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1 Industrial Emissions Review Application Dairygold Mallow P Attachment No. I.7 ATTACHMENT N o I.7 EPA Export :23:02:50

2 Noise Impact Assessment Dairygold Expansion IEL EPA Export :23:02:50

3 EPA Export :23:02:50

4 C Noise Impact Assessment December 2014 ISSUE FORM Project number Document number 6002 Document revision C Document title Noise Impact Assessment Document status Final Draft Document prepared by Peter Barry Document checked by CF (MWP) i EPA Export :23:02:50

5 C Noise Impact Assessment December 2014 Table of contents 1 INTRODUCTION Scope of the Assessment DETAILS OF NOISE EMISSIONS IMPACTS OF AN EXISTING OR PROPOSED NOISE EMISSIONS Existing Noise Emissions Description of the Existing (pre-expansion) Noise Environment Existing Operational Noise Levels (Prior to Re-development Construction and Demolition) Summary of pre-expansion noise emissions Proposed Noise Emissions Assessment Criteria AMBIENT NOISE MEASUREMENTS State the maximum Sound Pressure Levels which will be experienced at typical points on the boundary of the operation. (State sampling interval and duration) Normal Operations Non Normal Operations - CHP Steam Release Non Normal Operations Emergency Over-Pressurisation State the maximum Sound Pressure Levels which will be experienced at typical noise sensitive locations, outside the boundary of the operation Normal Operations Non Normal Operations - CHP Steam Release Non Normal Operations Emergency Over-Pressurisation Give details of the background (or residual) noise levels experienced at the site in the absence of noise from this operation Prediction models, maps (no larger than A3), diagrams and supporting documents, including details of noise attenuation and noise proposed control measures to be employed, should be included NOISE ATTENUATION AND NOISE CONTROL MEASURES ii EPA Export :23:02:50

6 C Noise Impact Assessment December 2014 List of figures Figure Ambient Noise Monitoring Locations B1 to B5. (As per IPPC Current Licence Requirements) Figure 2 Noise Impact Assessment Boundary and Noise Sensitive Locations List of tables Table 1 Sound Power Levels of main Site Noise Sources... 8 Table 2 Location B1 Northern Boundary Table 3 Location B2 - West Boundary Table 4 Location B2 - East Boundary Table 5 Location B4 NSL 1 (Near Entrance and Weighbridge) Table 6 Location B5 NSL 2 (Beecher Street) Table 7 Maximum Sound Pressure Levels at typical points on the boundary Table 8 Maximum Sound Pressure Levels at typical points on the boundary Table 9 Maximum Sound Pressure Levels at typical points on the boundary Table 10 Predicted Noise Emissions - Normal Operations Table 11 Predicted Noise Emissions - Non Normal Operations CHP Steam Release Table 12 Predicted Noise Emissions - Non Normal Operations Over Pressurisation Table 13 Noise Attenuation and Mitigation Measures iii EPA Export :23:02:50

7 C Noise Impact Assessment December INTRODUCTION As part of the environmental impact assessment (EIS) prepared for the planning application, an impact assessment of the noise emissions from the Dairygold Mallow installation at noise sensitive receptors in the vicinity of the installation was undertaken (Refer to EIS Volume 2 Chapter 9 and Volume 3 Appendix 9). The study examined noise emissions from the existing and proposed operational scenarios using noise prediction modelling software (Bruel & Kjaer Type 7810 Predictor Noise Modelling Package). This report reviews and updates the noise impact assessment undertaken for the planning application to take account of more recent information made available on equipment/plant. 1.1 SCOPE OF THE ASSESSMENT The scope of this assessment is primarily to inform the EPA in as much as possible about the noise emissions from the facility and the noise imissions in the receiving environment, specifically at the nearest sensitive receptors. The information is to supplement the information laid out in the tables and figures that form part of the IEL application. The relevant information is described in the following sections in this report. Section 2 Section 3 Details of Noise Emissions An overview of the noise emissions for which the Industrial Emissions Licence (IEL) will apply. These will include the existing noise emission sources that will remain and the future noise emission sources. Impacts of Any Proposed or Existing Noise Emissions Impacts of the site noise emissions on the receiving environment are discussed. These include existing noise emissions that will remain in combination with the new noise emissions associated with new equipment. The assessment was carried out using noise modelling software. The results are compared against recommended EPA noise limits. During the planning application stage these limits were used to inform design aspects of the proposed development. There are irregular non normal operations 1 that also occur on site. These are also discussed. 1 In some instances, licenced sites will have certain items of emergency equipment (e.g. standby generators) that will only operate in urgent situations (e.g. grid power failure). Depending upon the context, it may be permissible for such items of equipment to give rise to exceedances in the noise criteria/limits during limited testing and emergency operation only EPA NG4 pg 17 4 EPA Export :23:02:50

8 C Noise Impact Assessment December 2014 Section 4 Ambient Noise Measurements This section contains a description of the Ambient Noise environment. By definition the ambient noise environment is the totally encompassing sound in a given situation at a given time, usually composed from many sources near and far (EPA 2012). The results of the noise impact assessment are used to inform the analysis of the Ambient Noise environment. In this case the Ambient Noise environment is made up of all the specific noise emissions from the operational facility, at near and far locations. Residual noise is not included as there are no noise levels available for the area in the absence of Dairygold operations. Section 5 Noise attenuation and noise control measures This section outlines measures that are required in order to minimise noise emissions from the site. These include measures to screen, attenuate and reduce noise emissions from certain item of plant in order to achieve the EPA noise limit criteria. Measures set out in the grant of planning conditions are also included in this section. 5 EPA Export :23:02:50

9 C Noise Impact Assessment December DETAILS OF NOISE EMISSIONS A summary of all noise emission sources (existing and proposed) from the installation is set out below. The location of all existing and proposed noise sources are shown in Drawing No. 11 (Noise Emission Points). Details of emission characteristics from noise emission sources are presented in Table E.5(i) of the Industrial Emissions Licence Review Application form. In general terms the main noise sources on site can be divided into 7 groups as follows: Group 1 Group 2 Group 3 Existing Niro 2 Dryer and Associated Plant comprising of; Air Intake for Niro 2 Dryer Air Ducting for Niro 2 Dryer Davenport Cooling Tower Chimney Exhaust for Niro Dryer Niro 2 Dryer Explosion Vent Pneumatic Air Hammer New Dryer Building and Associated Plant comprising of; New Dryer 2 Exhaust Air from Dryer New Dryer 2 Air Inlet (x2) New Dryer 2 Explosion vent (x2) New Dryer 3 Exhaust Air from Dryer New Dryer 3 Air Inlet (x2) New Dryer 3 Explosion vent (x2) New Evaporator Building and Associated Plant comprising of; New Evaporator Building Cooling Tower New Evaporator Building Evap HVAC exhaust New Evaporator Building Dryer HVAC exhaust Group 4 New Refrigeration Building and Associated Plant comprising of; Pasteurisation/ refrigeration building Cooling Tower Dairy Pasteurisation/ refrigeration building Ammonia compressor (x3) Future Pasteurisation/ refrigeration building Ammonia compressor (x2) Pasteurisation/ Pasteurisation/ refrigeration building condenser (x3) Pasteurisation/ refrigeration building AHU 6 EPA Export :23:02:50

10 C Noise Impact Assessment December 2014 Group 5 Bagging Area Building and Associated Plant comprising of; HVAC Plant Area Evap Supply AHU HVAC Plant Area Dryer Supply AHU HVAC Plant Area Bagging Supply AHU HVAC Plant Area Bagging Exhaust AHU HVAC Plant Area Lab/ control supply AHU HVAC Plant Area Lab/ control exhaust AHU Group 6 Fugitive Noise Emissions from Milk Intake Area and Boiler House There will be noise emissions from the milk intake pumps and boiler house compressors. These have been represented as point sources outside the CHP (east and south) and milk intake areas (east and west). Group 7 Group 8 Access Road Traffic Noise There will be noise associated with the access road traffic particularly HGVs. HGVs will access the site 24hrs a day. The expected traffic volumes are 20HGV per hour during the day, 14 HGVs per hours during the evening and 6 HGVs per hour over night. These are total in and out movements. In addition an allowance has been made for the potential for idling at higher revs at the weighbridge. Non Normal Operations CHP Steam Release During winter when the dryers are not operating the CHP releases steam for two hours in the evening (5-7pm) which can be noise prone. A silencer has been incorporated into the pipe work and this is included the noise modelling predictions. CHP Over pressurisation The second non normal operation is also a steam release but is not predictable as the occurrence described above. Occasionally there is a requirement to release steam to avoid over pressurization of the boiler. This can occur at night and can be loud. This is already an existing practice. The sporadic steam release that is related to over pressurisation of the boiler in the CHP plant is a noisy event. The sound power levels associated with the items of plant/ emissions listed in each group are presented in the following table (Table 1). Of these groups, noise attenuation measures will be required for some of the plant, now or in the future in order to reduce the noise emissions to within the EPA NG 4 noise limit criteria. These are discussed further in Section 5 of this report. 7 EPA Export :23:02:50

11 C Noise Impact Assessment December 2014 Table 1 Sound Power Levels of main Site Noise Sources Source New Dryer Building and Associated Plant (Group 2) New Evaporator Building and Associated Plant (Group 3) Existing Niro 2 Dryer and Associated Plant (Group 1) New Refrigeration Building and Associated Plant (Group 4) ITEM Ref. No Sound Pressure Impulsive or tonal qualities Periods of Emission New Dryer 2 Exhaust Air from dryer N1 90dB LwA Broadband 24hrs New Dryer 2 Air inlet N2 78 db LwA Broadband 24hrs New Dryer 2 Air inlet N3 78 db LwA Broadband 24hrs New Dryer 2 Explosion vent N4 80 db LwA Broadband 24hrs New Dryer 2 Explosion vent N5 80 db LwA Broadband 24hrs New Dryer 3 Exhaust Air from dryer N6 90 db LwA Broadband 24hrs New Dryer 3 Air inlet N7 78 db LwA Broadband 24hrs New Dryer 3 Air inlet N8 78 db LwA Broadband 24hrs New Dryer 3 Explosion vent N9 80 db LwA Broadband 24hrs New Dryer 3 Explosion vent N10 80 db LwA Broadband 24hrs New Evaporator Building Cooling Tower N11 96 dba LwA Broadband 24hrs New Evaporator Building Evap HVAC exhaust N12 80 dba LwA Broadband 24hrs New Evaporator Building Dryer HVAC exhaust N13 80 dba LwA Broadband 24hrs Existing Niro Dryer Exhaust Air (N19 old) N14 1m Broadband 20hrs daily Existing Niro Dryer Air intake (N16 old) N15 1m Broadband 20hrs daily Existing Niro Dryer Air intake (Ducting) (N17 old) N16 1m Broadband 20hrs daily Existing Niro Dryer Explosion vent (assumed no info available) N17 80 db 1m Broadband 24hrs daily Davenport Cooling Tower N18 105dB LwA Broadband 24hrs daily Pasteurisation/refrigeration building Cooling Tower Dairy N20 96 dba LwA Broadband 24hrs Pasteurisation/refrigeration building Ammonia Compressor (1) Pasteurisation/refrigeration building Ammonia Compressor (2) Pasteurisation /refrigeration building Ammonia Compressor (3) N21 Broadband 24hrs N22 Broadband 24hrs N23 Broadband 24hrs 8 EPA Export :23:02:50

12 C Noise Impact Assessment December 2014 Source New Refrigeration Building and Associated Plant ctd (Group 4) Boiler House + CHP Plant (Group 5) Milk Intake Area (Group 6) Access Road (Group 7) Bagging Area Building and Associated Plant (Group 5) ITEM Ref. No Sound Pressure Pasteurisation /refrigeration building Refrigeration condenser (1) Pasteurisation /refrigeration building Refrigeration condenser (2) Pasteurisation /refrigeration building Refrigeration condenser (3) Impulsive or tonal qualities Periods of Emission N24 93 dba LwA Broadband 24hrs N25 93 db LwA Broadband 24hrs N26 93 db LwA Broadband 24hrs Pasteurisation /refrigeration building AHU N27 65 db LwA Broadband 24hrs Combined heat and power (Door Open) N28 1m Broadband 24hrs daily Pressure Relief Valve (including silencer) N db LwA Impulsive Infrequent emergency Boiler house Compressor (1) (internal) N30 90 db LwA Broadband 24hrs Boiler house Compressor (2) (internal) N31 90 db LwA Broadband 24hrs Boiler house Compressor (3) (internal) N32 90 db LwA Broadband 24hrs Milk Intake (West Entrance) (N20 old) N33 1m 24hrs daily Milk Intake (East Entrance) (N21 old) N34 1m Broadband 24hrs daily HGVs at Weighbridge (revving) N db LwA Intermittent 24hrs HVAC Plant Area (Bagging Area Roof) Evap supply AHU N36 68 db LwA Broadband 24hrs HVAC Plant Area (Bagging Area Roof) Dryer supply AHU N37 68 db LwA Broadband 24hrs HVAC Plant Area (Bagging Area Roof) Bagging supply AHU N38 68 db LwA Broadband 24hrs HVAC Plant Area (Bagging Area Roof) Bagging exhaust AHU N39 68 db LwA Broadband 24hrs HVAC Plant Area (Bagging Area Roof) Lab/control supply AHU N40 68 db LwA Broadband 24hrs HVAC Plant Area (Bagging Area Roof) Lab/control exhaust AHU Line Source HGV Traffic N41 68 db LwA Broadband 24hrs Access Road 102 db LwA Intermittent 24hrs 9 EPA Export :23:02:50

13 C Noise Impact Assessment December IMPACTS OF AN EXISTING OR PROPOSED NOISE EMISSIONS This section address the Application requirements stated as follows: Give details and an assessment of the impacts of any existing or proposed noise emissions on the environment, including environmental media other than those into which the emissions are to be made. 3.1 EXISTING NOISE EMISSIONS This section details the existing operational noise emissions, pre-redevelopment of the facility. The following sections describe the surrounding environment and the noise emission associated with Dairygold pre-expansion Description of the Existing Noise Environment (pre-expansion) The site is located in an urban area and traffic is the main contributing noise source in the wider area. The existing Dairygold facility contribution to noise levels in the area is confined to within the site and to a varying extent along the site boundary. The site is bounded to the west by the N20 dual carriageway. There are no noise sensitive locations on the western boundary. The nearest noise sensitive locations west of the site include the Cork County Council local area office and the fire station. The N20 separates these locations from the western site boundary and traffic on the N20 is by far the main contributor to noise levels at these locations. These locations are not residential and are not used at night. The site is bounded by West End Street and Davis College to the South, Shortcastle Street to the east and Lower Beecher Street to the north. There are several residential dwellings located along West End Street including Annabella Terrace and other dwellings along the south east boundary. The main noise sources at these locations include traffic from on the N20 and West End Street and to a greater or lesser extent, depending on the location along the boundary, from inside the Dairygold premises. There are several residential dwellings located along Lower Beecher Street, facing the northern part of the site. The main noise sources here include traffic from the N20, but noise from Dairygold is audible along Lower Beecher Street, in particular from the existing dryer building. There is also a detached residence bounding the north east corner of the site. Audible noise sources at this location include traffic on the N20, Dairygold and the stream which acts a natural boundary between Dairygold and this location. 10 EPA Export :23:02:50

14 C Noise Impact Assessment December 2014 There is a mixture of commercial and residential premises on Shortcastle Street which runs parallel to the eastern site perimeter. The majority of residential locations are located at the south east corner of the site at the junction of Shortcastle Street and West End Street Existing Operational Noise Levels (Prior to Re-development Construction and Demolition) A baseline during operations was undertaken in August 2012 by CLV Consulting. The survey was carried out at four boundary locations and two noise sensitive locations as part of IPPC licence compliance. The results of that survey are summarised and extracted below. A figure illustrating the ambient noise monitoring locations is also presented (see Figure 1). Annual noise reports are with the EPA and in general terms, the ambient noise environment, and contributing noise sources in the vicinity of Dairygold have been consistent over the years. The results extracted below are a solid indication of the ambient noise levels prior to expansion. Figure Ambient Noise Monitoring Locations B1 to B5. (As per IPPC Current Licence Requirements) 11 EPA Export :23:02:50

15 C Noise Impact Assessment December 2014 Location B1 Northern Boundary Table 2 Location B1 Northern Boundary Ref Start Time Period Measured Noise Levels (db re. 2x10-5 Pa) LAeq LAmax LAmin LA10 LA90 Comments 1 10:40 11: Facility. 2 14:21 14:51 Day Road 3 17:55 18: traffic. 4 21:42 22:12 Evening Facility. 5 00:08 00: Facility. 6 03:42-04:12 Night Road traffic. Production activities from the Dairygold facility were noted as the dominant source of noise for all three of the monitoring periods. The noise emissions were generally steady state and broadband in characteristic. A comparison between the LAeq and LA90 values show very little difference (1-2dB) which indicates a steady state noise source and suggests that there were few contributions of any magnitude from other sources. During the evening and night time monitoring periods road traffic noise was perceptible as a background source of marginal impact. No impulsive or tonal components were audible or present on the frequency spectrum at this location during the monitoring periods. Location B2 West Boundary Table 3 Location B2 - West Boundary Ref Start Time Period 7 11:23-11:53 Measured Noise Levels (db re. 2x10-5 Pa) LAeq LAmax LAmin LA10 LA :55 15:25 Day :28 18: :15 22:45 Evening :41-01: Night 12 04:15-04: Comments Facility At noise monitoring location B2 noise emissions from the Niro building were the most audible source for the duration of the three monitoring periods. A noticeable amount of this noise appeared to be emanating from the louvres on the north western facade of the building. There were no other contributory sources either external or internal present. Noise levels were steady state which is reflected in the consistency of the recorded values however values were observed from the air 12 EPA Export :23:02:50

16 C Noise Impact Assessment December 2014 activated hammer. No tonal components were audible or present on the frequency spectrum at this location during the monitoring periods. Location B3 East Boundary Table 4 Location B2 - East Boundary Ref Start Time Period Measured Noise Levels (db re. 2x10-5 Pa) LAeq LAmax LAmin LA10 LA90 Comments 19 10:04 10: Traffic :34 14:15 Day Facility :19 17: Birdsong :36 20:06 Evening Facility :34-00: Night Traffic :07-03: For the duration of the daytime and evening period and local traffic movements on Shortcastle Street were regarded as the dominant noise sources. Noise emissions from the Dairygold boilers were audible as a steady state background noise. Birdsong was also present as a background source however the impact from this had marginal impact on the noise levels. Noise associated with the production activities from the Dairygold facility were the chief noise source for the night time periods. The most audible sources were the boiler and the air activated hammer from the Niro building. The boiler noise was regarded as steady state and broadband however the air hammer noise was considered to be impulsive. There were several minor contributions from road traffic on Shortcastle Street. No tonal components were audible from site noise emissions at this location during the monitoring periods. Location B4 NSL 1 Table 5 Location B4 NSL 1 (Near Entrance and Weighbridge) Ref Start Time Period Measured Noise Levels (db re. 2x10-5 Pa) LAeq LAMax LAmin LA10 LA :30 10: :11-13:41 Day :45-17: :00-19:30 Evening :00-23: Night 18 02:31-03: Comments Road traffic. Facility. Road traffic noise from the nearby West End road was the principal source of noise for all the three monitoring periods. The road is approximately 25m distant from the monitoring location and it 13 EPA Export :23:02:50

17 C Noise Impact Assessment December 2014 caters for a high volume of traffic in and out of Mallow. During the night time monitoring periods there was a decrease of traffic on the West End road however traffic noise on the bypass then became apparent. There were a number of traffic movements entering and leaving the Dairygold facility which also impacted on the ambient noise levels. Noise from the Dairygold production activities was occasionally perceptible during very brief lulls in traffic movements. No impulsive or tonal components were audible or present on the frequency spectrum at this location during the monitoring periods. Location B5 NSL 2 Table 6 Location B5 NSL 2 (Lower Beecher Street) Ref Start Time Period 31 08:51-09:21 Measured Noise Levels (db re. 2x10-5 Pa) LAeq LAMax LAmin LA10 LA :35-13:05 Day :07-16: :02-21:32 Evening :18-01: Night 36 04:54-05: Comments Facility. Traffic. Stream. The daytime, evening and night time periods at NSL 2 were dominated by noise from the Dairygold facility. The noise emissions consisted on noise from the Niro building, general process noise and emission from the air activated hammer. The air activated hammer was regarded as an impulsive noise source. Distant traffic noise from the N20 was audible as a relatively continuous background noise source. There were a number of local traffic movements as cars passed the monitoring location however these had a marginal impact as they were travelling at a very low speed. No tonal components were audible from site noise emissions at this location during the monitoring periods Summary of pre-expansion noise emissions The main points to note from the review of previous ambient noise monitoring surveys are: Noise sensitive locations to the South, East and West of the site were mainly influenced by traffic and to the immediate north by Dairygold and by the N20. The dwellings along lower Beecher Street were mainly influenced by existing Dairygold plant associated with the existing dryer building. Noise associated with the milk intake and cooling plant at the dairy also contribute, however previous IPPC licence compliance reports indicate that the existing dryer building is the main contributor at this location. Historically the night time noise limit was exceeded at B5 (Lower Beecher Street) Impulsive noise from the air activated hammer It has not been possible to collect a baseline in the absence of the specific noise, i.e. Dairygold. This would require a complete shutdown of the facility. 14 EPA Export :23:02:50

18 C Noise Impact Assessment December PROPOSED NOISE EMISSIONS The main external noise emissions from the future redeveloped facility have been identified in Section 2 and Table 1. The impact of these emissions on the receiving environment was predicted using computer modelling software. Three scenarios were modelled to represent the day, evening and night time periods as defined in the EPA Noise Guidance Document NG4. The models would return the same results for all periods but because the traffic has also been included, the results are different for each period, given the different traffic volumes for each period. There is a greater volume of delivery traffic during the day, followed by evening, followed by night Assessment Criteria The current facility operates under the control of an Integrated Pollution Prevention and Control (IPPC) licence. This licence set emission limit values on all emissions from the site including noise. The recommended noise emission limits are 55 dba by day and 45 dba by night. The day time and night time periods are defined as follows: Daytime Night time 7 am to 7 pm 11 pm to 7 am Evening is defined as 7 pm to 11 pm and in accordance with the EPA, Guidance Note for Noise: Licence Applications, Surveys and Assessments in Relation to Scheduled Activities (NG4) During daytime and evening periods rigorous efforts should be made to avoid clearly audible tones and impulsive noise at all sensitive locations. A penalty of 5dB for tonal and/or impulsive elements is to be applied to the daytime and evening measured LAeq,T values to determine the appropriate rating level (LAr,T). During the night time period no tonal or impulsive noise from the facility should be clearly audible or measurable at any noise sensitive location (NSL). A noise sensitive location is defined as any dwelling house, hotel or hostel, health building, educational establishment, place of worship or entertainment, or any other facility or other area of high amenity which for its proposer enjoyment required the absence of noise at nuisance levels. The noise from the licensed facility shall not be so loud, so continuous, so repeated, of such duration or pitch and it should not occur at such times, as to give reasonable grounds for annoyance. 15 EPA Export :23:02:50

19 C Noise Impact Assessment December AMBIENT NOISE MEASUREMENTS The operational noise emissions have been predicted for both off site noise sensitive locations (NSL 1 to NSL 11) and on site boundary locations (B1 to B6). These are predicted rather than measured levels as the site is not yet operational. The prediction interval is one hour. All items of plant have been modelled as running 24hrs a day. The only variable will be the noise contributions from the variable traffic volumes over the day, evening and night time periods. It must be noted that the noise levels reported below are the noise emissions from Dairygold only. The noise thresholds apply to the operations noise emissions only. It is often the case that the noise thresholds are exceeded when in combination with the residual noise levels (in the absence of the specific noise, in this case Dairygold). This is because the residual noise levels from other non related sources are already elevated, i.e. traffic and other urban noise. To allow for this, the LA90 db rather than the LAeq db is compared against the threshold values when reporting the operational noise levels in compliance monitoring surveys. If a shut down were scheduled sometime in the near future, this opportunity should be used to capture a baseline in the absence of the specific noise (Dairygold). 4.1 MAXIMUM SOUND PRESSURE LEVELS WHICH WILL BE EXPERIENCED AT TPICAL POINTS ON THE BOUNDAR OF THE OPERATION. (STATE SAMPLING INTERVAL AND DURATION) The facility is currently under construction. It is therefore not possible to measure the maximum sound pressure levels at typical points on the boundary, and accordingly there is no sampling interval and duration. The maximum sound pressure levels which will be experienced at typical points on the boundary were predicted using simulation software. The results for the day, evening and night are presented in Table 7 below. The predictions have been carried out are considered day to day normal operations and also, the untypical non normal operations. The results are LAeq, 1hour values and relate to the specific noise only. The figure over leaf identifies the noise sensitive locations (NSL) and boundary locations used for the purpose of this noise impact assessment. These are more than currently used in the annual noise compliance monitoring (see Figure 1). It is not suggested that all these locations are monitored post completion as this would be excessive. It is suggested that the noise compliance noise monitoring locations remain as per figure 1 and the existing licence requirements. 16 EPA Export :23:02:50

20 C Noise Impact Assessment December 2014 Figure 2 Noise Impact Assessment Boundary and Noise Sensitive Locations 17 EPA Export :23:02:50

21 C Noise Impact Assessment December Normal Operations Table 7 presents the predicted results for the normal regular day to day operations required for production. All results presented include the following mitigation measures: Attenuation of all AHU s on packaging building (Group 5 Noise Emissions,); Screening and Silencing (Attenuators)of Niro 2 Dryer Building Equipment (Group 1 Noise emissions); Environmental Noise Barrier and earth berm alongside access road (Group 7 Noise Emissions). Table 7 Maximum Sound Pressure Levels at typical points on the boundary. Location Predicted Results dba (Leq 1 hour) Day Evening Night B1 North Boundary B2 North East Boundary B3 East Boundary B4 South Boundary B5 West Boundary B6 South West Boundary Non Normal Operations - CHP Steam Release Tables 8 and 9 include for the irregular operations including the CHP plant steam release and the emergency over pressurisation release. The results in table 8 include a reduction of 20dBA to account for a silencer which has been installed. Table 8 Maximum Sound Pressure Levels at typical points on the boundary. Day Evening Location With CHP Steam Release & Silencer B1 North Boundary B2 North East Boundary B3 East Boundary B4 South Boundary B5 West Boundary B6 South West Boundary EPA Export :23:02:50

22 C Noise Impact Assessment December Non Normal Operations Emergency Over-Pressurisation Table 9 Maximum Sound Pressure Levels at typical points on the boundary. Predicted Results Day/ Evening/ Night Day/ Evening/ Night Location Over pressurisation with Over pressurisation silencer B1 North Boundary B2 North East Boundary B3 East Boundary B4 South Boundary B5 West Boundary B6 South West Boundary MAXIMUM SOUND PRESSURE LEVELS WHICH WILL BE EXPERIENCED AT TPICAL NOISE SENSITIVE LOCATIONS, OUTSIDE THE BOUNDAR OF THE OPERATION. The noise emissions from the operations and the noise imissions (receiving noise levels) at the nearest dwellings have also been predicted. The noise emission points are labelled as NSL (Noise Sensitive Location) 1 to NSL 11. The results are presented in Tables 10 to 12 and also as contour maps (see section 4.4). The noise level at any point within the contours can be extrapolated from the noise contour mapping and the associated legend. All results presented include the following mitigation measures: Attenuation of all AHU s on packaging building; Screening and Silencing (Attenuators)of Niro 2 Dryer Building Equipment and Emission Points; Environmental Noise Barrier and earth berm alongside access road. 19 EPA Export :23:02:50

23 C Noise Impact Assessment December Normal Operations Table 10 Predicted Noise Emissions - Normal Operations Location Height above ground (m) Predicted Results dba Day Evening Night NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL EPA Export :23:02:50

24 C Noise Impact Assessment December Non Normal Operations - CHP Steam Release Table 11 Predicted Noise Emissions - Non Normal Operations CHP Steam Release Location Height Day Evening Night With CHP Steam Release & Silencer NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL

25 C Noise Impact Assessment December Non Normal Operations Emergency Over-Pressurisation Table 12 Predicted Noise Emissions - Non Normal Operations Over Pressurisation Location Height Day/ Evening/ Night Over pressurisation No silencer Predicted Results Day/ Evening/ Night Over pressurisation with silencer NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL NSL

26 C Noise Impact Assessment December DETAILS OF THE BACKGROUND (OR RESIDUAL) NOISE LEVELS EXPERIENCED AT THE SITE IN THE ABSENCE OF NOISE FROM THIS OPERATION. There are no background or residual noise levels in the vicinity of the site in the absence of noise from the operation (specific noise). This would require a complete shutdown of the facility to allow noise measurements to be taken in and around the site. The site has been in operation continuously for the last 15 years. 4.4 PREDICTION MODELS, MAPS (NO LARGER THAN A3), DIAGRAMS AND SUPPORTING DOCUMENTS, INCLUDING DETAILS OF NOISE ATTENUATION AND NOISE PROPOSED CONTROL MEASURES TO BE EMPLOED, SHOULD BE INCLUDED Contour mapping illustrating the results in the tables above are included in this section. The contour maps are presented for three scenarios, i.e. day, evening and night. The scenarios illustrated include Normal 24hr operations Day, Evening & Night (Figure 3, 4 & 5) Steam Dump Including Silencer Evening (Figure 6) Over Pressurisation Including Silencer Night (Figure 7) The proposed noise attenuation measures are discussed in Section 5 below and outlined in Table 13 overleaf. The measures include screening, housing and/or silencing (attenuators) of noise sources and emission point. 5 NOISE ATTENUATION AND NOISE CONTROL MEASURES Noise attenuation measures are required to minimise the noise emissions from several of the noise groups identified in section 2. The measures include a combination of acoustic screening, silencing of noise emission points and enclosures. To date, the only reported tonal or impulsive character which has attracted a 5dBA penalty has been the air activated hammer in the existing Niro dryer building. As the existing Niro dryer building and associated plant will remain this building and associated plant will require acoustic treatment going forward as historically it has been the source of elevated noise emissions along the northern boundary, in particular at night. Acoustic attenuation of up to dba will be required from the total noise emission identified in Group 1. As the air activated hammer is impulsive, if it is to continue to operate at night, it will require attenuation. General mitigation measures have been identified in the following table for areas which require a reduction in the noise emissions. 23

27 C Noise Impact Assessment December 2014 Table 13 Noise Attenuation and Mitigation Measures Group Identification Noise Source(s) Mitigation Mitigation Included in Impact Assessment Air Intake for Niro 2 Dryer Acoustic Screen (and) Attenuator (Silencer) es Air Ducting for Niro 2 Dryer Acoustic Screen (and) Attenuator (Silencer) es Davenport Cooling Tower Acoustic Screen (and) Attenuator (Silencer) es 1 Existing Niro 2 Dryer 2 New Dryer Building 3 New Evaporator Building Chimney Exhaust for Niro Dryer Acoustic Screen (and) Attenuator (Silencer) es Air Activated Hammer Explosion Vent on West Boundary New Dryer 2 Exhaust Air from Dryer New Dryer 2 Air Inlet (x2) New Dryer 2 Explosion vent (x2) New Dryer 3 Exhaust Air from Enclosure or specialist treatment to reduce impulsive No noise and to eliminate at night Reduction of internal noise or installation of acoustic No louver. es Sound Power Levels Provided by Suppliers including attenuation including any silencers and attenuators. Dryer New Dryer 3 Air Inlet (x2) New Dryer 3 Explosion vent (x2) New Evaporator Building Cooling Tower New Evaporator Building Evap Sound Power Levels Provided by Suppliers including HVAC exhaust attenuation including any silencers and attenuators. New Evaporator Building Dryer HVAC exhaust es es es es es es es es 24

28 C Noise Impact Assessment December 2014 Group Identification Noise Source(s) Mitigation Pasteurisation/ refrigeration building Cooling Tower Dairy 4 5 Pasteurisation/ refrigeration building Ammonia compressor (x3) Future Pasteurisation/ New Refrigeration refrigeration building Ammonia Building compressor (x2) Pasteurisation/ Pasteurisation/ refrigeration building condenser (x3) Pasteurisation/ refrigeration building AHU HVAC Plant Area Evap Supply AHU HVAC Plant Area Dryer Supply AHU Acoustic screen to control noise propagation east and south. Screen to block and absorb noise emission of roof mounted chillers. This is a precautionary measure as there is very little margin for error at the nearest potentially impacted noise sensitive locations in particular at night. The addition of two future condensers will likely cause the night time limit to be exceeded at offsite NSLs Bagging Area HVAC Plant Area Bagging Supply Building and AHU Attenuator/ Enclosure provided by Supplier Associated Plant HVAC Plant Area Bagging Exhaust AHU HVAC Plant Area Lab/ control supply AHU HVAC Plant Area Lab/ control Mitigation Included in Impact Assessment No No No No No es es es es es es 25

29 C Noise Impact Assessment December 2014 Group Identification Noise Source(s) Mitigation exhaust AHU Fugitive Noise Milk pumps Selection of quietest available pumps Emissions from Milk 6 Intake Area and Sealed building envelope, keep windows and doors Boiler House Internal boiler house plant closed Mitigation Included in Impact Assessment n/a n/a 7 8 Access Road Traffic Noise Non normal operations 2.5 m high road side barrier (As per EIS specification) + es 2 m high earth berm Low noise road surface, similar to the following es technical details (The top layer should have an HGV traffic aggregate size of 8mm, the bottom layer of 16 to 22mm. The top layer reflects the dust, but lets the sound pass, which is absorbed in the bottom layer. These surfaces need to be cleaned regularly using high pressure water (e.g. twice a year). CHP Steam Release Attenuator (Silencer already incorporated) es CHP Over pressurisation Attenuator (Silencer) es 26

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35 Industrial Emissions Review Application Dairygold Mallow P Attachment No. I.8 ATTACHMENT N o I.8

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37 Industrial Emissions Review Application Dairygold Mallow P Attachment No. I.8 Table I.8 (i) CONCLUSIONS ON BAT Title of Document BEST AVAILABLE TECHNIQUES FOR FOOD, DRINK& MILK INDUSTRIES BREF BAT reference Number BAT Statement Applicability to installation Proposed/ in place ensure, e.g. by training, that employees are aware of the environmental aspects of the company s operations and their personal responsibilities y Back to Work Training each ear. All staff required to complete Environmental Module as prescribed training design/select equipment, which optimises consumption and emission levels and facilitates correct operation and maintenance e.g. to optimise y All equipment selected through specifications, technical analysis and using ISO SOP developed for this purpose the pipework system for the capacity to minimise product losses and install pipes at a gradient to promote self-draining control noise emissions at source by designing, selecting, operating and As above maintaining equipment, including vehicles to avoid or reduce exposure and, where further reductions in noise levels are required, enclosing noisy equipment operate regular maintenance programmes PM programme in place and moving to AMISS system apply and maintain a methodology for preventing and minimising the consumption of water and energy and the production of waste y This is incorporated at design stage for example condensate recovery for reuse in utilities. Daily Energy Reports will be established and utilities will be monitored as normal business practice and part of the GHG permit requirements implement a system for monitoring and reviewing consumption and emission levels for both individual production processes and at site level, to enable actual performance levels to be optimised maintain an accurate inventory of inputs and outputs at all stages of the process from reception of raw materials to dispatch of products and endof-pipe treatments This is part of the site Visual management system of Daily meetings Flow meters and totalisers on all incoming fluids and batch process control along with SCADA control at all stages. Weighbridge is used to weigh incoming raw materials and outgoing wastes and products. TOC and conductivity with flow monitoring is used internally to determine milk losses during processing minimise storage times for perishable materials Warehouse management and automated production systems controls all aspects of storage prevent materials from falling on the floor, Process controls minimise losses. Floors in process areas are internally sloped to process drain point Page 1 of 8

38 Industrial Emissions Review Application Dairygold Mallow P Attachment No. I.8 Title of Document BAT reference BAT Statement Number collect water streams, such as condensate and cooling water separately to optimise reuse avoid using more energy than needed for heating and cooling processes, without harming the product BEST AVAILABLE TECHNIQUES FOR FOOD, DRINK& MILK INDUSTRIES BREF Applicability to installation Proposed/ in place Motors on equipment are IE3 minimum, VSDs are used where appropriate, heat recovery systems are used minimise noise nuisance from vehicles New entrance removes traffic through town with associated apply storage and handling methods as concluded in the Storage BREF [95, EC, 2005] optimise the application and use of process controls to, e.g. prevent and minimise the consumption of water and energy and to minimise the generation of waste and in particular: 19.1 where heat processes are applied and/or materials are stored or transferred at critical temperatures, or within critical temperature ranges, to control the temperature by dedicated measurement and correction 19.2 where materials are pumped or flow, to control flow and/or level, by dedicated measurement of pressure and/or dedicated measurement of flow and/or dedicated measurement of level and using control devices, such as valves 19.3 where liquids are stored or reacted in tanks or vessels, either during manufacturing or cleaning processes, use level-detecting sensors and level measurement sensors 19.4 to use analytical measurement and control techniques to reduce waste of material and water and reduce waste water generation in processing and cleaning and in particular to: measure ph to control additions of acid or alkali and to monitor waste water streams to control mixing and neutralising prior to further treatment or discharge measure conductivity to monitor levels of dissolved salts prior to water re-use and detect levels of detergent prior to detergent re-use and y berm and screening. New internal site road structure Storage of materials complies with EPA guidance Conductivity control and metering with automation SCADA used throughout process with critical temperature monitoring and alarms Flow meters and totalisers with automated valves installed as appropriate Level transmitters and level switches In process testing including automatic on line sampling Installed as standard in the WWTP Conductivity of condensate is measured before reuse Page 2 of 8

39 Industrial Emissions Review Application Dairygold Mallow P Attachment No. I.8 Title of Document BAT reference BAT Statement Number use automated water start/stop controls to supply process water only when it is required remove raw material residues as soon as possible after processing and clean materials storage areas frequently provide and use catchpots over floor drains and ensure they are inspected and cleaned frequently, to prevent entrainment of materials into waste water BEST AVAILABLE TECHNIQUES FOR FOOD, DRINK& MILK INDUSTRIES BREF Applicability to installation N Proposed/ in place PLC controlled Automated CIP process is programmed Not done for food hygiene reasons optimise the use of dry cleaning (including vacuum systems) of ATEX rated vacuum systems included in dryer areas equipment and installations, including after spillages prior to wet cleaning, where wet cleaning is necessary to achieve the required hygiene levels fit cleaning hoses used for manual cleaning with hand operated triggers Installing high pressure foam cleaning system with trigger where appropriate select and use cleaning and disinfection agents which cause minimum harm to the environment and provide effective hygiene control operate a cleaning-in-place (CIP) of closed equipment and ensure that it is used in an optimal way by, e.g. measuring turbidity, conductivity or ph and automatically dosing chemicals at the correct concentrations N For food safety reasons caustic and hypochlorite solutions are used in cleaning Automated CIP process in place using conductivity flow and temperature controls for optimisation where there are suitable variations in the phs of the waste water streams from CIP and other sources, apply self-neutralisation of alkaline and acidic waste water streams in a neutralisation tank minimise the use of EDTA, by only using it where it is required, with the frequency Waste waters are neutralised in the wwtp balance tank system Caustic and acid are used as main cleaning agents Page 3 of 8

40 Industrial Emissions Review Application Dairygold Mallow P Attachment No. I.8 Title of Document BAT reference Number BAT Statement required and by minimising the quantity used, e.g. by recycling cleaning solutions BEST AVAILABLE TECHNIQUES FOR FOOD, DRINK& MILK INDUSTRIES BREF Applicability to installation Proposed/ in place avoid the use of halogenated oxidising biocides, except where the alternatives are not effective IN PLACE Materials reception/despatch when vehicles are parked and during loading and unloading, switch off the vehicle engine and the refrigerator unit, if there is one and provide an alternative power supply Centrifugation/separation operate centrifuges to minimise the discharge of product in the waste stream Evaporation use multi-effect evaporators optimising vapour recompression related to heat and power availability in the installation, to concentrate liquids Freezing and refrigeration prevent emissions of substances that deplete the ozone layer by, e.g. not using halogenated substances as refrigerants avoid keeping air conditioned and refrigerated areas colder than necessary optimise the condensation pressure optimise the condensation temperature Policy on site New highly efficient separators were purchased and installed as part of this project. These minimise the de-sludge waste These are proposed as part of the site redevelopment R717 refrigerant used (Ammonia) Room temperature control is used VSD control of fans by PLC Done by PLC control Cooling optimise the operation of cooling water systems to avoid excessive Automated dosing systems and blowdown systems with Page 4 of 8