Annual Environmental Report of Jamestown Shot Blasting … · Jamestown Shot Blasting and Metal Coating Ltd ... Annual Environmental Report 2009 ... out using a Gietart fully integrated

Jamestown Shot Blasting and Metal Coating Ltd – Annual Environmental Report 2009

Licence Register Number: P0796-01

Licensee: Jamestown Shot Blasting and Metal Coating Ltd

Location of Activity: Jamestown Road

Inchicore

Dublin 8

Attention: OEE Administration

Licencing and Control Division

Environmental Protection Agency

P.O. Box 3000

Johnstown Castle Estate

Co. Wexford

Prepared by: Tom Collins

Environmental Health and Safety Manager

Jamestown Shot Blasting and Metal Coating Ltd

Jamestown Road

Inchicore

Dublin 8

Date: March 2010

Annual Environmental Report of

Jamestown Shot Blasting and Metal Coating

Ltd. in Compliance with the Requirements

of the IPPC Licence Register Number

P0796-01


CONTENTS Page No.

Section 1: Introduction

1.1 Overview 2

1.2 Name and Location of the Site 3

1.3 Description of the Activities of the Site 4

1.4 Company Environmental Policy 5

1.5 Company Organisation Chart for Environmental Management 7

Section 2: Summary Information

2.1 Self Monitoring Data 9

2.1.1 Emissions to Air 10

2.1.2 Storm and Ground Water Monitoring 19

2.1.4 Noise Emissions 25

2.1.5 Solid Waste Monitoring – Non-Hazardous 26

2.1.6 Solid Waste Monitoring - Hazardous 27

2.2 Energy and Water Consumption 28

2.3 Environmental Incidents and Complaints 28

2.4 Report on Emissions and Waste Transfers 29-39

Section 3: Management of the Activity

3.1 Environmental Management System 41

3.2 Environmental Management Programme Report (EMP) for 2008 42

3.2 Monitoring Program for 2009 43

3.3.1 Personnel Responsible 43

3.3.2 Monitoring Procedures 43

3.3.3 Monitoring for 2008 43 3.3.4 Proposed Monitoring for 2009 43

3.3.5 Contractors Commissioned to Conduct Emission Monitoring 43

3.2 Pollution Emission Register 44

3.2 Environmental Protection Spending 45

3.2 Environmental Training and Education 46


APPENDICES

Appendix 1 Environmental Organisation Chart

Appendix 2 EMF 014 – Complaints Register

Appendix 3 Objectives and Targets for 2009

Air

Water

Energy

Waste

Appendix 4 Programme Sampling and Analytical Methodologies

Appendix 5 Training


SECTION 1

Introduction


1.1 Overview

In accordance with Schedule D of IPPC licence register number P0796-01, the

following is the Annual Environmental Report for the year 2008 at Jamestown Shot

Blasting and Metal Coating Ltd., Dublin 8. This Installation was granted its licence on

18th

May 2007. It is considered that the company has made significant improvements in

the management of its environmental affairs and the protection of the local environment

in which it operates. The Environmental Management Team on site are committed to

implementing an ongoing improvements programme at the facility. An Environmental

Management System (EMS) has been put in place. Through ongoing training all

associates at the facility are involved in this improvement programme. The continuous

improvement requirement of the IPPC process is fully embraced by the Environmental

Management Team.

Jamestown Shot Blasting and Metal Coating Ltd. – Annual Environmental Report 2009

3

1.2 Name and Location of the Site

Jamestown Shot Blasting and Metal Coating Ltd. is situated in an industrial area on

Jamestown Road, which is located within a suburban setting in Inchicore, Dublin 8.

The plant occupies an area of approximately 3,822 square metres.


4

1.3 Description of the Activities at the Site

Jamestown Shot Blasting and Metal Coating Ltd. (JSB Ltd) is situated on the

Jamestown Road, Inchicore Dublin 8. The company is involved in the surface

preparation and coating of steel with primer for structural use. This process is carried

out using a Gietart fully integrated automatic shot blasting, painting and drying

system which was installed on the JSB premises in 2004. The facility operates over

one shift for a 8 hour working day with painting occurring for approximately 5-6

hours per day.

The process can be broken down into the following phases:

Virgin steel (material) is feed into the machine by a set of cross transfers located

outside the main building in the yard. Infeed rollers carry the steel to an automatic

blower, which removes debris such as stones and leaves. The material then passes

underneath a natural gas powered heater to improve the drying time of the paint.

The steel then moves into the shot blast unit, where it is exposed to metal shot

(Zeleznik) to be blasted to an industry standard of SA 2.5. The mill scale produced by

the blasting is removed via a dust extracting unit. The shot used is recycled in the

system to be used again while dust is separated into a dust bag under the filter unit.

The blasted material then passes through a brush unit where any remaining pieces of

shot are removed and returned back to the hopper for reuse.

The material is then passed through the automatic paint spraying system, this unit has

sensors to detect the size, number of pieces and the distance between the units. It then

automatically sets the shortest stroke possible for the piece being painted. JSB have

changed from solvent based primers to water based primers in November 2007 and

are currently operating at a 8:2 ratio of solvent to water based paints.

The painted material is then passed through a drying tunnel, which is heated by

natural gas burners. The material once passed this stage is said to be cured and is

again cross transferred to be packed into bundles.


5

1.4 Company Environmental Policy

Jamestown Shot Blasting and Metal Coating Ltd. recognise that in our day to day

operations, we as a business inevitably impact on the environment in a number of

ways. We are cognisant of this and are fully committed to minimising the potentially

harmful effects of our activities wherever and whenever possible.

This policy statement provides the framework on which our environmental

programme is based. The policy enables us to set targets for improvement and

measure progress in a tangible way. As a company we continually strive to mitigate

any harmful effects of our activities on the environment.

We are very conscious that we have to contribute to resource conservation and to

environmental protection and in the last twelve months we have invested heavily in

sourcing environmentally friendly products. We are currently implementing a major

process change at our Dublin facility which will result in much lower emissions than

achieved previously and in the future we will only be using water based products as

distinct from solvent based with major benefits for the environment.

We have undertaken to help every JSB employee further understand and appreciate

the environment through regular communication of our environmental objectives

through training programmes.

The Company Director has ultimate responsibility for the company's environmental

policy and performance which is managed by a core group of senior managers within

the company.


6

OUR COMMITMENT

JSB will:

- Meet all relevant legislation and other requirements

- Seek to reduce consumption of materials in our operations and reuse rather than

dispose whenever possible

- Reduce wherever practicable the levels of harmful emmissions

- Seek to minimise the visual, noise and other impacts on the local environment

when conducting our activities

- Introduce environmental issues through training programmes and encourage the

implementation by all JSB staff of sound environmental practices.

Signed Frank Moore

Company Director

Jamestown Shot Blasting and Metal Coating Ltd.

-


7

1.5 Company Organisation Chart for Environmental Management

The Environmental Manager is appointed as the specific Management Representative

as defined in the Standard (ISO 14001). The Environmental Manager reports directly

to the Board of Management.

The Environmental Manager is responsible for the overall operation of the

Environmental Management System and for reporting to senior management on the

performance of the system.

The Environmental Manager is assisted by a cross section of the work force as

determined by the Board of Management and detailed in the responsibility section of

the environmental management manuals.

Resource requirements are identified and approved as part of the Environmental

Management Programme (Plan) development. Jamestown Shot Blasting and Metal

Coating Ltd. is committed to providing adequate resources and personnel for the

effective operation of the Environmental Management System.

Each responsible person as designated by the Board of Management is responsible for

implementing Environmental Procedures in each relevant department as defined in the

Environmental Management System Structure and Organisation Chart.

The Environmental Management Programme is coordinated by the Environmental

Management Team (EMT) as represented in Table 1.1 below.

TABLE 1.1: ENVIRONMENTAL MANAGEMENT ORGANISATION

Name Job Title Responsibilities

Frank Moore Company Director Overall management

responsibility

Tom Collins Environmental Health and Safety

Manager

Overall Technical and

Environmental

responsibility

Brendan Nolan Production Manager Overall responsibility for

production related

environmental issues

Joe Maloney Production Supervisor Day-to-day responsibility

for production related


The Environmental Organisation Chart is included in Appendix 1


SECTION 2

Summary Information


2.1 Self-Monitoring Data

This section outlines all summary data derived from the ongoing monitoring programme at

Jamestown Shot Blasting and Metal Coating Ltd. as per the requirements of IPPC licence

register number P0796-01. Tables 2.1 to 2.4 give the results of monitoring for the following

emissions:

• Emissions to Air;

• Storm Water Emission;

• Solid Waste Monitoring-Non-Hazardous;

• Solid Waste Monitoring-Hazardous;

• Ambient Monitoring - Groundwater Monitoring;

• Noise Emissions.


4

2.1.1 Emissions to Air

The results of the monitoring programme are detailed in Tables 4.1 – 4.3 below:

TABLE 2.1: VOLUMETRIC FLOW MEASUREMENTS

Emission

Point Sampling Date

Temp.

(oC)

Volume Flow

(Nm3/hr)

Volume Flow Emission

Limit Value (m3/hr) Note 1

A2-1 9/3/09 14 6993 10,646

A2-2 9/3/09 40 1,777 3,185

Note 1

Emission limit value as per Schedule B.1 Emissions to Air, of Licence Register No. P0796-01

Note 2: Results are referenced to standard temperature 273k and pressure 1013.25kPa no correction for

oxygen or water content.

TABLE 2.2: RESULTS OF TOTAL ORGANICS (AS C) ANALYSIS

Emission Point Parameter Conc. (as C)

(mg/Nm3)

Mass Flow

(kg/hr)

Emission Limit Value

(Total Organics as C)

(mg/m3)

A2-1 Total Organics

(as C) 24.8 1.73 75

A2-2 Total Organics

(as C) 31.0 5.1 x 10

-2 50

Note: Results are referenced to temperature 273K and pressure 101.325 kPa, no correction for oxygen or

water content.


5

TABLE 2.3: TOTAL PARTICULATE RESULTS

Emission Point Parameter Concentration

(mg/Nm3)

Mass Flow

(kg/hr)

Guidance Limit

Value

(mg/m3)

A2-1

P

articula

tes

<0.29 <2.02 x 10-3

20

Note: Results are referenced to temperature 273K and pressure 101.325 kPa, no correction for oxygen or

water content.

There in no limit value for particulates specified in the IPPC licence P0796-01. For guidance, the result

has been compared with the TA Luft 2002 limit value for total dust, including micro dust as outlined

Section 5.2 General Requirements to Emission Limits.




Emission

Point Sampling Date and Time

Temp.

(oC)

Volume Flow

(Nm3/hr)



A2-1 7/7/09 (10.20-10:25) 24 5,827 10,646

A2-2 7/7/09 (09.50-09:55) 50 1,191 3,185

Note 1

Emission limit value as per Schedule B.1 Emissions to Air, of Licence Register No. P0796-01

Note 2: Results are referenced to standard temperature 273k and pressure 1013.25kPa

TABLE 2.6: SUMMARY OF TOC (AS C) READINGS

Emission

Point Parameter

Date &

Time

Conc. (as C)

(mg/Nm3)

Mass Flow

(kg/hr)

Emission Limit

Value (TOC as

C)

A2-1 Total Organic

Carbon (as C)

7/7/09

10.25-10.55 6.2 3.61 x 10-1 75mg/m

3

A2-2 Total Organic

Carbon (as C) 7/709 7.3 8.65 x 10-2 50mg/m

3

Note 1: Results are referenced to standard temperature 273k and pressure 1013.25kPa.

Note 2: Average of Total Organic Carbon (as C) results from Tables 4.3 and 4.4.


Note 1: Results are referenced to temperature 273K and pressure 101.325 kPa

Note 2: Emission limit value as per Schedule B.1 Emissions to Air, of Licence Register No.

P0796-01

TABLE 2.7 A2-1 TOTAL ORGANIC CARBON (TOC) RESULTS AS C

(PROPANE EQUIVALENT)

Time

(hr:min) mg/Nm

3

Time

(hr:min) mg/Nm

3

10.25.00 2.73 10:41:00 5.79

10.26:00 3.06 10:42:00 6.11

10/27:00 3.54 10:43:00 5.95

10.28:00 3.70 10:44:00 6.59

10.29:00 6.11 10:45:00 8.84

10:30:00 4.82 10:46:00 8.04

10:31:00 4.98 10:47:00 11.42

10:32:00 5.15 10:48:00 9.33

10:33:00 3.86 10:49:00 9.49

10:34:00 4.02 10:50:00 8.68

10.35:00 4.34 10:51:00 8.68

10.36::00 4.66 10:52:00 8.52

10.37::00 4.34 10:53:00 8.04

10.38::00 5.31 10:54:00 7.40

10:39:00 5.47 1o:55:00 7.08

10:40:00 5.95

Average Concentration: 6.19

IPPC Concentration Limit 75Note 2




P0796-01


( PROPANE EQUIVALENT )

Time

(hr:min) mg/Nm

3

Time

(hr:min) mg/Nm

3

09:50:00 8.68 12:16:00 4

09:51:00 8.52 12:17:00 4

09:52:00 9.81 12:18:00 5

09:53:00 8.84 12:19:00 4

09:54:00 9.00 12:20:00 4

09:55:00 7.88 12:21:00 4

09:56:00 9.33 12:22:00 4

09:57:00 9.00 12:23:00 4

09:58:00 9.33 12:24:00 4

10:59:00 9 12:25:00 4

10:00:00 6.59 12:26:00 4

10:01:00 7.88 12:27:00 4

10:02:00 8.36 12:28:00 4

10:03:00 6.91 12:29:00 4

10:04:00 5.95 12:30:00 4

10:05:00 7.88

Average Concentration: 7.3

IPPC Concentration Limit 50Note 2




Emission

Point Sampling Date and Time

Temp.

(oC)

Volume Flow

(Nm3/hr)



A2-1 09/03/09 (10.45-10.50) 14 6,993 10,646

A2-2 09/03/09 (10.50-10.55 40 1,777 3,185

Note 1 Emission limit value as per Schedule B.1 Emissions to Air, of Licence Register No. P0796-01

Note 2: Results are referenced to standard temperature 273k and pressure 1013.25kPa

TABLE 2.10: SUMMARY OF TOC (AS C) READINGS

Emission

Point Parameter

Date &

Time

Conc. (as C)

(mg/Nm3)

Mass Flow

(kg/hr)

Emission Limit

Value (TOC as

C)

A2-1 Total Organic

Carbon (as C)

09/03/08

10.50-11.20 24.8 1.73 75mg/m

3

A2-2 Total Organic

Carbon (as C)

09/03/09

10.10=10.40 31.0 5.1 x 10

-3 50mg/m

3

Note 1: Results are referenced to standard temperature 273k and pressure 1013.25kPa.

Note 2: Average of Total Organic Carbon (as C) results from Tables 4.3 and 4.4.




P0796-01


(METHANE EQUIVALENT)

Time

(hr:min) mg/Nm

3

Time

(hr:min) mg/Nm

3

10:50:00 20.3 11:06:00 34.6

10:51:00 21.2 11:07:00 28.3

10:52:00 22.0 11:08:00 27.2

10:53:00 20.7 11:09:00 27.7

10:54:00 23.5 11:10:00 27.7

10:55:00 24.3 11:11:00 27.8

10:56:00 24.4 11:12:00 24.6

10:57:00 24.3 11:13:00 19.5

10:58:00 24.1 11:14:00 18.5

10:59:00 27.5 11:15:00 21.7

11:00:00 29.6 11:16:00 20.7

11:01:00 30.9 11:17:00 20.6

11:03:00 31.2 11:17:00 18.5

11:04:00 30.7 11:18:00 19.5

11:05:00 31.8 11:19:00 19.0

Average Concentration: 24.8 IPPC Concentration

Limit 75Note 2 Concentration Limit 75Note 2


Note 1: Results are referenced to temperature

273K and pressure 101.325 kPa

Note 2: Emission limit value as per Schedule

B.1 Emissions to Air, of Licence Register No.

P0796-01


(METHANE EQUIVALENT)

Time

(hr:min) mg/Nm

3

Time

(hr:min) mg/Nm

3

10:10:00 30.1 10:26:00 24.4

10:11:00 33.0 10:27:00 22.5

10:12:00 31.5 10:28:00 23.0

10:13:00 33.6 10:29:00 23.8

10:14:00 33.4 10:30:00 24.3

10:15:00 34.4 10:31:00 28.6

10:16:00 33.3 10:32:00 30.7

10:17:00 31.4 10:33:00 35.4

10:18:00 31.0 10:34:00 37.9

10:19:00 30.4 10:35:00 38.8

10:20:00 28.1 10:36:00 34.3

10:21:00 30.7 10:37:00 36.8

10:22:00 31.8 10:38:00 37.0

10:23:00 25.1 10:40:00 40.7

10:24:00 22.7 37.1

Average Concentration: 31.0 IPPC Concentration

Limit 50Note 2 Concentration Limit 50

Note 2


10

TABLE 2.13 SOLVENT TUBE RESULTS

Solvent A2-1

Conc. (as C) (mg/Nm3)

A2-2

Conc. (as C) (mg/Nm3)

Date and Time of Sampling 09/03/09 10.50-11.20 09/03/09 10.10-10.40

Toluene - 0.2



11

2.1.2 Storm Water Emission

APHA - American Public Health Association, Standard Methods for the Examination of Waters and Waste Waters, 21st Edition 2005

Note 1: The European Communities (Quality of Surface Water Intended for the Abstraction of Drinking Water) Regulations, 1989 (SI. No. 294 of 1989) for A3 waters

APHA - American Public Health Association, Standard. 294 of 1989) for A3 waters.

.

TABLE 2.14 SAMPLE ANALYSIS REPORT OF STORM WATER

Facility Name: JSB Ltd IPPC Licence No. P0796-01

Sampling Location: South East Corner of

Facility

Sampling Date: 17/06/09

Sampled By: Ronan Connolly

Sample Type: Storm Water, SW2

Weather: Overcast, damp

Other Remarks:

Received at: BnM Newbridge, Kildare

By: Noelle Fox

Date: : 17/06/09

Sample Ref. No.: 203837

Parameter Units Results Limit of

Detection

Legislative

LimitNote 1

Analytical

Technique

Accreditation

pH pH Units 7.6 0.1-14 5.5-9.0 APHA G/05 Y

Conductivity µS/cm 131 - 1000 APHA G/06 Y

COD mg/l 32 <10 40 APHA G/03 Y


12

2.1.3 Ambient Monitoring – Groundwater Monitoring

TABLE 2.15 RESULTS OF FIELD DATA MEASUREMENT FOR

GROUNDWATER

Borehole Identification Parameter

GW1 GW2

Interim Guideline

Values

IGV Note 1

Analytical

Technique

Total Depth of

Groundwater Borehole

(mbgl)

6.23 7.14 ----- Electronic Dip

meter.

Static Water Level

(SWL) (mbgl) 0.82 1.45 -----

Electronic Dip

meter.

Temperature 12.7 12.5 ----- Conductivity

meter

Visual

Inspection/Odour

Grey/Cloudy,

few suspended

solids, slight

odour.

Clear, few

suspended

solids, slight

odour.

----- In situ


13

TABLE 2.16 CHEMICAL ANALYSIS OF GROUNDWATER

Parameter Component Units EPA IGV Limit of

Detection GW-1 GW-2

Conductivity @ 25ºC - µS/cm 1000 - 458 1360

Total Organic Carbon - mg/l - <5mg/l <5 8

Boron (Dissolved) - µg/l 1000 <2 120 100

Mercury - µg/l 1 <0.05 <1 <1

Metals (Dissolved) Arsenic

µg/l

10 <2 2 <2

Silver µg/l - <2 <2 <2

Aluminium µg/l 200 <2 139 122

Beryllium µg/l - <1 <1 <1

Barium µg/l 100 72 72 57

Chromium µg/l 30 <2 5 2

TABLE 2.17 CHEMICAL ANALYSIS OF GROUNDWATER (Contd.)

Parameter Component Units EPA IGV Limit of

Detection GW-1 GW-2

Metals (Dissolved) Tin µg/l - <1 <1 <1

Nickel µg/l 20 <2 11 4

Lead µg/l 10 <1 1 <1


14

Antimony µg/l - <1 <1 <1

Selenium µg/l - <2 2 <1

Zinc µg/l 100 <2 330 5

Cadmium µg/l 5 <0.4 0.4 <0.4

Cobalt µg/l - <1 <1 <1

Copper µg/l 30 <2 6 3

Manganese µg/l 50 <1 2 517

Iron mg/l 0.2 <0.1 0.1 0.01

Note 1: A Guide Value refers to EPA Guideline Values for the Protection of Groundwater in Ireland IGV = Interim Guideline Value. Note these standards are presented for

guideline purposes only, therefore, due care should be exercised in cross-referencing these standards with the groundwater results obtained.


15

2.1.4 Noise Emissions

Table 2.19 presents the results of the noise survey undertaken during normal daytime activities as part in the noise abatement programme.

The JSB Ltd. facility does not operate at night-time therefore no night-time monitoring was undertaken during this event.

TABLE 2.19: AMBIENT NOISE MEASUREMENT RESULTS

Location

No.

Period

(mins) Date

Start

Time

Leq

dB(A)

L10

dB(A)

L90

dB(A)

Lmax

dB(A)

N1 30:00 19/8/09 12:13 69.4 70.5 57.7 92.3

N2 30:00 19/8/09 10.55 67.1 67.5 60.9 91.4

N3 30:00 19/8/09 13.01 57.0 58.0 55.3 71.1

N4 30:00 19/8/09 11.38 66.8 65.5 53.5 92.9

NSR1 30:00 19/8/09 10.05 59.3 61.5 49.8 80


16

2.1.5 Solid Waste Monitoring – Non-Hazardous

Summary data for results of solid waste monitoring at Jamestown Shot Blasting and Metal Coating Ltd. in 2009 is detailed in Table 2.20 (non-

hazardous waste) and Table 2.21 (hazardous waste) below.

TABLE 2.20: NON-HAZARDOUS WASTE GENERATED ON-SITE

Waste Category Use EWC Code Quantity/Annum Recycled /

Removed By:

Wood Processed

or Chipped

19 12 07 0.41 Thorntons

Municipal Waste 20 03 01 1.50 tonnes Thorntons /ozo

Waste steel shot /

dust

Shotblasting 12 01 01 13.35 tonnes Galway metals

Packaging Waste Primers/ Curing/

Thinner agents

15 01 04 0.25 tonnes

Galway metals


17

2.1.6 Solid Waste Monitoring – Hazardous

TABLE 2.21: HAZARDOUS WASTE GENERATED ON SITE

Waste Category Use EWC Code Quantity/Annum Recycled /

Removed By:

Oil/ Solvent

contaminated rags

Cleaning 15 02 02 0.078 tonnes Enva

Waste solvent,

sludge, oily water

Washdown

residues

08 01 11 0.6 tonnes Enva


18

2.2 Energy and Water Consumption

Summary data for energy and water usage at Jamestown Shot Blasting and Metal Coating Ltd. is detailed in Table 2.11 below.

TABLE 2.11: ENERGY AND WATER USAGE ON SITE FOR 2009

Parameter Units 2009

Electricity Kilowatt Hours 235,019

Gas Kilowatt Hours 396,709

Water Cubic meters 250

Diesel Litres 2600

2.3 Environmental Incidents and Complaints

All environmental incidents and complaints are recorded in the incidents and complaints register (EMF014) which is submitted annually to the

EPA as part of the Annual Environmental Report.

Environmental Incidents are controlled under procedure EP 8.0 and form EPF 8.1. EP 8.0 is the procedure for notifying the agency in event of

an environmental incident - which outlines the mechanisms for the response to and reporting of incidents. EPF 8.0 is the log sheet that details

the incident. These documents are included in Appendix 2.

There were no environmental incidents reported for the reporting period between the 1st of January 2009 and the 31

st of December 2009.


19

Environmental Queries or Complaints are controlled under procedure EP 11.0 and form EPF 11.1. EP 11.0 is the procedure for handling

environmental incidents and complaints. EPF 11.1 is used to record details of the complaint including the description of the complaint, the cause

of the complaint, the initial investigation, corrective action summary and complaint resolution summary. Corrective action procedures and

environmental non-conformance are controlled under procedures EP 10.0 and EP 9.0 respectively. Potential and actual non-conforming

situations are documented on a environmental corrective action form, EPF 10.1. These documents are included in Appendix 2.

All completed forms are placed within a register of environmental complaints and maintained on file by the Environmental Manager.

2.4 Report on Emissions and Waste Transfers

This Annual Environmental Report contains the Report on the Emissions and Waste Transfers, which has additionally been submitted to the

EPA electronically.


20

| PRTR# : P0796 | Facility Name : Jamestown Shot Blasting & Metal Coating Limited | Filename : P0796_2009.xls | Return Year : 2009 |

AER Returns Worksheet Version 1.1.10

REFERENCE YEAR 2009

1. FACILITY IDENTIFICATION

Parent Company Name Jamestown Shot Blasting & Metal Coating Limited

Facility Name Jamestown Shot Blasting & Metal Coating Limited

PRTR Identification Number P0796

Licence Number P0796-01

Waste or IPPC Classes of Activity

No. class_name

12.2.2 #######################################################

Address 1 Jamestown Road

Address 2 Inchicore

Address 3 Dublin 8

Address 4

Country Ireland


21

Coordinates of Location -6.3397 53.3365

River Basin District IEEA

NACE Code 2561

Main Economic Activity Treatment and coating of metals

AER Returns Contact Name Frank Moore

AER Returns Contact Email Address [email protected]

AER Returns Contact Position Director

AER Returns Contact Telephone Number 01-4537331

AER Returns Contact Mobile Phone Number

AER Returns Contact Fax Number 01-4544322

Production Volume 0.0

Production Volume Units

Number of Installations 0

Number of Operating Hours in Year 0

Number of Employees 0

User Feedback/Comments

Web Address

2. PRTR CLASS ACTIVITIES

Activity Number Activity Name

50.1 General

3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)

Is it applicable? Yes

Have you been granted an exemption ? No

If applicable which activity class applies (as per Schedule 2 of the regulations) ?

Is the reduction scheme compliance route being used ?


22

For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane) flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4) emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:

Landfill:

Jamestown Shot Blasting & Metal Coating Limited

Please enter summary data on the quantities of methane flared and / or utilised Method Used

additional_pollutant_no T (Total) kg/Year M/C/E Method Code Designation or

Description

Facility Total Capacity m3

per hour

Total estimated methane generation (as per site model) 0.0 N/A

Methane flared 0.0 0.0 (Total Flaring Capacity)

Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)

Net methane emission (as reported in Section A above) 0.0 N/A


23

4.2 RELEASES TO WATERS | PRTR# : P0796 | Facility Name : Jamestown Shot Blasting & Metal Coating Limited | Filename : P0

8 8 16 16 24

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of youconcerns Releases from your facility

RELEASES TO WATERS

POLLUTANT

Method Used

No. Annex II Name M/C/E Method Code

Designation or Description Emission Point 1

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

SECTION B : REMAINING PRTR POLLUTANTS

RELEASES TO WATERS

POLLUTANT

Method Used

No. Annex II Name M/C/E Method Code



SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

RELEASES TO WATERS

POLLUTANT

Method Used


24

Pollutant No. Name M/C/E Method Code


4.3 RELEASES TO WASTEWATER OR SEWER

8 8 16 16

SECTION A : PRTR POLLUTANTS

OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

POLLUTANT METHOD

Method Used

No. Annex II Name M/C/E Method Code DesignationDescription


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

POLLUTANT METHOD

Method Used

Pollutant No. Name M/C/E Method Code DesignationDescription


25

4.4 RELEASES TO LAND | PRTR# : P0796 | Facility Name : Jamestown Shot Blasting & Metal Coating Limited | Filena

8 8 16 16 6

SECTION A : PRTR POLLUTANTS

RELEASES TO LAND

POLLUTANT METHOD

Method Used

No. Annex II Name M/C/E Method Code Designation or Description Emission


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

RELEASES TO LAND

POLLUTANT METHOD

Method Used

Pollutant No. Name M/C/E Method Code Designation or Description Emission

5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0796 | Facility Name : Jamestown Shot Blasting & Metal Coating Limited | Filename : P0796_2009.xls | Return Year : 2

5 12


26

Quantity (Tonnes per Year) Method Used

Transfer Destination European

Waste Code Hazardous Quantity T/Year

Description of Waste

Waste Treatment Operation M/C/E Method Used Location of Treatment

Within the Country 12 01 01 No 13.35 Waste Steel Shot R4 M Weighed Onsite in Ireland GaCo

To Other Countries 15 01 04 No 0.25 Packaging Waste R4 M Weighed Onsite in Ireland GaCo

To Other Countries 08 01 11 Yes 0.6 Waste Paint/oily water R2 M Weighed Abroad En

To Other Countries 15 02 02 Yes 0.078 Oily Rags R1 M Weighed Abroad En

Within the Country 20 03 01 No 0.9 Municipal Waste D1 M Weighed Onsite in Ireland ThoLtd

Within the Country 20 03 01 No 0.6 Municipal Waste D1 M Weighed Onsite in Ireland OZ

Within the Country 20 01 38 No 0.41 Wooden Pallets R1 M Weighed Onsite in Ireland ThoLtd


SECTION 3

Management of the Activity


3.1 Environmental Management System

In compliance with IPCC Licence Register Number P0796-01 (Condition 2, Section

2.2) an Environmental Management System has been established at Jamestown Shot

Blasting and Metal Coating Ltd. All documents, procedures, forms and record sheets

are controlled by revision numbers, stamped master copy and stored in the

Environmental Management filing cabinet in the Main Office.

The following documentation is controlled:

I. Environmental Management Forms

II. Environmental Management Procedures

See Appendix 3 for master lists of the Environmental Management Forms and

Procedures.


4

3.2 Environmental Management Programme Report (EMP) for 2009

In accordance with Condition 2, Section 2.2.2.3 of IPPC licence register number

P0796-01, the Environmental Management Team has developed an Environmental

Management Programme (EMP) for 2009. The purpose of the EMP is to ensure that

the objectives and targets are supported by a realistic programme that is implemented

throughout the organization. This programme reviews and measures the objectives

and targets set for 2009 and identifies and sets objectives and targets for 2010.

The implementation of a switchover from solvent based paints to water based paints

in November 2007 has removed fugitive emissions (e.g. toluene, isopropanol, isomers

of xylene) within Jamestown Shot Blasting.


5

3.3 Monitoring Programme for 2010

3.3.1 Personnel Responsible

Name Job Title

Frank Moore Company Director

Tom Collins Environmental Health and Safety Manager

Brendan Nolan Production Manager

Joe Maloney Production Supervisor

3.3.2 Monitoring Procedures

These are included in Appendix 6

3.3.3 Monitoring for 2009

• Air Emissions Monitoring

• Surface Water Monitoring

• Groundwater Monitoring

• Noise Survey

3.3.4 Proposed Monitoring for 2010

• Air Emissions Monitoring (Quarterly)

• Surface Water Monitoring (Biannual)

• Groundwater Monitoring (Annual)

• Noise Survey (Annual)

3.3.5 Contractors Commissioned to Conduct Emission Monitoring

Bord Na Mona, Environmental Consultancy Services, Newbridge, Co. Kildare

• Agreed Turn-Around Times with Contractors

One month from date of sampling

• Submission Dates to EPA

10 working days after end of half year being reported on.


6

3.4 Pollution Emission Register

A Pollution Emissions Register (PER) is a register of potentially harmful pollutant

releases or transfers, from industries regulated under the EPA Act of 1992. The annual

publication of the PER will provide the public with comprehensive information on the

use, control, transfer and release of pollutants in industry and create a powerful

motivation for waste reduction. Due to the changeover from solvent based paints in

the process to water based paints in 2007, it is our opinion that there is no pollutant

that requires tracking.


7

3.5 Environmental Protection Spending

Table 3.2 below details the spending on environmental protection during 2009

TABLE 3.1: ENVIRONMENTAL PROTECTION SPEND FOR 2009

Item Cost - Euro

Agency Fee 8,740

Bord na Mona:

Consultancy Costs

Monitoring Costs

10,800

1,550

Jamestown Shot Blasting and Metal Coating Ltd. Personnel Costs

Technical/Environmental Manager

Various other personnel

12,000

2700

Jamestown Shot Blasting and Metal Coating Ltd. Licence Compliance Costs

Environmental Training

Monitoring Equipment

800

1,850

TOTAL SPEND IN 2009 38,440

As a result of our switch from solvent to water based paints we have seen our gas

bill increase by ten times.


8

3.6 Environmental Training and Education

In compliance with IPPC Licence Register Number P0796-01, an Environmental

Training Programme has been established at Jamestown Shot Blasting and Metal

Coating Limiting.

This section details the programme including procedures to control Environmental

Awareness and Training.

These procedures ensure that there is awareness throughout the organization at all

levels of the following:

• The importance of compliance with the Licence

• The potential environmental effects of work activities and potential consequences

of departure from specified operating procedures

• Individual roles and responsibilities in achieving compliance with the Licence

• Environmental benefits of improved performance

Jamestown Shot Blasting and Metal Coating Ltd. has established procedures for

identifying environmental training needs and for providing appropriate training for all

personnel whose work can have significant effect upon the environment (EP 20). This

document is included in Appendix 7.


APPENDIX 1


10

Environmental Management Organisation Chart

General Manager

Frank Moore

Technical/Environmental Manager

Tom Collins

Production Manager

Joe Maloney


APPENDIX 2


12

Env. Impact Ass. Sheet. Document: EMF014

Jamestown Shot Blasting and

Metal Coating Ltd.

Revision: 0

Jamestown Road, Inchicore, Dublin 8 Page: 1 of 1

Title:

I. Complaints Register

II.

Period:

2009

Incident

Yes/No

Incident Date Incident Ref. No.

January No

February No

March No

April No

May No

June No

July No

August No

September No

October No

November No

December No


1

APPENDIX 3


2

Objectives & Targets Register for 2010 at Jamestown Shot Blasting

and Metal Coating Ltd. as part of IPPC Licence Requirments

ATTENTION: Environmental Protection Agency

P.O. Box 3000

Johnstown Castle

Co. Wexford

PREPARED BY: Mr. Tom Collins

Jamestown Road

Inchicore

Dublin 8

DATE: March 2010


3

1.0 INTERPRETATION

For the purpose of this document the following interpretations have been made on the definition of

“objectives”, “targets”, target date”, and “persons responsible”.

For the purpose of this document the following definitions are relevant:

Objectives

Environmental objectives are the means/actions by which targets will be achieved. This will include a

measurable range of activities.

Targets

Environmental targets are goals or aims, which when achieved will result in significant reductions in

emissions from the facility or general improvement in the overall performance of the facility.

Target Date

This is the date or time frame by which the ultimate target will be achieved.

Persons Responsible

These are the Jamestown Shot Blasting and Metal Coating Ltd. personnel with the overall

responsibility of ensuring that the objectives and targets presented in this document are completed on

schedule.


4

2.0 TIME FRAME

This document outlines the methodologies by which the programme will be implemented. It is

proposed to run the programme over a four-year time frame, which will be reviewed annually and

amended accordingly by the EMT.


5

3.0 ENVIRONMENTAL MANAGEMENT TEAM

The Objectives & Targets programme will be coordinated by the Environmental Management Team.

Members of this team are listed below together with their key responsibilities.

TABLE 1.1: ENVIRONMENTAL MANAGEMENT ORGANISATION

Name Job Title Responsibilities

Frank Moore General Manager Overall management

responsibility

Tom Collins Technical / Environmental Manager Overall Technical and

Environmental

responsibility

Joe Maloney Production Manager Day-to-day responsibility

for production related


4.0 REFERENCES

4.1 Air Emissions Form EMS 3.1

4.2 Water Emissions Form EMS 3.2

4.3 Noise Emissions Form EMS 3.3

4.4 Waste Emissions Form EMS 3.4

4.5 Energy Usage Reduction Form EMS 3.5


AIR EMISSIONS EMS 4.1

Target Target Date Objectives Person Responsible

To keep our emission levels as low as possible Throughout the

year

Brendan Nolan


7

WATER EMISSIONS EMS 4.2


To ensure that all water monitoring requirements are achieved. Throughout the

year

Tom Collins


8

NOISE EMISSIONS EMS 4.3


To keep our noise levels as low as possibe i. Tom Collins


9

WASTE EMISSIONS EMS 4.4


Tom Collins

To recycle as much timber waste as possible

To recycle as much maintenance oil as possible

To minimize all waste streams as much as possible


10

ENERGY USAGE REDUCTION EMS 4.5


To become more energy efficient in 2010 i. Tom Collins


11

Table 4.1

Activity/Emission Target Target Date Objective Responsibility Comments

Use of solvent based

compounds

Reduce or eliminate

solvent based compounds

Ongoing Reduce or eliminate solvent based

compounds

Tom Collins In November 2007, JSB

implemented a complete

switchover from solvent

based paints to water

based paints. They are

currently operating at a

9:1 water to solvent based

paint ratio.

Combustion gas emissions Reduce combustion gas

emissions from boiler

Ongoing annual

service/monitoring

1) Management of ongoing boiler

service programme

2) Minimise emissions by

reducing energy consumption

Tom Collins Ongoing

In-house practices Reduction in air emissions

by improved in-house

cleaning practices

Ongoing Maintain an ongoing cleaning and

work practices strategy

Tom Collins Ongoing

Air Emissions To monitor air emissions

in accordance with IPPC

licence

Ongoing Maintain ongoing monitoring

program

Tom Collins Ongoing


12

Table 4.2


Shipment of waste Maintain waste register Ongoing Maintain a hazardous waste

register

Maintain a non-hazardous waste

register

Tom Collins .In 2008 we kept an

accurate waste register

Recycling Maximise recycling of

waste materials

Ongoing 1) Review current recycling

practices

2) Implement any improvements

identified

Tom Collins Maintain an ongoing

programme of recycling

Waste production Minimise volume of waste

produced

Ongoing 1) Review current waste production


identified

Tom Collins During 2009 we will

continue to look for waste

reduction measures

Waste primer, curing

agent and thinner

containers, waste solvent,

waste oil

Minimise usage Ongoing Switch to water-based paints Tom Collins Process uses 80% water-

based paints. We will

strive to reduce this in

2009


agent and thinner


waste oil

To reduce

containers/drums

Ongoing Assess drum quantites and on-site

usage

Tom Collins Less containers with water

based paints in use. Water

based paint containers

refilled when empty and

then reused by JSB


13

Table 4.3


Storm water To monitor storm water

un accordance with IPPC

licence


programme

Tom Collins .

Ground water To monitor storm water

un accordance with IPPC

licence


programme

Tom Collins Ongoing


14

Table 4.4


Energy consumption Reduce the energy

requirements at JSB

Ongoing Maintain training and awareness

programme to inform and involve

the JSB associates in an energy

conservation strategy e.g. lighting,

heating etc.

Tom Collins .

Recycling Maximise recycling of

waste materials

Ongoing 3) Review current recycling

practices


identified



Waste production Minimise volume of waste

produced

Ongoing 3) Review current waste production


identified

Tom Collins


agent and thinner


waste oil

Minimise usage Ongoing Switch to water-based paints Tom Collins Process uses 80% water-

based paints


agent and thinner


waste oil

To reduce

containers/drums

Ongoing Assess drum quantites and on-site

usage

Tom Collins Less containers with water

based paints in use

Waste steel shot To reduce/recycle Ongoing 1) Review current recycling

practices


identified




15

APPENDIX 4


16

Monitoring Programme

Sampling and Analytical Methodologies


1.0 Sampling

1.1 Air

The site will be visited by sampling specialists from Bord na Mona to conduct air

emissions testing on stacks A2-1 and A2-2. Stack A2-1 will be tested on a quarterly

basis for particulates and for Total Organic Carbon. On an annual basis, monitoring

for organic solvents will be conducted at both stacks A2-1 and A2-2. Stack A2-2 will

also be sampled on a quarterly basis for Total Organic Carbon. In addition, volume

flow and temperature will be measured at the stacks.

• Volume Flow and Temperature

Volume flow is measured in accordance with ASTM standard test method D3154*91

for average velocity in a duct (pitot tube method). A standard L-type pitot tube and

digital monometer are used to record velocity pressures. A K-type is used for

measuring temperature.

• Particlates

Particulate matter is monitored isokinetically using the SCH.502 Gravimat instrument.

The monitoring is carried out according to the British Standard BS3405. On completion

of sampling, the filters are brought to the Bord na Móna laboratory complex where the

filters were weighed using a 5-point calibrated balance.

• Total Organic Carbon

Total Organics, quantified relative to methane, will be determined using a Signal

Total Hydrocarbon analyser. The instrument employs flame ionisation detection and

is calibrated against a reference methane standard prior to the commencement of the

measurement programme. Results from the instrument are expressed as Total

Hydrocarbons in ppm (methane equivalent). The results are subsequently converted

to mg/m3. Prior to commencement of monitoring, the Mini-FID is calibrated using a

500ppm Methane/Air gas mixture standard.

• Organic Solvents

The sample are collected onto a thermal desorption tube using a specialised SKC

sample pump for a period of thirty minutes at a flow rate of 200ml/min. Following

thermal desorption, the sample is analysed using Gas Chromatography/Mass

Spectrometry. This system consists of Agilent 6890N Gas Chromatograph interfaced


18

with an Agilent 5793 Network MSD and equipped with a high resuolution capillary

column allowing for the detection and resolution of thoses components expected to be

present. The reults are expressed in mg/Nm3.


19

1.2 Stormwater

A representative sample of the surface water runoff from the site is extracted from the

storm drain SW2 by Bord na Mona staff on a biannual basis using basic grab

sampling technique. The parameters that will be analysed by laboratory personnel are

pH and COD.

1.3 Groundwater

Groundwater samples are taken on an annual basis from locations GW1 and GW2.

Prior to collection of sample, the bore hole is purged to a volume equivalent of 2 and

5 bore hole volumes using the “watterra inertial lift pump” system. The parameters

that will be analysed by laboratoy personnel are pH, TOC, conductivity and heavy

metals.

1.4 Noise

The noise survey is carried out annually in accordance with the International Standard

Orgnisation (ISO) 1996 Acoustics – Description and Measurement of Environmental

Noise Part 1, 2 and 3 in addition to the Environmental Protection Agency

‘Environmental Noise Survey Guidance Document’. Noise is recorded during the day

for 15-minute periods at four boundary locations, N1, N2, N3and N4 and for 30

minutes at the nearest sensitive receptor NSR1. The measurement parameters that are

recorded are Leq(A), Lmax (A), L90(A) and L10(A).


20

As part of the Quality System in place in Bord na Móna, Environmental Ltd.,

measures are taken to ensure controlled chain of custody. An outline of the chain

of custody is given below.

CONTROLLED CHAIN OF CUSTODY

SITE TRANSPORT LABORATORY

Sampling and packaging

of all samples will be

carried out by Bord na Móna Technical Team:

Transport

Document Form

Transport to

laboratory by

Bord na Móna

Technical Team.

Sample

Reception Form

Receiving of samples at Bord na

Móna Environmental Laboratory

complex by:

Laboratory Manager

(Secure laboratory complex access

to authorised personnel only)

→ → ↓

Storage of all samples for 1 month period after report issue.

↓

Supervised Disposal


21

2.0 Analysis

All samples are returned to the Bord na Mona laboratory complex via a controlled

chain of custody route. Subsequent analysis is carried out in struct accordance with

standard methodologies as detailed in Tables 2.1 and 2.2 below:

TABLE 2.1: AIR

Parameter Method

Organic Solvents (volatile organic compounds) GC-MS

TABLE 2.2: STORM WATER

Parameter Method

pH G/05 Based on APHA, 2005, 21st Edition, Method 4500 H+B

COD G/03 Based on APHA, 2005, 21st Edition, Method 5220D

TABLE 2.3: GROUNDWATER

Parameter Method Limit of Detection

Boron (dissolved) ICP-MS <2 µg/l

COD G/03 Based on APHA, 2005, 21st Edition,

Method 5220D

<10 mg/l

Conductivity G/06 Based on APHA, 2005, 21st Edition,

Method 2510B

0.1-1999 µS/cm

Dissolved Scan G57 Based on EPA Method 200.8

Mercury ICP-MS <1 µg/l

Metals G57 Based on EPA Method 200.8 <2 mg/l (for iron LOD = <0.1 mg/l)

Organic Carbon TOC Analyser <5mg/l

pH G/05 Based on APHA, 2005, 21st Edition,

Method 4500 H+B

0.1-14


22

Note 1: G/ refers to In-House ILAB Accredited Method, SOP Manual


23

3.0 Accredited Quality System

3.1 INAB Accreditation

Bord na Móna Technical Services analytical laboratories were awarded INAB

accreditation by the National Accreditation Board (NAB) in 1997. It has

always been the policy of the laboratories to achieve and maintain a high

standard of quality consistent with client's requirements in all aspects of the

work carried out within the laboratory.

NAB as a member of the International Laboratory Accreditation Cooperation

(ILAC) and the European Co-operation for accreditation (EA) have adopted

ISO 17025 as the new standard for its laboratory accreditation programme

since January 2002.

This new standard contains all of the requirements that testing laboratories

have to meet if they wish to demonstrate that they operate a quality system, are

technically competent, and are able to generate technically valid results. ISO

17025 incorporates all those requirements of ISO 9000 that are relevant to the

scope of testing services that are covered by the laboratory's quality system.

Thus a laboratory that complies with ISO 17025 will therefore also operate in

accordance with ISO 9000.

3.2 Interlaboratory Proficiency Schemes

To ensure the accuracy of the analytical testing we participate in several

external proficiency schemes. The ongoing competence of the laboratory and

its staff is assessed by participation in various inter-laboratory proficiency

testing schemes, such as Aquacheck and the EPA scheme organised for

environmental laboratories throughout Ireland.

3.3 EPA Quality Control Register

Bord na Móna Technical Services Analytical Laboratories performance in the

EPA intercalibration scheme has insured its listing on the EPA’s register of

Quality Controlled Laboratories. Both accredited and non-accredited test

methods are assessed by these schemes.


24

3.4 Quality Control Audits

Bord na Móna Environmental Ltd. consistently strive to improve the quality of

the analytical work carried out in its laboratories. The laboratory has a full

time Quality Control Manager who assists in the organisation and execution of

the extensive programme of internal Quality Audits. These quality audits

examine all aspects of the laboratory’s Quality System, with particular focus

on auditing of test methods, and enable potential problems to be highlighted

and immediate corrective action to be taken.

3.5 Control Chain of Custody

It is the policy of Environmental Technical Services Analytical Laboratory to

achieve and maintain a high standard of quality consistent with the client’s

requirements in all aspects of the work carried out within the laboratory and to

provide the clients at all times, with a service complying with ISO 17025.


APPENDIX 5


26

Environmental Procedures Document: EP 20 Document Approved By : Jamestown Shot Blasting and

Metal Coating Ltd.

Revision: 0

Janestown Road, Inchicore, Dublin 8 Page: 1 of 1

Issued:

Environmental Manager ENVIRONMENTAL PROCEDURES

Title: Training

Purpose: To ensure all relevant personnel are trained regarding the requirements

of the Environmental Policy and EMS.

Scope: All training requirements

Responsibility: Environmental Manager

References: Training & Quality Manuals

Procedure:

1. All training, where required as part of the EMS and to ensure compliance with

the Environmental Policy, is carried out in accordance with the JSB Training

Manual, and Gietart 2002-2008 Operating Instructions, Chapter B.

2. Training requirements may be updated as a result of any of the following

Procedures:

• Setting and Monitoring of Environmental Objectives and Targets

• Environmental Management Programmes

• Corrective and Preventive Action

• Evaluation of New or Altered Processes or Materials

• Environmental Complaints

• Environmental Incident Investigation and Reporting

• Environmental Accident Response

• Operational Control Procedure

Training for 2010 will consist of Environmental Awareness Training and Spill kit

training.

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