attachment d1 - operational information requirements · cutting hall (mpc) unit operations 3.1.3...

Attachment D

Page D0-1

Attachment No. D: Infrastructure & Operation

Attachment D1 – Operational Information Requirements

Attachment D2 – Development & Operational History of Site

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Attachment D

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Attachment D1

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Attachment D1: Operational Information Requirements

1.0 Diagrams of activity Drawings of the items below are on the following pages • Each area of waste generation (DRAWING 06) • Emission points (DRAWING 07) • Pollution abatement measures employed (see DRAWING 07)

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2.0 List of Abatement/Treatment/Recovery Systems (see DRAWING 07)

2.1 Paint shop filters: the paint shop comprises a large open hanger 56m wide and 79m long. Six twin under floor extraction channels run parallel to each other along the floor leading to the six external extraction ducts outside the west wall (A2-1 to A2-6, formerly A1/A2/A5/A6/A7/A8). Each duct under the floor emerges into the paint shop by means of an array of steel grids (each approx. 1m2). The paint fume and overspray particles are drawn downward into the grids by means of extraction fans outside the west wall. Each grid is fitted with a pre-filter and a primary filter to arrest the flow of paint overspray particles from traveling though the extraction duct to atmosphere.

2.2 Emission point A2-7 (formerly licensed emission point A4) comes from a paint spray booth with and under-floor water curtain abatement system to extract paint overspray particles from the air stream. The overspray is collected by means of an automatic pro-aqua system and the addition of coagulation and flocculation agents to the water. The paint is skimmed off and collected in a filter bag where excess water drips off leaving non-hazardous paint waste for disposal.

2.3 A dry filter system is present up-stream from emission point A2-8 (formerly licensed emission point C1) to remove paint overspray from the automatic spray paint booth extraction system.

2.4 Two identical dry filter systems are present up-stream from emission points A2-9 and A2-10 (formerly a single licensed emission point E1, which was decommissioned) to remove steel dust from the plate steel cutting operations, which utilize plasma and oxygen-acetylene cutting processes.

2.5 A number of other systems exist in the plant but which do not give rise to any environmental emissions, neither in normal or potentially abnormal situations, i.e. extraction systems for shot-blasting processes.

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Attachment D1

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3.0 Unit Operation List A plan drawing of the facility is attached (DRAWING 08) with the name and reference number of each department. The unit operations in each department are listed below. Further details of each unit operations are presented with simple flow diagrams. Precise information is not presented for unit capacity and throughput as this would be misleading. – every container crane is custom-designed and manufactured and one crane may entail considerably more work than the next. The capacity and throughput in terms of production items per unit time is not possible.

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Attachment D1

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3.1 Cutting Hall (MPC) 3.1.1 Automatic Shot-blasting

3.1.2 Automatic Paint Priming

3.1.3 Plasma/Oxygen-Acetylene Cutting

3.1.4 Oxygen-Acetylene Chamfering

3.1.5 Machining Operations (saws, shears, bending, chamfering, cleaning, fettling, grinding)

3.1.6 Box Welding

3.2 Machine Room (MPM) 3.2.1 Machining Operations (lathes, milling machines, boring machines, drilling, grinding,

centering machine, saws, gear cutting)

3.2.2 Mechanical Assembly

3.3 Steel Fabrication / Welding (MPS/MPW/MPF) 3.3.1 Steel Fabrication (gas cutting/heating, welding, grinding)

3.3.2 Machining Operations (drilling, milling)

3.4 Layout (MPL) 3.4.1 Layout (trial assembly of crane sections)

3.5 Shotblasting & Painting (MPP) 3.5.1 Shotblasting

3.5.2 Painting

3.6 Final Assembly & Electrical Installation (MPA/MPE) 3.6.1 Machining Operations (drilling, shears, bending)

3.6.2 Mechanical Assembly (assembly of crane components)

3.6.3 Carpentry

3.6.4 Electrical Installation & Testing

3.7 Stores (FPM)

3.8 Transport (MST)

3.9 Canteen

3.10 Offices

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Cutting Hall (MPC) Unit Operations 3.1.1 Automatic Shot-blasting

• Flow Diagram

• Purpose: the purpose of the process is to clean raw steel of surface corrosion and mill scale, and to prepare the surface profile for adherence of paint.

• Process Control: process parameters are set via manual control panel by operators,

controlling speed and propulsion of shot. These are controlled by drive control logic, limit switches, etc. Waste steel shot is fed back into the feed hopper via conveyor elevator. Spent metal shot/dust is filtered, collected and removed for recycling.

• Environmental Emission Potential (normal): minor emission from LPG pre-heater, new

(proposed) emission point reference A3-19. Normal waste quantities.

• Environmental Emission Potential (abnormal): none envisaged

• Unit capacity & throughput: operates regularly through a 2-cycle shift

• Range of materials: see inputs in flow diagram

• Laboratory facilities: none.

Raw steel Electricity Steel Shot Compressed Air Dry filters LPG (for pre-heater)

Automatic Shot-blasting with LPG pre-heater

Production material: Clean Steel for cutting operations

Emissions (internal): air, noise

Emissions (to atmosphere): products of LPG combustion

Waste: steel shot/dust, dry filters

INPUTS OUTPUTS PROCESS

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Cutting Hall (MPC) Unit Operations 3.1.2 Automatic Paint Priming

• Flow Diagram

• Purpose: the purpose of the process is to prime steel profiles to prevent corrosion throughout the lengthy crane manufacturing process to preserve a suitable surface for application of paint after fabrication. The process is sporadic as plate steel is not primed – this can be cleaned again by shot-blasting prior to final painting.

• Process Control: process parameters are set via manual control panel by operators, controlling speed and paint film thickness. Parameters are controlled by drive control logic, limit switches, etc. Paint overspray is filtered before the VOC/air mix is channelled to atmosphere. Filters are changed at appropriate intervals as part of the preventive maintenance programme. Spent metal shot/dust is filtered, collected and removed for recycling.

• Environmental Emission Potential (normal): non-methane VOC emission to atmosphere. This emission point is currently licensed by IPC licence no. 146-01 as emission point reference C1, new (proposed) emission point reference A2-8. LCC has difficulty in meeting the existing emission limit value. LCC has submitted an air dispersion model report with this application. Normal waste quantities.

• Environmental Emission Potential (abnormal): LCC has difficulty in meeting the existing emission limit value of 150 mg/m3 Total Organics (as C).

• Unit capacity & throughput: In 2007 LCC used 4,260 litres of paint containing 2,731 kg of VOC having operated the machine for 996 hours in the year. The throughput each year can vary depending on total production output. The process would have the capacity to run continuously but this utilisation is unnecessary as only steel profiles are painted and this process is sporadic through a 2-cycle shift.



Paint primer base Curing Agent Solvent tool cleaner Steel for painting Electricity Dry filters

Automatic Paint Priming

Production material: Primed steel profiles for cutting operations

Emissions (to atmosphere): non-methane VOCs

Waste: Paint, solvent, dry filters


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Attachment D1

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Cutting Hall (MPC) Unit Operations 3.1.3 Plasma/Oxygen-Acetylene Cutting

• Flow Diagram

• Purpose: the purpose of the process is to cut steel plate for subsequent fabrication into crane components.

• Process Control: the cutting of the steel is a CNC-controlled process. The patterns to be cut

using the plasma or gas torch are designed on a PC and the pattern is transmitted electronically to the cutting machines. The steel plate is placed on the cutting bed with a crane and the extraction system draws the dust/fume downwards into a duct which is fed into a filtration plant comprising two emission stacks. The filters are self-cleaning with the dust being fed into collection sacks. The filtration plant is inspected as part of a preventive maintenance programme and filters changed as required.

• Environmental Emission Potential (normal): the dust extraction and filtration plant is a new

installation which replaced the existing plasma extraction system which was licensed by IPC licence no. 146-01 as emission point reference E1. The new plant is state of the art and both emission stacks produce emissions well below the licence limit for E1. The reference numbers for the new stacks are A2-9 and A2-10. Normal waste quantities.

• Environmental Emission Potential (abnormal): if the filtration system failed the dust

extracted from the plasma/gas machines could vent directly to atmosphere (concentration unknown).

• Unit capacity & throughput: the cutting machines currently operate on 2-cycle shift from

07:00 to 23:00 (with potential for further overtime) during which time the extraction system can be in operation.



Steel plate Electricity Compressed Air Oxygen Acetylene Dry filters

Plasma Cutting & Oxygen/Acetylene gas cutting

Production material: Steel plate for cleaning, chamfering and/or fabrication departments and machine room

Emissions (to atmosphere): heat, air, dust/fume

Waste: steel scrap, dry filters, metal dust


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Cutting Hall (MPC) Unit Operations 3.1.4 Oxygen-Acetylene Chamfering

• Flow Diagram

• Purpose: the purpose of the process is chamfer steel plate in preparation for welding.

• Process Control: entirely manual.

• Environmental Emission Potential (normal): no emissions to atmosphere. Normal waste quantities.


• Unit capacity & throughput: continuous operation though 2-cycle shift



Steel plate Electricity Oxygen Acetylene

Oxygen-Acetylene Chamfering

Production material: Chamfered steel plate for fabrication departments

Emissions (internal): dust/fume, products of gas combustion.

Emissions (to atmosphere: none

Waste: steel


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Cutting Hall (MPC) Unit Operations 3.1.5 Machining Operations (saws, shears, bending, chamfering, cleaning, fettling, grinding)

• Flow Diagram

• Purpose: the purpose of the machining processes is to cut steel raw material into desired lengths and shapes for steel fabrication and further machining processes in other departments.

• Process Control: these machining processes are operator driven in each case. The operator

specifies the desired outcome to the machine whereby the machine controls instruct the drives (where applicable) to adopt a desired position. Mechanical stops and limit switches are set as required to control the product dimensions.

• Environmental Emission Potential (normal): Normal waste quantities.

• Environmental Emission Potential (abnormal): none envisaged.




Electricity Steel Cutting Oil Machine tools

Mechanical metal machining: saws, shears, bending, chamfering, cleaning, grinding.

Production material: Steel profile and plate for fabrication departments and machine room

Emissions (internal): noise, dust, heat

Emissions (to atmosphere): none

Waste: Steel, cutting oil.


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Cutting Hall (MPC) Unit Operations 3.1.6 Box Welding

• Flow Diagram

• Purpose: the purpose of the process is to prepare welded steel box profile for MPF fabrication department.

• Process Control: the process is semi-automatic whereby the operator sets the travel speed of

the weld and the feed speed for the welding consumable electrode. The operator directly monitors the progress of the weld.

• Environmental Emission Potential (normal): one monitoring exercise was conducted on the

preparatory machine in August 2005. Particulates were measured at 143.1 mg/Nm3 with a flow rate of 1,650 Nm3/hr. Normal waste quantities.

• Environmental Emission Potential (abnormal): none envisaged in addition to normal

emission.




Electricity Steel Welding electrode Anti spatter release agent Carbon Dioxide Argon

Preparatory Machine for stitch welds (sporadic operation): Semi-automatic Metal Inert Gas (MIG) welding

Production material: Stitched box for principal machine

Waste: welding wire packaging, aerosols


Emissions (to atmosphere): welding fume

Principal Machine for seam welds (full-time operation): Semi-automatic Metal Inert Gas (MIG) welding

Production material: Steel box profile for fabrication departments

Emissions (internal): negligible (fumes filtered)

Waste: welding wire packaging, aerosols

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Machine Room (MPM) Unit Operations 3.2.1 Machining Operations (lathes, milling machines, boring machines, drilling, grinding,

centering machine, saws, gear cutting)

• Flow Diagram

• Purpose: the purpose of the machining processes is to shape metals and plastic raw materials into desired shapes and sizes for crane components to be assembled in other departments.

• Process Control: these machining processes are primarily operator driven in each case – 2

lathes are DNC controlled. The operator sets the required speeds and feeds to produce the required product dimensions.


• Environmental Emission Potential (abnormal): an uncontrolled oil spillage (max. 200 L)

might exit the building into surface water drain.

• Unit capacity & throughput: some machines operate continuously though 2-cycle shift, but most work a single shift.



Electricity Steel Bronze Plastics Oils & Lubricants-coolant, hydraulic and gear oil Cutting tools Packaging

Mechanical metal machining: lathes, milling machines, boring machines, drilling machines, grinding machines, centering machine, saws, slotting machine, gear cutting machines.

Production material: Machined steel fabrications, axles, gears, rope drums, etc., for crane component assemblies

Emissions (internal): noise


Waste: Waste metals, cardboard, oils, plastic waste (negligible)


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Machine Room (MPM) Unit Operations 3.2.1 Mechanical Assembly

• Flow Diagram

• Purpose: the purpose of the process is to assemble crane components produced by other processes into crane components. These components will be either incorporated into larger assemblies in the Final Assembly department or shipped to crane erection sites to form part of a complete crane as appropriate.

• Process Control: the process is conducted and controlled manually.


• Environmental Emission Potential (abnormal): an uncontrolled oil spillage (max. 200 L)

might exit the building into surface water drain.

• Unit capacity & throughput: continuous operation though a single shift



Components for assembly Hydraulic & gear oils Grease Electricity Compressed air Welding, grinding (minimal) Packaging

Mechanical crane component assembly.

Product: Assembled crane components

Emissions (internal): noise, welding fume


Waste: Oily rags, waste cardboard, general household waste


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Steel Fabrication / Welding (MPS/MPW/MPF) Unit Operations 3.3.1 Steel Fabrication (gas cutting/heating, welding, grinding)

• Flow Diagram

• Purpose: the purpose of the process is to fabricate crane sections.

• Process Control: these processes are generally manually controlled – some semi-automatic welding machines are operating. All process stages are directly carried out and/or monitored by an operator.

• Environmental Emission Potential (normal): the fabrication departments are equipped with

general area ventilation fans to the external environment. Normal waste quantities.





Electricity Steel Welding electrode Anti spatter release agent Acetylene Carbon Dioxide Argon Oxygen Compressed Air Grinding consumables Packaging

Production material: Fabricated crane components


Steel Fabrication:

Oxygen-acetylene gas cutting/heating

Metal Inert Gas (MIG), Metal Active Gas (MAG) and Manual Metal Arc (MMA) welding

Grinding

Emissions (internal): welding fume, grinding dust, products of gas combustion

Emissions (to atmosphere): as above through the general area ventilation fans, doors and windows

Waste: metal, general household, wood, cardboard, aerosols

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Steel Fabrication / Welding (MPS/MPW/MPF) Unit Operations 3.3.2 Machining Operations (drilling, milling)

Several large milling/boring and drilling machines are present in the steel fabrication departments

• Flow Diagram

• Purpose: the purpose of the process is to trial assemble crane components and make any necessary adjustments so that the components will assemble correctly on crane erection sites.

• Process Control: manually controlled by skilled operators using jigs, shims, overhead

cranes, and metrology equipment.






Electricity Crane components

Trial Assembly of components

Production material: crane components



Waste: none


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Layout (MPL) 3.4.1 Layout (trial assembly of crane sections)

• Flow Diagram

• Purpose: the purpose of the process is to machine crane components for subsequent mechanical assembly operations.

• Process Control: these processes use machines with manually operated internal drive system

speed and feed control.






Electricity Steel Crane components Cutting tools

Mechanical Machining: Milling/boring machines; drilling machines.

Production material: Machined steel fabrications and crane components



Waste: Waste metals, oils


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Shotblasting & Painting (MPP) 3.5.1 Shotblasting

• Flow Diagram

• Purpose: the purpose of the process is to clean crane components and prepare the surface profile for adherence of paint.

• Process Control: compressed air pressure range for propulsion of steel shot to achieve

desired component surface roughness values governed by pressure sensors in compressor system. Dust is taken from the shot-blast hall by an internal extraction and filtration system and air fed back into the hall. Steel shot on the floor is collected in underground channels serviced by a conveyor system leading back to the shot-blast plant. Spent shot is separated and removed, and reusable shot is fed back into the system.






Crane Components Electricity Steel Shot Compressed Air Dry filters

Semi-automatic Shot-blasting using robot arm and operator cabin: reusable shot recovered automatically; spent shot/fine dust collected

Production material: Clean crane components for painting operation

Emissions (internal): air, noise, dust


Waste: steel shot/dust, dry filters


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Shotblasting & Painting (MPP) 3.5.2 Painting

• Flow Diagram

• Purpose: the purpose of the process is to paint the product to provide sufficient protection against corrosion in an aggressive marine environment.

• Process Control: the temperature and humidity of the paint hall is kept within a specified

range by means of an LPG-fired air heater and temperature/humidity monitoring to control the quality of the paint as it dries – an alarm is produced in the supervisor’s office as a prompt to turn on the heating system. Mixing of paint and curing agent is performed manually with the aid of pneumatic tools and the paint is manually sprayed with pneumatic powered paint pumps by skilled painters. Paint film thickness is controlled by the skill of the painter supplemented with regular quality control checks. Solvent emissions from the paint are extracted from the large paint shop via under-floor extraction ducts to atmosphere with paint overspray arrested by dry filters at the entrance to the extraction grids, the filters being changed at appropriate intervals. Paint overspray is arrested in the small internal spray booth by a water curtain abatement system with paint solids extracted by addition of coagulation and flocculation agent and automatic removal.

• Environmental Emission Potential (normal): non-methane VOC emission to atmosphere

discussed in attached Solvent Management Plan – to be agreed with the Agency. Normal waste quantities.

• Environmental Emission Potential (abnormal): None envisaged except in the case of an

emergency situation, e.g. fire, spillage.

• Unit capacity & throughput: In 2007 LCC used 177,416 litres of paint in the paint shop containing 78,893 kg of NMVOC operating over a 2-cycle shift. 17 ship-to-shore (STS) container cranes and 16 rubber tyre gantry (RTG) cranes were painted, some parts of which

Steel product Solvent-based paints Curing Agents Paint Solvents Solvent tool cleaner Electricity Water Compressed air Extraction filters Coagulation agent Flocculation agent Painting consumables (brushes, masking tape, etc.)

Manual Spray Painting, solvent cleaning of paint equipment

Production material: Painted product components

Emissions (to atmosphere): non-methane VOCs

Waste: Paint, solvent, dry filters, paint drums and cans, paint consumables (brushes, etc.), water


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were painted during the previous and following calendar years. The throughput each year can vary depending on total production output.



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Final Assembly & Electrical Installation (MPA/MPE) 3.6.1 Machining Operations (drilling, shears, bending)

• Flow Diagram

• Purpose: the purpose of the machining processes is to cut and form material into desired lengths and shapes for final assembly to the painted steel crane fabricated components as part of the final assembly operations.

• Process Control: standard machine controls, manually set and operated.


• Environmental Emission Potential (abnormal): emergency oil spillage (good bunding and

proprietary spill kits in place).

• Unit capacity & throughput: single daily shift



Electricity Steel Cutting Oil Machine tools

Drilling machine, Plate shears, Bending machine, Portable machine tools (drills & saws)

Production material: Mechanical components, formed steel and aluminium for assembly processes



Waste: Steel, cutting oil (negligible).


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Final Assembly & Electrical Installation (MPA/MPE) 3.6.2 Mechanical Assembly (assembly of crane components)

• Flow Diagram

• Purpose: the purpose of the mechanical assembly process is to assemble component items to prepare the product for final despatch.

• Process Control: operational controls, manual tasks controlled by operators.


• Environmental Emission Potential (abnormal): emergency oil spillage (good bunding and

proprietary spill kits in place).




Components for assembly, Hydraulic & gear oils, Air conditioning fluid, Diesel (small quantity), Grease, Wood, Electricity, Compressed air, Packaging

Manual assembly by skilled fitters using manual and powered hand tools (hammers, screwdrivers, wrenches, drills, etc.) Welding, grinding (minimal, see 3.3 above) Some manual brush touch-up painting (see 3.5 above)

Production material: Finished product (crane components) for despatch, and crane components for electrical installation and testing.



Waste: Steel, oil, wood, cardboard, general household waste


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Final Assembly & Electrical Installation (MPA/MPE) 3.6.3 Carpentry

• Flow Diagram

• Purpose: the purpose of the carpentry process is to produce timber packaging for shipping of product.

• Process Control: manual operation of process.

• Environmental Emission Potential (normal): Filtered from local extraction on saws.

Normal waste quantities.

• Environmental Emission Potential (abnormal): none anticipated.




Electricity Wood Compressed air

Cutting with saws, sanding, wooden box fabrication using pneumatic nail gun.

Production material: Wood packaging


Emissions (to atmosphere): air (local extraction on saws – filtered)

Waste: Wood, wood chip, saw dust


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Final Assembly & Electrical Installation (MPA/MPE) 3.6.4 Electrical Installation & Testing

• Flow Diagram

• Purpose: the purpose of the carpentry process is to produce timber packaging for shipping of product.

• Process Control: manual operation of process.

• Environmental Emission Potential (normal): Filtered from local extraction on saws.

Normal waste quantities.





Electricity Wiring & Electronics Transformers Electric bulbs Crane switchgear

Manual wiring of crane components and testing of drive systems.

Production material: Finished product for despatch


Emissions (to atmosphere): air (local extraction on saws – filtered)

Waste: Wood, wood chip, saw dust


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3.7 Stores (FPM)

• Flow Diagram

• Purpose: the purpose of the stores process to receive material for use in the production of product and general administration of the company. This stock is issued to the required departments as appropriate.

• Process Control: operational control through direct management and supervision of the

stores process.


• Environmental Emission Potential (abnormal): Accidental spillage of oils/paints (emergency response plan in place).




Crane components for production Materials for company administration Cardboard & wood packaging Metal banding Polystyrene filler Plastic bags

Receipt and unpacking of stock, storage of stock, issue of stock to departments, packaging and despatch of spare parts to customers, packing of tools and equipment for crane erection sites.

Material: stock

Emissions (internal): none


Waste: Wood, plastic packaging, cardboard


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Attachment D1

Page D1-27

3.8 Transport (MST)

• Flow Diagram

• Purpose: the purpose of the transport process to move material and components around the factory as required for production and to prepare product for final despatch from the factory.

• Process Control: operational control through direct management and supervision of the

transport process.

• Environmental Emission Potential (normal): Vehicle emissions; Normal waste quantities.

• Environmental Emission Potential (abnormal): Accidental spillage of oils/paints (emergency response plan in place).




Mobile Cranes Forklifts Tractor Unit Diesel Lifting Accessories

Lifting and transport of material and components within factory grounds and preparation for despatch.

Material: Product


Emissions (to atmosphere): emissions from vehicles

Waste: Wood, plastic packaging, cardboard


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Attachment D1

Page D1-28

3.9 Canteen

• Flow Diagram

• Purpose: the purpose of the canteen process is to provide food.

• Process Control: operational control through direct management and supervision of the canteen process.

• Environmental Emission Potential (normal): Normal kitchen extraction; Normal waste

quantities.





Food and drink, Packaging Wash-up liquid, etc.

Cooking and wash-up Material: Food for consumption

Emissions (internal): food smells, heat

Emissions (to atmosphere): extraction from kitchen.

Waste: Food, packaging, grease


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Attachment D1

Page D1-29

3.10 Offices

• Flow Diagram

• Purpose: see process description in flow diagram.

• Process Control: operational control through direct management and supervision.






Electricity Paper Ink & Toner Photocopiers PC’s Printers Scanners Fax machines Phones, etc.

Sales & Marketing, Product Design, Purchasing, Production Planning, Customer Service, Financial Administration, General Management & Administration, etc.

Material: Service



Waste: Paper, ink/toner cartridges, WEEE, general household, etc.


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Attachment D1

Page D1-30

this page is intentionally blank

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Attachment D2

Page D2-1

Attachment D2: Development & Operational History of the Site

The following document entitled PRODUCT and COMPANY PROFILE, LIEBHERR CONTAINER CRANES LTD is attached.

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PRODUCT and COMPANY PROFILE

LIEBHERR CONTAINER CRANES LTD

Liebherr Container Cranes Ltd

Killarney, Co. Kerry Ireland Tel.: +353-64-70200 Fax.: +353-64-31602 E-mail: [email protected] Website: www.liebherr.com

PMD-Version 04/07

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CONTENTS

1. LIEBHERR GROUP

2. THE MARITIME SECTOR

3. LOCATION

4. HISTORY

5. FINANCIAL

6. PERSONNEL

7. EXPERIENCE

8. DESIGN

9. PRODUCT

10. PRODUCTION

11. QUALITY CONTROL

12. WELDING CERTIFICATE

13. ISO CERTIFICATE

14. TESTING

15. TRANSPORTATION and SHIPPING

16. CRANE INSTALLATION and COMMISSIONING

17. TRAINING

18. SAFETY—ENVIRONMENT

19. AFTER SALES SERVICE and SPARE PARTS

20. ORGANISATION PLAN OF LCC

21. SUMMARY OF GROUP COMPANIES

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The Liebherr Group

Among the products and services offered by the LIEBHERR group are:

• Maritime cranes • Earth-moving equipment • Mining equipment • Mixing technology • Tower cranes • Mobile cranes • Crawler cranes • Cargo handling • Aircraft equipment • Machine tools • Material-flow technology • Refrigerators, freezers • Industrial consultancy • Hotels

The company, founded in 1949 by Dr.Ing E.h.Hans Liebherr, is today an international group of more than 100 companies, on every continent of the world - with 23,762 employees. The group’s turnover in 2005 was 5,305.0 Mill. Euros. The Group is decentrally organised and consists of company units and divisions of practical size with responsibility for their own activities. Liebherr-International AG of Bulle, Switzerland, is the holding company. It has a direct or indirect 100 % share in all Group subsidiaries. Liebherr-International AG is owned entirely by members of the Liebherr family.

Company founder Dr.Ing.E.h. Hans Liebherr

The proprietors Dipl. Kfm. Isolde Liebherr and Dipl.Ing. Willi Liebherr

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LIEBHERR Maritime cranes

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LIEBHERR CONTAINER CRANES LTD

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LOCATION

FACTORY BUILDINGS

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The Company's offices and manufacturing plant are located at: Fossa, Killarney, County Kerry, Republic of Ireland The Company is registered as a limited liability company according to the laws of the Republic of Ireland and its registered office is at 90, South Mall, Cork, Ireland. Certificate of Incorporation Number 16968

in Killarney, Co. Kerry / Republic of Ireland

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LIEBHERR (Ireland) Ltd. was established in 1958 in Killarney in the south-western part of the Republic

of Ireland. It was the first LIEBHERR factory set up outside of Germany. The initial products manufactured were

large tower cranes for the English-speaking world and for many years the world's largest tower cranes were built in Killarney by LIEBHERR.

In 1967, LIEBHERR in Ireland began to manufacture container gantry cranes, initially for the Irish and U.K. markets, but subsequently spreading its activities world-wide. Involvement in the container crane business necessitated that, besides design and manufacturing facilities, this new and specialised business also called for other skills, such as shipping

and erection facilities, language and marketing expertise, after-sales service and spare parts provision. In order to provide these various services and skills, a new Company, LIEBHERR CONTAINER CRANES LTD., was set up in 1972 and this Company is now responsible

within the LIEBHERR group for world-wide marketing, design, manufacture, delivery, erection and servicing of rail-mounted quayside container cranes and container stacking cranes.

In 1999 LIEBHERR CONTAINER CRANES LTD added Rubber Tyre Gantry Cranes to the production

programme.

HISTORY

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The Share Capital of LIEBHERR Container Cranes Ltd. is € 2,000,000 and is ultimately

held by LIEBHERR-INTERNATIONAL AG of Bulle, Switzerland. LIEBHERR Container Cranes Ltd. annual turnover in 2006 amounted to over 100 million

Euros. Bank references may be obtained from:

CITIBANK EUROPE PLC 1, North Wall Quay, Dublin 1, Republic of Ireland BANK OF IRELAND LTD., Lower Baggot Street, Dublin 2, Republic of Ireland

PERSONNEL The Executive Directors of LIEBHERR CONTAINER CRANES LTD. are Pat O’Leary, John Coffey and Gerhard Frainer with responsibility respectively for Sales /

Design/ Manufacturing / and Financial affairs. The total number of employees is 450.

FINANCIAL

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EXPERIENCE LIEBHERR has been manufacturing container cranes since 1967 and has supplied over 285 of such cranes to the following countries:

Argentina Australia Barbados Belgium Canada Costa Rica Croatia Egypt Finland France Germany Iran Ireland Italy

Jordan Lebanon Malaysia Malta Morocco Netherlands New Zealand Nicaragua Norway Pakistan Philippines Poland Portugal Russia Saudi Arabia

Singapore South Africa Spain Sri Lanka Sweden Trinidad Tobago Turkey Ukraine United Arab Emirates United Kingdom U.S.A. Yemen

REFERENCES LIEBHERR has no doubt that any of the owners or operators of existing LIEBHERR container cranes will be happy to provide any reference or answer any enquiry, which a prospective LIEBHERR customer may have. All cranes customers and relevant contacts are provided in our crane reference list.

Cranes Liebherr customers

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DESIGN LIEBHERR has for many years a policy of retaining total crane project control under one roof. All

cranes are, therefore, fully designed in the factory in Killarney by LIEBHERR’s design team using specially prepared and standard structural analysis programmes and computer-aided-design (CAD) facilities. The equipment used is 32bit & 64bit computers with WindowsXP operating

system and HP Unix server. The software used is ProEngineer for 3D and ME10 for 2D, with Ansys & Enfram as FE packages. Promis & E3 are used for electrical design. All fabrication is

also carried out in Liebherr’s works, thus ensuring that our stringent quality control procedures are fully observed and that interface problems do not arise between structural, mechanical and

electrical crane systems

LIEBHERR first entered the container crane market by supplying cranes for small ports and for operation on feeder vessels, and was the undisputed world leader for such cranes.

Since 1976 LIEBHERR has applied this experience gained in that market to develop its own

special design for large, high-speed container cranes destined to operate in major international ports on Panamax, Post-Panamax and Super Post Panamax container vessels. The success of this type of crane is demonstrated by the installation and operation in the following ports with up to 13 cranes per port:

Manila, Philippines Rouen, France Tauranga, New Zealand Corinto, Nicaragua Sharjah, U.A.E. Colombo, Sri Lanka Aqaba, Jordan Alexandria, Egypt Limon, Costa Rica Sete, France Buenos Aires, Argentina Rotterdam, Netherlands Harwich, U.K. Belfast, Northern Ireland Montreal, Canada New York , USA Odessa Port, Ukraine

Wilmington, N.C., U.S.A. Port Said, Egypt Halifax, Canada Dublin, Ireland Bandar Shahid Rajai, Iran Lyttelton, New Zealand Khorfakkan, U.A.E. Dubai, U.A.E. Fujairah, U.A.E Barcelona, Spain Jeddah, Saudi-Arabia Port of Spain, Trinidad Thamesport/ U.K. Felixstowe, U.K. Liverpool, U.K. Giao Tauro, Italy Lisbon, Portugal

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LIEBHERR has kept pace with developments in design and technology over the past two decades and in many cases has been the world leader in such developments. Special design features can be offered, such as, for example:-

• trim, list and skew systems for the spreader • anti-snag system • slew system (±190°) for the trolley • spreader anti-sway system • A.C. or D.C. motors with Liebherr digivert thyristor and AC inverter controls • computerised fault-finding and crane management systems • automation and computerisation of crane operations • data communication between cranes PLC and port engineering office and to Liebherr's

service department • special designs for tropical, hurricane and seismic conditions • special long travel drive/structural design allowing crane travel on curved/misaligned quay

rails • Litronic EMS Electronic Monitor System for container cranes • personnel lift • a full range of lifting equipment, including automatic fixed length or telescopic spreaders;

hookbeams for general cargo LIEBHERR has manufactured in the past a range of fixed length and telescopic spreaders (of which well over 300 have been supplied to date) and general cargo hookbeams.

TECHNICAL EXCELLENCE

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THE PRODUCT RANGE LIEBHERR CONTAINER CRANES LTD manufactures, delivers, installs and services the follow-ing product range on a world wide basis: Rail-mounted quayside container gantry cranes up to Megamax size Rail-mounted container stacking cranes Rubber-tyre stacking cranes Lifting accessories

The ship-to-shore-container cranes are manufactured according to individual customer's requirements. Features of the Liebherr Ship-to-Shore Gantry include:

• High Hoist and Trolley speeds resulting in short cycle time (70/175 m/min Hoist and 240m/min Trolley).

• Simultaneous Hoisting, Trolley Travelling and Gantry Travel as standard. • Twinlift Operation up to 65 Tonnes. (2 x 32.5 Tonnes). • Tandem Lift Operations up to 80 Tonnes. (2 x 40 Tonne Containers). • The latest Speed Control Systems (Liebherr Digivert Thyristor and Acvert Speed Control). • Sophisticated Crane Management System providing extensive operational and crane per-

formance data. (Visuscan). • Proven Mechanical Anti-Sway System. • High reliability/availability figures with MTBF values of less than 0.2% per annum. • Fault Monitoring / Maintenance Support direct from the Liebherr factory via Fibre Optic,

RF Link / LAN and Modem. • Stable, rigid, sway resistant, high quality steel structure design.

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Rubber tyre gantry cranes RTG from Liebherr come in a variety of models with spans of between 5 and 8 containers wide (plus a truck lane) and hoisting heights between 1 over 3 to 1 over 6 containers. The Liebherr RTG is available in either 8 or 16 wheel configuration. Features of the Liebherr Rubber Tyre Gantry include:

• AC or DC Liebherr Drive Control System’s. • High hoist and traverse speeds resulting in short cycle time. (18-56 m/min hoist and 70 m/min transverse). • Gantry Travel Speed range is 70/130 m/min. • Simultaneous hoisting, trolley travelling and gantry travel motion is possible. Inching is available. • Gantry travel and trolley travel with rated load while carrying a 40.6 Tonnes container. • Twinlift operations up to 65 Tonne S.W.L. • Latest technology for G.P.S. Automatic Steering and Container Location Systems. • Electronic Fault Monitoring/memory and Electrical Check System (Visuscan). • Dual Steering System for responsive alignment with two and four wheel steering being driven on selection. • Accurate and responsive load control with proven Liebherr drive technology. • Facility for 360º spin turning on it’s own axis. • Unique anti-sway hoist rope reeving resulting in zero load sway and therefore very high productivity potential. • Trim and Skew functions for adjustment of the ropes and hence, adjustment of the spreader/container combination. • Diesel Generator set with Electronic Control. • Up to 30% of spare parts compatibility with Liebherr Gantry Cranes.

RUBBER TYRE GANTRY CRANE

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STACKING CRANES

Stacking cranes are manufactured according to individual customer’s requirements. Features of the Stacking Cranes include:

• High Hoist and Trolley speeds resulting in short cycle time (70/150 m/min Hoist and 200m/min Trolley).

• Simultaneous Hoisting, Trolley Travelling and Gantry Travel as standard. • Twinlift Operation up to 65 Tonnes. (2 x 32.5 Tonnes). • The latest Speed Control Systems (Liebherr Digivert Thyristor Speed Control). • Sophisticated Crane Management System providing extensive operational and crane perform-

ance data. (Visuscan). • Unique anti-sway hoist rope reeving resulting in zero load sway in all planes. • High reliability/availability figures with MTBF values of less than 0.2% per annum. • Fault Monitoring / Maintenance Support direct from the Liebherr factory via Fibre Optic, RF Link /

LAN and Modem. • Stable, rigid, sway resistant, high quality steel structure design. • Spare part compatibility with LIEBHERR Ship-to-Shore Cranes. • Driver’s Cabin Control

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THE PRODUCTION

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MATERIALS All structural steel used conforms to EN 10025. High tensile steel quality S355J2G3 (formerly

DIN 17100:1980, St 52-3) is used for the principal structural elements, while lighter items such as ladders, platforms, etc. are made from mild steel quality S235JR (formerly DIN 17100:1980, St 37-2). The type of steel is therefore suitable for dynamically loaded steel structures. Steel used for mechanical parts includes E295, E335, E360, 42CrMo4, 35NiCr and 16MnCr.

In addition to carrying out the steel fabrication, LIEBHERR also machines in its own works

mechanical components, such as wheels, rope drums, gears, pulleys, twistlocks, structural pins, etc. Other mechanical components are sourced exclusively from reputable and reliable West European suppliers.

The cranes' control and switchgear panels are designed and manufactured by our sister-

company, LIEBHERR Werk Biberach GmbH in Germany, to the specification of LIEBHERR CONTAINER CRANES LTD. The switchgear components used are supplied by well-known manufacturers, such as for example SIEMENS, ABB, G.E., Phoenix, etc. Electronic drive modules are manufactured by LIEBHERR.

The main electric motors are purchased from reputable international suppliers such as AEG/

LDW, SIEMENS, G.E., ABB, and Thrige Scott The crane electrical systems are specifically designed for container crane application and the

design combines maximum operational efficiency and reliability with ease of maintenance and economy in respect of spare parts stocks.

Overall design and manufacturing responsibility for all materials whether manufactured in

house or purchased, rests with LIEBHERR, who will pursue any guarantee or defect claim. Materials flow and production control is computer-controlled with high-speed real time data

links between various departments.

MANUFACTURING All structural steel is shot-blasted to Swedish Standard SIS 05 5900 - SA 2 1/2, either by

automatic process or by manual blasting in order to remove all mill scale and corrosion prior to start of manufacture.

Where LIEBHERR's standard paint system is used, a shop-primer with a thickness of 15 to 25

microns is applied immediately after the shot blasting of the lattice construction. Cutting and preparation for manufacturing is performed by mechanical saws, shears and

computer controlled oxy-acetylene and plasma gas cutting. A 400 tonnes bending machine, two Pullmax chamfering machines, computerised belt sander and gas chamfering are also employed in this process.

Production welding is carried out by semi-automatic, automatic and fully automatic processes

using electrode sizes from 1.0 mm to 4 mm and CO2 or mixed gas for shielding as well as using submerged arc process.

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All welders are tested according to EN 287 and audited by the German Welding Institute (SLV) in Munich and are controlled and certified according to the requirements of the quality control programme.

In general all the steel used in production is shot-blasted prior to fabrication. Re-shotblasting of

the finished components is performed in a large 66 m x 12 m blast hall by Blastrobot and manual blasting, a blast material recovery/recycling system being employed in this process. The paint system is only applied after the finished components are sandblasted and cleaned.

All paints are approved by the Department of Trade and Industry, London and by the Danish

Government Inspectorate of Ships. As a rule, the paints are supplied by either Hempel Marine Paints, International Paint or Tikkurila Coatings, all of whom are internationally known suppliers of specialised paint systems for maritime environments and under whose advice and controls the paints are applied in LIEBHERR's works in a controlled, heated environment.

PRODUCTION AREA Total Area 132,000 m2 Covered Area 53,439 m2 Office Floor Area 5,150 m2

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PRINCIPAL PRODUCTION MACHINERY Drying, shotblasting and priming plant for all profiles and plates up to a maximum width of 4,000 mm. Shotblasting hall for manual blasting 12m x 66m with re-cycling blast material system and extensive

extraction and heating systems. Blastrobot and manual blasting. Saws with power driven feed and discharge . Circular Band Saw with automatic feed for up to 360

mm. diameter material. Plate shears for shearing up to 15 mm. plate thickness and 2500 mm. plate widths. CNC tape network and fibre optic link controlled gas cutting co-ordinate machines (2x26 m long) with

cutting capacities up to 200 mm. thick plate. Acetylene/Oxygen and Plasma cutting using down draft tables with fine dust filters.

Bending machine with bending strength of 400 tonnes and bending width of 4000 mm. Deburring machine for smaller steel parts. Plate grind/cleaning machine CNC controlled lathes with up to 610 mm. turning diameter and 1500 mm. distance between centres. Conventional centre and turret lathes with up to 2400 mm. turning diameter and 4000 mm. between

centres. Vertical and horizontal milling and boring machines with up to 4000 mm. of vertical travel and 5000

mm. of horizontal travel. Gear hobbing machines for up to 900 mm. diameters and 350 mm. gear wheel widths. Cylindrical grinding machines for up to 450 mm. diameter and 600 mm. between centres. Drills with capacities up to 180 mm. dia. in solid. All welding by semi-automatic mig. (CO2 and mixed gas) welding with centralised supply system for

CO2 4 Semi-automatic rail mounted CO2 and submerged arc welding machine for weld lengths up to 50 m. Centralised acetylene and oxygen supply system. Heated and ventilated paint spray hall 55 m. x 77 m., and 22 m. x 28 m. with heating and extraction

systems and conveyor systems for smaller items with spray booth and drying oven. 110 Pillar cranes with capacities ranging from 0.25 tonnes to 4 tonnes. 46 Overhead cranes with capacities up to 80 tonnes. 17 wall creeper cranes ranging from 3 tonnes to 5 tonnes 10 Fork Lift trucks, 1.6 - 8 tonnes. 5 Mobile cranes with up to 90 tonnes capacity. 6 vacuum lifting frames with capacities ranging from 1 t to 7.1. tonnes. Assembly in the horizontal plane of all structural components is carried out in a specially designed

layout hall of 50 m. x 60 m. free space, with super-level floor using four 40 tonne overhead cranes with micro speed control.

Final assembly is carried out in a specially designed hall of 36 m x 122 m and 20 m clearance under

the 80 t SWL crane hooks. Test stations allow comprehensive testing of all mechanical, electrical components prior to delivery

from factory.

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QUALITY CONTROL WELDING CERTIFICATION All welding processes are certified by the Welding Institute in Munich, Germany, which issues a

comprehensive form of verifications which is available on request. The verification certification is issued for DIN 18800, part 7, Section 6.2. (steel structure,

predominantly static loaded) and according to DIN 15018 (steel structure predominantly dynamic loaded) using base materials S235 (ST37), S275 (St44) and S355 (ST52) according to DIN EN 10 025 and acc. to DIN 18800, part 1, version 1990.

All the following processes used are approved:

• active gas metal arc welding (135,tMAG/vMAG) • Flux-cored wire metal-arc welding with active gas shield (136) • manual arc welding with covered electrodes (111,E), • submerged arc welding (12, UP).

Qualified and graduate welding engineers and welding technicians are also certified by the Welding Institute Munich, Germany, as are the welding supervisors according to the requirements of above Standards and EN 719.

All welders are certified according to EN 287 for all the materials and processes in use. Where required, special welding tests or welding processes are certified on request. Such

certification may be made by the various Inspection Companies, Classification Companies and/or individual clients.

IN-HOUSE CONTROL The Quality Control Department is staffed by a dedicated team of trained and experienced inspectors.

Responsibilities include checking of all incoming goods, maintaining a check of processes and parts during manufacture, workshop testing and control of the despatch of cranes and spare parts.

Incoming structural steel is checked for physical dimensions and defects upon receipt. Random

ultrasonic checks for laminations are carried out during all stages of manufacture. Welds and the correct preparation for welding are inspected visually and by NDT (Non-destructive testing). Selected welds from static calculations are also subjected at varying stages to a rigorous programme of the most suitable form of NDT for the particular weld, be it radiographic, ultrasonic, dye penetrant or magnetic particle. The LIEBHERR Quality Control Department is staffed by personnel who are trained both by the Company and outside agencies in these techniques.

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Radiographic weld testing is carried out as required by the various standards and/or by special

request of the client, in conjunction with approved companies specialising in this technique. As part of our welding procedure specification approval according to EN 288 destructive testing is

conducted on weld samples prior to use in the production process. All electro-mechanical drives are fully test-run in the factory using actual crane cables, switchbox,

cabin and control panels. All gear boxes are test-run for several hours. All crane sections are trial assembled during production to ensure proper fit. Accurate measurements are taken and recorded of all frame-assemblies, which ensures trouble-free crane assembly and operation on site.

Certificate and assembly record files are delivered with every crane which contain information on

the types of motors, brakes, switches, gears, etc. as fitted prior to despatch. Certificates are also supplied in respect of each spreader, twistlock, hook, steel plates and wire rope, etc. despatched.

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TESTING

All crane main drives are fully test run prior to despatch

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TRANSPORTATION / SHIPPING LIEBHERR have extensive experience in shipping of cranes to all parts of the world. Cranes are normally exported by charter vessel through the local port of Fenit which is located

approximately 40 km. from the factory. Mobile cranes up to a capacity of 500 tonnes are available for the loading of parts in cases where

gearless vessels are used. In order to speed up the on-site installation, the crane sections are assembled to the maximum

extent possible prior to loading on the sea-going vessel. For convenience, shipment is normally done on self-geared vessels with overall length of up to

150 m with on-board cranes of 100-300 t. capacity for lifting crane pieces, which may be up to 75 m in length and 130 t. in weight.

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CRANE INSTALLATION Installation planning is carried out by LIEBHERR engineers, in close co-operation with the

client and with local installation companies, crane hire firms etc. at the installation location. All crane installations are undertaken by and under the supervision of, trained LIEBHERR

personnel. The Crane Installations Department is staffed by skilled and experienced engineers who have been selected on the basis of outstanding ability demonstrated in their various skills. Their wide international experience under a variety of working and climatic conditions has contributed greatly to LIEBHERR's world-wide success.

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TRAINING Regular training and retraining courses are arranged to up-date information and developments for technical staff of new and existing clients, as well as LIEBHERR personnel. On a number of occasions each year a two-week training course, one week mechanical and one week electrical, is held at our works in Killarney which can be attended by customers who wish to participate. Training is subdivided into individual modules, each of which deals with different aspects of the crane. The tutors delivering both courses have many years of experience in the fields of design, production, crane erection, troubleshooting and maintenance. The courses will therefore be practical and interactive as well as theoretical. The theoretical element will be in the form of classroom lectures and the practical element in the form of visits to the relevant production areas.

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SAFETY AND ENVIRONMENT

LIEBHERR is committed to the highest safety and health procedures and has an excellent safety record for its employees working in-house and abroad. LIEBHERR has an Integrated pollution control Licence ( IPC), registration No. 146 granted by the Irish Environmental Protection Agency EPA, which deals with all issues of pollution, emissions to air, waste disposal etc. As part of the IPC Licence, a documented Environmental Management System (EMS) is maintained to the satisfaction of the EPA. As a further initiative, LCC is currently in the process of adapting the EMS to enable certification to the international environmental standard EN ISO 14001.

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AFTER SALES SERVICE and SPARE PARTS LIEBHERR offers a “Service Department”, which acts as a single contact point for all customers with service related queries on Liebherr Container Cranes products. A summary of services available from the Service department will be: a) Technical support.

b) Actioning warranty claims.

c) Spare parts provision.

d) On site training courses.

e) Crane inspection reporting.

f) Crane refurbishing / upgrading.

g) Maintenance agreements.

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SUM

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attachment d1 - operational information requirements · cutting hall (mpc) unit operations 3.1.3...

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