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Home My WebLink About8505_Duke_Belews_RepairCQA_DIN25918_20160407Belews Creek Steam Station 3195 Pine Hall Road Belews Creek, NC 27009 336-445-0610 336-669-2994 www.duke-energy.com April 1, 2016 North Carolina Department of Environmental Quality Division of Waste Management Solid Waste Section 2090 U.S. Highway 70 Swannanoa, North Carolina 28778 Attn: Mr. Larry Frost Re: Duke Energy Carolinas - Belews Creek Steam Station FGD Residuals Landfill (Permit No. INDUS-8505) Stokes County Dear Mr. Frost, Attached you will find for your review the Construction Quality Assurance (CQA) Certification Report for the liner repair at the Flue Gas Desulfurization (FGD) Residual Landfill (Permit No. INDUS-8505). The CQA oversight and report was generated by Joyce Engineering. This document is being submitted electronically. Please let me know if you would like to receive paper copies. Respectfully submitted, Melonie Martin Environmental Services Attachments: FGD Residual Landfill Liner Repair CQA Cetification Report, Duke Energy Carolinas, Belews Creek Steam Station, FGD Residual Landfill cc (via e-mail): Will Harrison, Duke Evan Andrews, Duke Ed Sullivan, Duke Ed Mussler, NCDEQ Prepared for: DUKE ENERGY Belews Creek Steam Station 3195 Pine Hall Rd. Belews Creek, NC 27009 BELEWS CREEK STEAM STATION FGD RESIDUAL LANDFILL LINER REPAIR CONSTRUCTION QUALITY ASSURANCE CERTIFICATION REPORT March 31, 2016 Prepared by: 2211 West Meadowview Road, Suite 101 Greensboro, NC 27407 NC CORP LIC: C-0782 JEI Project: 845 Amy Davis, P.E. Senior Project Consultant Joyce Engineering, Inc. North Carolina Corporate Lic: C-078 Duke Energy Belews Creek Steam Station Page i Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report TABLE OF CONTENTS Page Table of Contents ......................................................................................................................... i 1.0 Introduction ...................................................................................................................... 1 2.0 Construction Quality Assurance Activities ................................................................... 1 2.1 General ................................................................................................................... 1 2.2 Liner Damage Survey ............................................................................................ 1 2.3 Liner Repair ........................................................................................................... 1 3.0 Conclusion ........................................................................................................................ 2 Attachments Photos Sequence of liner repair work Certifications Geosynthetic materials Drawing FGD Landfill Existing Conditions Duke Energy Belews Creek Steam Station Page 1 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report 1.0 INTRODUCTION Duke Energy operates the Flue Gas Desulfurization (FGD) landfill constructed in accordance with Sub-Title D Regulations, North Carolina Solid Waste Management Rules 15A NCAC 13B and the General Permit Conditions of Permit # 85-05. This report, prepared by Joyce Engineering, Inc. (JOYCE) for Duke Energy addresses the quality assurance activities performed on March 18, 2016 during FGD residuals landfill geosynthetic liner repair at the Belews Creek Steam Station. Charah had retained Chesapeake Containment Systems (CCS) to perform the geosynthetic liner damage repair. Joyce Engineering, Inc. retained by Duke Energy provided oversight and quality assurance for the liner repair work. The damaged section of the landfill liner system measured approximately 6 feet by 4 feet and damage to the liner system consisted of a tear in the protective geocomposite layer, geomembrane liner and the Geosynthetic Clay Liner (GCL). The liner damage had occurred during mining of gypsum on the east end of Cell 4 slope. The location is in the southeast corner of Cell 4 shown on the attached Drawing, Sheet 1, FGD Landfill Existing Conditions. 2.0 CONSTRUCTION QUALITY ASSURANCE ACTIVITIES 2.1 General Joyce Engineering, Inc. provided Construction Quality Assurance (CQA) activities for the repair work. The following sections describe the specific areas of CQA: 2.2 Liner Damage Survey Representatives of Duke Energy and Joyce Engineering, Inc. surveyed the extent of damage to the liner system prior to commencing the repair work. The damage to the liner system was observed in one location through the three layers of the geosynthetic liner system. The damage to the liner was reportedly caused by trackhoe bucket catching the synthetic liner system during excavation of the gypsum. No other locations of liner damage were observed, but the layer of gypsum was noted as being thin over the liner system in the east end of Cell 4 where the mining activity had been recently conducted. Fleming Engineering, retained by Duke Energy, surveyed the existing conditions and cut- fill of the gypsum grades. Drawing No. 1 of 2, attached with this report, shows the existing conditions of the achieved mining grades and the location of the damaged liner. 2.3 Liner Repair Chesapeake mobilized on March 18, 2016 to the FGD landfill for the liner repair work. Charah cleaned the damage area by brushing soil, gypsum and dust from the area to be worked on. The ripped geocomposite and geomembrane were cut and removed. CCS trimmed the Duke Energy Belews Creek Steam Station Page 2 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report damaged geomembrane edge to prepare for the new patch material placement. The existing GCL was pulled back in its placed and loose powder bentonite was poured over the perimeter of the repair area to provide a continuous seam between the existing and new GCL. A new piece of GCL was placed over the damaged GCL to cover the entire area. The new GCL panel extended a minimum of 12 inches in all direction beyond the damaged edges of the existing GCL. Prior to beginning the geomembrane patch installation, CCS turned the extrusion welder DemTech MX-43 on to allow the welding unit to heat and reach its operating temperature. The pre-heat temperature was observed and recorded 458 oF. The ambient temperature was recorded 72 oF. After the welder had reached its operating temperature a test weld was conducted on the new geomembrane. Two pieces of the geomembrane were welded together to form a weld approximately three feet long. Test sections of the welded seam were cut for shear and peel testing. Each test piece was one inch wide across the weld. Three test samples were tested in accordance with specification for shear and peel. Project specifications for the geomembrane: Parent material tensile stress at yield 130 lbs./in/min. Seam strength: Shear strength 95% of parent material = 123.5 Peel strength 62% of parent material = 80.6 Test results: Sample 1 Sample 2 Sample 3 Shear 160 145 166 Peel 103 102 108 Tensiometer for the shear/peel testing: Pro Tester T-100; Serial No. 207100; CCS Unit No. T 22 Calibration Date: August 14, 2015 Following the test weld, CCS proceeded to the production welding of the patch. The geomembrane liner was patched with new material and extrusion welded to the liner. The extrusion weld was tested for seam quality by use of a vacuum box. The entire welded seam was tested in segments, which were observed satisfactory by holding a 3 psi vacuum for 15 seconds. A new panel of geocomposite was placed over the repair and left un-attached. The repair area was covered with plastic sheeting until the staff from DEQ can visit the site and observe the membrane liner repair. Attached photos illustrate the sequence of the repair work. 3.0 CONCLUSION The damaged geosynthetic liner in the Cell 4 was repaired on Friday, March 18, 2016. The geocomposite cushion layer to protect the geomembrane was placed loosely over the geomembrane to allow personnel from DEQ to inspect the repair area. The repair area was then temporarily covered with black plastic to keep rain and run-on off the liner. DEQ visited the site Duke Energy Belews Creek Steam Station Page 3 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report on Wednesday March 23, 2016. The geocomposite has been secured in place after DEQ reviewed the repair. In general the area of excavation in Cell 4, where the landfill liner system was damaged, appears to have from few inches to one foot of gypsum cover over the geosynthetic liner system. Observed tire marks on the gypsum surface (photo 9) show no signs of pumping or rutting. Based on these observations, it does not appear the liner materials have been compromised. Based on the following, the weight of the dump trucks and the excavation equipment do not appear to exceed the bearing capacity of the subsoils, and therefore should not compromise the liner materials. • The FGD landfill design calculations indicate a minimum bearing capacity for the subsoils of 10.6 ksf or 10,600 psf. • The ground pressure for the Komatsu 330 excavator is approximately 1490 psf, less than the minimum bearing capacity of the subsoils. • The load per tire for a fully loaded tandem axle truck (80,000 lbs), assuming 4 tires per axle is 8,500 lbs per tire (34,000 lbs per axle/4 tires). Assuming a tire contact area of 1 sf, the ground pressure would be equal to 8,500 psf, less than the minimum bearing capacity of the subsoils. In accordance with the Construction Plan Application, a minimum of three feet of operational cover and waste must be placed over the liner before truck traffic is allowed. The mining operations in the future should be conducted in accordance with the permit documents. This report is to state that the repair to the FGD landfill geosynthetic liner was conducted in general accordance with plans and specifications. Sincerely, JOYCE ENGINEERING, INC. Amy Davis, P.E. Hannu Kemppinen, P.G. Senior Project Consultant Senior Project Consultant Reference: Geosynthetic Design Guidance for Hazardous Waste, Landfill Cells and Surface Impoundments by G.M Richardson and R.M. Koerner. Duke Energy Belews Creek Steam Station Page 4 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report 1. Damaged geosynthetic liner at Belews Creek FGD landfill 2. Damage area prepared for repair. Duke Energy Belews Creek Steam Station Page 5 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report 3. Powder bentonite was placed over existing GCL to seal with new GCL. 4. New panel of GCL placed to cover existing damaged GCL. Duke Energy Belews Creek Steam Station Page 6 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report 5. Installer tacking membrane patch before extrusion welding. 6. Patch edge was ground clean in preparation for extrusion welding. Duke Energy Belews Creek Steam Station Page 7 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report 7. Installer extrusion welding a patch to the damaged liner. 8. Installers conducting vacuum box test on completed extrusion weld around the patch. Duke Energy Belews Creek Steam Station Page 8 Joyce Engineering, Inc. FGD Landfill Geosynthetic Liner Repair March 2016 CQA Certification Report 9. FGD landfill east end of Cell 4 gypsum mining area. ROLL #LOT #LINER TYPE Thickness Measurement ASTM D5994 (Modified) METRIC ENGLISH MIN MAX AVE mm mil mm mm mil mil Thickness Length Width m m feet feet Specific Gravity ASTM D792 MFI ASTM D1238 COND. E Melt Flow Index 190C/2160 g ‐ g/10 min Carbon Black Content ASTM D4218 Range Carbon Black Dispersion ASTM D5596 Category Tensile Strength ASTM D6693 (2 inches / minute) MD TD Tensile Elongation ASTM D6693 (2 inches / minute) Lo = 1.3" Yield Lo = 2.0" Break Average Elongation @ Yield Average Elongation @Break Dimensional Stability ASTM D1204 (Modified)Average Dimensional Change Tear Resistance ASTM D1004 (Modified)Average Tear Resistance Puncture Resistance FTMS 101 Method 2065 Modified Puncture Resistance ASTM D4833 (Modified) ESCR ASTM D1693 Average Peak Load Minumum Hrs w/o Failures Notched Constant Tensile Load ASTM D5397 Pass/Fail @ 30% Customer PO Destination Date Signature Quality Control Department g/cc % % % % N N 1500 Hrs 300 Hrs ppi ppi psi psi OIT(Standard) ASTM D 3895 minutes lbs lbs N/mm N/mm mm mil G15C081001 HFA610150 60 HD MICROSPIKE B/W 1.42 1.81 1.54 56 71 61 60 153.926 7.01 1.52 505 23 182 .947 .20 2.4 10 in Category 1 ‐0.75 134 PASS CERTIFIED 156 19033 27 Asperity ASTM D7466 Top Bottom 33 32 mil mil Grade K307 2791 2599 3377 3169 16 14 409 549 63 57253.5 596.0 2/16/2015 psi psi TD ppiN/mm 167 ppi 29 MD N/mm 20335 Average Strength @ Yield Average Strength @ Break MD TD % % MD TD MD TD lbsN280.2 Chesapeake Containment Systems 15117 Lumberton, NC Average METRIC ENGLISH Average Density CERTIFIED mm mm .84 .81 OA#29693 Product: MARLEX POLYETHYLENE K307 BULK Lot Number: HFA610150 ____________________________________________________________________________ Property Test Method Value Unit____________________________________________________________________________ Melt Index ASTM D1238 0.20 g/10mi HLMI Flow Rate ASTM D1238 19 g/10mi Density D1505 or D4883 0.938 g/cm3 Pellet Count P02.08.03 29 pel/g Production Date 01/03/2015____________________________________________________________________________ The data set forth herein have been carefully compiled by Chevron Phillips Chemical Company LP (CPChem). However, there is no warranty of any kind, either expressed or implied, applicable to its use, and the user assumes all risk and liability in connection therewith. Troy Griffin Quality Systems Coordinator For CoA questions contact Customer Service Representative at +1-832-813-4806 AGRU AMERICA INC:GEORGETOWN 500 GARRISON RD GEORGETOWN SC 29440 USA Recipient: PALMER Fax: CoA Date: 01/16/2015 Delivery #: 88988285 Page 1 of 1 PO #: 008968 Weight: 190700 LB Ship Date: 01/16/2015 Package: BULK Mode: Hopper Car Car #: CHVX890305 Seal No: 16294 Shipped To: Certificate of Analysis PRODUCT DATA SHEET AT THE CORE: This composite clay liner is composed of a uniform layer of granular sodium bentonite between a nonwoven and scrim- nonwoven textile for dimensional stability. GSE BentoLiner NWL Geosynthetic Clay Liner METRIC GSE BentoLiner “NWL” is a needlepunched reinforced composite geosynthetic clay liner (GCL) comprised of a uniform layer of granular sodium bentonite encapsulated between a nonwoven and a scrim-nonwoven geotextile for dimensional stability. The product is intended for moderate to steep slopes and moderate to high load applications where in- creased internal shear strength is required. Product Specifications Tested Property Test Method Frequency Value Geotextile Property Cap Nonwoven, Mass/Unit Area ASTM D 5261 1/20,000 m2 200 g/m2 MARV(1) Carrier Scrim Nonwoven, Mass/Unit Area ASTM D 5261 1/20,000 m2 200 g/m2 MARV Bentonite Property Swell Index ASTM D 5890 1/50,000 kg 24 ml/2 g min Moisture Content ASTM D 4643 1/50,000 kg 12% max Fluid Loss ASTM D 5891 1/50,000 kg 18 ml max Finished GCL Property Bentonite, Mass/Unit Area(2)ASTM D 5993 1/4,000 m2 3.66 kg/m2 MARV Tensile Strength(3)ASTM D 6768 1/4,000 m2 7.8 kN/m MARV Peel Strength ASTM D 6496 ASTM D 4632(4) 1/4,000 m2 610 N/m MARV93 N MARV Hydraulic Conductivity(5)ASTM D 5887 1/Week 5 x 10-9 cm/sec max Index Flux(5)ASTM D 5887 1/Week 1 x 10-8 m3/m2/sec max Internal Shear Strength(6)ASTM D 6243 Periodically 24 kPa Typical TYPICAL ROLL DIMENSIONS Width x Length(7)Typical Every Roll 4.7 m x 45.7 m Area per Roll Typical Every Roll 216 m2 Packaged Weight Typical Every Roll 1,179 kg NOTES: • (1)Minimum Average Roll Value. • (2)At 0% moisture content. • (3)Tested in machine direction. • (4)Modified ASTM D 4632 to use a 100 mm wide grip. The maximum peak of five specimens averaged in machine direction. • (5)Deaired, deionized water @ 34.5 kPa maximum effective confining stress and 13.8 kPa head pressure. • (6)Typical peak value for specimen hydrated for 24 hours and sheared under a 9.6 kPa normal stress. • (7)Roll widths and lengths have a tolerance of ±1%. GSE is a leading manufacturer and marketer of geosynthetic lining products and services. We’ve built a reputation of reliability through our dedication to providing consistency of product, price and protection to our global customers. Our commitment to innovation, our focus on quality and our industry expertise allow us the flexibility to collaborate with our clients to develop a custom, purpose-fit solution. For more information on this product and others, please visit us at GSEworld.com, call 800.435.2008 or contact your local sales office. This Information is provided for reference purposes only and is not intended as a warranty or guarantee. GSE assumes no liability in connection with the use of this Information. Specifications subject to change without notice. GSE and other trademarks in this document are registered trademarks of GSE Lining Technology, LLC in the United States and certain foreign countries. REV 15JUN2012 Tremco Incorporated 3735 Green Road  Beachwood, Ohio 44122  216-292-5000 Sealant/Weatherproofing Division Tremco Mameco/VULKEM Paramount™ Technical Services We certify that PARAGRANULAR fine granular sodium bentonite system as manufactured by Tremco Inc. Beachwood, OH, meets the following physical properties. Fine Granular Sodium Bentonite: DESCRIPTION: Fine granular sodium bentonite with an average particle size ranging between 20 and 100 mesh PURITY: Hydrous Aluminum silicate comprised principally of the clay mineral montmorilonite 90% minimum. Contains small amounts of feldspar, biotite, selenite, ect. COMPOSITION: Typical Chemical Analysis (moisture free) SiO3 63.02% Al2O3 21.08% Fe2O3 3.25% FeO 0.35% MgO 2.67% Na2O 2.57% CaO 0.65% H2O 5.64% Trace elements 0.72% FORMULA: A tri-layer expanding mineral structure of approximately: (Al, Fe1.67,, Mg0.33) Si4O10(OH2)Na+Ca++0.33 MOISTURE CONTENT: Maximum 12% as shipped WATER ABSORPTION: 600% of weight minimum Sincerely, Wes Hensley Wes Hensley Technical Services Representative cc: File/Circ.