Kery Ingredients, Listowel Firewater Run-off Study

lOOMI-22-RPQOI, Issue B 17 May, 2004

SITE LAYOUT PLAN

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EPA Export 25-07-2013:14:50:52

Kerry Ingredients, Lisfowel 10081 I-2%RP-001, Issue 6 Firewater Run-off Study 17 May, 2004

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EPA Export 25-07-2013:14:50:52

Kerry Ingredients, t&towel Firewater Run-off Study

100811-22-RP-001, Issue 8 17 May, 2004

TANK REGISTER

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0 Kerry Ingredients External Tank Register Page 1 of 4

c

SERVICES TANK REGISTER ID No. No. of Tanks Contents

1 1 Ammonia Location/Description Size m3 Bunded

2 1 Old refrigeration sTL?,I--I h11-1 10 NO -._ -. - . crrw~eu vvaler

De-aerator Uld refrigeration 70 No

3 1 water/steam Oil boiler house roof 15 No ,

d 3 C..... .

I 7 _- No 1 1 soft ~ water backwash 1 Rear of new so I Soft water break

ft plant

3 Chilled (Rear of new soft plant

I Water Beside new refril -1 a

1 Ammonia

19 Be8 *

- , Hotwells water 20 2 Raw water

Wawr LI t3armenr pram 21 Storage tanks 6 186 c -.

side new refrigeration A..- .“--A---r -I- -1

.id bund

IO 1 No --s I 1 No

Suent plant

25 1 Balar Iv effluen

26 1

27 1

Tl,cI,, rressure vessel at DAF 2.3 nrce Tank -

No

t Effluent plant 4545 No bbic digestor - tlmirmhnc Effluent plant 4500 Na

Anaerc effkm a a llyl vyvu I I

.- e#i..*,r -l--L

c+nr

.I cnlorme u;...

[Effluent Dlant I 60 1 Yes 1 *,ci - t

effluent/microbes Effluent plant 340 No i 1 effluent concrete balance tank

I 500 No

i) External Tank Registerxls 12107104

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Kerry Ingredients External Tank Register Page 2 of 4

ID No. 1 NQ, of Tanks lConte I

Location/Description I I

, “I&W 111 , Y”.lUciU I I

61 2 Ammonia Receivers Roof of new refrigeration 6, 3 62 2 Sand Filters Water 70 63 1 Ammonia Receiver TBA

External Tank Register.xls 12107/&l

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Kerry Ingredients External Tank Register Page 3 of 4

Process Tank Register ID No. No. of Tanks Contents LocationlDescriptian Size m3 Bunded

64 18 Milk & Whey lnta ke Silos 1 to 18 275 No 65 1 Washwater Lorry wash intalcn Nn I .- . _-. . I ci . .- NC-I

1 Caustic Lorry washinta\._ .~ ~ reNo.2 i 4.5 1 .*- , No 1 : 1 Water Lorry wash inbkn Nn.3 1 4-i 1 No 1

.I--1 _ _-.-

1 kmrctic! t

. . v . -

Caustic 1 Water ICip to 1

1 lOlive Oit + blc

I 1 IVeg. Oil Spreaas silo 0 W

I 1 ISunflower oil Spreads silo 7 60 Ii:

t

1 IRape seed oil . .- $$msds siln fl I . - - - - - . . - - I

iin . . - ,

Nn

I

;

h/P, getable oil \Nhole milk

SE Ireads silo 9+10 1 110 1 ii; 73

. .A11 Cream stana s z1

I mm 55

I . . NO

3 Skim milk Cream stand 38, 39,40 4.5 No 1 Cmam Cream stand 32 73 No

Cream stand 33 114 NO #-d-A- -a--A 9.4 .Tbtz n)rl!

GIlllQlta I-

I 91

I No I

I I . _ -._.. -- --__

1 I C~II Istir! lktm

74

75 76

6 Fat Silos Vw Che,,u

A Renrwt Casein Casein Make up 1,2+3 68 No -__ -.,- --.-,-dent CIP make up for Casein 45 No

i Filtered water StlWXWk IA NC-3

1 Caustic .otmln OUllU 1 La 1 IYU 1 Anion water (soft) Demin “Bund” I 55 1 No

n-1.-.- a.,--, I I I 4 pia tlon vvasre

:idicS I Demin “Bund” I 36 I No I I tat.-.-, 1 Cation ret water jDemin “Bund” I 91 1 No

I 1 ICaustic for Demin ]Demin “Bund” I 91 ) No 1 ,

External Tank RegisterAs z z/07/04

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Kerry Ingredients External Tank Register Page 4 of 4

ID No.

76 No. elf Tanks

1 /Caustic 23% ,----“““‘“YY.l~ll,“,, Size m3 Bunded

1 ITank 4 f-P ,-. whey CIP ALA 4 -0, 9 No -~~ I IfwilU I-L70 I I~anK 3 whey CIP I 9 1 No *hey CIP 9 I No

1 JRecovery water ITank : 1 IWa , 4er Tsnlt 1 ruhn.r PID 2 ISoft water for ROlU i- I ~rreatel 1 Whey

Acid /AC 1 [RQ tan

1 Cal IStic I Caustic recou 1 Wh ey )I Nhe - _ 1 Whey , 1 Hold\ _ _

y Uemin balance tank i 23 inn Tank (snare1

1 No 1 7.1 1 Nn

.I- I IRQ

gent Tank La NO

23 No

1 Citric Acid I 1 Acid Nitric acid tank I Liquid Nitrogen Capacity II, 1

tonnes 1 Air Air recoivt 1 Anion Anion -was

tergent Tank 1 (caustic) lCtystallisation Tanks Citric Acid Tank

I15 litres 6.9

23 No

23 NO 45 No 36 NO

, , NO !r ;te

14 NO 9 Nfl

: Caustic n-

I Caustic recovery fhey 1 Permeate silos

I T

14 ii;

3 Hot water ICIP * . 68 NO

1 Vegetable -- 1 Butter Oil 1 Causti

ICheese make up I 45 1 No se CIP I . -

1 _ . .

lanK cheese .--- lT~..I .~ L 1 4.5 1 No 1 I -_ e oil 1Chew:s-e tsmmo cam I 60 I No I

IC IChef [Acid IChi

77

78

I 1 I Hot water I Prenearer crrcula 1 I Water 1 Hose Point Tank

>alor gas tank 16 No inklar System 340 No

1 Forklift gas fuel 1 Water

1 White Lorry diesel

I Petrol

1 Red Tractor Diesel

ionia

F c sE!L Weighbridge (undergrokd) Weighbridge Junderground) Green Tank bb weighbridge P&I Cold Store Plant

I I I f I

External Tank Reglster.xls f2/07/04

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EPA Export 25-07-2013:14:50:53

Kerry Ingredients, Listowat Firewater Rmoff Study

10081?-22-RP-001, Issue B 17 May, 2004

FIRE PREVENTION AND EMERGENCY RESPONSE AT KERRY INGREDIENTS

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Kerry Ingredients, Listowel Firewater Run-off Study

100811-22-RP-001, Issue B 17 May, 2004

I.

1.1.1

1.1.2

1.1.3

1.1.4

2.

2.1.1

2.1.2

FIRE PREVENTION

Site Security

Vehicular and pedestrian access to the site is restricted. Access is gained only via the manned security building at the weigh-bridge which controls both access to the front car park and administration buildinglcanteen and delivery/dispatch over the weigh-bridge.

The site is bounded by waHs along the western and southern perimeters and by a security fence along lhe eastern perimeter. The River Feale forms the northern site boundary.

Fire Prevention Kerry Ingredients has recognised the need to control fire risks at an acceptably low level. This is achieved through ongoing employee training and awareness campaigns. Potential sources of ignition are tightly regulated. In particular hot work and smoking are strictly controlled.

Hot Work Permits Kerry ingredients operate a Permit to Work system. A Valid Hot Work Permit must be issued prior to commencement of any burning, welding, grlndlng, or cutting (flame or disc).

Smoking Policy

There is a policy of no smoking on site except In designated areas.

EMERGENCY RESPONSE IN THE EVENT OF A FIRE

Emergency Response Procedure

The site emergency response procedures are documented in the Kerry Ingredients Site Emergency Plan, submitted to the Agency as Attachment 20 of the IPC Licence Application.

Lnsrgency Classification

Site emergencies are classified according to one of the following three levels:

Code 1: A!ert

This is the loiest level. It is associated with an unusual event that can easily be brought under control by plant personnel. Events such as small fires product release to environment, or minor releases of hazardous material with negligible impact on plant personnel or the Public are typically classified as Code I.

Code 2: Site Emergency

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Kerry Ingredients, Liitowel 100811~2%RP-001, Issue B Firewater Run-M Study 17 May, 2004

This intermediate emergency level is associated with fires, explosions or toxic material releases that mey have afready affected the plant but have not yet spread outside of the plant boundary limits. Off site personnel such as fire brigade, medical personnel, gardai may have to be notified.

Code 3: General Emergency

This is the most critical emergency level and arises if the effects of an incident have already spread or have the potential ‘for spreading beyond the site boundaries. It means that external emergency services personnel should be notified for assistance.

2.1.3 Emergency Management Structure

The Emergency Management Structure is comprised of the following personnel:

Factory Operations Manager

This person is in charge of the overall emergency response operation. His main function is that of overall guidance during the emergency. He is responsible for classifying the event. Managing the overall response to mitigate the event and ensuring notification of senior site management and of off-site agencies. He also must ensure notification, and call out of plant and support personnel, ongoing assessment and reclassification, on site personnel protective actions. Ensure off site public protective action is taken and brief Corporate Affairs on the extent of the emergency. Deal with media and members of the Public.

Relevant Department Manager

The Department Manager of the area in which the incident occurs fills this post, i.e. Casein, Powder,Services etc. He is the next ranking emergency response person on site and he functions at the direct scene of the accident, He is responsible for co-ordinating the specific responses necessary at the accident site, maintaining communications with the Control Centre and mobilising the Kerry Ingredients Fire Crew.

Plant Safety Manager

Located at the emergency control centre, this person maintains communications with the Department Manager and co-ordinates the activities at the control centre, advises the Factory Operations Manager of actions planned or initiated to help mitigate or recover from an incident. He will maintain an event log during the course of the incident and prepare a report of the incident.

Plant Engineering Manager

Responsible for controlling the engineering/technicat process during the emergency and ensures that fuel lines e.g. diesel to burner room ara disconnected and non-essential services isolated where necessary,

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Kerry Ingredients, Listowl Firewater Run-off Study

1ilOEW22-RP-001, Issue 3 17 May, 2004

Emergency Response Team (Plant Operators and Supervisars)

The plant Emergency Response Team will deal with the emergency until the arrival of the Fire Brigade when they will then be available to assist under the command of the highest ranking fire officer. They will undertake low hazard emergency operations such as the removal of injured or exposed personnel from the scene, and provide first aid to victims. They will control hazardous spills and in the case of fire, attack the fire and contain the run off of waste from the area.

Maintenance Personnd

Carry out duties e.g. disconnection, isolation as directed.

Site Security Officer

He will receive the initial emergency no%ation and will alert the appropriate personnel like Shtft Supervisor, Operations Manager, etc. He will mobilise the Ki Emergency Response Team when requested by the,Shift Supervisor or Plant Manager. One of his main respdnsibilities during the emergency is to ensure that plant security is maintained.

Shift Supervisor

In the event of an emergency occurring outside office hours, the relevant Department Shift Supervisor will assume the responsibilities of lhe Factory Operations Manager (FOM) until such time as the FOM or a member of senior management has been contacted and has arrived on site. The Shift Supervisor will arrange for ERT members to be contacted to assist and advise him.

Deputies ,

Outside office hours, the first person to be contacted during an emergency is the Factory Operations Manager. If he cannot be contacted, the next ranking person in the emergency contact list is contacted. The Department Manager where the emergency has occurred is to be contacted also.

2.1.4 Training

Emergency response training is provided on an ongoing basis for the fire crew and all personnel.

Fire Crew

The Kerry Ingredients Fire Crew is comprised of a group of employees who receive regular training so that they can respond effectively in the event of a Fire, Specialised training is provided to all members of the Fire Crew so that they can respond effectively in the event of a fire. Specialised fire crew training is carried out for one full day once per month.

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EPA Export 25-07-2013:14:50:53

Kerry Ingredients, &towel Firewater Run-oNStudy

10081 f -22-RP-001, Issue B 17 May, 2004

Kerry Ingredients Staff

Plant personnel are required to be knowledgeable of the possibility of various emergenties and emergency actions. General safety training is provided to all employees to familiarise them with alarms, evacuation routes, sheltering areas, etc. In addition, personnel required to be part of the Emergency Response Team are required to have additional training and to participate in periodic drills and exercises.

First response fire training is provided for all personnel who work in or near the control room. Training records are maintalned on-site.

2.1.5 Off-site Emergency Support

There are two fire appliances based in Listowel. The response time for a fire tender from Listowel is within 10 minutes after notification. This information was obtained from the Kerry Fire Service Assistant Fire Officer. Additional appliances are located at Ballybunnion (I), Castleisland (1) and Tralee (2). Response times for these appliances would be of the order of 20 minutes. If required, the Limerick County Fire Brigade at Abbeyfeale may be called upon (2 appliances). In addition the Kerry County Fire service has 2 high output hydraulic platforms, although it is understood that these would be used judiciously in the event of a fire, due to their high water output.

2.2 Fire Protection

Kerry Ingredients has a number of fire protection systems on site, including:

. Fire Suppression System

. Fire Quench System

l High Pressure Water Quench System

. Sprtnkler System

. Deluge System

. Firebreaks

. Fire Hydrants

. Hose Reels

. Portable Fire Extinguishers

2.2.1 Fire Suppression System

A Graviner explosion protection system is in operattion in the fluidised bed sections of the dryers. The system operates on the principle that a fire/explosion is detected In its early stages. A suppressant material, sodium bicarbonate is released into the dryer chamber before the fire or explosion can reach destructive proportions.

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Kerry Ingredients, Listowel 100811-2%RP-001, ksue I3 Firewater Run-off Study 17 May, 2004

2.2.2 Fire Quench System . A steam suppression system is in operation in both dryers. The system is activated by the temperature inside in the dryer. An alarm sounds at jZO*C and if the temperature exceeds ISO% an automatic steam valve will open allow steam at 2ODpsi to pass to the dryer.

2.2.3 High Pressure Water Quench System

This is a manually operated system whereby in the event of a fire being detected in a dryer by an operator, he can open a valve to atlow high pressure water to spray the dryer chamber.

2.2.4 Spr‘lnkler System

Automatic sprinkler systems are installed in the powder store, blending area and associated canopy, bottling plant, milk dryer area, casein dryer area, Niro bag-off and Powder Store II areas.

The system is pressurised and is connected to a new sprinkler water storage tank which is located immediately to the north of the general store area. The tank has a capacity of 540m3.

Supply to the sprinkler system is provided by 2 no. diesel pumps. The diesel pumps are on alternate duty/ standby cycles and are tested weekly, are alarmed to the security building at the weigh-bridge.

The pumps The system has been

designed to BS 5306:Part 2 and Loss Prevention Council (LPC) Rules for Automatic Sprinkler Systems and is installed in agreement with the company’s insurance providers.

The system has been Installed as part of a loss prevention programme the purpose of which is b minimise the potential consequences of incidents at the site. The installation of a dedicated sprinkler system increases the degree of protection from fire, allowing faster detection, response and control times.

2.2.5 Deluge System

The cheese plant is fitted with an external water dduge system to provide for cooling and as a firebreak between it and the cold stores.

2.2.6 Firebreaks

There are a number of firebreak partiUons located in the area of the whey and casein plants which function to prevent the spread of fire from one building to another. These include non-combustible canopies between the casein plant and the powder store opposite, non-combustible canopy between the powder store/blending area and cold stores, non-combustible canopy between the cold stores and adjacent cheese plant and fire doordpartitions.

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EPA Export 25-07-2013:14:50:54

Kerry Ingredients, Liitowe~ Firewater Run-off Study

10081 l-22-RP-001, Issue B 17 May, 2004

2,2.7 Fire Hydrants

There is a firewater ring main supplying water to 35 no. fire hydrants at a pressure of 5Opsi. appliances.

These hydrants are available for connection by attending fire

Each hydrant is tested once a year and a record Is kept of all tests, faults and repairs undertaken.

2.2.8 Fire Hoses

There are 45 hose reels on site. The hose reels are fed fom a 10” plant ring main which is operated at IOOpsi. The ring main supplies water for plant processes and is serviced by three pumps. The supply is from 2 No. 1220m3 storage tanks.

Hose reels are used by local area personnel in the event of an outbreak of fire, if deemed safe to do so.

2.2.9 Fire Extinguishers

There are approximately 369 portable extinguishers on sib. Extinguishers are provided for the range of fires potentially encountered at the plant (electrical, oil etc.) and compromise water, dry powder, foam and CO, extinguishers.

These are inspected quarterly in accordance with 18.291:1986.

2.2.10 Auxiliary Equipment

Kerry Ingredients maintains an inventory of emergency response facilities and equipment on the site. Emergency equipment includes:

. Personal protective equipment, including fire suits and I3.A sets.

* Medical equipment & supplies

. Generators for operation & emergency lighting.

. Training equipment and supplies

2.3 Fire Protection Systems

2.3.1 Fire Detection and Alarm System

All areas of the site are protected by an automatic fire detection and alarm system (FDAS). This system has been designed, installed and maintained to the standard L2 as defined in IS3218 (3989). The fire alarm systems are connected directly to security control at the weigh-bridge. Depending on location, the FDAS has detection elements installed which will result in activation based on one of the following occurrences.

l Smoke detector detecting smoke, steam or dust.

. A rise in temperature, causing heat detector to activate.

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EPA Export 25-07-2013:14:50:54

Keny Ingredients, Llstowel Firewater Run-off Study

100811-22-RP-001, Issue B 17 May, 2004

. Breakage of a break glass unit.

. Activation of a sprinkler system.

in the event of an alarm activation, the control panel at the weigh-bridge will indicate the area in which the system has been activated. The weigh-bridge security guard immediately notifies the shift co-ordinator or shift supervisor.

All alarm activations require a response and the relevant areas checked before alarms are reset. Alt alarm activations are recorded on a computer printout. A schedule of inspections for the fire alarm system is maintained by the Health and Safety Manager.

2.3.2

2.3.3

2.4

Spill Cktntainment

The bulk of hazardous materials fdERV, HFO etc.) are stored in bunded or contained areas.

In the event of a significant spillage to grade, the material would enter the wastewater treatment plant via the surface water drainage system and would thereby be prevented from leaving the site.

Site Drainage System

The site itself can be regarded as having secondary containment, in that all external areas drain to the wastewater treatment plant. There are no direct discharges to the river along the site perimeter. Treated effluent is pumped approximately 750m to the River Feaie to a point down stream of the plant.

Special Provisions for Spray Dryers The following text is taken from the Keny Group standards for Hazardous Processes,

Spray drying is used extensively throughout the food industry for converting liquids to powders and other dried products.

A number of losses have been experienced as a result of ignition of powders and dusts within the drier or spontaneous combustion. The ensuing fire has either destroyed the spray dryer or the spray dryer and the building.

it is therefore essential that preceunons be taken to ensure that an explosion originating in the dryer is adequately vented or suppressed to either protect the equipment and the building or just the building.

The following features should be provided:

% Explosion venting should be provided on the drier, fluid beds, cyclones, dust extraction and silos

> Explosion vents should be to outdoors or in to large, open, totally unobstructed spaces 100 times larger than the vessel that vents {space to be room volume less vessel/equipment volumes)

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EPA Export 25-07-2013:14:50:54

Kerry Ingredients, Listowel 100811-22.RP-001, Issue B Firewater Run-M Study 17 May, 2004

‘r Building explosion venting should be provided where a room explosion hazard exists from dust in the building or improper vessel venting

> Vents should be lightweight panels secured with fixings that are designed to fail at the recommended explosion pressure. Systems of vent fixing that require human precision (such as the use of sealant) are not recommended

Explosion vent sizing to be approved by the equipment supplier for vessel protection and not only operator protection and insurer

Explosion suppression should be provided in high value processes, processes with a history of a high frequency of explosions or in place of venting where outdoor vents cannot be provided

Grounding and Bonding should be provided throughout, including over flexible joints where parts are statically isolated

An automatic suppression system should be provided that is either:

9 Hot water suppression with steam back up or

l Hot water suppression with cold water back up if steam is not available

both using carbon monoxide detection or temperature and pressure protection with a manual switch in an accessible location to manually operate the system

Automatic suppression systems should be capable of providing 1 0-mmlmin per sq.m of dryer internal area

The minimum duration for the water suppression should be 30-minutes

Damage limiting construction to the building should be provided where equipment venting indoors presents a pressure build-up where equipment or building structure would be damaged. Or where dust levels internally present a room explosion hazard (typically more than IO-mm in depth)

Electrical equipment used in the vicinity of the dryers and associated equipment should be suitably rated

A Glean In Place system for all dryers, fluid beds and cyclones. An exception to this may be aluminium dryers where the caustic materials dissolve the aluminium. Stringent cleaning procedures and inspections should replace the CIP recommendation.

, 1

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EPA Export 25-07-2013:14:50:54

Kerry Ingredients, Listawet Firewater Runoff Study

lOOWl-22.RP-001, Issue B 17 May, 2004

DETAILS OF PROPOSED DRAINAGE MODIFICATIONS

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L

:,, f & :.

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EPA Export 25-07-2013:14:50:54