Final Draft Environmental Management Programme (EMPr) for the Proposed Installation of a Gas Fired Heat Treatment Furnace at Scaw Metals High Chrome

Size: px
Start display at page:

Download "Final Draft Environmental Management Programme (EMPr) for the Proposed Installation of a Gas Fired Heat Treatment Furnace at Scaw Metals High Chrome"

Transcription

1 Final Draft Environmental Management Programme (EMPr) for the Proposed Installation of a Gas Fired Heat Treatment Furnace at Scaw Metals High Chrome Ball Plant in Germiston A Report For: Scaw South Africa Pty Ltd GDARD Reference No: Gaut 002/13-14/E0162 Date: April 2014

2 DOCUMENT DESCRIPTION Client: Scaw South Africa Pty Ltd Report Name: Draft Environmental Management Programme (EMPr) for the Proposed Installation of a Gas Fired Furnace at Scaw Metal's High Chrome Ball Plant in Germiston. Royal HaskoningDHV Reference Number: T01.JNB GDARD Reference No: Gaut 002/13-14/E0162 Compiled by: Sibongile Gumbi Reviewer and Approver: Mark Freeman Royal HaskoningDHV All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, without the written permission from Royal Haskoning.DHV

3 TABLE OF CONTENTS 1 PROJECT DESCRIPTION Context and Background 1 2 LEGAL REQUIREMENTS 6 3 MANAGEMENT AND MONITORING PROCEDURES Roles and Responsibilities Training and Environmental Awareness Monitoring Checking and Corrective Action 9 4 ENVIRONMENTAL MANAGEMENT PROGRAMME Purpose and Objectives of the EMPr 9 5 CONSTRUCTION PHASE 11 6 POST CONSTRUCTION PHASE 14 7 OPERATIONAL PHASE 14 LIST OF TABLES TABLE 1: APPLICABLE LEGISLATION 6 TABLE 2:ROLES AND RESPONSIBILITIES 7 TABLE 3:ENVIRONMENTAL EDUCATION AND TRAINING 11 TABLE 4:CONSTRUCTION TRAFFIC AND SITE ACCESS 12 TABLE 5:AIR QUALITY MANAGEMENT 12 TABLE 6:GROUND AND SURFACE WATER MANAGEMENT 12 TABLE 7:WASTE MANAGEMENT 13 TABLE 8:REHABILITATION 14 TABLE 9:OPERATIONAL 14 LIST OF FIGURES FIGURE 1: LOCATION OF THE STUDY AREA WITHIN JOHANNESBURG 2 FIGURE 2: LOCATION OF THE STUDY AREA WITHIN UNION JUNCTION INDUSTRIAL PARK 3 FIGURE 3: SCAW METAL INDUSTRIAL COMPLEX 4 FIGURE 4: LOCATION OF SCAW METAL HIGH CHROME BALL PLANT 5

4 DEFINITIONS Environment Environmental Management Programme Scaw Project Manager Environmental Site Agent Environmental Control Officer Contractor Incident Environmental Impact Mitigation Measure Rehabilitation In terms of the National Environmental Management Act (NEMA) (No 107 of 1998), environment means the surroundings within which humans exist and that are made up of: (i) The land, water and atmosphere of the earth; (ii) Micro-organisms, plant and animal life, and Any part or combination of (i) of (ii) and the interrelationships among and between them; and the physical, chemical, aesthetic and cultural properties and conditions of the foregoing that influence human health and wellbeing. A detailed plan of action prepared to ensure that recommendations for enhancing or ensuring positive impacts and limiting or preventing negative environmental impacts are implemented during the life-cycle of a project. This Environmental Management Programme (EMPr) should preferably form part of Scaw s Environmental Management System and ISO standard compliance system. The person appointed by Scaw from time to time to act in the capacity and notified, by name and in writing by Scaw to the Contractor, to act as required in the Contract. An individual appointed by the Contractor to be present on site to act on behalf of the Contractor in matters concerning the implementation and day to day monitoring of the EMPr. An individual nominated through the Project Manager to be present periodically on site to act on behalf of the Project Manager in matters concerning the implementation and monitoring of the EMPr. A person or company appointed by Scaw to carry out stipulated activities. An undesired event which may result in significant environmental impacts but can be managed through internal response. A change to the environment, whether adverse or beneficial, wholly or partially resulting from an organisation s activities, products or services. Measures designed to avoid, reduce or remedy adverse impacts. Rehabilitation is the return of a disturbed area to a state which approximates the state (where possible) which it was in before construction.

5 1 PROJECT DESCRIPTION 1.1 Context and Background Scaw South Africa Pty Ltd ( Scaw Metals ) is proposing to install a gas fired heat treatment furnace at their High Chrome Ball Plant (HCBP) in their Union Junction facility located in Germiston, Gauteng Province. The heat treatment furnace will be a gas-fired furnace as opposed to the electric furnace currently installed. The new furnace will be installed within the current heat treatment section of the HCBP adjacent to the existing heat treatment furnace. Heat treatment of chrome balls is undertaken after casting in order to alter the internal structure and make it more suitable for its further purpose as a grinding agent. Scaw Metals manufactures a diverse range of steel products. The Grinding Media Division at Union Junction is the largest producer of cast high chrome grinding media in the southern hemisphere and has an opportunity to increase its production volume as a result of an increased market demand. Therefore, an additional heat treatment furnace will be required to meet this demand. Electrical supply is a limited resource both at Scaw Metals and in the entire country. From a strategic point of view, installing a gas-fired furnace utilising natural gas will reduce Scaw s demand on the electrical grid. In addition, the utilisation of natural gas as a fuel source will realise a reduction in energy costs when compared to electricity as a fuel source. The proposed project is located in the HCBP plant at Union Junction along Dekema and Centime Roads in the Wadeville industrial area, Germiston South, which falls within the jurisdiction of Ekurhuleni Metropolitan Municipality (refer to Figures 1 to 3). The study area is surrounded by industries, commercial businesses, residential houses (Dinwiddie) and Provincial Roads (M37, R103 and R554), as well as National Roads (N3 and N17). Page 1

6 FIGURE 1: LOCATION OF THE STUDY AREA WITHIN JOHANNESBURG Page 2

7 FIGURE 2: LOCATION OF THE STUDY AREA WITHIN UNION JUNCTION INDUSTRIAL PARK Page 3

8 FIGURE 3: SCAW METAL INDUSTRIAL COMPLEX Page 4

9 FIGURE 4: LOCATION OF SCAW METAL HIGH CHROME BALL PLANT Page 5

10 2 LEGAL REQUIREMENTS Table 1 below lists the relevant policies and legislation which are applicable to the proposed project. TABLE 1: APPLICABLE LEGISLATION LEGISLATION The Constitution ( Act No 108 of 1996) National Environmental Management Act ( Act No 107 of 1998) National Environmental Management: Air Quality Act (Act No 39 of 2004). National Water Act (Act 36 of 1998). National Environmental Management: Waste Act (No 59 of 2008) Ekurhuleni Metropolitan Municipality By Laws INTERPRETATION This relates to the environmental rights to a pollution free environment for the surrounding community, industries and commercial businesses. The developer has a general duty to care for the environment and to establish measures as may be needed to demonstrate such care. This relates to the control of dust, emissions, odour and noise. This relates to the use and management of water resources, including pollution prevention and remedy of incidents. It is the responsibility of the developer, and its contractors generating waste, to ensure that any waste (solid or liquid) is stored appropriately (containers) and safely, treated where required and then disposed of in an environmentally sound manner. Page 6

11 3 MANAGEMENT AND MONITORING PROCEDURES 3.1. Roles and Responsibilities It is anticipated that several key professionals will need to form part of the project execution team and their responsibilities in respect of the environment are outlined in Table 2 below. TABLE 2: ROLES AND RESPONSIBILITIES ROLES RESPONSIBILITIES Project Manager Environmental Control Officer Contractor Environmental Site Agent The Project Manager is responsible for overall management of the project, including the EMPr implementation. The following tasks will fall within his / her responsibilities: Be familiar with the recommendations and mitigation measures of this EMPr, and ensure implementation of these measures on site; Monitor site activities on a regular basis for compliance; Conduct internal audits of the construction site against the EMPr; Confine the construction site and construction activities to the demarcated area; and Rectify transgressions through the implementation of corrective action. The responsibilities of the Environmental Control Officer are to: Monitor the implementation of the EMPr during the construction phase; Be familiar with the recommendations and mitigation measures of the site-specific EMPr for the project; Ensure protection measures are implemented on site; Monitor all site activities on a biannual basis for compliance; Conduct biannual audits of the site according to the EMPr, and report findings to the Project Manager/Contractor; Recommend corrective action for any environmental non-compliance noted on site; Compile a biannual report highlighting any non-compliance issues as well as progress and compliance with the EMPr prescriptions; and Conduct once-off training with the Contractor on the EMPr and general environmental awareness. It must be noted that the responsibility of the ECO is to monitor compliance and give advice on the implementation of the EMPr, and not to enforce compliance. Ensuring compliance is the responsibility the Site Agent appointed by the Contractor. The Contractor and its sub-constructors are responsible for overall execution of the activities envisioned in the construction phase, including implementation and compliance with the recommendations and conditions of the EMPr. The Contractor shall therefore ensure compliance with the EMPr at all times during construction activities and maintain an environmental register which keeps a record of all environmental incidents which occur on site during construction. The incidents may include: Public involvement /complaints; Health and Safety incidents Incidents involving hazardous materials stored on site; and Non-compliances with the EMPr The Contractor is responsible for the implementation of corrective actions issued by the ECO and Project Manager within a reasonable or agreed period time. The Environmental Site Agent (ESA) should: Be fully conversant with the content of the EMPr; Be fully conversant with all relevant environmental legislation applicable to the project, and ensure compliance with any legal obligations; Compile the construction Method Statements together with the Contractor that will Page 7

12 ROLES RESPONSIBILITIES specify how potential environmental impacts in line with the requirements of the EMPr will be managed and how they will practically ensure that the objectives of the EMPr are achieved; Convey the contents of this EMPr to the construction site staff and discuss the contents in detail with the Contractor; Undertake regular and comprehensive daily inspections of the site and surrounding areas in order to monitor compliance with the EMPr; Take appropriate action if the specifications contained in the EMPr are not followed; Monitor and verify that environmental impacts are kept to a minimum, as far as practically possible; Order the removal from the construction site of any person(s) and/or equipment in contravention of the specifications of the EMPr; Maintain the following documents on site: o EMPr; o Construction layout plan (showing storage areas etc) o Construction method statements; o A site diary; o Environmental incidents register; and o Update Material Safety Data Sheets (MSDS) when necessary Training and Environmental Awareness It is important to ensure that the Contractor and their sub-contractors have the appropriate level of environmental awareness and competence to ensure continued environmental due diligence and ongoing minimisation of environmental harm during construction. Training needs should be identified based on the available and existing capacity of site personnel (including for all Contractors and sub-contractors) to undertake the required EMPr management actions and monitoring activities. It is vital that all personnel are adequately trained to perform their designated tasks to an acceptable standard. The environmental training is aimed at: Promoting environmental awareness; Informing the Contractor of all environmental procedures, policies and programmes applicable; Providing generic training on the implementation of environmental management specifications; and Providing job-specific environmental training in order to understand the key environmental features of the construction site and the surrounding environment. In addition to training, general environmental awareness must be fostered among the project s workforce to encourage the implementation of environmentally sound practices throughout the duration of the construction phase through regular toolbox information talks Monitoring A monitoring programme should be in place to ensure compliance with the EMPr and to monitor any environmental issues and impacts which could result in significant environmental impacts for which corrective action is required. A monitoring programme should be implemented for the duration of the construction phase of the project. This programme must include: Page 8

13 Biannual site audits that will be conducted by Environmental Control Officer Compilation of a biannual audit report which will document findings and recommend corrective action to be taken where required. Subsequent reports will provide feedback on whether previous non conformances raised have been resolved, thereby ensuring continual improvement of the site s environmental performance; and Daily site inspections will be conducted by the Environmental Site Agent to ensure daily implementation of the EMPr conditions and provide corrective actions Checking and Corrective Action Checking and corrective action forms part of the environmental management function and is aimed at ensuring that the necessary environmental management activities are being implemented according to the EMPr and that the desired outcomes are achieved. 4 ENVIRONMENTAL MANAGEMENT PROGRAMME 4.1. Purpose and Objectives of the EMPr The Environmental Management Programme (EMPr) has been compiled to provide recommendations and guidelines according to which construction activities at HCBP must be undertaken, as well as to ensure that all relevant factors are considered for implementing an environmentally responsible development. This EMPr informs all relevant parties, including the Project Manager, Contractor and all other staff employed by the Scaw Metals Group on site, as to their duties in the fulfilment of the environmental legal requirements for the construction of the gas fired heat treatment plant and its associated infrastructure, and with particular reference to the prevention and mitigation of anticipated potential environmental impacts. The objectives of the EMPr are to: Identify a range of mitigation measures which could reduce and mitigate the potential environmental impacts to minimal or insignificant levels; Detail specific actions deemed necessary to assist in mitigating the environmental impact of the project; Identify measures that could optimize beneficial impacts; To create management structures that address the concerns and complaints of the public with regards to the development; To establish a method of monitoring and auditing environmental management practices during all implementation phases of the project; Ensure that the final design, construction and operational phases of the project follow the principles of Integrated Environmental Management (IEM); Specify time periods within which the measures contemplated in the EMPr shall be implemented where appropriate. The emphasis of the EMPr is to: Avoid impacts by not performing certain actions; Minimise impacts by limiting aspects of an action; Page 9

14 Rectify impacts through consideration of the affected environment; Compensate for impacts by providing substitute resources or environments; Minimise impacts by optimising processes, structural elements and other design features; Maximise benefits accruing from the project and Provide ongoing monitoring and management of the environmental impacts of the development by documenting any EMPr digressions / good performances. Page 10

15 5 CONSTRUCTION PHASE TABLE 3: ENVIRONMENTAL EDUCATION AND TRAINING PHASE CONSTRUCTION CONTRACTOR & ESA WEEKLY ENVIRONMENTAL EDUCATION AND TRAINING (This section deals with the environmental training of employees) RESPONSIBILITY FREQUENCY / MONITORING REQUIREMENTS Environmental Training 1. The Environmental Site Agent (ESA) must ensure that all site personnel have a basic level of environmental awareness training. Topics covered should include; What is meant by Environment ; Why the environment needs to be protected and conserved; How construction activities can impact on the environment; What can be done to mitigate against such impacts; Awareness of emergency and spills response provisions; and 2. Environmental Training should be provided to the employees through toolbox information talks. These should be relevant to specific construction work or activities. 3. Staff operating equipment (such as excavators, loaders, etc.) shall be adequately trained and sensitised to any potential hazards associated with their tasks. Proof of training to be kept in an environmental file. 4. The ESA must be conversant with all legislation pertaining to the environment applicable to this contract and must be appropriately trained in environmental management and must possess the skills necessary to impart environmental management skills to all personnel involved in the contract. Page 11

16 TABLE 4: CONSTRUCTION TRAFFIC AND SITE ACCESS PHASE CONSTRUCTION DAILY CONTRACTOR & ESA IMPACT SOURCE MITIGATION MEASURE MONITORING ACTIONS & FREQUENCY RESPONSIBILITY FOR IMPLEMENTATION Disturbance to the neighbouring landowners. Construction vehicles 1. Appropriate traffic signage must be erected on site by the Contractor to alert other road users to construction activities. 2. The Contractor should strategically position the site entry and exit points to ensure that there is minimum impact to the traffic flow on neighbouring streets. 3. The Contractor must ensure that local access roads are not damaged by construction vehicles. If damage does occur, it needs to be attended to immediately to avoid long term problems. TABLE 5: AIR QUALITY MANAGEMENT PHASE CONSTRUCTION DAILY CONTRACTOR & ESA IMPACT SOURCE MITIGATION MEASURE MONITORING ACTIONS & FREQUENCY RESPONSIBILITY FOR IMPLEMENTATION Air emissions. Un-serviced construction vehicles and the servicing of vehicles on site. 1. The Contractor must regularly service the construction vehicles and machinery used on site at an approved off site service station. TABLE 6: GROUND AND SURFACE WATER MANAGEMENT PHASE CONSTRUCTION DAILY CONTRACTOR & ESA IMPACT SOURCE MITIGATION MEASURE MONITORING ACTIONS & FREQUENCY RESPONSIBILITY FOR IMPLEMENTATION Water contamination. Improper storage and use of hazardous substances including 1. Used oil on site must be managed accordingly. 2. Accidental spillages of hazardous substances that occur on site must be contained and Page 12

17 PHASE CONSTRUCTION DAILY CONTRACTOR & ESA IMPACT SOURCE MITIGATION MEASURE MONITORING ACTIONS & RESPONSIBILITY FOR IMPLEMENTATION FREQUENCY cement, paints and other remediated as soon as possible. chemicals. Water wastage. Misuse of water. 1. The Contractor and workers need to use water responsibly and avoid unnecessary wastage. Taps should not be left open and leaking taps should be repaired immediately. Disruption of Scaw Metals operational activities and services. TABLE 7: The Contractor and its workers accessing water and other services from Scaw Metals municipal supply. WASTE MANAGEMENT 1. The Contractor must liaise with the Project Manager with regards to accessing potable water and other services from the Scaw Metals supply, monitor the amounts utilised and pay Scaw Metals accordingly. PHASE CONSTRUCTION DAILY CONTRACTOR & ESA IMPACT SOURCE MITIGATION MEASURE MONITORING ACTIONS & FREQUENCY RESPONSIBILITY FOR IMPLEMENTATION Ground and water pollution and aesthetic impact. Insufficient waste bins, incorrect labelling of waste bins, mixing of general, construction rubble and hazardous waste and storage of waste on site. 1. Sufficient waste bins shall be provided on site to encourage waste separation and for recycling purposes. 2. Refuse bins shall be placed at strategic positions to ensure that litter does not accumulate on site. 3. Construction workers need to be encouraged to use the waste bins provided at all times, and littering should be prohibited. 4. Skip waste containers should be kept on site to dispose of construction rubble. Containers must be removed when they fill up to maintain a clean site. 5. Waste disposal certificates need to be obtained by the Contractor from the waste disposal facility. Page 13

18 6 POST CONSTRUCTION PHASE TABLE 8: REHABILITATION PHASE POST CONSTRUCTION CONTRACTOR & ESA DAILY IMPACT REHABILITATION (This section deals with the rehabilitation of construction sites) RESPONSIBILITY FREQUENCY / MONITORING REQUIREMENTS MITIGATION STATEMENT 1. The construction site and camp is to be checked for spills of substances such as oil, paint, etc, and these shall be cleaned up. 2. Surfaces are to be checked for waste products from activities such as concreting and cleared accordingly. 3. All construction waste and rubble is to be removed from the site and disposed of to the landfill site. 4. The site is to be cleared of all litter. 5. Fences, barriers and demarcations associated with the construction footprint are to be removed from the site. 7 OPERATIONAL PHASE TABLE 9: OPERATIONAL PHASE OPERATIONAL PHASE PLANT MANAGER ANNUALLY /CONTINUOUSLY IMPACT MITIGATION STATEMENT AIR QUALITY EMISSIONS, ENERGY CONSUMPTION AND SAVINGS (This section deals with the air quality impacts, energy consumption and savings at the HCBP) 1. HCBP will need to comply with the conditions that will be set by the Municipal Council for Air Emissions and conditions of the AEL/APPA certificate applicable at the time. RESPONSIBILITY FREQUENCY / MONITORING REQUIREMENTS Page 14