Workshop 1

Aspect – Impact Analysis

The Basics of ISO 14001:2004

- building blocks of your EMS!!

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Ground Rules

 Mobile Phone Switch Off / Silent Mode

 Participate in the training.

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Introduction

• Who am I ?
• Where am I from ?
• Who are all involved in the Management systems ISO 9001 & TS
16949 and in what capacity?
• What’s my position in my plant ?
• Expectations of this week ?

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What is Environment?
ENVIRONMENT
Surroundings in which an organization operates, including air, water, land, natural
resources, flora, fauna, humans, and their interrelation.

4
Environment Pollution
Pollution is the introduction of contaminants into the natural environment that
cause adverse change

Material pollutants can be in the form of

Chemical Substances solid, liquid or gas or
Energy, such as Noise, heat or light. 

Types of Pollution

Water Pollution
from chemical/ oil spillages
 
Air Pollution
From boilers etc.
Vehicle emissions
 
Soil Pollution
From chemical/ oil spillages
Incorrect disposal of waste

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Sources of Pollution
Sources of Waste
 Industries
 Commercial Establishments
 Domestic (Municipal)

Wastes are Classified into

 Non Hazardous Waste
 Hazardous waste
 Radioactive
 Hazardous Waste
 E-waste
 BioMedical wastes
 Batteries

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Why does the Environment Need Protecting?
Pollution,
The generation of wastes and
The depletion of natural resources leads to

local as well as global environmental problems including:

Health & safety issues
Global warming (the “greenhouse effect”)
Ozone depletion
Acid rain
Smog formation
Deforestation
Resource Depletion

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Environmental Aspect Impact Identification (Cont...)

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Examples of Aspects & Impacts

9
Environment Aspect
ISO14001 defines an environmental aspect as :
“An element of an organization’s activities, products or services that can interact with the
environment”

An environmental aspect is the cause of an environmental impact.

Environment Aspect e.g

Air Emissions
Liquid Emission /Effluent
Wastes (solid, Liquid, Gas)
Spills & Leaks
CAUSE
Noise
Energy Usage (Power, Steam, Compressed air)
Water Usage
Material Usage (Raw Materials, Fuels, Lubricants, Chemicals)

Aspects can be
Regulated or non-regulated
Natural or man-made
Positive or negative
Controlled or influenced by the organization

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Environment Impact

Environmental Impact: any change to the environment, whether adverse or

beneficial, wholly or partially resulting from industrial site processes, activities,
products, or services.

Examples of generic environmental impacts:

• reduction in the quality of air, soil, surface water and groundwater;
• visual impact;
•
•
noise;
significant reduction in natural resources;
Effect
• significant increase in acid rain;
• heat;
• unacceptable levels of radiation;
• damage to biodiversity, flora and fauna.

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Establishing Significant Aspects

START
YES
NO

Significant Aspects
International Issues
YES

Local Issues / interested parties

NO
YES

Legal and other requirements

YES
NO

Business concern
NO YES

Severity of Impact

Non-significant aspects

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ISO 14001:2004 4.3.1 REQUIREMENTS

13
Input Output Analysis /Turtle Diagram

Responsibility
Utilities Production Manager ,
Water Supervisors , Setters, Operators
Compressed air
Energy

INPUTS OUTPUTS
Raw Materials Product,
Fuel By product
PROCESS NAME:
Wastes
PRODUCTION Air Emission
Effluent
Noise
etc

Document & Record Reference

Key Performance Indicators
Work Instructions, Control Plan,
PEX
Production Plan, Production Card -
Env KPIs
Welding,
Conc
Production Card - Press shop,
Quantity
Production Card - Spring Coiling
Qulaity of env
15
Some Definitions

• Control Actions: measures taken to control, eliminate, minimize or mitigate the identified
impacts. Examples of control actions: monitoring, facilities, treatment systems,
standardization.

• Significant Environmental Aspect: an aspect which has (actual) or may have (potential)
an important impact on the environment, determined according to the ENV 5x5 Matrix
attached.
• Significant Environmental Aspects Conformance Rate (S-ECR): defines the
percentage of significant environmental aspects that has effective control measures in
place.

• Emergency: abnormal situation that causes (actual) or may cause (potential) accidents or
significant negative impacts on the environment. For example: explosions, fires, major
leakages.

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Pre-requisite before Starting Aspect Impact Identification

Prepare & Get Ready with the Following

1. Subdividing Your Facility into Appropriate Units
2. Process Flow Chart
3. Manufacturing Process
4. List of Raw Materials / Fuels
5. Consumption Details (power, water, Fuel, etc)
6. List of waste / Air Emission points / Effluent Generation Points
7. Previous Emergency Details
8. Services by Contractors, Suppliers etc
9. List of Incoming Materials, Chemicals

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Process of Identifying Aspects & Impacts

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Building Aspect Register

• Follow Gerdau Procedure

• Use Gerdau Aspect Impact Spread Sheet

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General identification of the spreadsheet

Department: Identify the department to be evaluated

Work cell/Process: Identify the work cell/process to be evaluated

Prepared by: Person responsible for the prior revision

Approved by: Person responsible for the prior revision

Document prepared on: Date the spreadsheet was prepared, implemented

Last Revision: Date the Spreadsheet was last revised

Revision Control: Spreadsheet revision number

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Task Identification

Operational areas, including, but Processes, activities and services

not limited to: executed
raw materials, by Gerdau,
handling, by contractors or
processing, by visitors over which Gerdau has an influence
storage, on, for example, through a contract.
tankage,
waste,
utilities, Processes, products and services from
facilities,
environmental protection, suppliers where Gerdau has influence
control systems, over the supplier, product or service.
material transport, among others.

Operating modes, including, but not

limited to:
start-up,
normal operation,
temporary operation,
scheduled downtime,
emergency downtime,
recycling,
maintenance work during operation,
abnormal or non-routine operation,
cleaning of equipment,
normal situations, abnormal or emergency
situations, previous situations, among
others.

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Task Identification (Cont…)
Aspects related to:
products (including raw materials and intermediate products) and
co-products;
support services and activities,
such as internal / external transportation,
construction,
expansion,
demolition,
cafeteria,
separation of trash,
maintenance,
lubrication,
cleaning services,
sanitation, and
gardening; and
new projects (e.g. expansion, modernization, new facilities or technologies, launching new products,
among others).

All aspects of activities should be identified even if they seem non-

significant. No environmental aspect should be disregarded until after the
impact evaluation stage.

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Concepts

Example 1: If the process is analyzed in the Area level:

PROCESS = MELT SHOP

Process Steps Tasks Activities

Melt Shop Scrap Yard Scrap Receiving Uncover the truck
Refractory Scrap Classification Inspection
Electric Furnace Scrap Process Type of scrap evaluation
Refine Melt shop charging Weighing
Casting
Concepts

Example 2: If the process is analyzed in the Cell level:

PROCESS = CASTING
Process
Steps Tasks Activities
Pan receive H2 Measurement Set up measurement
Casting
Preparation for the machine mechanism
Mold powder addition
start Fold mechanism in a way that
Discard long tube
the wire is perpendicular to the
Cast
Liquid pool measurement liquid bath
Cut
Flux powder high Position the mechanism
Dispatch measurement between the valve and the
Distributor fluxing mold
Wait 10 seconds
Identification of Aspects and Impacts
Environmental Aspects:
List the possible causes of changes in the environment, actual or
potential, associated with the activities identified by grouping similar
causes in order to simplify the analysis.

Examples of aspects:
air emissions,
wastewater generation,
solid waste generation, including industrial and ordinary or non-industrial waste,
noise emissions,
odors,
radioactivity,
vibration,
visual impact,
use of raw materials,
use of non-renewable natural resources such as raw or processed coal, diesel oil, etc.

Environmental Impacts: Record the impacts (effects) on the environment

associated with each aspect identified.

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Classifying Aspects According to their Nature

Actual Aspect:
an aspect that normally occurs and may take place under normal
circumstances (e.g. production and preventive maintenance) or
unusual circumstances (e.g. corrective maintenance).

Potential Aspect:
an aspect that may occur, such as in emergency situations.

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Classifying An Aspect By Its Operating Condition

OPERATING TASK
CONDITION
“Normal” environmental aspects are those arising from routine
NORMAL (N)
activities. Example: preventive maintenance tasks, furnace
operation, etc.
“Abnormal” environmental aspects are those arising from non-
ABNORMAL (A)
routine activities. Plant start-ups and shutdowns, equipment
undergoing corrective maintenance, etc.
“Emergency” environmental aspects are those arising from
EMERGENCY (E)
unplanned or unintentional potential situations: leakage, fire,
explosion, equipment failure, tank ruptures, etc.
Impacts identified in the present but arising from activity
PAST (L) undertaken in the past that has generated some liability. Examples:
Improper disposal of waste, underground structures and tanks,
retired equipment.

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Evaluation Criteria (frequency/probability and severity)
The basic criteria for evaluation are: frequency/probability and severity, with
progressive levels, according to the ENV 5x5 Matrix

Environmental aspect frequency (f):

Frequency is determined by the number of times an aspect occurs over a set period
of time, and which results in an impact associated with that aspect.

The existing controls are not taken into account.

Environmental aspect probability (p):

Probability is estimated by the expectation of the occurrence of an undesirable
event or a hazardous situation which results in a risk to the environment (Historical
events/Possibility).

The existing controls are taken into account

Environmental impact severity (s):

Considers the intensity of the impact, the effect in terms of numbers, and the
duration of the effect. The degree of contamination, concentration, toxicity,
reactivity, hazardousness, flammability, corrosiveness and radioactivity should be
evaluated.
The existing controls are not taken into account.

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Env 5 X 5 Matrix
1 2 3 4 5
FREQUENCY OF ENVIRONMENTAL ASPECT GENERATION
Low, occurs once or Eventual, occurs 3 Low, occurs once or
Frequent, occurs Continuous, occurs
twice in a to 4 times twice in a
weekly. daily.
year. per year. month.
PROBABILITY
Very unlikely, almost Possible. It has
Unlikely, very low. It
null. There are no Rare. It has happened more
has happened at Likely. It has
records of similar happened last year than once in the last
least once in the happened less than
Historical cases in the past 10 at Gerdau OR in the year at Gerdau OR
past 10 years in this a year ago on this
events/Possibility years in this kind of past 5 years on this more than once in
kind of process/ Site.
process/ Site. the past 5 years on
equipment.
equipment. this Site.

Possesses effective
Controls controls
Possesses controls
(engineering +
(engineering +
administrative +
administrative + Only administrative
monitoring) that Only administrative Week or absent
monitoring) that and monitoring
totally eliminate the controls are in place. controls.
partially eliminate controls are in place.
possibility of
the possibility of
occurrence or there
occurrence.
is no need
of controls.

ENVIRONMENT
5 a) Demands more than 10 years or more than US$ 50 million or
more than monthly planned EBITDA to mitigate.
b) Mill down for more than 30 days.
c) The community needs to be evacuated or near roads need to
be disrupted or public services have to be interrupted for longer 5 10 15 20 25
than 3 days. d) Might cause a public demonstration or expose the
company to international media.
e) Supply of natural resources can be depleted at a regional level.
f) Visible continuous atmospheric emissions or continuous
effluent emissions affecting neighboring community. 29
Env 5 X 5 Matrix (Cont...)
ENVIRONMENT
4 a) Demands up to 10 years or more than US$ 5 million or more than 50% of the monthly planned EBITDA to
mitigate.
b) Mill/ Department down for up to 30 days.
c) Residences nearby need to be evacuated or the public services have to be interrupted for up to 3 days.
4 8 12 16 20
d) Might cause a public demonstration or expose the company in the national media.
e) Supply of natural resources can be depleted at a local level. f) Visible intermittent atmospheric or
effluent emissions affecting neighboring community.

ENVIRONMENT
3 a) Demands up to 5 years or more than US$ 1 million or more than 25% of the monthly planned EBITDA to
mitigate.
b) Department/ Cell down for up to 24h.
SEVERITY

c) The community needs to be warned or the residences near have to be inspected. Evacuation is not
required and public services can operate normally.
d) Might cause a public demonstration or expose the company in state media. 3 6 9 12 15
e) Supply of natural resource might be compromised for the Mill.
f) Atmospheric emissions are visible from outside the Mill, but do not
affect the community.

ENVIRONMENT
2 a) Demands up to 1 year or up to US$ 1 million or up to 25% of the monthly planned EBITDA to mitigate.
b) Department/ Cell down for ≤ 4h. c) Limited to the Mill.
d) Might expose the company in the local media.
2 4 6 8 10
e) Does not compromise natural resource availability.
f) There are diffuse atmospheric emissions, which are not easily seen from outside the Mill.

ENVIRONMENT
a) It can be mitigated by immediate action or simply by regeneration of the environment itself.
b) There is no down.
c) Damage is limited to the area of occurrence. d) There is no exposion to external public.
1 e) Does not compromise resource availability. 1 2 3 4 5
f) Atmospheric emissions are not visible from outside the Mill.
Result (R)

Once the scores are identified, calculate the result using the equation below:

For actual situations: R = f x s

For potential situations: R = p x s

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Significance of Environmental Aspects

A result of more than 12 is considered Significant (S) and a result of less than
12 is considered Non-significant (N), as follows: That is:

RESULT SIGNIFICANCE SYMBOL

R > =12 Significant S

R < =12 Non-significant N

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Legal Requirements and Permits

There should be a list of legal requirements and possible permit restrictions to

assist in the control:

Applicable legislation requirements (federal, state or local) related to operational

controls and monitoring;

Permit restrictions;

Notifications and any other formal requests by qualified entities;

CATS - Conduct Adjustment Terms, among others.

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Control Action
Identify the existing control action(s) for all aspects evaluated as significant (R> =
12).

Examples of control actions: emission capture system, effluent treatment plant,

controls, among others.

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Environmental Compliance Evaluation

The Environmental Compliance column must be completed for the aspects

considered Significant (S), and should assess whether the Control Action is
effective – that is, whether the control action will ensure that governing
environmental legislation is being complied with, and that there are no complaints
from neighboring communities about disturbances caused by the Site’s
environmental aspects. This column should be completed with the following
symbols: C (compliant) and NC (non-compliant).

In cases where the impact is known to be significant, but there is no governing local
legislation, consideration should be given to following internationally- recognized
environmental legislation.

S-ECR = (total number of compliant significant environmental aspects) / total

number of significant environmental aspects) x 100

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S-ECR measurement frequency

The S-ECR should be measured, with the result the last position at the end
of the quarter.

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Proposed Action
For aspects that are rated as “S” and have an Environmental Compliance of “NC”
(non-compliant), actions for improvement to become compliant should be defined,
and where applicable, approval should be obtained from the environmental control
agency to continue operating while the control measure is being implemented.

This action should be included in the proposed action for the field. Considering:

RESULT
Between 20 & 25
(Significant)
Between 12 & 16
(Significant)
Between 8 and 10
(borderline and non-
significant)
Below 8 (non significant)
ACTION
Requires robust engineering measures for control
Should prioritize the goals and objectives for
improvement (projects), preferably, physical
systems, measurements and routine
standardization.
Maintain operational standard as minimum control,
if necessary.
Question the need to maintain existing operational
standards, eliminating/ simplifying whenever
possible.

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Table Top Exercise F-4 Conveyor RM-1 Conveyor

RM-2 Conveyor

IRON ORE

F-3 Conveyor
FINES
m
ixing dru
Primary m

M-1 Conveyor F-1 Conveyor

M-4 Conveyor

r
ey o F-2 Conveyor
onv
Secondary Mixing Drum

2 C
M- Ignition furnace
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Single roller crusher FS-3 Con

or
ey
nv
Co
-2
Product Bin

FS
r
yo
M-3 Conveyor nve
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- 1C
Sinter Machine FS
r
onveyo
FS-4 C

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Any Questions

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