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. Environmental Efficiency Consulting Engineers
Report on Inspection and Integrity
Testing of the Bunded Areas,
Underground Pipelines &
Underground Tanks
for
Dawn Meats and Western Proteins
at. Ballyhaunis
IPC Lice&e 048
(Document Number 458-01)
48 Main St., Bray, Co. Wicklow, Ireland. Tel: +353 1 276 1428 Fax: +353 1 276 1561 Email: [email protected] www.enviro-consult.com
Registered Office: 54 Dame St., Dublin 2. Registered Number 243412
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-rr J 1’ 1
Dawn Meats & Western Proteins Inspection & Integrity Testing
OF 1.02 Document Lead Sheet
erground Pip&nes
////~/~,//,/:/I/‘I/l/l’,/l/i///l/l/liil’li:,/,l,‘;i,‘:ii’~i’/~// /ii///iiiji/,~///~il/ii//j/l/l//)//li//l/l!//)/////~~/I/// ,1,1,,/ // f Inspection & Integrity Testing of Bunded Areas & ~,,,1/1,,1:/~1/,,/ Il,,/i/i’/,///,/‘/l,i/l/:!l
EEC Project Manager: Bob Sutcliffe
EEC Auditor/ Project Co-ordinator: Michael Quinn
Client Project Manager: Brian Cloonan
Document No.:458-01 Environmental Efficiency
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Dawn Meats & Western Proteins Inspection & Integrity Testing
TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................................ 4
2. SUMMARY OF RESULTS ......................................................................................................... 6
3. INTEGRITY TEST PROCEDURES .......................................................................................... 7
3.1 BUND INTEGRITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.2 UNDERGROUND PIPELINE INTEGRITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.3 UNDERGROUND TM INTEGRITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. RESULTS & COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 BUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 9 4.1.1 Boiler Oil Tank Bund . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1.2 Blood Tank Bund . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 UNDERGROUND PIPELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.2.1 Main Efluent Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.2.2 Riverside Pipeline at Dawn Meats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I 4.2.3 Pipelines at Western Proteins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
4.3 UNDERGROUND BLOOD STORAGE TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. CONCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 13
Table 1 Details of Bunded Areas on site.. .......................................................................................... 9 Table 2 Details of Underground Pipelines.. ..................................................................................... 10 Appendix 1 Bund Test Procedure ...................................................................................................... 14
Document No.:458-01 Environmental Effkiency
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, . I
Dawn Meats & Western Proteins Inspection & Integrity Testing
.I. Introduction
Environmental Efficiency were commissiotied by Charlie Coakley on behalf of Dawn
Meats and Western Proteins to conduct a series of inspections and integrity testing of
the bunded areas and underground effluent pipelines at their site in Ballyhaunis, Co.
Mayo. A preliminary site visit was arranged and took place on Monday llth and
Tuesday 12* of November 2002. This preliminary site inspection was used to
perform an initial visual inspection of the bunds, underground tanks and pipelines and
to decide on the best approach for performing the integrity tests. Effective capacities
of the bunds was also calculated at this stage. This work was undertaken in order to
ensure compliance with sections 9.3.1, 9.3.2 and 9.3.5 of Condition 9 Non-Process
Water, of the plants IPC Licence (Number 048) which states:
9.3.1 - “All storage tank areas shall be rendered impervious to the materials stored
therein. In addition storage tank areas shall be bunded either locally or remotely to a
volume of 1 IO% of the largest tank within each individual bunded area. ”
9.3.2 - “The integrity and water tightness of all the bunding structures and their
resistance to penetration by water or other materials stored therein shall be tested
and demonstrated by the licensee to the satisfaction of the Agency.... ”
9.3.5 - “The Licensee shall undertake a programme of testing and inspection of
0 underground tanks and pipelines to ensure that all underground ej?uent and foul
sewer pipes are tested at least once every three years. A report on such tests shall be
included in the AER. ”
The sites contain a red meat plant and an associated effluent treatment plant, both
located in Ballyhaunis, Co. Mayo. Typically, 20,000 to 25,000 tonnes of lamb and
beef are processed per year. The operations carried out on site include the following:
0 slaughter l chill l bone in and bone out operations l cut
l portioned l frozen
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. . 1
Dawn Meats & Western Proteins Inspection & Intearitv Testing
The process waste which is pumped through the underground pipelines to the effluent
treatment plant will be typical of these process. The underground tanks at the Dawn
Meats site are used for the storage of animal blood. There are two tanks on site, one
for lamb blood and one for cattle blood. There was six bunds in total to be tested.
The bunding structures at both sites are used to contains various substances such as
blood, heating oil and transport diesel. These are detailed below.
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Dawn Meats & Western Proteins Inspection & Integritv Testing
. 2. Summary of Results
Following the initial site visit, the necessary effective capacity of each of the bunded
areas was calculated by determining the volume of the storage tanks within each
bund. This was then compared to the actual capacity of the bunds. It was found that
the effective capacity of each of the bunds examined was adequate and in compliance
with the IPC Licence regulations.
Of the six bunds to be tested, it was possible to conduct integrity tests on only two of
them during this visit. However the two bunds tested, the Boiler Oil bund and the
Blood tank bund, are perhaps the most critical bunds as the tanks they contain are by
0 far the largest on site. Both bunds were found to be water tight during the test and so
are in compliance with section 9.3.2 of the IPC Licence.
From the initial site visits and by examining the site drainage map, it was found that a
considerable network of process waste pipelines exist. It was decided to
hydrostatically test these pipelines in sections to allow for better control. None of the
pipelines tested were found to show any signs of leaking with no drop in water levels
noticed.
Due to the high production levels at the sites at this time of year it was not possible to
conduct integrity testing of the underground blood tanks. The in flow of blood to the
l tanks was too great and so it was not possible to control the level of liquid in the tank
for the required monitoring time.
Full details and results of the work done to date are given below and any
recommendations for necessary remedial work are made.
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I . Dawn Meats & Western Proteins Inspection & Inte&y Testing
3. Integrity Test Procedures
3.1 Bund Integrity Test
Following the initial site visit, a work plan was drawn up which detailed necessary
preparatory work to be carried out by the company before testing could proceed. This
included clearing bunds of any rubbish etc., raising of any electrical equipment in the
bunds and arrangement of adequate water supply. When all necessary preparations
were made and all preliminary measurements taken, the bund integrity/water tightness
test was then performed according to the procedure defined in the Environmental
Agency (of England and Wales) R&D Technical Report P16 (See Appendix 1 for
details). Initial water levels were taken at and these were continuously monitored
during the test. Any drop in water level would indicate a bund failure and a non-
compliance with the IPC Licence. Although the test is described as a 6 hour test, if
failure was noticed at an earlier stage then the test would be stopped immediately.
3.2 Underground Pipeline Integrity Test
From examining the site drainage map it was decided that the most practical way to
test the pipelines was to divide it up into sections and then hydrostatically test each
section. The pipelines were divided up into a number of sections from manhole to
manhole. The inflow of process waste was controlled by turning off certain processes
during the test period. The pipe section was blocked at the outflow manhole for the
pipe section. The process waste was then allowed to back up to the first manhole
were the liquid level was monitored for a period of time. Any drop in water level
during this period would indicate a leak in the pipeline and result in a non-
compliance with the company’s IPC Licence. This monitoring period varied for some
of the pipelines and depended on how long certain processes in the plant could be
turned off for. When these processes had to resume normal operation, the pipelines
had to be unblocked to allow flow of effluent. However, although the time period
may have varied, it was never less than two hour.
3.3 Underground Tank Integrity Test
The method for testing the underground blood tanks follows the same principles as
the hydrostatic test carried out on the underground pipeline. Firstly, it is necessary to
perform these tests during a period of little or no production when the tanks do not
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Dawn Meats & Western Proteins Inspection & Integritv Testing
need to be used for a period of time. The inflow pipes to the tanks will be blocked off
to prevent any blood flow or surface water entering the tank during the test thus
allowing for control of the water level in the tank. The tank will be filled with wafer
until the level rises to the access manhole. The water level will then be monitored at
this manhole for the required monitoring period. Any drop in this water level will
indicate that the tank is leaking and so in non-compliance with the IPC Licence.
Document No.:458-01 8 Environmental Efficiency
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. .
Dawn Meats & Western Proteins Inspection & Integritv Testing
4. Results & Compliance
4.1 Bunds
Table 1 Details of Bunded Areas on site
Green Diesel tank Chemical Storage
Blood Tank Boiler Oil
Tank Heating Oil
30 2.5 0.7 To be tested
2.5 1 0.5 To be tested
30 22.5 0.45 Tested 75 28 0.7 Tested
7.6 2.5 0.6 To be tested
4.1.1 Boiler Oil Tank Bund
This bund contains two tanks for storing oil for the plant steam boilers. Only one of
these tank is now in use. As can be seen from table one above the effective capacity
of the bund is adequate for the amount of oil stored in the tank. The bund also
contains quite an amount of electrical equipment including heating elements and
pumps. It was not possible to raise this electrical equipment above the water fill
height level as it would have shut down production in the plant completely. The
water was filled to the highest level possible without affecting the equipment and
monitored at this level for the required period. No drop in water level was recorded
during this monitoring period and so the bund has passed the integrity test and is in
compliance with section 9.3.2 of the IPC Licence. Following the visual inspection of
the bund it was felt that the bund would pass the integrity test. It is a relatively new
bund and is a sound structure of mass concrete.
4.1.2 Blood Tank Bund
As with the boiler oil bund, the bund for the blood tank has been installed quite
recently and is a sound mass concrete structure. No cracks or defects were detected
during-the visual inspection. There is a gulley in the middle of the bund with the floor
of the bund sloping towards this. The gulley provides a drainage facility for the bund,
draining any water or blood into the main underground blood storage tank. This
Document No.:458-01 9 Environmental Efficiency
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Dawn Meats & Western Proteins Inspection & Integriti Testing
drainage system means that the bund acts only as a secondary containment facility
and so is not as critical. It would not have been possible to seal the drain securely
enough to ensure no escape of water and so any drop in water during the test could
not have been accurately attributed to the bund integrity. It is felt that if the
underground tank and pipeline pass its integrity test then the integrity of the entire
blood containment unit will be guaranteed. This test will take place at a further date
as production was too heavy to undertake the test at this visit.
4.2 Underground Pipelines
Table 2 Details of Underground Pipelines
Dawn Meats to Western Proteins Pipeline alongside river to sump in middle of Dawn Meats site
Passed Includes all pipelines off main line
All pipelines in Western Proteins
Passed 3 pipelines running into one main line
4.2.1 Main Effluent Line
The effluent treatment plant is situated on the Western Proteins site. The Dawn Meats
site is located approximately 1.5 Km from the Western Proteins plant. The effluent
from Dawn Meats is pumped along a main pipeline to the Western Proteins treatment
plant. During the test certain processes were turned off at Dawn Meats to reduce the
flow of effluent. The pumps in the effluent sump at Dawn Meats were turned off and
the seat valves were closed. This allowed the pipeline to fill with effluent. The
effluent was allowed to flow again for a short period to allow it build up to a certain
level in one of the tanks in the Treatment plant. This level was monitored
continuously during the test. Any drop in the level of the effluent would have
signified a leak in the pipeline. However, no drop was recorded during the test and so
the pipeline passed the integrity test. The test was conducted over a two hour period
after which time it had to be stopped to allow for normal effluent flow to resume in
order to prevent an over flow of effluent from the main sump at Dawn Meats.
Document N’o.:458-01 10 Environmental Efficiency
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Dawn Meats & Western Proteins Inspection & Integritv Testing
4.2.2 Riverside Pipeline at Dawn Meats
Difficulty was had during the arranging of this particular test due to the high volume
of effluent coming from the plant. However, the importance of testing this particular
pipeline due to its proximity to the river was recognized by the company. Therefore
in order to facilitate the test, several processes were shut down during the monitoring
period at expense to the company. The test was conducted in stages by testing the
pipeline in sections. For each section the pipeline was blocked at the end of the
section and the effluent was allowed build up to a certain level at one of the manholes.
This level was monitored and any drop in the effluent level was recorded. Each
section of the pipeline was tested monitored for approximately two hours after which
time certain processes in the plant had to resume operation. No drop in effluent level
was recorded for any of the pipeline sections monitored and so the entire pipeline
passed the integrity test and is in compliance with the company’s IPC Licence.
4.2.3 Pipelines at Western Proteins.
The drainage system tested at Western proteins consists of three tributary pipelines
running into one main pipeline. This main pipeline then runs into the main effluent
sump and t?om here the effluent is pumped to the treatment plant. The volume of
effluent flowing from the Western Proteins plant was significantly less than that from
Dawn Meats on the day and so controlling the flow was not as complicated. It was
decided the entire network could be tested at the same time. The pumps in the
effluent sump were turned off. This allowed the effluent to build up in the pipelines
and in the sump. The effluent was allowed to rise to a certain level in the sump and at
a number of manholes. These were used as the monitoring points. The effluent levels
in these manholes were monitored for approximately two hours. No drop in the
effluent level was recorded during this test period and so the pipelines have passed the
integrity test and are in compliance with the company’s IPC Licence.
Document No.:458-01 11 Environmental Efficiency
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Dawn Meats & Western Proteins Inspection & Intearitv Testing
4.3 Underground Blood Storage tanks
The level of production at Dawn Meats plant was very high on the days of testing.
This meant that the flow of blood into the storage tanks was also very large. It was
not possible to stop this inflow of blood as it would have resulted in a total shut down
of the plant and this was not feasible. As a result the tanks were not tested during this
visit. A second visit to the site shall be arranged in early 2003 when production is at a
lower level. The results of these tests shall be reported in due course.
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, Dawn Meats & Western Proteins Inspection & Integritv Testing
5. Conclusion
All pipelines and bunds tested during this visit were found to be without defects and
their integrity is confirmed from these tests. There is still an amount of work to be
carried out on site as part of this project. The reasons for not conducting these tests
has been highlighted above. This is however only a temporary delay and another site
visit to complete this work is planned for early 2003.
l
Document No.:458-01 13 Environmental Efficiency
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- ‘ - .’
Dawn Meats & Western Proteins Inspection & Integrity Testing
Appendix 1 Bund Test Procedure
The procedure used is defined in the Environmental Agency (of England and Wales)
R&D Technical Report P16. This procedure is specifically designed for the testing of
bunds or sumps intended for oil storage tanks for sites defined as being highly
sensitive. This is a six hour test over which there should be no loss of water.
The Environmental Agency protocol is as follows:
1. The company is expected to carry out any remedial work recommended e.g.
this may include concreting bund/sump base, plugging holes.
2. The company is to clear out the bund of all foreign material including
rainwater
3. The procedure is to be carried out on a cool, dry day.
4. The company is to supply manual labour to facilitate the water retention test.
This will include filling the bunds to required level. For large bunds, or poor
water supply, filling may be started the day before the test.
5. EEC will inspect the water level after 6 hours. Any drop in level will signify
failure.
6. The company is responsible for disposal of the test water. EEC will
qualitatively check for the presence of contaminants in the water if applicable
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Consulting Engineers
.
Air Infiltration Report
For
Western Proteins
Document Number 648-02
Environmental Efficiency Consultants (Ireland) Limited
Parnell House, 17 Quinsboro Road, Bray, Co. Wicllow. Tel 01 276 1428 Fax 01 276 1561
emsill [email protected] WWW.CWVilW-COIMllt.~O~
Registered CXfke: as above. Reg. No. 243412
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Western Proteins Air Infiltration
QF 1. Document Lead Sheet
Document Title Project No. Document No. Client
Air IntIkmtion Report 648 648-02 Western Proteins
Issue
1.00
Status
Approved
Date Author
14/06/2005 RBS
Signed for and on behalf of Environmental Client
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 SutcWe, CEng, MIMechE
Conditions relating to the issue of this report:
1. Reports issued by Environmental & Efficiency Consultants (Ireland) Limited are copyright and shall not be used, either in whole or in part, for the purposes of advertising or litigation without the prior written consent of a Director of Environmental & Efficiency Consultants (Ireland) Limited.
2. No alteration to this report by third parties is permitted
3. Where this report is reproduced, it shall only be reproduced in full.
4. Reports remain the property of Enviromental & Efficiency Consultants (Ireland) Limited until paid for in full.
Environmental Effkiencv Document No.: 648-02 vl.00; 3
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Western Proteins Air Infiltration
1. Introduction Western Proteins are required to have an air infiltration test carried out to determine whether certain areas are operating under negative pressure.
2. Summary The following buildings were tested and were confirmed as operating under negative pressure
l Process Building (from the intake to the mill)
3. Method and test results Environmental Efficiency was contracted by Western Proteins to carry out an integrity test on the process building from the intake to the mill.
The air movement tests were carried out I all areas by observation of smoke clouds generated by smoke tubes (Draeger air current Cl3216 smoke tubes).
There were no visible signs of leaks.
It was noted that the roof of the building had been replaced in recent times.
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Consulting Engineers
: . : ‘,
; : , -?,, ,’ : : . A / - y;,
‘!_, . I . ,
: ‘:
.,’ ;ii
Effluent Tank Inspection
For
Western Proteins
Document Number 648-03
Environmental Efficiency Consultants (Ireland) Limited
Pamell House, 17 Quinsboro Road, Bray, Co. Wicklow. Tel 01 276 1428 Fax 01276 1561
email [email protected] wwwxnviro-consuIt.com
Registered Office: as nbove. Reg. No. 243412
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Western Proteins Effluent Tank Inspection
QF 1. Document Lead Sheet
Document Title Project No. Document No. Clkllt
Effluent tad inspection 648 648-03 Western Proteins
Issue
1.00
Status
Approved
Date Author
14/06/2005 RBS
Signed for and on behalf of Environmental Client
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 Sutclif%e, CEng, MlMechE
Conditions relating to the issue of this report:
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Environmental Efficiency Document No. : 648-03 vl. 00; 3
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Western Proteins Air Infiltration
1. Introduction Western Proteins are required to have an inspection of the effluent tanks and associated pipework.
2. Summary The following tanks, together with their associated pipework, were inspected and were confirmed as having no leaks.
Balance Tank AT1 AT2 AT3 AT4 AT5 ST2 ST3 ST4/ Final Clarifer Decanter Sludge Holding Tank Flocculation Tanks Stand-By Balance Tank
3. Method and test results Environmental Efficiency was contracted by Western Proteins to carry out an inspection of the efnuent tanks and their associated pipework.
All tanks were reviewed to ensure that they were in use on the day of inspection. All tanks were in use. No leaks were observed fi-om any of the tanks.
Environmental Efficiencv DocumentNo.: 6X?-02vl.00: 3
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