NCD003446721_19960611_Celeanse Corporation - Shelby Fiber_FRBCERCLA RA_Well Completion Report for Replacement of Outer Tier Extraction-OCR

June 11, 1996
KJF:96:020
Mr. McKenzie Mallary
U.S.EPA
345 Courtland Street, NE
Atlanta, GA 30365
Dear Mr. Mallary:
Hoechst Celanese
Textile Fibers
Hoechst Celanese Corporation
PO Box 87
Shelby, NC 28151-0087
7ff482 2411
JUN 1 71996
SUPERFUND SECTION
Hoechst Celanese Corporation Shelby Site is pleased to submit two bound copies of ihe
enclosed "Well Completion Report for Replacement of Outer Tier Extraction Well
OT-2." The report details the abandonment of the Outer Tier 2 well and construction and
operation of its replacement. The original well had maintenance problems that
necessitated its replacement.
The report was prepared by Kubal-Furr.& Associates, Inc. on behalf of Hoechst Celanese
Corporation. The report is submitted as part of the long-term CERCLA remedial
activities at the site. If you have any questions or comments regarding the report, please
call me at [phone].
Sincerely,
/<~AJ
Kathryn Frank
Environmental Engineer
cc: /Mr. B. Nicholson, NC Division of Solid Waste Management
Enclosures
Hoechst CS
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Well Completion Report for
Replacement of
I
Outer Tier Extraction Well OT-2
Hoechst Celanese Corporation
Shelby, North Carolina
Document Control Number 026SB-0046 (c)
Submitted to
U.S. Environmental Protection Agency
Region IV
Atlanta, Georgia
Prepared for
Hoechst Celanese Corporation
Shelby, Nortb Carolina
June 1996
Kubal-Furr & Associates
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Contents
Introduction ............................................................ .
Work Performed ......................................................... .
Tables
Table 1. D<~velopment Data-OT-2R .... · ..................................... .
Figures
Figure 1. Site Plan-Hoechst Celanese Corporation-Shelby, NC
Attachment 1.
Attachment 2.
Attachments
Geologic Log & Well Construction Diagram-OT-2R
Well Construction Record and Well Abandonment Record
Submitted to NC DEHNR (Geologic Exploration, Inc.)
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INTRODUCTION
The Hoechst Celanese (HCC) Shelby plant has been operating a ground-water extraction and
treatment system since 1989. The extraction well system consists of two components: an Inner
Tier system consisting of nine wells which withdraw contaminated ·ground water from the vicinity
of a former source area (OU-2); and, an Outer Tier system, also consisting of nine wells, which
extracts ground water and maintains hydraulic· control along the property boundary (Figure 1).
HCC personnel track the flow rates of both the Inner and Outer Tier systems on a daily basis
and have an on-going maintenance program to keep the system performing in accordance with
design specifications. HCC had noted maintenance problems with several extraction wells during
the past year which became progressively worse and ultimately resulted in shutting down Outer
Tier well OT-1 and Inner Tier well IT-8. These wells were abandoned in June and July of 1995,
respectively, and were replaced by Outer Tier well OT-lR, and Inner Tier well IT-SR. Also in June
1995, following abandonment and replacement of OT-1, an additional well, OT-10, was installed
as a possible back-up in the event supplemental hydraulic control was required along the southern
prope1ty boundary.
The present report describes the work petformed during the period April 29 to May 2, 1996.
Dming this period, a replacement well (OT-2R) was installed adjacent to existing well OT-2. This
report also provides a lithologic log and construction diagram for the replacement well.
Kubal-Furr & Associates/Page I
Replacement of Outer Tier Extraction Well OT-2
Hoechst Celanese Corporatio11-Shelby, North Carolina
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• Monitor well
♦ Outer Tier Extraction Well liil HCC Building/Structure
□ Domestic Supply Well ♦ Abandoned Outer Tier Well
~ Abandoned Inner Tier Well A-A' Location of geologic cross-sections
Kubal-Furr & Associates
-Environmental Consultants-
Scale in Feet
400
Figure 1. Site Plan
Hoechst Celanese Corporation
Shelby, North Carolina
800
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WORK PERFORMED
Drilling and installation of outer-tier extraction well OT-2R was performed between April 29
and May 2, 1996. The well was constructed with an upper cased interval opposite saprolite and
a lower screened interval opposite an interlayered amphibolite gneiss and fclsic gneiss bedrock.
Well OT-2R was installed as a replacement for existing outer-tier well OT-2, which had
developed significant loss of filter pack and casing degradation problems over the past several
months. The scope of work also included proper abandonment of well OT-2 following successful
installation and start-up of the replacement well.
Well drilling, installation and development were performed by Geologic Exploration, Inc. of
Statesville, North Carolina under the supervision of a licensed well driller. A representative of
Kubal-Furr & Associates was on site during field activities to document geologic conditions and
as-built well specifications.
The following sections address specific methodology employed to accomplish the installation
of well OT-2R, and abandonment of well OT-2:
Kubal-Furr & Associates/Page 3
Replacement of Outer Tier Extracrion Well OT-2
Hoechst Celanese Corporation-Shelby, Nonh Carolina
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DRILLING AND WELL INSTALLATION
Well OT-2R was drilled and installed by the following methods, as summarized in the
following sections.
Pilot .. Hole Advancement/ Geologic Logging
At the drilling location, a 17.5-inch diameter pilot hole was advanced by the mud-rotary
method through silty, clayey saprolite to the top of competent bedrock (encountered at
approximately 32 feet below grade). Threaded Schedule 40 PVC surface casing was then set from
the surface to the top of bedrock and grouted into place using 5-percent bcntonite-cement grout. I The grout was allowed to cure approximately 36 hours before advancing the borehole into the
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underlying bedrock. The lower (bedrock) portion of the borehole was completed by drilling a
9.875-inch diameter hole by the air-hammer method to a total depth of 68.5 feet.
Samples of drill cuttings produced during advancement of the borehole were examined on-site
by the KF&A geologist, and a geologic log was prepared. The saprolite interval (32 feet thick)
generally comprises a red to brown micaceous silty, clayey, and sandy silt. The parent bedrock
underlying the saprolite is comprised of an interlayered sequence of amphibolite gneiss and
quartzofeldspathic gneiss. White vein quartz was encountered at various depths, suggesting the
presence of fractures. The driller also reported sporadic reductions in formational rcsistence
coincident with a slight increase in production of water, also suggestive of downhole fractures.
Kubal-Furr & Associates/Page 4
Replacement of Outer Tier EXJraction Well OT-2
Hoechst Celanese Corporation-Shelby, North Carolina
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:will Construction
Screen and casing were installed in the well immediately following completion of the pilot
hole to total depth. The screened interval was completed with a 6-inch diameter,
continuous-wrap, threaded stainless-steel well screen. The blank section above the screened
interval was completed with a 6-inch diameter, threaded Schedule 40 PVC casing. The casing
extends to approximately three feet above grade at well OT-2R.
The length of the screened interval in the well was predetermined to be 30 feel. The actual
length of the screened interval (reflected on the construction schematic) is slightly less than 30
feet, owing to the presence of six inch long blank segments at each end of the three 10 foot long
screen assemblies used in well construction. The bottom-most screen assembly was completed
with a welded end rather than an end cap, in order to maximize the actual screened length.
A filter pack consisting of0.8-mm to 1.2-mm graded silica sand was introduced into the
annular .space of the well from the total depth to a level approximately two feet above the top of
the screened interval. The well was then swabbed, and development was to be initiated immedi-
ately following placement of the filter pack, to allow for proper settling of the filter pack before
installation of the bentonite seal. However, the submersible pump used for development
malfunctioned, so the bentonite seal was installed after the well was thoroughly swabbed.
The annular space directly above the filter pack in the well was sealed with granular bentonitc
chips and pellets from the top of the filter pack to a point approximately two feet above the
bottom or the surface casing. The thickness of the bentonite seal is 7.1 feet. The seal was allowed
to hydrate for a minimum of one hour before proceeding with grouting operations, to preclude
fouling of the filter pack. The annular space above the bcntonite seal in the well was pressure
grouted to the surface with 5-percent bentonite-cement grout.
Kubal-Furr & Associates/Page 5
Replacement of Outer Tier Extraction Well OT-2
Hoechst Celanese Corporation-Shelby, North Carolina
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Well Development
Thi: well was developed by pumping at approximately 10 gallons-per-minute using an electric
submersible pump set at the bottom of the screened interval. The well was continually pumped
until the well ran dry. Approximately 440 gallons of water were removed during this phase of
development.
It should be noted that well OT-2, which is located approximately 15 feet to the north of
OT-2R, was operational and pumping while OT-2R was being developed. Therefore, OT-2R's
productivity during the first development phase was probably reduced, and is not indicative of a
stable, long-term pumping rate. Such a rate can only be determined from a well yield test that
would be performed afler OT-2 is removed from service.
After the well recharged for fifleen minutes, the driller surged and pumped the well until
ground water was free of suspended sediments, turbidity was minimal, and stable pH and
specific conductance readings were obtained. Well development data is presented in the following
table.
Time
10:00
10:50
10:55
10:57
11:00
Table 1. Development Data: Well OT-2R
Total Gallons pH
Removed (std. units)
(initial) -
440 6.5
445 5.9
465 5.7
495 5.7
Conductance Turbidity Sand Content
(microsiemens)
-mod-low minor
477 low trace
473 very low trace
463 minimal none
467 minimal none
Kubal-Furr & Associates/Page 6
Replacement of Outer Tier Extraction Well OT-2
Hoechst Celanese Corporation-Shelby, North Carolina
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WELL ABANDONMENT
Well OT-2 was properly abandoned in accordance with North Carolina Well Standards and
Regulations following the addition ofreplacement well OT-2R to the Outer Tier Extraction well
system. OT-2R was placed into service on May 21, 1996. Construction of a new pad and
protective housing, installation of additional piping, and rerouting of electrical service had to be
completed before this well could be placed on-line.
Abandonment of well OT-2 proceeded by(!), cutting of the carbon-steel well casing level
with the concrete protective pad, and (2), pressure grouting of unsilted portions of the well bore
to land surface with a 5-percent bentonite-cement slurry. The well had silted in to within 40 feet
below ground surface. Before the grout slurry was introduced, 50 lbs of 3/8 inch bentonite chips
were placed in the well bore, to seal off the top of the silted portion of the well bore.
It had been calculated that approximately 60 gallons of grout mix would be needed to fully
seal the OT-2 well bore (from the top of the unsilled portion of the well to approximately 2 feel
below grade); however, introduction of approximately 275 gallons of grout mixture was
necessary, apparently due to formational washout in the area adjoining the well bore. Surface
soils were placed above the former OT-2 location following completion of well abandonment
operations.
Kubal-Furr & Associates/Page 7
Replacement of Outer Tier Extraction Well 01'2
Hoechst Celanese Corporation-Shelby, North Carolina
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Kubal-Furr & Associates SO IL BORING LOG
-Environmental Consultants-____ ,._ .... ...,,.,.. ... ...., .. ,_.,..___ April 29 1996
Date ·
Client _.,_H.,,o""e"'c:'""h sa:;te..--><C"'-el"'a""ne"'s""e'---Project Number --'-"TFco0e.,2""6""T-"'S-"'0-"'9 __ _ Boring Number _O""T"--""Z""R,...__
Site Location-----"5"-'h"'e"'lb:.zY'-1 !..!N'-".C"-. ------Drilling 4/29/96
Started
Drilling 5/1/96 Completed
Total Depth Drilled 68·6 feet
~18 In. uppor
Boring Diameter-9·875 In. lowor inches Sampling cuttings Device
mud rotary-upper
Drilling Method----"a.u.ir.,_h"'alllmlLmwear_,-1,.,_ow"'""'r ___ _
potable water
Appalachain Products
Contractor ___ .,.G.,.e'"ol.,.o""gi.,.c_.E""x"'p"'lo-"ra"-t .. io""n'------
Drilling Fluids Used POI Y 100 Gel Log Prepared by-_,Kc,,Ac.u.l ,.al,!Jub"'e.,._r __ Sheet--'--of _.2.__
'O 0 Depth -5
(feet) <I) ::s
--5
--10
-15
-20
-
-25
-30
--32-
-35
-40
-45
-so
I Shelby
Tube
8~
~8 ~~
0.0
0.0
0.2
0.6
0.4
Description of Lithology
Red-brown clayey silt
Cuttings are brown/orange silt, some clay, some mica,
few coarse fragments of feldspar and hornblende.
As above
As above
As above
Drilled through small rock layer at 26'.
28-29'. Solid rock -then drilled through layer back into saprolite -cuttings are
angular feldspar, quartz. amphibole; back into solid rock at 32' -advanced ~6"
at highest down zressure -hard competent rock, 60% amphibole,
30% feldspar, 5'. qtz, 5% mica -trace red garnet, trace pyrite coats feldspars
amphlboles.
'-changed drilling method to 9.875 In. air hammer
As above -amphibole gneiss
41' -Fractures yield quartz rich rock & weathered gneiss. Mica content~ 10%.
43' rod added
47' little quartz -97% amphibole gneiss
As above
Split
Spoon DJ Air
Hammer [S] No
Recovery
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Kubal-Furr & Associates
-Environm,etttal Consultants-SOIL BORING LOG
CONTINUED Page-2-of -2-
Project Number _T'-'-F-"'0-"2""6-'-'TS"-'0"'9"--_ Boring Number 0T-2R
Depth
(feet)
-50
-55
-60
-65
-
-
-
-
-
-
-
-
-
-
I
'O 0 -5 0 ::8
Shelby
Tube
8~ e: a 8 p.. Description of Lithology 8 u.
0.4 As above -local thin <1' quartz rich horizon -probable fractures
'l
0.0
Pyrite on fracture faces -rock is still amphibole gneiss
0.0 Weathered zone 57' -hammer advances steadily -orange, muddy water produced
57'-58.5' weathered -58.5' back Into competent bedrock -return water
is grey not orange ·
0.0.
uartz rich at 60'
-Lost circulation slightly from 62-63' cuttings are coarse chips
· consisting of black amphibole gneiss.
63'-65' quartz rich -water production increases
~ End of Boring : 68.5' below ground surface
Split
Spoon DJ Air
Hammer [SJ No
Recovery
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Project#:
Date
Installed:
Depth
below
PVC
casing
top
0.Ofeet
eet
3.0 feet
32.0 feet
35.0feet
37.1 feet
40.5feet
70.0feet
71.5 feet
TF026TS09
E5/1/96
Depth
below
land
surface
-3.0 feet
eet
0.0 feet
29.0 feet
32.0 feet
34.1 feet
37.5 feet
67.0 feet
68.5 feet
WELL CONSTRUCTION
DIAGRAM
Land Surface
Client: Hoechst; Celanese
Location: Shelby, NC
Well Designation: OT-ZR
.,.
);):M---17.5-inch diameter ..... ~:H mud-rotary borehole ,., ..... ,., :.-::. .,. ,., ·:..-::.
:\,!:., ~'n--10-inch diameter Schedule -~-,:~,: 40 PVC surface casing .,. ::;..-: ,., .,. M»-~t!-Portland Cement I ......
:.-::. 5% Bentonite Grout .,. ,., .,. ,., ·:.,'!':., .,.
);) Bentonite seal ,.,
-~~~ consisting of
J~~ Volclay 3/8" chips
-1:i~---& DSI Sure-Seal
3/8" pellets
+"+--6-inch inside diameter
Schedule 40 PVC casing
=--6-inch inside diameter,
0.020-inch slot, type 304
stainless steel, wire-wrapped
screen
9.87-inch diameter air
hammer borehole
Vertical Scale: 1 inch =10 feet
Drawing Enlarged Horizontally To Show Detail
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Attachment 2
Well Construction Record and Well Abandonment Record
Submitted to NC DEHNR
(Geologic Exploration, Inc.)
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North Carolina , Department of Environment, Health, and Natural Rosources
Division of Envlronmental Management. Groundwater Section
f>.O. Box 29535 . Raleigh, N.C. 27626-0535
Phone [phone]
WELL CONSTRUCTION RECORD
FOR OFFICE USE ONLY
QUAD. NO. SERIAL NO. ____ _
Lat. ____ Long. ____ RO __ _
Minor Basin _____________ _
Basin Code ________ ...:._ ____ _
DRILLING CONTR,~CTOR: Geologic
I DRILLER REGISTFIATtON NUMBER:
Exploration,Inc L'..'.H•~•~d•~•~E~n~1.=========G~W~-1~E~n~1. ___ _1
STATE WELL CONSTRUCTION
1175 PERMIT NUMBER:
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3.
WELL LOCATION: (Show sketch of the location below)
Nearest Town: E:arl NC county: ___ C_l_e_v_e_l_a_nd _______ _
NC 198 south
(Rand, Community, or Sulx:livision and Loi No.)
OWNER Hoechst Celanese
ADDRESS Hwy 198 South
Shelby
City or Town .
(Street or Roule No.)
NC
Staie
28152
Zip Codo
DEPTH
From To
0.0' 10.0'
10.0' 28.0'
DRILLING LOG
Formation Description
Red silty clay
Brown Sandy Silty Clay
28 Q' 29 Q' Gra¥'i--'G,.,,rc..<a:,,in-1..iwt_,e,_ ___ _
___ 9_.Q_' __ 3L_~_ Brown g_!)ndy Silt
14.
5.
6.
D/\TE DRILLED 4-30-96 USE OF WELL .· Recovery
TOTAL DEPTH 67.0 ft.
CUTTINGS.COLLECTED YES O NO![]
---31 O' 67 0' Gray Granite
17
8.
DOES WELL REPLACE EXISTING WELL? YES [K]
STATIC WATEH LEVEL Below-Top of Casing: 12.0 NO □
FT.
TOP OF CASING IS __ 2_._5_
(Use-+-if Above Top of Casing)
FT. Above Land Surface•
• Casing Terminated at/or below land surface Is Illegal unlosa a varlanco Is l9suod ----------
1 In accordenco with 15A NCAC 2C .0118
9. YIELD (gpm): NA METHOD OF TEST NA
10. WATER ZONES (depth): ___ N_A _________________ _
I 11. CHLORINATIOt~: Type NA Arnau n t _ __,N,,A.,__ 1f additional space is needed use back of form
12. CASING:
I Depth
From 0.0 To 29.0 Ft.
I From Q.O To 37 .O Ft.
From To Ft.
13. GROUT:
I Depth
From O.O To 32.0 Ft.
From O.O To 27 .O Ft.
Wall Thickness
Diameter or Weight/Fl. Material
10 in. &b.40 ey:c
6 in. Sch.40 PVC
Material Method
Portland Bentonite Slurry
Portland Bentonite Slurry
LOCATION SKETCH
(Show direction and distance from at least two State
Roads, or other map reference points)
Nll~'r) @:te, )
Lt-veJa, Drt~
114. SCREEN:
Depth Diameter Slot Size Material
From 37 .O To 67 .0 Ft _6_ in. .020 in. __ * __ _
I From __ To __ Ft, __ in. __ in.
From __ To __ Ft. __ in. __ in.
15. SAND/GRAVEL PACK:
I Depth Size Material
From 34.5 To 67.0 Ft. 8720_ Fine Silica Sand
From ___ To ___ Ft. ___ _
116. REMARKS: ar 2-R Bentonite seal from 27.0 to 34.5 feet.
*304 stainless steel wire wrapped
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I DO HEREBY CERTIFY THAT THIS WELL WAS CONSTRUCTED IN ACCORDANCE WITH 15A NCAC 2C, WELL
CONSTRUCTION STANDARDS, AND THAT A COPY OF THIS RECORD HAS BEEN PROVIDED TO THE WELL OWNER.
5-7-96
SIGNATURE OF CONTRACTOR O DATE
Submit original I? Division of Environmental Management and copy to well owner.
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North Carolina
Department of Natural Resources and Community Development
Division of Environmental Management
Groundwater Section
P.O. Box 27687 -Raleigh, N.C. 27611
WELL ABANDONMENT RECORD
CONTRACTOR Geologic Exploration,Inc. REG. NO. 1175
1. WELL LOCATION: (Show a sketch of the locaUon on back of form.)
Nearest Town: Earl County __ C_l_e_v_e_l_a_n_d ________ _
NC 198
(Road. Commun.tty, Subdivision. Lot No.) Quadrangle No.
2. OWNER: Hoechst Celanaese WELL DIAGRAM: Draw a detailed sketch of
lhe well showtng total depth, depth and dta-
3. ADDRESS:Highway 198 South,Shelby,NC 28152 meter of screens rematnlng In the well. gravel
Interval. Intervals of castng perforatlons,
4. TOPOGRAPHY: draw.~hUltop, valley, flat and depths and types of fill materials used.
5. USE OF WE:LL: Reco~~ry,(ar-2)DAIT· 5 23 9E) ' ' I ,\
6. TOTAL DEPTH: 65.0 ft.DIAMETER: 6 inch
7. CASING REMOVED:
&>,,,,,. t-fill diameter
NIA N//1 wbo.1
e, ..... h,,,; I-<.
G<v'-'r
51-o?J l~.il'
l 8. SEALING MATERIAL: P-i'ser
Neat cement Sand cement
bags of cement 22 bags of cement (.S.o
-fe,_,.f-
3'\P
,
gals. of water 143 yds. of sand Solb; J/'b' -\Jol0'."'1 CJ-lps
A..O ,0
gals. of water
.QtJm \/ 1.\5.D Type mateiial Bentonite e2wder,hole elug 3/8" --I
--Amount 5~5 l00lb 5.,ildp,d -5t,. :, I e5> 5J.u..l
9. EXPLAlN METHOD EMPL'I.CEMENT OF MATERIAL. -Ser Le-vJ -Tremie pipe from top of caved in material ---(40 feet below groundsurface) to ground 'V ',.
surface ~,'/\e,h
I do hereby certify that this well abandonment record ls true and exact.
Signature of Contractor or Agent 7~ ~ Date _ __,5'---=3'-=l~--=-9-=-6 ____ _
WELL LOCATION: Draw a location sketch on the reverse of lhls sheet, showing the dJrec-
Uon and distance of the well to at least two (2) nearby reference potnts
such as roads, lntcrsectlons and streams. Identify roads Wlth Slate High
way road ldenllflcatlon numbers.
SubmJt original to lhe Dlvlslon of Environmental Management, one copy to the Drlller,
and one copy to the owner. ·
GW -30 Revised t;/ 15/89