.
• Ambient monitoring summary.
• Tank and pipeline testing and inspection report.
• Reported incidents summary.
• Energy efficiency audit report summary.
• Report on the assessment of the efficiency of use of raw materials in processes
and the reduction in waste generated.
• Statement of measures in relation to prevention of environmental damage and
remedial actions (Environmental Liabilities).
• Any other items specified by the Agency.
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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2 Company Information
Table 2-1 Company details
Company P. Carney Ltd
Address Crossakiel,
Kells.
County / City Co. Meath
Business Manufacturers of Aluminium Ingot,
Copper Granules, and Aluminium
Granules
Employees 36
Contact Name Mr. Declan Clarke
Position Company Manager
Telephone 046 9243634
Fax 046 9243916
Email dclarke@pcarneyltd.ie
IPPC Registration Number P0402-02
Table 2-2 Summary of IPC licence
IP(P)C Licence Reg: No. Period
402 (IPC licence) 30/4/1999 – 30/4/2006
PO402-02 (IPPC licence) 30/4/2006 - present
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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3 Copy of the Company Environmental Policy
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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4 Site Description
4.1 Company Profile
P. Carney Ltd is located on a site in the village of Crossakiel, Co. Meath,
approximately 9 km west of Kells. The company employs 36 people in total and
normally operates on a 5 day week schedule.
P. Carney Ltd is an Irish company established in 1964 and originally was a metal
trader that took in various types scrap metal. The main site process is taking in
aluminium and processing it into aluminium ingots for use in the automotive industry.
There is also a further side to the business that produces copper and aluminium
granules from copper and aluminium cables. The company falls under Class 3.4.2 of
the first schedule of the Protection of the Environment Act, 2003:-
“The production, recovery or processing of non-ferrous metals, their compounds or
other alloys including antimony, arsenic, beryllium, chromium, lead, magnesium,
manganese, phosphorus, selenium, cadmium or mercury, by thermal, chemical or
electrolytic means in installations with a batch capacity exceeding 0.5 tonnes, not
included in paragraph 3.4.1”.
P. Carney Ltd is a TS 16949 (automotive standard) and an ISO 9002 approved
company. The two main processes undertaken onsite comprise the production of the
following:
1. Aluminium Ingots, and
2. Aluminium and Copper Granules.
The company is committed to continuous improvement, which is the core of the
environmental management programme currently in operation at the facility.
4.2 Description of Equipment
The main pieces of equipment are as follows:
• Furnacing equipment with loading and casting machine equipment
• On site weighing facilities
• 3 no. complete granulation systems
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• HGVs, trailers, skips, bins etc for transportation of material
• Forklifts and materials handling equipment
4.3 Manufacturing Process
The company is involved in the manufacture of aluminium ingots for the automotive
industry and the production of copper and aluminium granules.
A summary of the manufacturing process is given below:
High End Quality Scrap
Aluminium and Various Cables
Aluminium (sorted by quality)
Copper and Aluminium Cable
Copper Cable
Aluminium Cable
Furnace
Aluminium Ingot
Granulating
Process
Plastic/Rubber
Copper Granules
Aluminium Granules
Quality Control
Aluminium Ingot Product
Copper Granules Product
Aluminium Granules Product
Sold to horse arenas
Client
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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5 Summary of Emissions
The company has the following licensed emissions:
� Emissions to Surface Water
� Emissions to Atmosphere
� Waste Emissions
5.1 Emissions from Storm Water
Emission from Storm Water, monitoring programme
Under Schedule C.2.3 of the IPPC Licence P0402-02, Storm Water Emission
monitoring is required. The monitoring schedule for emissions to storm water is
provided in Table 5-1 below:
Table 5-1 Parameters and Monitoring Schedule (licence number: P0402-02)
Parameter Monitoring Frequency Analysis Method / Technique
COD Bi-annually Standard Method
Aluminium Bi-annually Standard Method
Copper Bi-annually Standard Method
Visual Inspection Weekly Sample and examine for colour
and odour
Emission from storm water, monitoring results
Analysis of emissions to surface water is carried out by Analytical Services and
Environmental Projects (ASEP), Queen’s University, Belfast on the 16th April 2008
and the 29th September 2008. A summary of monitoring results for 2008 is provided
in Table 5-2 along with results for the four previous years. There are no ELVs for
storm water emissions, however results were examined in the context of the Urban
Wastewater Treatment Regulations (S.I. No. 254 of 2001) 2001 and the Water Quality
(Dangerous Substances) Regulations, 2001. No chemical parameter exceeded the
specified limits of these regulations during 2008. Certificates of analysis are provided
in Appendix 1 of this report.
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Table 5-2 Emissions to Storm Water – Monitoring results (2005-2008)
Parameters pH COD
(mg/l)
Aluminium
(ppm)
Copper
(ppm)
Lead
(ppm)
Temp
(0C)
2005 7.32 18 0.41 0.062 0.031 N/A
2006 7.4 8 0.01 0.02 0.04 N/A
2006 7.4 4 0.04 0.04 <0.01 6.0
2007 7.7 14 0.02 <0.01 <0.01 20.2
2007 7.0 19 0.29 0.05 0.11 22.8
2008 7.0 18 0.01 0.02 <0.01 21.4
2008 7.0 1.0 0.04 0.03 <0.01 20.8
N/A – Not available The pH readings for the storm water samples are relatively constant and within the
recommended pH 6-9 limit range.
pH Value 2005-2008
7.37.4 7.4
7.7
7 7 7
6.6
6.8
7
7.2
7.4
7.6
7.8
2005 2006 2006 2007 2007 2008 2008
Year
pH Value
Figure 5-1: pH Storm Water Results (2005-2008)
There are no ELVs for storm water emissions. The COD level monitored in April
2008 was similar to 2007 however there was a significant decrease in COD levels as
determined by the September 2008 result. Nonetheless, levels remain within the
levels specified in Urban Wastewater Treatment Regulations (S.I. No. 254 of 2001)
2001.
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COD
18
8
4
14
19 18
1
0
5
10
15
20
2005 2006 2006 2007 2007 2008 2008
Year
COD Value (mg/l)
Figure 5-2: COD Surface Water Results (2005-2008)
Aluminium
0.41
0.01 0.04 0.02
0.29
0.01 0.04
0
0.1
0.2
0.3
0.4
0.5
2005 2006 2006 2007 2007 2008 2008
Year
Al Value (ppm)
Figure 5-3: Aluminium Storm Water Results (2005-2008)
Copper level recording from the second monitoring half of 2008 demonstrated a slight
increase on 2008 first half levels. Results remain within the threshold of 0.05 mg/l as
specified under the Water Quality (Dangerous Substances) Regulations, 2001.
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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Copper
0
0.02
0.04
0.06
0.08
2005 2006 2006 2007 2007 2008 2008
Year
Cu Value (ppm)
Figure 5-4: Copper Surface Water Results (2005-2008)
Note 1
Note 1 – The value for first sample of 2007 is <0.01ppm
There are no ELVs for storm water emissions. Lead levels in the storm water
monitored during 2008 were <0.01 and within the environmental quality standards
(EQS) for surface waters.
Lead
0
0.02
0.04
0.06
0.08
0.1
0.12
2005 2006 2006 2007 2007 2008 2008
Year
Pb Value (ppm)
Figure 5-5: Lead Surface Water Results (2004-2008)
Note 2
Note 2
Lead values which are not denoted in the graph model are values of <0.01ppm.
2008 values for lead (Pb) are both less than 0.01ppm as indicated in Table 5-2.
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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Temperature
20.2
22.8
21.420.8
18
19
20
21
22
23
2007 2007 2008 2008
Year
Temperature Value
(Celsius)
2007 temperature values are given for comparative purposes only. Temperature values
for 2008 are all within the EPA recommended values of 6-9 pH.
5.2 Emissions to Atmosphere
Emissions to Atmosphere -monitoring programme
In accordance with Schedule C.1.2 of the IPPC Licence, monitoring of emissions to
atmosphere (A2-1) is required for the following parameters:
1. Fluorides (as HF)
2. Chlorine
3. Chlorides
4. Sulphur dioxide (as SO2)
5. Particulates
6. Dioxins
7. NOx
8. CO
A summary of the air monitoring programmes is in Table 5-3 and a summary of the
results and relevant ELVs are given in Table 5-4.
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Table 5-3 Air Monitoring Programme A2-1 (IPPC licence PO402-02)
Emission point
reference
Parameters Monitoring
Frequency
Volumes &
Concentrations
Licensed Volume
Particulates Continuously 50 mg/m3
Chlorides (as HCl) Biannually 30 mg/m3
Chlorine (as Cl2) Biannually 5 mg/m3
Fluorides (as HF) Biannually 5 mg/m3
Sulphur dioxide (as SO2) Biannually 350 mg/m3
Dioxins Biannually 0.5 ng I-TEQ/Nm3
NOx Biannually Note 1
A2-1
CO Quarterly Note 1
Note 1: Not Specified
Emissions to atmosphere – Monitoring results
Monitoring on site was carried out during 2008 by ASEP C/O Queens University,
Belfast. The results for 2008 are summarised in Table 5-4. As can be seen from the
results below, none of the emission limit values (ELV) were breached in 2008.
Monitoring reports are provided in Appendix 2 of this report. Dioxin analysis of
emission point A2-1 was carried out in April 2008 and September 2008. The dioxin
level was 0.048 ng TEQ/Nm3 (April 2008) and 0.011 ng TEQ/Nm3 (September 2008).
The monitoring reports are attached in Appendix 3 and Appendix 4.
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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Table 5-4 Monitoring Results 2008 from Emission Stack A2-1
April 2008 September 2008 Parameter ELV
Run 1 Run 2 Run 1 Run 2
Flue Temperature (0C) - 93 94 95 97
Stack Flow (m3/h) 29,000 23014 23549 21718 22254
Particulate
(mg/m3)
50 26.9 9.94 10.48 3.41
Mass Flow (kg/h) - 0.619 0.117 0.228 0.076
Oxides of Nitrogen (mg/m3) - <5 <5 6 11
Sulphur Dioxide (mg/m3) 350 <5 <5 <5 <5
Carbon Monoxide (mg/m3) - <5 <5 <5 <5
Hydrogen Chloride (mg/m3) 30 <5 <5 <5 <5
Hydrogen Fluoride (mg/m3) - <1 <1 <1 <1
Chlorine (mg/m3) 5 <1 <1 <1 <1
Copper (mg/m3) - <0.05 <0.05 <0.05 <0.05
Titanium (mg/m3) - <0.05 <0.05 <0.05 <0.05
IPPC Licence Ref. P0402-2: P. Carney Ltd.
Annual Environmental Report 2008
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6 Waste Management
A summary of all wastes generated during 2008 are summarised in Table 6-1 below.
Table 6-1 W
aste Generation during 2008
Waste
EWC No.
Hazardous
Annual
Quantity
(tonnes) 2008
Current Disposal
Waste
Contractor
Destination of
Waste – Onsite or
offsite
Permit /Licence number
of waste contractor
Oil
13 01 01*
Yes
0 Litres
Not applicable in 2008
Enva Portlaoise
Off site
WCP MH2001/107D
Plastic and
Plastic Dust
19 12 04
No
203.860 tonnes D1 Deposit on, in or under
land.
Green Energy
Recycling
Off site
WCP OY08058501
Timber
17 02 01
No
66.440 tonnes
Recycling
R3 Recycling/reclamation of
organic substances which are
not used as solvents
Greenstar
Doherty Waste
Management Ltd
Off site
WCP/MH/2005/63B
WP 2006/48b
General
Waste
20 03 01
No
91.200 tonnes
D1 Deposit on, in or under
land.
Green Energy
Recycling
Off site
WCP OY08058501
IPPC Licence Ref. P0402-2: P. Carney Ltd. Annual Environmental Report 2008
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A breakdown of the amount of waste disposed and recovered is provided in Table 6-2
below.
Table 6-2 Summary of wastes generated in 2008
Quantity of wastes Quantity of wastes
disposed on site
Quantity of wastes
disposed off-site
Quantity of waste
recovered off-site
Non-hazardous
wastes
0 361.50 tonnes 66.44 tonnes
Hazardous wastes 0 - -
7 Resource Consumption
This section of the report details the total annual usage levels of water and energy.
7.1 Water Consumption
Water consumption for 2008 is detailed in Table 7-1 below. Water usage primarily
comes from the municipal supply though groundwater from the on site well is used. P.
Carney Ltd. installed metering of groundwater in mid-2007, therefore over the coming
3 years, water consumption will be carefully examined to assess consumption
volumes and determine where improved conservation measures can be applied.
Table 7-1 Water Consumption 2008
Year 2008
Water
Reading
m3
On-site
ground
851
On-site
surface
-
Municipal
supply
1225
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7.2 Energy Consumption
Energy is provided by the following sources at the company namely:
� Oil
� Electricity
� Propane gas
A summary of energy consumption in 2008, in terms of the above, is shown in the
below.
Table 7-0-1 Energy Consumption for 2007-2008:
Source Consumption 2007 Consumption 2008 Units
Oil 901,249 702,763 Litre
Electricity 611,011 566,100 KWh
Propane gas 4,850 4,120 Litre
In 2008, energy consumption decreased significantly at the P. Carney facility. In
2008, oil consumption decreased by 22% whilst propane gas consumption decreased
by 15% over the same period. Electricity consumption at the facility was reduced by
over 7% during 2008, based on the consumption figures of 2007.
7.3 Environmental Incidents and Complaints
Reported Incidents Summary
There were no reported incidents during 2008.
Complaints Summary
There were no complaints from any member of the public or the Local Authority or
EPA during 2008 in relation to environmental matters at the site.
P. Carney Ltd. Annual Environmental Report 2008
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8 Environmental Management of Activity
The company has operated in accordance with the Environmental Management
System (EMS) since 1999. The EMS was updated in 2007 to reflect the new IPPC
licence requirements. As part of EMS, an Environmental Management Programme
(EMP) was formulated, outlining specific environmental objectives and targets for the
company. This section of this report summarises the objectives and targets proposed
for the coming year, 2009. A progress report on the EMP objectives and targets
implemented during 2008 is also provided. The schedule of environmental objectives
and targets has been established taking into account instruction within Condition 2.2.2
of the IPPC Licence.
8.1 Report on Environmental Objectives and targets for 2008
A report on the implementation of the 2008 environmental objectives and targets is
provided in Table 8-1.
P. Carney Ltd.
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Table 8-1 Report on Objectives and targets for 2008
Objective
reference No.
Objective
Target/Outcome
Achievem
ent / Additional Comment
1
Water Usage: Monitor
groundwater well abstraction
Monitoring of groundwater abstraction was
ongoing throughout 2008
A meter was installed onsite to monitor
volume of water abstraction from well and
water consumption at the facility
continues to be monitored.
2
Noise: Undertake noise survey in
compliance with licence
requirements
An annual environmental noise survey was
completed in 2008 in compliance with the
IPPC licence.
This report determined that noise levels at
the site were within the specified limits of
the licence, and in accordance with the
recommended levels as specified by the
EPA. This report is included in this AER.
3
Energy efficiency and resource
use: Review energy audit
undertaken at facility in 2007 and
oversee implementation of
recommendations to improve
energy efficiency at the facility e.g.
electricity use.
Continuing assessment of energy and
resources use throughout the facility.
Energy consumption fell significantly in
2008 at the P. Carney facility.
In 2008, oil consumption decreased by
22% whilst propane gas consumption
decreased by 15% over the same period.
4
Update MSDS relating to
hazardous substances in use onsite
e.g. fuels
MSDS were sought for all substances used
onsite.
All MSDS are kept on file in a specified
location in the event of an emergency.
P. Carney Ltd.
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Objective
reference No.
Objective
Target/Outcome
Achievem
ent / Additional Comment
5
Improve environmental awareness
amongst staff
Training of staff has been implemented
during 2008
Continue updated training of staff and
ensure all new personnel receive training
upon commencement.
6
Storm water: Continue to conduct
a visual examination of the on site
storm water discharge on a daily
basis in accordance with licence.
Undertaken on a regular basis and is
working successfully.
There have been no incidents reported at
the facility and this system is proving
successful.
7
Undertake a Gap Analysis study to
assess current oil separator on site
with reference to I.S EN 858-
2:2003
Review of the current existing system has
been undertaken by the facility and a report
is pending.
Currently under review
8
Hydro-geological assessment: On
approval of hydro-geological
assessment by the Agency, the
proposal shall be implemented
Proposal submitted to EPA authorities and
P. Carney currently awaiting response.
Currently under review
Table 8-2 Objectives and Targets for 2009
Objective
No. Objective Target Date
OT1 Daily storm water inspection of site Ongoing
OT2
Bund integrity test to be undertaken in 2009 under
Condition 3.6.5 of the licence which stipulates such
testing every 3 years.
September 2009
OT3
Inspection and testing of oil tank and transporting
pipelines to be undertaken in 2009 under Condition
8.3.3 of the licence.
September 2009
OT4 Staff environmental training September 2009
OT5
Annual Noise monitoring to be undertaken under
condition 6.13.1 of the licence in accordance with
the EPA guidance document ‘Environmental Noise
Survey Guidance Document’
October 2009
OT6 Monitoring of the groundwater abstraction December 2009
QT7 Review MSDS pertaining to all hazardous materials
used onsite December 2009
OT8 Review of procedures to assess the efficient
operations of the facilities flue gas abatement system December 2009
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Objective 1
Objective Number OT1
Objective Title Undertake a visual inspection of storm water discharge daily
Target Ongoing
Responsibility Environmental Manager
Plan
Means by which target is to achieved Who Target
• Undertake an examination of storm water discharge daily
to ensure the discharge is free from contamination
Environmental
Manager Daily/ Ongoing
Objective 2
Objective Number OT2
Objective Title Undertake a Bund Integrity test in accordance with Condition 3.6.5 of the IPPC licence
Target June 2009
Responsibility Environmental Manager
Plan
Means by which target is to achieved Who Target
• Arrange for a bund integrity test to be completed on site in
compliance with IPPC Licence condition 3.6.5
Environmental
Manager September
• Review results to ensure compliance with IPPC licence
conditions
Environmental
Manager September
• *Should the existing bunds be determined to be in breach of
licence conditions, remediation works shall be undertaken in
accordance with the recommendations of the report without
delay. Upon completion of these works, a follow up bund
integrity test shall be undertaken.
Environmental
Manager September (*if required)
• Insert copy of the Bund Integrity Assessment Report in
AER 2010 in accordance with licence conditions
Environmental
Manager March 2010
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Objective 3
Objective Number OT3
Objective Title Undertake an inspection and testing of onsite oil tanks and transporting pipelines in accordance with Condition 8.3.3 of the IPPC licence
Target July 2009
Responsibility Environmental Manager
Plan
Means by which target is to achieved Who Target
• Arrange for an assessment and testing of all onsite oil tanks
and associated transporting pipelines in accordance with
Condition 8.3.3 of the IPPC licence
Environmental
Manager September
• Review results to ensure compliance with IPPC licence
conditions
Environmental
Manager September
• *Should the existing onsite oil tanks and associated
transporting pipelines be determined to be in breach of
licence conditions, remediation works shall be undertaken in
accordance with the recommendations of the report without
delay. Upon completion of these works, a follow up
assessment shall be undertaken.
Environmental
Manager September (*if required)
• Insert copy of the report in AER 2010 in accordance with
licence conditions
Environmental
Manager March 2010
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 26
Document No. 1012-01 v1.00
Objective 4
Objective Number OT4
Objective Title Improve environmental awareness amongst staff
Target September 2009
Responsibility Environmental Manager
Plan
Means by which target is to achieved Who Target
• All staff from management level down to undergo and
update environmental training
Environmental
Manager August 2009
• Ensure all employees are aware of the impacts from
hazardous materials spills on site, and receive appropriate
training on hazardous materials spills or leakages, in
addition to non-hazardous material accidents.
Environmental
Manager August 2009
• All employees should be familiar with the Emergency
Response Procedure and of the appropriate actions to take in
the event of an emergency, and of the relevant emergency
and statutory bodies to contact if such a situation arises.
Environmental
Manager September 2009
• Ensure the Emergency Response Procedure is updated
includes the correct contact details of the EPA (both a
contact number for normal office hours and out of
office/emergency hours). Also include provisions for
minimising the effects of a spill/leakage on the environment
e.g. inspect all spill kits onsite and order new kits if
required.
Environmental
Manager September 2009
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 27
Document No. 1012-01 v1.00
Objective 5
Objective Number OT5
Objective Title Undertake Environmental Noise Survey at the facility
Target October 2009
Responsibility Environmental Manager to contact Environmental Efficiency Consultants Ltd
Plan
Means by which target is to achieved Who Target
• Arrange for environmental noise survey to be completed on
site in compliance with IPPC Licence condition 6.13
Environmental
Manager /
EEC
September 2009
• Review results to ensure compliance with IPPC licence
conditions
Environmental
Manager /
EEC
October2009
• Should noise levels be determined to breach licence
conditions, a review of procedures at the facility should be
implemented to address the issue without delay
Company
Director /
Environmental
Manager
October 2009
(*if licence conditions are breached)
• Insert Environmental Noise Report (2009) in AER 2010
Environmental
Manager /
EEC
March 2010
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 28
Document No. 1012-01 v1.00
Objective 6
Objective Number OT6
Objective Title Water Usage: Maintain a record of the volume of water abstraction (m3) from the groundwater well on site
Target December 2009
Responsibility Environmental Manager
Plan
Means by which target is to achieved Who Target
• Keep a record of the quantity m3. Environmental Manager Ongoing
• Compare the volume of water usage for with 2008 figures Environmental Manager
December
2009
• Assess quantities of water usage at the facility and
implement a programme to improve water efficiency onsite
Environmental Manager
December
2009
• AER 2010 to report on water consumption at the facility
EEC March 2010
Objective 7
Objective Number OT7
Objective Title Update Material Safety Data Sheets (MSDS) for hazardous substances used onsite e.g. fuel
Target December 2009
Responsibility Environmental Manager
Plan
Means by which target is to achieved Who Target
• Review all substances used onsite and assess whether
MSDS are available for each
Environmental Manager October
2009
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 29
Document No. 1012-01 v1.00
Means by which target is to achieved Who Target
• Ensure all MSDS onsite are up to date. These should be
reviewed and updated annually.
Environmental Manager November
2009
• Keep all MSDS on file and ensure all staff are aware of
location in the event of an emergency.
Environmental Manager December
2009
Objective 8
Objective Number OT8
Objective Title Review of procedures to assess the efficient operations of the facilities flue gas abatement system
Target December 2009
Responsibility Environmental Manager
Plan
Means by which target is to achieved Who Target
• Review of procedures to assess operation and effectiveness
of the facilities flue gas abatement system
Environmental
Manager June 2009
• Based on the review, the facility to update all procedures
incl. operational & maintenance, to maintain the most
efficient operations of the facilities abatement system
Environmental
Manager August 2009
• Implement any changed or new procedures and provide the
necessary staff training where required
Environmental
Manager
August / September 2009
• Continue with monitoring and recording as stated in the
IPPC licence conditions
Environmental
Manager Ongoing
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 30
Document No. 1012-01 v1.00
9 Licence Specific Reports (IPPC licence PO402-02)
9.1 Pollution Emissions Register (PER) 2008
In accordance with Condition 6.15 Pollution Emissions Register (PER): “The licensee shall
prepare and maintain a PER for the site. The substances to be included in the PER shall be
agreed by the agency each year by reference to the lists specified in the Agency’s’ AER
Guidance Notes. The PER shall be prepared in accordance with any relevant guidelines
issued by the Agency and shall be submitted as part of the AER”.
9.2 Determine PERL for site
Having examined the substances used on site and reviewed the MSDSs for each substance
and compared them with the PERL, the following are the substances are included in the PER.
� Copper – present in copper cables
� Lead – present in cables. Lead containing cables are sometimes present in a
mixed batch of cables purchased. The lead containing cables are segregated for
sale. They are not subject to processing on site.
� Titanium – titanium is added to various grades of aluminium.
P. Carney Ltd.
Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd
31
Document No. 1012-01 v1.00
Table 9-1 PER 2008
Facility Name
P. Carney Ltd.
Register Number:
P0402-02
Reporting Period
1ST Jan 2008 to 31st December 2008
Production Units
Aluminium alloy ingot and copper granules
Employees Number:
36
Pollution Emissions Register
Pollutant
CAS no.
Input (kg)
Gross
Usage
Air (kg)
MOM
Liquid
Effluent Kg
(storm
water)
Note 1
MOM
Waste
(kg)
MOM
Product
Kg
MOM
Recovery
Treated
Un-
accounted
Copper Cu
7440-50-8
448,000
448,000
- -
0.286
C
- -
477,999.71
- -
- -
Cable
containing
Lead
7439-92-1
13,400
13,400
- -
<0.114
C
- -
13,399.88
- -
- -
Titanium
7440-32-6
3,240
3,240
Note 2
- -
C
- -
-
- -
- C: Calculation
Note 1: Based on Met Éireann figures for annual rainfall (942.6mm rainfall/yr) and total surface area of site (1.214 ha or 1,2140.5sqm)
Note 2: Not recorded, trace quantities may be present.
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 32
Document No. 1012-01 v1.00
9.3 PER Proposal 2008
It is proposed that during 2009 a review of all materials used on site will be carried
out to ensure that any PERL substances used on site are included. As per 2008 the
following substances will be included in the PER:
� Copper
� Lead
� Titanium
9.4 Noise Monitoring Report 2008
Noise monitoring is required to be undertaken annually under Condition 6.13 of the
licence. A noise monitoring assessment and report was completed by Environmental
Efficiency Consultants (Ire) Ltd and is attached in Appendix 6. The noise monitoring
report determined that P. Carney is not in breach of its IPPC licence as all noise levels
were within the permitted levels.
9.5 Bund Integrity
A bund integrity test was carried out by Environmental Efficiency Consultants in July
2006 and was passed. In accordance with condition 3.6.5 of the licence:
‘The integrity and water tightness of all the bunded structures, tanks and containers
and their resistance to penetration by water or other materials stored therein shall be
tested and demonstrated by the licensee at least once every three years. This testing
shall be carried out in accordance with any guidance published by the Agency’.
The latest bund inspection report carried out at the facility in 2006 and was submitted
to the Agency previously. The next Bund integrity test is required to be undertaken in
2009 in accordance with Condition 3.6.5 of the licence and will be included into the
AER 2010.
9.6 Tank and pipeline testing report
Inspection and testing of oil transporting pipelines was carried out by Cathal Usher,
Plumbing Contractor. Condition 8.3.3 of the licence requires that “The licensee shall
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 33
Document No. 1012-01 v1.00
undertake a programme of testing and inspection of pipelines to ensure that all oil
transporting pipes are tested at least once every three years”. The most recent testing
and inspection was undertaken in August 2006 and the associated inspection report is
available in Appendix 5. In accordance with the licence conditions, testing should
once again be undertaken in 2009 and will be included into the AER 2010.
9.7 Energy Efficiency Audit Report
Environmental Efficiency Consultants have been contracted by P. Carney Ltd. to
carry out an energy audit at their site and premises. This is in accordance with
Condition 7.1 of the IPPC licence. See to view Appendix 7 summary report.
9.8 Raw Materials Assessment
In 2007, an assessment of raw materials was undertaken for P. Carney Ltd by
Environmental Efficiency Consultants to comply with Condition 7.4 of the licence.
This report identified areas where significant raw materials are used / wasted and their
associated waste streams; and gave recommendations in relation to the most
significant issues relating to the site.
With relation to raw materials used onsite, the raw materials are predetermined by the
quantities available for processing, available markets and production capacity of the
plant. As such these raw materials can not be changed. Recyclable materials are
stored separately from material being sent to landfill. The objectives and targets for
2008 has included assessing certain raw materials used onsite with the objective of
reducing the use of raw materials use i.e. water usage. This monitoring programme is
ongoing at the facility.
9.9 Water minimisation study
In compliance with Condition 7.3, a water minimisation study was carried out in
2007. As part of the water minimisation programme, it was recommended that the
water be metered. This was undertaken in 2007 and as part of the objectives and
targets, the water use onsite will continue to be monitored in order to determine use
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 34
Document No. 1012-01 v1.00
and where if any, reductions can be made or improved conservation methods can be
applied. This monitoring programme is ongoing at the facility.
9.10 Environmental Liabilities and financial provisions
A statement of measures in relation to the prevention of environmental damage and
remedial actions (environmental liabilities) is provided in Table 9-2:
Table 9-2 Environmental liabilities
Measures Progress to
date
Environmental Objectives
• Oversee implementation of Objectives and Targets 2009
• Keep a record (noting quantity m3) of all abstractions from groundwater
well on site
• Ensure all the correct waste documentation is present on site
• Undertake bund integrity testing in 2009 in accordance with licence
conditions
• Assess study regarding the current oil separator onsite in with reference to
I.S EN 858-2:2003
• Undertake inspection and testing of oil pipelines in accordance with licence
condition 8.3.3
• Upon response/approval from EPA, carry out hydro-geological assessment
of the site in accordance with Condition 6.12 of the IPPC licence on
confirmation by the EPA to proceed according to proposal Doc. no. 861-14
v2.01.
• Carry out annual noise monitoring survey in accordance with licence
conditions
• Ensure Compliance with Condition 9: Accident Prevention and Emergency
Response
• Continue with the implementation of the updated Environmental
Management System in line with the existing Environmental Management
System.
Ongoing
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 35
Document No. 1012-01 v1.00
Measures Progress to
date
Training
� All staff and new employees are provided with appropriate training
relevant to the individual’s particular job description.
� Records of training are kept and updated as appropriate
Ongoing
Equipment maintenance
� Ensure equipment in use is regularly checked in order to identify and
remedy any faults, which may compromise the health and safety of staff
or have a negative impact on the environment.
Ongoing
Environmental Monitoring
� Continue to monitor emissions to air as required by the IPPC licence
(Reg. No PO.402-02)
� Every effort is made to ensure the emissions are within emission limit
values. Investigations into non-conformances (if any) and ensure that
corrective actions are put in place if emission limit values are exceeded.
Ongoing
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 36
Document No. 1012-01 v1.00
Appendix 1 Copy of Certificates of Analysis – Storm water 2008
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P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 37
Document No. 1012-01 v1.00
P CARNEY Crossakiel Kells Co Meath
A Report To P Carney on the analysis of a water sample.
Our Ref. 08ap053A
Your Ref. Water sample
Sample description 1 x 1l water sample in 1L plastic bottle
Samples Dated -------
Analysis Requested Temp, pH, COD, Al, Cu, Pb
Samples Received 16-4-08
Samples received by Paul Cole
Analysis report Issued 13-5-08
ANALYSIS METHOD / PROCEDURE
The samples as supplied were analysed by meter for temperature by digital thermometer, pH, by HACH for Cod and by ICP for Al, Cu and Pb.
SPECIAL CONDITIONS None. The samples were analysed according to standard operating procedures. DISPOSAL OF SAMPLES
It is our normal policy that the samples will be disposed of two months after the report has been issued. CONTACTS The client should contact Mr. Trevor Sewell with any queries about the analysis report and Ms W McKinney about administration / invoices.
ANALYSIS RESULTS pH 7.0 COD mg/l 18 Temperature 0C 21.4 Al ppm 0.01 Cu ppm 0.02 Pb ppm < 0.01 Compiled By Approved By
-------------------------------- ------------------------- P. Cole R.A.Patrick Technical Director
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 38
Document No. 1012-01 v1.00
P CARNEY Crossakiel Kells Co Meath
A Report To P Carney on the analysis of a water sample.
Our Ref. 08oct011
Your Ref. Water sample
Sample description 1 x 1l water sample in 1L plastic bottle
Samples Dated -------
Analysis Requested Temp, pH, COD, Al, Cu, Pb
Samples Received 29-9-08
Samples received by Paul Cole
Analysis report Issued 14-10-08
ANALYSIS METHOD / PROCEDURE
The samples as supplied were analysed by meter for temperature by digital thermometer, pH, by HACH for Cod and by ICP for Al, Cu and Pb.
SPECIAL CONDITIONS None. The samples were analysed according to standard operating procedures. DISPOSAL OF SAMPLES
It is our normal policy that the samples will be disposed of two months after the report has been issued. CONTACTS The client should contact Mr. Trevor Sewell with any queries about the analysis report and Ms W McKinney about administration / invoices.
ANALYSIS RESULTS pH 7.0 COD mg/l 1.0 Temperature 0C 20.8 Al ppm 0.04 Cu ppm 0.03 Pb ppm < 0.01 Compiled By Approved By
-------------------------------- ------------------------- P. Cole R.A.Patrick Technical Director
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 39
Document No. 1012-01 v1.00
Appendix 2 Copy of Certificates of Analysis – Air Monitoring 2008
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P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 40
Document No. 1012-01 v1.00
Declan Clarke P Carney Ltd. Crossakiel Kells Co. Meath Ireland
Emission Analysis from Stack A2-1 at P. Carney Ltd., Crossakiel.
Emissions from the Stack A2-1 at P. Carney Ltd., Crossakiel were monitored using the following procedures. Particulate: Gravimetric determination, using a BCURA probe under isokinetic conditions Oxides of Nitrogen )
Oxides of Sulphur ) Electrochemical determination using a Kane-May Flue Carbon monoxide ) Gas Analyser Hydrogen Chloride )
Hydrogen Fluoride ) Self indicating adsorption tubes Chlorine ) Sampling was carried out using ports in the stack accessible via a permanent platform. Results Concentrations are quoted under standard conditions: 273
0K, 1.013 kPa,
Particulate was collected on the same filter assembly from the port over a continuous period. Gaseous parameters were determined during the particulate monitoring. Monitoring was carried out on the 17th April 2008
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 41
Document No. 1012-01 v1.00
Smelting Process: Run 1 Run 2 Sample Period: 07.45 – 08.15 08.20 – 08.50 Flue temperature: 93 0C 94 0C Stack Flow: 23014 m3/hr 23549 m3/hr
Particulate: 26.9 mg/m3 9.94 mg/m3
Mass Flow: 0.619 kg/hr 0.117 kg/hr Oxides of Nitrogen: < 5 mg/m3 < 5 mg/m3
Sulphur Dioxide: < 5 mg/m3 < 5 mg/m3 Carbon monoxide: < 5 mg/m3 < 5 mg/m3
Hydrogen Chloride: < 5 mg/m3 < 5 mg/m3
Hydrogen Fluoride: < 1 mg/m3 < 1 mg/m3 Chlorine: < 1 mg/m3 < 1 mg/m3 Copper: < 0.05mg/m3 < 0.05 mg/m3 Titanium: < 0.05 mg/m3 < 0.05 mg/m3
.
______________________ _____________________ Paul Cole Dr. Robin Patrick
Technical Director 11th July, 2008
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 42
Document No. 1012-01 v1.00
Declan Clarke P Carney Ltd. Crossakiel Kells Co. Meath Ireland
Emission Analysis from Stack A2-1 at P. Carney Ltd., Crossakiel.
Emissions from the Stack A2-1 at P. Carney Ltd., Crossakiel were monitored using the following procedures. Particulate: Gravimetric determination, using a BCURA probe under isokinetic conditions Oxides of Nitrogen )
Oxides of Sulphur ) Electrochemical determination using a Kane-May Flue Carbon monoxide ) Gas Analyser Hydrogen Chloride )
Hydrogen Fluoride ) Self indicating adsorption tubes Chlorine ) Sampling was carried out using ports in the stack accessible via a permanent platform. Results Concentrations are quoted under standard conditions: 273
0K, 1.013 kPa,
Particulate was collected on the same filter assembly from the port over a continuous period. Gaseous parameters were determined during the particulate monitoring. Monitoring was carried out on the 29th September 2008
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 43
Document No. 1012-01 v1.00
Smelting Process: Run 1 Run 2 Sample Period: 07.38 – 08.08 08.11 – 08.41 Flue temperature: 95 0C 97 0C Stack Flow: 21718 m3/hr 22254 m3/hr
Particulate: 10.48 mg/m3 3.41 mg/m3
Mass Flow: 0.228 kg/hr 0.076 kg/hr Oxides of Nitrogen: 6 mg/m3 11 mg/m3
Sulphur Dioxide: < 5 mg/m3 < 5 mg/m3 Carbon monoxide: < 5 mg/m3 < 5 mg/m3
Hydrogen Chloride: < 5 mg/m3 < 5 mg/m3
Hydrogen Fluoride: < 1 mg/m3 < 1 mg/m3 Chlorine: < 1 mg/m3 < 1 mg/m3 Copper: < 0.05mg/m3 < 0.05 mg/m3 Titanium: < 0.05 mg/m3 < 0.05 mg/m3
.
______________________ _____________________ Paul Cole Dr. Robin Patrick
Technical Director 4th December, 2008
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 44
Document No. 1012-01 v1.00
Appendix 3 Copy of Dioxin Monitoring Report – May 2008
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P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 45
Document No. 1012-01 v1.00
DIOXIN MONITORING
AT THE
CARNEY SMELTER
A Report to
P CARNEY
Crossakiel
Kells
Co Meath
April, 2008
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 46
Document No. 1012-01 v1.00
1. Introduction
Polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans, commonly
referred to as dioxins and furans or simply as "dioxins" are produced as by-products
from various chemical manufacturing processes and from combustion processes
where chlorine is present. This group of compounds has a very high toxicity to human
health and consequently very low guideline values have been set for human exposure.
2. Toxic Equivalent Value (TEQ)
There are a great many different isomeric chlorinated species covered by the term
"dioxins". Of these, the most toxic is the 2,3,7,8 tetrachlorodibenzo-p-dioxin. In
relative terms, many other "dioxins" are much less toxic. The accepted convention is
to derive a total toxic equivalent value for any sample relative to the 2,3,7,8 TCDD
which is given a TEQ of unity. This is achieved by applying the relevant agreed toxic
equivalent factor to the concentration of each dioxin and furan species.
3. IPC Licensing
P. Carney operate an aluminium recovery plant at Crossakiel in County Meath. The
operation of the plant is covered by an IPC Licence issued by the Environmental
Protection Agency.
This report presents the results of a monitoring exercise carried out by ASEP in April,
2008
4. Sampling Protocol
Sampling was carried out using a sampling train, compliant with IS EN 1948, which
has been described in detail previously.
5. Sampling Programme
A sample was collected from the smelter at a point after the dust abatement system by
ASEP personnel over an 8 hour period on 14-15 April. Sample details are tabulated
below.
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 47
Document No. 1012-01 v1.00
Table 1: Samples
Sampling Period Volume Nm3
23.50 – 07.50 3.105
The sample was delivered directly to the analytical laboratory by a member of staff
from ASEP.
6. Analysis
Analysis was carried out by Envirolab, a specialist "dioxin" laboratory, based in
Manchester. The analytical procedure, which has been detailed previously, involves a
complex extraction, clean-up and concentration programme, followed by multiple ion
high resolution gas chromatography - high resolution mass spectrometry, allied with
UK acceptance criteria (Chemosphere, 21, 999 1990). All laboratory work is
undertaken under fully documented QA/QC control, providing reproducible and
traceable results under the UK UKAS scheme.
7. Results
Results are tabulated below, giving the weights of the various isomers detected in the
samples, together with the toxic equivalent value (derived from NATO/CCMS Toxic
Equivalent Factors). These data were used in conjunction with sampling data (air
volume, temperature and atmospheric pressure) to derive concentrations of "dioxins"
expressed to the standard reference conditions of 273oK and 101.3kPa, dry gas.
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 48
Document No. 1012-01 v1.00
Table 2: Dioxin/Furan Content of Stack Emission Samples
( ng total in sample as received)
Envirolab Ref. No 83612
ASEP Ref. No. PC1
2378-TCDD 0.009
Total TCDD 0.58
12378 PeCDD 0.041
Total PeCDD 0.083
123478-HxCDD 0.021
123678-HxCDD 0.042
123789-HxCDD 0.014
Total HxCDD 1.6
1234678-HpCDD 0.51
Total HpCDD 1.5
OCDD 0.37
2378-TCDF 0.014
Total TCDF 2.5
23478-PeCDF 0.16
12378 PeCDF 0.067
Total PeCDF 1.1
123478-HxCDF 0.071
123678-HxCDF 0.070
234678-HxCDF 0.052
123789-HxCDF 0.004
Total HxCDF 0.59
1234678-HpCDF 0.23
1234789-HpCDF 0.046
Total HpCDF < 0.01
OCDF 0.18
I-TEQ (max) 0.15
Note: Total refers to all isomers of the congener group.
ITEQ (max) calculated with “<” values at their reported limits.
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 49
Document No. 1012-01 v1.00
8. Emission to Atmosphere
The emission data, corrected to normal temperature and pressure, dry gas is tabulated
below.
Table 3: Emissions to Atmosphere
Sample Volume
in Nm3
Oxygen
%
Dioxin
ng TEQ
Dioxin Emission
in ng TEQ/Nm3
PC1 3.105 20.7 0.15 0.048
No correction has been made for oxygen content.
9. Confidence Limits
The emission standards applicable to "dioxins" emissions push sampling and
analytical techniques to the limit. The difficulty of collecting representative samples,
allied to the complexity of the extraction process, work-up and analytical procedures
results in precision of the order of + 50% at best.
Where the levels recorded above for individual targets are at or below the limit of
detection, in applying the TEQ factors, the approach adopted is to take the “less than”
value as absolute i.e. the worse case.
In determining the final emission to atmosphere, the worse case approach has been
adopted in that no correction has been made for any apparatus blank and “less than”
values have been taken as absolute.
_____________________________________ R.A. Patrick BSc. PhD, FICI, CChem FRSC 22 May, 2008
Technical Director
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 50
Document No. 1012-01 v1.00
Appendix 4 Copy of Dioxin Monitoring Report – September 2008
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P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 51
Document No. 1012-01 v1.00
DIOXIN MONITORING
AT THE
CARNEY SMELTER
A Report to
P CARNEY
Crossakiel
Kells
Co Meath
September, 2008
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 52
Document No. 1012-01 v1.00
1. Introduction
Polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans, commonly
referred to as dioxins and furans or simply as "dioxins" are produced as by-products
from various chemical manufacturing processes and from combustion processes
where chlorine is present. This group of compounds has a very high toxicity to human
health and consequently very low guideline values have been set for human exposure.
2. Toxic Equivalent Value (TEQ)
There are a great many different isomeric chlorinated species covered by the term
"dioxins". Of these, the most toxic is the 2,3,7,8 tetrachlorodibenzo-p-dioxin. In
relative terms, many other "dioxins" are much less toxic. The accepted convention is
to derive a total toxic equivalent value for any sample relative to the 2,3,7,8 TCDD
which is given a TEQ of unity. This is achieved by applying the relevant agreed toxic
equivalent factor to the concentration of each dioxin and furan species.
3. IPC Licensing
P. Carney operate an aluminium recovery plant at Crossakiel in County Meath. The
operation of the plant is covered by an IPC Licence issued by the Environmental
Protection Agency.
This report presents the results of a monitoring exercise carried out by ASEP in
September, 2008
4. Sampling Protocol
Sampling was carried out using a sampling train, compliant with IS EN 1948, which
has been described in detail previously.
5. Sampling Programme
A sample was collected from the smelter at a point after the dust abatement system by
ASEP personnel over an 8 hour period on 28 – 29 September, 2008. Sample details
are tabulated below.
Table 1: Samples
Sampling Period Volume Nm3
23.25 – 07.25 3.395
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 53
Document No. 1012-01 v1.00
The sample was delivered directly to the analytical laboratory by a member of staff
from ASEP.
6. Analysis
Analysis was carried out by Envirolab, a specialist "dioxin" laboratory, based in
Manchester. The analytical procedure, which has been detailed previously, involves a
complex extraction, clean-up and concentration programme, followed by multiple ion
high resolution gas chromatography - high resolution mass spectrometry, allied with
UK acceptance criteria (Chemosphere, 21, 999 1990). All laboratory work is
undertaken under fully documented QA/QC control, providing reproducible and
traceable results under the UK UKAS scheme.
7. Results
Results are tabulated below, giving the weights of the various isomers detected in the
samples, together with the toxic equivalent value (derived from NATO/CCMS Toxic
Equivalent Factors). These data were used in conjunction with sampling data (air
volume, temperature and atmospheric pressure) to derive concentrations of "dioxins"
expressed to the standard reference conditions of 273oK and 101.3kPa, dry gas.
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 54
Document No. 1012-01 v1.00
Table 2: Dioxin/Furan Content of Stack Emission Samples
( ng total in sample as received)
Envirolab Ref. No 92731
ASEP Ref. No. PC1
2378-TCDD 0.006
12378 PeCDD 0.020
123478-HxCDD 0.033
123678-HxCDD 0.031
123789-HxCDD 0.038
1234678-HpCDD 0.16
OCDD 0.093
2378-TCDF 0.023
23478-PeCDF 0.028
12378 PeCDF 0.020
123478-HxCDF 0.048
123678-HxCDF 0.040
234678-HxCDF 0.072
123789-HxCDF 0.044
1234678-HpCDF 0.23
1234789-HpCDF 0.023
OCDF 0.029
I-TEQ (max) 0.068
Note: ITEQ (max) calculated with “<” values at their reported limits.
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 55
Document No. 1012-01 v1.00
8. Emission to Atmosphere
The emission data, corrected to normal temperature and pressure, dry gas is tabulated
below.
Table 3: Emissions to Atmosphere
Sample Volume
in Nm3
Oxygen
%
Dioxin
ng TEQ
Dioxin Emission
in ng TEQ/Nm3
PC1 6.00 20.7 0.07 0.011
No correction has been made for oxygen content.
9. Confidence Limits
The emission standards applicable to "dioxins" emissions push sampling and
analytical techniques to the limit. The difficulty of collecting representative samples,
allied to the complexity of the extraction process, work-up and analytical procedures
results in precision of the order of + 50% at best.
Where the levels recorded above for individual targets are at or below the limit of
detection, in applying the TEQ factors, the approach adopted is to take the “less than”
value as absolute i.e. the worse case.
In determining the final emission to atmosphere, the worse case approach has been
adopted in that no correction has been made for any apparatus blank and “less than”
values have been taken as absolute.
_____________________________________ R.A. Patrick BSc. PhD, FICI, CChem FRSC 9 January, 2009
Technical Director
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 56
Document No. 1012-01 v1.00
Appendix 5 Tank and pipeline inspection report
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 57
Document No. 1012-01 v1.00
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency Consultants (Ire) Ltd 58
Document No. 1012-01 v1.00
Appendix 6 Noise Monitoring Report 2008
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(To be inserted)
Document No. 1144-01 v1.00
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 1 Document No. 1144-01 v1.00
Environmental Noise Survey 2008
For
P. Carney Limited.
Crossakiel, Kells,
Co. Meath.
IPPC Licence: PO402-02
Document Number: 1144-01 v1.00
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 2 Document No. 1144-01 v1.00
QF 1. v2 Document Lead Sheet
Document Title Environmental Noise Survey 2008 Project No. 1144 Document No. 1144-01 v1.00 Client P. Carney Ltd. Address Crossakiel, Kells, County Meath
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00 Approved 01/05/2009 RND
Where it is a requirement that this report be issued to a regulatory or other authority,
then the client should sign the appropriate place in the above table and, unless
specifically agreed in writing to the contrary, forward copies to the appropriate
authority (e.g. EPA).
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: Róisín Ní Dhubhda B.Sc., M.Sc., AIEMA
Richard McElroy, B.Eng.
Conditions relating to the issue of this report:
4. No alteration to this report by third parties is permitted
5. Where this report is reproduced, it shall only be reproduced in full.
6. Reports remain the property of Environmental & Efficiency Consultants
(Ireland) Limited until paid for in full.
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 3 Document No. 1144-01 v1.00
Table of Contents
1. Introduction ..........................................................................................................4 2. Noise.......................................................................................................................4 3. Summary ...............................................................................................................4 4. Sampling Methodology and Analytical Techniques..........................................5 3.1 Instrumentation Used .....................................................................................5 3.2 Noise Survey Personnel .................................................................................5 3.3 Report Terminology .......................................................................................5 3.4 Meteorological Conditions.............................................................................6 3.5 Measurement Positions ..................................................................................6 3.6 Measurement Locations .................................................................................6
5. Noise Survey..........................................................................................................8 6. Discussion & Conclussion..................................................................................10
Figure 3-1: Identified Nearest Noise Sensitive Locations.........................................................................7
Table 3-1: Equipment Used to Conduct Noise Monitoring Surveys.........................................................5
Table 4-1: Environmental Noise Monitoring Results ...............................................................................9
Appendix 1 Certificates of Calibration ..........................................................................................11
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 4 Document No. 1144-01 v1.00
1 Introduction Environmental Efficiency Consultants (Ire) Limited was commissioned by P. Carney
Limited to carry out an annual environmental noise survey, in accordance with
Condition 6.13 of the IPPC licence. Condition 4.5 of the licence states: -
“Noise from the installation shall not give rise to sound pressure levels (Leq,T)
measured at noise sensitive locations of the installation which exceed the limit values
by more than 2 dB(A).”
These limit values are specified in Schedule B.4 as daytime noise values of 55 dB (A)
LAeq (30 minutes) and night-time noise values of 45 dB (A) LAeq (30 minutes). This
environmental noise survey report pertains to the licence year 2008 and has been
undertaken in accordance with the EPA publication “Environmental Noise Survey
Guidance Document” (2003).
2 Noise Excessive noise from development and commercial sites can have a significant
adverse effect on those living in close proximity to such sites. In Ireland, there are no
statutory limits for noise emissions or ambient noise levels; however the
Environmental Protection Agency (EPA)1 has produced noise guidelines, which
define the levels of acceptability in relation to noise from industrial/commercial
operations. The EPA endorse limit values of a maximum of 55 dB(A) during daytime
hours2 and night-time values of 45 db(A). These values should be measured at the
identified noise sensitive locations (NSLs). A Noise sensitive location is described by
the EPA as follows: -
‘Any dwelling, hotel or hostel, health building, educational establishment, place of
worship or entertainment, or any other facility or area of high amenity, which for its
proper enjoyment requires the absence of noise at nuisance levels3’.
3 Summary The noise levels recorded at the identified noise sensitive locations i.e. nearest two
residential dwellings are determined to be below the emission limit values set forth in
the licence. As such P. Carney Ltd. is NOT in breach of their IPPC licence Condition
6.13.
1 EPA (2006) Guidance Note for Noise in Relation to Scheduled Activities. 2nd Edition 2 Daytime hours (08.00-22.00): Night-time hours (22.00-08.00) 3 Guidance Note for Noise in Relation to Scheduled Activities, 2nd Ed. (2006) EPA
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 5 Document No. 1144-01 v1.00
4 Sampling Methodology and Analytical Techniques
3.1 Instrumentation Used
The following equipment was used during the noise assessment:
Table 3-1 Equipment Used to Conduct Noise Monitoring Surveys Equipment Model (Cirrus) Serial No. EEC Lab ID.
Sound Level Meter (SLM) (Type 1) CR: 811B C16569FD LEN 002
Microphone MK: 224 20020028 N/A
Calibrator CR: 511E 035066 LEN 003
Tripod N/A N/A N/A
The SLM were calibrated to 93.7 dB (A) on-site immediately before
measurement and reassessed on completion. No drift in calibration level was
recorded. See Appendix for certificate of calibration.
3.2 Noise Survey Personnel
The noise survey was undertaken by Environmental Efficiency Consultants (Ire) Ltd.,
environmental consultant, Mr. Richard McElroy, B.Eng.
3.3 Report Terminology
The parameters used to assess the noise are as follows:
Leq (t): is the continuous equivalent sound level over a specified time (t),
where t represented a 30-minute period during this survey. This
measure is used to give an indication of the average noise level over
the specified time period.
L10 and L90: are both statistical noise levels. L10 indicates that for 10% of the
monitoring period, the sound levels were greater than the quoted value.
L90 indicates that for 90% of the monitoring period, the sound levels
were greater than the quoted value. L10 is used to express event noise.
L90 is used to express background noise, usually filtering out loud,
intermittent interferences such as traffic noise.
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 6 Document No. 1144-01 v1.00
The following terms may be used to describe the characteristics of the noise:
Continuous: noise produced without interruption.
Intermittent: noise that is punctuated with interruptions e.g. equipment operating in
cycles or events such as single passing vehicle
Impulsive: a noise of short duration (typically less than one second), the sound
pressure of which is significantly higher than the background; brief and
abrupt.
Tonal: noise that contains a clearly audible tone i.e. a distinguishable, discrete
or continuous note (whine, hiss, hum or screech, etc.).
The noise measurements were ‘A’ weighted and the time-weighting ‘Fast’ was
applied (to equate to human ear hearing).
3.4 Meteorological Conditions
Weather conditions on the day of monitoring was considered appropriate for
surveying purposes and therefore, did not affect the readings i.e. conditions were dry
and wind speed was less than 5 m/s (the normal upper limit for taking measurements).
The Sound Level Meter was also fitted with a windshield to minimise interference
from potential meteorological conditions, in keeping with good practice.
3.5 Measurement Positions
All measurements were taken at between:
• 1.2 – 1.5 m height above local ground level
3.6 Measurement Locations
The locations of noise monitoring points are described in the following table and
shown in Figure. All readings were taken during daytime operating hours when the
facility was in operation and all equipment was in use.
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 7 Document No. 1144-01 v1.00
Figure 3.1: Identified Nearest Noise Sensitive Locations
NSL1
NSL2
P. Carney Site
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 8 Document No. 1144-01 v1.00
5 Noise Survey
Table shows the measurement results for the monitoring locations at the site at P.
Carney. Associated particulars such as a description of the noise recorded, in each
location are also provided in the table.
P. Carney Limited
Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd.
9 Document No. 1144-01 v1.00
Table 4.1: Environmental Noise Monitoring Results Noise Result
Location
Reference
NSL Description
Type
Leq
(30 mins)
Leq
L10
L90
Description of On-site Noise
Sources
Description of Off-site
Noise Interference
NSL1
Residential Dwelling
Day
*
30
54.9 54.4 48.1 o
Transportation of
materials onsite
o Passing traffic from
adjacent public road
NSL2
Residential Dwelling
Day*
30
54.1 53.9 46.2 o
Transportation of
materials onsite
o Passing traffic from
adjacent public road
* Emission lim
it values as specified in the EPA (2003) Environmental Noise Survey Guidance Document
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 10 Document No. 1144-01 v1.00
6 Discussion & Conclusion As can be seen in Table 3-1 the results for NSL 1 and NSL 2 are below the limits set
forth in the licence. Therefore P. Carney Ltd is within the terms of their licence
conditions.
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 11 Document No. 1144-01 v1.00
Appendix 1 Certificates of Calibration
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 12 Document No. 1144-01 v1.00
P. Carney Limited Environmental Noise Survey 2008
Environmental Efficiency Consultants (Ire) Ltd. 59 Document No. 1144-01 v1.00
Appendix 7 Energy Audit Report Summary
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(To be inserted)
Document No. 861-19 v1.01
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency 1 Document No 861-19; Version No. 1.01
EPA SUMMARY ENERGY AUDIT
FOR
P. CARNEY
Document No. 861-19
Version 1.01
P. Carney Emergency Response Plan
Environmental Efficiency 2 Document No 861-19; Version No. 1.01
QF 1. v2 Document Lead Sheet Document Title EPA Summary Energy Audit Project No. 861 Document No. 861-19 Client P. Carney Ltd. Address Crossakiel, Kells, Co. Meath.
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.01 Approved 26/09/2007 DR
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: David Reilly B.E.
Conditions relating to the issue of this report:
7. No alteration to this report by third parties is permitted
8. Where this report is reproduced, it shall only be reproduced in full. Where extracts are taken for inclusion in the site’s AER or other management summary, then the extracts shall be identified as being taken from this report by quoting Environmental Efficiency as the corporate authors and the document number.
9. Reports remain the property of Environmental & Efficiency Consultants
(Ireland) Limited until paid for in full.
P. Carney Emergency Response Plan
Environmental Efficiency 3 Document No 861-19; Version No. 1.01
Table of Contents
1. Introduction ......................................................................................................... 4
2. Energy Management System.............................................................................. 4
3. Site energy consumption..................................................................................... 5
4. Energy Performance Indicators......................................................................... 7
5. Recommendations ............................................................................................... 8
6. Implication of audit findings ............................................................................ 10
Table 1 Site Energy Consumption .....................................................................................5 Table 2 SEC for the site .....................................................................................................7 Table 2 Recommendations .................................................................................................8 Appendix 1 Energy Management Matrix……………………………………………11
P. Carney Emergency Response Plan
Environmental Efficiency 4 Document No 861-19; Version No. 1.01
1 Introduction P. Carney has a licence issued by the EPA (Licence No. P0402-02). This licence requires that P. Carney have an energy audit carried out according to The EPA Document ‘Guidance Note on Energy Efficiency Auditing’. This document states that “two reports should be prepared for the Energy Audit, viz.:
Main Report for site use; Summary Report for submission to the Agency as part of the Annual
Environmental Report.”
The energy audit was carried out on the 25/07/2007. The main report was issued to P. Carney (Document No. 861-15). This report is the summary report requested for submission to the Agency as part of the Annual Environmental Report and was prepared in accordance with the Guidance Note, i.e. it includes:
• Table setting out the consumption of the different energy streams at the site • Table setting out the final list of Audit Recommendations that could be
incorporated into the implementation programme. • An overview of the status of the energy management system at the site • Any energy performance indicators calculated for the site for the Audit period
and previous periods • A summary of the implications of Audit findings.
2 Energy Management System An energy management system is a system to track the energy usage at a site in order to highlight any areas in need of improved energy management. The effectiveness of an energy management system can be determined by use of the matrix shown in Appendix . The status of the client’s energy management system is shown by the shaded boxes on the matrix. Level 4 of the matrix represents best practice. The energy consumption at the site is reviewed regularly. The relevant personnel have a very good awareness of energy issues and are knowledgeable of energy saving and energy cost saving techniques. A number of improvements have already been carried out, including:
• VSDs options exhausted on the site • Investigations made regarding upgrading of site furnace • In dept monitoring of furnace oil consumption
This indicates that the company is investing in energy saving equipment and is actively working to reduce the energy usage of the site.
P. Carney Ltd.
Annual Environmental Report 2008
Environmental Efficiency
5
Document No 861-19; Version No. 1.01
3 Site energy consumption
The site energy consumption for the period 01/2006 to 12/2006 is shown below. Transport fuels are excluded.
Table 1 Site Energy Consumption
Fuel
Typ
e
El
ec tr ic it y
G a s O il
M o t o r D i e s e l
K e r o s e n e
P r o p a n e
T o t a l
Con
sum
ptio
n ,
kW h
6 0 2, 8 3 5
7 , 3 1 5 , 0 3 7
7 5 2 , 3 1 7
2 6 , 7 0 3
2 5 , 3 3 4
8 , 7 2 2 , 2 3 6 %
Con
sum
ptio
n
6. 9
8 3 . 8 7
8 . 6 3
0 . 3 1
0 . 2 9
1 0 0
P. Carney
Emergency Response Plan
Environmental Efficiency
6
Document No 861-19; Version No. 1.01
Ton
nes
CO
2
4 6 7. 8
1 , 4 4 8 . 4
1 4 9
6 . 9
5 . 8
2 , 0 7 7 . 8
%
CO
2
2 2. 5
6 9 . 7 1
7 . 1 7
0 . 3 3
0 . 2 8
1 0 0
Ann
ual
Cos
t, €
9 6, 4 1 9
3 5 4 , 9 4 5
6 0 , 4 3 5
1 , 6 8 3
2 , 3 5 6
5 1 5 , 8 3 6 %
Ann
ual
Cos
t
1 8. 6 3
6 8 . 5 9
1 1 . 6 8
0 . 6 5
0 . 4 6
1 0 0
Cos
t,
c/k
1 6. 9
4 . 8
8 . 0
6 . 3
9 . 3
5 . 9
P. Carney
Emergency Response Plan
Environmental Efficiency
7
Document No 861-19; Version No. 1.01
Wh
2 5
3
4 Energy Perform
ance Indicators
The overall Specific Energy Consumption (also known as EPI) for the site is shown below.
Table 2 SEC for the site
2006
Total
Annual Production Figure (tonnes)
4,744.09
Energy Consumption, kWh
8,722,236
SEC for site (kWh/tonne)
1,839
Previous SEC for site (kWh/tonne)
N/A
Best Practice SEC (kWh/tonne) 1
10,055
•
1 Best Practise SEC taken from Energy Consumption Guide 38 – Non-Ferrous Foundries. It must be noted that this figure is now 10 years old and includes processing of
aluminium ingots into their final end format, which does not happen at P. Carney
P. Carney
Emergency Response Plan
Environmental Efficiency
8
Document No 861-19; Version No. 1.01
5 Recommendations
The audit recommendations are shown in the table below.
Table 2 Recommendations
Ref.
Measure
Predicted
annual
savings,
kWh
Predicted
annual
GHG
savings,
t CO
2
Predicted
annual cost
saving, €
Capital cost
measure, €
Sim
ple
payback
period, yrs
Target
Completion
Date
Person
Responsible
1
Reduce compressed air leaks
4,226
3.28
735
0 0
To be
determined
To be
determined
2
Investigate the possibility of
reducing compressed air pressure
1,942
1.51
338
0 0
To be
determined
To be
determined
3
Vent compressed air exhaust
outside
280
0.22
48
0 0
To be
determined
To be
determined
4
Investigate changing office
lighting to electronic ballast
900
0.7
157
800
5.11
To be
determined
To be
determined
5
Investigate changing process
lighting to electronic ballast
9,990
7.75
1,736
1,550
0.89
To be
determined
To be
determined
6
Investigate the introduction of
daylight sensors
216
0.17
37.54
50
1.33
To be
determined
To be
determined
7
Investigate the introduction of
occupancy sensors
216
0.17
37.54
65
1.73
To be
determined
To be
determined
8
Insulate all valves & flanges
1,620
0.32
102.1
125
1.22
To be
determined
To be
determined
9
Investigate using exhaust heat
from furnace for space heating
20,027
5.18
1,262
2,500
1.99
To be
determined
To be
determined
10
Use fuel additives in motor diesel
75,232
14.9
4,944
0 0
To be
determined
To be
determined
11
Change electricity supplier
0 0
7,000
0 0
To be
determined
To be
determined
P. Carney
Emergency Response Plan
Environmental Efficiency
9
Document No 861-19; Version No. 1.01
Ref.
Measure
Predicted
annual
savings,
kWh
Predicted
annual
GHG
savings,
t CO
2
Predicted
annual cost
saving, €
Capital cost
measure, €
Sim
ple
payback
period, yrs
Target
Completion
Date
Person
Responsible
12
Monitoring & Targeting
436,111
107
25,792
4,000
0.16
To be
determined
To be
determined
Totals
550,760
(6% saving)
141
(7% saving)
42,189
(8% saving)
9,090
0.22
(average)
To be
determined
To be
determined
Full details for each recommendation are available in document 861-15.
P. Carney Emergency Response Plan
Environmental Efficiency 10 Document No 861-19; Version No. 1.01
6 Implication of audit findings The energy audit identified the site SEC. This will be used as a benchmark to identify the success or otherwise of the implementation of the recommendations. The energy audit identified a number of recommendations that could be implemented. Implementation of these will result in a significant reduction in energy cost and GHG emissions.
P. Carney Ltd.
Annual Environmental Report 2008
Environmental Efficiency
11
Document No 861-19; Version No. 1.01
Appendix 1 Energy M
anagem
ent Matrix
Level
Energy Policy
Organising
Motivation
Information systems
Marketing
Investm
ent
4
Energy policy, action plan
and regular review have
commitment of top
management as part of an
environmental strategy
Energy management fully
integrated into
management structure.
Clear delegation of
responsibility for energy
consumption.
Formal and informal
channels of communication
regularly exploited by
energy manager and
energy staff at all levels.
Comprehensive system sets
targets, monitors
consumption, identifies
faults, quantifies savings
and provides budget
tracking.
Marketing the value of
energy efficiency and the
performance of energy
management both within
the organisation and
outside it.
Positive discrimination in
favour of ‘green’
schemes with detailed
investment appraisal of
all new-build and
refurbishment
opportunities.
3
Formal energy policy, but
no active commitment
from top management.
Energy manager
accountable to energy
committee representing all
users chaired by a member
of the managing board.
Energy committee used as
main channel together with
direct contact with major
users.
M&T reports for individual
premises based on sub-
metering, but savings not
reported effectively to
users.
Programme of staff
awareness and regular
publicity campaigns.
Same pay back criteria
employed as for all other
investment.
2
Un-adopted energy policy
set by energy manager or
senior departmental
manager.
Energy manager in post,
reporting to ad-hoc
committee, but line
management and authority
are unclear.
Contact with major users
through ad-hoc committee
chaired by senior
departmental manager.
Monitoring and targeting
reports based on supply
meter data. Energy unit has
ad-hoc involvement in
budget setting.
Some ad-hoc staff
awareness training.
Investment using short-
term payback criteria
only.
1
An unwritten set of
guidelines
Energy management is the
part-time responsibility of
someone with limited
authority or influence
Informal contacts between
engineer and a few users.
Cost reporting based on
invoice data. Engineer
compiles reports for
internal use within
technical department.
Informal contacts used to
promote energy
efficiency.
Only low cost measures
taken.
0
No explicit policy
No energy management or
any formal delegation of
responsibility for energy
consumption
No contact with users.
No information system. No
accounting for energy
consumption.
No promotion of energy
efficiency.
No investment in
increasing energy
efficiency in premises.
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency 60 Document No 861-19; Version No. 1.01
Appendix 8 Emergency Response Plan
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(To be inserted)
Document No. 861-17 v2.00
P. Carney Ltd. Annual Environmental Report 2008
Environmental Efficiency 1 Document No 861-19; Version No. 1.01
Emergency Response Plan
P. Carney Ltd
Document No.: 861-17
P. Carney Emergency Response Plan
Environmental Efficiency 2 Document No 861-19; Version No. 1.01
QF 1. V2.00 Document Lead Sheet
Document Title Emergency Response Plan Project No. 861 Document No. 861-17 Client P. Carney Ltd. Address Crossakiel, Kells, Co. Meath
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
2.00 Approved 05/04/2007 PG
Where it is a requirement that this report be issued to a regulatory or other authority, then the client should sign the appropriate place in the above table and, unless specifically agreed in writing to the contrary, forward copies to the appropriate authority (e.g. EPA). EEC Project Manager: Bob Sutcliffe, CEng, MIMechE EEC Document Author: Paula Galvin, M.A
Conditions relating to the issue of this report:
� No alteration to this report by third parties is permitted
� Where this report is reproduced, it shall only be reproduced in full.
� Reports remain the property of Environmental & Efficiency Consultants (Ireland) Limited until paid for in full.
P. Carney Emergency Response Plan
Environmental Efficiency 3 Document No 861-19; Version No. 1.01
Table of Contents 1 Emergency Response Procedure............................................................................. 4 1.1 Introduction: .............................................................................................................. 4 1.2 Purpose: ..................................................................................................................... 4 1.3 Priorities: ................................................................................................................... 4 1.4 Potential Situations:................................................................................................... 4 1.5 Responsibilities: ........................................................................................................ 5 1.6 Training ..................................................................................................................... 5 1.7 Emergency Response Procedures.............................................................................. 6 1.8 Evacuation Procedures: ............................................................................................. 7 1.9 Containment Procedures: .......................................................................................... 7 1.10 Decontamination Procedure .................................................................................. 10 1.11 Follow-Up Procedure ............................................................................................ 10 1.12Review of Emergency Response Procedure........................................................... 13
Table 1 Emergency Preparedness & response training………………………6 Table 2 Spill response procedure…………………………………………….8 Table 11 Environmental incidence log……………………………………….11 Table 12 Environmental Incidence Record Form……………………………12
P. Carney Emergency Response Plan
Environmental Efficiency 4 Document No 861-19; Version No. 1.01
1 Emergency Response Procedure
1.1 Introduction: An emergency is any unplanned event that can potentially cause deaths or significant injuries to employees, customers or the public, or that can shut down the business, disrupt operations, cause environmental damage, or threaten the facility’s financial standing. The process of preparing for, mitigating, responding to and recovering from an emergency is integral to P. Carney Ltd’s management procedures. Training, undertaking drills, testing equipment and coordinating activities are integral to the process. 1.2 Purpose: The primary purpose of this plan is to provide management and staff at P. Carney Ltd’s premises with timely and effective response to any emergencies that may arise at the facility.
The goals of this emergency response plan are, to protect the lives of employees, customers or the public, to protect against environmental damage and to protect and minimise damage to the company property in the event of an emergency. 1.3 Priorities: The objectives of the plan are:
1. To evacuate and account for all employees and visitors 2. To contact local emergency services organisations; 3. To assemble the company’s emergency response team (ERT) for the
implementation of the response plan; 4. Contact pertinent regulatory agencies; 5. Turn off utilities; 6. Control any hazardous chemical spills or releases; 7. Perform cleanup and salvage as required; 8. Undertake post incident evaluation 9. File any applicable reports with regulatory agencies
1.4 Potential Situations: As part of this plan the following potential accidents or emergency situations that could arise at P. Carney Ltd’s premises have been identified as being:
1. Fire, storms, floods etc. 2. Spillages/leaks 3. Gas leaks 4. Power failures/surges 5. Transport accidents 6. Miscellaneous
P. Carney Emergency Response Plan
Environmental Efficiency 5 Document No 861-19; Version No. 1.01
1.5 Responsibilities: Personnel at P. Carney Ltd. that form the Emergency Response Team include: Name Role Mr. Jim McCabe Managing Director Mr. Declan Clarke Quality and Environmental Manager Mr. John Garry Works Manager Mr. Michael Farrelly Maintenance Manager Mr. Johnny Mongey First Aider Mr. John Garry has been designated as the primary Emergency Response Co-ordinator. In the event that Mr. Garry is absent during the incident Mr. Michael Farrelly will assume this responsibility. Emergency Response Co-ordinator
1. Evaluate the number and types of hazards and review on a regular basis; 2. Provide training for all employees for their roles in all emergency plans; 3. Conduct drills to practice response to emergency situations; 4. All other activities necessary to the development and implementation of an
effective Emergency Response Plan; The Maintenance Manager
1. Maintain sufficient inventory of emergency response equipment; 2. Ensure maintenance and inspection of process equipment; 3. Help train emergency response teams.
1.6 Training P. Carney Ltd. will train all employees on the procedures contained in this plan. New employees will be trained upon hiring, and re-trained any time the employees responsibilities under the plan change or whenever the plan changes. The company will provide copies of emergency response plans to be posted at various locations around the site. Supervisors and/or lead men in all work areas will be trained to assist in the safe and orderly evacuation of employees and visitors. Training will include:
o Emergency reporting; o Evacuation routes; o Alarm systems; o Specific assigned duties.
Periodic drills will be held to ensure that all employees know the appropriate actions to take in case of an emergency. The company will consult with local emergency services and invite them on site where necessary to participate in training. (See outline procedure below Table ).
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Table 1 Emergency preparedness and response training
P. Carney Ltd. –Emergency Response Procedure
Author: EEC Approved by: RBS Date: 23/03/07 Revision No: 1.00
Status: Approved
Emergency Preparedness and Response Training Purpose:
Procedure to ensure that employees are trained in the relevant emergency procedures.
Procedure: 1. An assigned selection of staff shall be trained as the emergency response team on
fire safety, major spill control and/or first aid. 2. Staff must be made aware of the significant environmental issues related to their
job during staff training sessions. 3. Staff should also be made aware of non-conformance criteria and the importance
of reporting all problems. 4. Staff shall be trained so that in the event of an accident, malfunction or non-
conformance they will be aware whom to report the issue to. 5. Any changes in the processes must be reviewed to determine if there is a need to
update the training. 6. Staff shall all be aware that in the event of a fire, serious accident or major spillage
that all staff exit to the safety points except for those designated and trained as the emergency response team.
1.7 Emergency Response Procedures
Incident Notification If an emergency or situation that could become an emergency occurs, staff are to inform management immediately. Mr. John Garry will maintain an up-to-date emergency response notification list. Emergency Reponse Team Notification Contact Names and Telephone Numbers: P. Carney Ltd Personnel Contact Number Jim McCabe 046 9243732 John Garry 046 9433021 Michael Farrelly 044 9374793 / 087 673 8244 Declan Clarke 087 616 5156 Johnny Mongey 086 3658353
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Emergency Services Contact Number Dr Lapin (Doctor) 046 9240052 Kells Fire Brigade 046 9240666 Ambulance Service 046 9021210 All Emergency Services 999/911 Authorities/Agencies Contact Number Meath County Council 046 9097200 Environmental Protection Agency 053 9160600 Employee Notification The alarm system or direct supervisory contact can be used to notify employees of emergency situations in the facility. External Notification Call 999 or equivalent to contact the local fire or Garda Siochana unit. Notify neighbours, local authorities, environmental agencies etc. 1.8 Evacuation Procedures: After the senior manager on the scene determines that evacuation is required, the evacuation alarm should be sounded, with instruction issued over the public address system. Specific responsibilities are as follows: Supervisors
1. Lead employees from the premises; 2. Assist any employees with disabilities and/or injuries; 3. Escort employees to the designated assembly area at the main gate; 4. Account for all employees upon reaching the designated assembly area; 5. Notify senior management of any employee not accounted for; 6. Ensure that employees remain in the assembly area until otherwise notified.
Fire Fighting No employee shall fight a fire that is beyond the incipient stage (able to be put out with a fire extinguisher), enter if the building is on fire to undertake search and rescue, or provide advanced medical care and treatment. These situations must be left to emergency services professionals, who have the necessary training, equipment and experience. 1.9 Containment Procedures: If there is an emergency stop button/shut off power switch in the vicinity of the incident, this should be pressed. If safe, directly stop at the source. Stop spill, leak, machine, shut off oil or gas etc where applicable. If the Fire Brigade is on site and there is a possibility of contaminated fire water leaving the site, it is the responsibility of the Emergency Response Co-ordinator to close the shut-off valve to the surface water drainage system.
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Contaminated materials should be identified and every effort made to hold the damage within one area. Drains, doorways etc should be blocked off where possible to prevent the incident from dispersing. All high risk materials should be put in a sealed impervious container. All unsafe equipment should be taken out of service. Spill response procedure is provided in Table below. Table 2 Spill response procedure
P. Carney Ltd. –Emergency Response Procedure Author: EEC Approved by: RBS
Date: 22/03/2007 Revision No: 1.00
Status: Approved
Spill response procedure Purpose:
Procedure to ensure that spills are cleaned up in the proper manner and the least amount of environmental pollution occurs. Procedure:
Response and Clean-up Procedure for Low Risk Spills
Low risk spills are defined as spills that have a low risk of spreading and reaching on-site drains or nearby water courses and these spills can generally be handled by internal personnel and do not usually require an emergency response by fire department personnel. Spills of less than 2 metres in diameter are normally cleaned up by the spiller.
1. Always ensure that the absorbent material is suitable for the spilled material. 2. First, quickly contain the spill by stopping or securing the spill source. This may be
as simple as up-righting a drum/container and using absorbent material (oil dri) to soak up spilled material. Wear gloves and protective clothing, if necessary.
3. Isolate all near-by drains with absorbent containment materials or other measures e.g. close valve.
4. Put spill material and used absorbents into a secure container. 5. Wash any equipment or floors so that no traces of the chemical remain. 6. Absorb the wash water with absorbent material and place this material in the same
container as the contaminated absorbent materials. 7. Label the container with the appropriate contents, workplace and shipping labels. 8. Ensure the spill is contained before reopening the drain for normal operation.
Response and Clean-up Procedure for HIGH RISK SPILLS
High-risk spills are defined as spills that have a high risk of spreading quickly to on-site drains or nearby watercourses. The fire service and Local Authority may be required to help clean up high-risk spills. However, common sense also should be used when determining if outside help is necessary. High risk spills require the following actions:
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P. Carney Ltd. –Emergency Response Procedure Author: EEC Approved by: RBS
Date: 22/03/2007 Revision No: 1.00
Status: Approved
Spill response procedure 1. Try to contain the spill at its source e.g. quickly upright a container, put a lid on it or
put it in a spill-tray. If necessary, put on the personal protective equipment (PPE). 2. Once you have made a quick attempt to contain the spill, leave the area and alert the
Maintenance Manager and Environmental Manager. 3. Ensure that all near-by drains are protected with absorbent containment materials if
possible and if safe to do so. 4. Evaluate the spill and make the decision if the spill requires the assistance of the
emergency services: 5. Contacting the Fire Brigade
� Dial 999 � Ask for the fire brigade � Inform the operator that there is a spill at P. Carney Ltd, � Provide details regarding quantity and chemical type if known
6. After emergency personnel have arrived on site, be prepared to assist them with any other information that may be necessary e.g. MSDS sheets
7. A summary of the environmental incidence record and the method of response and
clean up is written by the Maintenance Manager and presented to the Environmental Manager.
8. The Environmental Manager will inform Meath County Council as soon as
practicable after the incident. (Meath County Council Ph. No: 046 9097000)
9. The Environmental Manager will inform Environmental Protection Agency as soon as practicable after the incident. EPA Headquarters Tel: 053-9160600
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1.10 Decontamination Procedure 1. Remove all faulty equipment; 2. Identify and safely collect the hazardous or contaminated material; 3. Arrange for correct treatment or disposal of the contaminated material; 4. Use only authorised waste disposal companies. 5. Hold all relevant documents on site for inspection.
1.11 Follow-Up Procedure 1. Identify and document the cause of the incident and any contributing factors; 2. Identify what safety precautions were taken; 3. Record, inform and report on the incident using the Environmental incidence
log and records forms provided below (Table 3 & Table 4) 4. Analyse data collected and document a procedure to eliminate this and similar
occurrences taking place again.
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Table 3 Environmental incidence log P. Carney Ltd. –Emergency Response Procedure
Author: EEC Approved by: RBS
Date: 22/03/2007 Revision No: 1.00
Status: Approved
Environmental Incidence Log Date of
Incidence:
Area of
Incidence:
Description of
Incidence:
Area
Supervisor:
Action Taken:
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Table 4 Environmental Incidence Record Form P. Carney Ltd. –Emergency Response Procedure
Author: EEC Approved by: RBS
Date: 22/03/07 Revision No: 1.00
Status: Approved
Environmental Incidence Record Form Incidence Recorded: EPA/ 3
rd Parties Informed (Y/N):
Date of Incidence: Time of Incidence:
Staff Member:
Maintenance Manager:
Cause of Incidence: (if cause not known, record ‘unknown’. Cause to be determined as soon as practical after incident)
Nature of Substance Involved:
Nature of losses: (life, injury, adverse environmental impact and property)
Actions Taken to Minimise Adverse Impacts:
Specific Advice of Environmental Manager regarding Incidence:
I have inspected the area of concern and all actions have been taken to
lessen/eliminate any negative impact on the environment.
Signature of Maintenance Manager:_______________________________________
Signature of Environmental Manager:______________________ Date:_____________
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1.12 Review of Emergency Response Procedure
This procedure will be reviewed in the case of: 1. Revised environmental regulations; 2. Inadequacy of procedure during an emergency; 3. Major process changes 4. Major equipment change.
P. Carney Ltd. Annual Environmental Report 2008
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Appendix 9 Accident Prevention Policy
This page is left intentionally blank
(To be inserted)
Document No. 861-12 v1.00
1
Accident Prevention Policy
For
P. Carney Ltd.
Crossakiel, Kells, Co. Meath
IPC Licence Reg No. P0402-02
(Document No: 861-12)
P. Carney Limited Accident Prevention Policy
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Document No. 861-12 v 1.00
QF 2. Document Lead Sheet
Document Title Accident Prevention Policy
Project No. 861 Document No. 861-12 Client P. Carney Ltd. Address Crossakiel, Kells, Co. Meath
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00 Approved 05/04/2007 TG & MR
Where it is a requirement that this report be issued to a regulatory or other authority, then the client should sign the appropriate place in the above table and, unless specifically agreed in writing to the contrary, forward copies to the appropriate authority (e.g. EPA).
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: Tom Griffiths, MSc., BSc., ESAI
Maria Rochford, BSc. Env. Mgnt.
Conditions relating to the issue of this report:
10. No alteration to this report by third parties is permitted
11. Where this report is reproduced, it shall only be reproduced in full.
12. Reports remain the property of Environmental & Efficiency Consultants (Ireland)
Limited until paid for in full.
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Document No. 861-12 v 1.00
TABLE OF CONTENTS 1. Introduction ......................................................................................................... 4
2. Purpose................................................................................................................. 4
3. Potential Incidents............................................................................................... 4
4. Accident Prevention Procedure ......................................................................... 5
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1 Introduction P. Carney Ltd are based in Crossakiel, Kells, Co. Meath and have IPPC licence number
P0402-02. Condition 9.1 of the licence states that:
“The licensee shall, within six months of the date of grant of this licence, ensure that a
documented Accident Prevention Policy is in place, which will address the hazards on-
site, particularly in relation to the prevention of accidents with a possible impact on the
environment. This procedure shall be reviewed annually and updated as necessary.”
This report is the Accident Prevention Policy (APP). The APP is designed to be
accompanied by the Emergency Response Plan (ERP) and supported by the
Environmental Management System (EMS) and the IPPC licence.
The IPPC licence requires the company to implement an environmental management
system at the facility in order to control and minimise and prevent all emissions to
environmental media.
Through the terms of the IPPC licence (register no. PO402-02)) P. Carney Ltd. are
required to carry out sampling and analysis of emissions to air, noise and storm water
emissions. Emission Limit Values have been set for all emissions and regular monitoring
is undertaken to establish compliance with the limits.
2 Purpose The primary purpose of this plan is to ensure management and staff at P. Carney Ltd’s
premises are provided with the training and knowledge needed to ensure the continued
protection of the environment and human health and eliminate the risk of accidents
occurring at the site.
3 Potential Incidents As part of this plan potential accidents that could arise at P. Carney Ltd’s premises have
been identified as being:
7. Fire, storms, floods etc.
8. Spillages/leaks from hazardous materials stored on site
9. Accidental release/emission to environmental media
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10. Gas leaks
11. Power failures/surges
12. Transport accidents
13. Miscellaneous
4 Accident Prevention Procedure The company operates a comprehensive environmental management system (EMS). The
EMS is designed to manage the company’s environmental aspects in conjunction with the
IPPC licence. The EMS involves the implementation of a range of procedures at the
company, to ensure the elimination, prevention and control of all environmental hazards
on-site. The relevant procedures that will prevent the occurance of accidents on site are
outlined in the Environmental Management System Manual. The accident prevention
procedure provides the framework for which control and monitoring of the companies
activities are to be managed in order to avoid accidents.
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P. Carney Ltd - Accident Prevention Policy Procedure
Author: P. Carney& EEC
Approved by: RBS Page 1 of 2
Date: 25/03/07 Revision No: 2.00 Status: Approved
Purpose:
To address the hazards on-site, particularly in relation to the prevention of accidents with a possible impact on the environment and to provide the framework for establishment of measures and controls to be implemented in order to avoid accidents occurring on site. General Procedure:
The accident prevention procedure outlines the processes in place at P. Carney Ltd that aid in the elimination and avoidance of accidents which are likely to impact of the environment. 1. Organisation and personnnel The roles and responsibilities of personnel involved in the management of hazards with environmental impacts at all levels in the organisation should be clearly defined. Regular management meetings are to be carried out to monitor compliance with the terms of IPPC and
continual improvement of environmental performance. The training needs of relevant personnel
are to be defined and the provision of the training determined. Training should involve the communication to all personnel regarding known potential hazards on site with environmental risks.
2. Hazard identification
All potential hazards associated with the process activities and other activities such as unloading of raw materials, which have the potential to impact on the environment, must be identified and appropriate controls determined, implemented and reviewed. Hazards and the associated controls should be communicated to all relevant staff.
3. Operational control Operational controls for the safe design and operation of plant, processes, equipment and storage facilities on site should be defined. Operational controls are to cover all phases of normal process activities and should include engineering and administrative controls. Operational control should also encompass a regular check, maintenance and inspection programme for process and all abatement equipment used on site.
4. Monitoring performance (continual improvement) Management are to regularly review compliance with the objectives set by the IPPC licence and environmental management system, and establish measures for investigation and taking corrective action in cases of non achievement of objectives and targets.
5. Audit and review
In addition to the routine monitoring of performance, regular audits of the environmental management system are to be carried out. The findings of previous audits will be reviewed prior to conducting of any internal audit and any past non-conformances raised will be included in the schedule for the audit. An audit should determine whether the overall performance of the Environmental Management System conforms to requirements, both external and those of the operator. The results of these audits should be used to decide what improvements should be made to the elements of the EMS and their implementation in order to achieve full compliance with the IPPC licence and prevent the possibility of accidental release of emissions or other accidents with environmental consequences.
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P. Carney Ltd - Accident Prevention Policy Procedure
Author: P. Carney& EEC
Approved by: RBS Page 1 of 2
Date: 25/03/07 Revision No: 2.00 Status: Approved
Procedure References (see EMS Manual): � Procedure for a management review � Procedure for an EMS Audit � Procedure for the Determination & Update of Objectives, Targets and EMP � Environmental Audit Log � Audit and non conformance sheet � Internal EMS Audit Schedule Form � Corrective action request form � Procedure for environmental training of staff � Procedure to reduce leaks and spills on site
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