NCD003446721_19900423_Celeanse Corporation - Shelby Fiber_FRBCERCLA RA_60% Remedial Design Report and Draft Remedial Action Work Plan Appendix I - Project Opreation Plan-OCR

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Westinghwse Environmental
and Gllllechnical Services, Inc.
5050N013
•
OPERABLE UNIT 2
4000 DeKalb Technology Parkway. NE
Suite 250
Atlanta. Georgia 30340
[phone]
FAX [phone]
60% REMEDIAL DESIGN REPORT AND
DRAFT REMEDIAL ACTION WORK PLAN
HOECHST CELANESE CORPORATION
SHELBY, NORTH CAROLINA
WESTINGHOUSE PROJECT 4124-85-0S0N
DOCUMENT CONTROL BS0S0N-0227
APPENDIX I
PROJECT OPERATION PLAN
Prepared For:
WESTINGHOUSE ENVIRONMENTAL AND
GEOTECHNICAL SERVICES, INC.
Atlanta, Georgia
and
HOECHST CELANESE CORPORATION
Shelby, North Carolina
Prepared By:
GDC ENGINEERING, INC.
April 1990
A Westinghouse Electric Corporation subsidiary.
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GDC ENGINEERING INC.
Consulting Engineers. Hydrogeologists & Environmental Scien1is1s
SPECIALIZING IN WASTE MANAGEMENT ANO SITE RESTOR.~TION
REMEDIAL ACTION WORK PLAN
ON-SITE INCINERATION AND SOLIDIFICATION
HOECHST CELANFSE CORPORATION
SHELBY, NORTH CAROLINA
Submitted To:
HOECHST CELANFSE
P.O. BOX 87
SHELBY, NC 28151-0087
Prepared By:
GDC ENGINEERING INC.
822 NEOSHO AVENUE
BATON ROUGE, LOUISIANA 70802
APRa 23, Im [ff) [B !lJ [} rr
822 NEOSHO AVENUE • BATON ROUGE, LOUISIANA 70802 • [phone] • FAX [phone]
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GDC ENGINEERING INC.
Consulting Engineers. Hydrogeologists & Environmental Scientists
SPECIALIZING IN WASTE MANAGEMENT AND SITE RESTORATION
TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 PROJECT OPERATIONS PLAN
2.1 REMEDIAL ACTIVITIES ON SCHEDULE
2.1.1 Mobilization for Materials Handling
2.1.2 Implementation of Materials Handling
2.1.3 Incineration Schedule
2.2 MATERIALS HANDLING OPERATIONS
2. 2.1 Site Investigations
2.2.2 Excavation Procedures
2.2.3 Waste/Soil Stockpiling Plans
2.2.4 Water Management Plan
2.2.4.1 Contaminated Stormwater and Groundwater
2.2.4.2 Scrubber Water
2.2.4.3 Centrate Water
2.2.5 Solidification Technique
2.2.6
2.2.7
2.2.8
2.2.9
2.2.5.1 Bench Scale Testing
2.2.5.2 Solidification Systems
Stream Sedimer.t Remediation Technique
2.2.6.1 Existing Condition
2.2.6.2 Remediation Approach
Backfilling Plan
Quantification of Remediated Materials
Sampling Materials and Process Sampling
2.3 THERMAL TREATMENT UNIT -OPERATION PROCEDURE
2.3.1 Mobilization
2.3.2 Incineration Run-In and Optimization
2.3.3 Incineration System Trial Burn
2.3.4 Incineration of Waste Material
2.3.5 Incineration Sy~tem Maintenance
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TABLE OF CONTENTS
(Continued)
2.4 INCINERATION SYSTEM DESCRIPTION
2.4. l Incinerator Design
2.4.1.1 Operating Conditions
2.4.1.2 Design Basis Assumptions
2.4.2 General Description
3.0 SAMPLING PLAN
3.1 INTRODUCTION
3.1.1 Project Description
3.1.2 Purpose
3.2 SAMPLING EQUIPMENT AND MATERIALS
3.2.1 Sampling Equipment
3.2.2 Sample Containers
3.3 AIR MONITORING
3.3.1 Baseline Air Quality
3.3.2 Air Quality Monitoring
3.3.3 Air Emission Monitoring
3.4 WATER MONITORING
3.4.1 Treatment System Monitoring
3.4.2 Stream Sediment Centrate Water
3.5 WASTE SAMPLING
3.5.1 Solidification Bench Scale Sampling
3.5.2 Incineration Feed and Ash Sampling
3.5.3 Solidified Material Sampling
3.6 SAMPLE HANDLING PROCEDURE
4.0 HEALTH AND SAFETY PLAN
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5.0 PERMITTING PLAN
5.1 INTRODUCTION
TABLE OF CONTENTS
(Continued)
5.2 PERMITS AND APPROVALS
6.0 QUALITY ASSURANCE PROJECT PLAN
6.1 PROJECT DESCRIPTION
6.1.1 Project Background
6.1.2 Project Objectives
6.2 PROJECT ORGANIZATION AND RESPONSIBILITY
6.2.1 Project Organiution and Personnel
6.2.1.1 Project Director
6.2.1.2 Advisory Team
6.2.1.3 Project Manager
6.2.1.4 Incinerator Operations Manager
6.2.1.5 Field Engineer
6.2.1.6 Site Operations Supervisors
6.2.1. 7 Company Health and Safety Officer
6.2.1.8 Site Health and Safety Coordinators
6.2.1.9 Company Quality Assurance/Quality Control Manager
6.3
6.2.2
6.2.3
Project Communications
Subcontractor Procurement
DATA QUALITY OBJECTIVES
MEASUREMENTS
6.3.1 Data Precision and Accuracy
6.3.2 Data Comparability
6.3.3 Data Representativeness
6.3.4 Data Completeness
AND ASSESSMENTS OF CRITICAL
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6.4
6.5
TABLE OF CONTENTS
( Continued)
SAMPLE COLLECTION AND HANDLING PROCEDURES
6.4.1 General Field Activities
6.4.2 Sample Collection Procedures
6.4.2.1 Containers and Equipment
6.4.2.2 Decontamination Procedures
6.4.2.3 Incinerator Systems Sample Collection and Analysis
6.4.2.4 Water Sample Collection and Analysis
6.4.2.5 Stabilired Material Sampling Collection
6.4.3 Sample Identification
6.4.4 Preservation, Shipping and Holding Times
6.4.5 Chain-of-Custody
CALIBRATION PROCEDURES AND FREQUENCY
6.6 DATA REDUCTION, VALIDATING AND REPORTING
6.7
6.8
6.6.1 Laboratory Data
6.6.2 Engineering Da•a
6.6.2.1 Numerical Analysis Procedures
6.6.2.2 Calculations
6.6.2.3 Peer Review
INTERNAL QUALITY CONTROL CHECKS
6. 7 .1 Field Operations
6.7.2 Laboratory Operation
6. 7.3 Data Evaluation and Report Preparation
PERFORMANCE AND.SYSTEM AUDITS
6.8.1 Laboratory Audits
6.8.2 Engineering Audits
6.8.3 Performance of Audits
ill 00 fil ~ II
6.8.4 Reports to Management/Project Response/Closure
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TABLE OF CONTENTS
( Continued)
6.9 PREVENTATIVE MAINTENANCE
6.10 ROlfTING PROCEDURES FOR QUALITY ASSURANCE
6.10.1 Laboratory Procedures
6.10.2 Data Quality Indication
6.11 CORRECTIVE ACTION
6.11.1 Laboratory Corrective Action
6.11.2 Engineering Corrective Action
6.12 QUALITY ASSURANCE REPORTS TO MANAGEMENT
6.12.1 Laboratory Reports
6.12.2 Engineering Reports
APPENDIX A Trial Bum
APPENDIX B State Permit Application
APPENDIX C Chain-of-Custody
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LIST OF FIGURES
2-1 Remediation Areas
2-2 Management Structure
2-3 Remediation Activities
2-4 Project Schedule
2-5 Support Facilities Layout Plan
2-6 Northern Area Exclusion Plan
2-7 Southern Area Exclusion Plan
2-8 Final Processing Layout Plan
2-9 Demobilizing and Restoration Plan
2-10 Staging Areas
2-11 Incinerator Equipment Pad and GRU Material Storage Area
2-12 Concrete Equipment Pad Details
2-13 GRU Materials Storage Area Cover
2-14 Decontamination Pad
2-15 Generalized Storage Pile
2-16 Conceptual Contaminated Water Treatment Plan
@mm ~ u
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[Ge DJ
LIST OF FIGURES
(Continued)
2-17 Water Treatment System Schematic
2-18 Incinerator Ash Solidification System
2-19 Pugmill Solidification System
2-20 Comceptualize Hydraulic Sediment Removal System
2-21 Mobile Rotary Incinerator
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1.0 INTRODUCTION
This Remedial Action Work Plan details the remediation activities described in the
Remedial Design Report to be completed by GDC Engineering under the oversite of
Westinghouse Environmental and Geotechnical Services Inc. This Work Plan contains the Project
Operations Plan and the Sampling Plan and the Quality Control/Quality Assurance Plan which
covers GDC monitoring of the various remediation processes such as incineration, solidification
and storm and process water treatment.
The require Health and Safety Plan to cover GDC's remediation activities is included with
the Trial Bum Plan contained in Appendix 2,.
Although permits are not required for this approved superfund remediation, compliance
with permit standards is necessary. A Permitting Plan is included with the Work Plan which
outlines the procedures used to ensure that the incinerator portion of the project complys with
the EPA and State of North Carolina air pollution standards.
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2.0 PROJECT OPERATIONS PLAN
2.1 REMEDIAL ACTIVITIES AND SCHEDULE
This section identifies the activities required to remediate the site and presents a tentative schedule
for accomplishing the work. The areas to be remediated are identified in Figure 2-1. GDC will
be performing all of the proposed remediation work, without any subcontractors, except for the
trial bum monitoring. The organization to manage the project is described in this section and
is shown on Figure 2-2. The management structure has been designed to provide for effective
coordination with the Engineer (Westinghouse Environmental and Geotechnical, Inc.), Hoechst
Celanese Corporation and the regulatory agencies. This is important in order to facilitate the
Engineer's oversight role to ensure the required quantities of waste/soil are excavated, the
solidification goals are met, and incineration performance standards are obtained. The activities
specified in Figure 2-3 are divided into the following steps:
Step 1 -Work Plan Development and Initial Site Activities:
Development of a Work Plan (Health and Safety Plan & Excavation and Backfill
Plan), Trial Bum Plan, and completion of the air quality permit application. In
addition, provide support to the Engineer for community relations and developing
the Remedial Design and Quality Assurance/Quality Control Plan.
Step 2 -Mobilization anj Site Set-up:
Mobilization, site preparation (decontamination pad, incinerator pad, etc.) and set-
up the portable water treatment system.
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Page 2.2
Step 3 -Site Remediation:
a)
b)
c)
d)
e)
Excavate GRU, plastic chips and bum pit residual from Pit Areas 6, 7 and
8, followed by materials from Pit Areas 4 and S (Note Figure 2-1 for Pit
Area numbers).
Incinerator mobilization, erection, run-in and shakedown, system
optimization, trial bum and processing.
Remove stream sediment and solidify along with the plastic chips and bum
pit residual.
Continue excavation and processing materials from the other areas.
Scrape smear areas, backfill final excavation with final volume of
incinerator ash and revegetate the excavation area.
Step 4 -Demobilization:
Decontaminate equipment, restore staging area, and demobilize equipment.
2.1.1 Mobilization for Materials Handling
As discussed, Step 1 involves developing the various plans and permit application
and assisting the Engineer with the Remedial Design and QA/QC Plans, and
community relations. These activities must be completed and approved by EPA
prior to initiation of any site work.
Once the approvals have been obtained, site preparation and the delivery of
equipment to the site can be started under Step 2. Equipment required for
remediation can be divided into support and task specific equipment. The support
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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Page 2.3
equipment includes the office trailer, tool/supply trailer and small trucks. This
equipment along with the decontamination trailer and backhoe will be the first
items sent to the site.
Once utilities are connected and the decontamination pad has been constructed, the
excavation equipment (dump trucks, mixing truck and trackhoe) will be delivered
to the site. At the same time, the frac tanks and carbon absorption units, which
are part of the portable water treatment system, will be sent to the site.
The schedule for Step I is presented in Figure 2-4. The schedule could be
adversely impacted by weather conditions.
2.1.2 Implementation of Materials Handling
The technical approach for material handling is presented in Section 2.2 and
includes stabilization of the GRU material with sawdust to facilitate handling for
incineration and solidification of the ash and "other" materials which include bum
pit residuals, plastic chips and stream sediments. Major activities include the
removal of the overburden, the stabilization of the GRU material, the
transportation and storage of the stabilized GRU material, the incineration of the
GRU material, the solidification of the ash and "other" materials, the
backfilling/restoration of the site, equipment decontamination, and demobilization.
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822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
Page 2.4
These activities have been divided into Steps 3 and 4. A detail listing of activities
is presented on Figure 2-5 through 2-9. The schedule for these steps is presented
in Figure 2-4.
2.1.3 Incineration Schedule
The incineration schedule is a critical path item in the material handling. The
activities for incineration which include permit application and trial bum plan
development, mobilization, shakedown, trial bum, production bum and
demobilization. The associated schedule for these items is presented in Figure 2-
4.
Meeting the schedule for the initial excavation of waste is important to maintain
the overall project schedule. Once a supply of waste material is available, slippage
of subsequent excavation schedule would not adversely affect the overall remedial
schedule. In the case of incineration, it is imperative that all milestones are met
as identified on the schedule (Figure 2-4).
2.2 MATERIALS HANDLING OPERATIONS
This section provides details about the initial site activities, site remediation and site restoration.
Figure 2-1 shows areas requiring site remediation. Remediation and excavation activities include
_,;og app,~;m,"'1y 2000 ~b;, yanl, (cy) ofGRU -(iodifiJ"Jii} u
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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Page 2.5
cy of burn pit residuals, 600 cy of plastic chips and 110 cy of stream sediments. The GRU
material will be stabilized with sawdust, incinerated and the ash solidified. The "other" materials
will be blended and remediated by solidification.
The stream sediment will be removed from a portion of three on-site streams (Figure 2-1) by
slurrying with water and processing through a centrifuge. The resulting solids will be stabilized
and disposed of on-site as backfill in the original excavations of Pit Areas 4, 5, 6, 7 and 8.
2.2.1 Initial Site Activities
Initial site activities will involve locating staging areas, pits in the excavation areas,
foundation investigations for the incinerator and review of the stream sediments
to identify stream access points (Figure 2-1 and 2-10). Prior to excavation,
elevations will be established across both the excavation and staging area. These
elevations will be established on one-foot contours. Specific emphasis will be
placed on identifying routes of surface drainage. This information will be used
to support the surface drainage management plans. In addition, the appropriate
boundaries of each pit will be outlined and taped.
Foundation investigations will be conducted in the staging area to determine
suitability and design parameters for supporting various components of the
incinerator. Based on the information that is already available, soil testing may
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822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
Page 2.6
not be necessary. However, a magnetometer survey may be conducted if
construction debris or undesirable fill is suspected in the staging area. Proof
rolling may also be used prior to construction of the pads.
A survey of stream sediments will be conducted to aid in the determination of
sediment quantity and locations so that the operational plans can be finalized. This
information will be used to select darn and pumping points for the sediment
removal operations. The survey will consist of using the existing base topographic
map at a l • equals l 00 ft. scale and walking the stream to identify the areas with
sediment deposits and those which are at bedrock. These areas will then be
identified on the base topographic map.
2.2.2 Excavation Procedures
A total of eight areas or pits which contain waste have been identified as shown
in Figure 2-10. The associated volume of waste material, by type, is specified for
each area in Table 2.1.
GDC has designed the excavation procedure to meet the following objectives:
1)
2)
3)
4)
Prevent the spread of contamination.
Minimize the moisture content in the GRU material feed to the incinerator.
Control the amount of water which comes in coniact with the waste.
Minimize the time the excavation is open, thereby reducing the potential
of cave-ins, surface erosion and sedimentation, etc.
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Page 2.7
In order to minimize the amount of soil removed with the bum pit material and
plastic chip, the number and size of equipment used will be limited, also close
management and quality control of the excavation program will ensure that this
objective is met. A designated management or quality control person will be
directing the excavator operator during all times of waste excavation.
Step I includes this Work Plan development and the initial site activities. Steps
2 through 4 of the proposed remediation have been broken down into discrete and
sequential tasks for the purpose of describing the flow of activities associated with
waste handling and site restoration. These discrete tasks will also facilitate
instruction of field crews. However, the separation of the work into these Task
Descriptions must not prevent the smooth and logical flow of work in the field.
These Task Descriptions are consistent with major steps of the Work Plan as
described in Section 2.1 of this document. The tasks are illustrated (Figures 2-
5 through 2-9) and the following is a cross reference for each task and
corresponding figure number.
TASK FIGURE NO.
Step 2 Task I 2-5
Task 2 2-6
Step 3 Task 1 2-6
Task 2 2-6
Task 3 2-6
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Task4
TaskS
Task6
Task 7
Step 4 Task l
FIGURE NO.
2-7
2-7
2-8
2-8
2-9
Page 2.8
The Pit Areas referred to in the Task Descriptions are not numbered on the
illustration sketches prepared for each sketch. Refer to Figure 2-1 for numerical
identification of each of the Pit Areas. Table 2.1 provides an estimate of waste
material by type. Pit Areas 4, 5, 6, 7 and 8 are located in the area north of the
road passing through the central portion of the proposed excavation area. Pit
Areas 1, 2 and 3 are located ln the area south of the road passing through the
central portion of the proposed excavation area.
Step 2 Task l (Figure 2-5) provides for the preliminary mobilization of the support
facilities and foundations for the incinerator as follows:
Step 2 Task l A.
B.
C.
Build the incinerator and materials handling pad, 200' X
150'. See Figures 2-11 and 2-12 for layout.
Build the GRU materials storage pad, 40' X 150', with a 40'
X 152' temporary cover. See Figure 2-11 for layout of this
area and Figure 2-13 for details of the temporary cover.
Build an equipment decontamination pad, 16' X 60', as
shown on Figure 2-14.
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D.
Page 2.9
Set up project offices, control rooms, personnel
decontamination facility and other support facilities. See
Figure 2-11 for layout.
E. Set up a portable water treatment facility. See Figure 2-
11 for details.
Step 2 Task 2 (Figure 2-6) involves additional work which can be accomplished
prior to mobilization of the incinerator, but minimizes the time that the area to be
opened is disturbed as follows:
Step 2 Task 2 A.
B.
c.
Establish an Exclusion Zone (EZ) around the first area to be
opened and excavated, Pit Areas 4, 5, 6, 7 and 8.
Strip the clean soils from these areas over the GRU and
Bum Pit Areas 4, 5, 6, 7 and 8, utilizing tracked hydraulic
excavator type equipment.
Build earthen berms, utilizing a small dozer, around the areas
to be ·excavated with the strippings to control run-on and
run-off. The Exclusion Zone will coincide with the crown
of the berms and concrete curbs in the GRU storage area and
incinerator feed area.
Step 3 Task 1 (Figure 2-6) is the mobilization of the incinerator and associated
equipment and begins the excavation of the materials to be processed as follows:
Step 3 Task 1 A.
B.
Mobilize and erect the incinerator and the ash solidification
equipment.
Mobilize and erect the equipment for solidifying bum pit
residuals, plastic chips, and stream sediments ("other"
materials).
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c.
D.
E.
Page 2.10
Begin excavation of Pit Areas 4, 5, 6, 7 and 8. Stabilize and
store GRU materials in the covered GR U storage area. Store
"other" materials in the area designated for pugmill
solidification.
Complete excavation of Pit Area 8 and obtain certification
for backfilling for Pit Area 8.
Shape and line the area of Pit 8 for use as a collection basin
and sump area for run-off. All stormwater will be
transferred to this point .
Step 3 Task 2 (Figure 2-6) is the incinerator start-up and the processing_ of "other"
materials. The excavation and solidification of "other" materials will begin after
the Pit Areas in the northern section of the excavation area are determined to be
successfully cleaned.
Step 3 Task 2 A. Incinerator run-in and shakedown, system optimization and
trial bum using stabilized GRU materials from Pit Areas 5,
6 and 7. The first 60 tons of material to be burned for the
trial bum will be mixed with a surrogate POHC (Note Trial
Bum Plan).
822 NEOSHO AVENUE
B. Complete excavation of all GRU materials from Pit Areas
5, 6 and 7. Store these materials in the covered GRU
storage area. Complete excavation of all "other" materials
from Pit Areas 4, 5, 6 and 7. Stockpile these materials in
the area designated for stabilization.
C. Obtain a certificate from the Engineer for Pit Areas 4, 5, 6
and 7.
D. Stabiliz.e ash as it is produced and transport the stabilized ash
to Pit Areas 4, 5, 6 and 7 for permanent storage.
BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
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Page 2.11
E. Stabilize "other" materials after a certification is received
from the Engineer and backfill the stabilized • other" material
into Pit Areas 4, 5, 6 and 7 excavation.
Step 3 Task 3 (Figure 2-6) is the completion of processing of all "other" materials
available from northern Pit Areas and also stream sediments as available, and then
demobilization of the excavation and processing crew(s) while incinerating the
stored GRU materials.
Step 3 Task 3 A.
B.
C.
Operate incinerator, processing GRU materials obtained from
Pit Areas 5, 6 and 7.
Solidify ash as it is produced and transport the solidify ash
to cleaned Pit Areas 4, 5, 6 and 7 for permanent storage.
Complete solidification of all "other" materials excavated
from Areas 4, 5, 6, 7 and 8 and backfill into Areas 4, 5, 6,
and 7.
Step 3 Task 4 (Figure 2-7) is the opening of the area in the southern section of the
proposed excavation area.
Step 3 Task 4 A.
B.
Prior to depleting all GRU materials stored from Pit Areas
5, 6 and 7, expand the Exclusion Zone to encompass Pit
Areas 1, 2 and 3.
Strip the clean soils from the areas over the GRU and Bum
Pit Areas 1, 2 and 3, utilizing tracked hydraulic excavator
type equipment.
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C.
D.
Page 2.12
Build earthen benns around the areas to be excavated,
utilizing a small dozer, to control run-on and run-off. The
Exclusion '.Zone will coincide with the crown of the benns.
Grade the interior of the benn area to drain to the sump in
Pit 8.
Continue incinerator operations, processing GRU materials,
stabilizing ash and transporting the stabilized ash to Pit
Areas 4, 5, 6 and 7 for storage.
Step 3 Task 5 (Figure 2-7) is the excavation of all contaminated materials in the
Pit Areas in the southern portion of the proposed excavation area.
Step 3 Task 5 A.
B.
C.
D.
Excavate all GRU materials from Pit Areas l and 3.
Stabilize and store all GRU materials in the GRU storage
area.
Excavate all "other" materials to a stockpile in area
designated for solidification.
Obtain certification from Engineer for Pit Areas l, 2 and 3.
Continue incinerator operations, processing GRU materials,
solidifying ash and transporting the solidified ash to Pit Areas
4, 5, 6 and 7 for backfill.
Step 3 Task 6 (Figure 2-8) is the reduction of the Exclusion '.Zone to include only
the GRU materials storage area and equipment decontamination area.
Step 3 Task 6 A. After all GRU materials are stored in the covered GRU
storage area, collapse the EZ to encompass only the GRU
storage area and the equipment decontamination station.
@ffil1J[}U
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B.
C.
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Page 2.13
Continue incinerator operations, processing GRU materials,
solidifying ash and transporting the solidified ash to cleaned
Pit Areas 4, 5, 6 and 7 for storage.
Complete processing all "other" materials from Pit Areas 1,
2 and 3 and backfill all solidified materials into Pit Areas
4, 5, 6 and 7.
If stream bed materials are available during this phase, those
materials should be handled with "other" materials.
Step 3 Task 7 (Figure 2-8) is the reclamation of all excavation areas except for
sufficient area to store remaining solidified ash from the incinerator operations and
from stream sediment cleaning operations.
Step 3 Task 7 A.
B.
C.
D.
Utilizing small dozer, push berm materials over all Pit Areas
except for sump in Pit Areas 6, 7 and 8, grading site to
drain to facilitate a stable base for revegetating all disturbed
areas. · Excess materials from the northern area stripping
should be used to backfill the southern area excavations.
Revegetate all disturbed areas except Pit Areas 6, 7 and 8.
Continue and complete incinerator processing of all GRU
materials, solidifying ash and transporting the solidified ash
to Pit Areas 6, 7 and 8 for storage.
Complete removal of all stream bed sediments, solidify and
store these materials in Pit Areas 6, 7 and 8.
Step 4 Task 1 (Figure 2-9) is the completion of incinerator operations and other
remedial activities, reclamation and restoration of the site as follows:
fID ill ill ~ 11
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Step 4 Task 1 A.
B.
C.
D.
E.
F.
G.
Page 2.14
Decontaminate all equipment and GRU storage area,
incinerate all recoverable decontamination media, solidify
the ash and transport the solidified ash to Pit Areas 6, 7 and
8 for storage.
Dispose of carbon from the portable water treatment system
off-site and finish decontamination work.
Collapse and remove Exclusion Zone.
Grade remaining Pit Areas 6, 7 and 8 to drain and
revegetate. Obtain clean fill from off-site sources, as
necessary.
Demobilize all equipment, except equipment required for
reclamation.
Reclaim and restore all staging areas. The GRU storage area
and slab structures may be left for Hoechst Celanese use.
Revegetate all disturbed areas and final demobilization.
During excavation, dust control may be necessary at the pits. If necessary, GDC
proposes to use a mist system in the excavation areas. The spray heads are the key
element of this mist system. A wetting agent can also be used in the mist system,
if necessary.
Routing of truck traffic is important to minimize disturbance of plant traffic and
the spread of contamination. GDC plans to utilize a combination of portable mats
and a board road within the excavation areas as necessary. These roads will limit
spread of contamination and will be easy to decontaminate at the end of the
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802
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Page 2.15
project, and keep on-site production vehicles off the permanent Hoechst Celanese
access roads as much as possible.
Bum pit residuals sometimes contain construction scrap such as crushed drums,
banding steel, strel-pipeand other miscellaneous material. This construction scrap
will be mechanically separated when encountered and stockpiled separately from
the balance of "other" material after surface decontamination. This scrap material
will be placed directly into the cleaned Pit Areas 4, 5, 6, 7 and 8 along with the
solidified incinerator ash and solidified "other" materials. If wood waste such as
pallets is encountered, it will be separated and chipped for incineration along with
the GRU and sawdust mixture.
As part of good housekeeping practice, truck cleaning procedures will be used at
the excavation areas to limit soil scattering. Cleaning personnel will scrape off
loose soil from the exterior portions of trucks after they are loaded, as necessary,
to prevent the spread of contaminant and solid wastes.
Any equipment to be removed from the site will be decontaminated. The
decontamination procedure as specified in this plan will be performed on a concrete
pad (Figure 2-14). The specified decontamination procedure is as follows:
I.
2.
Scrape the equipment clean of loose dirt.
Steam clean the exterior.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
3.
4.
Wash with Alconox or trisodium phosphate and water.
Rinse with potable water.
2.2.3 Waste/Soil Stockpiline Ptans
Page 2. 16
The incinerator feed material stockpile, stabilized GRU materials, will be located
adjacent to the incinerator on a concrete pad and covered by a temporary open
sided building (see Figures 1-11 and 1-12 for details). This storage area has been
sized to contain approximately 1200 cubic yards when material is piled six feet
high, which equals a 50 to 60 day feed supply. This volume capacity is also
sufficient to store at least half of the total quantity of GRU material after it has
been stabilized with sawdust. Sufficient quantities of sawdust will be utilized to
absorb all free liquids in the GRU sludges and to give the mix the proper
consistency for handling with a "Bobcat" sized front end loader. The front end
loader will stockpile the stabilized materials for maximum and orderly use of the
storage area.
Naphthalene, a surrogate POHC, will be added to the first 60 tons of stabilized
material for use in the Trial Bum. The rationale for selection of the surrogate
POHC and methods used to mix and sample the material is specified in the Trial
Bum Plan.
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Page 2.17
"Other" materials to be solidified will be stockpiled in the excavation area east of
the GRU and Bum Pits in the northern section of the excavation area. This
location is shown on Figures 2-5 through 2-8. "Other" materials consist of bum
pit residuals, plastic chips and stream bed sediments. The materials will be
transported to this stockpile area by a dump truck from the excavation. Stream
sediments will be transported to the stockpile from the stream area in roll-off
boxes. The stockpile will be built by a small dozer pushing the material up into
a stockpile shape after dumping. This will aid in the blending process as each
dumped load is pushed out in relatively thin layers in the stockpile.
The inactive portions of the stockpile, as it is being built, will be covered with a
HOPE 40 mil liner. A conceptual sketch of the stockpile cover system is shown
in Figure 2-15.
Overburden soils stripped from the excavation areas will be stored temporarily
adjacent to the excavations in berms. The berms will control run-on and run-
off waters. The l:erms will be shaped with a dozer after the material is excavated
by tracked hydraulic excavators and placed in the berm area. The dozer tracking
over the berms will densify and seal the berms.
Security is a concern for both the excavation and stockpile areas. Posts with
highly visible barrier tape will be erected along the crests of the berms to prevent
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 "~,~,® OOll.l~Jr
Page 2.18
inadvertent intrusions. As stated in this plan, this will correspond to the Exclusion
Z.One. The Exclusion Z.One will always be completely encircled by highly visible
barrier tape and posted to limit access. Once the incineration phase is started,
security will be provided on a 24 hour basis by the crew manning the incinerator.
2.2.4 Water Management Plan
Water requiring treatment may be generated from four sources:
a) Water from the incinerator scrubber.
b)
c)
d)
Stormwater or water trapped in the excavations.
Centrate water from the centrifugation of slurried stream sediments.
Decontamination water.
These waters are required to be treated to meet Hoechst Celanese's NPDES
discharge requirements. Once these standards are met, the water may be
discharged into the polishing ponds prior to the plant's NPDES outfall (Figure 2-
10). The proposed treatment approaches are presented in Figure 2-16 and
discussed below for each source of water requiring treatment.
2.2.4.1
822 NEOSHO AVENUE
Scrubber Water
By properly controlling the incinerator temperature and retention
times, all the organics will be destroyed during incineration.
Accordingly, little if any organics and contaminants will appear in
fIDrIDfil~U
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2.2.4.2
822 NEOSHO AVENUE
Page 2. 19
the scrubber water. The most likely contaminants in the scrubber
water will be particulates and metals from two sources: (I) carry
over of metal oxides in the particulates and (2) the formation of
vo!atile metal compounds such antimmiy. On this basis, the
scrubber water could require the following treatment: pH
adjustment and polymer addition for particulate and metals removal.
Contaminated Stormwater
In order to limit the amount of water to be managed, procedures
will be used to protect the excavations and stockpiles from contact
with water. The excavation area will have a berm to prevent run~
on and covered or backfilled, as soon as possible. The overburden
stockpiles of materials to be solidified will be covered with HOPE
material to prevent water infiltration. Also each stockpile will be
bermed and provided with a sump system to prevent run-on and
collect run-off. Similarly, the incinerator feed stockpile will be in
a temporary building on a pad to prevent contact with water.
In order to select portable water treatment system components, an
estimate of water quality was needed. Since data on contaminated
groundwater was available, it was used to estimate stormwater
quality which will need to be treated.
There is a host of organic chemical compounds reported in the
groundwater analysis as shown in Tables I and 4 of Westinghouse's
Remedial Investigation/Feasibility Study. A review of these tables
ini:icates that the materials present can be described as falling into
three classes:
(a)
(b)
(c)
Chlorinated hydrocarbons
Polynuclear hydrocarbons
Metals
Th~ above classifications are somewhat arbitrary since several
compounds present can be placed in either category (a) or (b). As
a simplification, these dual class compounds have been placed in
category (a) or (b) depending on their volatility.
ill 00 ill ~ U
BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
2.2.4.3
822 NEOSHO AVENUE
Page 2.20
In general, the chlorinated hydrocarbons exhibit a high enough
vapor pressure to render them amenable to air stripping.
Furthennore, only two compounds (carbon tetrachloride and benzyl
alcohol) are reported in sufficient concentration to exceed the
Federal OCPSF guideline. Both of these compounds are quite
volatile and can be removed by air stripping in a properly designed
system.
If this water stream is air stripped, substantial reductions in the
concentrations of the other chlorinated hydrocarbons will be
achieved also. Non-chlorinated hydrocarbons such as toluene,
benrene and xylene will also be removed in the air stripper.
The polynuclear materials, which includes some higher molecular
weight compounds which are not polynuclear, are probably best
removed by carbon absorption. None of the polynuclear compounds
are present in the groundwater in concentrations greater than those
listed in the guidelines.
Due to the low level of organic loading, carbon absorption is the
anticipated method for organic removal. An anticipated treatment
sequence is presented in Figure 2-18. The approach includes
primary solids removal in a clarifier followed by filtration and
carbon absorption.
Centrate Water
Making the assumption that the slurry water will contain the same
species as the groundwater, the treatment would be the same; i.e.,
carbon treatment for volatile organics and polynuclear hydrocarbon
removal, and possible removal of metals.
Analysis of this centrate water from the recirculation tank will be
COilducted to detennine applicable treatment technology.
Figure 2-16 is a conceptual flow sheet of the proposed treatment
sequence for all three sources of water. It can be noted that treated
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2.2.4.4
Page 2.21
Decontamination Water
Ttie decontamination water should be similar to the stormwater in
characteristics. Therefore, it will be treated as described in Section
2.2.4.2.
2.2.5 Solidification Technique
2.2.5.1
822 NEOSHO AVENUE
Bench Scale Testing
The purpose of the solidification process is to ensure that the waste
will not exceed Toxic Characteristic Leaching Procedure ('I'CLP)
maximum contaminant levels or I mg/I for extracted ethylene
glycol. The percentage of cement addition may be varied as
necessary to meet the solidification goals. This will be determined
for each type of material to be solidified by bench scale testing in
GDC's laboratory with confirming analyses performed by an outside
commercial laboratory.
As discussed in Section 3.5 of the Sampling Plan, samples for the
bench scale testing will be taken from the GRU stockpile burn pit
residual/plastic chips stockpile and roll-off boxes containing the
stream sediments. This approach will help to ensure representative
samples are used because the material should be well mixed prior
to sampling as a result of stockpiling or processing.
Prior to solidification, the GRU material will be ashed. Each
material (incinerator ash, burn pit residual, plastic chips mixture and
stream sediments) will then be subjected to bench scale testing using
admixtures of various percentages of cement. The samples will first
be tested using JO percent and 15 percent cement by weight. A
minimum of three samples from each mixture will be tested for
TCLP plus extractable ethylene glycol and antimony. The cure time
wi!l be 28 days for the chemical analyses and 7 and 28 days for
compressive strength analysis.
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
2.2.5.2
822 NEOSHO AVENUE
Page 2.22
Solidification Systems
Two separate solidification systems will be used with a common
disposal area. The incinerator ash will be solidified using a
dedicated system associated with the incinerator (Figure 2-18). The
other materials will be solidified in the pugmill system (Figure 2-
19) which will be set-up adjacent to the solidified material repository
area.
The incinerator ash handling system and the solidification system
will be connected. As shown in Figure 2-18, the incinerator ash
will be discharged from the kiln barrel to a wet sump supplied with
polymer feed to promote settling. Liquid level will be automatically
controlled in the wet sump by a float actuated valve. From the wet
sump, the continuous drag belt assembly conveys the ash up the
inclined beach surface. The dewatered incinerator ash is discharged
to a hopper. The hopper discharges the materials into the low pitch
conveyor-blender with twin augers. Materials are mixed in the
conveyor-blender and discharged onto a belt conveyor to a dump
truck for transport back to the designated excavation.
The feed to the incinerator ash solidification system is controlled
manually by the operator. The ash reaches an equilibrium condition
in the wet sump. Since the quantity of cement addition is dictated
by water content, cement addition will be controlled manually based
on visual inspection of the water content of the solidified ash.
The ash generated during the trial bum will be partly solidified in
the incinerator ash solidification system to control excess water and
stored in a covered roll-off box. Once it has been tested, it will be
solidified for backfilling.
The proposed solidification system for the other materials is shown
in Figure 2-19. Materials will be transferred from the stockpile to
the feed hopper by a backhoe. The feed hopper has a grizzly grate
to remove construction debris. The material from the hopper
discharges into the pugmill over a weigh belt. Based on weight,
cement will be added directly to the pugmill via the screw conveyor
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from the storage hopper. Water addition is controlled manually I
-oo ~aw;,-of~ .. w ="'/ 0)1mti w 1J I
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Page 2.23
2.2.6 Stream Sediment Remediation Technique
2.2.6.1
822 NEOSHO AVENUE
Existing Condition
The Final Feasibility Study Report Operable Unit 2 characterized
the, area streams and associated sediment as follows:
"Examination of existing data and mapping the appearance of the
perimeter streams show that they contain little bedload and are
frequently incised to rock. The streams are typically effluent
streams receiving their baseflow from groundwater discharge from
the banks or through the stream bottoms. Exceptions to complete
groundwater capture by the streams could occur on the smaller
tributaries or where flow in isolated rock fractures extends beyond
the stream. However, based on available data, the perimeter
streams appear to be the discharge lines for groundwater exiting the
si~!:."
The stream segments which require sediment removal are not even
designated as intermittent streams on the U.S. G. S. topographic map.
These drainages are mere! y topographic reliefs which convey surface
drainage during rainfall events. Based on historic information and
a site visit by GDC personnel, it appears that stream sediment in
these areas is limited to pool or low areas and point bars. Also, the
seoiment characteristics will change; i.e. coarse in the headwaters
to fine at the lower end where backwater effect from the stream
co9fluent occurs (Figure 2-1). Also, flow is seasonal with zero or
low flow during the late summer/early fall period.
It is assumed that contamination will be primarily associated with
the fine clay sediment. Field data from the Final Feasibility Study
Report Operable Unit 2 confirms this assumption with high
concentrations in the upper end where contaminants were introduced
and the confluent of the stream where fine sediments are deposited.
BA~ON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
2.2.6.2
822 NEOSHO AVENUE
Page 2.24
Remediation Approach
Prior to remediation, a survey of the stream will be conducted to
identify areas with sediment.
Due to the poor accessibility to the stream, GDC has developed a
unique remediation approach. GDC plans to remove the surface
sediment (6 inches) by slurrying with water and pumping the
mixture to a centrifuge system for dewatering. Solids from the
system will be trucked to the excavation area for solidification and
the water (centrate) will be reused. To prevent discharge of water
from the flushing action, a temporary dam will be installed
downgradient. Once the stream sediments have been removed from
all stream segments, the water will be treated as discussed in Section
2.2.4 and discharged to Hoechst Celanese's wastewater treatment
system.
The procedure is to block off a small section of the drainage (50 to
150 feet) using sand bag dams with HOPE liner upstream and
downstream, set up a pump and bypass pipeline, and begin the
sediment slurrying process (Figure 2-20). After sediment removal
is complete, the system will be moved downgradient to the next
section of the drainage. This procedure will be repeated as
necessary until the entire segment is cleaned.
This approach requires remediation to coincide with the dry season
to limit the need for major diversion of the surface water.
Temporary or contingency water diversion can be accomplished by
use of a temporary upgradient dam and sump with pumping as
needed (Figure 2-20). The water to be bypassed will be pumped
via a temporary PVC pipeline or discharge hose to a point in the
ravine below the active area of sediment removal.
BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
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Page 2.25
2.2. 7 Backfilling Plan
All excavations will be backfilled to approximate original grade and all areas will
be graded to drain to provide a stable surface to facilitate future mowing and
maintenance operations.
Some excavations are designated to be backfilled with fill and topsoil only. These
excavations are Pit Areas 1, 2 and 3 located to the south of the road passing
through the excavation central area.
The fill for these designated fill only areas will be obtained entirely from the
overburden soils stripped from over the excavation areas on-site both in the south
area and in the north area or borrowed on-site, if necessary. The fill material will
be placed in approximate 8 inch lifts and compacted. Top soil will be brought in
from off-site and compacted. This area to the south of the central excavation area
will be the first area completely backfilled and graded.
Other excavation areas are designated to be backfilled with solidified waste
materials, then capped with fill material and topsoil. These excavations are Pit
Areas 4, S, 6, 7 and 8, located to the north of the road passing through the
excavation central areas.
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Page 2.26
Solidified ash from the incinerator will be transported to these designated
excavations and clumped prior to the initial set or curing of the portlaild cement.
The solidified ash will be spread sufficiently to ensure no air voids are
incorporated in the fill. Solidified "other" materials will also be transported to
these designated excavations and dumped prior to initial set of the portland cement.
The solidified "other" materials will also be spread sufficiently to ensure no air
voids are incorporated in the fill.
The excavation areas designated for backfill with solidified wastes will be
backfilled starting with Pit Area 4 and working towards Pit Area 6 and then
towards Pit Area 8. The solidified wastes will be brought to a maximum of I 8
inches below the original grade, if possible. A minimum of 12 inches of
compacted low JX!rrnability fine grained soils will be placed on top of the solidified
wastes and a minimum of 6 inches of topsoil will be placed on the compacted low
J)(!rtnability fine grained soils.
Depending on the volume lost in the incineration process and on the volume of
stream sediment materials, a small amount of additional fill from on-site sources
may be required ior the final cover of Pit Areas 6, 7 and 8.
As stated in the excavation plan, when encountered, construction scrap such as
crushed drums, steel strapping and other miscellaneous material not suitable for
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[phone] FAX [phone] I 822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802
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lGcDJ
Page 2.27
pugmill processing will be mechanically separated and surface decontaminated
during the excavation and storage process. Porous material such as wood will be
chipped and fed to the incinerator. During backfill operations, these construction
non-porous scraps will be placed in the backfill areas along with the solidified
waste materials from the incinerator operation and from the solidification of
"other" materials.
A dozer will be used to spread the 6 inches of topsoil. All areas will then be
revegetated by fertilizing and seeding with fescue or similar grass.
2. 2. 8 Ouanti fication of Remediation Materials
Two methods will be used to quantify the volumes handled during remediation.
The preferred method will be to weigh the material fed to the incinerator or the
solidification equipment. These weights can then be converted to volumes as
necessary. The other method will be the use of standard survey techniques to
quantify volumes removed or backfilled.
2.2.9 Materials and Process Sampling
Specified decontamination steps will be as follows:
0 Wash in Alconox and tap water solution.
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Page 2.28
o Rinse with hot tap water.
o Rinse with pesticide grade isopropyl alcohol.
o Rinse with deionized water.
o Wrap in aluminum foil.
o Seal foil with custody seal if equipment is to be stored for later use.
Pertinent data relating to each samples will be recorded on a sample documentation
form, label/tag and in the field log book. Each sample will be defined with the
following entries at a minimum:
o Date and time sample is collected.
o Sample I.D. number.
o Location of sampling point.
o Type of sample.
o Field measurements.
o Collector.
In addition, information regarding shipment of samples will be recorded on the
chain-of-custody forms. To ensure valid results, the laboratory testing will be
performed under the laboratory's own in-house laboratory QA/QC program
(Section 6. 0). This program will include the following type of checks:
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Page 2.29
o Duplicate samples.
o Internal audit samples.
o Documentation of analytical methods used.
o Documentation of equipment maintenance, testing, and calibration.
o Use of an adequate record system for documentation.
2.3 THERMAL TREATMENT UNIT-OPERATIONAL PROCEDURES
GDC Engineering Inc. 's thermal treatment unit is a totally integrated incineration system for
destroying waste (Figure 2-21). The incineration system consists of a feed system, a rotary kiln,
a secondary combustion chamber and air pollution control equipment. The rotary kiln is a direct
fired rotating chamber that volatilires the organics in the waste material. The secondary
combustion chamber utilires supplemental fossil fuel to maintain destruction temperatures up to
approximately 2200 degrees Fahrenheit. The combustion off-gases from the secondary chamber
go into the air pollution control system for quenching and removal of particulate before exiting
the system through the exhaust stack. A detailed description of the incineration system is given
in Section 2.4 of this document.
The incineration of the waste materials will be conducted in accordance with the EPA Office of
Solid Waste and Emergency Response's "Guidance Manual for Hazardous Waste Incinerator
Permits (SW-966)", dated July, 1983. RCRA regulations governing the thermal destruction of
hazardous wastes requires the demonstration of a POHC destruction and removal efficiency
rn rm m ~ 1r
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 2.30
(DRE) of 99.99%. This DRE determination is made by comparing the POHC(s) concentration
in the feed material to the results of exhaust gas sampling performed during the treatment period.
To ensure that the guidelines established by the EPA and the state agencies for incineration of
hazardous wastes are followed, the GDC Incineration Operations Team will use the operational
procedures outlined below.
2.3.1 Mobilization
The mobilization activities of the incineration system include transporting the
equipment to the site, mobilizing the operating personnel, preparing the site for
the incineration equipment and setting up the incineration system on-site. The
Field Engineer will direct the mobilization activities utilizing the operations
personnel to ensure proper site preparation and equipment erection. The key
mobilization activities include, but are not limited to, the following:
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Site Preparation: The site preparation work consists of leveling an area for
the incineration system, pouring a concrete pad, erecting barriers around
the excavation areas, setting the spill prevention measures and designing
the site for efficient operation.
Equipment Transport: GDC will engage licensed carriers to transport all
equipment to the job site.
Equipment Erection: The activities of this phase include erecting the
equipment, piping up the utilities and setting up the ancillary equipment.
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Page 2.31
2.3.2 Incineration Run-In and Optimization
The incinerator run-in process entails running in all motors, blowers, fans and
drives, checking out all electrical circuits, calibrating all instrument loops and
setting all alarms and interlocks at the required setpoints. Incinerator optimization
requires the start-up and operation of the incinerator to establish the optimum
operating parameters for processing material at the highest throughput. The
Incinerator Operations Team will perform the operating tasks necessary for
optimizing the incineration system. The major exercises for this phase include the
following:
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All electrical circuits will be checked for proper wiring and connection
before any equipment is started.
Run-in of all electrical motors and drives before being connected to the
fans, blowers, pumps and driven equipment. The motors and drives must
be checked for proper alignment and leveling before connecting the
electrical power. During the initial run-in of the motors and drives,
vibration readings will be taken to establish a data base of information for
future reference. After the drives are run-in and checked, they will be
connected to the fans, blowers, pumps and driven equipment according
to manufacturers' specifications. The equipment is then operated without
loading to check alignment and vibration.
All instrumentation loops from the incineration equipment to the control
center will be verified for proper response and then calibrated according
to the vendors' specification.
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Page 2.32
When the above tasks are completed, the incineration system start-up will
commence. The electrical circuits will be energized and all alarms and
interlocks will be initiated as the first step in the start-up sequence. Next,
all utility supply lines (water, gas, air ... etc) will be activated.
The pilot burner in the rotary kiln will then be ignited to begin a slow dry-
out and curing of the refractory in the chamber. After an initial drying
period, the main gas burner will be put into service to continue refractory
curing. The temperature in the rotary kiln will be increased to complete
the curing process as specified by the refractory vendor. The air pollution
control system will be activated at this point to prevent overheating of the
quenching and scrubbing equipment. The heated gases from the kiln will
flow through the secondary combustion chamber as the temperature is
increased and will begin the dry-out and curing of the refractory in that
chamber. The main gas burner in the secondary chamber will be fired as
necessary to complete the curing of the refractory. When the refractory
curing is completed, the unit will be shutdown and cooled in order to
inspect for incomplete curing and excessive cracks in the refractory.
After the refractory curing and subsequent inspection is complete, the
incineration system will be put into service to optimize the operating
parameters for burning waste at the highest possible throughput. The
optimization of the incineration system may require a period of 720
operating hours and will be conducted in accordance with EPA regulations
40 CFR 270.62. During the system optimization, waste material from the
stockpile will be processed after the established operating parameters and
conditions are met.
The alarms and interlocks will be checked to ensure proper operation. The
air pollution control equipment will then be put into service and the correct
flows established. The burner in the rotary kiln will be fired to begin
system heat-up. As the rotary kiln approaches operating temperature, the
burner in the secondary chamber will be ignited to complete system heat-
up. When the system is operating at the pre-selected temperatures, waste
material will be introduced into the rotary kiln. As the waste processing
continues, adjustment will be made to the operating temperatures, flows
and residence times to establish the optimum operating parameters required
for obtaining complete burnout at the highest possible throughput.
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Page 2.33
2. 3. 3 Incineration System Trial Burn
A trial burn test will be conducted on the incineration system before proceeding
to full thermal treatment of the waste. The trial burn will be run in accordance
with 40 CFR 270.62 and the approved Trial Burn Plan. The data from the trial
burn test will provide infonnation about the incineration system under different
operating conditions while ensuring that POHCs (principal organic hazardous
constituents) are destroyed during the combustion process. The GDC Project
Manager will oversee the activities of the GDC Operations Team and the outside
subcontractors required for sampling and analytical work, and will liaison with the
Engineer and the EPA to ensure that the trial burn is conducted according to the
regulations. The Incinerator Operations Manager will direct the work activities
of the operating personnel and the subcontract people and act as liaison between
the two groups during the trial burn tests. The key tasks of the trial burn include
the following:
0
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The electrical circuits will be energized and all alarms and interlocks will
be initiated as the first step in the start-up sequence. Next, all utility
supply lines (water, gas, .. etc) will be activated. All instrumentation loops
from the incineration equipment to the control center will verified for
proper response and then calibrated, if necessary.
The alarms and interlocks will be checked to ensure proper operation. The
air pollution control equipment will then be put into service and the correct
flows established. The burner in the rotary kiln will be fired on
supplemental fuel to begin system heat-up. As the rotary kiln approaches
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Page 2.34
operating temperature, the burner in the secondary chamber will be ignited
to complete system heat-up. When the system is operating at the pre-
selected temperatures, waste material will be introduced into the rotary kiln.
As the waste processing continues, adjustment will be made to the operating
parameters to establish the operating conditions for the first trial bum test.
When the conditions for the first test are reached and the incineration
system is ~tabilized, the sampling crew will begin pulling samples from the
feed stream, the ash discharge, the scrubber water effluent stream and the
exhaust stack. When sampling for the first test is completed, the sample
crews will remove the sampling apparatus and install clean equipment for
the second test.
While the sampling apparatus is being changed, the incineration operations
personnel will make the appropriate changes to the operating conditions to
ready the system for the next test at different operating parameters.
When the sampling crews are ready and the incineration system is stabilized
at the new operating conditions, the second test will be conducted as
described above. Depending on the time required for pulling enough
sample material for proper analysis, it may be necessary to run each trial
bum test on separate days.
The above, procedures will be followed for each successive test required by
the Trial Bum Plan. After the last trial bum test is completed, the
incineration system will continue to process material under temporary
operating conditions established by the EPA.
The samples collected during the trial bum tests will be shipped to the
selected laboratory for complete analysis. The laboratory will use the
appropriate methods as specified by SW-846 for analyzing the respective
samples. When analysis of all samples is complete, the data will be
compiled and put into a report for submission to the Engineer and the
EPA.
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Page 2.35
2.3.4 Incineration of Waste Material
The final operating conditions for the incineration of the waste will be set by the
EPA according to the results of the trial bum tests. The GDC Incineration
Operations Team will operate the incineration system in a manner to achieve
complete destruction of the contaminants in accordance to the guidelines
established by the EPA. The processing of the waste will be a 24 hour, 7 day
operation with the operating personnel working rotating shifts. The major tasks
of the incineration operations include, but are not limited to, the following:
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Start-up of the incineration system as described above.
Operation of the system according to the operating manual and
wi'.hin the guidelines established by the EPA.
Maintenance of the incineration system in accordance with the
procedures set forth in the operating manual.
,,
2.3.S Incineration System Maintenance
The Incineration Operations Team will perform routine maintenance tasks on the
incineration system on daily and weekly schedules. In addition to these tasks,
preventive maintenance items that can be accomplished while the system is in
operation will be completed on a periodic basis. The key maintenance chores
include, but are not limited to, the following:
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Page 2.36
Daily Maintenance
Inspect mounting bolts for motors, blowers, fans, conveyor belts,
instrument panels, valves, drives, pumps, screws, bearings, instruments
and all other related equipment.
Inspect the feed system hopper for proper material distribution on the
transfer belt.
Inspect the transfer conveyor belt for wear and alignment.
Inspect the rotary drive system for proper contact with the kiln.
Inspect the kiln support bearings for wear and overheating.
Inspect all drive connections and lubricate as necessary;
Inspect all kiln seals for leakage.
Inspect the burner system fuel lines and connections for leakage.
Inspect ash discharge system for noise caused by bearings and
misalignment.
Inspect all bearings for excessive temperature.
Inspect th:: secondary combustion chamber burner system for a possible
leakage of gas. Inspect the inside burner plate and insulation for cracks
and damage.
Check the scrubber flows in conjunction with the discharge pressure of the
pumps for possible plugging.
Inspect the scrubber area piping and scrubber for possible leaks; Inspect
the scrubber pumps for seal leaks, bearing temperatures and oil level.
Inspect the ID fan for excessive vibration, bearing temperatures and drive
belt tension.
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Page 2.37
Inspect all piping for movement.
Inspect the pH probe flow rate and adjust for proper flow.
Inspect pressure differential and flow rates on the quench nozzles.
Weekly Maintenance
Inspect all electrical connections for possible loose wiring.
Run emergency diesel generator.
Lubricate and check all drives.
' Inspect air compressor oil level, bearing temperatures and check air supply
for excess moisture.
Service feed preparation equipment.
Perform service on material handling equipment.
Inspect the primary and secondary chamber walls for hot spots that indicate
refractory,or insulation problems.
Inspect base support grouting and metal supports for corrosion.
Inspect all drive belts for wear, tension and brittleness.
Preventive Maintenance
If belts slip on start-up of the blowers, stop the blower and tighten belts.
Maintain a daily vibration log from first start-up of the ID fan and plot the
upward trend of the vibration.
Check daily for pump packing leaks. Tighten packing evenly. Replace
packing when the thickness is reduced to 1/4".
Change gearbox oil every six (6) months.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 2.38
Check all bearing temperatures daily. The temperature should not exceed
175°F.
Check bearings daily for housing cracks.
Remove spray nozzles and clean during every unit shutdown. Flush all
supply lines with nozzles removed.
Pull all strainer elements during each shutdown and clean.
2.4 INCINERATION SYSTEM DESCRIPTION
2.4.1 Design Basis Assumptions
GDC Engineering Inc. has engineered an incineration system to decontaminate the
wastes at the Hoechst Celanese plant in Shelby, NC, based on the following
assumptions:
Waste Analysis
moisture
carbon
hydrogen
oxygen
nitrogen
sodium
chlorine
ash
antimony
lead
chromium
upper
heating
value
36.1 %
7.8%
54.8%
0.003%
0.004%
0.03%
1.3%
4,000 mg/kg
0.75 mg/kg
3.0 mg/kg
5,440 BTU/lb
range 6-40%
average
average
average
average
average
average range 0.013-0.05%
average
average range 87-6,400 mg/kg
average range <0.02-53 mg/kg
average range 1.5-40.0 mg/kg
average range < 2000-7800
BTU/lb
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arsenic < 0.02 mg/kg
barium ,< 0.1 mg/kg
cadmium < 0.01 mg/kg
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chromium< 0.03 mg/kg
lead < 0.005 mg/kg
mercury < 0.0005 mg/kg
selenium < 0.005 mg/kg
silver < 0.05 mg/kg
Waste Characteristics
Page 2.39
o MixtureofGRU material and soil with no large rocks, debris
or other foreign objects.
0 Scrubber effluent water can be discharged into the plant
treatment system after any pretreatment.
o Waste analysis can be described in general by duLong's
approximation.
The incinerator is designed to process approximately 2,500 lbs/hr of waste with
an average of 30% moisture and a heating value of 5000 BTU/lb.
2 .4. 2 Detail Description
GDC Engineering Inc. 's mobile incineration system consists of a feed system, a
rotary kiln, a secondary combustion chamber and air pollution control equipment.
The rotary kiln is a direct fired rotating chamber that volatilires the organics in
the waste material. The secondary combustion chamber utilires supplemental fossil
fuel to maintain destruction temperatures up to approximate! y 2200 degrees
Fahrenheit. The combustion off-gases from the secondary chamber go into the air
pollution control system for quenching and removal of particulate before exiting
the system through the exhaust stack.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 2.40
Waste is continuously supplied to the rotary kiln by a feed system consisting of
a live bottom hopper, a weigh belt conveyor, and a screw feeder. The live bottom
hopper is located at grade for ease of filling with a front-end loader. It has
negative taper sides to eliminate bridging and is fitted with a variable speed drive
to meter the contaminated material onto the weigh belt conveyor. The weigh belt
conveyor moves the waste from the hopper to the rotary kiln feed screw. By
adjusting the speed of the feed screws, the feed rate to the kiln can be controlled
within the desired range.
The rotary kiln is a horirontal refractory-lined cylinder which turns about its
horirontal axis. It is set at approximately two degrees inclination. The kiln
rotates, continually exposing the waste material surfaces to the heat and oxygen
as the feed moves through the chamber. The kiln utilizes a fossil fuel burner to
vaporize the moisture and organic contaminants and remove them from the waste
feed. The volatiles are partially burned in the kiln and then pass into the
secondary combu~tion chamber. The solid residue, ash, exits the kiln through a
wet ash collection system that minimizes ingress of ambient air.
The exhaust gases from the kiln enter the secondary chamber where they are
heated up to 1800 to 2200°F by a fossil fueled burner and combustion air control
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Page 2.41
system. Contaminants in the flow stream are destroyed by the turbulent conditions
that prevail in the secondary combustion chamber.
The hot gases exit the secondary chamber and enter the pollution abatement
(scrubber) system for gas clean-up to meet the stringent requirements placed on
stack gases for hydrogen chloride, sulfur oxides and particulate emissions. The
incinerator off gases first enter a vertical "wet approach" quench duct. The gases
are saturated and quenched to the adiabatic dewpoint by two air atomizing cluster
nozzles. The gases then enter the first of two fiberglass reinforced plastic (FRP)
contact chambers where atomizing nozzles are used to intimately mix scrubber
liquid with the particulates and acid gases present in the gas stream to effect
primary removal of the high loading solids and gases. -Subsequently, the gases
enter the second c.ontact chamber where a finer distribution of droplets is sprayed
to contact and remove smaller particulate matter. The gases then enter the
turbulent agglomeration rone. The finest droplets are then sprayed in a vortex of
a specially modified exhauster where turbulence, mixing and subsequently
centrifugal separation take place. The droplets that escape separation in the fan
are removed in the entrainment separator. The entrainment separator (mist
eliminator) utilizes a chevron blade bank which provides plug free performance
followed by mesh eliminator banks with higher capture efficiency.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone]. FAX [phone]
! ,' Page 2.42
The incineration of the waste materials will be conducted in accordance with the
': ;-
EPA Office of Solid Waste and Emergency Response's "Guidance Manual for
i Hazardous Waste Incinerator Permits (SW-966)", dated July, 1983. RCRA
regulations governing the thermal destruction of hazardous wastes, requires t!.ie
demonstration of a POHC destruction and removal efficiency (DRE) of 99.99%.
This DRE determination is made by comparing the POHC(s) concentration in the
stabilized GRU material to the results of exhaust gas, residual ash and scrubb_er
water sampling performed during the treatment:period.
822 NEOSHO A.VENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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TABLE2.1
QUANTITY FSTIMA TE OF MATERIAL TO BE EXCAVATED
AREA OR ONE-FOOT
PIT NO. OF SOILS GRU RESIDUALS PLASTIC CHIPS 10fAI.S
•I 209 625 · '313 417 1564
-2 347 347
3 ,, .. 74 222 C . ,. 296
: ·4 : 178 ,, 178
::5 ·'l. 15 59. , 74
6 20 185 -205
7 74 148 17 239
8 74 297 139 37 547
TOTALS 466 1536 994 454 3450
NOTE: Volume of GRU, Bum Remedial and Plastic Chips are obtained from S&ME
Calculations Contained in the RI/FS.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 (504) 383°8556 FAX[phone]
~-~-_/._/----------~-~ ~% ----770 -760 50 ", I / ; .· · ........ · ~ ---------{\\ / I---"'-X\i . ~ ~ ----------------------------\ \ \\ I --------..:;'·\: .,,,------\ . ·•· .•·. (____ @ ~--:---<lo~~~ J. ~ ~ ~o t:::::i I I ~ ~"'---I 2 \\ ~---~-----~ \ !l/'l,Q ~y1 t)~ @ff Hoechst q(} / G-88,5 (j)G-50 0 F-55 • ~ Celanese Q Corp. Oj ~-. 11 I~ \ \ L.1 I F~·. If\\ ,,,---I &? C) 1;-K} § ,. __ I .. 'l , I I I (, I -. ., 0 Q::> -vo· 111 \\\: ~ / l___,,,.. \ J \ f:2 B 11 \ ~ __ / I'-._ /q; I II '\'-! ~ ------eoo I I ~ '--------~ 1y ~'-B-34.5 ~ -I/ \ • ---._________ I; ,J ~ I; ~~)~--...__~--:~-.___ ~~ ______--~ ~ _,// ~ --/' / / /', ' :\ ) 2 I'-._ 2000 Pro~osed Staging Area (Gulley Cleaning) Vicinity Map_ 0 2000 Scale In Feet i -/ ( \ . ......_ -------...____----..__ .,__________,....--' ..._,__ -I / / / / . ,..,,•>•••••<' -vn-,..,_,?-!7if -----7&J '·· / · ......_ ·, ------.. ~ ~ ~~-=--=--=-~--~------,..--_ _/ / / ,/:.c, .. •·tn.V11!¼1'11111--_~-=--.,-----?<10 ~~ "" ~ ~ ~0----------... ·· <> •/ ·. : ;J /A, ------------' , "-------~ ~,.,., ~ ~'~,:=-~• :•:'• •• """~ ,,§f, _-J'il f ~-------------~.>6'o ------"' \\\ ~ --\ .,,,--. ,{)(ff!' -~ -----...~ ::--..: :---..... IT'----------------.:_',,/ ~ / I -.......___ "\ \~'-/~/ \ :@:}(if{~--Pu(~: J~~~i~~trea ~__/ / ~ ~~ (j) H-79.5 H-59 ,,,, x·</l,r:> #~ "' ' ,.. ..--"\ 1/---------/,-,,-~ ✓ )."' ~ \.---' -..._____ /; .___ ------------. ; ," I\_/ ----•' /;/ ~~ ~----J. ~---------1:V ~ \r _ _...-:;:-_...------. ~ ----.._,_-, .. ••-~·,, (j} AA-41 _,,,,,,-'56 .,, l:-·~---....---.... -----~ :::tt---// ~ \ \ 1J1 ~ ------I (j) N-53.5 .·/ ~---P-58.4 ( ~~__..,,/ / / // X \ N-29 ; P-31.5~ / / / • I I / ____-/ / I ~ <il ~ / 1/ ~ l(.~A r---..__ ~ ~ ~----.~~/ / /~ "'011,.,,;,,9 ,,0 I ~-::::---.:.: __ . ·;':'.' / / h1 ,,~ tj ,.....----t:: b ~ /JO// , ,c~J ;,§' § / ,\ fl!J1,,ll p l I I . -~+ t::; [] 1/ 100 0 100 200 0 0 .....___ • ~ q.o"}' ,it///.i <:J"/ // //,-7 1• f: ~ / 1 011rl ,-;< // f ( 1/// ,,, & .:::::::: t \ I /,{d ! i I \______ _/ 1// o.l?~ I • V-23.4 / ~ _/ / / • U-38.6 '1 /\ Scale In Feet 4000 ,f ,,,., 0 LEGEND \ ,_,:.o;;,;,/ -.,-+' .. 'l ----~1/ o.! I ; ~ -----~-790 ®IBill~'IT B-34.5 • Y-74.4 Y-38.8 \Q) SINGLE MONITOR WELLS MULTIPLE MONITOR WELLS AREA TO BE CLEANED , ~-,_o -~~· '· / ,·.;: \ / ; .; . I ( __ ...___ ~ /1 0 I I i '4e,..,,,o,, ) 11,,8. ~ ,,, . i 1/ ' ~\ elarllie ,a,l\CC-64 \, -4.,,,,,. ,@, CC-33 , '-•10,, ,. '--' Q<>s;,, . ~ --....:::" ~ ( \ '-----::::: ~ ~ i j\ I t'-i ~ .. ,t r.-p 1 Q:i \__ §l I ~ /4c-~ ~ I "'01;,.,,. '"9 "'o,,rl ,';< ---....______ -/1 ------------780 REMEDIATION AREAS HOECHST CELANESE COR~ Remediation Project Shelby, North Carolina DRAWN JC 2/5/90 ENGINEERC'E-· CHECKED Gll GDC ENGINEERING INC. ~ CONSUL.TING ENGIN[EltS 822 NEOSHO AVENUI (!504)~83·8'56 BATON lfOUGE, LA. 70102 PROJECT NO. 90-503 SHEET OF EXHIBIT NO. 2 -I I -... ,:<--....... (·_:._::::c F-.. (~:~; r'::" .. ----.-_ ~--··-· l ..... ,,' ~-,..:: I:'':.·. i~-.. ---··· 1·: -O-f·•-r~c;,:·. I· ...... • .. · -~. ,--~_;._ .. ,. ,·.: ~----.:-1·: -----:<· :::-o:;·-::.-t· ...... ~ ~-::•::.~-f .. ',c" 1•.=:~c ' -.-r::,=: l,.C C' -_. -.,. .. -..;. .. _.. I • .. (t I . . ··---.-. ' r.-.--. , .. __ -i.• .. ::< ,_: --· ::-.---• I.• '. -_ -:·.: ('.:.:.:~ -.-1·-_-::-..:::. ! -::::,.:.'. ~--=-~ ;._: ··--:-.-·-~ --. ,, ... ,;, I,.;··--,. r:-:--.•, I."• 1-~~--· 1-··, -~-f ·: ---:--i 5-~
-------------------I HOECHS,: CELANESE CORPORATION
I WESTI_NGHOUSE ENVIRONMENTAL I
PROJECT DIRECTOR ; ADVISORY TEAM l N.BORDELON
..• . .. •! • .. ,
QA/ QC MANAGER PROJECT MANAGE.R HEALTH & SAFETY OFFICER
M. EGER C. TWILLEY .................... $.BONE .
I
•••••••••••••••••••••••••••• HEALTH & SAFl;TY COORDINATORS
. . . . ( or\e. per shift) . . ..
....
I FIELD ENGINE_ER I .•
I I SITE OPERATION SUPERViSOR I INCINERATOR OPE~ATIONS MANAGER, I [ SUBCONTRACTOR/SUPPLIES I I EQUIPMENT OPERATOR'S
I
I TECHNICIANS I
J1NCINERATOR OPERATION SUPERVISOR I illJWill~ll ,.
.. HO.ECHST CELANESE CORP. I INCINERATOR OPERATORS I
MANAGEMENT STRUCTURE Remediation Project
Shelby' North Carolina
~ GDC ENGINEERING INC. OWN. JC. 12/11/89 PROJ. NO. sD-503 ;
C CO~SULTIHG CNOINEERS
ENG. C~7 ~/:i...?,/7a SHEET OF . .
' a;z NEOSHO .-'V_c,NuE CHK0 c:i. , ,
FIGURE ·No .. (S,04)31!13-85!5& BATON ftOUGE, LA. 70802: 2::-2 .
REMEDIATION ACTIVITIES
MATERIALS HANDLING INCINERATION
~ ...,
::,_-
Project Start-Up Conference -,:,
I DJ :::,
Site Reconnaissance 0 I (1) < Plans (1)
I 0 en "O 3 -I
EPA Approval (1) m :::,
I : ...+ ,,
~
(J) -Existing Utility Location -SI te Layout .....
I (1)
)>
"' "' (1)
Outline Waste Pits -Outline Work Zones "' I "' 3
Stream Sediment Review --Foundation Review Obtain (1) :::, I -Staging Area Layout -Proposed Utility Locations
Office & Break Trailers -Support Equipment -Utility Connections ~
(J) I ;,;::
Construct Equipment Storage Areas __. ~ r (J) 0 en -·
Construct Decon Facilities ..... cr -I (1) -· -I -· m (J) N
DJ Construct Materials/ Incinerator Pad (1) ..... ,,
I --· I 0 C :::,
Install Stormwater Treatment System ~ -0 ~ N
I (J)
Strip Clean Soil-Areas 4,5,6, 7 & 8 ;,;::
Build Berms I\)
Excavate GRU Materials From Areas 5,6,7 & 8. Materials Handling/Incinerator Equipment ~ Transport, Stablllze, and Store in GAU Storage Facility Run-in & Check-out Equipment (J) :;,;::
Excavate Burn Pit Residuals and Plastic Chips Refractory Cure _.
From Areas 4,5,6,7 & 8. Transport and Stockpile
in Pugmill Operations Area. Bring Incinerator On Line
Obtain Certification From Engineer For Pit Incinerator Optimization ~ Areas 4,5,6,7 & 8 (J) Trial Burn :;,;::
Stabilize Burn Pit Residuals and Plastic Chips From Areas Incinerate GRU Materials From Areas I\)
4,5,6,7 & 8 in Pugmill Operations and Backfill Starting With Pit 4. 5, 6, 7, & 8
Transport Stream Bed Sediments to Pugmill Operations Area. ~ (J) ;,;:: ~ -en w CD
I :a -I Strip Clean Soil-Areas 1,2, & 3. CD m Build Berms. ~ 3
(J) (1) "'C
;,;:: Q. o5· w .+:>, -i5"
J
Excavate GRU Materials From Areas 1,2 & 3.
Incinerate GRU Materials From Areas ~ Transport, Stabilize and Store in GAU Storage Facility.
1 & 3 (J) ;,;::
0 rri 0 (JI
I z :::0 Excavate Burn Pit Residuals and Plastic Chips From 1'11 G) l> ~ 0 -~ Areas 1,2 & 3. Transport and Stockpile in Pugmill Operations Area. :;:s;: z
1'11 z (J) 1'11 :::0 0 1'11 (") ;,;::
r.,~ CD )> f'T1 Obtain Certification From Engineer for Pit Areas 1,2 & 3. (j)
fl\ 0 0 ~ --\ -I :c --f'T1 0 ~ ;:; I'\) < C Backfill Areas 1,2, & 3 With Clean Fill. Revegetate. ' -ITI (J) -.r:. -)> (") ;,;:: --I Stabilize Burn Pit Residuals and Plastic Ch~s From Areas ~ ' :::r: --(X) --I (./) :::0 1,2, & 3 and Stream Sediments in Pugmill perations. --.J
~ U) ITI -=r .,, en Backfill into Areas 4,5,6,7 & 8. en 0 ~ s;: -i z C"' fTI ':-a (") Backfill Areas 5, 6, 7, & 8 and Revegetate. )>
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0 -r ... 0 )> -2 "Tl (/) "'O (o~) :::r G) :I: :::0 ;; :B z Decontamination 1'11 0 0 c:: .. (") ITI I ::0 1'11 '---I fTI "' 0 0 CJ) rn a, ~ (') "' ... c... Demobilization
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E!J I UJ 0 " -(J) (1) ... G) -· z "' ::, ;,;:: 3 0 0 0 -I (") -t 0 0 (") 0 __. cr m "Tl " Grade Site/Erosion Control N 0 rr1 :u N. -a ! ~ "' z z .. "' DJ (,) .. C G) .,,
I 0 ,--z ... -• o· .,::. g "' i z ., N :::, Q N " rr1 OI C Z "' rr1 " "' z "'0 .. :;u -"' ,-Jt ;z -,.o ... z MATERIALS HANDLING INCINERATION "' ► • G) .. < "' 0"' -• z z oC N Ill r>
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STEP ·.
. 1
2
3
4
.•.
ACTIVITIES
·DESCRIPTION
Final_ Plan,Oevelopment. &
Permit Applications
EPA Approval"
Site Development· Activities
site Preparation:
. ..
· Water Treatment Facility lnstallatiori
!Mobil!zat!oo-Material Handling Equip,
Moblhzat1011, Erection-Incinerator
,Run !n and Check Out of Incinerator
Incinerator Optimization
. Trial Burn ..
Excavatioo and Mixing
Process Stream Sediments
lnci neration -
Solidification .
Backtuling ..
Site Restoration .
Decon tarni na ti Ol1
Demoblli zati oo
'·
Legend
Continuous Activities · ,.
,zzzzz~ lnt<>rmittent Activities.
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..
1 2 ·3
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' SCHE'DUL:E··· :(months)
ih fM i ?b&t+N¥ GA . Mi
' '4 5 "6 ' ·':7 8 9 10 11 12 . i3' "
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®IBffi~'\1 PROJECT SCHEDULE HOECHST CELANESE CORP.
Remediation Project
Shelby, North Carollna
• ·-~-! .
~ OWN. csb PROJ. NO. GDC ENGINEERING INC. 12/11/89 90-503 .
CONSULTING ENGINEERS .. ENG.
('._ {( 1 l. I l'l., / i<J SHEET OF
822 NEOSHO AVENUE CHK'O. ($0<\)'583·8~56 BATON ROUGE• LA. 70802 FIGURE NO. 2-4
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I f ~ s ::> .__ _ __,_ ________ ____,11,__ _______ .....1.. ____ _.J
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X 60' Equipment -~
~
\ncineratot Pa~
_ 200· .,_ 150
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I Scale: 1·"' 100'
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Earthen
\
Exclusion Zone
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HOECHST. CELANESE CORP.
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~~ #
6' X 60' Equ!pmeot
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//Drainage
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Ditch
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I g c:..--__.L...-------------ll...-------..l---------
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50 0 50 100 Scale In Feet ~/ • J.. __ _r-7 --~-..J ' C iii co co t __ r-7 C ---L _ _j 0 ' L.. -__r -7 ~--L--..J • ... ~ ~ Q) <( I 4 ' -----X-----X l --840 @H-79.5 H-59 X I (' 111 /<7 // ------i::::-r ;;--· ~-• ------_. ~ ~ -I ~~x ~ 'u ~ ~ ~ ~-// // ;II X i u. O" .5 -~ " Ul ~() ~ X ix I I 7. /I---~~ " :J ----···~ • ---• • 'i. ' ---..;:--._zG~---f:::;:::----.---_ ~ ~ • •' /~ ~t~ -----,.-.... :::--.....,...___ ...__.,_ ·-----, /r· / '¾' 830\ r' -';;;:, '-.. -., ,;: d Staging Area ~ '\':.·\ ..._ '-,-_ '----'"-. ----,". •.; ~ Propose \ I • U-38.6 ' -"~ ............ • ~-@ J-29.5 .-----",j o }. ~ --------'-.__ J-59.5 ----'--"°f\• ·,, \ \\ ''°':;:;;-?::,,_____·2::___~.-:e::-:::.:.-=--f\:-,_ \i ~ l //~ \\\ \ ~ ,-,,; ~ =-:::,_ ~ -' \ r-7 ___ J J -----,-7 __ _.J ____ _J ~ C iii co co C 0 ~ Q) <( L---------------c,c, q; ) I ,® :\ \. 5 ' ){' " 6 '\ .,, X:\ . V / ~ \ @ ''vv ""'" x >;??_/ \. \ \'\_ ~--\ / '\ ,;~¾ ...,__,_____~ \~\~ -7 ) \\\ \\ // \__,,./ t\ ~~-~-~~':::~-,ca,ation A,ea \ \ . -""'"= \ \ : \\\\ ~-I / t\ I I , ...... ~;;::•,::-,_, .,_ \_.V . , . / \1 ''r .... ~. ~ -\ \ \\\ ,, © / \ \'\ ",--_ --------\]\ J ---_ _,/ e V-23.4 \ \ \ " IT--< :::-"----------\ 1/ _y\ y.. \ /\ \ -~\ ' / ~~ i ~ \ 1 I I I I I I I i I I I I 1/ I I @ lfi"l;J @H ~ .. ofJ 2000 , LEGEND ev-23.4 @K-58 K-28 Hoechst Celanese Corp. \) @ VicinitY~P.. 0 2000 Scale In Feet 4000 ~CD~ SINGLE MONITOR WELL MULTIPLE MONITOR WELL AREAS OF BURIED WASTE ~~\. ~··· \\ ~ \-•'" \~' \. '-\,_ K-58 ;i,., '\\ I ~ \ 'V / '\_'\."' @K-28 \\ \\ \ Y-74.4@ ' '\ ' ' , • \ \ I y -38.8 • BB-18.5 ----, --,✓ Clarifier ~ ''" \,,_; Clarifier CC-64 @/ CC-33 =-------= -. __ .. ~ Polishin~ Pond ~'\ I -------810 -------f," ----~~~__..,..~--------,~ l .I ·•\ ~; \' I \ . .. '"":".._._________ \ \ I i / I N-53.5 '---.__ I 1 \. I .. @ N29 'I"· I I ·', . /1/ nd ,; \ \• \ 1 I ~. \ \ :_ t :\1 Emergency Po t~ ] \ I ;I "'l,, I I ' \, '-"', ... . .. , -""" I i' '·1 • -=¾-<~ ' :r gency Pond :__ "'" -~~= Erne, 'I •~•,,,,~ __ , 11 ' ., .. _, I \ --~ 'I' ,f '--'", , __ J) O 59.2 -· . ,_ 1 • i'f) d #2 (I ,,, _ . _ __, __ , _ _ _ ,_._,, _ , •<. ---1 0-25 ~-l) ~ Polishing Pon iC--------.. --'d-·-=""'-====-~= !) I Ii r-··· --Polishing Pond X \ @ 00 El ~ il HOECHST CELANESE CORPORATION REMEDIATION PROJECT Shelby. North Carolina STAGING AREAS f co] Goe,~-~:,~~::~~~.~, ,Ne. 822 NfQS>tO AVENU[ l".,04)'8'1 e~,6 BATON ~OUGE, LA 70101 DRAWN CBD 2/2/90 PROJECT NO 90-503 ENGINEER C:.£1 _;7.,g/70 SHEET OF CHECKED FIGURE NO. 2-10 Cf) [fl l ~\; !':" C .. _ -,-r.:.,. ·--· .-. .. _, .. t·,i ::~~ l", [;:-" r . ' I I I ' l -i I r· -r,-,: ! --1.• · . ,.,. ' -r ( i:• -~· r -_-3' X <:) \I)
·1 :I ., .J _, ·1 ~ ' 'i " (1 ti " ., ., :.1 --.. ·-~ ··., ' :~ ., :-J Ci j ~ 1 ~ ~ 1 ,-1 ' -. l ' . 7 Finish End 01 Slab -Ramp To Grade 6H:1V ♦ ♦ I t f + ♦ GRU MATERIALS COVERED STORAGE AREA 40' X 150' Leave 2 Panels Open (Without Concrete Block Wall) In Area Of Incinerator Feed Conveyor -Paint Exclusion Zone Border With Yellow Paint > • -. + I ------Exclusion Zone 2 Block High Concrete Block Wall-Typical 3 Sides I I I I I I Decon Unit / t ____ ---- ---- - - ------~ I I I I I I I I I I E e " LL "' Qi ! ~.!2 ~~ --;g .! " 0 " ,~ ~ I ~ C .. ,= "" -X N -g .. u: = ,n C .. .!2 ~ c'l e-~ <II -.c :!!I ii Ml ~ $ ~ -C .!2 "-:,. Breok Trailer 7//( / / / / ./ Alor'm Afln~nciotot / / / Office Trailer WATER TREATMENT FACILITY 30' X 30' I I ;,_ __________ _!;;;;;;;;;i· '_)l'w>el I I I I I I I I I I I I I I I I I I I I I I I Exclusion Zone I I I Control Unit 1 sec I I ,it . ' ,. -CONCRETE EQUIPMENT PAD Air Compressor \ Residence Chomber Air Compressor \Effluent \Rec,r. \ Tank Mist Eliminator I ~ o Ton~ 0 • Particulate Drop -Out Chamber I I ·:;:r· I I IEE " ( + : I ++ -'Q1_ ~ PRELIMINARY DESIGN ~ .,,-----/ (Sub1ect To Change) "'----............ " I -. I ~sec Comb.a --···-·----I \ ,. Neigh Oper. Cabinet -~ + + rnttl ,.., "••¥• 1 111111 , II ---------------------~-~ ➔u, I -----10 0 10 20 i-Scale In Feet / II Jt. I / :J---U--U-~~ '" 71 -1:-+ JI II+ Quench a Contact \ Chamber No. 1 ~ - r Contact Chomber No.2 ·f=:J Lscrubber Fon :;_ <.;J <:J"--PAS flow . ' ~-"-. ' \,-----7 Metering Patltl \' ' ~----------;:~L-----~ 0 Ash Disposal Ash Discharge a Solidification System ;r------7 1'---I / ----' Containers :J I C i ; ~ ls "' Parkrg Area I I I Diesel i71..tlQ Eng.----1,____J-J"c_ ~water Supply f'uff1p ---Emergency I.D Fan /Exhaust Strr ...l----l_-~ -CEM Monitor '-Main I.D. Fon -" C (l C I > " C .. "' ~ ~ "' Incinerator a Materia Is Handt ing Pad HOECHST CELANESE CORP. Remediation Project Shelby, North Carolina DRAWN CBD 4/10/90 ENGINEER CHECKED IG[)l GDC ENGINEERING INC. [c=J CONSUi.TiNG !NGIN!!ftS 122 NEOSHO AVENUE (504)313·1S56 IATON ROUGE, LA. 70101 PROJECT NO. 90-503 SHEET OF FIGURE NO. 2-11 ~o '{ \0 MfrP <-/
-------""'~-.. ~~,.,.----••.,,,,~. ,,,.,,...,-.: ·-•--". , ~~ /G' ROLL-OVER CONC. CURB _, I ~vv I -I -,-I Ii 11 II ii ii ii H ii ii I j, ' """CJ" -6" ROLL-OVER CONC. CURB~ , ' 150' RAMP (SEE DETAIL2) ""'-'II EXACT LOCATION TO BE SET IN FIELD -V -24'x24" CATCH BASIN (SEE DETAIL.1 "" V -< 1> lb ' ~ (])' """ I 5'x-5~ CATCH BASIN 24"x 24~CATC~ASIN, ~•• 12" M~L PIPE =I= I II J II ! J ! 7,}SEE ~ETAl_i-_L ' /7 I , II II f, _,_ -<,_0 (:,'<, ~'9' -<..o~+ ":,-<..,,. ~~✓ /1/ 'l/ // i.)> SITE PLAN SCALE= 1"=20' 6" ROLL-OVER CONC. CURB7 1-E-----------------lf/J-'---------------~ ':'. a• P.C. CONCRETE • •~ .... ..... ............... "" ......... ... .. ... .. ...... ...,, " ... . .. ... .. ..... . . • -"·•·• ............. ~.. ..,. .... "" ................. io"'""•o..,. .. ,, ................. •·.••11-••·· --. 6" SAND OR GRAVEL (TYPICAL) t .#~,g:'?"// Ch ,--I ~7 ~12• METAL PIPE SECTION A-A SCALE: I'.= 20' RAMP (SEE DETAIL 2) EXACT LOCATION TO BE SET IN FIELD 1", 4"REI WCO: JO:t:·: VUc.CAN FOUNDRY SERIES VFG 24 x 24 CAST IRON GRATE AND FRAME • 4 BARS CONT. ALL SlllES :> .. ', F<i.-\R.S .'.?1' LUNG 9" PVC WATER --STOf• '._, ' -' 114 (JJ DOWELS Is" LONG -24'' cu:, WRAP El TAPf ONE END--12'\J r ·\ l! 4 Pt\ R~. I. C r~ CCRr,>·,··;J~Tr;-, •.;r· '"/\! r; f. 0 I : ' l r ·1 • • /1'· nr J1 :~E., 8 ;.l_ R ,: ! ~1 ·J C L ,\r::H W -~ · 9" PVC w,.:..rr~R '.~,TCH s" I :_2:J Lit;_ .=-~~: :--,.-•,, ' . . . , , / " . 6"x 6"x6 --WELDED I WIRE MESH ..l-' ' :) l , \__ 2-l"x 4" #01 __ \/i;.N!ZL.1_; WOCD .JOINT € 'll!L \'1~~:; -'Ef·J DETAIL I t • I ~--::-:_ .• ~-~---~ • • '_ •, 6 ., -j -' ., 1 ' I 4 I .-' , ~ r<:·)•t,,'Y -' L . ·--··------------·~···--..... _ .. ---3/4" x [8'' ~;()WC"L'.::' 12"c.c. DETAIL 2 -N. TS \ -----,-, ------lfj···--···;.~ . .• :1 I . ~:-ff _-l, _'-'-' -. :..:.,___' ': ·-------'-2::. ! r· I 11 -f :.! -·I I ~ 11 I ~~-, ---~---i .r1 ! . . _' .-' 4'' ' I Q uJ 0:--:, 0 uJ a:: 'II " 1 AS R~·.,,'.'i iEf' CATCH 8ASII'\ DETAIL N. T S. NOTES ..... 1. ALL CONCRETE IS TO HAVE A 28 DAY STRENGTH OF 4000 PSI. 2{MINIMUM OF 6" OF GRAVEL F1lL OR AS REQUIRED TO OBTAIN REQUIRED ' ELEVATIONS BENEATH ALL SLAB$. 3. CONCRETE PAD DESIGN IS TENTATIVE. CHANGES MAY OCCUR PRIOR TO ACTUAL CONSTRUCTION. HOECHST CELANESE CORPORATION REMEDIATION PROJECT Shelby, North CMOllna CONCRETE EQUIPMENT PAD DETAILS JC 4/10/90 ,/"·---. :G 01 G'.JC ! C ! ·-____ .) 4' .. ~~ ~~",/, PF/OJECT NO E'<GiNEER!NG !N~-,.: f ... :.•"11:f.'l'', eu dOIMO AV[k'VE :>:,l,!)N ROUSE, L.,11, 1.;eoz 90-503 SHEET OF FIGURE NO. 2-12 """-"'~,--,--<>,~--~--.... ~-. _..,._,. __ . .,_. -~·-~----"""' .,,,.,,_, ____ ,,,.,.,_~_,..,.,_ ,,_,_ ----~---------..,-,,. .... ,,.,._.,,_.,, _ _. .. ,..,..,,., ....... ' . ..... ________________ .._ __________ .. tr) ) ;) ;,< s
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,v,"--,
DETAIL "A"
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SEE DETAIL 'A'
DOUBLE 2"x10" NOM. RAFTE
(ONE EACH SIDE)
SLAB ON GRADE
i
z'.;_4' BRACE
TYP. EVERY FOST
2-BLOCK HIGH CONCRETE WALL
SLAB ON GRADE
STD. GAGE V-NOTCH GAL\' SHEET METAL
CROWN-FULL LENGTH, MIN. 6" LAP JOINTS
13' CLEAR
STD. GAGE V-NOTCH GAL\' SHEET METAL,
_4" OVERHANG AT BOTTOM, MIN. 6' LAP.
PRE-MANUFACTURED TRUSSES PER STD. CONDITIONS FOR
TEMPORARY SHELTERS W/ OPEN SIDES, 4' O.C. FULL LENGTH 148',
3'0.C. AT ENDS (!'OVERHANG PURLOINS EACH END)
lk----4'x4'x 16' TREATED TIMBER B'O.C., FULL LENGTH 148:
3' O.C. AT ENDS TYP.
....,_--FOST SET IN CONCRETE FOOTING
i/----------40' TRUss,--.:_--------V''r:
·END.·VIEW
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4O.C.ITRUSSES
TYi' I
17 I
B 8 ___ llii SPACES~•= 144'
TYP.
PARTIAL SIDE VIEW
~ GDC
(504)383-115515
• _ -( PURLOIN OVERHANG
I
BLE BRACE EVERY 3RD PANEL BOTH SIDES
W/ i"x4' NOM. x 16' LONG TIMBER
ENGINEERING INC.
CONSULTING [NGIHEERS
ezz NEOSHO AVENUE
BA.TON ROUGE, LA. TOIIOZ
ill) [2 ill ~ 'IT
GRU MATERIALS
STORAGEAREA COVER
HOECHST CELANESE CORPORATION
INCINERATION PROJECT
Shelby, North Carolina
OWN. JC 4/9/90 PROJ. NO . 90-503
ENG. SHEET OF 0
CHK D. FIGURE NO. 2t-j3
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_,-6" CONCRETE CURB
--16' -SLOPE: 1/8" /FT.
3' DEEP SET-_IF\.
55 GAL ORUM --v-,v
t
.
~1-I.=::-==========:·(,:.:;~·~:·
;i-------------60'--------------l;
N.G,7 _
//l~/IIE°/1/::,_ , . .,
!;/2'/ ! /// , _ _.
:_o' •
6"
PLAN
I
• • • • • • • •
DETAIL ::;;: .,,.....-6 mil VISQUEEN
·.1; .. ~.
6 BAG CONCRETE MIX
10"
---
, 12"-2" ROCK OR CRUSHED
' STONE
[ID [2 ill:~ u HOECHST CELANESE CORP.
DECONTAMINATION PAD Remediation Project
Shelby, North Carolina
GDC ENGINEERING INC. OWN. CBD 12/11/89 PROJ. NO. 90-503
CONSULTING ENGONEERS ENG SHEET OF
.,, NCOSNO AVENUE -CHK,f f.-( J.iµ.2/.I!i.. __
<•0•1,e,-e,00 BATON •ouGE. LA. 7oeoz FIGURE NO. 2 _14
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Note:
Waste HOPE 40 mil liner
Dik
One Foot Dike
Compacted Soil
CROSS SECTION
Sump
Waste ------------------------A-l-+---+------+----+--+--+,-A ------------------------------------
PLAN VIEW
Sand Bags
Sumps.will be located to collect run-off water.
GENERALIZED STORAGE PILE
HOECHST CELANESE CORP.
Remediation Project
Shelby, North Carolina
I (G7] GDC ,:N~:L~~;:~,~~E~S INC. , w '22 N(OSHO ,V(NU(
DWN. 12/5/89 PROJ. NO. 90-503 JC
ENG. Cf71-;_/1ij_rl_ SHEET OF
l (~04)383·85:56 BATON. ROUGE, LA. 7080Z ,..__ ____________ .J-____ __._ ____ __ CHK D. FIGURE NO. 2-15
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STORAGE • CARBON · · TANK -l -+-+-+-+ -♦ A~RPTION -~--:♦ -+-+-+-+-+-+-+-+-+-+-+ , -+ !
t
t STORM ·wATER.-+-+-+ -+-+ ➔-+ -+t
t
t
1,
!
!
! +-+-BACKWASH T0-4--+-
SOLIDIFICATION
STREAM + +-· . t S.EDIMEJ~T -i>-+--:♦--t,· CENTRIFUGE. -+ ~~-+
SLURRY pH ADJUSTMENT J.
!
! SOLIDS FROM J_ SLURRY
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& POLYMER ADDITION I TO NPDES ! !-+DISCHARGE-+
t SCRUBBED FLUE GAS ! .l,.
t TO ATMOSf>HERE t METALS
vTREATMENT ~--~· !
rl t ~ SCRUBBER -► _. ➔ l ➔ _.. .... ➔ -+ CLARIFIER 1 ➔ /!!~i~i~f~~E _,.
SCRUBBER· -+ -+ -+ -+ -SLOWDOWN -~ · t·· -+ t t +--4- -4-METAL SLUD.GE TO +--+-i !
WASTE & SOILS _I -e )! t t SOLIDIFICATION . i ·-♦ ➔-+-+-+-+ -+-+! INCINERATOR ' -:!:-:-, +--+--+-+-+--+-+-+--+--+--+--·+--+--+-...,_;+-+--+-,..__SIDE STREAM FOR,._;. _ . -,, • SCRUBBER WATER.
!
i ! CONCEPTUAL CONTAMINATED WATER 00 w□. rui R. u· ➔ -+-+-+-+-+ ➔-+ _,..!,. TREATMENT SCHEME U lf
!
!
RECLAIMED SOILS FROM. SURFACE
AND SLURRY, TO SOLIDIFICATION
AND BACKFILL
HOECHST CELANESE CORP:
Remediation Project
Shelby, North Carolina fc9 GDC c:~~L~~;~~~~E~S INC. ... □_w_N_._J_c_,2_/_11/_89_-l~P-R_o_J_. _N_o._9_0-_so_3_--,1
ENG. r f.7 t~/1)., IN SHEET OF
•22 Hf:OSMO AV[NU[ CHKT 0. . ~ FIGURE NO. 2_16 BATON "ou;,[ • LA. 70802
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Storm
& Centrate Wat,o.r'---~>---1
LEGEND
---Q-
9 --.
Feed
Tank
Pump
Valve
Clarifier
Polymer Caustic 3" Discharge 0---_:.-=..:..::..::.:..:.=:c.;,.: ___ -111:1_ Discharge to HCC Polishing Pond .#2
Scrubber Water Solids to
Ash Solidification
SCRUBBER WATER TREATMENT SYSTEM
Re tu rn_-----41---"
Line
.u.. •
Backwash
C-100 C-75
Backwash
EXCAVATION & CENTRATE WATER TREATMENT SYSTEM
Union
WATER TREATMENT
SYSTEM SCHEMATIC
Dis~harge or Recycle
[ID [2 ffi ~ 1J
NOTES
*Cartridge Filter Including Housing
Cansorb C-100 w / 3000 lb. TIGG 50 12 x 40.
Cansorb C-75 w / 1600 lb. TIGG 50 12 x 40.
HOECHST CELANESE CORPORATION
REMEDIATION PROJECT
Shelby, North Carolina
--ID-GDC ENGINEERING INC. OWN. JC 4/11/90 PROJ. NO. 90-503
Pressure Indicator ~ 2 • Hose w/ Flow Direction co•suLTIHG ••••••••• <o-3o psi) Er a ENG . SHEET OF
1!!122 l'IEOSHO AVENUE l--.,..::;;..:c....~:..,:;._~~-+----------4
Sample Port/ --0--Flow Meter <00~)>8'-80,0 ••rn• ROUGE• L•. 7080> CHK D. FIGURE NO. 2-17
TOG Monitoring•·-------------------------..11.---------------..a..----------'-----------'
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'" a,
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"' r---"' N .; ...
"' z
z :::, a: CD
Polymer Feed
Incinerator Ash System
(Wet Sump)
Water Supply
Dry Reagent Silo
Drag Belt Conveyor
Auger
. Hopper
-' .
Conveyor-Blender ltl-------------1' 'I LI quid 7 ...:..a:1-+,---------l' Re agent J
.
Belt CC41_veyor
..
To Waste Disposal Area
~ Storage
Variable Speed
Feed. Pump
PROPOSED
SOLIDIFICATION SYSTEM
@ m liJ [} u HOECHST CELANESE CORP.
Remediation Project
Shelby, North Carolina
lG"7)j GDC ENGINEERING INC. OWN. CBD 12/4/89
~ CONSULTING ENGINEERS ENG. Cftt")../tl./f''l SHEET OF
PROJ. NO. 90-503,
822 NEOSHO AVENUE --,----~_;_;;j..:...L--4---------~
BATON ROUGE. LA. 7O8OZ CHK D. FIGURE NO. 2-18
•r--------------
1
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. I LOADER I l
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I wooo CHIPPER ~+-+-......JGRISSLY GRATE I-+-+-+-+ METALS J ·· ' I . DECONTAMINATION
. I '-------__1
+ !
i i I HOPPER_/
I WATER SUPPLY I-+-+-+➔-+, !
. . i ... !
I DRY CEMENT SIW 1-~~-I P~ILL I
TRUCK TO
WASTE DISPOSAL AREA
!
! I :BELT CONVEYOR I
! '
!
!
TRUCK TO WASTE.DISPOSAL AREA
[ID 00 ill~ TI
PUGMILL SOLIDIFICATJON
I SYSTEM
(FOR BURN PIT RESIDUALS, PLASTIC
HOECHST CELANESE CORPORATION
REMEDIATION PROJECT
I . CHIPS, AND STREAM SEDIMENTS)
fG""l51 GDC ENGINEERING INC. DWN. JC 4/10/90
Shelby, North Carolina
PROJ. N 0. 90-503
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w CON s u LT INO [NOIN[E•S r.E:-:-N-:-:::G-/-'£"--7--.ij/,2__3_ //-9,0-+-S-H-E-ET ___ O_F_~
322 Ni:OStlO ... ,,,E .. '\U( ~r~~~P,r1~-------l
BATON ROUO[' LA. 10,oz CHK D. FIGURE Nu.. 2-19
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' 0 "' (/)
I-
I z w ::;
CJ w
(/)
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w n,
z :t,. :J
(/) ~ (/) ~ ' >-(D
0 w 71 a. ::; r ::, 0 a.
::; ~ <l'. w i a: I-(/)
PLAN SCHEMATIC
SEDIMENTS TO PUGMILL
FOR SOLIDIFICATION
t
CENTRIFUGE SYSTEM
SEDIMENT REMOVAL
WATER TO BE RECIRCULATED THRU
CENTRIFUGE FOR SEDIMENT REMOVAL
40 MIL HDPE WRAP
SEDIMENTS TO BE REMOVED
AND TRA!°'lSPORTED TO PUGMILL
FOR SOLIDIFICATION
SANDBAGS AS REQUIRED
SECTION THROUGH DAM
(TYPICAL)
!ITT~ ffi TT
L_) uuuuu LJ
CONCEPTUALIZED HYDRAULIC
SEDIMENT REMOVAL SYSTEM
HOECHST CELANESE CORPORATION
REMEDIATION PROJECT
Shelby, North Carolina
DWN. JC 4/11/90 PROJ. N 0. 90-503
-------------------
SAMPLING
PORTS
SCRUBBER
STACK
ENTRAINMENT
SEPARATOR
RECIRCULATION TANK
D
CONTACT
CHAMBER
-i------:i;;.._.,.,,,,
u
/ WET WASH
SECONDARY COMBUSTION CHAMBER
BURNER
ROT<.RY PRIMARY
COMBUSTOR
BURNER F=rf-ri----__J_~rn----+-
ASH
MOBILE ROTARY INCINERATOR HOECHST CELANESE CORP.
Remediation Project
Shelby, North Carolina
IIU N[OSHO AVUIUE
UTOH ROVGE, LA. 10102 CHK D. : FIGURE NO. 2-21
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3.0 SAMPLING PLAN
3.1 INTRODUCTION
GDC Engineering Inc. is responsible for monitoring the health and safety of the site work force
plus the various remediation operations such as incineration, solidification and storm and process
water treatment.
This Sampling Plan has been developed to support GDC's monitoring in the following areas:
0
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Monitor air emission resulting from this removal action.
Verify destruction effectiveness of the incinerator (Note Trial Burn Plan).
Monitor the continued or destruction effectiveness of the incinerator by
monitoring waste feed, ash and stack emissions.
Bench scale testing of waste solidification.
Operation of the solidification systems for incinerator ash, plastic chips,
and burn residue.
Operation of the water treatment system which includes the centrifuge used
for stream sediment remediation.
During remediation activities, the excavation, incineration, and solidification work areas will be
monitored for total volatile organic chemicals (VOC), priority pollutant analysis for the VOC
fraction and particulate analyses for metals (antimony, arsenic, and chromium).
822 NEOSHO AVENUE BATON. ROUGE. LOUISIANA 70802 [phone] FAX [phone]
Page 3.2
In order to comply with the technical requirements of the hazardous waste incineration regulations
(40 CFR 264.Part 0), stack emissions will be monitored for carbon monoxide, oxygen, and
carbon dioxide. During the trial burn, additional parameters will be monitored, including
nitrogen oxides. In addition, both waste feed and incinerator ash characteristics and quantity will
be monitored. The waste feed will be tested for BTU, percent moisture, percent ash, antimony
and ethylene glycol. The incinerator ash will be tested for antimony and ethylene glycol.
Two systems will be used for solidification of waste materials; an incinerator ash system (Figure
2-18) and a pugmill (Figure 2-19) in the excavation area. The solidification process must meet
two performance goals.
1) Bind contaminants as confirmed by TCLP analyses, and
2) Ensure adequate structural integrity of the waste.
Bench scale testing will be required to select the solidification mix ratio for the various waste
materials. In addition, QA/QC:, testing will be performed periodically to confirm the performance
goals are meet.
A water treatment system will be used to handle incinerator scrubber water, centrate water from
stream sediment removal, and stormwater from the excavation area and decontaminate liquids
(Figure 2-16). Discharge from the system will be monitored to ensure it meets HCC's NPDES
discharge requirements. This will consist of daily TOC monitoring. In addition, testing will be
used at various points in the system to confirm proper system operation (Figure 2-17).
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[phone] FAX [phone] I 822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802
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Page 3.3
3.2 SAMPLING EQUIPMENT AND MATERIALS
The equipment and materials required to sample air, water or solids varies depending on the type
of material. The general list of sampling equipment and materials presented in this section may
need to be adjusted to accommodate different situations.
These equipment and materials will be assembled as needed at the site. Only a small inventory
of equipment and materials will be maintained at the site in order to limit possible cross
contamination. All sampling equipment and containers will be precleaned prior to use at the site.
3.2.1 Samplin& Equipment
Sampling equipment will vary depending on the media to be sampled and may
include direct reading instruments or sample collection equipment. The material
of construction for samplers could vary and include glass, teflon, or stainless steel.
Selection of the sampler material of construction is based on the type of planned
analyses.
Type of sampling equipment, material of construction, and parameters are listed
below: ·
Coliwasa
Coliwasa
Thief (liquid)
Material
Glass
Glass
Teflon
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone]
Megia
Organics
Metals
FAX[phone]
Thief (liquid)
Spatula
Spatula
Auger
Auger
Thief (Solids)
Thief (Solids)
3.2.2 Sample Containers
Material
Teflon
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Page 3.4
Metals
Organics
Metals
Organics
Metals
Metals
Metals
Sample containers should be glass for samples destined for organic analyses.
Container size will vary depending on the number and type of analyses required.
Listed below are the volume required for the various types of anticipated analyses.
Parameters
Air
voe, total
Priority Pollutant
voe Fraction .
Particulates
Carbon Monoxide
Oxygen
Container Type
Direct Reading
Carbon Tube
Filter Cartridge
Direct Reading
Direct Reading
Volume Requirements
N.A.
. 2 liters
30 liters
N.A.
N.A.
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Toe Glass 50 ml I
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822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone] I
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3.3
Page 3.5
Parameters Container T)l)C Volume Requirements
~
BTU Glass 50 grams
Percent Moisture Glass 100 grams
Percent Ash Glass 50 grams
Antimony Glass 50 grams
Ethylene Glycol Glass 100 grams
Solidified Waste
TCLP Glass 500 grams
Structural Integrity Plastic/Cardboard 4 liters
AIR MONITORING
3.3.1 Air Quality Monitoring
Section 2.3. 7 of the Health and Safety Plan describes the air quality monitoring
which will be conducted during the Removal Action. The purpose ofthis sampling
is to· verify worker safety in the Exclusion Zones and the Support Zone. In
addition, perimeter monitoring will be used around the Exclusion Zone to ensure
standards are met.
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
3.4
Page 3.6
3.3.2 Air Emission Monitoring
The Trial Bum Plan describes the stack emission monitoring which will be
conducted for the incinerator. The purpose of this sampling is to confirm that the
incinerator is operating within parameters to meet the performance criteria
specified in 40 CPR 264 Subpart O of the hazardous waste regulations. After the
trial bum, stack emissions will continue to be monitored for carbon monoxide,
oxygen and caroon dioxide to ensure proper operation of the incinerator.
WATER MONITORING
3.4.1 Treatment System Monitoring
A temporary treatment system will be used for the four types of wastewater
generated during the Removal Action (Figure 2-16). These waters include
scrubber water, water removed from the open excavations which could consist of
both stormwater and trapped water, decontamination water, and stream sediment
centrate water. Scrubber water will be routed to a clarifier tank for metal removal.
The other waters will be settled and metered through the water treatment carbon
unit for discharge to the HCC polishing pond or used as scrubber make-up water
(Figure 2-17).
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Page 3.7
Sampling ports are available at each transfer point within the treatment system.
Therefore, grab samples will be collected directly into the appropriate sampling
containers.
A continuous TOC monitor will be used to assess operation of the treatment at up
to four points. The water will be removed from the lines by the dedicated tubing
and peristaltic pump. The monitor has a recorder to document testing results.
3.4.2 Stream Sediment Centrate Water
The stream sediment centrate water is a reuse system involving a mixtank,
centrifuge and storage tank. In order to confirm operation of the centrifuge,
centrate water going to the storage tank will be tested for settleable solids using
an Imhoff cone. Samples will be collected directly into appropriate sampling
containers from the sampling port provided in the transfer line.
As necessary, water from the storage tank will be transferred by truck to the water
treatment system. This water will be tested at various points in the treatment
system or described in Section 3 .4. I .
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 3.8
3.5 WASTE SAMPLING
Waste sampling will involve the following:
0
0
0
Collection of samples to conduct the bench scale testing of the solidification
mixture.
Collection of waste feed and ash from the incinerator during both the trial burn
and processing period.
Collection of solidified samples.
3.5. l Solidification Bench Scale Sampling
Samples for the various types of materials will be collected so that bench scale
solidification testing can be conducted. Due to the location of the material, two
methods will be used to collect component samples for aliquot compositing in the
lab.
The GRU will be'excavated, stabilized and transferred to the storage pile prior to
sampling. Once a minimum of 600 cubic yards has been transferred, of the
material will be sampled using a three-dimensional sampling pattern. The pile will
be sampled on transects opposite each roof support, which are located on eight-
foot centers. Each transect will be sampled at three equally spaced points. One
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(IDffijffi~LJI
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone] I
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Page 3.9
sample each will be taken from the outer points at mid depth and two samples from
the middle point equally spaced vertically. The one liter samples will be collected
at each point using a bucket auger or thief.
The plastic chips and burn pit residual will be excavated and transferred to a
combined storage pile in the excavation area prior to sampling. Sampling will be
conducted when a minimum of 600 cubic yards of material is in storage. The pile
will be sampled by using a backhoe or trackhoe to dig two access cuts in the pile
from opposite sides. Samples will be collected directly from the hoe's bucket
using a trier or spatula. Samples will be taken which represent approximately one
foot intervals from the top to the bottom of the pile. Minimum sample size will
be one liter volume.
Once the component samples for solidification testing are in the laboratory,
aliquots will be taken to form a composite sample for testing. The GRU material
will tie ashed to simulate incineration prior to testing. Moisture content of the
samples will be d:termined and they will then be combined with various mixtures
of cement by weight. Three samples of each type of waste will first be tested at
a 10 and 15 percent ratio. If this proves satisfactory, no additional testing will
be necessary.
[ID OOfil~lf
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
[GcDJ
3.6
Page 3.10
3.5.2 Incineration Fee¢ and Ash Samplini:
Sampling of the incinerator waste feed will occur initially as described in Section
3.5.1 and will occur periodically to verify moisture content, percent ash and BTU
value. As discussed in the Trial Burn Plan, the feed and ash will be tested to
document incineration efficiency. The feed for the trial burn will be mixed with
naphthalene, a surrogate POHC (Note Trial Burn Plan). The sampling procedure
for the feed and zsh is detailed in the Trial Burn Plan.
SAMPLE HANDLING PROCEDURE
Once samples are collected, they will be handled in a manner to ensure against:
0
0
0
Liberation of contaminants prior to analysis,
Contamination of the sample from foreign sources, and
Cross contamination of the sample from contact with other samples.
The procedures used to handle F11ples is detailed in Section 6.4 of the QA/QC Plan. Also
discussed are the procedures to be used to document control of the samples.
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4.0 HEALTH AND SAFETY PLAN
The Health and Safety Plan which covers these remediation activities is contained in Appendix
B of Trial Burn Plan.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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5.0 PERMITTING PLAN
5.1 INTRODUCTION
The permitting process for this remedial action includes approval of this Work Plan and the
associated Trial Burn Plan and submitting a State air permit application. The incineration phase
of the work must meet the technical requirements of the hazardous waste incineration
requirements as set forth in 40 CFR Subpart O and of the North Carolina Air Toxic Regulations
as listed in the North Carolina Administrative Code, Title 15, Chapter 2, subchapter 2D.
5.2 PERMITS AND APPROVALS
Pursuant to the Consent Decree and associated Record of Division (ROD), a Remedial Design
Report is to be submitted to EPA for approval. This report must include a Remedial Action
Work Plan containing the following project plans:
o Project Operations Plan.
o Sampling and Analysis Plan.
o Health and Safety Plan.
o Permitting Plan.
o Quality Assuranre/Quality Control Plan.
o Operations and Maintenance Plan.
ill 00 ffi ~ TI
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
[GcDJ
Page 5.2
This report contains the above referenced plans with the exception of the Operations and
Maintenance Plan which will be submitted after completion of the remedial action. ·
A mandatory schedule for submittal and approval of these documents is contained in the Consent
Decree.
As part of the approval process for operating the incinerator, a Trial Bum Plan has been
developed and is presented as a separate document. A copy of the State air permit application
is contained in Appendix A. The permit application will be completed after initial comments on
the Trial Bum Plan has been obtained. A copy of the State air permit application is contained
in Appendix A.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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6.0 QUALITY ASSURANCFJQUALITY CONTROL PLAN
6.1 PROJECT DESCRIPTION
GDC Engineering Inc. (GDC) has been retained by the Participating Parties to perform Operable
Unit 2 of the Remedial Action at the Hoechst Celanese Corporation (HCC) site in Shelby, North
Carolina. The Remedial Investigation and Feasibility Study have been completed. Quantities
and chemical characteristics of the waste requiring removal have been defined.
6.1.1 Project Background
The HCC-Shelby site is an active polyester resin and fiber production facility
which has been in operation since 1960. The facility is located in Shelby, North
Carolina, approximately 35 miles west of Charlotte.
The site consists of eight former waste disposal areas which contain varying
amounts of glycol recovery unit (GRU) sludges, bum pit residues and plastic chips.
Three stream beds are included in the site remediation plan for sediment removal.
6.1. 2 Project Objectives
The purpose of ·mis Remedial Action is the safe destruction of the GRU still
bottoms and the stabiliz.ation/immobilization of the plastic wastes, bum pit residues
and contaminated stream sediments at the HCC-Shelby site. The GRU material
fIDOOill~U
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 6.2
will be excavated and incinerated on-site. The plastic chips, bum pit residues and
streams sedimenl3 will be extracted and stabilized on-site along with· incinerator
process residues. The resultant inert materials will be backfilled into the original
excavations. The area will be regraded and restored to a natural condition.
Details of the material handling and process design are specified in Section 2.0 of
this Work Plan.
Solidified materials will meet the following performance criteria:
o Toxicity Characteristic Leachate Procedure (TCLP) standards,
o 1 ppm extractable ethylene glycol, and
0 Compressive strength of 2000 psf.
6.2 PROJECT ORGANIZATION AND RESPONSIBILITY
6.2.1 Project Organil.ation and Personnel
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The responsibility of individual positions for this project are described in the I
following sections.
6.2.1.1
822 NEOSHO AVENUE
PrQject Director
The Project Director is responsible for the overall direction,
coordination, review and implementation of the entire project. He
will operate from GDC's home office and is expected to devote wMWuti=i•R<W~-oo•~rnoom•~rr
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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6.2.1.2
6.2.1.3
822 NEOSHO AVENUE
Page 6.3
. The Project Director's responsibilities include, but are not limited
to, the following:
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Reviewing and approving work plans, project budgets and
costs, schedules, contract changes and manpower allocations;
Guiding the technical and administrative approach to specific
problems which may arise on major tasks;
Ensuring coordination among project managers, field teams
and support personnel to assure consistency of performance;
Act as liaison to the Company Management and Advisory
team and interacting with the Westinghouse Environmental
Project Director and Hoechst Celanese Corporation Project
Coordinator.
Advismy Team
The Advisory Team will consist of three members of the upper
management of GDC and a Consultant specializing in the technical
aspects of the incineration system. The role of the Advisory Team
will include: Evaluation of the progress of the project execution;
provide assistance whenever unforeseen situations develop; interface
with the regulatory agencies as may be necessary and participate in
the Community Relations activity.
The Advisory Team will be informed by the Health and Safety
Officer of the status of compliance with the Health and Safety Plan
and of any violation, accidents or personnel related problems.
Project Manager
The Project Manager is responsible for the technical and regulatory
support for the project, including demonstration and operational
permit activities, and the technical review and assessment of project
~ti~ti~. Th< --u is Marn Toi ~t
BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
6.2.1.4
822 NEOSHO AVENUE
Page 6.4
in the field and reports to the Project Director. Specific
responsibilities include, but are not limited to, the following:
0
0
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Reviewing all components of the regulatory requirements and
coordinating all permitting requirements;
Reviewing all work plans including the technical review and
assessment of project designs;
Auditing the site during construction, prior to initial
operations and during operations, for technical reviews;
Managing Incinerator Operations Manager and Site
Operations Supervisor;
Managing of any subcontracting work;
Tracking costs and managing all funds for labor and material;
Direct day-to-day communication and liaison with the
Engineer; and
Working with the Project Director and the Company
Management and Advisory Team to ensure that project
designs and equipment meet all technical requirements and
guidelines established by all regulatory agencies.
Incinerator Qperations Manager
The Incinerator Operations Manager (IOM) is responsible for the
day-to-day management of all incineration operations. The IOM
reports directly to the Project Manager. Specific responsibilities
include, but are not limited to, the following:
0 Review of incinerator operation, sampling, testing and QA
plans;
[ID ill ill ~ IT
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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6.2.1.5
6.2.1.6
822 NEOSHO AVENUE
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Page 6.5
Review of chemical analyses parameters, schedules,
equipment requirements and manpower allocations;
Preparing cost and perfonnance reports;
Direct supervision of the Incinerator Operations Supervisor;
and
Coordination of trial burn activities with the operations team,
the sampling and analytical personnel and other required
subcontractors.
Field Engineer
The Field Engineer is responsible for all site work and material
handling. He will be in charge of technical aspects associated with
such tasks as: excavation sequence; backfilling operation and
quality control; stream sediments removal and water treatment; run-
off/run-on and water collection and treatment; waste movements
between pits and to incinerator storage and feed system; ash
stabilization and backfilling; and site restoration. The Field
Engineer will report to the Project Manager and will work closely
with the Incinerator Operations Manager. He will enforce all
matters pertaining to Health and Safety.
Site Q.perations Supervisors
Two Site Operations Supervisors will be assigned to the project; one
to handle the incineration phase and the other for the material
handling phase. They are responsible for site operations and
maintenance personnel and for adherence to health and safety plans.
Specific responsibilities include, but are not limited to, the
following:
o Scheduling all operational work efforts to ensure that
sufficient equipment, supplies and personnel are available;
BATON ROUGE, LOUISIANA 70802
6.2.1.7
822 NEOSHO AVENUE
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Page 6.6
Supervising all site operations and maintenance personnel,
including subcontractors to ensure adherence to all operating
procedures and health and safety plans;
Reporting daily labor and equipment charges as well as the
volume of waste material processed;
Coordinating the logistics between the materials handling
crew and operations team for sample analysis, maintenance
and operating activities; and
o Resolving site problems and identifying support requirement.
Company Health and Safety Officer
The Company Health and Safety Officer is responsible for the
overall coordination of field health and safety activities and the
implementation of training programs. The training programs
encompass the basic 40 hour hazardous material training program
required by OSHA, additional 8 hour training for management
personnel, classes for sampling techniques and operation of field
safety equipment. Specific responsibilities include, but are not
limited to, the following:
o Ensuring that all personnel associated with the site are
properly trained as required by OSHA and other applicable
regulatory agencies;
o Briefing of all field and laboratory personnel regarding
unique health and safety hazards;
o Monitoring and auditing of field safety procedures; and
0 Preparing Site Safety and Contingency Plans, including spill
prevention control plans.
BATON ROUGE, LOUISIANA 70802 ( 504) 383-8556 FAX[phone]
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6.2.1.8
6.2.1.9
822 NEOSHO AVENUE
Page 6.7
Site Health and Safety Coordinators
The Site Health and Safety Coordinators (HSC) are responsible for
the coordination and implementation of site-specific field health and
safety procedures and activities. One HSC will be assigned to each
shift. The HSC reports to the Company Health and Safety Officer.
The HSC's responsibilities include, but are not limited to, the
following:
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Ensuring that all procedures and guidelines as set forth in
the Health and Safety Plan are implemented and followed
by all field personnel;
Monitoring field safety procedures;
Monitoring the labeling, shipping and control of hazardous
or potentially hazardous samples;
Preparing field health and safety reports; and
Conducting field air sampling and monitoring.
Company Ouality Assurance/Ouality Control Officer
The Company Quality Assurance/Quality Control Officer is
responsible for the overall coordination of QA/QC analytical
procedures and documentation. The QA/QC Officer's
responsibilities include, but are not limited to, the following:
0 Monitoring and periodically auditing the procedures used by
the chemical analysis and field sampling teams;
o Reviewing all chemical analysis data for compliance with
QA/QC requirements and technical accuracy;
0 Performing field audits of sampling activities in accordance
with the required frequencies of established EPA standards;
BATON ROUGE, LOUISIANA 70802 ,~ .. ®~ ®,~,rr
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Page 6.8
Assuring that adequate data collection and QA/Q<:,
documentation is provided in accordance with the
requirements of established EPA standards;
Assuring that all QA/Q<:, problems are resolved in an
expeditious manner and brought to the attention of the
Project Manager;
o Coordinating site-specific QA/Q<:, analytical procedures and
documentation; and
o Communicating with Westinghouse regarding data validation
·and other quality control considerations.
6.2.2 Project Communications
Project-related materials that come in to GDC in the form of correspondence,
sketches, logs, authorizations, or other information will be routed to the Project
Manager, or someone designated by him, after the original is marked with the date
received and an identifying project number. The Project Manager will then
determine which personnel should review the incoming materials and route the
materials according! y.
As soon as practical, incoming correspondence originals will be placed in a project
central file. If the correspondence is required by the project personnel for
reference, a copy will be made and the original will remain in the central file.
Correspondence addressed to project personnel that is important to the project
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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Page 6.9
Project-related materials transmitted from GDC including correspondence, reports,
and drawings, will be appropriately reviewed, approved, and signed prior to
transmission. Outgoing correspondence will be signed by the Project Manager or
key level individuals assigned this responsibility. Quality assurance
correspondence will be signed by the QA/QC Manager. Outgoing project reports
will be read by the Project Manager prior to mailing to the Participating Parties
and/or their representative. The office copy of project correspondence will bear
routing information and be routed to the appropriate project personnel.
Communications relative to the project from third parties (e.g., media, interested
individuals and groups) will be referred directly to the Participating Parties
designated representative(s) without comment. A copy of all such communications
will be kept in the project central file by GDC.
6.2.3 Subcontractor Procurement
For this project, the responsibility for subcontractor (York Research Consultants)
compliance with applicable QA/QC requirements will be retained by GDC who
shall specify the performance or appropriate quality requirements to each
subcontractor. This will permit appropriate requirements to be met without
necessarily asking subcontractors to have their own quality assurance program.
[ID 00 fil ~ 1Y
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
Page 6.10
Each subcontractor will complete the necessary training required for implementing
the Health and Safety Plan. If necessary, prequalification audits may be performed
by GDC to determine subcontractor acceptability. Subcontractors will be required
to complete and submit copies of all project-related records to the Project
Manager.
To verify subcontractor conformance to project QNQ<:, requirements, GDC will,
as appropriate, perform field quality control inspections, review subcontractor-
prepared documentation, and perform audits of subcontractor activities.
Subcontractors will provide access to their work areas and records for this
inspection and auditing.
For field operations, project personnel will perform a quality control inspection
of each subcontractor. The intention of this check is to verify that the
subcontractor has, fulfilled the requirements necessary to perform their activities.
The inspection shall include the type and condition of equipment, calibration of
equipment, and qualifications of personnel. If requirements are not met, activity
will be suspended until requirements are met. &juipment that does not meet
project requirements will not be used without repair to the satisfaction of the
appropriate project personnel. The results of the inspection will be documented
by the appropriate field supervisor and sent to the Project Manager.
@[Jd!Jj~iJ
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Page 6.11
Audits of subcontractor project activities will be performed as discussed in Section
6.8 of this plan.
6.3 DATA QUALITY OBJECTIVES AND ASSESSMENTS OF CRITICAL
MEASUREMENTS
This QA/QC Plan sets the procedures GDC will use to produce data of known and acceptable
quality in conformance with the requirements of the Remedial Action at the HCC site. Quality
assurance is a system for ensuring that all information, data, and resulting decisions compiled
under a specific task are technically sound, statistically valid, and properly documented. Quality
control is the mechanism through which quality assurance achieves its goals. A quality control
program defines the frequency and methods of checks, audits, and reviews necessary to identify
problems and dictate corrective action, thus verifying product quality. The QA/QC Plan presents
the technical approach, project organiz.ation, data quality objectives, sampling procedures,
analytical procedures, data management procedures, quality control checks, and corrective action
procedures.
The overall objectives of the QA/QC Plan are to ensure that:
o All procedures used in data acquisition, analysis and management do not detract
from the quality of the results.
o Scientific data generated will be of sufficient quality to stand up to scientific and
legal scrutiny.
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Data will be gathered or developed in accordance with procedures appropriate for
the intended use of the data.
Data will be of known or acceptable precision, accurate representativeness,
completeness, and comparability.
The objectives of quality assurance in the field are to ensure the validity and reliability of data
acquired in the field by establishing an approved protocol for all field procedures, properly
documenting all field activities, and training all field team members in the use of equipment,
protocol, and documentation.
The objective of the analytical portion of the QA/QC Plan is to provide an adequate quality
control program for all analytical functions. The laboratory's quality control program includes:
o Spikes, duplicates, and internal audit samples.
0 Documentation of analytical methods to be used.
o Documentation of equipment maintenance, testing and calibration.
0 An adequate documentation record system.
The definitions of these field and analytical objectives and how compliance with them will be
assessed is described in the following sections.
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Page 6.13
6.3.1 Data Precision and Accuracy
Accuracy reflects the relative agreement of a measurement with an accepted
reference or true value, and is a measure of system bias. Precision is a measure
of the mutual agreement among individual measurements of the same property, and
reflects the repeatability of the measurement. The accuracy and precision of all
data collected during the Remedial Action will be controlled by the methods of
collection and analysis.
All field measurements and observations will be carried out by experienced
technical personnel using standard methods of investigation in the engineering and
environmental science profession. Methods to be employed are detailed in the
sections that follow and in the Sampling Plan (Section 3.0) and Project Operations
Plan (Section 2.0). All field data collection activities will be thoroughly
documented to allow subsequent evaluation of data accuracy and precision.
Trip blank, field blank, equipment rinse blank and duplicate samples will be used
to provide a mechanism for control and evaluation of the accuracy and precision
of samples obtained in the field. Field blank samples will be analyzed to check
for procedural contamination. Trip blanks allow a check for ambient conditions
at the site that may cause sample contamination. Equipment rinse blanks verify
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\
Parameter
Volatiles
Page 6.14
the success of decontamination procedures. Field duplicates will be analyzed to
allow an evaluation of analytical reproducibility.
The quality control limits of accuracy and precision for laboratory analyses are
governed by the methods and equipment used. Laboratory requirements of this
program are designed to ensure that acceptable levels of data accuracy and
precision are maintained throughout the analytical program. The requirements are
detailed in the methods to be used, and will be followed by the chosen laboratory
for this project. Analytical protocols for methods and QA/QC for this project will
be followed as specified in Test Methods for Evaluating Solid Waste (USEP A
Office of Solid Waste, SW-846 3rd Edition, 1986), or equivalent. Analytical
procedures for TCLP analyses will be followed according to the protocols set forth
in Appendix II of 40 CFR Part 261.
Matrix Method <SW-846, 3rd ed.)
8240 (SW-846, 3rd ed.)
Purgeable Hydrocarbons
Aqueous
Solid
Semi-volatiles
Pesticide/PCB
Metals
TCLP
822 NEOSHO AVENUE
Aqueous
Solid
Aqueous
Solid
Aqueous
Solid
Solid
BATON ROUGE, LOUISIANA 70802
8270 (SW-846, 3rd ed.)
8080 (SW-846, 3rd ed.)
7000-series (SW-846, 3rd ed.)
40 CFR Part 261, App. II
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Page 6.15
Parameter Matrix Method <SW-846, 3rd ed.)
Total Organic Carbon
Total Chlorides
Aqueous
Aqueous
9060 (SW-846, 3rd ed.)
9250 (SW-846, 3rd ed.)
Laboratory physical analyses will be conducted usmg appropriate American
Standard for Testing and Materials (ASTM) methods. Testing of soil samples for
physical properties, if necessary, will follow standard accepted procedures that are
used for determining estimates of the engineering properties of the material.
6.3.2 Data Comparability
Comparability is a measure of the confidence with which one data set can be
compared to ancther. The following measures will be taken to ensure the
comparability of the data:
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Standardiz.ed written sampling and analysis procedures.
Standard handling and shipping procedures for all collected samples.
A uniform, clean supply of sampling containers.
Results reported in consistent units.
6.3.3 Data Re»resentativeness
The representativeness of a sample is controlled by the collection and handling
methods employed. Representativeness of specific samples will be evaluated
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Page 6. 16
through the collection and analysis of duplicate samples. Methods of sample
collection and handling are designed to minimize sample contamination,
•
disturbance, or alteration prior to analysis by the laboratory. Detailed methods
of all sample collection methods planned are included in the sections that follow,
as well as in the site Sampling Plan (Section 3.0).
6.3.4 Data Completeness
Completeness is a measure of all information necessary for a valid study.
Completeness will be evaluated by carefully comparing project objectives with the
proposed data acquisition and resulting potential short falls in needed information.
In addition, completeness is a measure of the amount of valid data obtained from
a measurement system compared to the amount that was collected. Completeness
will be assessed for each parameter in the following manner:
C = YX 100
D
where C = percentage of valid data for each parameter
V = number of valid results for each parameter
D = number of samples collected for each parameter
The goal for completeness is greater than 90 percent.
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Page 6.17
6.4 SAMPLE COLLECTION AND HANDLING PROCEDURES
This section of the QNQC Plan presents the scope and methodology of sampling activities at the
HCC-Shelby site. Normal operation of the incineration and water treatment systems will require
monitoring of incinerator feed_ and ash composition, stack emissions, scrubber water and
wastewater effluent quality. Sampling of the various matrices will be conducted at regular
intervals to ensure the quality of systems operations. Additional details of the sampling
methodologies are presented in the Sampling Plan (Section 3.0). The following considerations
form the basis for the site-specific sampling program:
o Methods of sampling to be employed,
o Number of samples to be collected,
o Volume of samples to be collected,
o Type and kind of analyses to be performed in the field,
o Laboratory analyses to be performed,
o Procedures and precautions to be followed during sampling, and
o Methods of preservation and shipment.
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Page 6. 18
6.4.1 General Field Activities
All activities performed during the site remediation shall be recorded and
documented. Re<1.uired documentation of field investigation and sampling includes
a daily log of project activities, a photographic record (as approved by plant
personnel) and the appropriate laboratory results.
Members of the Project Staff working in field operations shall keep a daily log of
the project activities. Items to be included in the daily log, as appropriate, are:
0 Field activity subject,
0 General work activity,
0 Unusual events,
0 Changes to plans and specifications,
0 Visitors on-site,
0 Subcontractor progress or problems,
0 Communication with the EPA or others,
0 Weather conditions, and
0 GDC personnel on-site.
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Page 6.19
Copies of the daily log entries will be sent to the Project Manager approximately
once a week. If the logs are not submitted, as required, it is the responsibility of
the Project Manager to contact the field personnel.
As part of field operations, a photographic record shall be prepared (This will
require approval by plant personnel). Photographs should be in color. As
examples, photographs should be taken of the general site layout, geologic
features, field equipment and installations, sampling stations and field operations.
For any excavations, photographs should be taken of the subsurface profiles and
any visible conta.'Ilination, if possible.
Photographs are to be identified with the project number, date taken and a brief
description. This may be done individually on the back of the photographs or in
an album in which the photographs are mounted. Album photographs must be
provided with individual descriptions and dates taken.
Appropriate sample data forms shall be prepared. They shall include, as
appropriate, the sample location (e.g., sampling station, elevation and field
coordinates) and the appropriate form for field activities. All requested
information shall be addressed. If not applicable, requested information should
be designated as such.
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Page 6.20
All field records shall be collected and maintained by the Field Engineer until
completion of the remediation activities or until they are submitted to the project
central files. During the performance of remediation activities, it is anticipated
that a copy of the field records will be periodically made and sent to the Project
Manager. These copies can provide adequate documentation of work activities
should originals be destroyed, lost or stolen.
6.4.2 Sample Collection Procedures
6.4.2. l
822 NEOSHO AVENUE
Containers and Equipment
The constituents for which the samples will be analyzed determine
the types of laboratory-grade container to be used, the preparation
of the container, and the preservation required while the sample is
transported from the site to the laboratory for analysis. Sample
preservation is addressed in detail in Section 6 .4 .4.
Clean sample containers are essential to the accuracy of the
analytical results. All sample containers are supplied by the
laboratory. From the date of purchase from the container
manufacturer, to the arrival of these containers at the site, all
preparation procedures are handled by the laboratory. Container
preparation conforms to the National Enforcement Investigations
Center (NEIC) Guidelines for contractor laboratories. These
specifications were published by the EPA NElC in 1980 in
Enforcement Considerations for Evaluations of Uncontrolled
Ra111rrlous Waste Sites by Contractors. Details of the sample
container preparation will be provided in the suppliers QA Plan.
The approved quality control procedures for recommended sampling
containers and preservation techniques are made available to the
sampling manager so that the correct containers are chosen for the
type of sampling planned.
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6.4.2.2
822 NEOSHO AVENUE
Page 6.21
0 Sampling Containers
Th: quality of data resulting from sampling surveys depends on
several factors. Representative samples must be collected
according to a well-planned set of objectives. They must also be
properly handled, preserved, and labeled.
The number of sample containers taken to a site includes those
required for background samples, field blanks, preservative blanks,
and duplicate samples. The number of sample containers needed
also depends on the goal of the program.
0 Sampling Equipment
Sampling equipment will be cleaned prior to sampling. The piece
of equipment will be cleaned, i.e., decontaminated, prior to reuse.
The equipment will be wrapped in aluminum foil or plastic
(whichever is appropriate) between uses to prevent accidental
contamination.
Decontamination Procedures
Disposable or dedicated sampling equipment will be used whenever
possible. All sampling and field testing equipment that is not
dedicated will be decontaminated between each use to prevent cross
contamination at sampling locations and to provide more accurate
data. Decontamination procedures for non-dedicated equipment
incudes the following steps:
o Washing with detergent (Alconox) and tap water.
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Rinsing with 10% HNO, (inorganics sampling only).
Rinsing with pesticide grade isopropanol ( organics sampling
only).
Rinsing with deionized water.
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6.4.2.3
822 NEOSHO AVENUE
Page 6.22
0 Air drying.
Decontamination procedures for field test equipment such as pH
meters, specific conductivity meters, and water level measurement
tapes and probes, will consist of rinsing with deionized water
between each use.
Field blanks will be prepared using organic-free, distilled or
deionized water. E.quipment rinse samples will consist of collecting
the final deionized rinse from sampling equipment decontaminate.
Trip blanks will be provided by the laboratory for each batch of
VOA samples.
All waste decontamination water will be routed to the wastewater
treatment system, as necessary, prior to discharge.
Incinerator Systems Sample Collection and Analysis
Grab samples of incinerator feed stocks, ash residues and scrubber
liquor will be collected on a regular basis. Samples will be
composited as necessary and sent to the laboratory for analysis.
Analytical results from each matrix will be used to confirm the
efficient operation of the incinerator.
The Continual Emissions Monitoring (CEM) system will provide
instantaneous data for stack emission and scrubber liquor quality.
Calibration procedures of applicable system components are
presented in Appendix C of this plan.
Incinerator feed material and ash samples will be obtained utilizing
stainless steel trowels, as required. When using composite
sampling, the sample will be homogenized in stainless steel bowls
prior to being placed into the sample container. The following
procedures will be followed for sample recovery:
0 Verify integrity of sample container.
0 Extract sample with appropriate scoop and place into sample
container. ill 00 fil ~ 1I
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6.4.2.4
822 NEOSHO AVENUE
Page 6.23
o Verify the presence of Teflon liner in cap, if required.
Secure cap tightly.
o , Label the sample bottle with appropriate sample tag. Label
the tag clearly; address all categories and parameters.
Complete all chain-of-custody documents and record in field
log book.
o Decontaminate equipment after use, as necessary.
GDC will retain the services of a subcontractor to conduct stack
an J scrubber liquor sampling. The subcontractor will adhere to all
QA/cy::, protocols specified in this plan. Sampling methodologies
are detailed in the Trial Bum Plan.
Water Sample Collection and Analysis
Wastewater generated from stream bed remediation, storm water
re:overy from excavation pits, and incinerator scrubber water will
be· processed in the GDC wastewater treatment system prior to
di~harge into the HCC polishing pond. The effluent will be
sampled at regular intervals during normal operations. Analytical
results will be used to document that effluent quality meets or
exceeds the requirements of the HCC wastewater treatment facility.
Samples will be obtained from an access valve located between the
cluifier unit and the effluent outfall. Sampling procedures are as
follows:
o Verify integrity of sample container.
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Verify the presence of Teflon liner in cap, if required.
Secure cap tightly.
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Page 6.24
Label the sample bottle with appropriate sample tag or
label. Fill in the label or tag clearly; address all categories
and parameters. Complete all chain-of-custody documents
and record in field log books.
6.4.3 Sample Identification
All samples shall be adequately marked for identification from the time of
collection and packaging through shipping and storage. Marking shall generally
be on the sample container (jar, bottle, bag, etc.), but may be applied on a tag or
label attached to the sample container.
Sample identification shall include, as a minimum:
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Project name and number,
Sample number,
o Sampling location,
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822 NEOSHO AVENUE
Sampling date,
Individual performing the sampling, and
Preservation or conditioning employed (samples for chemical
analysis).
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6.4.4 Preservation. Shipping and Holding Times
Samples for chemical analysis will be preserved and maintained according to the
appropriate methods. Samples to be shipped off-site for chemical testing shall be
placed in ice chests containing "blue ice" (or a similar pack of frozen gel) and
wrapped with packing material to prevent jarring during shipment. The ice chest
shall be addressed, identified and placarded, as appropriate.
Samples will be analyzed as soon as possible after collection. The times listed in
SW 846, November, 1986, are the maximum times that samples may be held
before analysis and still be considered valid.
Holding times and preservation for samples by parameters (method) listed below.
Parameters Method Preservative Ana!):sis Time
1
Volatiles 8240 Cool, 4°C 14 days
Semivolatiles· 8270 Cool, 4°C Extract 7 days
Analysis in 30 days
PCB/PEST 8080 Cool, 4•c Extract 7 days
Analysis in 30 days
Metals 7000-series pH<2 w/HNO,* 180 days
TOC 900) pH<2 w/HCI 2 hours from collection if not
preserved w/HCI
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Page 6.26
Parameters Method Preservative Analysis Time
Total Chlorides 9250 N/ A NIA
TCLP ~N/A 14 days
*Low concentration aqueous samples only.
Sample storage in the laboratory will be in a refrigerated, secure area until all
required analyses are completed.
6.4.5 Chain-of-Custody
' Chain-of-custody procedures will document sample possession from the time of
collection to disposal, in accordance with federal guidelines. For the purpose of
these procedures, a sample is considered in custody if it is:
o In one's actual possession,
o · In view, after being in physical possession,
o Locked so that no one can tamper with it, after having been in physical
custody, or
o In a secured area, restricted to authorized personnel.
These procedures will be followed for all samples subject to chemical analysis for
this project:
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Page 6.27
A chain-of-custody record (Appendix C) will be initiated in the field for
every set of samples. This record will accompany the samples.
Each time responsibility for custody of the sample changes, the new
custodian will sign the record made by the previous custodian and the
original will be sent to the receiving laboratory to allow tracking of sample
possession. All change of custody of samples must be a person-to-person
exchange of custody documents and samples.
Upon sample destruction or disposal, the custodian responsible for the
disposal will complete the chain-of-custody record, file a copy, and send
a copy to the Project Manager or to his designated representative for
recordkeeping. All samples not consumed during analysis shall be kept
for three months.
The custody of individual sample containers will be documented by
indicating appropriate chain-of-custody information on each sample tag or
label for ill chemical analysis samples.
The following documentation will supplement the chain-of-custody
records:
Field log book ultimately to be filed in the project files,
Sample label/tag on each sample,
Sample seal on each sample, and
o · Prior to ~mpling, all personnel involved will have received copies of the
chain-of-custody procedure. A briefing for these personnel will be held
and documented in conjunction with the Health and Safety training
program/session to detail the chain-of-custody procedure (as well as
sampling and sample handling procedures). Briefing of personnel is the
responsibility of the on-site Field Engineer or designated representative.
GDC will not be shipping samples to the laboratory directly unless otherwise
requested. GDC personnel will transmit properly packaged samples to Hoechst
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Page 6.28
Celanese Corporation personnel or their representative. Proper chain-of-custody
protocol will be strictly adhered to. A copy of the chain-of-custody form to be
used is presented in Appendix A of this plan.
6.5 CALIBRATION PROCEDURES AND FREQUENCY
A maintenance, calibration and operation program is implemented to ensure that routine
calibration and maintenance is performed on all instruments. The program is administered in
the laboratory by the Laboratory Supervisor and in the field by the Sampling Team Leader.
They perform the scheduled calibration and maintenance checks, routine calibrations and
instrument maintenance prior to use.
Ambient levels of organic vapors will be measured with Foxboro Model 128-GC Organic Vapor
Analyzer (OVA). The OVA will be calibrated on a weekly basis following manufacturer
specifications. Manufacturer provided calibration gas (methane mixture in air) will be used.
Temperature measurements will be made using a laboratory-grade, liquid-filled thermometers.
Field measurement of pH will be made using a digital pH meter. The meter will be calibrated
before each sampling event using pH 4, 7 and 10 reference solutions. Calibration will be
checked at each sampling location using a pH 7 reference solution.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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Page 6.29
Calibration procedures for applicable incinerator monitoring systems are presented in Appendix
B of this plan. All systems calibrations will be made according to manufacturer specifications.
Records of all field instrument calibrations and field checks are kept in the field log books.
6.6 DATA REDUCTION, VALIDATION AND REPORTING
6.6.1 Laboratory Data
Laboratory data reduction, verification and reporting are the responsibility of the
laboratory director or his designee. Details should be provided in the QA Manual
of the laboratory of choice.
6.6.2 Engineering Data
Data reduction and verification for the Removal Action include the following
major activities associated with the site operations:
o Waste excavation,
o Waste incineration,
o Waste stabilization, and
o Wastewater treatment.
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Page 6.30
Reports will consist of technical documents utilizing verified data for the basis of
the decision making process during the site activities. The following procedures
will be utilized to reduce and verify the required engineering data.
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6.6.2.1
6.6.2.2
822 NEOSHO AVENUE
NJ.1merical Analysis Procedures
Analysis activities shall be performed in a planned and controlled
manner. Performance responsibility rests with the Project
Engineer. Prior to initiating the activities, the Project Engineer
shall discuss the Scope of Work, contractual and regulatory
requirements, and applicable quality assurance/quality control
procedures with assigned personnel.
Calculations
Calculations shall be legible and in a form suitable for
reproduction, filing and retrieval. Documentation shall be
sufficient to permit a technically qualified individual to review and
understand the calculations and verify the results. Calculations
shall be performed on GDC standard calculation paper, when
possible. All calculation pages shall be individually identified with
the exception of large computer output. GDC calculation paper
provides spaces for the originator's name and date of work, the
checker's name and date, calculation subject, project number and
page number. All of this information shall be completed for each
page. For extra pages, such as large graphs, this information shall
also be included.
Calculations should, as appropriate, include a title page, statement I
of calculation intent, description of methodology used, assumptions
and their justification, input data and equation references,
numerical calculations including units and results. I
Computer printouts that become an integral part of the calculations
shall be referenced in the calculations by run number or other I
unjque means of identification.
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BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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6.6.2.3
Page 6.31
J>eyReview
'
At the discretion of the QA/(X, Manager, peer reviews will be
performed by GDC technical personnel on critical project activities
and submittals. The peer review process is intended to complement
the verifications (checking) process. While verification provides
review and confirmation of largely definitive work, peer review
provides evaluation and assessment of interpretations, judgements
and decisions made.
The results of peer review will be documented and transmitted to
the Project Manager.
6. 7 INTERNAL QUALITY CONTROL CHECKS
6. 7 .1 Field Ol)Crations ~
The sampling team will maintain detailed records of the sampling location,
procedures, devices, containers, preservation, date, and time. This will enable
the lead personnel to review the entire sampling procedure during data validation.
All field measurements and observations will be recorded in project log books and
on field data records. Field measurements may include pH, temperature,
conductivity, and certain air quality parameters.
All data will be ~rded directly and legibly in field data records and log books
with all entries signed and dated. If entries must be changed, the change will not
obscure the original entry. The reason for the change and explanation will be
signed and dated or identified at the time the change is made. Field data records
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802
Page 6.32
will be organized into standard formats, wherever possible, and be retained in
permanent files.
6.7.2 1;,hQratory Ol)eration
HCC or their designee will be coordinating analytical services. Quality control
samples commonly utilized to routinely check laboratory results are suggested and
should be included in the laboratory's Quality Assurance Manual.
6. 7.3 Data Evaluation wd Report Pre.paration
Data evaluation and report preparation will be done by the Project Engineer and
other project scientists. The Project Manager will ensure that the overall project
objectives are met and that the final report is technically sound and complete.
The QA Manager will ensure that the project QA/QC requirements have been
met.
6.8 PERFORMANCE AND SYSTEM AUDITS
6. 8.1 Laboratory Audits
Laboratory audits should be included in the chosen laboratory's Quality Assurance
Manual.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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Page 6.33
6.8.2 Engineering Audits
To verify compliance with GDC and specific project QA/QC requirements, the
QA/QC Manager shall perform planned and documented audits of project
activities. These audits shall consist, as appropriate, of an evaluation of quality
assurance/quality control procedures and the effectiveness of their
implementation, an evaluation of work areas and activities, and a review of the
project documentation. Audits shall be performed in accordance with written
checklists by trained members of the Quality Assurance Group and, as
appropriate, technical specialists. Audit results shall be formally documented and
sent to project management.
Planned audits for the HCC-Shelby project will cover the field activities. These
audits may include, but not be limited to, the following areas:
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Subcontractor prequalification,
Subcontractor performance,
Laboratory testing and records,
Equipment calibration and records,
Identification and control of samples,
Numerical analyses,
eom,, .. ~--m~ratioo aw 'IWW jjj ~, v~
BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
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Transmittal of information, and/or
Record preparation, control and retention.
6.8.3 Performance of Audits
Page 6.34
The field operations audit will involve periodic site visits by a QA/QC Manager.
Items to be examined may, as appropriate, include the availability and
implementation of approved work procedures; calibration and operation of
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equipment; labeling, packaging, storage and shipping of samples obtained; site
investigation and testing performance documentation and checking; subcontractor
performance; and nonconformance documentation.
The report audit may examine, as appropriate, the documentation and verification
of field and laboratory data and results; performance, documentation, and
verification of analyses; documentation and verification of computer programs;
preparation and verification of drawings, Jogs and tables; content, consistency and
,
conclusions of the report; compliance with project requirements; and maintenance
and filing of project records.
The report preparation process shall be reviewed so that:
0 The report correctly and accurately presents the results obtained by
the project work.
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Page 6.35
AI: information presented in the report is substantiated by project
work.
The tables and figures presented in the report are prepared and
checked according to GDC requirements.
The report satisfies the Scope of Work and EPA requirements, and
any other pertinent regulatory requirements.
During an audit and upon its completion, the auditors will discuss the findings
with the individuals audited and cite corrective actions to be initiated. Minor
administrative findings which can be resolved to the satisfaction of the auditors
during an audit a.--e not required to be cited as items requiring corrective action.
All findings that are not resolved during the course of the audit and all findings
affecting the quality of the project, regardless of when they are resolved, shall be
noted.
6. 8.4 Reports to Manacement/ PrQject Response/Closure
Following completion of an audit, the QA/QC Manager shall prepare and submit
an audit report 'to GDC's Project Director, Project Manager, and Project
Engineer. This report may also be sent to individuals contacted during the audit
and the management of any affected subcontractor.
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Page 6.36
The report shall be prepared as soon as possible (within 30 days) after the audit
and contain, as appropriate:
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Date and location of the audit,
Identification of audit participants,
Identification of activities audited,
Audit results,
Descriptions of items requiring corrective action and, if possible,
the means for correction,
o DLie date for completion of corrective actions and/or audit
re:;ponse, and
0 Means for audit response (in writing).
If corrective action is required by the audit report, the corrective action shall be
undertaken and completed on schedule unless sufficient evidence can be provided
through management receiving the post audit report to prove that the action is
unnecessary. If required, the QA/QC Manager is empowered to stop work on the
project pending resolution.
The individuals audited shall respond in writing to any deficiencies identified in
the audit report. The response shall clearly state the corrective action taken or
planned.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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Page 6.37
If all corrective actions have not been completed prior to issuance of the audit
response, a scheduled date for completion should be provided. It is noted that all
requests for corrective action must be addressed to the satisfaction of the QA/QC
Manager.
Completion of corrective action shall be verified by the auditors through written
communication, reaudit or other appropriate means.
After acceptance and verification of all corrective actions, an audit closure shall
be issued by the auditors to the same individuals receiving the post audit report.
6.9 PREVENTATIVE MAINTENANCE
Preventative maintenance procedures will be carried out on all field and laboratory equipment in
accordance with the procedures recommended by each manufacturer.
Field equipment is subject to a routine maintenance program, prior to and after use. Equipment
is cleaned and its integrity checked after each use. In addition, parts with a limited life (such as
batteries, membranes, and some electronic components) are periodically checked and replaced.
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Page 6.38
6.10 ROUTINE PROCEDURES FOR QUALITY ASSURANCE
6.10.11..aboratory Procedures
The type of data required to assess data precision, accuracy and completeness is
qualitative and quantitative. Examples of activities which must be carried out to
assess data accuracy are given below.
2.
Reference or Spike Samples -Recoveries must be within predetermined
acceptable limits.
Performance Audits -Each task will include performance audits to
demonstrate that all measurements are within acceptable limits. The
standards used for preparing audit samples must be independent of, or
different from, those used during routine analyses. If available, EPA
quality control or Performance Evaluation (PE) samples will be used.
Examples of activities which must be carried out in order to assess precision are:
2.
Replicate Samples -Replicate sample data must be within predetermined
acceptance limits.
Instrument Performance Checks -For each measurement device, routine
checks must be performed as part of the analyses to demonstrate that
variables are within predetermined acceptance limits. Real-time control
charts should be kept for each parameter in the study. Some of the
applicable statistical procedures are given below:
A. Central tendency and dispersion -Arithmetic mean, range, standard
deviation, relative standard deviation, pooled standard deviation
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and geometric means. []Jf2ffi~lf I
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6.11
B.
C.
Page 6.39
Measures of yariabjlity -Accuracy, bias and precision; within
laboratory and between laboratories.
Significance test -T-test, F-test, Chi-squares tests, confidence
limits and testing for outliners.
6. 10.2 Data Quality Indication
In addition to the data quality objectives discussed in Section 6.3, as part of the
data validation and evaluation, the data will be examined for consistency and
reasonableness. Several criteria will be used for this judgement, including the
following questions:
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How do the analysis results compare to literature results (i.e., any
similar properties exhibited)?
How do the chemical analysis results compare to results from
previous investigations?
How do the results compare to each other?
CORRECTIVE ACTION
6.11.1 Laboratory Corrective Action
Laboratory corrective action will be the responsibility of HCC's chosen
laboratory.
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Page 6.40
6.11.2 Engineering Corrective Action
Nonconforming items and activities are those which do not meet the project
requirements, procurement document criteria or approved work procedures. Each
nonconforrnance shall be documented by the personnel identifying or originating
it. For this purpose, results of laboratory analysis control tests, audit report,
internal memorandum or letter shall be used, as appropriate. Documentation
shall, when necessary, include:
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nonconforrnance,
Description of the nonconformance,
Any required approval signatures,
Method(s) for correcting the nonconforrnance (corrective action) or
description of the variance granted, and
o Schedule for completing corrective action.
Documentation shall be made available to GDC project, laboratory, and/or quality
assurance management and, if applicable, subcontractor management. It is the
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responsibility of .the Project Manager, applicable Laboratory Director, and/or
QA/QC Manager to then notify appropriate personnel of the nonconforrnance. In
addition, the Project Manager will notify the Participating Parties or their
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Page 6.41
representative of significant nonconformances which could impact the results of
the work and indicate the corrective action taken or planned.
Completion of corrective actions for significant nonconformance should be
verified by the QA/(X, Manager as part of future auditing activities.
Any significant recurring nonconformance should be evaluated by project,
laboratory and/or quality assurance personnel to determine its cause and
appropriate changes instituted in project requirements and procedures to prevent
future recurrence. When such an evaluation is performed, the results shall be
documented and made available to the Project Manager or his representative.
6.12 QUALITY ASSURANCE REPORTS TO MANAGEMENT
6.12. I Laboratory Rel)Orts
Quality assurance reports to management for laboratory data should be presented
in the chosen laboratories Quality Assurance Manual.
6.12.2 Engineering Re.ports
Engineering reports are continuously updated incorporating the appropriate
measures generated as part of the data reduction, validification and reporting,
pm-,ruj ""'m ,.na ,ruj =ti~ 1fi1m!Z1? iT
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Page 6.42
reports will be generated to provide information on activities and scheduling
performance. At the conclusion of specific work elements, final reports will
generate document results and conclusions, as required.
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APPENDIX A
NORTH CAROLINA AIR PERMIT APPLICATION
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L"<STRUCTIONS
FLOW DlAGRA.'I FOR PROCESSES OR FUEL BURNING SOURCES
INCLUDING AIR CONTROL DEVICES
onw • compln1 flow dbcram of ltM proc;ne or flld bumlfll IDUI' .. indudlftl w conn <Hrice(1). lndl<ai. all equiP<llffl&,,,.... flow 0
m.1uriol, IOQllon of direct hu<ln1, inlet and oudel lamp,r.uwe,, .IIICI &It floe ma ~ flow raon fo, ••• uood 11dle, a ...,.inl 0
.. 1Cn1bl>tn1-llldlca11 pollUQffl colleelld and lfflisai<lm •""'""'-td lO 1M ffllOIPNft, If a sci-or a mlll of !GI-, lnkl, palfta 0
olhet ,.._ui. liquid mix".,.. lned, ,....,,p1,w die Hydrocat1ion Endalon ~ Fomt "E•. All 1111111Ni1 tffl«in1 dlls s--inoui<
>1>pear In llcm a, pocc 1.
FOR EXAMP\.E:
u.. ..
l&CIIClll ... l
. '"''"'' Mitt ... , ....
I. Rock, sr1vel, und, flnrl, eu:. -200,000 lbs/hr or 100 ,on,/hr.
l. Rock, ,n>et, und, fines, eu:. -200,000 lb,1llr or 100 1on1/hr.
I. Ory •8'f'Ople -199,000 lbs/hr or 99.50 1on,/hr.
1
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4. 30,000 CfM@ 180" F; 1,000 lbl/hr p.artia.olau: en1erin1 cyclone; 8°" C'1clone efficiffl<Y. i--:=i
S. 800 lbs/hr rewrned 10 dry agrcplc. . m ~ \j
6. Ory •pnp11 en1e,in1 Y1bruin1........,. -199,800 lbs/hr. w rn
7. 30,000 CFM @ 180" F; panicul•les 10 scrubber -200 lb1/hr. ~
8. w.,,r 200 G!'M; scrubber ,rliclen,:y -90%. ·.
9. '2!.000 CFl\l Eil 140" F: PutlC\llalc cmi>llon110 •<motphcrc -20 lbs/hr.
10. Asphalt production 219,800 lbs1hr or 109.9 1om,hr.
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AIR POLLUTION CONTROL DEVICE C
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Ai', D
AV•ILABLE ENGINEERING DRAWINGS.
1. ,\,r(ontrol D .. "e •nd 10 No. (FROM GENERAL INFORMATION FORM '"A", ITEM 6)
2.
\11 ------\l) --____ \3) --------TOTAL UNITS __ _
l. lndocue Emission Source and ID No. !hat Control Device(>) 11 insulled on:
~~.1rrit1"e Oes,ripuon of Control Deviccls):
M•nufacturer
Model Nam• Model Nurnb<r
s. Estim>ted Cost of Control Device Period of Tine Conuol Device is Estim.ated to be Adequ.ue:
L------
______ Years
I). Permit Application i< madt for (CHECK ONE ONLY):
( ) Ntw Source ( ) Elistin1 Source ( ) Modltleation -List Permit No. __________ _
Commence Construction D•te __________ , 19_ Operation Dau, _______ _ ,l<J •. _
-.-----------------P-R __________________________ _
,. Emission P•rameters: A T. S01 SO, CO \IOC LEAD OTIIER OTHER
Polluunt(s) Controlled ( ) ( ) • ( ) ( l ( ) ( l
Erniuion R•te Before Control (lb/hr) •
Emi«ion Rne Alter Control (lb/hr) =
Rem.,.,I Efficiency Per«nt I") = -.
Panicl• Size Oisuibution of Pmicul•ces Enlfflnl Control Device ('6 Mlcrun):
_ -·· _0•1 ___ 1-10 ___ l0•25 ___ 2s-so ___ 50.100
----------------------------------------·-·---·
:i G•s <.:onctiuon, •t Conuoi Ocvi(e: INLET
Flow Ra1e (ACFM) 9
T empemure ID•1-f) :
\lelocicy (ftJsec.J =
PrruuR Drop (in. H10) •
Moiffllff\%1 =
'J. O•scribe Ultim•ic Di-,.1 of Collected Mate<lals:
10. Suck or ErniSS1on Point O,u:
Hei1ht AboYf Inside Aru Oin:ct1on of Exit
Groand ift.l !sq. ft.) (up, down, or horiionul)
INTERMEDIATE LOCATIONS
I JiM \J
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OUTLET
-------·-·------·· .
Ii Kufoldinc i-v,1it~blt for sources testinc?
: ) ~. I l Ye,
Ar• ,.rnt>lins pons •••~able!
( ) No ( ) Yu
-------------------'-------------------·-
··-
11 l."mmenu:
. ------------------------------
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Efficirncy (%)
SUPPLEMENTAL DATA FOR AIR CONTROL DEVICES
••• "CYCLONE" (MECHANICAL SEPARATORS) •••
/ v olumctric Flow Prrssure Oroc> (in. H10) S.ffles or L~u•ers (specify) I Posll1<1n in Series
C
, R•tc (ACfM)
1 :t f
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j ___ o ______ i..ni,
------'-----------i---------+---------------·--
-
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----
Cyclone Oimrruions (inchn) I Cyclone Body Oiuncter Cyclone BoJy Hti&f,1 (It.)
Inlet Ou~et 1 (inches)
/ CyclOM Cone Height ( ft.I
Wei Spr•y j No. of Nozzles
I Flow Raet (GPM)
I
M•k<Up Race (GP!>!) I * Recirculuea
l i No I ) Yes !
A process flow di•anm must be uw:tied If cydone iJ routed lo .nocher cyclone O¥ other equipment, snow sketch 01 en11re w nen
13.
CK(CI( lPPRCPtlllf OIITLrr cc,.,IGUl!ATl:iN B(LCII SKlTCII OTHU
C:O~tGl#AUON
ON ou11.111J1 oucr
Below
L'ILET
T
ecor
DIMENSION +----+
••• "MULTICYCLONE" •••
No, of Cones Position in Series
leOOY
I Hf;GHT
Efficiency(!') / Volumetric: Flow
Rate (ACFM)
# ____ of _____ Units
Louven
!)No() I lnlrt Dimension of Individual
Yes Cyclone (Inches) I. Oudel Olmtmion of Individual
, Cyclone (Inches)
Individual Cyclone
Diameter (inches) I Inlet Temperature
, (Deg. F)
'
14.
••• "FILTRATION" (BAGHOUSE) •••
=---,...,..-,---------,~-----,--------,-------------·
-
-
•

Efficlenc:v (%) Volumetric Flow FH~r Surface AiMo-filc.r Aru Ratio Preffllr~ Drop (In. H10)
lqte (ACfM) Atea (SQ. ft.) (ft./min.) _____ .._ ______ __. _________________ ,.__ ______ ,_ -·----·-
TYPE Of FILTER FILTER MATERIAL BAt. CL~NING
( ) Fabric Filter (BAGHOUSE) ( I Fi!Mrglass I ) N)·lon ( I M1<11.n1QI ( ) S.,nic
( I Pick.rd Bed ( ) Mat FHw ( ) Nomex ( ) Teflon ( J R1verse Flow ( I ,,ir Pulse
l 1'1nel Filur ( ) Wool. ( ) Oieron ( ) Simple B>ll i l Rin;ed B•
( ) Other ( ) Conon ( ) Orlon Cull•pse Coll,pse
( ) Other ________ ( ) Ocher __
r,;-·o-.-.,-, C-o-m-putm--•-n_ts __ ...... T_i_m_e_B_e_tw_ff_n_O_~_l_n_1___ I Inlet Temperawre --
1
~1 -Pos,-·u---·on-l;;;ies --------· ·
(mins./hr.) I (Des-Fl f . tt _____ o ___ Unit
IS.
rype of Attert>urner:
I } Oirrct Fl•m•
! l c.. ulytic l) Qu,cr ________ _
••• "AFTERBURNER" (FUME INCINERATOR)•••
I Efficiency(~,)
I
Volumetric Flow
Rate (CfM) L.ni1
----------~-----'-.r------+'',;,,1-~=-------
·

.. ------
~uimum Burner fbtin1
i'1illion BTU/hr)
-------------
I Comt>uttion Chamber
! Trmp. (Ort. F)
Cl.lmbunion Chamber Oimemions (ft.): _______ Length
Reteniion Time
(sec.)
I Fuel Type ___ _
Uwp ______ _
_______ Diameter
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16.
Type of Scrublar:
( ) Venturi
( ) Impingement Pl,ie
( J p,c~ed Tower
) Gravity Tower
) .\fat Eliminatot
G.s flow
( ) Countercurrent
( ) Coocurttflt
., 'I
SUPPLEMENTAL DAT A FOR AIR CONTROL DEVICES -continued
( ) Orifice Type
( ) Cydonlc
( l Condenser
l I O!her
: Liquid Scrubbin1 Medium
; wd Additives (specify)
, .. "SCRUBBER"•••
j Efficiency(%) : Volumeuic Flow
' 1 Race lACFM)
: Position In Series
I ' tt ____ of ______ l.)nlcs
I. Preuure Drop
(in. H10)
; Inlet Tempe,.wre i Mist Eliminator FITter Area
) (Oe3. F) I (sq. ft.)
: Tow Liquid lnltction (CPM) i Make Up lute (GPM)
-:--------------------------
Venturi
Scrubber
Dau:
Inlet Arca (sq. in.) Throat Area (sq. ·in.) ; Throat Velocity (ft./sec.) , ( ) Fixed Throu
; ( ) Vatimle Throu
P,cked or Surface Aru (sq. ft.)
Pl,te Tower
D,u,
Pitkin& Depth (ft.) I Type of Pickln1:
/ ( ) Rings ( ) Saddles
( ) Other
No. of Plates I Type of Platt;
i
17. , .. "ELECTROSTATIC PRECIPITATOR" ...
c---=-------~--.,....-,,--,-,---:c--------,.------r---·
·
-
-
-
-
-
---
Efficiency(%) : Volumetric Flow Rate (CFM) Tow Collection Plate Pressure Drop Inlet T~""""
Area (sq. ft.) (in H20) (Dea. FJ
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•. Re<1,11vity of G•s Viscosity (poise) OW1in1 Field Suengih (volts) i Collecting F~ld Stt•neth (volul
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Polluunt (OllM-CM)
---·-----------------'-----------------. CLEANING METHOD
) Singje Su~
I fwoSu~
PRECIPIT A TOR TYPE
( l Low Voluge
( ) HlahVoltase
( l Hot Side
( ) Cold Side
( ) P111e Rappins ( J w uhing
( ) Plaut Vibratin1 ( } None
) Other __ _
( J Othtt ____ _
CoroN Power
I Wrn.,/ l000 cfm)
/ Electrical U,.ge (kw ./hr.)
'
I No. l)f Coml)fflmlnts
'
i No. of Cells/Comp. 1 Position in Series
: # ____ of ____ t.:niu
.J
:s. •" .• ._DSORPTION" •• •
T'ro-t of Ac:borption:
, Efficiency (I') , Volumeuic flow Rau, (ACfMI
: ~ One.Pus Re-generative ( ) R1circulalin1
i } Ooe•P.tss Nonrr~Mntive (}Othu _______ _
. ------------------
Regonera ti•• ',lethod:
i ! Di<eirded ( } Tliennal (dry head
' l (hcmical ( ) Therm.ti (steam}
I j Orhtr
! A,i<orpaon Material:
i ( ) Activated c.,t,on
I ( ) Hydrous Silicattd
; ( l Other _______ _
--------
: Posi1ion in Seriet
'.# ____ of ______ Uniu
------------------------------..------· ------------
: ~o. of Computmenu ! How art emissions conuoUed during
Prt1iure Drop
iinH20l
; Inlet T emper.1.ture
/ lD•1-fl
\1ZC' ,>I ,\dsO<bent Bed I fc.}
Length _ , Width _
; rejener,uion? _____ _
Rt1encr.1trve ~chedule: Muimum Time fOf OnorptiCltt -------------;-\,l-J'-...\.,,._=--
Lcngth of Time to M~imum S.uurat1on --------------------------------
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. AREA DIAGRAM D
Sh-.all -,OUt1<1ln1 buildinp ...c:t roods within UOO feet of tile equ19men, cowred by this ac,plicauon. Atu<II a site diasnm identify•
inc ,act, emission source 1oc.auon(1), propeny boundarin And buadina (suuccute) dimensions (heiat11 .. width, and lcn&lhl.
INSTRUCTIONS
1. Indicate loution and type of buadll\9 br lhe uso of small
numbered circles with the dectlption below,
2. Show roads u line, rtprescntln9 the r<Md <tdse,. Indicate
llre<t name, <nd highway numbtn.
J. Show wooded or cteared >tea by approximate boundv,
!inn .ind the words "woods", ""de.ued", "'cornfltid", etc."·
1500 feet
1000 feet
COOE
I I)
(2)
(3)
(4)
(S)
(6)
(7)
(8)
(91
( 10)
Example:
DESCRIPTION
(1) Church
\2) Krndenco
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HYDROCARBON EMISSION SOt.:RCES E
~OTE: For emis,ion sources of vola.tile otpnic compound.$ indud,nC spn,v toolhs. paJntln1, flnlshin11 plintin& ~nd 10lvent uuse.
PLEASE TYPE OR PRINT. ATTACH TO THE GENERAL INFORMATION FORM "A". IF APPLICABLE, ATTACH AIR POLLUTION
LONTROL DEVICE FORM "C".
1. Emi,sion Source ind ID NO. (FROM GENERAL INFORMATION FORM "A". ITEM 6)
~-Proc,,s Ot,cript1on (ll'<DICATE l'<O. Of IDENTICAL PROCESSES -BOOTHS, FINISHING LINES. ETC.):
J. Permit Appli<>tion is midi for (CHECK ONE ONLY):
I ) New Source ( I Exiitln1 Source ( ) Modification -Last Permit No. ________ _
Commence Construction D1te ---------• 19__ Operation Date---------· 19 __ _
4. '-iuimum Source Optration: ____ Hours/Diy ___ Days/Week ___ WeeksiYu,
S. List all VOLATILE ORGANIC COMPOUNDS u used: USE NEXT PAGE (PRODUCT ANALYSIS WORKSHEET) TO DETERMINE
If PRODUCT IS REACTIVE (R) OR NONREACTIVE (NR) AS DEFINED BY IS NCAC 20 .0518.
PRODUCT NAME R NR
PRODUCT
WEIGHT
(lb/Kai)
----------------·---------
PRODUCT
USAGE
(111/day) X
TOTAL
VOLATILE
BY WEIGHT
(lb/Kall -
·-----X -----•
----~---X ·-___ s
--•. -·-····-----------------------X ------"
-----------X ---•
·-·· ··-... ·----·-----------X ·----=
·-----·-------· ------------------X
----------·---------X ... --.. --=
•··-·· -·--------------------·· X •. =
t!SE ~EPARATE SHEET(S) If NEEDED TOTAL •
voe
EMISSION
RATES
(lb/day) (ton/yr)
Ii. Desct1be the stor11e •nd h•ndllns mathods used in employinc the orpnic &>toduca listed above. Include the ultimate disPOS,11 method:
.
.
ol the cotlttted wute and wastewater.
----------
1. ~u• f.\cr Co.1rin11, Oper2ttons:
D•>4r•be ~rt,cle, Bein1 Cooted:
----··--·------·----------------------·--. I .
\.1t'lhnd ot Son.v:
, l ._i,len , ) .,;, Atomi11 ( ) Elecuosutic ( ) Other _______ _
E~h.aun
Cnnuol:
None
) Watcrwash
( ) Dry Filter
{ ) Baffle,
( ) Adsorption
( ) Incineration
l OIiier ________ _
------
· Ovor,puv ( 11 I
i
· Stack Flow
' R.tte \Cf:-.tl
I Conuol .Effitlency •
i Putiwl~te ______ ~S
1 Hvdroc.ubon !~
No. of B•ke Ovens I Method of ( ) Steam ) Direct Fired I Fuel Type ·-..
_ __ _ __ .. _____ _:H::_:•:_:•~ti::_:n~~::...__..'..(_)'.__::E:'.:le:::c:,:tr,:ic:,_~)~Ot:::h:•::.;.:========.....:...' _::U::so~ce::_:======::::::.::.=
'( Sc1lvirnt Oegre.u1n<4 0pf'r.Uions:
-... -,
;~:~;~~~;-:-~'-.:-:-~"-• __ u_·-~-:-~-.-d-,-•• ,.. ( ) ,_oo,., ' ) ... ~ ra U\W 'ti~~
T •nk C,pici1v j .\11keup Rate j Exhaust Control: ( ) None ( ) foriice i:lt.scn
lslllon,) • \glllon,/d>Vi ( ) Adsorption ( ) Oo,.d Loop
! ( } Oth~r ------
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E PRODUCT ANALYSIS WORKSHEET
(SOL VENTS. PAINTS. FINISHING MA TE RIALS. £TC)
:.•.!.~e 2 .Jf
INSTRUCTIONS: COMPLETE ONE SHEET FOR EACH TYPE OF PRODUCT. GIVE CHEMICAL NAMES. NOT BRANO NAMES o
... aaREVIATIONS. FOLLOW THESE PROCEDURES IN DETERMINING WHETHER OR NOT A PRODUCT OF VARIOl
SOLVENTS IS REACTIVE (R) OR NONREACTIVE (NR). .
8)
Cl
GROUP THE CONSTITUENTS ACCORDING TO WHETHER OR NOT THEY FIT THE DESCRIPTION IN CLASS I l) r ·
(J) OR NONE OF THE ABOVE CLASSES. IF A CONSTITUENT COULD FALL IN TWO GROUPS, IT IS PLACED IN ·T;
~10RE LIMITED GROVP.
DETERMINE THE VOLUME PERCE:"lT OF ALL LIQUID CONSTITUENTS OF THE PRODUCT AS APPLIED. (THIS SHOUI
TOTAL 100%.J
TOTAL THE VOLUME PERCENT FOR EACH CLASS (1, 2, ANO J). IF THE VOLUME PERCENT FOR ANY CLA:
EXCEEDS THE PERCENT LIMIT FOR THAT CLASS OR IF THE TOTAL FOR CLASSES (1), (l), (3) EXCEEDS 20 PERCEN
THEN THE PRODUCT IS REACTIVE. If NONE Of THESE LIMITS ARE EXCEEDED, THE PRODUCT IS NONREACTIV
Product Nimc Produtt No. This Produtt is Owifitd as:
( ) Reactive (R) ( ) Nonreattlve (NR)
PRODUCT COMPOSITION
ORGANIC
CLASS DESCRIPTION OF ORGANIC CLASS NAME OF CONSTITUENTS
------------------------
( 1)
A COMBINATION OF HYDROCARBONS, ------------
ALCOHOLS, ALDEHYDES, ESTERS, OR
KETONES HAVING AN OLEFINIC OR
~ BY VOLUME OF THE
TOTAL VOLATILES
ACTUAL ~ LIMIT
CYCLOOLEFINIC TYPE Of UNSATURA· --------------____ _
(3)
TION EXCEPT PERCHLOROETHYLENE
-SPERCENT
. A COMBINATION Of ARO~A TIC
HYDROCARBONS WITH EIGHT OR
MORE CARBON ATOMS TO THE
~OlECULE EXCEPT ETHYLBENZENE
-~ PERCENT
A CO~BINATION OF ETHYLBENZENE,
KETO:-.ES HAVING BRANCHED
HYOROCARBONSTRU~7'UR~
TRICHLOROETHYLENE, OR
TOLUENE
-lOPERCENT
ALL SOLVENTS NOT LISTED ABOVE
Produtl Uuge (Jlljhrl __________ ------
Produtt Wt1ct,t (lb/gal) _________ _
Weist,1 of voiatile, in produ<1 (lb/gal) _____ _
iouJ % vol~uie1 by volume: in product ______ % ·
SUB-TOTALs _____ _
SUB-TOTAL" _____ _
SUB• l OT AL -=
IF THE TOTAL REACTIVE PRODUCT EMISSIONS EXCEED 40 POUNDS/DAY FROM YOUR FACILITY, DESCR18l
CONTROL METHODS E~PLOYEO FOR MEETING COMPLIANCE WITH DEM REGUU TION 1.S NCAC :::0 .0518:
-----------------------
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: = : -: .· = :
INCINERATOR F
P•&• 1 of 2
PLEASE TYPE OR PRINT. ATTACH TO THE GENERAL INFORMATION FORM "A". IF APPLICABLE, ATTACH AIR POLLUTION
CONTROL UcVICE FORM '"C".
I. cm1111on S<>urce ,nu 10 NO. (FROM GENERAL INFORMATION FORM '"A"', ITEM 6):
\1anutacn1rrr Model Name Modol Number
~p°;,;;;;, Applicarion Is made few (CHECK ONE ONLY):
( ) New Source ( ) Exlstln1 Source ( ) !\1odificalion -Last Permit No.-------
Commence Con«ructlon Date·----------, 19._ Open1lon Dalt---------, 19 __
4. Maximum Source Open1ion:
S. Type of WaSlo Burned:
(See <OMS on next pas<)
Ii. Comb<mible --"
-7. Primary Chambcf:
Volume .cu. ft.
___ Hours/Day
Muimum Char&in1 Race (lb/hr)
Design I Acwal
Noncombu11ible -"
S.condary Clwnbtr:
Volume cu. ft.
.. Temper.iture •F J Temperaiure •F
8. Burner Dau: BURNER RATING (BTU/HR)
___ Days/Week ____ Week1/Yur
Tons{Year Burned Tow Waste Genented (lb/day)
!\1oi11Wt ___ " Heat Value ______ (BTU/lb)
s«oncwv Chamber Type of Feed
Reltntion Time: ( ) Mam,al
Seconds ( ) Au1omadc
AIR FLOW (CFM) Excess Air(%)
Primary· I Secondary Overtire I Underflre
----
9 h there • preheai llmer1 ( ) No ( ) Yes, Preheating Time ________ Min.
10. Auxiliary Fuel D•u: Primary Fuel Type(s) -------------·---------
SecondMy Fuel Type(,) _______________________ _
FUEL rYPE FUEL USAGE "'"'·" Max.%
Mu. Oesisn Mu.Acwal Annual Sulfur Ash BTU Value
=l F.,el Oil
11. "'' ConuminM1u
Emined:
(SCFl (SCFl (SCf lYrt
(pl/lWJ lalll/h<l la»IY<I
l'wW<lmum Actual Emissions
Before Conuol After Conuol
(lbt/hr) (lbt/hr)
N1uoaen Oio-.icJe. . . . p
'
Embslon D
E11ima1e
Method•
(BTU/SCF) ___ ...,__ ___
(BTU/tall
\...__..;
P .&njfuU.tcs . . ! ' I
5ulfur 01oule ...... -------,•,-------+1---+-------------
(Al bon Muno.,de . . . . ;
1
'
1 ltydrocori>on,.iVOC) .. ---------'---------1 ____ ....,__ ---------------
:..~.ad. . I
I l>lhe, 1 ____ 1
Other t ____ l. .. -------~---------------------------
•REFER TO BACK OF GENERAL INFORMATION FORM "A" FOR EMISSION ESTIMATION CODE
'""-TTACH APPROPRIATE AIR CONTROL DEVICE FORM "C"
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11
l~Cl.''<ERATOR -continued F
iT°"-D~,cribe any liquid or ,olid w .. ,., gener>1ed and method of dis~:
--------------------------
t 3. suck Or Emiuion Pc,int Oiu:
Heigh! Abo•• Ground (ft.) j Inside Arei (sq. ft.)
Volumetric Flow Rue
(ACFM)
VelocitY (ft./sec.)
G.s Tempenwrc (Dea. F)
Arc umplln( pons available!
( ) No ( ) Yes
l Direction of hit
(up, down, ur hori1onul)
Is nln cap ur other -uuctlon over
sack! ( ) No ( ) Yes, (specify)
I~. h • RCRA permit required by the N. C. Department of HulTWI Resources! ( ) No ( ) y.,
lfye,, hu • RCRA permit application been submitted! ______ Oiu: --~--------, 19 __
1S. List ALL inclnented HAZARDOUS WASTE specified in the RESOURCE CONSERVATION ANO RECOVERY ACT (RCRA)
(40 CFR 261) in the comment> 1«1i<>n below:
16. Cumments:
CODE
I)
3
-------------------------
••• TYPE OF WASTE BURNED CODE TABLE•••
Principal componeocs, lllual soun:e. and cyptcal moiscw. content
Hisftly combustible waste. pepcr, wood, c:anlboud c:utOM, (lnclud>D( up to 10':> crested papen, plastic or rubber scrup,1
fr0111 commercial and llld11111tal ,ources: IM. molsnin,.
Combustible wale. paper, cartons, rap, wood scraps, combustible floo, .weepings: irom domestic, commercial, 2nd indu•·
trial iewce-s: 25% n1oisrurt.
Rubbish and garbase; from midciuial sourcn; SO'll, moisture.
~ominandy animal and nge<ablc waste: Ctom re,ui,raacs, hotels, markets. in,titulional, commcrc.al and dub ,uurcc,
~()% mvislW"C.
Cucasses, orpns, wlid orpnic ,.,., .. , from hospilllb. bboralotia. slau,i,1crl!owcs. animal pounds. and samuar ,ources
65% muislurc.
Gaseous and serni--Uquid UldU5lnal process w&S&e; ~ariable moi:Sturc. Oe$cribe in dcwl w1dcr comment,.
Solid and !oemi-10lid by-product WISle. such as rubber. plasUCS. wood was1e. etc .• Crom indusuial operations. '-:.m11l,lc
mounue. Describe in delail unJer cumm.:nrs.
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5050N004
APPENDIX III
AIR PERMIT APPLICA TIONS
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TEL No.l-704-482-2411-4411
-.
Nov 12,89 22:00 No.001 P.03
Nonh Cuotlna D•Patt'"ent of N1t1.1nl Rnouten and Community Or,cloptnant
EltWonm•nul MaN.leffltflt Comm\SMOft
AIR PERMIT Af'PUCATION•
GENERAL INFORMATION
INSTIWCT/ONS ON IACK
•T" con1tl'\K.I 11\d open.tt: Air EmklkKI S4>"~1 and Conuol Oerieel in ~1nc;a wldl N. C. GINral Statut .. Chu,sar 143. Artlc11 21.
A
page I of I
PLEASE TYPE OR PRINT. ATTACH APPROPRIATE EMISSION SOURCE ANO CONTROL DEVICE FORMS FOR EACH SOURCE
LISTED IN ITEM 6 BELOW.
1. Fu,litv Name (Compa"v, fatablishment, Town, Etc.): Date FOR OEM USE ONLY
OATt. RECEIVt.D:
2. Site L..xotio" (St./RdJHwy.): City Zip Codo County
Latiwde Lonaiwde SICCode
3. M,,lin& Addms (P. 0. 8ox/SIJRd./Hwy.):
Clly State ZipCode Phone ., i th Area Code
4. Applicant Technical Contact: TilMI Phone with Area Code PERMIT NUMBER:
DATE ISSUED:
..
De,cr,plton of oper•toon conducted •I abo,,e fac1hty;
6. Li>1 each EMISSION SOURCE and CONTROL DEVICE for which application is made. Assi1n an 10 NUMBER touch eminion source
•nd control device which uniquely identif'ocs th•t $0Urce. Attach appropri•te emission source and control device forms for uch.
EMISSION SOURCE 10 NO. CONTROL DEVICE
USE SEPARATE SHEET(S) tr NEEDED
Hours/O•v ·
: N.ime and 1ddress ot engintcrrng firm th.it prepared appHauon or plan,:
./
9. s;gnuurc a; rc10on\ible person or comp.any offic:i~l:
0.vs/Week
IONO.
Weeks/Yur
__________________________________
Oate ______ _
s;gner, Name 1TYPE OR PRINT) Tille Phone with Area C~Oe
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GENERAL DATA FOR PROCESSES OR FUEL BURNING SOURCES B
P•c• \ oi 3
NOTE: DO NOT USE THIS FORM FOR INCINERATORS. USE FORM "f".
PLEASE TYPE OR PRINT. ATTACH TO THE GENERAL INFORMATION FORM "A". If APPLICABLE, ATTACH AIR POLLUTION
CONTKOL DEVICE FORM "C". l:SE SEPARATE FORM FOR EACH SOURCE.
1. lm,s,ion Sourc• •nd ID NO. (FROM GENERAL INFORMATION FORM "A", ITEM 61:
1. Dncription of Proc•ss or Fuel Bu,ning Source lncludin1 Air Control Device:
·----··----
-------------
J. Perm11 Applic .. io,, is m•de for (CHECK ONE ONLY):
I ) New Source I ) Exlstin1 Source ( ) Modifitalion -L•n Permit No. _____ _
Commence Construction Date , 19 Opemlon D•t•
.i. Mu tmum .Sourc::e Ope.ration: ___ Hours/O•Y
; . Air Conumininu Maximum Actual Emissions Emission
lm1tted: Before Control After Control Eiwmte Control
(lb/hr) (lb/hr) Method• Dttlcc••
P•nkulot ........ ·, . ; .
Sulfur Dio,ide ...•....
~iuogcn Dioxide .......
C.,bon Monoule .•...•
Hydrocwons (VOC) ....
!
Le,d ...............
I
Other ( ) ---
Utner\ ) . _L_
•RffER TO BACK OF GENERAL INFORMATION FORM "A" FOR EMISSION ESTIMATION CODE
••ArTACH AIR CONTROL OEVICE FORM "C"
6 r., pt of Source:
t.HECKOf'<E
~ GENERAL PROCESS -Source nor covcm! by 8 •nd C below. (Complete i1em1 7, 8, 18 througt, 22)
___ WHks/Yu,
Control
E lflcicncy ~
-
B GENERAL PROCESS WITH IN.PROC!;SS FUEL -Soutce where producu of combustion cont•ct m"erlal1 hemd.
(Complete items 7, 8, 9, 13, 14, 18 through 22)
I I C FUEL BURNING SOURCE (boilen, etc.) -Source where prodU<ts of combustion •re tor lhe primary purp01c ut pr<
Ju,;ins Ile.It or power b\' indireCI heat 1rv,,fu. IComplet• items 9 throu~h 2;
7. Process Oi,cmion: I ) Continuous ( ) Batch -Normal B•tch Time ______ No. Baich .. pr, D•v ____ _
8: Procen :'i1~e _____________ _
\1itenits Enterin1 Proceu•:
· I I d I S I'd f I ) : nc u e n.prouu 01 urs
D
, ..
K . ._
...•
C. --u. __
I -
E. -------
F.
G. ____
!
TOTAL WEIGHT ENTERING PROCESS I
Input R•tH (lb/hr) I• \bx. Requcsi•d
Permit Input
es1sn A ctu •m I r .. I R ( b/h )
r--~ -\ __, \ \
,,.-.\ t\·tr \1--'_, \ .l
\ \ I \ ~) : -
\ ) I ~-
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'1)0 "<OT LIST .,_,-~y '.'OLA Tll.E HYDROCARBONS. VSE HYDROCARBON E~ISSION SOURCES FOR~ "E"
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DATA FOR PROCESSES OR FUEL BURNING ~OURCES -continued B
Pac• 2 of
9. Type of Fuel Buminc Source:
( ) Industrial Soff,r ( ) lnstltutiona.1/Rnidendal SoUer ( ) Electric Udlliy Boiler ( ) Procesa Burnet(,)
( J 01her ____________________ Make and Model No.------_____ _
10. Type of Solid Fuel 8umin1 Equipment Used:
( ) . Hand Fired ( ) O,,.rfeed Scoker
( ) Spreader Stoker ( ) Travelin1 Grace
( ) Underlced Stoker ( ) Stukln1 Grace
( ) Pulv«lud
{ ) Wtte.d
{ ) Ory a..!
( ) Other{~cifiy) ______________________________
_
11. Is coUccic<I flyai/1 reinj«ccd1 { ) NO YES PercMlt Reinjected ______ _
Combustion Air: Pereent Excess Air ______ !6 Natural { ) Induced
Specify method •nd sdledute of tube cle.anln1:
( ) landn1 ( ) Tube Blowing ) Omer ________ Schedule _________ _
ti. Boller Horsepower R•ting _________ Boller Steam Flow {lb,i,r) ---------------
13. Fuel Burning Source Hut Input: Maximum ______ Million BTU/hr Aver;iso ______ Mlllion BTU/hr
U. fuel Dau: Primary Fuel Type{s) {specify)--------------------------
Sundby Fuel Type{s) (specify)-------------------
FUEL TYPE FUEL USAGE Mu.% Max.%
Max. Oesian Max. Actual AMual Sulfur Ash BTU Val
(111/hr) ,,.,,hrl laal/yrl· l8TU/1,u)
116 Fuel Oil I ---
fc•Vhrf (pl/hrJ (pl/yr) f8TU/11IJ
::S rue\ Oil ---
(gal/hr) (Cal/hr) •Cal/rrl I BTU/Call
.,.4 l'uel 011
lib/ht) (lb/hr) (Ion/yr)
--(dTU/lbl
<.:oaf
. ---
lib/hr dry) (ib/l>r dry) (10ft/y, dry) I (BTU/lb)
'Nuod ________
d OQO
.,...._.
Other l
1 ~-If• combln .. ion of fuels is used, specify d1e maximum BTU/hr heat input for euh:
f•,cl Oil ______ Coal _______ Wood _______ Other __________ _
16. Toul muimum h .. t input in malion BTU/hr of JII indirect fired fuel burnlns sourai within propeny boundarie, excluding tr
:ndlcated .t.buv~:
Fud 011 __ · _____ Coal ______ _ Wood _______ Other-------·----
17. ToUI No. of Indirect fired fuel bumtn1 sources "'llhln property boundaries:
Fuel Oil _______ Coal _______ Wood------Other--------,,---
: 3. Are <her< .nv fu111ti-.e •minions (Stot>ae piles, product handlin1, haul roads, etc.)?
con,menu below. lhe iype, site, esdm~ted emissions .and <ontrol mea.surn.
19. Describe any liquid or solid wutH generated and method of disposal:
---------------------------------------------
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•
DATA FOR PROCESSES OR FUEL BURNING SOURCES -continued B
:!O. Su.:1< or t:mi .. ion Point Oau:
H•iaht Ab= Ground (ft.) Inside Area (s<l, ft.)
Volum<!uiC flow Ra1e Velocity (ft.face.)
IACFM)
1, scalfoldins available for SOYrce testin1!
( )No ( )Ye,
Gas Temperature (Oq. F)
Are sarnplin1 poru naiublel
( ) No ( I Yes
,,ge 3 oi 1
Oirtction of ult
(up, down or horitonUI)
Is rain cap or olhct obscrucclon ove
sQ<:kl ( ) No ( ) YH, (specify)
Stuk 10 No. ---------Sourcn with • commo,
stuk will have the some suck number.
21. Indicate monitorln1 u,d r<cordln1 instnunents lnsulled on "'1Ck:
( ) Opacity Monitor ( ) S02 Monitor ( I NOx Monitor ) Other ----------------
22. Atuch or sketch • flow diagram of the process or fuel bumins source. lndude air control dcvicc(s). (SEE INSTRUCTIONS or
BACK OF THIS PAGE):
13. Commenu:
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APPENDIX B
INCINERATOR MONITORING SYSTEMS
CALIBRATION PROCEDURES
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I.
II.
III.
S E C T I O N 4
INDEX -THERMOX REMOTE CALIBRATION UNIT
PAGE
Adding Optional Remote Calibration •••••••.••• 1
Adjustments •••••••••••••••••••••••••••••••••• 6
Description •.....••.......................... 6
Figure 1 .........................•....... 3
Figure 2 ••••••••••••••••••••••••••••••••• 4
Figure 3............ . . . . . . . . . . . . . . . . . . . . . 5
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I. ADDING OPTIONAL REMOTE CALIBRATION
The control unit provides two methods of calibration via the
Calibration Key --Remote or Manual (refer to the Key Operation
and Description section for an explanation of each method). If
the system was ordered with the Remote option, the control unit
has been set at the factory for this mode. However, if the
Remote Calibration option was not ordered with the control unit,
it can be added at any time if desired~
INSTALLATION: Refer to Figures 1 & 2 for Mounting & Dimension,
Flow & Wiring details.
1. LOCATION: The Remote Calibration Box should be mounted to a
vertical surface in a convenient location. The location
should be within a few feet of the sensor (not more than 15
feet of 1/4" O.D. tubing). The maximum ambient temperature
should be less than 160°F (70°C).
2. MOUNTING: Mount tAe unit to the wall with (2) 10'' screws.
Remove the lid to expose the mounting holes. Only the upper
left, and lower right holes are used, the others hold the box
to the base plate.
3. PLUMBING: Connect instrument air to the pressure regulator on
the left side of the box. Connect the 02 calibration gas to
the port below the regulator on the left side of the box, 2%
oxygen in Nitrogen is recommended. Connect the calibration
gas outlet to the sensor calibration gas inlet. The supplied
check-valve goes into this line, near the sensor.
4.
a) WDG-IV: Connect the aspirator li.ne (top port on the right
side of the box) to the sensor air inlet.
b) WDG-HP & WDG-Insitu: For the HP and Insitu, the aspirator
air outlet is plugged.
INTERCONNECTING: Interconnect terminals 13, 14,
the same numbered terminals in the control unit
shielded wire for distances below 500 feet
shielded wire for distances over 500 feet.
15, and 16 to
using #18 AWG
or #16 AWG
5. CONTROL UNIT: The control unit must be configured for the
Remote Cal option. ·
a) Remove power from the control unit.
b) Open the "upper'' meter door inside the control
move JP2 to the Auto position (see Fig. 3).
upper door and turn the control unit power on.
1
unit
Close
an<l
the
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c) Remove the Rack mounted control unit and remove the top
panel (4 screws).
d) Locate the jumper shown in Figure 3 on the circuit board
behind the front panel. Move JP2 to the AUTO position.
e) Replace the top panel (4 screws); install the unit in the
rack and turn the control unit power on.
2
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.500' r 1.27cr, ~----------
---1 I ,_
1/2' CONDUIT ENTRY
IN BOTTOM Of BOX
i~H~,.
INSTRUMENT AIR INLtT
1/4 NPT (D 1S-30 PSI I
CALIBRATION GAS INLET--
1/8 NPT <F> 2% 02 BAL, N2
REGULATED TO 5 PSI BY
11.00cl'I
~ ,95c:i,
S.51'
14.00c:i,
6.2~'
15.97c:r,
'il
CUSTOMER .1, ___ ~__,!_L __ ____::::::~.J__
INSTRUMENT AIR TO
ASPIRATOR AIR LINE
1/8 NPT <F>
CALIBRATION GAS OUTLET
TC SENSOR Co-lNECTIDN
f □R CALIBRATION GAS
1/8 NPT <F>
CA LIBRA TI□N GAS
fLO\Jt1ETER, SET
II 2 SCfH
;;:.... ____ '-_-_j-1/ 4' MOUNTING
HOLES (2 PLACES> 9.2S'
23,49cr,
FIGURE l
3
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FLD\J DIAGRAM
r--ASPIRAT □R----1 I114
• ,□D __ 7
REG SOLENOID
INSTRUMENT ,-s..~ VAL VE I A SPIRA TOR I I
AIR _ I* AIR I I
SPAN
SOLENOID
VALVE
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I CAL LINE I I
I '-' I SENSOR I
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"v I I
I I L ___ _j REG I ZERO
SOLENOID
VALVE ZERO
CALIBRATI□N-~­
,-L.___c,._,I
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....,__1 -1 PSI
CHECK
VALVE
GAS
l _ REMOTE CAL BOX __ j
I TD BE 1--KEPT TD --i
A MINIMUM
ll< w'DG IV -TD ASP IRA TOR AIR REGULA TOR ON SENSOR
w'DG HP -NOT NEEDER THIS OUTLET JS PLUGGED
ST ACK GAS -ASP IRA TOR IS OPTIONAL
(12VDC COILS)
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\ I 1-1=>
\_Ls A~G :, -:soon ,;-;.
#16 A\JG 501-lOOOFT &R \ \
SHIELDED CABLE \ ~ ~ h . \_f \j
\JIRING -~ ~
FIGURE 2
4
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ADDING THE REMOTE OPTION
--=-Q! '1g
0 1-Q Clll Clll ooc==, --=-
-t
-c:J-
-c:J-
Q [:::::::::::~:::::J o I · 1 o
______,'IQ I ·1y -~
-·iQ I -<=>-11; I ·10
~ --=--c:J-
_____ ·1 Q 1 Q Q Q Q Q ~
I 9Q
JP2
AUTO
FIG J
5
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II. ADJUSTMENTS
Set the regulator on the air inlet of the calibration box to 5
psi. Set the air regulator on the sensor fully clockwise so that
it will not override the upstream regulator. The calibration
sequence must be started for this adjustment by pushing the
''Calibrate" pushbutton at the control unit. With one of the
calibration gases flowing, set the flowmeter to the recommended
calibration flow rate.
WDG-IV & WDG-HP
WDG-Insitu (3/4'-3')
WDG-Insitu (6' & 9' )
Stack Gas
= 2 cfh = 3 cfh
= 6 cfh
= 5 cfh
The internal pressure regulator has been preset to 5 psi, and
should not require adjustment.
III. DESCRIPTION
The Remote Calibration Box controls the introduction of
calibration gases to the sensor in response to commands from the
microprocessor control unit. It contains the following
components:
1. An air pressure regulator to reduce the incoming instrument
air to 5 psig.
2. A normally open solenoid
aspirator air* to the sensor.
off during calibration).
valve to control
(The aspirator
the flow of
air is turned
3. Normally closed solenoid valves to control instrument air for
span checks and cylinder gases for zero and span checks.
4. A pressure regulator to assure that all gases going to the
sensor are at the same pressure, and therefore at the same
flow.
S. A flowmeter and needle valve to control and monitor the
calibration flow to the sensor.
6. A weather-proof box to house the above.
7. A check valve mounted
calibration gas from
calibrations. It has a
at the
leaking
cracking
sensor to
into the
pressure of
*NOTE: -Aspirator Air is not required for HP
outlet sensors. The Aspirator Air
Calibration Unit is plugged.
6
prevent air or
sensor bet ween
1 psi (26" H O).
& Insitu
on the
2
style
Remote
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SECTION
FIVE
5.1
CALIBRATION
OPERATION
ENDA-1000
After the Analyzer has been warmed up for enough time to stabilize, as
explained in 4.2, it should be calibrated according to the following
procedure.
The directions below refer to a manual control version for which NOx/S02/02
have been specified (equivalent to the ENDA-1400). For automatic control
versions, refer to the separate ECU-350 Option Unit Operation Manual.
NOTE: The following explanation covers calibration RANGE l for NOx
and so, and RANGE 2 for 02 •
Turn the RANGE SELECT switches on the Analyzer Unit to the following
positions:
NOx: Rl
SO,: Rl
02 : R2
ZERO CALIBRATION FOR NOx AND SO, READINGS
NOTE: It is not necessary to carry out the following zero calibration
procedures for an automatic control version.
·a. Turn the Analyzer System selector valves to the CAL-ZERO position. The
following gases will flow to the Analyzer Unit at this time:
l. In the case of an air zero/span version,
Purified air: This is zero gas for the NOx and SO, analyzer
modules, 21.0 vol% span gas for the 02 analyzer.
2. In the case of a gas cylinder version,
99.99% N, gas: This is zero gas for all analyzer modules.
CAUTION
Check that .the air bubbles in the Pressure Relief Water
Trap are as shown in 4.2 h. and the flowmeter readings
are normal. These checks should be made every time the
position of the selector valves is changed.
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SECTION
FIVE
5.2
CALIBRATION
OPERAllUN_
ENDA-1OO0
b. Turn the SELECT switch on the Analyzer Unit to the NOx position and
read the DATA DISPLAY. After the reading stabilizes, open the front
panel of the Analyzer Unit and adjust the CHl zero potentiometer inside
until the display reads zero (000).
CH.,-2 ZERO CH-3 ZERO
FRONT PANEL (OPENED)__j
CH-1 ZERO
NOTE: The zero readings of the analyzer modules in the ENDA-1000
Series are extremely stable and it is often unnecessary to
adjust the zero potentiometers provided that sufficient
time is allowed for proper warm-up.
c. Turn the SELECT switch on the Analyzer Unit to the S02 position and read
the DATA DISPLAY. After the reading stabilizes, open the front panel
of the Analyzer Unit and adjust the CH2 zero potentiometer inside until
the display reads zero (000).
The above procedure completes zero calibration for NOx and S02 readings.
SPAN CALIBRATION FOR NOx AND S02 READINGS
NOTE: It is not necessary to carry out the following span
calibration procedures for an automatic control version.
a. Turn the Analyzer System selector valves to the CAL-SPAN-CHl (NOx)
position. N2 base NOx span gas will flow to the Analyzer Unit at this
time.
Page 5-2 '(40) •
SECTION
FIVE
5.3
CALIBRATION
CAUTION
OPERATION
ENDA-1OOO
The span gas should have a·va1ue 80% to 90% of the fu11-
sca1e reading of the analyzer being calibrated.
b. Turn the SELECT switch on the Analyzer Unit to the NOx position and
read the DATA DISPLAY. After the reading stabilizes, push in and turn
the NOx SPAN control on the front panel of the Analyzer Unit until the
reading matches the NOx· span gas value.
NOTE: The SPAN control is designed to turn while being continuously
depressed; it will return to the original position if one's
hand is removed. The SPAN control must not be turned once
span calibration is completed. The same applies to the SPAN
control in all of the following calibration steps.
c. Repeat steps a. and b. for S02•
This completes span calibration for NOx and S02 readings.
ZERO/SPAN CALIBRATION FOR THE 02 READING
NOTE: This step varies depending upon the version.
a. In the case of an air zero/span version,
1. Leave the selector valves as they are to allow the N2 base span gas
to flow as zero gas for the 02 analyzer module, turn the SELECT
switch on the Analyzer Unit to 02 and read the DATA DISPLAY. After
checking that the reading has stabilized, open the front panel of
the Analyzer Unit and adjust the CH3 zero potentiometer inside until
the display reads zero (000).
2. Turn the Analyzer System selector valves to the CAL-ZERO position.
Purified air will flow to the Analyzer Unit. Check .that the DATA
DISPLAY reading has stabilized and push in and turn the 02 SPAN
control on the front panel of the Analyzer Unit until the display
reads 21.0 vol%.
Page 5-3
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SECTION
FIVE CALIBRATION
Ut't.KA UUI\ I ENDA-1000
b. In the case of a gas cylinder version,
I. Turn the SELECT switch on the Analyzer Unit to the 02 position and
read the DATA DISPLAY. After the reading stabilizes, open the front
panel of the Analyzer Unit and adjust the CH3 zero potentiometer
inside until the display reads zero (000).
2. Turn the selector valves to the CAL-SPAN-CH3 (02 ) position. N, base
o, span gas will flow to the Analyzer Unit. After the reading has
stabilized, push in and turn the 02 SPAN control on the front panel
of the Analyzer Unit until the reading matches the value of the 02
span gas.
Steps 5 .. 1 through 5.3 complete calibration. The Analyzer Unit will read
the sample values once the selector valves are returned to the MEAS
position.
NOTE: Except in the case of an automatic calibration version, close
the main valves of.the zero gas and span gas cylinders when
calibration is completed.
CB-2 ZERO ..--CH-3 ZERO
FRONT PANEL (OPENED)__]
.....__ CH-1 ZERO
Page 5-4 ·(42f
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APPENDIX C
CHAIN-OF-CUSTODY
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GDC ENGiNEERING INC.
-co .. •u~TUMi t.-.•E!"ftS
IZZ Nl[QS..0 M1'£flU[
l&TON ltOUl'iC •...... 1'0•az
JOB NO. ______ _
CHAIN OF CUSTODY RECORD
. SAMPLE COLLECTION•
Location Of Sampling: ________________________ _
Facility Type•---Producer ___ Hauler _Disposal Site _Other _______ _
Sampler Na~•----------------Telephone•-------
Generator Name•---------------------------
Address• -------------------------------
Date Sampled: ________________ Time •----------
Type Of Process Or Facility Sampled•------------------
Field Information: _________________________ _
,.
Sampler's Signature: ________________________ _
CHAIN OF POSSESSION•
Relinquished By (Signature)
Relinquished By (Signature)
Relinquished By (Signature)
'
Relinquished By (Signature)
Returned Or Disposed Of By: (Sign.)
Received By (Signature) Date/Time
Received By (Signature) Date/Time
Received By (Signature ) Date/Time
Received By (Signature) Date/Time