NCD003200383_19960301_Koppers Co. Inc._FRBCERCLA RA_Construction Operations Plan - Groundwater Remediation-OCR

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CONSTRUCTION OPERATIONS PLAN
GROUNDWATER REMEDIATION
KOPPERS COMPANY SUPERFUND SITE
MORRISVILLE, NORTH CAROLINA
March 1996
"
Prepared for:
Beazer East, Inc.
436 Seventh Avenue
Pittsburgh, PA 15219
Rust Environment & Infrastructure
5510 Six Forks Road
Raleigh, NC 27609
Project No. 34321.000
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Chapter
1.0
2.0
3.0
TABLE OF CONTENTS
Constrnction Operations Plan
Groundwater Remediation
Koppers Company Superfund Site
~
INTRODUCTION .............................................. 1
PROJECT ORGANIZATION ..................................... 1
2.1 PROJECT MANAGEMENT ................................. I
2.2 SITE MANAGEMENT ..................................... 2
2.3 HEALTH & SAFETY ...................................... 2
2.4 QUALITY CONTROL ...................................... 3
PLAN OF OPERATION ......................................... 4
3.1 TASK DESCRIPTION ...................................... 5
3.2
3.3
3.4
3. I. I Equipment Procurement ............................... 5
3.1.2 Mobilization ........................................ 5
3. I. 3 Site Preparation ...................................... 5
3.1.4 Potable Water Line ................................... 5
3.1.5 Well Vault .......................................... 5
3. I. 6 Groundwater Conveyance Pipeline ....................... 6
3. L 7 Discharge Pipeline .................................... 6
3.1.8 Treatment Building Foundation .......................... 6
3.1.9 Treatment Building Installation .......................... 6
3. I. IO Electrical Service ..................................... 6
3. I. I I Demobilization ...................................... 7
3 .1.12 Operation & Maintenance Manual and As-Built Drawings ...... 7
3 .1.13 System Startup ...................................... 7
3 .1.14 Initial Operation ............................. 7
PROJECT SCHEDULE ................ 7.
SUBCONTRACTING ...................................... 8
PERMITS ................................................ 8
G:lENVIR\PROJECn34321.000\GDWATERIOPSPLAN.RPT March 1996
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Constrnction Operations Plan
Groundwater Remediation
Koppers Company Supe,fund Site
LIST OF FIGURES AND DRAWINGS
Figure Follows Page
Organization Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Drawing
34321-M-0l -General Equipment Arrangement
34321-S-0l -Treatment Slab and Containment
34331-S-02 -Extraction Well Vault and Meter Vault
G:\ENVIR\PROJECT13432/.000\GDWATER\OPSPL4.N.RPT ii March 1996
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1.0 INTRODUCTION
Construction Operations Plan
Groundwater Remediation
Koppers Company Superfund Sile
This Construction Operations Plan describes the project organization, work tasks and construction
schedule Rust Environment & Infrastructure (Rust) will implement for construction, startup, and
initial operation of the groundwater remediation system located at the Koppers Superfund Site in
Morrisville, North Carolina.
2.0 PROJECT ORGANIZATION
This section provides the project organization for groundwater remediation at the Koppers Site in
Morrisville, North Carolina. Rust will subcontract portions of the work to INCO, Inc. An
organization chart of the Rust and INCO team is provided in Figure I. Site management will be the
responsibility ofINCO. Rust will provide overall project management, support for sample collection
and data quality, construction quality control, health and safety support, system startup, Operation
& Maintenance Manual preparation, and initial system operation.. Brief descriptions of the project
team and brief resumes of key personnel identified in the organization chart are provided.
2.1 PROJECT MANAGEMENT
Division Manager· Ms. Pamela Townsend, PE, is the Division Manager for the Rust Environment
& Infrastructure, Raleigh, North Carolina office. Ms. Townsend is responsible for assignment of
personnel to the Koppers Superfund Site groundwater remediation project and ensuring
implementation of and compliance with this project quality control plan. The Project Manager and
the Quality Control Engineer will report independently to Ms. Townsend during the course of this
project.
Ms. Townsend has over 10 years of engineering experience and she was project manager for
groundwater remediation at the Raleigh-Durham Airport Joint Fueling Facility and for other soil and
groundwater remediation projects in North Carolina.
Project Manager: Mr. John Funk, PE, will be the Project Manager for the project. Mr. Funk will be
the primary point of contact with the Beazer East Project Manager and Cummings/Riter Engineer foi:
this project. Mr. Funk will responsible for project scheduling, cost control, engineering design, and
coordination of subcontractor activities. He also is responsible for ensuring that the work carried out
by Rust is in conformance with corporate quality control procedures.
Mr. Funk has more than IO years hazardous waste site experience and more than 20 years of
engineering experience. He is a licensed engineer in North Carolina and has design and project
management experience that is directly applicable to the project. He prepared a Chemical Data
G:lENVJR\PROJECnJ4321.000\GDWATER\OPSPl.AN.RPT I Marchl996
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FIGURE - 1
~ENVIRONMENT & ORGANIZATION CHART
lINFR.ASfRUCTUruE BEAZER EAST, KOPPERS SITE
MORRISVILLE, NC
CADFIL[: 34 321.000\orgcht.dgn DATE PLOTTED: 03/04/95
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Construction Operations Plan
Groundwater Remediation
Koppers Company Superfund Site
Acquisition Plan for Langley AFB Site OT-56 (Storm Sewer System), which is a proposed NPL site.
He prepared work plans and performed construction oversight for interim closure at several NPL sites
in Bloomington, Indiana, including cap construction at Lemon Landfill, surface and groundwater
collection and treatment at Neal's Landfill, and sediment removal from Clear and Stout's Creek.
Mr. Funk has prepared plans and specifications, performed construction oversight, and start up
testing for numerous groundwater remediation projects in North Carolina. Projects have included
soil and groundwater remediation at the Raleigh-Durham Airport Joint Fueling Facility, City of
Raleigh Equipment Services Depot, and Piedmont Electric.
2.2 SITE MANAGEMENT
Site Manager· Mr. Roger Gosselin will be the INCO Site Manager for the project. He will be
responsible for ensuring that the construction work is performed in accordance with the project plans
and specifications. He will collect construction test samples and perform the construction tests
identified in this Quality Control Plan. He also will be responsible for completion of the Daily
Construction Quality Control Report.
He has extensive and diversified experience of more than 20 years involving all phases of industrial
maintenance and construction. Major experience background includes the supervision and
management of projects in the areas of pharmaceutical, wood products, chemical, textile and electric
power plants. He supervised the installation and fabrication of various equipment; carbon steel and
stainless process piping; rigging, relocation and setting of heavy equipment; forming, placing, and
finishing of concrete; and fabrication and erection of structural steel.
2.3 HEALTH AND SAFETY
Health and Safety Manager· Mr. Sherman Woodson will be the Health and Safety Manager (HSM)
for the project. Mr. Woodson is responsible for Rust corporate health and safety for the southeast
region. He is responsible for corporate health and safety training and for review of all health and
safety plans.
He holds certification from the American Board oflndustrial Hygiene and is responsible for industrial
hygiene and safety investigations and supervision of health and safety concerns for workers. He
performs surveys of hazards to develop site safety procedures, recommends levels of protective
clothing and equipment, and provides pre-site health and safety briefing for site workers. At the
Department of Energy Facility in Oak Ridge Tennessee, he developed carcinogen control safety plans,
evaluated confined space entry and airline respirator programs, and provided industrial hygiene
monitoring and general site safety monitoring during covering of hazardous waste trenches with a
G:\ENVJRlPROJECnJ4J2/.000IGDWATER\OPSPLAN.RPT 2 March 1996
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Constroction Operations Plan
Groundwater Remediation
Koppers Company Superfund Site
liner and at other hazardous waste sites at the Oak Ridge Y-12 Plant. At Diversified Scientific
Services, Inc. in Kingston, Tennessee, he developed health and safety programs including confined
space entry, respiratory protection, air monitoring plan, hazard communication, fire prevention, and
hearing conservation. He also provided safety oversight for construction activities at the facility.
Health and Safety Supervisor· Ms. Maria Longcore will be the Health and Safety Supervisor for the
project. Ms. Longcore will prepare the site health and safety plan and be responsible for plan
implementation. The site safety and health officer will report to Ms. Longcore.
She has IO years environmental assessment and industrial hygiene experience. She has managed
hazard communications/right-to-know programs and provided information training to employees
concerning hazards of chemicals in the workplace and protective measures to reduce exposure to
these hazards; prepared numerous health and safety plans for sample collection of surface water, soil
and groundwater, and for remediation at state Superfund and RCRA sites in North Carolina,
investigated indoor air pollution problems, and performed periodic monitoring of employee exposure
to toxic and carcinogenic substances. She has performed the duties of Site Safety and Health Officer
and Field Task Manager during the site assessment at a Superfund site in Aberdeen, North Carolina,
and at the Tarheel Army Missile Plant in Burlington, North Carolina.
2.4 QUALITY CONTROL
Quality Control Supervisory Engineer: Mr. Randall Foulke, PE, DEE, will be the Quality Control
Supervisory Engineer for the Groundwater remediation project. Mr. Foulke will be responsible for
review of the Daily Construction Quality Control Reports, the Chemical Quality Control Project
Summary Report, as-built drawings, and the construction test reports identified in the project
specifications and this Quality Control Plan. Mr. Foulke will be responsible for all quality control
testing, and he will report to the Division Manager. The Quality Control Engineer and Quality
control Technician will report to Mr. Foulke.
Mr. Foulke has more than 24 years of engineering experience, including approximately 10 years of
experience as a resident engineer or resident inspector on construction sites. Mr. Foulke also has
experience in the storage, treatment, and disposal of hazardous waste and closure of hazardous waste
sites. He is a licensed engineer in North Carolina and has experience that is directly applicable to the ·
project. He prepared construction specifications and performed construction oversight for numerous
groundwater remediation projects in North Carolina including the Zebulon facility of Glaxo
Wellcome, Inc, Abbott Laboratory facility in Laurinburg, Ashland Chemical in Raleigh, and others.
Quality Control Engineer· Mr. Richard Burt will be the Quality Control Engineers for the
groundwater remediation project. Mr. Burt will witness electrical and mechanical tests performed
G:\ENV!R\PROJEC113432/.000IGDWATERIOPSPLAN.RPT 3 March 1996
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Construction Operations Plan
Groundwater Remediation
Koppers Company Superfund Sire
by the contractor to ensure conformance with the requirements of the construction specifications,
prepare test reports for review by the Supervisory Engineer, review the Daily Constructio~ Quality
Control Report prepared by the contractor. Mr. Burt will also perform startup and operational testing
of the remediation system.
Mr. Richard Burt is a chemical engineer with fourteen years engineering experience. He has
performed system operation, maintenance and troubleshooting for a groundwater remediation system
in Raliegh, North Carolina. The system included air stripping and liquid phase actavated carbon
adsorption. He has also performed process troubleshooting and process engineering at several
pharmaceutical and chemical plants. Duties have included preparing process operating instructions
and supervising process startups, installing and maintaining chemical additive systems, and preparing
process flow and instrumentation diagrams.
Quality Control Technician\Safety and Health Officer: Mr. Dennis Jones will be the Quality Control
Technician and Safety and Health Officer for the groundwater remediation project. He will witness
construction tests performed by the contractor to ensure conformance with the requirements of the
construction specifications, prepare test reports for review by the Supervisory Engineer, review the
Daily Construction Quality Control Report prepared by the contractor, and conduct moisture density
tests of excavation backfill material.
Mr. Jones fields of expertise include environmental assessment, well installation and development,
foundation and subgrade evaluations, laboratory soil testing, and concrete and asphalt quality control.
He has conducted groundwater, surface water, and soil sampling for numerous industrial clients,
including Hoechst Celanese, Westinghouse, and Amoco. He has three years experience with the
North Carolina Department of Transportation as a Construction Inspector for subgrade testing of soil
and concrete and asphalt plant quality control. He also performed subgrade evaluation testing at
Hartsfield Atlanta International Airport and Falcon Field Airport.
3.0 PLAN OF OPERATION
This section provides a brief description of the tasks required for construction, startup, and operation
of the groundwater remediation system; a project schedule; subcontracting plan; and list of permits ·
required for construction. The Rust site specific Health and Safety Plan and Construction Quality
Control Plan were prepared separately.
G:\ENV!R\PROJECn34321.0001GDWATER!OPSPl.AN.RPT 4 March 1996
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3.1 TASK DESCRIPTION
Construction Operations Plan
Groundwater Remediation
Koppers Company Superfund Site
The following tasks comprise the scope of services Rust will perform to construct, startup and
initially operate the groundwater remediation system at the Koppers Superfund Site in Morrisville,
North Carolina.
3.1.1 Equipment Procurement
Rust's subcontractor INCO, Inc. will place purchase orders for major equipment items to include the
treatment system building with equalization tank, transfer pumps, media filters, carbon filters, control
panel and instrumentation, valves, building electrical system and other miscellaneous equipment. The
treatment system will be pre-fabricated off-site and supplied with equipment pre-plumbed and pre-
wired in the building. The subcontrzctor will also place purchase orders for the well vault system to
include well pump, vault, instrumentation and meter, valves, and other miscellaneous equipment.
3.1.2 Mobilization
Mobilization will include setup of a construction trailer for storage of equipment and supplies and
setup of temporary sanitary facilities. Electrical power and potable water line installation will be
provided as separate work tasks.
I 3.1.3 Site Preparation
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Site preparation will include clearing for the potable water line and grading for installation of the well
vault and treatment system building.
3.1.4 Potable Water Line
A l" copper, or a l" high density polyethylene (HDPE) potable water line will be installed as shown
on Cummings/Riter drawings. The line will terminate at a 3/4" hose spigot in the treatment system
building. The water line will be installed at a minimum burial depth of 12 inches to conform with
Building Code requirements. The line will be disinfected after installation in accordance with
Cumming/Riter specifications.
3.1.5 Well Vault
The well vault will consist ofa 4 foot by 4 foot concrete manhole as shown on Rust Drawing 34321-
S-02. This work task will include installation of the well pump and conductivity electrodes,
installation of the concrete vault, and installation of piping, valves, meter, and fittings located within
the vault.
G:\ENVJR\PROJECn34321.000IGDWATER\OPSPl.AN.RPT 5 March 1996
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3.1.6 Groundwater Conveyance Pipeline
Construction Operations Plan
Groundwater Remediation
KopPers Company Superfund Site
The groundwater conveyance pipeline will run from the well vault to the treatment system building.
The line will be constructed using I" diameter high density polyethylene (HDPE) which is enclosed
within a 3" diameter schedule 40 polyvinyl Chloride (PVC) pipeline which functions as secondary
containment for the HDPE pipeline. The pipeline will be installed a minimum 12 inches below ground
as shown on Cummings/Riter Drawings and leak tested prior to acceptance and backfilling in
accordance with Cummings/Riter Specifications. Work of this task also includes installation of PVC
conduit from the treatment system building to the well vault to provide electrical service to the well
vault. The PVC conduit will be installed within the same trench as the conveyance pipeline.
3.1. 7 Discharge Pipeline
The treatment system discharge pipeline will run from the treatment system building to a site drainage
ditch as shown on Cummings/Riter drawings. Alternatively, the dishcarge pipeline may terminate in
the Fire Pond area at the direction the Cummings/Riter. The pipeline will be constructed of 2"
diameter schedule 40 PVC. The pipeline will be leak testing prior to acceptance and backfilling in
accordance with Cummings/Riter Specifications.
3.1.8 Treatment Building Foundation
The treatment system building will be installed on a reinforced concrete slab as shown on Rust
Drawing 34321-S-Ol. The building will be supported on a concrete block enclosure which provides
secondary containment for treatment system equalization tank and other vessels within the treatment
building. The concrete block enclosure provides 1,450 gallon storage capacity which is equal to the
maximum volume of the equalization tank and greater than the equalization tank operating volume
of 1,325 gallons. The concrete slab will be slopped to a sump area as shown on the drawings.
3.1.9 Treatment Building Installation
The groundwater treatment system will be factory fabricated and installed in a IO foot by 20 foot pre-
fabricated building which has a ribbed aluminum exterior and reinforced steel floor. The work of this
task will consist of setting the building on the concrete block enclosure, connection of the conveyance
pipeline, discharge pipeline, and electrical service to the well vault.
3.1.10 Electrical Service
Work of this task consists of installing electrical power to the treatment system building and well
vault as shown on Cummings/Riter Drawings, installing the electrical meter base at the building, and
providing the electrical service entrance to the building electrical panel.
G:\ENV!R\PROJECTl3432 /. 000\GDWATER\OPSPLAN.RPT 6 March 1996
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Construction Operations Plan
Groundwater Remediation
Koppers Company Superfund Site
3.1.11 Demobilization
Demobilization includes removal and disposal of construction trash and debris, removal of
construction equipment, construction trailer, and temporary sanitary facilities.
3.1.12 Operation & Maintenance Manual and As-Built Drawings
A system Operation & Maintenance Manual will be prepared for the groundwater remediation system
and operation procedures contained within the manual will be verified during system startup. As-
Built drawings will also be prepared to document the construction of the system. The manual and
drawings will be prepared in accordance with Cummings/Riter specifications.
3.1.13 System Startup
System startup will be performed in accordance with Cummings/Riter specifications. Tests of system
components will be performed as specified and operation of the system will be demonstrated. Influent
and effluent water samples will be collected for chemical analysis in accordanct; with the Construction
Quality Control Plan.
3.1.14 Initial Operation
Rust personnel will observe the automatic operation of the groundwater remediation system for a two
week period commencing immediately after startup and acceptance. Rust personnel will inspect the
system daily during the two week period to observe that the system is function as intended. Daily
logs will be maintained of meter reading and observations during the two week initial operation
period.
3.2 PROJECT SCHEDULE
The following schedule for construction and initial operation of the groundwater remediation system
is based upon a Notice To Proceed on February 29, 1996:
Water Meter Installation . . . . . . . . . . . . . . . . . . . . March 29, 1996
Mobilization . . . . . . . . . . . . . . . April 8, 1996
Complete Building Slab .............................. • . . . . . April 17, 1996
Set Building on Slab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . April 24, 1996
Complete Discharge, Well Vault and Lines ........................ May 3, 1996
Complete Water Line ....................................... May 10, 1996
Initiate Startup ............................................ May 13, 1996
Initiate Operation .......................................... May 15, 1996
Complete Initial Operation ................................... May 29, 1996
G:\ENVJR\PROJECnJ432J.000\GDWATER\OPSPl.AN.RPT 7 March 1996
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Construction Operations Plan
Groundwater Remediation
Koppers Company Superfund Site
The above schedule does not include possible delays due to adverse weather conditions.
3.3 SUBCONTRACTING
Rust has subcontracted the procurement and installation of the groundwater remediation system
equipment to INCO, Inc. ofRocky Mount, North Carolina.
3.4 PERMITS
It is anticipated that building, plumbing and electrical permits may be required for construction of the
groundwater remediation. Rust or its subcontractor will obtain permits required for construction.
G:lENV/RlPROJECnJ4321. 000\GDWATER\OPSPLAN.RPT 8 March 1996
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N'f>'O: BEAZER EAST, INC. RUST DWG 34321-M-01 13~~~ 0 ISSUED FOR BID N>P'O, KOPPERS COMP!>NY SUPERFUND SITE """ER CLIENT OWG I SHEET "'-'EER ,o. RE~s,oos -CH>< DATE "°· REV1Sl0"5 "''" CH( om ,o. '"''"""' "''" CH< DATIC N>P'O, MORRISVILLE, NORTH CAROLINA ....,,,
The drawii91, spedfication1 and othcir documentl prepared by the Engineer for thi1 p,ojcict or• instr,..._,tl of tha Engi,e...-'1 1erYic1 for UH ■olaly ,.;th raspact to thi1 projcicl end, I ,,,,,._,_ ~l'.::rrLl:: IIHn otherwisa Pf'Ovlded, the Engineer shcJII be deemed the outhor of these docunet1tl end st>OII retoi, dlcomTIOl'I low, ■totutory ol'ld other reurved rlghtl, l~g the copyright. =·-
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APP'D' BEAZER EAST INC. RUST DWG 34321-S-01 I ~2~~N • 0 ISSUED FOR BO ,,PP,D, KOPPERS COMPANY SUPERFUND SITE -ER
CLIENT owe I StfiT "'-ll.EIER
HO. REVlSIONS ""' CHK DATE NO. : REVISIONS "''" CH< DATE ,o. REVISIONS """ C><K DATE ,.PP'D: MORRISVILLE. NORTH CAROLINA ..,"8ER
Th• dro•ings. apocifieotions Ol'>d oth•r document.,, prepa,•d by th• Engioear !or this proj•ct er• instrumc,UI of th• Engne.,.•• ■...-vica for ....,., ■olaly with re.sp•cl to this proj•ct aid, i.nln• othe,..;se provided. the Engineer shol be deemed th• outhor of these documents ond aho!I retoii oll com-non low, statutory and other reserved rk]hts. lneluding the copyright.
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Cot<AETE GROOT ~ r 26' -,--!---STL. MANHOLE RING ANO MIN. I / COVER w /DROP HAI-OLE
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~ ..... GROOT .....
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:r.j ~ 3' SCH 40 PVC
. ~ CONTAl""'1ENT PIPE
y,-'---EX!ST!NG CONCRETE SEAL
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GRN'HIC SCALE
B SECTION A-A
t«lTE ELECTRICAL CONOOJT ANO .n..tlCTl~ BOXES NOT SHO',/N
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PRESSURE GAUGE 1' SCH 40 STL 1' HOPE
( 3' Sa-I 40 PVC
SAMPLE VALVE
1' SALL VALVE
"'-" ,,,,,.,,,-'w'ELL CASING -
1' SCH 40 PVC FLOW METER
PIPING ISOMETRIC
NOT TO SCALE
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/ SAMPLE VALVE
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:~~~A~.OPENING
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SCH 40 PVC PIPE -----, READER
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PVC CONDUIT -_...
l' CHECK VAL VE
I' GATE VALVE
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FLOW l'ETER J
0 .5' 1'
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GRAPHIC SCALE
PUN VIEW
DATE
~ 4' ~ '4' MANHOLE STAY RIGHT TANK
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A l--l---------.l---1----+----l~-+----------+--+---l--lf--l------------+--+--+----I DESIGN=
CI-ECKED:
GROUND WATER REMEDIATION SYSTEM
EXTRACTION WELL VAL VE
AND METER VAULT
I'll llrW' ENVJRONMENT & l~U~ I INFRASfRUCTURE
' !Sst.lEO FOR 810
I.IAOE CHK OAT( REVISIONS t.lJDE CHI( DATE REVISIONS
Tt., dra..-inga, specifications and oth.,. docum,snla prepor8d by the Engineer for thi• pf"ofect ore W\atrUT>enla of the [ng1Mer'a ■arv,ce for""" solely with respect to this project aid, unlen otherwise provided, the Erufr,eer ahallbe deemed the author al tt,,,,e document. ond ahallretoln cllcotTYTIOO la,,, stotuto.-y and other reserv8d rights, .-.eluding the copyright.
,t,PP'O:
JPP'O:
om
BEAZER EAST
KOPPERS COMPANY SUPERFUND SITE
MORRISVILL[, NORTH CAROLINA
PROJECT NLM:IER .H32t.OOO
~&•' 34321-S-02
CLIENT owe """'"'
DATE 3-20-96 I FLE ""-Jt.lBER 3~321502.0GN I SHEET r-a.J!,,j8£R
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