NCD980602163_20000301_Warren County PCB Landfill_SERB C_Site Operations Work Plan and Construction Quality Assurance Plan - BCD Detoxification-OCR

WARREN COUNTY
PCB LANDFILL
SITE OPERATIONS
WORK PLAN
and
CONSTRUCTION QUALITY
ASSURANCE PLAN -
BCD DETOXIFICATION
Prepared for:
North Carolina
Department of Environment
and Natural Resources
Division of Waste Management
E.,.-.r■rc».,. ... ~.,.t.-1_ ■.,.c_
BF A Environmental Consultants
Barnes, Ferland and Associates, Inc.
March 2000
WARREN COUNTY
PCB LANDFILL
SITE OPERATIONS
WORK PLAN
Prepared for:
North Carolina
Department of Environment
and Natural Resources
Division of Waste Management
-==• '--E.,.V'ire>.-.--~ ... t..-1., ■ ... c_
BF A Environmental Consultants
Barnes, Ferland and Associates, Inc.
March 2000
Site Operations Work Plan Warren County PCB Landfill
1.0
2.0
3.0
SITE OPERA TIO NS WORK PLAN
TABLE OF CONTENTS
INTRODUCTION. ...................... . ·········· ....... ·················································· 1
1.1 Purpose and Scope.......... . ................................................................... 1
1.2 Content of the Site Operations Plan ............................................................... l
1.3 Site Setting ..................................................................................................... 2
SCOPE AND OVER VIEW ....................................................................................... 6
2.1 Site Facilities/Site Preparation ..................................................................... 6
2.1 .1 Required Utilities .............................................................................. 6
2.2 Sequence of Activities ............................ · ............ · ..................................... 8
2.3 Detoxification Criteria .................................................................................. 9
2.3.1 Criteria for Excavation ...................................................................... 9
2.3 .2 Criteria for Treatment and Backfilling .......................................... 10
2.4 Site Restoration ............................................................................................ 10
2.4.1 Equipment Decontamination, Dismantlement
and Demobilization ......................................................................... 10
2.4.2 Final Site Grading ........................................................................... 11
2.4.3 Restoration of Site Vegetation ....................................................... -11
SITE EXCAVATION PLAN 12
3.1 Introduction ................................................................................................. 12
3 .1.1 Existing Features .......................................................................... 12
3.1.2 General Sequence ............................................................................. 14
3.1.3 Design Basis Criteria ...................................................................... 14
3.2 Quantities ....................................................................................................... 25
3.2.1 Clean Material ............................................................................... 25
3 .2.2 Contaminated Material 26
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3.3 Environmental Controls ........................................................... . 26
3.3.1 Dust Suppression..................................................... ... 26
3.3.2 Erosion and Sediment Controls .................................................. 26
3.3.3 Demarcation Zones ........................................................................ 27
3.4 Support Facilities ................................................................................. . 27
3.4.1 Material Storage Area ................................................................... 27
3.4.2 Vehicle Management Areas .......................................................... 28
3.4.3 Detoxification Support Area .......................................................... 28
4.0 BASE CATALYZED DECOMPOSITION (BCD)
DETOXIFICATION PROCESS........................................................ . ............ 31
4.1 BCD Detoxification Process Set Up ........................................................... 31
4. 2 Performance Demonstration Test 3 2
4 .2.1 Contam~nated Material Preparation ............................................... 3 3
4.2.2 Clean Material Testing ................ ; ................................................... 34
4.2.3 CBCD Ramp Up Test .................................................................... 34
4.2.4 BBCD PD Testing ........ : .................................................................. 35
4.2.5 CBCD PD Testing ......................................................................... 35
4.2.6 LBCD PD Testing ......... ~ ................................................................. 36
4.2.7 Performance Demonstration Report ............................................ 37
4.3 •Interim Operations ............................................... : ....................................... 37
4 .4 Full Scale Operation Material Preparation ................................................. 3 7
4.4.1 Landfill Excavation and Staging Area.............. ............... 38
4.4.2 Untreated Material Sampling and Analytical Screening ............. 38
4.4.3 Screening Plant ............................................................................... 38
4. 4. 4 Magnetic Separator ............................................................ 3 9
4.4.5 Pugmill Plant ................................................................................... 39
4.4.6 Blended Material Stockpile ............................................................ 40
4.4 .7 Material Blending Control System................................... 40
4.5 Continuous Solid Phase BCD System ...................................................... 41
4.5 .1 CBCD Feed System ....................................................................... 41
4.5.2 CBCD Desorber ............................................................................... 42
4.5 .3 CBCD Rehydration System .......................................................... 43
4.5.4 CBCD Vapor Recovery System (VRS) ......................................... 43
4.5 .5 Cooling Tower ................................................................................. 44
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SITE OPERA TIO NS WORK PLAN
TABLE OF CONTENTS
(Continued)
Warren County PCB Landfill
4.5.6 Chiller ........................................................................................... 45
4.5.7 Emergency Backup Systems .......................................................... 45
4.5.8 CBCD Process Monitoring Procedures .......................................... 46
4.5.9 CBCD Waste Feed Cutoff Systems ............................................... 48
4.6 Batch Solid Phase BCD (BBCD System) .................................................. 50
4.6.1 BBCD Feed System ....................................................................... 51
4.6.2 BBCD-Desorber .............................................................................. 51
4.6.3 BBCD Rehydration System ............................................................. 52
4.6.4 BBCD Vapor Recovery System (VRS) ......................................... 52
4.6.5 Cooling Tower .................................................................................. 53
4.6.6 Chiller ............................................................................................... 53
4.6. 7 Emergency Backup Systems .......................................................... 53
4.6.8 BBCD Process Monitoring Procedures .......................................... 54
4.7 Batch Liquid Phase BCD (LBCD System) ................................................ 54
4. 7.1 LBCD Process Monitoring Procedures .......................................... 56
4.8 Process Condensate Separation and Aqueous Phase
Treatment (PCSAPT) System ..................................................................... 58
4.8.1 Process Condensate Separation System ......................................... 58
4.8.2 Aqueous Phase Treatment System ................................................. 59
4.8.3 PCSAPT System Operation ............................................................ 59
4.9 Common Systems ......................................................................................... 60
4.9.1
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6
4.9.7
4.9.8
4.9.9
No. 2 Fuel Oil System ..................................................................... 60
Nitrogen Cylinders .......................................................................... 61
Propane System ............................................................................... 61
Plant and Instrument Compressed Air ........................................... 61
Water Storage Tank. ........................................................................ 61
Cooling Tower and Chiller ............................................................. 61
Supervisory Control and Data Acquisition System ...................... 62
Electrical Distribution Center 65
Maintenance/ Parts Inventory ........................................................ 65
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5.0
6.0
4.10
SITE OPERA TIO NS WORK PLAN
TABLE OF CONTENTS
(Continued)
Project Schedule ........................................................................................ 66
4.10.1 Site Work Hours ....................................................................... . 67
PERSONNEL OPERA TIO NS AND STAFFING ............................................... 68
5.1 Key Personnel...................................................................................... 68
5. 2 Organizational Responsibility ................................................................... 68
5. 3 Supervisor Safety Responsibilities............................................. . . . . .. . . . . . 69
5.4 Employee Safety Responsibility ............................................................... 69
5.5 Subcontractor Responsibilities................................................................. 70
5.6 Site Staffing ................................................................................................ 70
5. 7 Site Personnel Training.......................................................................... . .. 71
5. 7. 1 Health & Safety Training .............................................. , . . . . . . . . . . 71
5.7.2 Emergency Response Training.................................................. . 72
5.7.3 Site Operations Training....................................................... . 72
SAMPLING AND ANALYSIS FULL-SCALE OPERATION .......................... 73
6.1 Types of Samples ......................................................................................... 73
6.2 Untreated Materials................................................................................... 78
6.3
6.2.1 Performance Demonstration (PD) Sampling
Untreated Materials...................................................................... 78
6.2.2 Excavation Sampling Untreated Materials .................................. 78
6.2.3 Post Excavation Sampling Untreated Soils ................................. 78
Treated Materials ........................................................................................ 79
6.3.1 Performance Demonstration (PD) Sampling
Treated Materials................................................................ . 79
6.3.2 First Two Weeks Full-scale Operations
Sampling Treated Materials......................................................... . 79
6.3 .3 Remainder Full-scale Operations Sampling
Treated Materials ............................................................................ 79
6.4 Liquid BCD Detoxification System Sampling ......................................... 80
6.5 Process Condensate Separation and Aqueous
.Phase Treatment Sampling....................................................................... 80
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7.0
SITE OPERA TIO NS WORK PLAN
TABLE OF CONTENTS
(Continued)
6.5.1 Filter Cake Sampling ..................................................................... 80
6.5 .2 Sand Filter Influent Sampling ........................................................ 80
6.5.3 Midfluent Carbon System SamplinK ............................................. 81
6.5.4 Effiuent Carbon Treatment Sampling ............................................ 81
6.6 CBCD Quencher/ Scrubber Recycle ......................................................... 81
6.7 Storm Watch/ Decontamination Water Sampling .................................... 81
6.8 Miscellaneous Sampling ............................................................................. 82
AIR MONITORING ··················•···•·•······························································83
7 .1 Background Monitoring .............................................................................. 83
7.2 Meteorological Station ................................................................................. 83
7.3 Construction Monitoring ............................................................................. 83
7.4 Landfill Excavation ..................................................................................... 83
7.5 BCD Processing Area .................................................................................. 83
7.6 Stack Emission Monitoring ......................................................................... 84
7. 7 Stack Testing ................................................................................................. 84
7. 8 Perimeter Area ............................................................................................. 84
7.9 Engineering Controls ................................................................................... 84
8.0 PERMITTING .......................................................................................................... 85
FIGURES
1-1 Vicinity Map
1-2 Site Survey
2-1 Proposed Site Layout
3-1 Typical Cross Section through Proposed Landfill
3-2 Proposed Excavation Cells
3-3 Phase I Excavation Activities
3-4 Phase 2 Excavation Activities
3-5 Phase 3 Excavation Activities
3-6 Phase 4 Excavation Activities
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TABLES
SITE OPERA TIO NS WORK PLAN
TABLE OF CONTENTS
(Continued)
4. 5-1 Process Monitoring for CBCD
Warren County PCB Landfill
4.5-2 Preliminary List of Waste Feed Cutoff Conditions for CBCD
4.6 Process Monitoring for BBCD
4. 7 Process Monitoring for LBCD
6-1 Sampling / Analysis Full Scale Operation
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Site Operations Work Plan Warren County PCB Landfill
AMP
BCD
BBCD
CBCD
CHSO
CLP
CP&L
CPM
CPR
CQAP
EPA
ETG
FD
FTO
FVCSP
HASP
ID
LBCD
NCAC
NCDENR
PCSAPT
PD
PDP
PLC
PM
PPE
QA
QC
SM
SOP
SOWP
TAHA
THC
TOC
TSCA
TSS
SITE OPERA TIO NS WORK PLAN
. TABLE OF CONTENTS
(Continued)
LIST OF ACRONYMS
Air Monitoring Plan
Base Catalyzed Decomposition
Batch Vacuum Solid Phase BCD/Thermal Desorption Unit
Continuous Solid Phase BCD/Thermal Desorption Unit
Corporate Health and Safety Officer
Contract Laboratory Program
Carolina Power & Light
Continuous Process Monitor
Cardio Pulmonary Resuscitation
Contractor Quality Assurance Plan
Environmental Protection Agency
ETG Environmental, Inc.
F creed Draft
Flameless Thermal Oxidizer
Final Verification/Confirmation Sampling Plan
Health and Safety Plan
Induced Draft
Liquid Phase BCD
North Carolina Administrative Code
North Carolina Department of Environmental and Natural Resource
Process Condensate Separation and Aqueous Phase Treatment
Performance Demonstration
Performance Demonstration Plan
Programmable Logic Controller
Project Manager
Personal Protective Equipment
Quality Assurance
Quality Control
Site Manager
Environmental Investigations Standard Operating Procedures and
Quality Assurance Manual
Site Operations Work Plan
Task Assessment/Hazard Analyses
Total Hydrocarbon
Total Organic Carbon
Toxic Substance Control Act
Total Suspended Solids
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Site Operations Work Plan
UPS
YRS
WESP
WFC
SITE OPERA TIO NS WORK PLAN
TABLE--OF CONTENTS
(Continued)
LIST OF ACRONYMS
(Continued)
Uninterruptible Power Supply
Vapor Recovery Systems
Wet Electrostatic Precipitator
Waste Feed Cutoff
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1.0 INTRODUCTION
1.1 Purpose and Scope
The State of North Carolina (State) has retained the services of ETG Environmental, Inc.
(ETG) and Barnes, Ferland and Associates, Inc. (BF A) to prepare this site-specific Site
Operations Work Plan (SOWP) for the detoxification of the existing PCB Landfill
located in Warren County, North Carolina. This project has been authorized by the North
Carolina Department of Environmental and Natural Resources (NCDENR) and will be
funded jointly by the State of North Carolina and the Environmental Protection Agency
(EPA). The SOWP describes the logistics to be used at the site to detoxify the PCB
Landfill based upon the contract documents. The contract documents are performance
based and therefore, allows for contractor discretion and variances in approaches and
techniques. The successful contractor will need to modify this SOWP to be consistent
with and specific to its operation.
The general scope of the detoxification project is to (1) prepare the site and construct the
required infrastructure; (2) excavate the affected material; (3) treat the affected material
utilizing BCD technology for both solid and liquid phases; (4) construct a stormwater
management system which will adequately capture and treat stormwater sufficiently for
reuse or discharge; (5) perform site restoration involving backfilling and compaction of
treated material and re-vegetating the site; and (6) involve the community in the project
to encourage economic development and ultimate reuse of the site.
In March 1998, ETG submitted a preliminary design document (Phase II) to the State for
detoxification of the Warren County PCB Landfill using Base Catalyzed Decomposition
(BCD) technology. This document was approved by the State as the basis for final
design for the detoxification of the Landfill facility. Such closure was deemed by the
State to be an effective means of fairly addressing key issues of the "Notice of Non-
compliance" issued by the EPA for the facility, as well as meeting the commitment made
by the State to detoxify the landfill when technically feasible. Since the submittal of the
preliminary design document, the North Carolina legislature has incorporated the
utilization of BCD for the landfill detoxification into law and has specified the
appropriate treatment standards required for the detoxification of the landfill. It is
anticipated that full funding for the project will be secured through appropriations from
the North Carolina Legislature with some matching funds from the Federal Government.
1.2 Content of the Site Operations Plan
Sections 2 through 8 of this document provide the operating scenario and sequence for
the proposed actions required to detoxify and restore this site in conformance with the
contract documents including the following plans, developed for this project.
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Site Operations Work Plan Warren County PCB Landfill
• Health and Safety Plan
.~ Community Outreach and Involvement Plan
• Performance Demonstration Plan
• Air Monitoring Plan
• Quality Assurance Plan
• Final Verification/Confirmation Sampling Plan
• Construction Quality Assurance Plan
• Emergency Response Plan
These documents outline a minimum level of detail that the Contractor will be required to
provide. Upon contract execution, the selected Contractor will be required to make each
plan consistent with and specific to its operation.
1.3 Site Setting
The existing PCB Landfill is located in the southwestern portion of Warren County,
North Carolina. The State owns 19 .317 acres of the property surrounded by the property
owned by Warren County. The landfill site is accessed from State Road 1604 by a dirt
road located in a State right-of-way vehicular. Access to the property is restricted by a
chain at the landfill property line and personnel access to the landfill is restricted then by
a chain link fence that surrounds the landfill proper. The landfill is currently closed and
is covered by vegetation (i.e., grass). The area surrounding the landfill varies from
cleared, grassy areas to dense forest. Figure 1-1 provides a vicinity map of the site,
Figure 1-2 shows the property boundaries, and Figure 1-3 shows the survey of the
existing site.
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Site Operations Work Plan Warren County PCB Landfill
2.0 SCOPE OVERVIEW
This section provides a general overview of the work that the Contractor must complete
to meet the project objectives. It also identifies the criteria under which the contaminated
material will be excavated and treated and the requirements that must be met by the
Contractor for restoration of the site.
2.1 Site Facilities/Site Preparation
The Contractor is required to construct and maintain site facilities that are necessary to
support the BCD Process and associated excavation activities. Specific requirements are
detailed in the contract documents. At a minimum, the Contractor shall provide the
following support facilities:
• Office Facilities for the project duration
• Electrical Power Distribution System
• Potable Water Distribution System
• Fuel Storage and Distribution System
• Telephone and Fax Service
• Site and Security Lighting
• Access/Haul Roads and Parking Areas
• Sanitary Waste Provisions
• Concrete and Asphalt pads for BCD Process and Soil Handling Areas
• Stabilized Areas for Soil Stockpile Areas
• Stormwater Management System
• Shelters for the Process Condensate Treatment System and Soil Handling Areas
The Contractor is responsible for constructing a facility as detailed in the Contract
Construction Drawings and Specifications. Figure 2-1 shows the general arrangement of
the proposed site layout. The Contractor is also responsible for operating and
maintaining the site and site facilities in a safe and efficient manner.
2.1.1 Required Utilities
Utilities required to support the detoxification of this site include electricity,
water, sanitary waste handling, fuel and telephone. Utilities will be provided as
follows:
• Electricity -The Contractor will coordinate with Carolina Power and Light to
provide an electric service to the site via overhead power lines. The
Contractor will be responsible for providing power distribution throughout the
site.
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Site Operations Work Plan Warren County PCB Landfill
• Water -Warren County will provide potable water service to the site. The
Contractor will be responsible for connecting to Warren County's existing 6-
inch line on SR 1604 and running a 6-inch PVC water main to the site in
accordance with the Contract Documents.
• Sanitary Waste Handling -The Contractor will be responsible for providing
sanitary waste handling provisions throughout the site. Since there are no
domestic waste facilities near the site, temporary facilities must be utilized.
Sufficient temporary toilets will be located throughout the site in addition to
facilities in the office trailers. Holding tanks will be necessary for the office
trailers; the Contractor will be responsible for maintaining sanitary conditions
at all times.
• Fuel -No. 2 fuel will be required by the BCD process. No. 2 fuel would be
delivered by tanker truck and transferred to a storage tank to be located on site
by the Contractor. The Contractor will be responsible for providing the fuel
storage and distribution system in conformance with the Contract Documents.
• · Telephone -'-Six (6) telephone lines and two (2) Fax/Data lines will be
required for this site: The Co~tr~ctor is respons~ble for arr~~ing this service.
2.2 Sequence of Activities
The following is provided as an overview of the suggested sequence of the major
activities required to detoxify the PCB Landfill. It is only provided as a general
guide, and the successful Contractor will need to provide a detailed project
schedule in accordance with the Contract Documents prior to commencement of
work activities. This guide is not intended to include every task or to dictate the
sequence of events.
1. Prepare and submit required plans.
2. Apply for and obtain necessary permits.
3. Establish a community involvement program for acquisition for supplies and
local labor.
4. Mobilize equipment, labor and support facilities including office trailers to the
site.
5. Perform baseline air monitoring.
6. Establish utilities to the site.
7. Clear and grub process and stockpile areas.
8. Remove existing site fencing and install new perimeter fencing.
9. Install storm water management system and erosion control devices.
10 . Construct access roads.
11 . Construct equipment decontamination areas.
12 . Construct material process pad and install BCD process equipment.
13. Construct lined stormwater pond and install stormwater treatment equipment.
14 . Excavate material from existing storm water pond until clean material is
expQsed and confirmed. Contaminated material from the pond will be
stockpiled for future treatment.
15 . Establish haul road between landfill and material treatment areas.
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Site Operations Work Plan Warren County PCB Landfill
16 . Install and have ready for operation stormwater pumping system required for
excavation areas.
17 . Excavation and stockpile of clean material on top of landfill and excavation of
contaminated material from landfill for performance demonstration tests and
Phase I excavation activities.
18. Conduct performance demonstration tests.
19. Prepare and submit performance demonstration reports.
20. Shut down site until TSCA interim permit is received.
21 . Begin detoxification in conformance with permit requirements.
22. Begin backfilling of treated material.
23 . Remove the haul road between the soil treatment process area and the landfill
and treat soil as necessary.
24. Test sediment within the stormwater management system; treat contaminated
sediment as necessary.
25 . Estal;,lish.vegetation within the excavated areas.
26. Decontaminate, dismantle _and demobilize the BCD process equipment.
27 . Decontaminate, dismantle and demobilize the storm water treatment
equipment.
28. Demobilize the temporary site facilities.
29 . Remove site erosion and sediment control devices.
30. Restore site in conformance with the Contract Documents.
2.3 Detoxification Criteria
The remediation objectives for this site are based on the clean-up and restoration criteria
developed by the State and presented in the Phase I Site Remediation Study. These
criteria form the basis for excavation and treatment of material at the site.
The established cleanup standards for this site are:
• PCBs: less than or equal to 200 parts per billion (ppb ).
• Dioxins: less than or equal to 200 parts per trillion (ppt) (TEQ).
2.3.1 Criteria for Excavation
The criteria for the excavation of any material at this site is as follows :
• All soil within the limits of the actual landfill and outside of the top clay liner
will be excavated and stockpiled as clean material suitable for general
backfilling.
• All material below the top clay liner and above the bottom clay layer is
considered contaminated with PCBs and will be excavated for treatment.
• The bottom clay layer will be removed in 6-inch lifts until testing confirms
PCB contamination is below the cleanup standards. It is anticipated that much
of the clay layer will be clean and will be left in place.
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Site Operations Work Plan Warren County PCB Landfill
• Sediment within the existing stormwater pond above the cleanup standard will
be excavated and treated. Confirmation testing will dictate the excavation
limits.
2.3.2 Criteria for Treatment and Backfilling
Treated material meeting the cleanup standards will be backfilled into the landfill.
Treated material that does not meet these requirements will be retreated by the
Contractor at his own expense.
2.4 Site Restoration
Final restoration of the detoxified PCB Landfill will be in conformance with the site
reuse intentions of the State and Warren County.
2.4.1 Equipment Decontamination, Dismantlement and Demobilization
Mobil equipment, process equipment, structures and process pads that have come
in contact with PCB contaminated material will be decontaminated, when
feasible. Equipment and/or materials that can not be decontaminated readily will
require disposal off site. Equipment will be decontaminated in accordance with
CFR title 40, Section 761.360 through 761.375, and as described in the Final
Verification/Confirmation Sampling Plan. Prior to demobilizing equipment off-
site, the equipment will be either tested for residual PCBs or visually inspected.
Equipment will be dismantled for demobilization from the site. Dismantlement
activities may include, but not be limited to:
• Cutting and burning;
• Rigging and lifting;
• De-energizing and disconnecting electrical power;
• De-pressurizing and draining lines and vessels;
• Confined space entry; and,
• Handling potentially hazardous/corrosive chemicals.
Task Assessment Hazard Analyses (TAHA) will be required for each of these
activities to prepare specific procedures for the safe implementation of each
activity. The health and safety plan contains the TAHA forms and procedures.
The process pads and stormwater pipelines will be washed down and all sediment
accumulated and analyzed for PCBs. This process will be repeated until
confirmation testing shows acceptable levels. The lined pond will be cleaned and
the liner removed. The curbing around the process pad will be removed, but the
process pad, stormwater lines and ponds will remain.
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March 2000
Site Operations Work Plan Warren County PCB Landfill
2.4.2 Final Site Grading
The final site grading will commence once detoxification activities have been
completed. The site and the landfill proper will be graded in accordance with
contract drawings. In general, the site will be regraded to the original contours
and detoxified material will be contained within the original confines of the
landfill. Various factors will affect the actual final grades including:
• Excavation bulking factor
• Moisture content of feed soil to the treatment process
• Removal of contaminants and water during the treatment process
• Adjustment of water content following treatment
• Volume of debris encountered during excavation
• Compaction of backfilled soil
The final grades on the drawings are based on the assumption that excavated
volumes will match backfilled volumes; however, due to the uncertainty
associated with the balance between excavated material and backfilled material,
the areas outside of the lined portion of the landfill should be regraded to match
existing grades and original drainage patterns. Any excess or deficit that is
realized between excavated and backfilled material should be applied to the area
inside the original limits of the lined portion of the landfill.
The improved areas outside the immediate limits of the detoxified PCB landfill
will remain. These include the haul roads, parking areas, process pad(s),
perimeter fencing, stormwater containment swales, and the two ponds.
2.4.3 Restoration of Site Vegetation
Following the final grading of the detoxified PCB landfill, the original landfill
cover (fill and topsoil) will be reinstalled. Note: the clay liner removed from the
landfill cover will be backfilled in the landfill with the treated materials.
Following placement of the fill and topsoil, the site will be hydro-seeded with a
mixture of native ground cover designed to return the area to a stabilized old field
environment. The seed mix and application rates are provided in the
specifications.
Following seeding, monthly inspections for six months will be conducted to
ensure a successful stand of vegetation cover has been achieved. These
inspections will also be required to identify and repair erosion gullies and to apply
additional seed in areas that did not support vegetation growth.
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C) :s-: -0 w 2 <{ z w _J IL e ,: ~ . ., ~~ •r0t; REGRADED EXISTING PONO NEW UNm POND STOIIMWATER PUIIP STATION i! ~ I c----------~· .. ~ ~~ HAUL ROAD " " " / / / .. r ----·· e EXISTING SECTION or F04CC TO REMAIN IN Pl.ACE. .. ----··-r EXISTING LANDFILL 8 )-.. ____ ·-----------·--·-------.. -l / '--··-··-·_:71 / / / '--'--. '--l{ _______________________________________________________ .-: :J STABIUZED HAUL ROAD Pill£ BARN .--TREATED -MATEIIIAL ----~~~!/} DJ MAlDIIAL PIID'ARAl)ON Nl£A " WIDE CURB TYP. rrmu l'II0COSUIQ MEA (IBCO Nl6J C8CO) l'IIC~ METAt. IUILDIN0"'---ON --ON 0 0 STORWWATER --10 0 ----TR£ATMEKT SYS10I Do 1 ' I 10 ~ 16' WIDE ACCESS ROAD ~ ------N~~~_AREA __ _ ----m )~L -L Nog,o·•s·w 1076.00' --~ i=i\:I ENVIROMENTAL, INC. OVERfl.OW ELEV. 317.50 SEE DETAIL ! BF A Environmental Consultants Barnes, Ferland and Associates, Inc. 3655 Maguire Blvd. Suite 150, Orlando, R.., 32803 PH: [phone] FAX: (407) ~1822 .,~~, -'"' :~ -I_ i l -~ I . -i I I i ;; j e l -~ I -i ~ J· j 1,·4-r I """""'""" ; l -~ ST AREA iJ . ~-~ ·o I er-0 ~ u j • I I ti i i . " iii ~ ~ I I Ii i ! ~ <I~ j I a, I 11 -\ lj \ l \ :1 \.NEW fr PVC WATUI MAIN .,-EXIST. PROPERTY UNE -~ ------• ACCESS CATE, SEE DETAIL ON owe~ /\( ,\ f\ ~"-=s PROPOSED SITE LAYOUT ROAD PRO..CCT NO.: 99001 SCALL, FIGURE 2-1
Site Operations Work Plan Warren County PCB Landfill
3.0 SITE EXCAVATION PLAN
3.1 Introduction
The State owns and maintains a landfill, which was constructed as a disposal facility for
material that was contaminated with PCBs. The landfill is located in a fairly remote
location near the north central portion of the State. The material that was placed in the
landfill resulted from the illegal disposal of PCBs along the shoulders of highways
throughout the state.
3.3.1 Existing Landfill Features
Figure 3-1 shows a typical cross section through the landfill. The landfill was
constructed by excavating the general shape of the landfill and then placing
approximately 9 inches of sand on the floor of the excavation. This layer of sand
was intended to protect the groundwater in the event of a breach in the
impermeable layers above by allowing leachate to migrate towards a leachate
collection system located at the northern end of the landfill at the lowest area of
the landfill.
After installation of a simple lower leachate collection system, a 30 mil PVC liner
was installed to contain contaminants within the landfill. A I-foot layer of clean
fill was placed to prevent bridging and to level the surface. A 5-foot layer of clay
was then installed as the primary impermeable layer.
Once the clay layer was in place, a final 9-inch layer of sand was placed. This
layer serves as the primary conduit for leachate contained within the landfill. A
layer of filter fabric was installed on top of the sand layer to restrict the migration
of fine soil particles that would cause blinding.
The landfill was filled starting at the southwest corner and proceeding to the
northeast corner. The depth of the landfill averaged approximately 22 feet, and it
was verbally reported that the contaminated material compacted well during
placement. Once placement of the contaminated material was complete, the cover
was constructed by placing 1 foot of clean fill on top of the contaminated
material. A 2-foot layer of clay was then installed as the first impermeable layer,
and a 10 mil PVC liner was installed on top of the clay as the second impermeable
layer. The cover was completed by placing 1 foot of clean fill on top of the liner,
ETG Environmental, Inc / BF A Environmental Consultants
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~ .. .. -":~ ~· l ;, ~-0 w L <t z w _J ,, I_) ·1 350 DISIIG CMlE i ·-·-·-+--·····------340 I·-• 330 ······-:-----3201 1 1 1 , 1 , ~ r ~·········1 ........... 1 ....................... . : __ . r 1 ~ ; ~;-2·m:nn:n:m·nmnmnn*::----:n· 310 -160 -140 ·-120 -100 -80 ....... J ........ . -60 -40 -20 y<tlMftl. ·--··~--· -·----------f--CME, - -~ 350 -I -l 340 ---i---' J30 320 --------·------~-------············••·• ___ J_ ___ _ , . . .. __ j 310 60 80 100 120 140 160 TYPICAL SECTION -EXISTING LANDFILL (EAST-WEST) lft.... .. llNLCIIID ,_Ila.__.. ... WI\' 'H trA• OI NOlnN CMaUIM 'H canw:D 11W.L. ...V Cllllnlla MCM 'H 11P INII ,_. 10 Sl'Mlll81l1CA¥A .. ACINWIS. ~~~ ~,~ ENVIROMENTAL, INC. SCALE: HORIZ.I: '\/ERT. 1 • • 1 0' .BF A Environmental Consultants Barnes, Ferland and Associates, Inc. 3655 Maguire Blvd. Suite 150, Orlando, FL, 32803 PH: [phone] FAX: [phone]YPICAL CROSS SECTION THROUGH LANDFILL PR:o...ECT NO.: 99001 = FIGURE 3-1
Site Operations Work Plan Warren County PCB Landfill
and then placing 1 foot of topsoil on top of the fill. Grass was then planted to
mm1m1ze erosion.
3.1.2 General Sequence
The bottom of the landfill slopes from the southern end to the deepest area of the
landfill, which is located in the northeast comer. In order to keep water within the
landfill from migrating from the contaminated areas to the clean areas, excavation
within the landfill will proceed from south to north. The landfill will be
excavated in ten phases. Excavation activities will proceed by dividing the length
of the landfill into ten cells. The cells are presented for volume determination and
excavation sequencing purposes only.
The topsoil and fill layers will be removed and stockpiled for future use during
backfilling procedures. The liner will be exposed and then cut in pieces for
disposal _in a sanitary landfill. As much as practical, the clay layer will be
separated and stockpiled separately_ for future use. The fill layer underneath the
clay liner will be considered contaminated and will be treated.
Excavation of each cell will proceed until the contaminated material is completely
removed. Each cell will be cut into the next cell at a 2: 1 slope so that erosion and
slope instability is minimized. Material will be removed from the cell proceeding
from east to west. In this manner, stormwater will be directed to the deeper
portions of the landfill. Once the clay layer is exposed, testing will be performed
to verify that the material is clean. Once this material is considered clean, a
stormwater diversion berm may be constructed to maintain separation between
clean areas and contaminated areas.
Once excavation of Cell No. 3 begins, the filling of Cell No. 1 can commence.
Stockpiled clean treated material will be placed and compacted into the landfill in
1 to 2 foot lifts. Compaction of each layer will take place prior to placement of
subsequent layers. The remaining layers will be excavated and filled in this
general fashion until decontamination is complete. Figures 3-2 through 3-11
shows how excavation and backfilling operations will proceed through the
landfill.
3.1.3 Design Basis Criteria
Excavation will typically proceed at a faster rate than treatment of the
contaminated material. Therefore, the provision of stockpiling areas will be
critical to the successful flow of material. Material will be excavated from the
designated cell using a standard excavator which will be of a sufficient size to
efficiently maintain removal rates. The excavator will transfer material to a
dedicated dump truck(s), which will remain in the contaminated area of the site.
ETG Environmental, Inc / BFA Environmental Consultants
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March 2000
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ii j I : I ~ 0 w L <l'. z w _J LL 0 n ( EXCAVA11011 Nl£A NO. II BA0CRJ.. Nl£A NO. II BCD f'W)CCiS 'IRFA1ED ll1ERIN. . 8/IQIRJBJ IIIO INUl1. It lMlf1/li IIBZ. I.RS ICM)SS _,,,, (T lNIRL NIJ CIJIRCIEDPER~ NORTH END SEED NIJ IU.Qf .._IDI rMIIIIC 1.M1S -/~~ .,, -.~:7:4t-s:,~ ~'>:.!'f,:.;, '-t·t.5 ~i~, . 11B1ED MC7E1ilMI. 5" --Sl.0f£ T'fP • 25" WAX Sl.0f£ 10 WA TDf DIST. TYP. AT PERME1ER 101o~m ___ x=r.. --~~.l-------------------------------------------------------#Ne ~ £JtPaSED F1CC <T PCB Ml1E1k 10 IE EXOM1E]} II A /Oll1ERN IJREr:tDi ,_ lOP DOIII .._'IERF"MIIIIC rSNC> «r QAY 1rFUMAlDUL 30 Ill. P'fC II011llll I.et r SAND #Ne £JtPaSED F1CC '1RDJE1) MVEllNl 10 IE BIOlllB) It A IOf1IE1IJI IJRr:tDi ~ ~ ~ 101' OF<& PCB INalJ.IIER SOUTH END SECTION -EXCAVATION AREA NO. 8 : BACKFILL AREA NO. 6 ii ('I .., N 476'± , 1,. .,·5'TJ!!:'. <F ~~~-~ ~~---·--·~f-·Fl:JER--:~;:~:~·:t:::~~~\, .. \ \ ---:-::1.:// j>,----~ ~~------t·, , ' ' I _, _ = _ CCC j / · . _ -~-=~: ::;---.,,:: \ \ \ / / . I .: I' ii~ .. ~-~•/,I •~hfflf',,ft--.:--~ ' 'j\ . \ i l I,\ -=----=:. .. .. I I I i J' ---...,.. \ \ \ I ; r • I PROFl£ LIE \ \ \ 'i ; i : i ; : II •. ! : . ! I I I I \ \ l I : j ! ' : i I I ! ' ) I I I I : i ! I~➔--+ i 7-; ++ !1 I i 1 ; ; I I ' It !I ' '. ·: / / / ) : I ; I l . ~\ll ··,,,'.'\II . ' · •,\1 -~-·I· ','·\\ .. ,. .. ·--· -,..,.._.~4)~~··· --·· -··. --·--.. --~ ;-(_/>)I; ~:~-1¥-· ~;----------------~ -/ ; ' ' \ ./ / / / 11 '11 ! ' --·-'-.-~ / I•------· __ ......._ _/ , ' I ' ' I --·---/i! l, I •I~'-., --=---=----- -~-··· . --. -· ·--OIJ1lH2 ~/ I \\,'-<~--:.::_ ____ _: _____ ~ . ·-----liJWfR-1.IIER \ \',,,>, -----. -------~ -----1~~:-\~:~>i;~:~~-=-=_-_ ·_ -.:. =-~--= ~----------.. ---.. -,., ------------·--------EXCAVA 110N / FILL KEY PLAN SCALE: 1. g50' __ _.... a;;;j\j ENVIROMENTAL, INC. SCA!£: 3/16"-1'-o" EXCAVATION ANO BACKFILL ·TABLE ·TOTALS MC1Bill. 7)f£ IBD1DI a'JIIPSOl trlll.Ml&llll ·,< I 1(/ -ltC 10P UEJt N'QI/T ,r Ill. MIISlllt ,a ~ MCIEK IUERRSIC r.-r QlfT ,r Ill. MVEK .1tJ Ml ltC IOf1rJII llER r.-RJIIS>MCIEK QIJWT1T'f '1411 .1tJIJ# ,10 ltS nvironmental Consultants Barnes, Ferland and Associates, Inc. 3655 Maguire Blvd. Suite ISO, Orlando, f1_, 32803 PH. [phone] FAX: [phone] INTS OF IIEAS'IRJEJfT MC1E1K IIWUIG / FM. USE .tr. C.[ c.r; .tr. c.r. c.r. c.r. s:r. c.r. c.r. c.r. s:r. c.r. C.l SIIF MJ SIOt:1(J'I£ / Ill. StlF -SIOt:1(/'I£ / Ill. sa, -SIOt:1(/'I£ / Ill. IIBOC MJ aBllt / /JtSPQSC If tuSS I IIIIOU StlF -SIOt:1(/'I£ / /LOO -Dll6l Ill. BCDIEIIIIDf"/lf.l. BCD 1IIBllE1iT / Ill. IIBOC .-, aBllt / DtSPQSC If tuSS t IIIIOU BCD 1IIElf1IE1IT / FU IIBOC r LOfJI BCD '1IEXltE1IT / Ill. lDl£lfPUCE lDI£ If PUCE lDI£ If PUCE -.J.AllfJll«lf PHASE 8 EXCAVATION ACTIVITIES ~O..ECT NO.: 99001 = FIGURE 3-9
~ 0 w 2 <( z w _J u.. 0 0 --f _) ~ /IIO(/fJ..Mf.lllD.. 7 ,sm, NI} ILfDI ID) l'fDCESS 1REA1ED M41E1K /IIICKFlHD 1111D LWR1. N REJtRE>OCE P<JHT IMRIIII WJRIZ. tnS AClitl5S /fL'IEII F.aAIC u,r,s am, (F LWR1. NI} I I \ I COll'J/C1E1) PfR SPHS. -1 ,_-. 5UlF£ I 7. TIP. 25S MAX 5UlF£ 10 MA 10i DIST. TlP.ATPERIMElIR ---..... , .... _.-..::_ ------~ ~-------,11;;;~" ------------------... -------. .• ..-~"-,.,.s :c;,, • 1REXIEDM11E11Nt. NORTH END -------~----------------------------------------------------------------------,_ __ W QAY 12" FU. MA1DIIJoL :,c).._PIICIIOTla.ll..at ~ SAIC) 476'± /DIC: EXl'05ED F1t:£ 1REA1ED MaE1IMf. 10 IE BIOFl1B) II A IIOltl1DN IJIIEDDf 1lJE ~ ., /' -----. ·-~ ~ ~ SECTION -BACKFILL AREA NO. 7 SCAt£: J/16°-r-o· ~ '/fP<Far;. PCB INIR.1 LIER ---SOUTH END !Ill~ .___---·--··-~ ----._ . >"" \\ \ // ~-' --__:~~-;___~---·_··_______ -----~~~ ----.>!',, ___ \ ! BACKl-lll TABLE ~--"---++,t'-1/c.+-;.,;,l(?,...;;~':,-.. -:.:.:-::.~-::.:::;ffl -=--=-=-=-~------~--===:=-~:.::~~:~ ::.<>~:~:;\ \ ' 'I I I -+i .,. ,,, N ··11/,~i!/'· --~--~--= . ),/1\ \: I ,, I ----· _JD£ 1-1 I ,./III i rJ.-;;;:::-_===-=~~-=-~---.. -::::._::-~~..:::. _--~_-e-::r !( :W PROFlE UE . I I -----' : / , I 1 . · ----"' \. \ · I ! i . i \-"',ft+< -------------· . ...;,_.J___._ ..:..i.J~ --.. '\ \1 I =--·----BJFmM---' j I i i i ! I ' ~\~\\ M----=-.-----~-=:_--~~-! : "-, °!\\''' ~------I '..._\~ \' \ ~----'---+~~ ~~r------------==~::::.:.==.:::.:..~~ : \ '~t. ---------~~=,~~-=-=-~-,;) ' i: I \ ~ ~---=-:. ______ --"' --:=::°:::=:=:=:=:=:==::: ____ ._, --~ _,.' : ,\ ___ \", __ ,::~;~::~-=~-:_~----·· _____ roe.a:~~-----. ----L~, ~.. ..... .. ---,.. -. ----EXCAVATION / FILL KEY PLAN SCAl£: 1. =50' !J!!lla~~ s:;1\a ENVIROMENTAL, INC. MlBK m!' QUWIT1Y IBEll7ltW -,r IIIP.Sl:ll -I ,r Fil --•A 10 M. ltC 111P UER -:K'aAY -U'IILMll!lk -/Jal~--FVER RIIRC -r.wo -.,. aAY -,r Fil Mll!lK -JD M. ltC /IOT1QI UER -,. .WO -'/IIEJl1fD--.BF A Environmental Consultants Barnes, Ferland and Associates, inc. 3655 Maguire Blvd. Suite 150, Orlando, R.., 32803 PH: [phone] FAX: [phone] IIIIS !F IBSIIEJEJIT M1BK Hl/laMG / 111M. lJ!i£ .tr. sa'MJ~/Fll er sa'MJ~/Fll er. SIIPMJ~/Fll .tr. ma£ M) aBllt / DtSP05E II aASS I UID'U er. SIIP MJ ~ / IIIBIJ -DOER Fil er. IDl1IERIEJIT/Fll er. BCD 1IERIEJIT / Fil .tr. ma£ Ill) aBllt / DtSP05E II aASS I UID'U er. BCD 1lllRIEJIT / Fil er. ma£ r uisr BaJ 'fll01IBl1 / Fil er. lDII£ II /11,fCC .tr. lDII£ II /11,fCC er. lDlt£ II /11,fCC Ct /J/IOf1I.J. -II0.1 PHASE 9 EXCAVATION ACTIVITIES PRO-.ECT NO.: 900Q1 = FIGURE 3-10
0 3: 0 w L <( z w ...J LL 0 0 <l'. u WtDEXr IXJST CIJN11D. -.M-\ SEED NIJ laDf WO(FIJII) llf10 INDU Ii R£rnlD<E POl<l llfiJRI/ #alZ. IRS Aail'J5S /"-lDI FABRIC lMlS WDDIOFIND'UNIJ ,_ BCD PIIOC6S 1REA1ED IM1E1IIM. CtJIBDBJ PER 51'8:S. ~~~i~~pr ----. i~~_i-, ---7, ~2@ ·, ---~.-,; 'T1E»ED ltM1ERML ------'~~~ ----,:(.;~~~~ t:1..5 ---iwt~ -----------------------------------------------------------------------------------;{'(Y.;~~-tK~ ~ ~ ~ ~ ~ 51'-1;l.OP£ ""· NORlH END ,_ 1111' DCMI tc1' CUY 1r fll MAlDIIM. ,a> OFQIC PCB /Nal.J..IIER SOUlH END :,o IL PIIC IIOT10II I.a ---SECTION -BACKFILL AREA NO. 8 476'± ~' __ ,::/~:,/ •• -~ --------·-~ :~~---: ~---..... ~~~~ i. --/ / ----------6l/lll,/£<Jr -------~ ,\ \ / -------=------__ ,,.,.. _.✓/,. -----------------"" ...... \' \ IKJ. 8 ....__ /// ,,,Y.,----==--:-.-::-..--....::· --~--'-/~-------_____ f-F1.-1ER--~--:--:_----...._" \ \ \\ \ ----~ ---------......... ~, ' \ \ \ ' \ ~ N .., N --·-•-------.., •• \ \ •'1\ I ( ,.--_. ----· .\\\ \' I ----•:•11,\ --· \·I , . -----. , I -----~---, 1 ,, ·1 , -~----· ----· .LIA.----'-! i , . I I ! -----------= --· \ I I , ! i : PROFl£ LIE 'I l/'11\ '::: ---~-~--_:----"',, \ \ \ 1· :, :,I,:: ljf; 11_ :: / 1 ----· --• , 1 ~ I , 1, , / / ----.-·------,. \ \ 1 \ J..j ! : , •1.J . I -·• ----+-~-+--,--1--,--j ' I ' -/"T"r.-'f"til1; . ---------· ' , I I i . ! . I I \ "'1 tKllTOI/ j / k 1';1 i I ' \ ------------j :' I ! ! I I I : I \111 -··----=---:-=~~ i ::\~1\ -----~ ---~~--~=--=~ -------= / ;~ /)}.J ! \ \'.\\ ~-------------------·-··· __ 1 · / / . I 11 I 1,•11 ~---------·' ' .' I ' -,~:~~~~;~· ~~~~_c -t~c:"~-c==.-:'. __ ..: =:.!=~~-_-: -~.;ii EXCAVATION / FILL KEY PLAN SCALE: 1 • -so· __ ._ j;j\:1-ENVIROMENTAL, INC. SCA!.£: J/16°=1'-0° BACKALL TABLE AM1EJN.nPE (1JMl1l1'f IBEilllW -,r D>5Dl -•A• I f¥'11lMl!lK -,o ._ l"I/C D' llER -N'aAY -,r Ill Ml1!lillll -PCB~ Ml1BIK -IVBIRIIIII: -rSIIO -Id' QAY -f¥' Ill M1l1W -JO._ l"I/C BtmDII UEII -r SIIO -~MIEIW -Environmental Consultants Barnes, Ferland and Associates, Inc. 3655 Maguire Blvd. Suite 150, Orlando, FL, 32803 PH: [phone] FAX: [phone] IM1S (F IEASIIIBEllf AM1EJN. HMaMC I FfW. USE sr. SIIF Jl#J SIOt:lfl1I£ / Ill c.r. Sl1F Ml SIOOR£ / Ill c.r. Sl1F Jl#J SIOt:lfl1I£ / Ill sr. ~ Ill) QDlt / OIS1'0SC # tlASS I IMHl c.r. Sl1F Ml SIOt:lfl1I£ / lUJD -OIIER Ill c.r. BCD 11IDTIIEJtr / Ill c.r. BCD 11IDTIIEJtr / Ill sr. ~ Ill) QDI( / OIS1'0SC # QASS I IMHl c.r. BCD 1IIEJUIBlr / Ill c.r. l&l:JIE I' LAlfR B:IJ 11l91IEJIT / Ill c.r. IDKltl'Ut:C sr. lDII£ tit FUt:C c.r. IDI£ It FUt:C C.[ /IIIOIR1. MD 1126 PHASE 10 EXCAVATION ACTIVITIES PRO..CCT NO., 99001 = FIGURE 3-11
Site Operations Work Plan Warren County PCB Landfill
The dump truck(s) will proceed from the west end of the cell along a haul road
located on the west side of the landfill. Material will be weighed on a certified
scale prior to being dumped onto the material preparation stockpile area prior to
processing. A front-end loader will be utilized to transfer material from the
stockpile area to a screening plant equipped with a 2-inch mesh screen, which will
remove larger materials from the waste stream. An incline transfer conveyor will
take the screened material and transfer the material to a pugmill plant for blending
of BCD reagents with the screened material. The incline transfer conveyor is also
equipped with a magnet to remove magnetic materials from the contaminated
materials. BCD reagent will be blended at a ratio of 2% to 5% with the
contaminated materials. The blended materials will be transferred via transfer and
radial-stacking conveyor to a blended stockpile area. The material preparation
stockpile area will be sized for 2 days CBCD and BBCD production storage and
the blended stockpile area will be sized for 5 days of CBCD and BBCD
production storage.
Blended material will then be processed through either the BBCD or CBCD
systems. Processed material will then be stockpiled at the south end of the
process area. This area will be sized for· up to 14 days. of storage for the CBCD
processed material and up to 30 days storage for the BBCD' proc.essed material.
Once analytical results are received verifying that the treated material is below the
treatment standard, this material will be transferred to a separate stockpile area
located at the south end of the landfill. This area will be sized to accommodate
the maximum void volume before backfilling can commence. From a logistics
point of view, the amount of material which will exist within the process and the
stockpiling areas will need to approximately equal the amount contained within
Cells Nos. 1 and 2. As stated previously, once excavation on Cell No. 3 begins,
the backfilling of Cell No. 1 can commence.
3.2 Quantities
Material quantities have been estimated based on record information provided by the
State of North Carolina regarding the construction of the original landfill. Estimated
quantities are provided so that general equipment sizing activities can occur. The
payment to the Contractor will be based on the actual quantities treated as measured in
tons by the certified truck scale.
3.2.1 Clean Material
Clean material will generally include all soil including and above the top landfill
clay liner excluding sediment within the existing stormwater pond. This volume
of clean material to be excavated is estimated as follows :
Material Type Quantity
Vegetation 12,866
12" Top Soil 3,471
12" Fill Material 3,471
10 mil PVC top liner 12,866
24" clay 6,942
ETG Environmental, Inc / BF A Environmental Consultants
25
Units of Measure
Square yards
Cubic yards
Cubic yards
Square yards
Cubic yards
March 2000
Site Operations Work Plan Warren County PCB Landfill
3.2.2 Contaminated Material
The contaminated material will generally include all of the material below the top
landfill clay liner and at a minimum six inches into the lower layer of clay. The
contaminated material will also include sediment within the existing stormwater
pond. The volume of contaminated material is estimated as follows:
Material Type Ouantitv Units of Measure
12" Fill Material 3,471 Cubic yards
PCB Contaminated Material 34,029 Cubic yards
Filter Fabric 12,629 Square yards
9" Sand 3,601 Cubic yards
6" Clay removal of 60" Clay Liner 2,592 Cubic yards
3.3 Environmental Controls
The Contractor will utilize various environmental controls to protect both on-site
personnel and the surrounding community. At a minimum, the Contractor will
implement dust suppression controls and erosion and sediment controls. In addition,
demarcation zones will be provided between clean areas and contaminated areas to allow
decontamination of personnel and equipment.
3.3.1 Dust Suppression
Since PCBs adhere to the soil particles, the dust generated from the material
handling activities must be kept to a minimum. It will be the responsibility of the
Contractor to recognize when dry conditions have the potential of generating
excessive dust and to implement dust control measures as necessary. In general,
wetting of exposed soil with clean stormwater (when available) will be utilized
for dust suppression. The Contractor must provide equipment for applying water
for dust suppression purposes. Also, in the event that clean stormwater is not
available, the Contractor must provide sufficient potable water for this use.
3.3.2 Erosion and Sediment Controls
The Contractor is required to conduct excavation activities in a manner that will
minimize the effects of erosion and the transport of sediment from exposed areas
of the site. The Contractor shall develop an Erosion Control Plan which will
incorporate erosion control devices required by the construction drawings and by
the State of North Carolina's requirements for erosion and sediment control (refer
to Erosion and Sediment Control Planning and Design Manual, NCDEHNR).
[Soils that will be exposed for more than 14 days shall be stabilized by fabrics or
should be seeded in accordance with the specifications.] At a minimum, the
following erosion and sediment control methods shall be incorporated into the site
management in accordance with the construction documents:
ETG Environmental, Inc / BF A Environmental Consultants
26
March2000
Site Operations Work Plan Warren County PCB Landfill
• Stabilized access roads
• Stormwater collection and retention areas
• Silt fences and hay bales
• Diversion dikes
• Overflow structures
• Swales and rock-lined channels
The Contractor is responsible for installing and maintaining erosion and sediment
control structures in accordance with the construction documents. Additional
erosion and sediment control measures, which may prove necessary, shall be
installed in accordance with the Erosion and Sediment Control Planning and
Design Manual, NCDEHNR.
3.3.3 Demarcation Zones
Demarcation Zones will be provided to allow for the decontamination of
personnel and equipment that will be leaving contaminated areas. Demarcation
Zones intended for use by personnel shall include provisions for washing down
outer clothing and boots with a low-pressure water source. The area shall also
have receptacles suitable for disposal of any disposable-type protective wear such
as coveralls, gloves, boot covers, or any other item which may be required.
Demarcation Zones intended for decontamination of equipment shall be sized to
allow for the placement of the intended equipment entirely within the designated
area. The facility shall be equipped with high-pressure low-volume pressure
washers capable of cleaning construction vehicles in an efficient manner.
Contaminated materials washed off during decontamination shall be collected in
the contaminated stormwater management system for discharge into the lined
pond for future treatment.
3.4 Support Facilities
Areas of the site will be developed to support the various activities associated with the
detoxification efforts. These areas include Material Storage Areas, Vehicle Management
Areas, and Detoxification Areas.
3.4.1 Material Storage Areas
Contaminated material is processed at a continuous, but slower rate than the rate at which
material can be excavated and transported from the landfill. Also, it takes time to
sample and confirm that detoxified material has been treated to the treatment
standards. For these reasons, areas are needed throughout the site to stockpile
material as it travels through the process. Three main stockpile areas will be
needed: excavated material that has been screened and is ready for treatment,
processed material that has been tested to confirm treatment levels, and material
that is waiting to be backfilled into the landfill.
ETG Environmental, Inc / BF A Environmental Consultants
27
March 2000
Site Operations Work Plan Warren County PCB Landfill
In order to maintain a steady processing rate during periods of inclement weather
or excavation equipment problems, a 5-day stockpile area shall be provided in
between the material preparation facility and the feed conveyor for the BCD
process. The 5-day period was chosen to allow for adequate time after a severe
storm event to remove standing water and to allow dewatering procedures to
proceed.
Confirmation sampling and analysis is a process that takes up to two weeks for
completion. The stockpile area after the BCD process shall be designed to
accommodate up to two weeks worth of processed soil. The area shall be
separated into individual holding bins. Each bin shall be capable of storing up to
two-days of processed soil for the CBCD system
Treated material will be backfilled into the landfill once there is sufficient
capacity and separation between the cells. For this reason, a stockpile area shall
be provided at the south end of the landfill to allow for interim storage. This area
will also allow for interim storage of the clean soils stripped from the landfill
cover (topsoil, fill and clay).
3.4.2 Vehicle Management Areas
Vehicle Management Areas shall consist of access roads, parking areas and haul
roads. Access roads and parking areas will be considered clean and will be
constructed -0f a stabilized subgrade, a geotextile and a gravel surface. [Haul
roads for clean material will be constructed in a similar fashion to the access roads
and parking areas. Haul roads for contaminated material will also be constructed
in a similar fashion to the clean haul road, but all drainage will be diverted back
into the landfill.]
3.4.3 Detoxification Support Area
The support areas for the detoxification system include the following:
• asphalt area for material preparation
• concrete slab for the BCD process
• asphalt area for treated material stockpile
• pole barn for weather protection of prepared contaminated material
• pre-engineered metal building for PCSAPT System
• administration trailers
• guard house
• stormwater containment and treatment system
A description of each area is provided in the following:
ETG Environmental, Inc / BF A Environmental Consultants
28
March2000
Site Operations Work Plan Warren County PCB Landfill
Concrete Slab for the BCD Process: An impervious concrete slab shall be
provided for material processing and support of the BCD Process. The slab will
have a continuous curb around the perimeter to retain stormwater.
Asphalt Areas for Material Preparation and Treated Material Stockpile: The
asphalt area will be provided adjacent to the concrete slab. The function of these
areas is for storage and handling of prepared and treated material. The asphalt
area will also have perimeter curbing to retain stormwater Stockpile areas will be
separated by prefabricated concrete barriers commonly referred to as Jersey
Barriers. The areas will need to be designed to accommodate earth moving
equipment and to support the anticipated soil loading.
Pole Barn for Weather Protection of Material Handling: In order to minimize the
moisture content of the material prior to treatment, a shelter will be provided to
cover the area where the prepared material is stockpiled prior to treatment. The
shelter, commonly referred to as a pole barn, will be designed to allow 22 feet of
clear operating height.
Pre-Engineered Metal Building for PCSAPT System: A pre-engineered metal
building shall be provided for the PCSAPT system. The building will be sized as
shown on the construction drawings. The building shall have an inside height of
20 feet. The building shall also have two coiling-type doors that are 12 ft. wide
by 16 ft. high and one access door. Standard lighting and ventilation shall be
provided, but heating and air conditioning will not be needed.
Administration Trailers:
Trailers will be provided as follows:
Designation
Contractor
State
Decontamination
Employee
Personal Protective Equipment
Parts
Electrical
Control
Guard Shack
Function
Administration and Management
Administration and Management
Employee Decontamination
Employee Meals and Breaks
Storage of Employee Safety
Equipment
Parts and Supplies Storage
Electrical Distribution System
Housing
BCD Related Process Control
Equipment Housing
Security
Typically, these trailers will be leased from local suppliers.
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Stormwater Containment and Treatment System: In order to mm1m1ze the
potential of PCB contamination, the concrete and asphalt areas that will be
provided for the BCD process and for material handling will be designed to
capture stormwater runoff. An enclosed stormwater collection system will be
provided with sufficient inlets to prevent ponding during storm events. All
collected stormwater will be conveyed through a gravity piping system and the
lined stormwater retention pond. The lined stormwater retention pond will be
provided with a 30 mil polyethylene liner to prevent contamination of the
underlying materials.
The stormwater collection and retention system will be designed to accommodate
a 100 year, 24-hour storm event. A stormwater pumping system will be provided
to pump retained stormwater to a stormwater treatment system. The pumping
system will be designed to operate at a rate sufficient to empty the pond in a
three-day period. Two pumps will be provided; one pump will operate and one
pump will be a standby unit.
The stormwater treatment system will consist of sand filters followed by carbon
filters. The sand filters will remove suspended solids and the carbon filters will
remove any organic compounds. Sufficient units will be provided so that one unit
can be taken out of service without disrupting operations.
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4.0 BASE CATALYZED DECOMPOSITION (BCD) DETOXIFICATION
PROCESS
The PCB landfill detoxification project combines the use of thermal desorption with solid
and liquid phase BCD technology to completely dechlorinate the contaminated material.
The BCD detoxification system will include the following:
1. A reagent blending system consisting of a certified scale, screening and reagent
blending plant, and stockpile areas.
2. One continuous solid phase BCD/thermal desorption unit (CBCD)
3. One batch vacuum solid phase BCD/thermal desorption unit (BBCD)
4. Two air pollution control systems or vapor recovery systems (VRS), one each for
the CBCD (CBCD-VRS) and BBCD (BBCD-VRS),
5. One process condensate separation and aqueous phase treatment system
(PCSAPT), and
6. One liquid phase BCD detoxification system (LBCD)
The operation of BCD detoxification process is described in this section.
4.1 BCD Detoxification Process Set Up
The selection and procurement of the BCD process system components will be initiated
upon project award to allow ample time for manufacturing and delivery of the systems to
the site. Delivery of system components to the site will commence after construction of
the process pad.
The larger process components ( e.g. CBCD and BBCD) will be delivered to the site first
to facilitate ease of placement. Placing the equipment includes:
• mark the placement location,
• determine rigging requirements and follow safety protocols,
• lift the equipment and set into place,
• level the equipment, and
• anchor/secure the equipment.
Once the process equipment is set, auxiliary components (conveyors, pumps, tanks, etc.)
will be placed. Installation of the equipment includes, but is not limited to, the following:
1. Duct work and Piping,
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2. Structural Steel
• Walkways
• Ladders
• Platforms
• Supports
• Building enclosures and/or roof covered areas
3. Utility Connections
• Water
• Air
• Electrical equipment, conduit/wiring
• Fuel oil
• Nitrogen
• Propane
• Lighting
4. Instruments,
• control wiring,
• control stations
To facilitate ease of installation, the larger process equipment components will be set in
place prior to constructing the building enclosures and roof covered areas.
System components will be checked and inspected once installed and energized.
• Motors will be started and checked for proper rotation, voltage, phases, and amperage
draws.
• Piping, where applicable, will be pressure tested and/or checked for leaks.
• Equipment will be tested for proper mechanical/electrical functions .
• Instruments will be calibrated and tested for proper function.
• The control system will be tested for proper indication and actuation.
• All subsystems including utility systems will be tested for proper functioning.
• Vendor representatives will inspect their equipment for proper installation and
provide startup assistance.
4.2 Performance Demonstration Test
The purpose of the Performance Demonstration (PD) Test is to establish that the solid
and liquid phase BCD systems, while operating at maximum throughput, will meet the
material treatment standards, North Carolina air regulations, and to obtain an operating
permit from Toxic Substance Control Act (TSCA). A Performance Demonstration Plan
(PDP) will be developed by the Contractor and submitted for the review and approval of
NCDENR, EPA, and other regulating bodies as dictated by NCDENR. A draft PDP has
been developed and is part of the Bid Specifications.
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Three PD tests will be performed for each of the three systems (BBCD, CBCD and
LBCD). A rigorous monitoring and sampling program will ensure that the requirements
are met for all systems during , full-scale operations. The following plans reference
specific procedures to be incorporated into the PD testing:
• Health and Safety Plan (HASP) for all health and safety issues including personal
monitoring and sampling.
• Performance Demonstration Plan (PDP) for specific sampling and analytical
requirements including stack testing.
• Air Monitoring Plan (AMP) for monitoring and sampling procedures.
• Final Verification/Confirmation sampling Plan (FVCSP) for sampling and analytical
procedures including quality assurance (QA) and quality control (QC) issues
pertaining to sampling and analytical procedures.
• Contractor Quality Assurance Plan (CQAP).
• Emergency Response Plan.
• Community Outreach and Involvement Plan.
The PD test will follow the following sequence of activities:
4.2.1 Contaminated Material Preparation:
In accordance with the excavation plan described previously in this plan, the
southern end of the PCB landfill will be uncovered and PCB contaminated
material excavated. The excavated material will be transported via trucks to the
screening and blending plant. The material will be weighed using a truck scale
that has been certified prior to staging at the screening and blending plant.
Sufficient material will be excavated to perform the ramp up test on the CBCD
and the three PD tests to be performed on the CBCD and BBCD systems.
Samples of the staged excavated material will be collected. The samples will be
screened in the field for PCBs using the immunoassay kits and analyzed for
moisture content. In addition, samples will be submitted to a laboratory for PCBs,
dioxin/furans and hazardous waste chemical characterization. The PCB and
dioxin/furans analyses provide data on the concentration of the PCBs in the
material, and the hazardous waste chemical characterization will confirm that no
other chemicals of concern exist in the PCB contaminated materials. It is desired
to perform the PD tests with materials representative of the levels of PCBs
anticipated to be encountered throughout the project. If the material excavated is
not of sufficient PCB concentrations then it will be spiked with PCBs. Materials
with a moisture content greater than 15 percent will be treated in the BBCD
system.
The staged material will be loaded into the hopper of the screening plant
containing a maximum screen mesh size of 2-inch by 2-inch. Material not
passing through the 2-inch by 2-inch screen will be discarded into an oversize
pile.
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Material passing through the 2-inch by 2-inch screen will pass under a magnet to
remove magnetic materials. Magnetic material collected on the magnet will be
removed manually and placed in a stockpile for future decontamination and
disposal. The non-magnetic screened material will be transferred to the pug mill
plant where BCD reagents will be blended at a ratio of 2% to 5% by weight.
4.2.2 Clean Material Testing
The purpose of the clean soil testing is to verify mechanical operation of the
CBCD and BBCD systems. Prior to operations with contaminated materials, both
CBCD and BBCD systems will process clean soil for a minimum of 8 hours at
anticipated feed rates and retention times. This amount of time is the minimum
needed to ensure that all system components are functioning properly.
Key information to be collected for the CBCD includes: soil feed rate, clean soil
moisture content, soil exit temperature, and material handling and vapor recovery
system (CBCD-VRS) equipment performance.
Key information to be collected for the BBCD clean soil test includes: batch
volume, vacuum at the hot cyclone inlet, soil temperature versus time, and
material handling and BBCD-VRS equipment performance.
Approximately 10 to 12 tons of clean soil will be processed in the BBCD system
and 60 -200 tons of clean soil processed in the CBCD' system.
4.2.3 CBCD Ramp UP Test
The purpose of the CBCD ramp up test is to determine the highest feed rate that
will still produce material meeting the soil cleanup standard of 200 ppb PCBs.
The CBCD VRS system will be started in reverse order [flameless thermal
oxidizer (CBCD-FTO) to quencher/scrubber]. The control system will be started
and verified that read out points are operational. The continuous process monitor
(CPM) will be started and verified to be calibrated and operational. The common
systems, such as the cooling tower, chiller, fuel delivery, air compressor, and
make-up water will be started and verified to be operational. The CBCD desorber
will be preheated to an inner shell temperature of 1,500-1600 °F. Once the
CBCD-FTO and CBCD desorber have reached temperature the ramp up test can
commence.
The ·feed rate of the contaminated material into the CBCD desorber will be slowly
increased to maximum throughput conditions. The Contractor will collect
samples, as necessary, of both contaminated material and treated material and
analyze them for PCBs using the immunoassay PCB test kit. The field testing
results will indicate the highest feed rate that will produce material at or below the
cleanup standard. The ramp up test may take 24 hours or more to complete. The
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CBCD system will then be shutdown for analysis of the operating data to
determine optimun conditions for the PD tests. In parallel with this analysis, PD
testing of the BBCD system may begin.
4.2.4 BBCD PD Testing
Similarly to the CBCD system, the BBCD-VRS, process monitoring system ,
CPM and common systems will be started and verified to be operating properly.
The stack testing subcontractor will setup for the collection of gases entering the
BBCD-FTO and off gases from the BBCD-FTO. A known volume of
contaminated material will be loaded into the BBCD desorber (approximately 10
cubic yards). Once the BBCD-FTO is at operating temperature and all other
processing components verified to be operating properly, heat will be applied to
the BBCD desorber. Applying heat to the BBCD desorber will indicate the start
of the PD test.
The batch will be operated for a predetermined time based on the contaminated
material moisture content, and the data generated during the clean soil test. At the
end of the batch run, the heat to the BBCD desorber will be cut off. To unload the
treated material, the rotation of the BBCD desorber will be reversed. The treated
materials will be discharged into the BBCD discharge/cooling screw where water
will be added for both cooling and to recondition the materials to a moisture
content of approximately 10 percent.
The conditioned treated materials will be deposited on to the BBCD radial stacker
belt conveyor. The BBCD-radial stacker will deposit the treated material into a
stockpile in the treated material stockpile area. A composite sample to be
analyzed for non-volatile compounds and two grab samples to be analyzed for
volatile compounds will be collected from the treated stockpile. The PDP
describes the specific analyses to be performed and the QNQC protocols to be
followed.
While the treated materials from the BBCD desorber are being unloaded, cooled
and conditioned, the process condensate collected during the PD test will be
pumped to the PCSAPT system. The PCSAPT system is described in detail later
in this Plan
It is anticipated that the first BBCD PD test will be completed within 9 to 12
hours. The second and third BBCD PD tests are expected to occur during the two
days following the first test.
4.2.5 CBCD PD Testing
Once the BBCD testing is compete the first of three PD tests will be performed on
the CBCD system. The same equipment start up procedures employed for the
CBCD ramp up test will be used for the PD test. In addition, the stack testing
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subcontractor will setup to collect gases prior to the CBCD-FTO and off-gases
from the CBCD-FTO. The PDP details the specific samples to be collected and
analyses to be performed.
Once the CBCD desorber reaches temperature, contaminated material will be
processed at the predetermined (from the ramp up test) feed rate. Once the
process conditions reach steady state, the PD test will commence and stack testing
will begin. The CBCD will process contaminated materials for sufficient time for
the stack testing samples to be completed.
Unlike the BBCD system, the rehydration of the materials and treatment of the
process condensate operates continually. The rehydrated materials exiting off the
CBCD discharge stacking conveyor will be segregated into four distinct
stockpiles. A composite sample to be analyzed for non-volatile compounds and
two grab samples to be analyzed for volatile compounds will be collected from
the treated stockpile. The PDP describes the specific analyses to be performed
and the QNQC protocols to be followed.
It is anticipated that the first test will be completed within 9 to 16 hours of starting
up the CBCD desorber. In between PD tests, the CBCD will most likely be kept
at or near temperature. All three PD tests will be conducted at maximum
throughput operating conditions. The second and third CBCD PD tests are
expected to occur during the next few days following the first test.
4.2.6 . LBCD PD Testing
The goal of the PD testing for the LBCD system is to demonstrate that the
contaminated organic liquids from the BBCD ano CBCD process condensate will
be treated to the required criteria (less than 2 ppm PCBs). Therefore, the PD test
for the LBCD system will most likely be performed after the BBCD and CBCD
PD tests are completed in order to collect the largest quantity of organics to be
treated in the LBCD system. The collected organics will be sampled from the
LBCD Organic Feed Tank and screened for PCBs using the immunoassay PCB
test kit and a split sample submitted to a laboratory certified to perform the
analysis. If sufficient treatable organics are not generated during the BBCD and
CBCD PD tests then the organic liquids will be spiked with PCB oil to achieve
the desired PCB concentration levels.
Samples of the organic mixture from within the LBCD reactor will be collected
and screened for PCBs using the immunoassay PCB test kit to determine the
completion of the LBCD process. At the end of the batch, process oil samples
will be taken and submitted to a commercial laboratory for detail analysis
according to the PDP.
A single PD test is anticipated to be completed in 12 to 16 hours. The second and
third LBCD PD tests are expected to occur during the next few days following the
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first test. Critical process control data will also be monitored and recorded as
described in the PDP.
4.2. 7 Performance Demonstration Report
The Contractor will be responsible for compiling data from the PD tests and
preparing a Performance Demonstration Report. The suggested outline of the
Performance Demonstration Report can be found in Appendix G of the PDP. The
Performance Demonstration Report will provide sufficient details of the process
operating parameters, feed characteristics, performance results, and quality
assurance and quality control results to obtain a TSCA permit (interim and full-
scale) and satisfy the treatment standards for the project along with State of North
Carolina Air Regulations to begin full-scale operations
4.3 Interim Operations
The BCD detoxification system . will be shutdown until a TSCA operating permit 1s
received. According to Mr. Winston Lue of the office of Pollution, Prevention, and
Toxics, an interim permit may be issued to shorten the downtime between the conclusion
of the PD test and the startup of the full-scale remediation operations. Factors affecting
the review process for both the interim permit and full-scale operating permit are:
• Turnaround time for the stack testing res_ults and laboratory analytical results;
• Submission and quality of the Performance Demonstration Report;
. • Quality As~urance and Quality Control of the analytical data;
• Consistency of analytical results collected from the three PD tests;
• The analytical results versus the treatment standards (air and treated materials).
• Mechanical performance of the processes (consistency, accuracy, instrumentation,
operating parameters, etc.)
A recommended procedure to expedite the TSCA permitting process starting from the
completion of the PD test to issuance of the interim and final permit is included in
Section 10 of the PDP.
It will be the Contractor's responsibility to secure the site during all down time periods,
including between the PD test and the start of the full-scale operations.
4.4 Full Scale Operation Material Preparation
The material preparation area includes the following:
• Certified truck scale with recorder;
• Excavated material staging area on the process pad equivalent to two days of
processing through the BBCD and CBCD systems;
• Screening plant equipped with 2-inch by 2-inch mesh screen, hopper and transfer
conveyor(s) with shrouds and belt scrappers;
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• Magnet for separation of metals,
• Pug mill plant for blending materials and reagents, equipped with surge hopper,
transfer conveyor(s) c~pable of adjusting feed rate to pug mill, and twin paddle mixer
pug mill;
• Weigh belt scale for measuring screened material feed rate to pttg mill;
• Storage silo with variable speed discharge valve, dust collector and level sensor;
• Transfer and stacking conveyors with shrouds and belt scrappers;
• Staging area for contaminated over size debris;
• Staging area for contaminated magnetic debris;
• Decontamination area and equipment to decontaminate and/or segregate materials
capable of being decontaminated from those materials requiring disposal;
• Fail safe system to protect equipment should mechanical failure occur;
• Instrumentation, (PLC), and software to measure, indicate, alarm, and record process
parameters;
• Tools and personnel to operate and maintain the equipment.
4.4.1 Landfill Excavation and Staging Area
Excavation of the contaminated materials from the landfill will be performed with
excavator(s) and dozer(s). The excavation will start at the southern end of the
landfill and proceed in the north direction. See section 3.3 for further details of
the excavation plan. The excavated material will be transported via trucks to the
material preparation area located at the northern end of the processing pad. The
material will be weighed using a certified truck scale prior to staging. The
certified weigh scale will be used to measure for payment the quantity of material
processed by the BBCD and CBCD systems.
The staging area will be of sufficient size to accommodate the equivalent of two
days of combined processing through the BBCD and.CBCD systems.
4.4.2 Untreated Material Sampling and Analytical Screening
A composite sample of the excavated material will be collected everyday that the
material is excavated and staged. The samples will be screened in the field for
PCBs using the immunoassay PCB test kits and analyzed for moisture content.
Materials with a PCB concentration above 750 ppm and/or a moisture content
greater than 15 % will be treated in the BBCD or blended with other materials and
treated in the CBCD .
. 4.4.3 Screening Plant
The staged material will be loaded into the hopper of the screening plant using a
front-end loader. The screening plant will be equipped with a hopper, screen
hopper conveyor, and screened material incline belt conveyor, and have a
maximum screen mesh size of 2-inch by 2-inch. Material not passing through the
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2-inch by 2-inch screen will be discarded into an oversize pile. The oversize
material will be either:
• Re-screened,
• Decontaminated for disposal on-site,
• Decontaminated for disposal off-site, or
• Disposed off-site.
4.4.4 Magnetic Separator
Material passing through the 2-inch by 2-inch screen will be conveyed from the
bottom of the screen hopper to a shrouded incline belt conveyor. The screened
material will pass under a magnet to remove magnetic materials. Magnetic
material collected on the magnet will be removed manually and placed in a
stockpile for future decontamination and disposal. The non-magnetic screened
material will continue on the incline conveyor and be deposited directly into the
hopper of the pug mill plant.
4.4.5 Pugmill Plant
The hopper of the pug mill plant will serve as a surge hopper for the pug mill. A
belt conveyor located at the bottom of the pug mill hopper will transfer material
from the pug mill hopper to a shrouded incline belt conveyor feeding the pug mill
mixer. The feed rate to the pug mill mixer will be controlled by adjusting the
speed rate of the pug mill hopper conveyor belt and/or adjusting the height of the
slide gate opening which will limit the quantity of material that can be carried by
the conveyor.
The pug mill incline feed conveyor will be equipped with a belt scale to provide
feed material rate (instantaneous) as well as the total feed quantity. The flow rate
will then utilized to control the reagent feed rate.
Dry reagent (sodium bicarbonate) will be delivered in pneumatic tanker trucks.
The reagents will be off-loaded directly into the silo located in the material
preparation area. The silo will be equipped with a baghouse to prevent dusting,
level indicator, and variable speed rotary valve. Reagents will be protected from
the weather at all times.
The silo will deliver the designated rate of reagent directly to the pug mill based
upon the calculated weight of the material being conveyed by the pug mill incline
feed conveyor. The reagent and materials will be blended in the twin shaft paddle
pug mill. If necessary, water can be added through a spray bar located in the pug
mill to control dust. The blended material will exit the opposite end of the pug
mill and be deposited onto a shrouded transfer belt conveyor. The transfer
conveyor will deposit the blended material onto a stacking conveyor where the
material is staged awaiting processing through the CBCD or BBCD.
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4.4.6 Blended Material Stockpile
The blended material stockpile will be sized to accommodate five (5) days of
processing through the CBCD and BBCD systems, at maximum throughput. A
pole barn will be provided to protect the blended material from precipitation. The
five day blended material stockpile ensures that there is sufficient material
protected from the elements to process through the CBCD and BBCD systems.
Segregated stockpiles will be made when materials containing PCBs greater than
750 ppm and/or 15 percent moisture content are processed through the BBCD
system; otherwise, the blended materials may be processed in either the BBCD or
CBCD system.
4.4. 7 Material Blending Control System
The material blending control system is comprised of the following maJor
components:
• Motor control center equipped with power main disconnects, variable speed
drive, motor starters and transformers.
• Programmable logic controller (PLC) 5/05 processor with power supply and
input/output analog modules.
• PLC and operator interface software program.
The PLC and operator interface program will be developed to:
• Provide pug mill feed rate control.
• Control the speed of the silo discharge valve drive based on the belt scale
input.
• Calculate the output of the silo.
• Input% reagent to be added by the silo.
• Display level for the silo.
• Display daily and project totals for the silo and weigh belt scale with zero
reset.
• Display speed 0% to 100% for the silo discharge valve motor.
The Contractor will install the processing system and perform the necessary
calibrations and fine-tuning prior to the commencement of the PD tests.
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4.5 Continuous Solid Phase BCD system
The CBCD system allows for continuous processing of the contaminated BCD blended
materials. The continuous nature of the CBCD allows for higher throughput, however, it
also restricts the range of feed characteristics that the CBCD system can operate to meet
the cleanup standards.
The CBCD process flow is provided in drawing PFD-202, which shows the major
equipment components and solid, liquid and gas flows.
The following sections describe the CBCD system.
4.5.1 CBCD Feed System
Blended material with a PCB concentration below 750 ppm and a moisture
content below 15 percent will be loaded into the CBCD feed hopper using a front-
end loader. The CBCD feed hopper works as a surge · hopper for the CBCD
system. Material is conveyed from the bottom of the CBCD feed hopper by the
feed material hopper conveyor. The discharge rate is controlled by the speed of
the belt and/or the discharge gate opening.
The feed material hopper conveyor discharges material on the feed material
incline conveyor. The feed material incline conveyor is shrouded and contains a
weigh belt scale. The weigh belt scale provides data to the CBCD operator on
flow rate of material to the CBCD desorber feed hopper.
The feed material incline conveyor discharges into .the CBCD desorber feed
hopper. The purpose of CBCD feed hopper is to have material available to enter
into the CBCD desorber and to create a vapor seal for the CBCD desorber.
Therefore, the CBCD desorber feed hopper contains level control for low low,
low, and high levels. At low low level the CBCD desorber twin screw feeder
would be stopped so the vapor seal to the CBCD desorber is not broken. At the
low level setting the CBCD feed material hopper conveyor and feed material
incline conveyor would be activated. At a high setting the CBCD feed material
hopper conveyor and feed material incline conveyor would be stopped.
The CBCD operator will have visual contact of the CBCD desorber feed hopper
via monitor. The CBCD operator will also control the system and have immediate
access to critical system components via operator control panel. The same data
will be available to be monitored but not controlled in the site manager's trailer.
The operator will control the feed into the CBCD desorber by varying the speed
of the CBCD desorber twin screw feeder, which transports materials from the
CBCD desorber feed hopper and discharges the material inside the CBCD
desorber.
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The variable speed screw conveyor to the CBCD desorber will be calibrated prior
to the start of work. It will be calibrated using variable speed settings in order to
produce a graphical representation of the full operating range of the screw. The
volumetric feed calibration procedure will be used to conduct the calibration.
This procedure entails positioning a tare truck or loader bucket at the discharge
end of the screw feeder and running the screw feeder at differing speeds in ten-
minute increments. The amount of soil in the tare truck or loader bucket will be
measured at the end of each segment to determine the amount of soil moved at
each speed. Three trials will be conducted at the different speeds in order to
achieve an average for each speed. All points at each speed setting will be plotted
on a graph to develop a speed/weight curve for all soils at that specific density.
Soil density tests will be performed periodically to determine if a density factor
will be applied.
4.5.2 CBCD Desorber
As material will move continuously through the CBCD desorber, the temperature
of the material will increase by indirect heat. The desorber is essentially an inner-
rotating drum surrounded by a fixed outer drum. Heated air produced from the
combustion of #2 fuel oil (the oil burners are located external to the desorber) will
be released into the space between the inner and outer drums. The heat from this
air will be transferred into the inner drum, heating the material as it moves
through the desorber. The heated air (burner exhaust gas) will not contact the
waste material and will be released through stacks located on top of the CBCD.
As the contaminated material travels from the feed end to the discharge end, the
desired material temperature will be reached, resulting in partial chemical
dechlorination/detoxification and physical separation of the contaminants (PCBs
and dioxins/furans) from the materials into the vapor phase. A small portion of the
burner exhaust gas, which has a low oxygen level, will be sent to the feed end of
the desorber and used as sweep gas to remove the contaminants/organics and
water from the desorber. The environment within the desorber will be maintained
as low oxygen (inert) to prevent combustion of organics within the desorber.
Nitrogen or inert gas will be added to the desorber inlet and outlet seals to
minimize oxygen intake, assuring the inert environment within the desorber. A
seal will be provided to prevent leakage of air into the desorber from the material
discharge end.
The fuel oil and burner systems consist of a fuel tank, supply and return lines, fuel
pumps, a minimum of three burner zones for the CBCD system and a CBCD
combustion air fan.
The CBCD operator will monitor the CBCD desorber for proper operation,
including but not limited to:
• Pressure at CBCD desorber inlet
• Temperatures (shell, exit material, and exit gas)
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• Burner control system
• Reyhdration of treated material (dusting, excess water)
• Mechanical/electrical equipment (e.g. bearings, chain, drive, etc.)
• Sweep gas flow and temperature.
4.5.3 CBCD Rehydration System
The hot, treated material from the CBCD will be transferred by the CBCD
discharge screw conveyor into the double-shaft paddle mixer where water will be
added to cool and rehydrate the treated material. Steam (from cooling of the
material) and carryover particulates will be fed into the CBCD steam scrubber,
which will remove particulate carryover and discharge steam/air into the
atmosphere. The cooled, hydrated material will be discharged to the treated
material stockpile area, utilizing a radial CBCD stacking conveyor. The treated
material will then be sampled and analyzed to assure that the soil treatment
standards are met. Once tested as clean, the materials will be relocated or
backfilled.
4.5.4 CBCD Vapor Recovery system (VRS)
· The CBCD exhaust gases ( consisting of sweep gas, steam, and particulates) will
pass through a hot cyclone to remove larger sized particulates. The CBCD hot
cyclone will be insulated and heat traced to prevent loss of temperature through
the unit. This will eliminate condensation from forming and dropping out with
, the solid particulates, which will be mixed with the treated materials for cooling
· , and rehydration.
The CBCD· exhaust gases will exit the hot cyclone and enter into a direct contact
quencher/scrubber. The CBCD quencher/scrubber uses the direct contact water to
rapidly cool the exhaust gases to condense steam and contaminants, as well as, to
achieve additional particulate removal.
The CBCD quencher/scrubber will decrease the off gas stream from 900°F to
below l 30°F and remove particulates. The bleed from the quencher/scrubber will
be discharged into the condensate collection tank. The quencher/scrubber recycle
stream will be cooled utilizing a heat exchanger (See Section 4.5 .5 Cooling
Tower).
The exhaust gases pass through a mist eliminator contained in the
quencher/scrubber before continuing into the chilled water scrubber to achieve
additional cooling/condensing and particulate removal. Periodic maintenance of
the mist eliminator includes spraying the mist eliminator with water from the
water storage tank.
The chilled water scrubber will reduce the gas stream to below 80°F. The chilled
water scrubber includes a recycle tank and recirculation pumps. The recycle
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stream will be pumped through a heat exchanger before being recirculated to the
chilled water scrubber. The chiller is discussed in Section 4.5.6. The bleed from
the chilled water scrubber will be pumped to the condensate collection tank.
The exhaust gases pass through a mist eliminator contained in the chilled water
scrubber before continuing into the wet electrostatic precipitator (WESP) to
achieve additional particulate and mist removal. Periodic maintenance of the mist
eliminator includes spraying the mist eliminator with water from the water storage
tank.
The WESP contains a cooling jacket to promote condensation on the internal
tubes of the WESP where particulates adhere. The WESP contains a sump to
collect and recirculate water to the spray bars of the WESP. Liquid is bled from
the WESP sump continuously to remove collected particulates and is pumped to
the condensate collection tank.
The gases from the WESP will be reheated to reduce the relative humidity before
entering the vapor recovery system induced draft (ID) fan. The vapor recovery ID
fan located downstream of the reheater will be utilized to pull the gases through
the CBCD-VRS and maintain a slight negative pressure at the CBCD desorber
inlet. A flame arrester is installed between the vapor recovery system ID fan and
the flameless thermal oxidizer (FTO) to prevent a backflash through the CBCD-
VRS system. The FTO provides final polishing of the gases prior to discharge
into the atmosphere through the process stack. The FTO virtually eliminates any
non-condensable organics and residual organic contaminants that were not
removed by the components of the CBCD-VRS described above. Flow through
the CBCD FTO is controlled by the CBCD-FTO forced draft (FD) fan and
ambient air intake bleed valve. The FTO operates between 1,500 °F and 1,800
oF.
The process stack will be equipped with a continuous stack monitor (CSM) to
measure and record total hydrocarbons in the stack gas. The testing of stack
emissions to determine that air treatment standards established for the project are
met is further described in the PDP (Sections 3, 9, 11), as well as the Air
Monitoring Plan.
Should a problem occur with the CBCD-FTO, then the air stream will by-pass the
FTO and will be treated with vapor phase carbon. Two vapor carbon units will be
placed in series to treat the air stream.
4.5.5 Cooling Tower ·
The cooling tower is a. common system for both the CBCD and BBCD. CBCD
quencher/scrubber recycle will be cooled utilizing cooling tower water and a non-
contact heat exchanger. The return water to the cooling tower absorbs the heat
and is re-cooled in the cooling tower. During re-cooling of the water in the
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cooling tower, water vapor is released to the atmosphere. The release of water
vapor to the atmosphere causes two affects:
1. loss of recirculation water, and
2. Buildup of impurities in the recycle water which may cause fouling of the
cooling tower.
As a result, clean city water is used to replenish the loss of water in the cooling
tower. Cooling water will be bled to reduce the buildup of impurities in the
system.
4.5.6 Chiller
The chiller is a common system for both the CBCD and BBCD systems. The
chiller is used to cool the chilfed water scrubber recycle and is used in the cooling
jacket of the WESP to promote condensation within the WESP. Recycle stream
returning to the CBCD chilled water scrubber is cooled by passing through a non
contact heat exchanger cooled by liquid coming from the chiller.
4.5. 7 Emergency Backup Systems
In the case of emergency the following backup systems are incorporated into the
CBCD system:
l . Emergency generator to operate critical process equipment should an
electrical power outage occur. Critical equipment includes discharge
conveyor, induced draft fan, scrubber(s) recycle pumps, cooling tower
recycle pumps, emergency plant lighting, FTO fan, etc.
2. Emergency propane power drive to continue rotating the CBCD drum at a
very slow rate in case of power failure or electric motor failure.
3. Redundant pumps for all critical operating components.
4. Inert gas/N2 system to maintain/generate oxygen deficient environments in
the CBCD and BBCD desorbers.
5. Backup water supply sources (treated process water, treated stormwater,
city water, and process recirculation water).
6. The discharge screw has an alternate discharge to a by-pass container to
unload materials from the CBCD desorber should an upset condition
occur.
7. An emergency relief valve is provided upstream of the hot cyclone.
8. An emergency bypass, located upstream of the FTO FD fan, is provided to
continue system operation in case of FTO upset. In this event, the by
passed air vapor will pass through carbon beds before being discharged to
the atmosphere.
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4.5.8 CBCD Process Monitoring Procedures
Operating parameters will be monitored to assure the efficient operation of system
components and to establish the acceptable range of operating conditions. Table
4.5-1 identifies critical monitoring points with their parameters, instruments,
target values, frequency, instrument range, accuracy and calibration for the
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Site Opera..-.1ns Work Plan Warren County PCB Landfill Table 4.5-1 Process Monitoring for CBCD '•# 1· .·.>i+':'.:t~~'METERJt\ft0~Ftil%i411§:SqiR.~~1tW4~i~~~ti~flU~~l~~tful .... · f~i~~I'.1,1'· · >,-~~'EI~& I · ~:Al!Bc~lflQN I RECORDED (YES/NO) f"":~'f':'.\Ujt<,s' ·I Soil Feed Rate I Conveyor Weigh 4-15TPH Continuous 0-25 tph I Factory Calibrated Yes Scale +5% per 24 hr. period 2 I Thermal Desorber Face Pressure +0.25" WC to -2" WC Continuous ~JO" to 15" WC I Factory calibrated I Yes Pressure Transmitter +0.25% of full scale 3 I Thermal Desorber Shell Thermocouple 1000° -1700° F Continuous 0-2,200°F I Factory calibrated I Yes Temperature ±4°F (0-559°F) 4 I Soil Exit Temperature I Thermocouple I 875° -950° F I Continuous I +0.75% ~559-2,200°F) 0-2,200°F I Factory calibrated I Yes ±4°F (0-559°F) ±0.75% 559-2,200°F 5 I Hot Cyclone Inlet Gas I Thermocouple I 750° -1150° F Continuous 0-2,200°F I Factory calibrated I Yes Temperature ±4°F (0-559°F) +0.75%(559-2,200°F 6 I Quencher/Scrubber Thermocouple 50° -180° F Continuous 0-2,200°F I Automatically Checked I Yes Outlet Gas ±4°F (0-559°F) Daily Temperature +0.75% (559-2,200°F 7 I Chilled Water Scrubber 02 Level 1-10% Continuous 0-100% 02 I Factory calibrated I Yes Outlet 02 Level Analyzer +/-0.1% 02 8 I WESP Gas Exit Thermocouple 50° -150° F Continuous .0-2,200°F I Factory calibrated I Yes Temperature ±4°F (0-559°F) ±0.75% {559-2,200°F 9 I Cooling Tower Thermocouple 35° -120° F Continuous 0-2,200°F I Factory calibrated I Yes Recycle Pump Outlet ±4°F (0-559°F) Temperature +0.75% (559-2,200°F IO I FTO Bed Temperature Thermocouple 1500° -1800° F Continuous 0-2,200°F I Factory calibrated I Yes ±4°F (0-559°F) ±0.75% 559-2,200°F 11 I CPM THC Level I FID Analyzer I To be determined after I Continuous I 3-10,000 PPM Timed Automatic I Yes Performance Demonstration <I% of full span in 24 Calibration Check hours Note: All values are for normal steady state operation and will not apply during start-up or shut-down. ETG Environmental, Inc/ BFA Environmental Consultants March 2000 47
Site Operations Work Plan Warren County PCB Landfill
CBCD. The values for these parameters will be sent to the CBCD operator station
where they can be viewed on a panel view. The values will also be stored in a
computer and can be made available for review. All data will be connected to the
data highway, so that operators from other stations along with the site manager
can observe operating parameters across the site which may impact other systems.
When process instrumentation indicates operations outside prescribed ranges, an
alarm will be triggered warning the CBCD operator. The CBCD operator can then
make the necessary adjustments to allow the system to operate within normal
parameters.
4.5.9 CBCD Waste Feed Cutoff Systems
The purpose of the Waste Feed Cutoff (WFC) systems is to provide a mechanism
for immediate action whenever operating parameters deviate outside normal
control limits. There are both automatic and manual waste feed cutoff conditions.
The WFC systems are only applicable to CBCD system. Table 4.5-2 provides a
preliminary list of the WFC parameters and actions to take if parameters deviate
outside of the normal operations range. The CBCD desorber twin screw feeder
will be shut off automatically if the following parameters are outside limits for
normal operations: 1) CBCD desorber face pressure; 2) CBCD material exit
temperature; 3) CBCD gas exit temperature; and 4) WESP exit gas temperature.
In addition to the operating parameters shown on Table 4.5-1 the total
hydrocarbon analyzer in the stack continuous process monitoring system will be
checked for calibration every day. The allowable operating range will be
determined during the performance demonstration test. If the drift of the analyzer
exceeds the allowable limit, the analyzer's calibration will be re-checked for
accuracy. If accurate, the process will be shut off pending further evaluation. The
waste feed system will also shut off automatically if a power failure occurs or the
discharge system fails.
Any unusual situation that may occur that would require further inspection will
trigger a manual WFC. When the parameters deviate from the target values listed
in Table 4.5-2 for the amount of time indicated, an automatic WFC will be
activated. These parameters will be monitored continuously by the CBCD
operators.
The WFC procedures provide assurances that the system will be operated within
accepted operating conditions to accomplish the following:
1) protection of human health ( off-site and on-site) and the environment, and
2) Prevent damage to the equipment.
If the WFC system is initiated, discharged soil will be segregated and sampled to
determine if soil treatment standards have been met.
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Table 4.5-2
• \l~rq,c~~s·@pe~~g ,e6n:,ditititis ·· ,
CBCD Desorber Face
Pressure
CBCD Soil Exit
Tern erature
CBCD Gas Exit
Temperature
THC at Stack
WESP Exit Gas
Temperature
Warren County PCB Landfill
Preliminary List of Waste Feed Cutoff Conditions for CBCD
for 3 minutes
<850° F
for 20 minutes
> I I 50° F for 15
minutes or I 200°F
instantaneous
To be established
during Performance
Demonstration test
>200° F for 15
minutes
• c: 'e,µ,~~neyer•Parameters
qntrctl'cl't,imits
Increase fan speed.
Lower feed rate.
Lower CTDU shell temperature
Check unit calibration. Check air stream flow to the FTO
and increase if necessary. Next check scrubbers and
WESP o eration and make ad·ustments ifnecess
Check water level in the WESP recycle tank and add
water, if required. Run both quencher/scrubber recycle
pumps. Check cooling tower and chiller recycle water
tern erature.
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At any point during operation of the CBCD system, the operator has the option to
initiate a WFC sequence manually. The protocol for conducting a WFC is as
follows:
a. The operator will first stop the feed and operation of the feed conveyor to
a level in the hopper portion where a material seal is maintained to prevent
ambient air from entering the desorber.
b. The desorber will continue to process material until it is empty and
discharge to the stockpile through the discharge screw, double paddle
mixer/cooler, and stacking conveyor.
c. The firing rate for the desorber burners will be reduced due to the
termination of material feed. Shell temperature will be closely monitored
as the remaining material progresses through the unit.
d. The use of treated process aqueous phase condensate to re-hydrate the
treated materials will be discontinued when material is no longer being
discharged into the double paddle mixer/cooler.
e. The induced draft fan will maintain a slight draft in the desorber to purge
the system of process gases. Therefore, condensation of cooled gases and
subsequent vapor phase treatment will continue to occur. Condensate
collection separation and treatment will continue to occur until flows
decline to a negligible level.
f. The scrubbers will be manually shut down as the process gas drops below
minimum temperature.
g. The induced draft fan will be shut down.
4.6 Batch Solid Phase BCD (BBCD System)
The BBCD system allows for batch processing of the contaminated materials. The batch
BBCD system allows for:
• Treatment of materials that contain elevated levels of PCBs and/or moisture content
without interfering with the production of the CBCD system,
• The BBCD can treat sludges, filter cake, spent carbon and filter aid produced in the
process condensate separation and aqueous phase treatment (PCSAPT) system,
• The BBCD allows for the treatment of concentrated organics,
• The BBCD may be the main producer of the organic stream for the liquid BCD
(LBCD) system, and
• The BBCD and LBCD systems provide end points for the detoxification of the PCB
contaminated materials.
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It is important to note that the BBCD system can treat all levels of PCB contamination
and moisture content. The BBCD process flow is provided in drawing PFD-203, which
shows the major equipment components and solid, liquid and gas flows .
The following sections describe the BBCD system.
4.6.1 BBCD Feed System
The BBCD desorber is loaded and unloaded from the front of the unit. The
BBCD feed hopper and feed hopper conveyor are placed in position in the front of
the BBCD desorber. Blended material will be loaded into the BBCD feed hopper
using a front-end loader. The BBCD feed hopper functions as a surge hopper for
the BBCD feed conveyor, which feeds the BBCD desorber. The BBCD is loaded
on a volumetric basis, generally, number of loader buckets.
Once the BBCD desorber is loaded the BBCD feed hopper and feed conveyor are
removed and the BBCD desorber closed up.
4.6.2 BBCD Desorber
Once the BBCD operator has secured the BBCD desorber doors and confirmed
the proper operation of the BBCD-VRS system, heat will be applied to the inner
shell drum of the BBCD desorber. The temperature of the material in the BBCD
desorber will increase by indirect heat. The BBCD is essentially an inner-rotating
drum with internal piping surrounded by a fixed outer drum. Heated air produced
from the combustion of #2 fuel_oil (the oil burners are located external to the
BBCD) will be released into the internal piping, and the space between the inner
and outer drums, heating the material in the BBCD. The heated air (burner
exhaust gas) will not contact the waste material and will be released through a
stack locatea on top of the BBCD. As the shell drum adsorbs the heat the desired
material temperature will be reached, resulting in partial chemical
dechlorination/detoxification and physical separation of the contaminants (PCBs
and dioxins/furans) from the materials into the vapor phase.
The fuel oil and burner systems consists of a fuel tank, supply and return lines,
fuel pumps, a burner box for the BBCD system and a BBCD combustion air fan .
The BBCD operator will monitor the following BBCD desorber for proper
operation, including but not limited to:
• Vacuum at the BBCD desorber outlet
• Temperatures (shell, material, burner box outlet, gas, and desorber exit gas)
• Burner control system
• Reyhdration of treated material (dusting, excess water)
• Mechanical/electrical equipment (e.g. bearings, chain, drive, etc.)
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4.6.3 BBCD Rehydration System
At the conclusion of the batch cycle, the treated material will be removed by
reversing the rotational direction of the BBCD inner drum. This hot, treated
material is discharged into a mixer where water is added to cool and rehydrate the
treated material. As with the CBCD, steam and particulates from the mixer enter
a scrubber to be removed prior to discharge to the atmosphere. The cool,
hydrated treated material will be discharged to the treated material stockpile for
sampling and analysis. Clean treated material will be relocated or backfilled.
4.6.4 BBCD Vapor Recovery System (YRS)
The BBCD ex~aust gases (consisting of steam, organics and particulates) will
pass through a hot cyclone to remove larger sized particulates. The BBCD hot
cyclo_ne will be insulated an_p heat traced to prevent loss of temperature through
the unit. This will eliminate condensation from forming and dropping out with the
solid particulates. The removed particulates are collected in a container for
cooling and hydration. The particulates will be sampled and tested to determine if
they meet the material treatment standards. If clean, they will be mixed with the
treated materials for cooling and rehydration. Otherwise, they will be returned to
the CBCD or BBCD for retreatment.
The BBCD exhaust gases will exit the hot cyclone and enter into a direct contact
quencher/scrubber. The BBCD quencher/scrubber uses the direct contact water to
rapidly cool the exhaust gases to condense steam and contaminants, as well as, to
achieve additional particulate removal.
The BBCD quencher/scrubber will decrease the off gas stream from 900°F to
below 130°F. The BBCD quencher/scrubber is a self-contained unit with a
recycle tank that collects the liquid passing through the quencher/scrubber.
Scrubber recycle pumps liquid from the recycle tank back to the
quencher/scrubber after passing through a heat exchanger for cooling (see Section
4.6.5 Cooling Tower).
The exhaust gases pass through a mist eliminator contained in the
quencher/scrubber before continuing into a series of non-contact condensers to
achieve additional cooling/condensing. Periodic maintenance of the mist
eliminator includes spraying the mist eliminator with water from the water storage
tank.
The gases proceed through a primary non-contact condenser located on the
vacuum side of the BBCD liquid ring· pump. The warm' gases pass through a
primary shell and tube condenser that is cooled with ~hilled water from the chiller
unit. The chiller is discussed in Section 4.6.6. ·
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The liquid condensate is collected in the condensate tank and the gases continue,
through the liquid ring vacuum pump to a secondary non-contact condenser on the
positive side of the vacuum pump. The liquid ring pump provides the vacuum on
the BBCD desorber and pulls the gases through the BBCD-VRS. The secondary
non-contact condenser is chilled with water from the chiller and has its own
condevsate tank.
· The gases from the secondary non-contact pass through a flame arrester installed
before the BBCD flameless thermal oxidizer (FTO). The flame arrester prevents
.a backflash through the BBCD-VRS system. The FTO provides final polishing of
the gases prior to discharge into the atmosphere through the process stack. The
FTO virtually eliminates any non-condensable organics and residual organic
contaminants that were not removed by the components of the BBCD-VRS
described above. Flow through the BBCD FTO is controlled by the BBCD-FTO
FD fan and ambient air intake bleed valve. The BBCD-FTO operates between
1,500 °F and 1,800 °F.
The process stack will be equipped with a continuous process monitor (CPM) to
measure and record total hydrocarbons in the stack gas. The testing of stack
emissions to determine that air treatment standards established for the project are
met is further described in the PDP (Sections 3, 9, 11), as well as the Air
Monitoring Plan.
Should a problem occur with the BBCD-FTO, then the air stream will by-pass the
BBCD-FTO and will be treated with vapor phase carbon. Two vapor carbon units
will be placed in series to treat the air stream.
4.6.5 Cooling Tower
The cooling tower is a common system for both the CBCD and BBCD
quencher/scrubbers. Recycle st~eam from the BBCD quencher/scrubber and water
from the cooling tower pass through a non-contact heat exchanger. See Section
4.5.5 for further operating parameters for the cooling tower.
4.6.6 Chiller
The chiller is a common system for the CBCD, BBCD, and CBCD systems. The
chiller is used to supply chilled non-contact water that passes through the two
BBCD non-contact condensers and to cool seal water for the BBCD vacuum
pump. See section 4.5.6 for additional information the chiller unit.
4.6. 7 Emergency Backup Systems
In the case of emergency the following backup systems are incorporated into the
BBCD system:
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1. Emergency generator to operate critical process equipment should an
electrical power outage occur. Critical equipment includes vacuum pump,
quencher/scrubber recycle pumps, cooling tower recycle pumps, emergency
plant lighting, BBCD FTO fan, etc.
2: Redundant pumps for all critical operating components.
3. Backup water supply sources (treated process water, treated stormwater, city
water, and process recirculation water).
4. An emergency bypass, located upstream of the FTO FD fan, is provided to
continue system operation in case of FTO upset. In this event, the by passed
air vapor will pass through carbon beds before being discharged to the
atmosphere.
4.6.8 BBCD Process Monitoring Procedures
Operating parameters will be monitored to assure the efficient operation of system
components and to establish the acceptable range of operating conditions. Table
4.6 identifies critical monitoring points with their parameters, instruments, target
values, frequency, instrument range, accuracy and calibration for the BBCD. The
values for these parameters will be sent to the BBCD operator station where they
can be viewed on a panel view. The values will also be stored in a computer and
can be made available for review. All data will be connected to the data highway,
so that operators from other stations along with the • site manager can observe
operating parameters across the site which may impact other systems.
When process instrumentation indicates operations outside prescribed ranges, an
alarm will be triggered warning the BBCD operator. The BBCD operator can then
make the necessary adjustments to allow the system to operate within normal
parameters.
4.7 Batch Liquid Phase BCD (LBCD System)
The LBCD system allows for batch processing of the PCB contaminated liquids and/or
sludges. The batch LBCD system provides for an end point for the detoxification of the
PCB contaminated materials. Organic materials from the PCSAPT will be sent to the
liquid phase BCD detoxification system (LBCD). LBCD employs a potassium/sodium-
based reagent, a hydrogen donor in the form of a high boiling point carrier oil, and
catalyst to chemically detoxify the chlorinated contaminants (PCBs, dioxins/furans).
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Site Operations Work Plan Batch Size (tons) Loader Buckets 2 I Burner Box Exit Thermocouple Gas Temperature 3 I Burner Stack Gas I Thermocouple Temperature 4 I Hot Cyclone I Thermocouple Temperature 5 I Hot Cyclone I Vacuum Transmitter Vacuum 6 I Chiller Recycle I Thermocouple Pump 7 I Cooling Tower I Thermocouple Recycle Pump Outlet Temperature 8 I Vacuum Pump I Thermocouple Inlet Temperature 9 I Vacuum Pump I Gauge Inlet Pressure 10 I FTO Bed I Thermocouple Temperature 11 I CPM THC Level I FID Analyzer Table 4.6 Process Monitoring for BBCD 10-18 Tons I 000° -2000° F 800° -1100° F Ambient -900° F 10" Hg-28" Hg 35° -55° F 35° -120° F Ambient - 1 I 0°F 15" Hg-30" Hg 1500° -1800° F To be determined after Performance Demonstration Per Batch Continuous Continuous Continuous Continuous Continuous Continuous Once every 12 hours Once every 12 hours Continuous Continuous 10-25 tons per batch ±5% per batch 32-2,200°F ±4°F (0-559°F) +0.75% (559-2,200°F 32-2,200°F ±4°F (0-559°F) _±Q]5% (559-2,200°F 32-2,200°F ±4°F (0-559°F) _±0. 75°/o (559-_2,200°F 0-30" Hg _±I% Full scale 32-2,200°F ±4°F (0-559°F) +0.75% (559-2,200°F 32-2,200°F ±4°F (0-559°F) ±0.75% (559-2,200°F) 32-2,200°F ±4°F (0-559°F) +0.75% (559-2,200°F 0-30" Hg _±1.5% 32-2,200°F ±4°F (0-559°F) +0.75% (559-2,200°F 3-10,000 PPM <I% of full span in 24 Warreri County PCB Landfill .@~LIBRA'FI0N Volumetric measurement converted to tons (yd' X densitv'* Factory calibrated Factory calibrated Factory calibrated Factory calibrated Factory calibrated Factory calibrated Factory calibrated Factory calibrated Factory calibrated Timed Automatic Calibration Check RECORDED.· (Yl?SfNO) Yes Yes Yes Yes Yes Yes Yes No (but is monitored) No (but is monitored Yes Yes • The batch units are known to contain a given volume of soil. To obtain the batch size, in tons, the volume of soil is simply multiplied by the soil density. • Note: All values are for normal steady state operation and will not apply during start-up and shut-down. ETG Environmental, Inc/ BFA Environmental Consultants March 2000 55
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The carrier oils along with reagent, catalyst, and the contaminated liquids are placed in
the reactor and heated to 600-650° F. The overall liquid BCD reaction process is
represented as follows:
Catalysts
Acceptor -Cl + NaOH + Donor -H
H20
------➔Donor + Acceptor -H + NaCl +
600-650 .f
(Acceptor-Cl represents PCBs and polychlorinated d_ioxins/furans)
During the LBCD process, gases (steam and light organics) will be forced through a
condenser by the vapor pressure generated by the gas stream. The condenser will cool
the gases using non-contact chilled liquid from the chiller and separate gases that
condense above 60-80°F. The gases will be vented to the CBCD-FTO for polishing
before being discharged to the atmosphere. Samples of the oil mixture will be drawn
from the sampling ports and screened for PCBs during processing. Once the PCBs have
been dechlorinated to a concentration acceptable for off-site disposal, the batch will be
continued for an additional 1-2 hours to ensure the completion of dechlorination. At the
end of each batch, the liquid mixture will be cooled using a heat exchanger.. The liquid
will then be sent to the organics transfer tank for phase separation. The water phase, if
any, will be pumped to the PCSAPT for further treatment. Organics will then be pumped
to the treated organic tank. When sufficient quantity of organics are collected for
disposal off-site, a sample will be obtained and analyzed for the parameters required by
the specific disposal facility. Upon acceptance by the disposal facility, the treated
organics will be transported to their facility.
Drawing PFD-205 contains a process flow diagram for the batch liquid BCD
detoxification system.
4.7.1 LBCD Process Monitoring Procedures
Operating parameters will be monitored to assure the efficient operation of system
components and to establish the acceptable range of operating conditions. Table
4.7 identifies critical monitoring points with their parameters, instruments, target
values, frequency, instrument range, accuracy and calibration for the LBCD. The
values for these parameters will be sent to the operator station where they can be
viewed on a panel view. The values will also be stored in a computer and can be
made available for review. All data will be connected to the data highway, so that
operators from other stations along with the site manager can observe operating
parameters across the site which may impact other systems.
When process instrumentation indicates operations outside prescribed ranges, an
alarm will be triggered warning the LBCD operator. The LBCD operator can then
make the necessary adjustments to allow the system to operate within normal
parameters.
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Site Operations Work Plan Warren County PCB Landfill Table 4.7 Process Monitoring for LBCD # RECORDEP {YE§/NO) 0-500 gallon I Factory Yes + 1% er Batch 2 I Carry Oil Flow Totalizer 150-450 gal Per Batch 0-500 gallon I Factory Yes ± 1% er Batch 3 I Caustic Flow Totalizer 10-25 gal Per Batch 0-500 gallon I Factory Yes 4 I Catalysts I Flow Totalizer I 15 -50 gal I Per Batch I + 1% per Batch 0-500 gallon I Factory Yes + I% per Batch 5 Total Batch Volume None Sum Of Items 1-4 above Per Batch Not Aoolicable Manual Calculation No 6 Pressure Valve Setting Gauge 2-5 psig Continuous 0-10 psig Facto Yes 7 Process Liquid Thermocouple 630 -670° F Continuous 0-2,200 °F Factory Yes Temperature ±4 °F (0-559 °F) ±0.75 ¾ (559-2,200°F) ------------ETG Environmental, Inc / BF A Environmental Consultants March 2000 57
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4.8 Process Condensate Separation and Aqueous Phase Treatment (PCSAPT)
System
The PCSAPT system treats all process condensate generated from the CBCD-VRS,
BBCD-VRS and LBCD systems. The PCSAPT process flow diagram is shown on
drawing 204. Section. The following sections describe the PCSAPT system.
4.8.1 Process Condensate Separation System
Condensate from the BBCD will be treated after the soil desorption process is
complete. The condensate collected in the quencher/scrubber and the two
condensate tanks associated with the non-contact condensers will be pumped to
the BBCD centrifuge feed tank. The BBCD-VRS system has been specifically
designed to concentrate the process condensate by limiting the amount of contact
water generated by the BBCD-VRS system.
The process condensate is pumped from the centrifuge feed tank through a
centrifuge for separation of solids and water from the organic phase. The
separated organics will be pumped to the LBCD organic feed tank. The aqueous
phase will be pumped to the condensate collection tank.
The bleed from the quencher/scrubber of the CBCD-VRS discharges into the
condensate collection tank. This tank also collects bleed from the chilled water
scrubber and WESP. Light organics may separate as "floaters" which can be
skimmed off of the top and sent to the LBCD organic feed tank.
The liquor pumped from the bottom of the condensate collection tank will enter a
sludge holding tank to be homogenized prior to feed into a filter press to achieve
liquid/solids separation. The sludge holding and condensate collection tank also
act as surge tanks when the filter press is in its cake discharge cycle.
Due to the anticipated oily nature of the sludge holding tank liquor, a precoat will
be used during each filter press cycle. The filter press system includes a precoat
feed tank and precoat feed pumps.
The sludge holding tank liquor will be pumped through the filter press using a
diaphragm pump. When the pressure in the filter press reaches the maximum
desired operating pressure, the diaphragm pump will be turned off and the filter
press plates pressed to remove additional entrapped filtrate. At the completion of
the press cycle, the pressure'is released and the plates opened to drop the filter
cake. The filter cake will be dumped into a storage container designed to be
watertight and easily transported via fork truck, Filter cake will be sent to the
BBCD for treatment as contaminated materials.
Filtrate from the filter press will continue into the filtrate storage tank. The
filtrate storage tank serves as a surge tank and allows for additional physical
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separation of the filtrate into organic and aqueous phases. The organic fraction, if
any, from the filtrate storage tank will be transferred to the LBCD organic feed
tank. The aqueous phase will continue into the aqueous phase treatment
components of the PCSAPT.
4.8.2 Aqueous Phase Treatment System
The aqueous phase treatment will consist of particulate and organic removal
devices. Filtrate from the filter storage tank will be pumped through a sand filter
for final polishing of suspended solids. Depending upon the concentration and
particle size distribution of the residual suspended solids and oil content of the
filtrate, a multi media filter maybe substituted for the single layer sand filter. In
either situation, the filter system will be equipped with a backwash system
capable of removing sediment buildup. Water from the water storage tank will be
used to backwash the filter media. The backwash water will be discharged into
the condensate collection tank. _ The backwash system can be operated manually
or automatically using either a differential pressure gauge or on a timed backup
system. At a minimum, two media filters will be available to permit backwashing
of one unit while the other is in operation.
The filtrate passing through the filter media will pass through a minimum of two
carbon vessels placed in series. There will be two dual carbon systems to permit
continuous processing through the carbon system while the one system is under
going a carbon change. Spent carbon and spent media filter will be treated in the
BBCD system.
The treated aqueous phase will be stored in the water storage tank.. The effluent
standard for the treated aqueous phase is set at the same standard for the treated
soils, i.e. 200 ppb PCBs or less. The treated aqueous phase will then be suitable
for recycling back into the BCD process, being primarily used for rehydration of
the treated soils. As a backup system to ensure sufficient water is always
available for the rehydration of the treated soils, a city water line will also be
connected to the water storage tank.
4.8.3 PCSAPT System Operation
A plant operator is required to monitor the PCSAPT and the scrubbers in the
CBCD-VRS. The quantity of process condensate is dependent upon the
production rate and moisture content of the feed materials to the BBCD and
CBCD systems. The water usage rate from the water storage tank is dependent
upon the treated material production rate from the CBCD and BBCD units. Parts
of the BCD systems operate continuously, while others operate in a batch mode.
Therefore, it is imperative that the PCSAPT operator be informed of all processes
throughout the BCD system. To assist the PCSAPT operator, the
PCSAPT/LBCD control station will be connected to the data highway, which
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allows the operator to view all the BCD system processes. The operator at the
control station will be able to monitor and control the PCSAPT/LBCD system.
Th~ operator will monitor the PCSAPT system f.or proper operation, including but
not limited to:
• Organic floating layers in the condensate collection and filtrate storage
tanks,
• Level in the condensate collection tank,
• Level in the sludge ho,lding tank,
• Cycle period of the filter press and precoat system status,
• Status of the BBCD system and operation of the batch centrifuge for the
BBCD process condensate,
• Liquid level of filtrate storage tank,
• Backwash cycle and change over to backup sand filter system,
• Carbon change out requirements and switch over to backup carbon filter
systems,
• Liquid level in LBCD organic feed tank, and
• Liquid level in the water storage tank.
The minimum sampling and analysis requirements for full-scale operation are
summarized in Section 6.0 and Table 6-1 of this plan. The Final
Verification/Confirmation Sampling Plan details the BCD Detoxification
sampling and analysis requirements.
4.9 Common Systems
There are a number of systems that are common to various components of the BCD
detoxification system. Below is a brief description of the systems and their operation:
4.9.1 No. 2 Fuel Oil System
Drawing PFD-206 depicts the No. 2 fuel oil system. Number 2 fuel oil will be
combusted to provide heat for the CBCD and BBCD desorbers. The No. 2 fuel
oil will be stored in a 15,000 gallon doubled wall above ground fuel storage tank.
The No.2 fuel oil tank will be equipped with spill and overflow protection and
protected from vehicular and equipment traffic. The CBCD and BBCD systems
contain separate duplex fuel oil pumps to supply fuel oil to the burners. The
duplex pumps also contain a return line to the No. 2 fuel oil storage tank.
The 15,000-gallon No.2 fuel oil tank has a dispenser nozzle for filling the fuel
tanks for heavy equipment utilized on-site. However, due to the location of the
15,000-gallon fuel tank to the processing pad and landfill, additional day fuel
tanks will be strategically located to provide fuel for equipment confined to an
exclusion zone.
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4.9.2 Nitrogen Cylinders
Nitrogen is used for the seals on the CBCD desorber and on the WESP to ensure
that the units are maintained under an oxygen deficient non-explosive
environment.
4.9.3 Propane System
Propane will be used to power the emergency generator should a power failure
occur. Propane is also used as a fuel source to preheat the beds of the BBCD-
FTO and CBCD-FTO units. In addition, there is a backup motor that is propane
powered to continue rotating the CBCD desorber drum in case of power failure.
4.9.4 Plant and Instrument Compressed Air
Compressed air will be used to operate the diaphragm pumps and the filter press.
In addition compressed air is used for numerous instrument-monitoring devices
on all the major system components. The instrument air will require to be
conditioned for moisture prior to use. Therefore, two separate compressed air
systems will be used; plant air and instrumentation air.
4.9.5 Water Storage Tank
The water storage tank primarily receives water treated from the PCSAPT and the
majority of the water use will be for the rehydration of the treated materials. The
water storage tank can also receive treated water from the storm water and
decontamination-treatment system when available and when water storage tank
level is low. A tertiary backup system will be to use city wat~r to replenish the
tank.
Water from the water storage tank will also be used in the VRS and PCSAPT
systems and to periodically clean equipment components such as mist eliminators.
4.9.6 Cooling Tower and Chiller
As discussed in Sections 4.5 and 4.6 of this plan, the cooling tower and chiller
service both the CBCD and BBCD systems. The cooling tower is used to cool
recirculation water for the CBCD quencher/scrubber and the BBCD
quencher/scrubber. The chiller provides cooling water for the BBCD non-contact
condensers, the heat exchanger for the BBCD vacuum pump seal water, the heat
exchangers for the chilled water scrubbers, jacket of the WESP, and CBCD
condenser.
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4.9. 7 Process Monitoring and Data Acquisition System
The Process Monitoring and Data Acquisition system includes workstations with
computers and monitors at each of the following work areas:
• CBCD and CBCD-YRS Processing Area,
• BBCD and BBCD-VRS Processing Area,
• PCSAPT/LBCD Processing Area, and
• Site Managers Trailer.
The operators at each workstation have the capability of observing operating
status and conditions at any of the four major areas, but only are able to control
their individual processing area equipment from their workstation.
The process monitoring system will interface with Allen Bradley SLC 5/05's on
Datahighway Plus. The system will also interface with the Continuous Stack
Monitors (CSM) via Ethernet Connection. The process monitoring system will be
isolated and/or protected against power surges, ground potential differences,
nearby lightening strikes, and other interference's such as two-way radios.
Designated site personnel will receive standard training course for Allen Bradley
SLC 5/05 maintenance and troubleshooting. The site manager, engineers, and
operators will receive training on-site for their specific process monitoring system
using the actual .equipment configuration and displays. This course will provide
the training necessary for personnel designated by the Contractor to fully
.configure and operate the system, and will include instruction on the entire system
using the actual application programming and software.
The operators console contains one fully programmed desktop operator
workstation. The workstation includes at a minimum:
• 400 MHz Pentium based PC
• 3.5" floppy drive
• CD ROM drive
• 64MEGRAM
• 4 GIG hard drive
• 17" VGA color monitor
• Operators keyboard
• Cursor positioning method such as a mouse
• Dedicated electronics and recordable CD writer.
The 17" monitor supports graphics building software that allows generation of
full displays, symbols, characters, etc. at the pixel level.
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The operator station keyboard is sealed using tactile and audible feedback. It has
keys for accessing the most often performed operations such as, display selection,
alarm acknowledge, CRT copy, etc. It also contains a group of keys, which are
dedicated to access critical displays.
The cursor positioning method (touch screen, trackball, mouse) is used by the
operator for rapid selection of vectoring to new displays, aids in graphics, etc.
The operator station has the means of rapidly toggling between an alarm page and
the operating page.
The laser printer will be located in the site manager's trailer. The printer is used
for alarms, report generation and operational logs.
The operator workstations have the following standard displays:
• Overview or Summary Display: This display allows for overview of the
facilities in a single display. The display allows for the location of specific
points in the groups and indicates the status of each point regarding alarm
conditions, mode of operation, etc. With one or two keystrokes the operator is
able to select and call up a desired group display.
• Point Summary Display: All designated analog input and output signctl values
and motor command and status values are displayed on the Point Summary
Display(s). The analog and motor values are grouped together in a logical
fashion (i.e. by process unit operation).
• Process Graphic Display: The operator workstations support a minimum of 20
custom graphic displays. The following are the minimum configured displays
on the system:
1. Overview Display
2. CBCD System
3. CBCD-VRS
4. BBCD and BBCD-VRS
5. LBCD System
6. PCSAPT
7. Common Systems
Each graphic supports at least 50 dynamic variables. The graphics support
display vectoring (where the operator is able to move from graphic to graphic
by cursor without having to remember a display number to call up). For
example, from an overview graphic, the operator calls up associated graphics
by selecting a certain area or points on the graphic and then with one
keystroke, vectors to the detailed graphic for that area or point. Similarly, if
the operator wants to see a trend, point, group, alarm, etc. type of a display
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after selecting the desired point or area on the graphic, a single keystroke is all
that is necessary. A menu bar is included for key operator functions.
All graphic building functions are available at the pixel level, including
character and symbol generation. The system has a standard set of symbols
and characters as well as the ability to generate custom ones.
• Historical Trends: The console is capable of displaying at least-200 historical
trend points. The trend data resides at the operator workstation. The display
can plot at least four different variables simultaneously on a time base and
scale that is easily selected by the operator.
The display has a cursor technique that allows the operator to read the
engineering units of any desired variable at any point on the trend display. The
trend data is configurable to represent the minimum, maximum, average, and
instantaneous value for the sample period.
• Alarm Handling: All designated tags in the system are available for alarming.
For an analog point, high/high, high, low, low/low, deviation, and
rate-of-change alarms are available. Digital variables such as contact closures
are alarmable on a transition in either direction or transitions in both
directions. All alarms are time stamped with one-second resolution. All points
have assignable areas and appropriate alarm summaries to review alarms
grouped by process area.
The system maintains the last 200 alarms on hard disk for rapid playback and
review. It is possible to archive all alarms to floppy disks and CD backup.
The system maintains alarm reviews by priority, process area, time order, and
system alarms. It is possible, with password protection, to easily disable
groups of alarms during start-ups, shutdowns, maintenance turnovers, etc.
There are also dedicated lines on the CRT which always display the most
recent, highest priority, unacknowledged alarm in the system regardless of the
type of display that is currently on the main part of the screen."
Subsystems
• Data Historian: The historian is capable of storing at least 200 variables at
selectable scan rates. There is no loss of data to the archiving disk if the disk
is changed prior to it being full. The system prompts the operator to change
disks as it approaches full capacity and prompts him repeatedly before losing
data. The data stored by the historian is stored on disk in a popular database
format to allow file access from a Personal Computer. The historian
computes, stores and formats analog and digital data onto routine reports. The
three basic reports are:
• Daily Data Analysis -Provides hourly minimum, maximum, and average
for analog inputs.
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• Alarm Analysis Report -Provides a summary of each alarm condition by
providing time of alarm occurrence, time of alarm resetting and net time in
the Alarm State.
• Motor Analysis Report -Motor run time listing the operating time of each
motor.
Miscellaneous
The major system components have a battery backup or other method of retaining
program memory to avoid the need to reload the system after a power outage.
The uninterruptible power supply (UPS) is designed to keep the main PC
workstatio~ operational for 30 minutes in the event of a power loss to the system.
The process .mqnitoring system has the capability to self-document its entire
system configuration. This capability will be evaluated as a trouble shooting and
debugging aid when testing and commissioning.
4.9.8 Electrical Distribution Center
Carolina Power & Light (CP&L) will supply electrical power to the site. The
electrical service will be provided by overhead lines to a transformer located
adjacent to the electrical distribution trailer. The power supply will be 3-phase
480-volt service with a minimum of 1,600 amperes. ·
The electrical feed will be connected in the electrical distribution trailer equipped
with ground fault_ intercept and power main disconnect. Inside the electrical
distribution trailer, the power will be distributed to circuit breakers for each of the
major system areas (e.g. CBCD, BBCD, LBCD, PCSAPT, common systems,
support areas). This enables the contractor to electrically isolate an area. The
electrical power for each major system area will likewise have a master panel or
motor control center central to its location from which the electrical power will be
distributed.
As discussed previously, the site will be equipped with an emergency generator
such that critical system components can be maintained in the event of loss of
CP&L power. The generator is powered by fuel oil.
4.9.9 Maintenance/ Parts Inventory
Maintaining systems and equipment is vital to operating a project safely,
economically, and with a minimum amount of downtime. The contractor will be
required to have a staff knowledgeable in mechanical, electrical and
instrumentation maintenance. At a minimum, there will be at least one
maintenance person on-site at all times. The maintenance staff will be trained to
perform routine maintenance on the equipment. The maintenance staff will be
equipped with the proper maintenance equipment and tools necessary to perform
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preventative/routine maintenance and anticipated repairs to the systems. The
contractor will provide a detailed preventative/routine maintenance schedule for
the equipment, identifying the daily, weekly and manufacturer recommended
milestone services ( e.g., hours of service operation). The maintenance supervisor
will maintain records of all the preventative/routine servicing and repairs
performed during the project.
The Contractor will be required to maintain a detailed inventory of spare parts.
Parts critical to the operation will be inventoried on-site. The maintenance
supervisor will identify local sources for emergency parts, and repairs that cannot
be performed by the on-site maintenance staff. As necessary, service contracts
will be executed with specialty subcontractors for parts, supplies, and/or services.
4.10 Project Schedule
An overview of the project schedule for the detoxification of the PCB Landfill is as
follows:
TIME ACTIVITY
Month 1-3 Prepare plans, submit permit applications, ... equipment 1mtlate
procurement, implement Community Out Reach and Involvement
Plan
Month 4 Continue with Month 1-3 's activities; initiate site preparation
activities -base line monitoring, clearing & grubbing, site security,
temporary facilities, and install utilities.
Month 5-6 Install process pad and begin receiving equipment,
Month 7-9 Build roof covered areas for soil, install power, complete receipt of
equipment, finish component assembly, install conveyance piping
from/to process condensate treatment facility and storm water
treatment plants, begin shakedown and perform clean soil tests.
Month 10 Finish clean soil tests, and begin first of six PD tests.
Month 11 Receive preliminary stack test results and other analytical results,
prepare draft PD report.
Month 12 Receive final stack test results and finalize PD Report and submit to
State and TSCA.
Month 13 TSCA review period.
Month 14 Receive interim TSCA permit begin full -scale operations.
Months 15-25 Operate full-scale system; receive TSCA final permit during this
period.
Month 26 Commence decontamination of process equipment, complete
backfilling of landfill
Month 27 Continue decontamination of equipment, demobilization of
equipment, disposal of waste materials, complete site restoration
activities, and issue final reports ..
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4.10.1 Site Work Hours
Site preparation activities will be performed during daylight hours, normally 8 to
10 hours per day, five days per week.
During full-scale operations excavation activities will take place during daylight
hours for one, eight to ten hour, shift per day. It is anticipated that excavation will
take place five days per week; this will vary with workload and weather
requirements.
Several varied activities will occur in the BCD processing area. On the north end,
soil screening, mixing and stockpiling will take place. The screening and mixing
activities will be intermittent -three to six hours per day and approximately five
days per week. Soil stockpiles will be maintained continuously. The batch and
continuous BCD treatment equipment and the liquid BCD processing equipment
will be located in the central area. This work area will be active 24 hours per day,
seven days per week. Clean soil stockpiles awaiting final laboratory confirmation
will be located along the south area. Clean soil stockpiles will be maintained
continuous! y.
Site restoration activities will be performed during daylight activities, generally 8-
10 hours per day, five days per week.
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5.0 PERSONNEL OPERA TIO NS AND STAFFING
All on-site personnel are subject to the requirements of the HASP. Under no
circumstances may work be performed in a manner that conflicts with the information
presented in the Contractor's HASP. The Contractor will provide a project organization
figure, health and safety organizational structure and personnel roles and responsibilities
as part of the HASP.
5.1 Key Personnel
As a minimum, the Contractor will provide a site-specific organizational structure for
personnel considered critical to the planned activities at the site, and provide resumes for
those personnel. Below is a recommended list of key personnel to be provided at a
mm1mum:
Project Executive -
Project Manager -
Site Manager -
Project Engineer -
Site Shift Supervisor(s) -
Corporate Health and Safety Officer -
Site Health and Safety Officer -
5.2 Organizational Responsibility
The Contractor's Project Executive provides technical, management, and administrative
direction to the Project_ Manager as ri:eeded to ensure the project is progressing in
accordance with the HASP. ·
The Contractor's Project Manager (PM) is the primary point of contact for the NCDENR
and has overall responsibility for the project. The PM prepares correspondence,
submittals, and additional project documentation required for the project, and
coordinates, schedules, and administers the Contract. The PM prepares purchase
requisitions, prepares and submits requests for payment to the client, and approves
vendor/subcontractor invoices. The PM controls all subcontractors and suppliers during
site activities. The PM will review, approve, and become familiar with the HASP and
any amendments to the HASP.
The Contractor's Corporate Health and Safety Officer (CHSO), who will be a certified
safety professional or a certified industrial hygienist, oversees the Corporate Health and
Safety Program and develops standard operating procedures for the site activities. The
CHSO is responsible for data collection activities in response to health and safety issues.
The CHSO will visit the Site at least once every six months for the duration of activities
for the purpose of performing site health and safety inspections. The CHSO provides
consultation as needed to ensure the HASP is fully implemented and coordinate any
necessary modification to the HASP with the HSO, PM, and Site Manger (SM).
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The HSO assists and represent the CHSO in the continued on-site implementation and
enforcement of the HASP. Due to the work schedule, 7 days per week, 24 hours per day,
multiple HSO's will be employed and have the responsibility of ensuring safe work
practices are followed during all field activitit?s. A HSO will be on-site full time for the
entire duration of field activities, and will have no other duties other than health and
safety. The HSO will ensure that all aspects of the HASP are complied with as far as
preparation of records, air monitoring, use of PPE, decontamination, and site control.
The HSO will be responsible for perimeter and personal air monitoring and sampling
operations on-site including calibration and operation of equipment, compilation and
interpretation of data, and reporting and posting of qualified sampling results. The HSO
shall serve as a member of the quality control staff on matters related to safety and health,
and will consult and coordinate any necessary modification to the HASP with the CHSO,
PM, and SM . The HSO shall have the authority to stop work if on-site health and/or
safety conditions warrant such action.
The SM is responsible for overseeing all facility operations. This individual ensures that
all aspects of the Site are operational, maintained, and the HASP is implemented and that
progress is constant. The SM shall be on-site full time for the entire duration of field
activities or as the project dictates. The SM shall assist in the development of site
specific Task Assessment/Hazard Analyses (TAHA) for all principle tasks; correct
deficiencies noted within safety inspections/audits within defined time frames; and assist
with investigations of any incidents/accidents occurring on-site; and implement
corrective actions. The SM shall assist the HSO in the preparation, presentation, and
documentation of daily safety meetings.
5.3 Supervisor Safety Responsibilittes
Supervisors shall be responsible not only for their own safety, but also for the safe work
performance of the employees under their supervision. Before assigning work to an
employee the supervisor shall ensure that the employee knows and understands the
hazards associated with the work, and the proper procedure to perform the work safely.
Supervisors at all levels shall accept, in a cooperative manner, all reports of hazards, and
employees shall not be reprimanded or penalized for reporting hazards. Supervisors are
responsible for the complete and accurate reporting of employee injuries/accidents
5.4 Employee Safety Responsibility
Each employee is responsible for their own safety, as well as the safety of those around
them. Employees shall be required to know and understand the rules, which apply to the
work being performed.
If a condition or practice is observed that is either unsafe, defective, or destructive to the
employee or Contractor's property, or hazardous to the public or its property, it is the
employee's duty to correct the condition, if possible, or report it to his/her supervisor. If
an employee is assigned work, which he/she feels, will contribute to the destruction of
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equipment or is hazardous and without proper protection, the employee shall bring the
matter to the attention of their supervisor prior to starting the work. Employees shall use
care in the performance of their duties, assuring at all times maximum protection against
accidents involving themselves, other employees, the public, and Contractor's property or
the property of others.
Employees shall use protective devices as required by the HASP, and shall exercise
proper care and treatment of such equipment. All personnel will follow the policies set
forth in this plan and other applicable health and safety procedure documents.
5.5 Subcontractor Responsibilities
Each subcontractor performing work on-site is responsible for compliance with all
applicable federal, State, and local statutes, ordinances, codes and regulations regarding
health and safety. Each subc9ntractor shall prepare and conform to a health and safety
plan that provides planning at least as stringent ~ this plan. Each subcontractor must
identify a lead individual responsible for the health anci safety compliance of his or her
employees, lower tier subcontractors, and consultants. This person shall be responsible
for reporting to the HSO, and for demonstrating compliance with health and safety
procedures. The Contractor shall perform monitoring of subcontractor personnel and
shall be responsible for ensuring compliance to the HASP.
Each subcontractor employee proposed for on-site activities within the exclusion zone
must participate in a medical monitoring program, must be certified for hazardous waste
fieldwork by a licensed physician, and must have successfully completed the required
health and safety training, as per 29CFR1910.l20/1926.65. In addition, each individual
will participate in the drug-testing program. The drug-testing program includes testing
for pre-employment, random testing and testing for cause. Failure to pass the drug test
will preclude the individual form working on the site and maybe subject to immediate
termination from employment. Subcontractor employees working on-site exclusively in
the support zone (e.g. site preparation and site restoration activities) will require the
necessary training per 29 CFR 19190.120/1926.65 and participate in the drug testing
program.
5.6 Site Staffing
To ensure the safe and efficient operation of the project the minimum staffing
requirements are:
Site Management:
• Site Manager
• Project Engineer
• Health & Safety Officer/Safety Technicians
• Shift Supervisors
• Quality Assurance/Quality Control Technicians
• Office Clerk
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Landfill Operations:
• Equipment Operators
• Truck Drivers
Material Preparation Area:
• Process Operators
• Equipment Operators
• Laborers
CBCD & BBCD Processing Area:
• Lead Operators
• Process Operators
• Equipment Operators
• Laborers
LBCD Processing Area:
• Process Operators
• Laborers
PCSAPT:
• Process Operators
Loadout & Backfill Operations:
• Equipment Operators
• Truck drivers
Maintenance/Electrical:
• Mechanic/Electrician
5. 7 Site Personnel Training
Some of the site personnel will be long term employees of the Contractor, that have had
experience in similar projects to the Warren County PCB Landfill Detoxification project.
However, through the implementation of the Community Outreach and Involvement Plan
established for this project, local personnel will be hired for this project. Regardless of
experience level training in health and safety, and emergency response procedures will be
provided to all personnel.
5. 7 .1 Health & Safety Training
All personnel working on-site with the potential of coming in contact with
contaminated materials will require 40 hour OSHA training. Annual 8-hour
refresher training is required for personnel to maintain current their 40-hour
training. Supervisors will be required to have an additional 8-hour Supervisor
training.
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Daily tailgate safety meetings are conducted to review health and safety
procedures, disseminate monitoring sampling results, and to identify personnel of
new tasks to be performed and safety procedures to be followed .
5.7.2 Emergency Resp?nse Training
Site personnel will receive training during the site orientation concerning proper
emergency response procedures. In addition, specific individuals representing all
shifts and work areas at the site will be assigned to the Emergency Response
Team. An individual and alternate designees from this group will be assigned the
emergency coordinator and alternates positions .All personnel on the Emergency
Response Team will receive special training to include but not be limited to:
• First Aid,
• Cardio Pulmonary Resuscitation (CPR),
• Basic emergency response training, and
• Specific site emergency response training with representatives of the
community including, Fire Department, EMS and County HAZMA T
Response personnel.
• Blood Borne Pathogens.
5.7.3 Site Operations Training
Prior to the start of any task or operation a Task Assessment/Hazard Analysis
(TAHA) will be prepared. The requirements for preparing a TAHA are provided
in the HASP. In addition, the Contractor will provide a critical hazard operation
evaluation for each equipment component. The critical hazard operation
evaluation ,will determine the scenario for each component should it fail, and the
contingency plan to be implemented should a failure occur. Personnel will be
trained for their specific position requir.ements based upon the TAHA and critical
hazard operation evaluation.
The operators for the major system processes ( e.g. CBCD, BBCD, LBCD,
Material Preparation, Common Systems, and PCSAPT) will receive specific on
the job training related to the use of the process monitoring system.
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6.0 SAMPLING AND ANALYSIS FULL-SCALE OPERATION
The Final Verification/Confirmation Sampling Plan (FVCSP) details the minimum full-
scale sampling and analysis to be performed for the PCB Landfill Detoxification project.
Special sampling and analysis requirements to be performed during the Performance
Demonstration testing are contained in the Performance Demonstration Plan. Table 6-1
summarizes the full-scale sampling and analyses to be performed for the BCD operation.
6.1 Types Of Samples
The FVCSP describes four categories of samples to be collected and analyzed for this
project:
1) Verification Samples: Verification samples will be collected and analyzed in the field
to provide the site management with information to make daily operational decisions.
2) Confirmation Samples: C:::onfirmation samples will be analyzed by a laboratory
certified to perform· the applicable • parameters under either North Carolina
Administrative Code (NCAC) Subchapter 2H.0800, or the Environmental Protection
Agency's (EPA) Contract Laboratory Program (CLP). Unless otherwise noted in the
FVCSP, field procedures must be in compliance with the May 1996.US EPA Region
IV Environmental Investigations Standard Operating Procedures and Quality
Assurance Manual (SOP). Field procedures include, but are not limited to, proper
chain of custody protocols, sampling methods, preservation, containerization, field
blanks, duplicates, matrix and matrix spikes and shipping procedures.
3) Informational Samples: lnforma~ional samples can be analyzed either through field
screening methods or the use of laboratory analysis. The designation "informational"
means that the sample is not a regulatory or permitted sample/ discharge parameter.
The informational samples are generally influent or intermediate process samples to
determine the effectiveness of a process system or components of a process system.
These samples allow the Contractor to monitor and adjust the effectiveness of the
process system. The Contractor may desire to collect samples from additional
locations or increase frequency of an informational sample location, as they deem
appropriate. However, the Contractor will not be compensated by NCDENR for
additional information samples collected and analyzed.
4) Control Samples: Control samples are collected at points of discharge (regulatory or
required by permit). Only certified laboratories can analyze control samples, as these
are considered confirmation samples. The sampling frequency of control samples
shall not be decreased without the approval of the State and regulatory agency. As
with confirmation samples, field procedures must be compliant with the EPA Region
IV Environmental Investigations Standard Operating Procedures and Quality
Assurance Manual (SOP).
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Site Of!.~-_ .ion Work Plan Description Matrix Untreated Solid Material Solid Solid Table 6-1 Sampling/Analysis Full Scale Operation Samples Frequency Quality Type Data Use Control InformationaVControl Every day of excavation As required by Composite Excavated Material: Informational test procedure Segregate for BBCD/CBCD Selection Guideline Floor and sidewalls of As required by Composite Post Excavation: Informational excavation every 50' x test procedure Confirm excavation limits in landfill 50' grid Floor and sidewalls of CLP Lab Composite Post Excavation: Control excavation every 50' x Protocol, Verify excavation limits in landfill 50' grid minimum, one in every 20 samples Warren Coun!i'_ PCB Landfi11 Preparation/ Analytical Methods PCB Immunoassay % Moisture Field Test PCB Immunoassay PCB 8082 Solid Floor of existing pond CLP Lab Composite Post Sediment Excavation: Control PCB 8082 after excavation of Protocol Verify remaining sediments Meet sediments one sample cleanup standards every 50 linear feet Treated Solid First 2 weeks full scale CLP Lab Composite Treated Material: Control PCB 8082 Material production one sample Protocol, Verify treated soil meets clean-up Dioxin/Furan 8290 every 2 days of minimum one in standards from CBCD production through every 20 samples CBCD Solid First 2 weeks full scale CLP Lab Composite Treated Material: Control verify PCB 8082 production one sample Protocol, treated soil meets cleanup standards Dioxin/Furan 8290 every 2 days of minimum one in forBBCD production through every 20 samples BBCD Solid Remainder of project CLP Lab Composite Treated Material: Control PCB 8082 one sample every 2 days Protocol, Verify treated soil meets cleanup of production through minimum one in standards CBCD every 20 samples Field blank one/week ETG Environmental, Inc/ BF A Environmental Consultants 74 March 2000
Site O£'-•~don Work Plan Description Matrix Treated Solid Material (Continued) Storm water/ Liquid Decon water Warren Coun~ PCB Landfill Table 6-1 Sampling/Analysis Full Scale Operation Samples Frequency Quality Type Data Use Control "Informational/Control Remainder of project CLP Lab Composite Treated Material: Control minimum one composite Protocol Verify treated soil meets cleanup sample per month of standards production through BBCD, or one sample per batch when untreated PCB concentration >750ppm Once/ week first 4 weeks CLP Lab Grab Influent to Pond: Informational Monthly Thereafter Protocol, Evaluate water quality into storm minimum one water treatment process every 20 samples Midfluent to Pond: Informational Evaluate break though of first carbon bed Effluent to Pond: Control Evaluate effiuent quality for discharge compliance (Note: dictated by spray irrigation permit) Preparation/ Analytical Methods PCB 8082 Dioxin/Furan 8290 PCB 8082 PCB 8082 PCB 8082 ETG Environmental, Inc/ BFA Environmental Consultants 75 March 2000
Site O.Q_erntion Work Plan ·Description Matrix Process Solid Condensate Liquid Liquid . Liquid Table 6-1 Sampling/Analysis Full Scale Operation Samples Data Use Frequency Quality Type Informational/Control Control Daily during PD and first As required by Composite Filter cake: Informational 14 days of processing, test procedure Determine PCB concentration of then, once per week cake and further treatment requirements Daily first 14 days of As required by Grab Sand filter Influent: Informational processing, then test procedure Evaluate water quality off centrifuge Once per week and loading on down stream polishing systems Daily first 14 days, then As required by Grab First carbon: Informational once per week. Note: test procedure Determine loading, breakthrough of frequency may increase first carbon unit if field data indicates CLP Lab Grab Effluent: Control carbon break through Protocol, Determine effluent quality of water will occur at greater minimum one used for rehydration frequency every 20 samples Once every two days As required by Grab Pretreatment Organic storage test procedure tank: Informational Warren County PCB Landfill Preparation/ Analytical Methods PCB Immunoassay Solid Content PCB Immunoassay TSS 160.2 PCB Immunoassay PCB 8082 PCB Immunoassay Determine if recovered organics from clarifier and centrifuge requires further treatment ETG Environmental, Inc / BF A Environmental Consultants 76 March 2000
Site OQe,uLIOn Work Plan Description Matrix CBCD Liquid Quencher/ Scrubber Recyle Condensate Liquid Collection Tank Discharge Contaminated Liquid Organics Feed to LBCD Reactor LBCD Effluent Liquid Table 6-1 Sampling/Analysis Full Scale Operation Samples Data Use Frequency Quality Type Informational/Control Control Daily during PD test and As required by test Grab Recycle Scrubber Water: first 14 days of procedure Informational processing, then; once Evaluate quality of quencher/scrubber per week recycle water. Daily during PD test and As required by test Grab Condensate Collection Tank: first 14 days of procedure Informational processing, then; once Evaluate filter press feed per week Once per batch As required by test Grab LBCD Organic Feed Tank: procedure Informational Determine PCB carryover with organics. Once per tanker load to CLP Lab Protocol, Grab Organic Treated Tank: recycling facility minimum one every Control 20 samples, or as Verify that treated organics can be required by transported and accepted at disposal recycling facility facility ETG Environmental, Inc/ BF A Environmental Consultants 77 Warren Counb'._ PCB Landfill Preparation/ Analytical Methods TSS 160.2 pH 150.1 Chlorides 325.2 TOC 415.2 TSS 160.2 pH 150.1 Chlorides 325.2 TOC 415.2 PCB Jmmunoassay PCB 8082 Other parameters as required by recycling facility March 2000
Site Operations Work Plan Warren County PCB Landfill
Table 6-1 provides the sampling location, frequency, quality control requirements, type
of sample, data use (Informational or Control), analysis and minimum estimated samples
for the full-scale operations. The following sections describe each sample area.
6.2 Untreated Materials
Vntreated materials will be sampled and analyzed during three phases of the project:
• Performance Demonstration,
• Excavation Activities, and
• Post Excavation.
6.2.1 Performance Demonstration (PD) Sampling Untreated Materials
Samples collected during the PD are to provide a baseline of the material
contaminants and concentrations. The analysis will provide information on the
PCB and dioxins/furans concentrations prior to treatment. In addition to the PCB
and dioxins/furans analysis, untreated materials will be analyzed to fully
characterize the materials to be treated.
6.2.2 Excavation Sampling Untreated Materials
During full-scale operations, samples of the untreated material will be collected
everyday of excavation activities. These samples, referred to as Informational
samples in Table 6-1, are for segregating the excavated materials prior to
treatment through the CBCD or the BBCD. The following guideline will apply:
• BBCD-Untreated material with a PCB concentration of 750 ppm or greater,
or a percent moisture content of 15 percent or greater;
• All other untreated materials to either the CBCD or BBCD.
6.2.3 Post Excavation Sampling Untreated Soils
Verification and confirmation samples will be collected from the sidewalls and
floor of the excavated landfill. Excavation will continue until the PCB
contaminated materials, the filter fabric and six-inches of the five-foot thick clay
liner are removed. The Contractor will design a sampling grid over the base and
sidewalls of the excavation. Grid nodes will not be greater than 50 feet apart.
A portion of the sediments located in the existing pond have been tested and
determined to contain elevated levels of PCBs above the cleanup standard. The
affected area extends from the discharge pipe of the existing water treatment
system and proceeds toward the center of the pond. The sediments will be
excavated from the pond and post excavation samples will be collected and
analyzed in the field using the PCB immunoassay test (verification) and then
submitted to a laboratory for PCBs ( confirmation). At a minimum, three sediment
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samples will be collected to verify/confirm the remaining sediments are at or
below the PCB cleanup standard of 200 ppb.
6.3 Treated Materials
Treated soils will be sampled and analyzed during three phases of the project:
• Performance Demonstration
• First Two Weeks Of Full-scale Operations, and
• Remainder Of Project.
6.3.1 Performance Demonstration (PD) Sampling Treated Materials
Treated samples will be collected from each CBCD and BBCD PD test. The
analytical results will confirm the treated materials meet the soil cleanup criteria
for this project, and also that the treated materials are not hazardous for other
constituents.
6.3.2 First Two Weeks Full-scale Operations Sampling Treated Materials
The sampling plan for treated materials is predicated on the successful completion
of the performance demonstration test and that no other contaminants of concern
were identified.
Treated materials from the CBCD and BBCD will be separated into distinct
stockpiles. Each CBCD stockpile will contain two days of processed material and
each BBCD stockpile will contain one week of processed material. One
composite sample for each stockpile will be collected sent to a laboratory for
PCBs and dioxin/furans analysis.
6.3.3 Remainder Full-scale Operations Sampling Treated Material
Treated materials from the CBCD will continue to be grouped in two-day
stockpiles. The sampling protocol will remain the same, with one composite
sample collected and analyzed by a laboratory for PCBs.
A monthly stockpile will be generated of materials treated in the BBCD unit or
one sample per batch for materials treated with an initial PCB concentration
greater than 750 ppm. One monthly composite sample will be collected and
analyzed by a laboratory for PCBs and dioxin/furans. Similarly, each batch
stockpile treated from materials containing PCBs greater than 750 ppm will have
one composite sample collected and analyzed for by a laboratory for PCBs and
dioxin/furans.
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6.4 Liquid BCD Detoxification System Sampling
Organics containing PCB concentrations will require detoxification/dechlorination
treatment in the LBCD process. The sampling frequency may be modified to correspond
with the quantity of organics being treated per LBCD batch and the variance of PCB
concentrations contained in the collected organic stream.
At a predetermined time, when the reaction period is anticipated to be completed (note:
batch specific, dependant upon initial PCB concentration and other variables) samples
will be collected from set sample ports. The sample will be screened for PCBs using the
immunoassay test. When sufficient quantity of organics are collected in the treated
organic storage tank, a confirmation sample will be collected and analyzed for PCBs, and
any other parameters required by the disposal facility. A certified laboratory will analyze
the confirmation sample.
6.5 Process Condensate Separation and Aqueous Phase Treatment Sampling
The following samples will be collected, at a minimum, to monitor the PCSAPT
performance.
6.5.1 Filter Cake Sampling
A composite sample of each day's production of filter cake during the PD and
first two weeks of full scale operation will be screened for PCBs using the
immunoassay test and tested on site for percent moisture. These samples are for
informational purposes, as the filter cake may be reprocessed through the BBCD
process, due to the anticipated elevated level of PCBs in the filter cake.
It is anticipated that after two weeks of full-scale production, the sampling
frequency can be reduced to once a week.
6.5.2 Sand Filter Influent Sampling
To evaluate the performance of the process condensate separation system, a
sample of the aqueous filtrate will be collected prior to proceeding through the
aqueous phase portion of the treatment system (sand filtration and carbon
polishing).
During the PD and first two weeks of full-scale operations a sample will be
collected daily. After which a sample will be collected, at a minimum, once per
week. The sample will be analyzed on site for total suspended solids (TSS) and
for PCBs.
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6.5.3 Midfluent Carbon System Sampling
The aqueous phase treatment system concludes with, a minimum of two carbon
units placed in series for polishing. A sample will be collected after the first
carbon unit and analyzed on site for PCBs using the immunoassay test. This data
will determine when break through for PCBs has occurred, and carbon change-out
is required. The data will also provide information to the treatment operator
regarding carbon efficiency and anticipated carbon change-outs. A sample result
above 200 ppb will require the carbon to-be changed-out.
Sample frequency will be, at a minimum, one sample per week, data results may
dictate more frequent sampling.
6.5.4 Effluent Carbon Treatment Sampling
To monitor the effectiveness of the PCSAPT system for treatment of PCBs, an
effluent sample will be collected at least weekly. The sample will be sent to
laboratory and analyzed for PCBs. The target cleanup level is less than <200 ppb.
6.6 CBCD Quencher/Scrubber Recycle
In an effort to evaluate the quality of the CBCD quencher/scrubber recycle, samples will
be collected from the CBCD quencher/scrubber system. Data from these samples will
allow the treatment operator to evaluate the CBCD quencher/scrubber performance.
Samples will be collected form either a sample port installed in the recycle line, or
directly from the recycle tank.
The samples will be analyzed for TSS, pH, total organic carbon (TOC) and chlorides.
The results are for informational purposes only. During the first PD and two weeks of
full-scale operations a sample will be collected daily from each unit. Thereafter, the
minimum sample schedule will be weekly.
6.7 Storm Water/Decontamination Water Sampling
Sampling ports will be installed on the Storm Water/Decontamination Water treatment
system in order to collect samples prior to treatment, midfluent of the carbon system and
effluent quality. The influent and midfluent samples are for informational purposes, the
effluent sample is a Control sample and subject to applicable permit requirements.
Currently, the Spray Irrigation System permit requires that the concentration of PCBs in
the effluent wastewater to be applied by the system shall not exceed 1 ppb PCBs. The
sampling frequency is once per month. The proposed sampling frequency for this project
is once per week for the first four weeks of full-scale operation, followed by monthly,
thereafter. The samples will be analyzed for PCBs. At a minimum, the effluent sample
(Control sample) must be analyzed by a laboratory certified to perform PCB analysis.
The actual permit received by the Contractor for the spray irrigation system will predicate
the sampling frequency and analytical requirements.
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6.8 Miscellaneous Sampling
The intent of the project is to treat all PCB contaminated materials on-site. However, due
to logistics, there will be a relatively small quantity of residual materials that will require
disposal off-site. These may include, but not be limited to:
• Spent Personal Protective Equipment (PPE),
• Porous oversize debris,
• Sand and carbon from last units used for treatment,
• Decontamination water generated after treatment systems are dismantled,
• Spent rags and materials used for decontaminating equipment, and
• Miscellaneous trash and debris including scrap steel.
These waste streams will require sampling and analytical data for proper disposal and
documentation. The disposal facility requirements, the physical nature of the waste
stream (porous, non-porous, solid, liquid, etc.), and how the waste was generated will
determine the sampling and analytical requirements.
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7.0 AIR MONITORING
The Air Monitoring Plan details the air monitoring and sampling requirements for the
full-scale operation of the site. Special sampling and analysis requirements to be
performed during the Performance Demonstration testing are contained in the
Performance Demonstration Plan. Monitoring and sampling for the health and safety of
the site personnel and surrounding community is contained in the HASP. The following
sections highlight the air-monitoring program.
7.1 Background Monitoring
Background air monitoring data will be compared against operational air monitoring data
to determine the impact of the remediation activities on air quality.
7.2 Meteorological Station
A meteorological station will be located on-site to monitor temperature, barometric
pressure, relative humidity, wind speed, wind direction and precipitation. The data
collected from the station will be recorded daily in the logbook. The daily wind direction
will determine the up-and downwind locations for air monitoring and sample collection.
7.3 Construction Moi:iitoring
During the equipment mobilization and set-up phase, prior to any excavation, daily
monitoring will be performed. Real time organic vapor and dust monitoring equipment
will measure dust and particulate levels within and outside of the work areas.
7.4 Landfill Excavation
The HSO will monitor airborne emissions and operator exposures during excavation
activities. Emissions will be monitored in the landfill work area and up-and downwind
from the excavation. Direct reading instruments will monitor for respirable dust and for
V OCs twice per shift.
During the first few weeks of excavation, periodic personnel samples will be collected
and submitted for laboratory analysis (see the HASP). This sampling will occur
concurrent with the excavation of PCB contaminated soils.
7.5 BCD Processing Area
The HSO will monitor the airborne emissions and personnel exposures during all work
shifts within and downwind of the BCD processing area. Direct reading instruments will
monitor for VOCs at a minimum of twice per shift. · Dust monitoring will occur
concurrent with screening and stockpiling activities.
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7.6 Stack Emission Monitoring
In addition to the process area monitoring, continuous process stack monitoring will be
conducted. The monitoring points will be located at the discharge of the thermal
oxidizers for both the CBCD and BBCD systems. Stack emission monitoring provides
tota~ hydrocarbon (THC) readings us1ng a THC analyzer.
7.7 StackTesting
Stack emission tests will be conducted during the POP testing to verify that CBCD and
BBCD stack emissions do not exceed established federal and state action levels off-site.
A qualified stack-testing contractor will conduct all stack tests. During each of the three
performance test runs, two stacks, one each for the BBCD and CBCD systems will be
tested. The stack sampling will occur at the discharge of the thermal oxidizers.
7.8 Perimeter Area
The site perimeter has been established as the State boundary. During all operations, the
HSO or his/her representative will monitor the airborne emissions at least twice per shift,
adjacent to the perimeter, at one upwind and two downwind locations. Direct reading
instruments will monitor for VOCs and respirable dust.
Additional quantitative monitoring will take place during the POP and early phases of
work. See Table 3-2 of the Air Monitoring Plan for a summary of the sampling plan.
The frequency and numbers of samples collected will decrease as site work continues
(assuming earlier analysis proves low or no levels of constituents).
7.9 Engineering Controls
· Appropriate engineering controls will be instituted to reduce emissions in the event the
action level is exceeded during remedial activities. Examples of engineering controls for
dust control include spraying of water, covering sources of dust, and reducing vehicle
speeds on access roads or speed of excavation. Examples of engineering controls for
VOCs include spraying stockpiles with foam or covering stockpiles with plastic sheeting
or other barriers.
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8.0 PERMITTING
The Contractor will be responsible for obtaining all necessary local, state and federal
permits. The permits include, but not limited to:
• TSCA Operating
• State Of North Carolina Division Of Air Quality
• Irrigation Permit for Treated Stormwater/Decontarnination Water Used For Dust
Control
• Erosion Control
• Local Construction
• Local Building
• Local Electrical
• Local Land Disturbance/Use
• Local Plumbing
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I f ' ' i t. r ' f }" 1 f l TO CBCO FTO CHIL1.£R aRCU[ ,----< DWG I PFD-203 I I . I I I I I • I f"ROM BBCD CENTRIFUGE ~4 FROM FlLTRATE STORAGE TANK .1.BQ2 ORGANIC ffED JN:iK ~ CATALYSTS CARRY OIL .IAliK I 1 I I I i Lry--i~ i . .CAUSIK; I I CATALYSTS I f[[D PUMP i i ffED PUMP I .. I --'-Ll---II I L __ ~ --7., I .LeCD ORGANIC ffED PUMP ---·-·----·-·-· I ! ! ,--------~_J i ! ! i CARRY OIL I I i TANK PUMP .LeCD REACTOR '< ) ----------------¥---l! __ Si-- -_ p I I HEATING/ ,COOLING . I . .lllilI L-----01--j j I ,-----7 l r---7 . I I I i I -~-ORGANICS TRANSFER ..IAtiK ORGANICS TRANSF£R .eu.MP ACID NEUTRALIZATION r--cc3--~ I • I I -, I . .. I t I I I L ~--< DWG PFD-204 I \:::.J TO CONDENSATE WATER RETURN COU£CTION TANK BHil.f CONDENSATE JANK 13 REACTOR TRANSF£R fUMf.' I L----------____________ _j . I I r----IB--_J ! -----------~ I -----------L_ __________________________________________ _ .G.6CQ CONDENSATE fUMf.' ETG [NVlROt.1£:NTAL INC. NOm« CAROlMA DO'ARlWDIT Of OMROKVOll AICl IIAI\JIW. IIESOl-=c; DIVISION Of WAST[ WANA~(V[NT WARREN COUNTY PCR I ANnn, 1 nnnv,nr .. nnN Pon tC"rT ..BFA Environmenlal C-onsu1tants ----=----------Barnes. Ferland LJr>d Assocuotes. Inc. LBCD PROCESS FLOW DIAGRAM .IfilAI£Q QRG6t:{K; Ml::ilS l I I I I I L ___ EJ}--.HQIL .IB.EAJID ~ £UMP LEGEND: FW..t0:•• DJ)--U>UI) -·-o:xuc:...,.,. -,ass IOC[R WHO!£ TWO PUMPS "11£. SHOWN. OH£ IS OPIJlATlNC AHO OH( IS A SPARE.. DttAnc; N"OltW.lllOH OAT£ _.., -,u:,..., -=-@ft CO< PFD-205 au.• n rwc -
No. 2 FlJEL OIL TANK NITROG(N CYLINDERS PROPANE TANK PLANT AIR COMPRESSOR WITH DESICCANT DRYER ,__ OWG Pf0-202 TO C8CO SEALS & WESP OWG PFD-202 FROM OUPLfX OIL PUMPS CBCO OWG PFD-203 FROM OUPLfX OIL PUMPS BBCD OWC PFD-202 TO CBCO OUPlfX FUEL PUMPS OWG PFD-203 TO 88CD OUPUX FUEL PUMPS owe PfD-202 TO C8CO owe PfD-203 TO 88CO TO EMERGENCY G~ERATOR TO C8CO TO BBCD TO CBCD VRS TO BBCO VRS TO GENERAL PURPOSE PLANT TO PCSAPT TO LBCD ETG ENVIROMEHT AL INC. NOllTM CAl!OlMA 0CPAll1\4)(T Of OMl()IIIIOIT AICl MATUIUL ll£:SOIAICCS DIVISION or WI.ST( 114N4,Cll(Nt WARREN COUtm' PCB 1.ANDFlLL DCTOXlflCATION PROJECT FROM COOLING TOWER -··-··-··1--------FROM TREATED STORMWATER ( OWG Pf0-202 h TO coco I I I ( owe PF0-203 H TO BBCO i I I I I I CITY MAKE-UP WATtR I I I I • I -----+----_ FROM PCSAPT WATtR STORAGE TANK ~-----{7"'\__I_ i \..._/ I ~------' I TREATED WATER I I FEED PUMP I L---v_J TREATED WATER FEED PUMP .BF A. Environmenlal C.onsultants ~--.------------&mes. Ferland ,u,cJ Assocuttes. Inc. COMMON SYSTEMS PROCESS FLOW DIAGRAM LEGEND: f\E.. ta a.._ ------------SOLD IIQEJl,,,lltc_ -----------U1ID -·-·-·-·-·-·-·-·-Coll$ .. ~ -··-·-----··-··-··-··-an,c -.J"EJlt -·-----PIIDCCSS WAJtJI _ ... DIIA....C IHfootWATIOI( NO.O:f'"" ODl>O ft ~ DATE PFD-201 ou.-rr. rwc ......... OO)([D rr. PAS
WARREN COUNTY
PCB LANDFILL
CONSTRUCTION QUALITY
ASSURANCE PLAN -
BCD DETOXIFICATION
Prepared for:
North Carolina
Department of Environment
and Natural Resources
Division of Waste Management
E.,.v-irc».,.me-.. t.al, ■ .. c_
BF A Environmental Consultants
Barnes, Ferland and Associates, Inc.
March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
CONSTRUCTION QUALITY ASSURANCE PLAN -
BCD DETOXIFICATION
TABLE OF CONTENTS
1.0 INTRODUCTION ....................................................................................................... l
1.1 Purpose ............................................................................................................ 1
1.2 Overview ......................................................................................................... 2
1.3 History ............................................................................................................. 2
1.4 Project Summary of Work .............................................................................. 3
2.0 GENERAL ............................................................................................................. 4
2.1 Requirements ................................................................................................... 4
2.2 Testing Firms ................................................................................................... 4
2.3 Owner/ Agency Access .................................................................................... 4
2.4 Conformance ................................................................................................... 5
2.5 Acceptance by NCDENR ............................................................................... 5
3.0 PROJECT ORGANIZATION AND RESPONSIBILITIES .................................... 6
3. I General ............................................................................................................ 6
3.2 Quality Control Supervisor ............................................................................ 6
Figure 1 -CQAP Organizational Chart ................................................. -7
3.3 Quality Control Technicians/Resident Inspectors ......................................... 9
3.4 Site Manager ................................................................................................... 9
4.0 SUBMITTAL MANAGEMENT ............................................................................. 10
4.1 General Requirements .................................................................................. 10
4.2 Project Submittals ........................................................................................ 10
4.2.1 Shop Drawings ................................................................................ 11
4.2.2 Samples ............................................................................................. 11
4.2.3 Certificates of Compliance .............................................................. 12
4.3 Project Records ............................................................................................. 12
4.4 Transmittals to NCDENR 13
ETG Environmental, lnc./BFA Environmental, Inc. -i-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
CONSTRUCTION QUALITY ASSURANCE PLAN -
BCD DETOXIFICATION
TABLE. OF CONTENTS
(Continued)
5.0 INSPECTION REQUIREMENTS ........................................................................... 14
5 .1 General ........................................................................................................... 14
5.2 Testing phases ............................................................................................... 14
5.2.1 Phase I Inspections ........................................................................... 14
5 .2.2 Phase II Inspections ......................................................................... 15
5.2.3 Phase III Inspections ....................................................................... 15
5 .3 Reporting ....................................................................................................... 15
5 .4 Deficient work ............................................................................................... 16
5.5 Construction Quality Control Test Schedule ............................................ ..16
5.6 Materials 18
5.6.1 Storage ............................................................................................... 18
Table 1 -Construction Quality Control Test Schedule ............... J 9
6.0 DOCUMENTATION ............................................................................................... 24
6.1 Record Keeping····························································································24
6.2 Daily Inspection Report ................................................................................ 24
6.3 Daily Test Reports ........................................................................................ 25
6.4 Notice of Non-Compliance .......................................................................... 26
LIST OF TABLES AND FIGURES
Figure 1-CQAP Organizational Chart .................................................... 7
Table I-Construction Quality Control Test Schedule ................................. 19
APPENDICES
I. Contractor's Staff Resumes/ Responsibility
IL Letter of Authorization
III . Testing Laboratory Qualifications
IV. Forms
Quality Control Daily Inspection Report
Notice of Non-Compliance
Submittal Register
Submittal Form
Testing Laboratory(s) Qualifications
ETG Environmental, lnc./BF A Environmental, Inc. -II-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
AASHTO
ASTM
BCD
BFA
CFR
CQAP
CQC
EM
ENG
ER
ETG
FVCSP
NCAC
NCDENR
O&M
PCB
ppb
ppm
ppt
QC
RCRA
Site
TEQ
TDU
TSCA
CONSTRUCTION QUALITY ASSURANCE PLAN -
BCD DETOXIFICATION
TABLE OF CONTENTS
(Continued)
LIST OF ACRONYMS
American Association of State Highway and Transportation Officials
· American Society for Testing and Materials
Base Catalyzed Decomposition
Barnes, Ferland & Associates, Inc.
Code of Federal Regulations
Construction Quality Assurance Plan
Construction Quality Control
Engineering Manual
Engineering Form
Engineering Regulation
ETG Environmental Corporation
Final Verification/Confirmation Sampling Plan
North Carolina Administrative Code
North Carolina.Department of Environment & Natural Resources
Operations and Maintenance
Polychlorinated Biphenyl
part per billion
part per million
part per trillion
Quality Control
Resource Conservation and Recovery Act
Warren County PCB Landfill
Toxicity Equivalent Concentration
Thermal Desorption Unit
Toxic Substance Control Act
ETG Environmental, lnc./BF A Environmental, Inc. -iii-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
1.0 INTRODUCTION
1.1 Purpose
The Construction Quality Assurance Plan (CQAP) describes the quality control (QC)
organization and program for the detoxification activities of the Warren County PCB
(polychlorinated biphenyls) Landfill (the Site). Chemical quality management aspects of
this QC program are addressed in the Final Verification/Confirmation Sampling Plan
(FVCSP). The CQAP and the requirements and systems established herein are relevant
and applicable to the project work performed by the Contractor, and his subcontractors
and suppliers.
The objectives of this CQAP are to anticipate the specific operating requirements of the
project, and to establish procedures to ensure that the construction quality meets technical
design specifications and conforms to the requirements of the Contract. Specifically, this
plan:
• Identifies the project, QC organization and defines each individual's respective
authority, responsibilities, and qualifications;
• Defines project communication, documentation, and record keeping procedures;
and
• Establishes QC procedures, including the necessary supervision and tests, to ensure
that work meets applicable specifications and drawings.
ETG Environmental, lnc./BF A Environmental, Inc. -1-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
1.2 Overview
The Warren County PCB Landfill is a closed Toxic Substances Control Act (TSCA)
landfill. The detoxification of the landfill represents a voluntary closure of the facility.
The State of North Carolina has selected Base Catalyzed Decomposition (BCD)
technology to detoxify the PCB and dioxin contaminated materials at the Warren County
PCB Landfill. The State of North Carolina legislature has incorporated the utilization of
BCD for the landfill detoxification into law and has specified the appropriate treatment
standards required for the detoxification of the landfill.
The treatment standards for material are as follows : A) PCBs -200 parts per billion
(ppb) and B) dioxins/furans -200 parts per trillion (ppt) Toxicity Equivalent
Concentration (TEQ).
1.3 History
The Warren County PCB Landfill is located in Warren County, North Carolina,
approximately 50 miles north of Raleigh, North Carolina. The Site is situated within a
tract of land owned by the State of North Carolina that covers 19 .317 acres. The Site
includes a 2.54 acre landfill cell (PCB Landfill) that contains materials with elevated
levels of PCBs. A gravel road approximately 3,000 feet long provides access to the Site
from State Road 1604.
The PCB Landfill is approximately 250 feet wide (measured in an east to west direction)
and 500 feet long and contains approximately 40,000 cubic yards of materials that were
deposited into the landfill from remediation of roadways throughout the state that were
illegally sprayed with PCB contaminated oils. Approximately ten percent of the
materials originated from the Fort Bragg Military Reservation near Southern Pines, North
Carolina and are assumed to be of a similar nature to the balance of the contaminated
materials.
ETG Environmental, lnc./BFA Environmental, Inc. -2-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
The PCB concentrations in the materials range from 259 parts per million (ppm) to a high
of 853 ppm, with an average concentration of 500 ppm. Dioxin/furan concentrations
range from 147 ppt TEQ to 238 ppt, with an average concentration of200 ppt TEQ.
The maximum depth of the PCB Landfill at the center is approximately 40 feet, which
includes the lower liner and existing cover. The depth at the perimeter is approximately
20 feet. In addition to the PCB materials, a relatively small amount of kiln dust (less than
l % of the total volume) occupies the northeast comer of the PCB Landfill.
Approximately one-half of the PCB Landfill rises above the existing ground surface. The
PCB Landfill was completed in 1983.
1.4 Project Summary of Work
ETG Environmental, Inc./BF A Environmental Consultants, Inc. have developed the bid
specifications for the detoxification of the PCB Landfill. The scope of work for the
detoxification of the PCB Landfill is as follows:
I. Mobilization and site preparation activities including clearing and grubbing,
construction of staging areas, utilities, haul roads, support zones, sediment
control/stormwater management facilities, fencing, and process pads and buildings;
assembly/installation of full scale detoxification technology equipment; and
temporary construction/support trailers.
II. Landfill opening, excavation of contaminated materials, performance demonstration
testing, detoxification of contaminated materials, verification and confirmation
sampling and analysis, work area/perimeter air monitoring, process condensate
treatment, and off-site recycling/disposal of solid and liquid residues.
Ill. Landfill backfill and compaction, decontamination/demobilization of all equipment
from the site, restoration and vegetation/planting of all work areas.
ETG Environmental, lnc./BF A Environmental, Inc. -3-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
2.0 GENERAL
2.1 Requirements
The CQAP defines the site personnel, procedures and protocols to be performed to ensure
the quality of the work, at a minimum, satisfies the bid specifications. The CQAP
focuses on the personnel organization and respective duties, and the quality assurance for
the general construction activities to be performed at the site. Quality assurance issues
regarding health and safety, air monitoring, verification and confirmation sampling and
analysis, and performance determination are addressed within their respective plans that
are included as part of the Bid Specifications.
2.2 Tes ting Firms
The laboratory testing firm(s) to be used for construction quality control tests are listed
with their qualifications in Appendix III . Qualifications for the laboratory firms
performing environmental testing (e.g., air, water soil and personnel air monitoring) are
located within their respective plans. The selected licensed testing firm(s) shall be
experienced in performing the work required.
2.3 Owner/ Agency Access
Representatives of the North Carolina Department of Environment and Natural Resources
(NCDENR) or their authorized agencies will have access to the work at all times for
observations, inspection and testing. The Contractor will provide proper and safe
conditions for such access. The Contractor will give NCDENR timely notice of readiness
of all work that requires their inspection, tests, observations or approvals.
ETG Environmental, Inc./BF A Environmental, Inc. -4-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
2.4 Conformance
The Contractor will insure conformance of all items of work, including that undertaken
by his subcontractors, to the applicable Drawings and Specifications with respect to
materials and workmanship.
2.5 Acceptance by NCDENR
Acceptance of this plan is conditional and will be predicated on satisfactory Contractor
performance during the detoxification. The NCDENR reserves the right to require the
Contractor to make changes in the CQAP including removal of personnel, as necessary,
to obtain the quality specified.
ETG Environmental, lnc./BFA Environmental, Inc. -5-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
3.0 PROJECT ORGANIZATION AND RESPONSIBILITIES
3.1 General
The organization established for this project is depicted in Figure 1 attached. This plan
includes the project management, technical and QC staff. Additional QC staff may be
added as necessary to meet QC requirements for each definable feature of work. The
quality related responsibilities and authority of the key members of this organization are
outlined below. Their resumes are included in Appendix I of this plan.
The Letter of Authorization from the Contractor ass1gmng the QC Supervisor the
authority to enforce the procedures defined in_ the CQAP and also the authority to stop
work until project activities comply with the requirements of this CQAP is included in
Appendix II.
3.2 Quality Control Supervisor
The on-site Quality Control Supervisor will be responsible for planning and executing
QC oversight of project operations, and ensuring compliance with specified QC
requirements. The QC Supervisor will be employed by the Contractor and will be
accountable to the Contractor's Site Manager. The position of QC Supervisor may be
held by different individuals during different stages of the project; the qualifications and
experience of each such individual will be relevant to the project activities taking place
during his/her tenure. For example, during the construction-related phases of the project
(site preparation and closeout), the QC Supervisor shall be a professional engineer,
licensed by the State of North Carolina, with qualifications and experience pertinent to
the construction-related phases of the project. During the BCD Detoxification phase of
the project, the QC Supervisor shall have qualifications and experience pertinent to
verifying performance of the BCD Detoxification process. The QC Supervisor and
designated alternates are subject to NCDENR approval.
ETG Environmental, lnc./BFA Environmental, Inc. -6-March2000
CQAP ORGANIZATIONAL CHART Site Manager ' Quality Control Supervisor I I I Quality Control Resident Tech(s) Inspectors (As Needed) Figure 1
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
Specifically, the QC Supervisor will be responsible for :
1) developing, assessing the effectiveness of, and maintaining this CQAP and related
procedures;
2) rev1ewmg and approvmg the qualifications of proposed technical staff and
subcontractors;
Figure 1
3) planning and ensuring the performance of preparatory, initial, follow-up, and
completion inspections for each definable feature of work;
4) identifying quality problems and verifying that appropriate corrective actions are
implemented;
5) ensuring that the requisite QC records including submittals are generated and retained
as prescribed by this CQAP;
6) verifying that subcontracted laboratories have appropriate certifications and operate
under a documented QC that complies with the CQAP and applicable requirements of
the contract; and
7) notifying the NCDENR representative 48 hours pnor to beginning any actions
required of the preparatory and initial phases.
The QC Supervisor shall also prepare QC reports upon completion of each of the three
phases of the project (site preparation, BCD Detoxification, and closeout). In each QC
report, the QC Supervisor shall certify compliance with the Plans and Specifications. For
the construction-related phases of the project (site preparation and closeout), the QC
Supervisor shall sign and seal the reports in his/her capacity as a North Carolina-licensed
Professional Engineer.
ETG Environmental, lnc./BFA Environmental, Inc. -8-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
The QC Supervisor or his designated alternate will be physically on-site whenever
project-related field work is in progress. Planned absences (e.g.: vacation) of the QC
Supervisor which coincide with project-related field work, are subject to prior NCDENR
approval. The QC Supervisor shall notify the NCDENR representative in writing of all
planned absences and of the proposed designated altemate(s) who will fulfill the duties of
QC Supervisor during the planned absence no later than four weeks prior to the first date
of the planned absence. The written notification shall include the qualifications of the
proposed designated altemate(s). The NCDENR representative shall provide its written
response to the QC Supervisor no later than three weeks prior to the first date of the
planned absence.
3.3 Quality Control Technicians/Resident Inspectors
As needed the QC Supervisor will assign quality control technicians and resident
inspectors to adequately implement the CQAP. These personnel will be either engineers,
engineering technicians, or experienced craftsman with qualifications in the appropriate
fields of construction materials and/or hazardous waste remediation. The quality control
technicians report directly to the QC Supervisor (e.g. concrete field tests, soil compaction
tests, etc.).
3.4 Site Manager
The Site Manager will be responsible for all daily site operations. He will ensure the
implementation of the CQAP and support the efforts of the QC Supervisor and his staff.
ETG Environmental, lnc./BF A Environmental, Inc. -9-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
4.0 SUB MITT AL MANAGEMENT
4.1 General Requirements
The QC Supervisor has the sole responsibility of ensuring submittals fully comply with
project requirements. Each project submittal shall be signed and sealed by the PE in
responsible charge of the submittal, where required by the statutes governing the practice
of engineering in North Carolina. Submittal control is required to regulate the timely
. flow of materials and work, to ensure problem prevention and to demonstrate that
materials and work are in compliance with applicable ~pecifications. Project submittal
procedures will be implemented in accordance with the project procedures prescribed
herein and in accordance with the project Submittal Register and Submittal Form which
are provided in Appendix IV ofthis CQAP.
The Project Manager will be responsible for overall management and control of project
submittals. The Site Manager will be responsible for submittal scheduling and tracking.
The QC Supervisor will be responsible for ensuring, through detailed review, that
submittals, as well as the materials and the work they represent are in full compliance
with applicable contract specifications. The QC Supervisor will also be responsible for
ensuring that a project file is established and maintained.
4.2 Project Submittals
Submittals will be listed and tracked using the referenced submittal register. Submittals
include all deliverables generated on site or off site by the Contractor, subcontractors,
fabricators, manufacturers, suppliers or purchasing agents. The QC Supervisor will
review the list to ensure its completeness and may expand general category listings to
show individual entries for each item.
ETG Environmental, lnc./BF A Environmental, Inc. March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
4.2.1 Shop Drawings
Shop drawings from subcontractors and suppliers will be initially screened by
the subcontractor's / supplier's in-house QC personnel. Shop drawings
approved by the subcontractors and suppliers will be forwarded to the QC
Supervisor for review to ensure that the items represented are in accordance
with the contract drawings and specifications. Shop drawings not in
compliance will be returned to the subcontractor or supplier for review and
correction. Shop drawings in compliance will be signed by the QC Supervisor
and forwarded as listed on the submittal register for that particular item.
As the material/equipment arrives on the job site, the shop drawings and other
pertinent data will be consulted to perform the receiving inspection and
ascertain that the material/ equipment conforms to contract specifications.
4.2.2 Samples
Saµiples being provided by subcontractors, manufacturers and suppliers will
be checked by ·· the QC Supervisor, for conformance with the contract
specifications. Conformance samples will be stored for future comparison
with the project materials as they arrive at the construction site. Receipt of
conformance samples will be recorded in the submittal register; copies of the
conformance samples will be forwarded to the NCDENR for technical review.
ETG Environmental, Inc./BFA Environmental, Inc. -11 -March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
4.2.3 Certificates of Compliance
Materials and equipment for which visual appearance is not adequate for
demonstra_tion of compliance will require a Certificate of Compliance from
the manufacturer. The Certificate of Compliance must accompany the
material and attest that the material or equipment conforms to contract
specifications where required.
These Certificates of Compliance will be forwarded to the NCDENR when
listed on the submittal register for technical review. It is important to note
that the Certificate of Compliance must be issued by the manufacturer's QC
department and not the supplier or wholesaler of the material or equipment.
Some materials specified in Table 1 may be tested in the field in addition to
having Certificates of Compliance.
4.3 Project Records
The QC Supervisor is to establish and maintain an on-site project file for document
control. The purpose of this file is to maintain a complete set of all documents, reports,
certifications and other records that provide information on project plans, contract
agreements, and project activities. The initial file will be structured to include a record
copy of the following documents:
• Construction schedule and progress reports
• Technical specifications, including addenda and modifications thereof
• Change orders and other contract modifications
• Engineer field orders
• Manufacturer's certificates
• Daily work activity summary reports, including:
* Daily QC report (including QC log)
* Daily Health and Safety Report
ETG Environmental, Inc./BF A Environmental, Inc. -12-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
* Daily Superintendent Report (including activity log)
* Reports on any emergency response actions
* Test records
* Record of site work
* Chain-of-custody records
* Reports on any spill incidents
* Truckload and tickets and shipping papers
* Laboratory results
* Records of quantities of soil treated
* Noted Deficiencies (master deficiency log submitted monthly)
* Landfill excavation and sampling map (weekly)
* Other items required by the NCDENR
• Conversation logs
• Meeting minutes and agenda
• Inspection logs and schedules
• Photo documentation
• Site maps
• As-built drawings
4.4 Transmittal to NCDENR
Submittals that require NCDENR approval will be reviewed and approved by the QC
Supervisor before submission with proper listings of the specifications, paragraph, and/or
sheet number of the plans pertinent to the data submitted for each item requiring
approval.
ETG Environmental, lnc./BF A Environmental, Inc. -13-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
5.0 INSPECTION REQUIREMENTS
5.1 General
Quality control inspection functions are organized to provide inspections for all definable
features of work as detailed below. All inspections will be documented by the Contractor
as specified in Section 6.0 "Documentation" of the CQAP. Inspection shall be performed
daily to ensure continuing compliance with contract requirements until completion of the
particular feature of work.
5.2 Testing Phases
The CQAP includes three phases of inspections and tests for each feature of the work to
insure that work is carried out in accordance with the Drawings and "Specifications. The
Contractor will not conceal any feature of work containing uncorrected defects. The
NCDENR will be notified at least 48 hours in advance of each test and inspection.
5.2.1 Phase I Inspections
Phase I Inspections will be performed prior to beginning each feature of
construction work. Phase I inspections for the applicable feature of work
include:
a. A review of submittal requirements and all other contract requirements
with the foreman or supervisor directly responsible for the performance of
the work.
b. Checks to assure that provisions have been made to provide required field
control testing.
ETG Environmental, Inc./BFA Environmental, Inc. -14-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
c. Examination of the work area to ascertain that all preliminary work has
been completed.
d. Verification of all field dimensions and advise the NCDENR of any
discrepancies.
e. Physical examination of materials and equipment to assure that they
conform to approved shop drawings or submittal data and that all material
and/or equipment are on hand.
5.2.2 Phase II Inspections
Phase II. Inspections will be performed as soon as work begins on a
representative portion of the particular feature of work and include
examination of the quality of workmanship as well as a review of control
testing for compliance with Contract Requirements ( e.g. soil compaction test,
concrete testing, etc.
5.2.3 Phase III Inspections
Will be performed continuously as any particular feature of work progresses,
to assure compliance with Contract requirements including control testing,
until completion of that feature of the work.
5.3 Reporting
All inspections and test results shall be recorded daily. The "Quality Control Daily
Inspection Report" and any "Daily Test Report" (see Section 6.0 "Documentation") shall
be reproduced and fully executed to show all inspections and tests and shall be submitted
to the NCDENR of the first work day following the date covered by the report.
ETG Environmental, Inc./BF A Environmental, Inc. -15-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
5.4 Deficient Work
The Contractor shall stop work on any item or feature, pending satisfactory correction of
any deficiency noted by his quality control staff or by the NCDENR. Construction shall
not proceed upon any feature of work containing uncorrected work. If recurring
deficiencies in an item or items indicate that the quality control system is inadequate,
corrective action shall be taken as directed by the NCDENR. If the Contractor refuses or
fails to comply promptly, the NCDENR may issue an order stopping all or part of the
work until satisfactory corrective action has been taken.
5.5 Construction Quality Control Test Schedule
As part of the overall CQAP the Contractor wi_ll implement a construction quality control
test schedule (Table 1, ori pages following Section 5.5). The testing schedule includes
the minimum tests and frequencies required by each technical specification item, as well
as any additional quality control tests that the Contractor deems necessary to adequately
control production and/or construction processes. The testing schedule is developed in a
spreadsheet fashion and includes the following:
a. Specification item number
b. Item description ( e.g., concrete mix)
c. Test type (e.g., gradation, compaction, grade)
d. Test standard (e.g., ASTM, AASHTO test number)
e. Test frequency (e.g., as required by technical specifications or minimum frequency
when requirements are not stated)
f. Control requirement (e:g., % compaction, target, permissible deviations)
ETG Environmental, lnc./BF A Environmental, Inc. -16-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
The elements of construction to which the testing schedule applies include construction
of the water main, electrical services, haul roads, erosion control/storm water management
facilities, process pads and buildings, and backfill and compaction of the landfill
following successful detoxification of the PCB-contaminated materials.
Construction of the water and stormwater mains will involve Excavating, Backfilling and
Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and Designation and
Testing of Piping Materials (Spec. 15044).
Electrical services construction will conform to the North Carolina State Building Code,
Volume · 4 (National Electrical Code). Applicable specifications include Excavating,
Backfilling & Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and
Electrical (Spec. 16050).
Elements of the erosion control/stormwater management facility are the stormwater
collection system, new lined pond, pump station and forced main, and wet pond.
Applicable specifications are Earthwork (Spec. 02200), Excavation, Backfilling and
Compaction (Spec. 02220), HDPE Liner (Spec. 02750), Cast-in-Place Concrete (Spec.
03300), Designation and Testing of Piping Materials (Spec. 15044), and Electrical (Spec.
16050). ,
Haul road construction will involve Earthwork (Spec. 02200), Excavating, Backfilling
and Compaction (Spec. 02200), Aggregate for Non-Asphalt Flexible Type Base (Spec.
0 l 0 l 0), Road Base (Spec. 02232), and Stabilized Subgrade (Spec. 02240).
ETG Environmental, Inc./BFA Environmental, Inc. -17-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
Specifications applicable to construction of process pads include Earthwork (Spec.
02200), Excavating, Backfilling and Compaction (Spec. 02220), and Cast-in-Place
Concrete (Spec. 03300). Construction of the storage containment area will involve
Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220),
Stabilized Subgrade (Spec. 02240), Pavement Base (Spec. 02232), and Bituminous
Paving (Spec. 02500).
Construction of the pole barn and erection of the Pre-Engineered Building will involve
Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220), Cast-
in-Place Concrete (Spec. 03300), and Structural Steel (Spec. 05120).
Backfilling and compaction of the landfill following successful detoxification of the
PCB-contaminated material will involve Earthwork (Spec. 02200) and Excavating,
Backfilling and Compaction (Spec. 02220).
5.6 Materials
All materials and equipment, except as otherwise provided in the contract documents will
be of good quality and condition. All materials and equipment will be applied, installed,
connected, erected, used, cleaned and conditioned in accordance with the bid
specifications and recommendations of the applicable supplier. Where the bid
specification and manufacturer recommendations differ, the more stringent requirement
will apply.
5.6.1 Storage
Materials will be shipped, delivered and stored in the manufacturer's
undamaged crating and packaging. Material will be stored off the ground on
blocking, appropriately covered, and be protected from sunlight, weather and
vandalism.
ETG Environmental, lnc./BFA Environmental, Inc. -18-March 2000
TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequencv of Testing Acceptance Criteria/Other 01010 Aggregate for • Gradation test Two random samples per 1,000 As specified in NCDOT Non-Asphalt tons or fraction thereof requirement IO 10 Flexible Type Bases • Liquid limits plasticity index 02200 Earthwork • In place soil density determined by Load-Bearing Areas: 95 percent either the Sand Replacement (ASTM modified Proctor Method (ASTM D-D1556), Nuclear (ASTM D2922), or 1557). Drive Sleeve (ASTM D2937) Methods. Non-Load Bearing Areas: 90% Modified Proctor Method. Area One ( 1) 'Test per 2,500 Sq. Ft. per -Beneath and around all structures Lift or'Min. of two (2) tests, which7ver is greater One ( 1) test per 10,000 Sq. Ft. per -Beneath paved areas lift. One (I) test per I 00 linear feet -Wall Footings One (I) test per 100 linear feet for -Pipes yard piping. Min. one ( 1) test per lift for pipes under structures As directed by Engineer -Other Areas
TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 02220 Excavating, Backfilling • In place soil density determined by Reference Spec. Section 02200 & Compaction Nuclear Density Meter per (ASTM D2922) or Drive Sleeve Method per (ASTM D2937) Area Material -Utility Trenches, Structural Fill 8 inch lifts Compaction to 95% of modified Backfill beneath Proctor Method (ASTM D-1557) structures and roadways -Around structures Structural Fill 8 inch lifts Compaction to 95% of modified Proctor Method (ASTM D-1557) -From cleared Common Fill 12 inch lifts Compaction to 95% of modified existing surface Proctor Method (ASTM D-1557) to subgrade for paved and gravel -Non-load bearing Common Fill 12 inch lifts Compaction to 90% of modified Proctor Method (ASTM D-1557) 02232 Road Base • Modified Proctor I 00 ft. of roadway, on center Compaction to ~ 98% Modified (ASTM Dl557) Proctor 02240 Stabilized Subgrade • Modified Proctor Test Density every Compaction to ~ 98% Modified (ASTM D 1557) 300 feet or less, on center, Proctor of roadways 02500 Paving and Surfacing • Temperature Per Load/Placement (Min.) 235° (Max.) 275° • Compaction One (I) Test Per 1600 Sq. Ft. I 00 percent of approved Mix Design Density
TABLE! CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testin~ Acceptance Criteria/Other 02750 PE Liner • Thickness (ASTM D7 51) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Density (ASTM D792) Random samples of each shipment, Spec. 02750, Table 1 as specified PE Liner • Melt Index (ASTM D1238) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Carbon Black Content Random samples of each shipment, Spec. 02750, Table I (ASTM Dl603) as specified PE Liner • Tensile Properties (ASTM D638) Random samples 9f each shipment, Spec. 02750, Table l as specified PE Liner • Tear Resistance (ASTM DI004) Random samples of each shipment, Spec. 02750, Table I as specified PE Seams • Peel (ASTM D413) Test seams, twice or more daily As specified in Spec. 02750, PE Seams • Shear (ASTM D3083) per machine, + I sample/seamer para. 3.048 PE Seams • Vacuum or Pressure Test Entire length, each field seam As specified in Spec. 02750, para. 3.04C.1 or 2 PE Seams • Destructive tesing of seams Every 500 feet As specified in Spec. 027 50, para. 3.04C.3 Anchor Trench • Standard Proctor (ASTM D698) One (I) test/ I 00 lineal feet 90% maximum dry density Backfill 03300 Cast-in-Place Concrete • Slump (ASTM 39) 3" -4" Perform @ Concrete • Temperature Placement for Each Load 68° ± 2° F • Air Content (ASTM C 173) Every other truck 6%± ½% or (ASTM C23 l) • Compressive Strength (ASTM C39) l Set per Day or 50 CY 3000 PSI @ 28 Day Set of (5) Cylinders (ASTM C3 l) (Max.) [Test (2) @ 7 days, (2) ~ 28 Days, (I) Reserve]
TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testine Acceptance Criteria/Other 03483 Precast Concrete • Slump Perform @ concrete placement for 3"-4" Structures -each load Cement Mortar • Temperature 68° ± 2° F used for Repairs • Air Content (ASTM C 173) or (ASTM Every other truck 6%± ½% C231) • Compressive Strength (ASTM C39) I Set per Day or 50 CY (Max.) 4,000 psi @ 7 days Set of (5) Cylinders (ASTM C31) (Test (2) @ 7 days, 2 @ (28) days, 5,000 psi @ 28 days ( 1 ) Reserve) 03610 Floor Grouting • Compressive Strength (ASTM C39) 1 Set per 75 CY or per day if See Section 03300 Set of (5) Cylinders (ASTM C31) < 45 CY/Day. Test in accordance with Section 03300 11190 ASTs • Visual At delivery As specified • Leak monitoring As specified by NCAC As specified by NC AST regulations 13200 Process Tanks • Visual At delivery No visible defects • Hydrostatic Test At installation Watertight at 24 hours
TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification .. Section Item Required Test(s) Frequency of Testin~ Acceptance Criteria/Other 15044 Piping Materials, • Hydrostatic Test, as specified Each piping installation Check for leaks and correct until no Designation and leaks Testing • Pneumatic Test, as specified Each piping installation Check for leaks and correct until no leaks • Infiltration/Exfiltration Tests, as Each piping installation Leaks :s;25 gal./in. -mile of pipe per specified 24 hours 16050 Electrical • Protective relays Prior to energizing Meet manufacturer's specifications and requirements ofN.C. Building • Operation of circuit breakers and Code, Vol. 4 (NEC) interrupters • Switchgear, switches, power and control panels
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
6.0 DOCUMENTATION
6.1 Record Keeping
The Contractor will maintain current quality control records of all inspections and tests
performed. These records include factual evidence that the required inspections or tests
have been performed, including the individuals and organization performing inspections
or tests, type and number of inspections or tests involved; results of inspections or tests;
nature of defects, deviations, causes for rejection, etc.; proposed remedial action; and
corrective action taken.
These records cover both conforming and defective or deficient features, and include a
statement that all supplies and materials incorporated in the work are in full compliance
with the terms of the contract. Legible copies of these records shall be furnished to the
NCDENR daily. The record~ will cover all work placed subsequent to the previously
furnished records and signed and sealed by the QC Supervisor.
6.2 Daily Inspection Report
\
Each Contractor quality control technician will maintain a daily log of all inspections
performed for both Contractor and subcontractor operations on a form acceptable to the
NCDENR. These technician's daily reports provide factual evidence that continuous
quality control inspections have been performed and include the following:
a. Technical specification item number and description
b. Compliance with approved submittals
c. Proper storage of materials and equipment
d. Proper operation of all equipment
ETG Environmental, lnc./BFA Environmental, Inc. -24-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
e. Adherence to plans and technical specifications
f. Review of quality control tests
g. Safety inspection
h. Names and signatures of the technician and QC Supervisor.
The daily inspection reports identify inspections conducted, results of inspections,
location and nature of defects found, causes for rejection, and remedial or corrective
actions taken or proposed.
The daily inspection reports will be signed by the responsible quality control technician
and the Quality Control Supervisor. The NCDENR will be provided at least one copy of
each daily inspection report on the work day following the day of record.
6.3 Daily Test Reports
The Quality Control Supervisor will establish a system which will record all quality
control test results. Daily test reports shall document the following information:
a. Technical Specification item number and description;
b. Test designation;
c. Location;
d. Date of test;
e. Control requirements;
ETG Environmental, Inc./BFA Environmental, Inc. -25-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
f. Test results;
g. Causes for rejection;
h. Recommended remedial actions; and
1. Retest.
Test results from each day's work period shall be submitted to the NCDENR the
following day. When required by the technical specifications, the Contractor will
maintain statistical quality control charts. The daily test reports will be signed by the
responsible quality control technician and the QC Supervisor.
6.4 Notice of Non-Compliance
The QC Supervisor shall notify the Site Manager in writing of any deficiency in
workmanship and/or materials documenting the corrective action taken by Contractor to
correct situation. This notice shall include the following information:
a. Date
b. Specification section and/or drawing number
c. Description of deficiency
d. Corrective action taken by Contractor
e. Signature of technician and Contractor.
ETG Environmental, lnc./BFA Environmental, Inc. -26-March2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
If there is no resolution or deficiency or continued reoccurrences, the Site Manager shall
notify NCDENR immediately. See attached sample form for reporting noncompliance in
Appendix IV.
ETG Environmental, Inc./BFA Environmental, Inc. -27-March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
APPENDIX I
CONTRACTOR'S STAFF RESUMES/RESPONSIBILITY
ETG Environmental, Inc./BF A Environmental, Inc. March 2000
I
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
APPENDIX II
LETTER OF AUTHORIZATION
ETG Environmental, lnc./BF A Environmental, Inc. March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
APPENDIX III
TESTING LABORATORY QUALIFICATIONS
ETG Environmental, Inc./BFA Environmental, Inc. March2000
Construction Quality Assurance Plan -BCD Detoxification
ETG Environmental, Inc./BFA Environmental, Inc.
APPENDIX IV
FORMS
Warren County PCB Landfill
March 2000
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' TRANSMITTAl OF SHOP DRAWINGS, EQU1PMENT DATA, MATERl~L SAMPLES, OR OATI TIIAHIMITTAL HO, .,., MANUFACTURER'S CEITTIFICATES OF COMPLIANCE /R1.d l1uuwlllotu M the,~_,,, 11ft friii' • .,,,,.1/ttf ~ fiNm/ SECTION I· REQUEST FOR APPROVAL UI', fHE r:;~c,,.1rcu ITEMS (T1te rttl!IM dh"'1fMr.o-, lh• ro,11,Mtotl TOI "'OMt COH11\AC1 HO, :Hl!Clt OHi!: ants II A HrW TIIAHSMTTAl THIS II A IIUueMmAL o, TIIAHSMITTAL ll'!OFICA TIOH UC. HO, (C..,., Mly -IH-rwrll 11'110.JlC'r llfLI AND •••~•~n OUCll OHf: nus TJIAHSMrnAL. uch trM11mitull ""'" OU~OfITTM~ 110. tr'r,M ... --t.nfa.l .. ... 1'oo 1(1 I tNCLOIUIIU Ml\JI\H[.0 ,U.t tr lf,m Ne.I (HQ FO I\M -4029-ll. MAIi ti lf'lf " .. ,.,"' ,011 0 ,10 □ OOY't. A/'ff\OYAl WCIOIIC:Otffll. -INMITIIAotlltt~ '°" tAIIIAtlOtl '°" CA'I'.., CUINI 0, DOCUMDIT CONTUoCTOII "" c:c DMWINGO.-CONI uu c:ooc ....__ UII IIIOQMII IIIO. lrtD. DMWIIIG Ila." C1'0C , . ,.H,__ ___ '"""-"°· IHrl'TlfO. .. " .. ,. ,. ... ' I Mt1lty ..,_. ... .._ ..-,lnM heffil ,...,. h-n --, Ir, ,_. .. M4 .,.. ...,..., "'4 Ir, tcrfet ...,, • ._. ,,.flt, M -·-....... -4 -,Idle ........ .,, .. •th« .... sttte4 • . , .. HAMI ANO IIONAT\Jftl OP COHTllACTOII ·.·, n11:.l.1turt·tl.-~.~PROVAL AC-mm . 11!1111 HIii 11!11 lllllllll■I Ill l■IIIH!ll 11111111111 ~ L__ 111111 • IIDffl0tt Of 10 n • onoun. lfffff_o, -Cl-
INSTRUCTIONS .. Section I will be Initiated by th~ Contractor In the required number of copies. ~-/ 2 Each transmittal shall be numbered consecutively In the space provided !or 'Transmittal No.'. This number, in aodrtion to the contract number. wtll form a senel number for ldentlty1ng each submlttal. For new submtttals or resubmlttals mar11 the appropr1ate box: on resubmi:".alS. insert transmittal number of last submission well as the new submittal number. 3. The "Item No." wtll be the same •item No.' as Indicated on ENG FORM. "'288-R tor eadl entry on this form. 4. Submlttals requir1ng expeditious handling will be submitted on I separate form. 51 Separate transmittal form wfll be used for submlttals under separate aectJor\s of the specfflcadons. 6. A check shell be placed In the -Vartatlon· column when a submittal Is not in accordance with the plans and specHlcatlons•also, a written statement to that effect shall be lnduded In tea apace provided for "Remar11a". 7. Form Is setf-transmrttal, letter of transmittal Is not required. 8. When a sample of material or Manvtacturer's Certificate of Compllance Is transmitted, Indicate ·Sample" or ·~te· In column c. Section L 9. U.S. Anmy Corps of Englneef'3 approving authority wtll assign action o,des as Indicated below In space provided In Section 1, o,lumn 1 to each leem submitted. In addition they wlll ensure enclosures are Indicated and attached to the 'onm pnor to return lo the contractor. The Contractor wfD assign action CX>des as Indicated bet<,,. In Section 1, column g, to eadl Item submitted. THE FOLLOWING ACTION COOES ARE GIVEN TO ITEMS SUBMIITED A B C D Approved as submitted. Approved, except as noted on drawings. Approved, except as noted on drawings. Re1er to attached sheet resubmission required. WIii be retumed by separate correspondence. E F FX G CXaapproved (See I ttached). RltOl!ipt acknowtedged. RltOl!lpt acknowledged. does not comply as noted wfth contract requirements. Other (Specify) 1 O. Approval of Items does nol relleve lhe conlractor from comp tying wfth al the requirements of the oontract plans and speclllcatlons. (Re\191"39 of ENG Form 4025-R)
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
PAGE I OF3
,. 11 . QUALITY CONTROL DAI7 v INSPESTI?~ REPORT EL . ··-.SJ
GENERAL INFORMATION
Re12ort No: Contract No.
Date: Project:
Weather: Prime Contractor:
□CLEAR □CLOUDY DRAIN □SNOW
Tem12erature Range: Subcontractors:
F to F ----
DAILY WORKFORCE AND EQUIPMENT
MAJOR TRADE NO. OF PERSONS MAJOR EQUIPMENT
TOT AL PERSON:
D YES D NO
(IF YES PREPARE A NOTICE OF NON-COMPLIANCE FOR EACH ITEM)
ETG Environmental, Inc./BFA Environmental, Inc. March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
PAGE 20F3
CONTRACTORS WORK
SUBCONTRACTOR(S) WORK
ETG Env1ronmental, Inc./BF A Env1ronmental, Inc. March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
PAGE 3 OF3
1. i 1 iiiiLLL.
QUALITY CONTROL DAILY INSPECTION REPORT
£LU£ Li& UL£ ts £2 I ... L LL i&tk&U& UL., L J&S&LZ
INSPECTIONS & TESTS .
INSTRUCTIONS RECEIVED & REMARKS
SIGNATURE
QUALITY CONTROL TECHNICIAN:
(SIGNATURE) (PRINTED NAME)
,J£££!LJ,.H I
(DATE)
I CERTIFY THAT THE ABOVE REPORT IS COMPLETE AND CORRECT AND THAT I, OR MY
AUTHORIZED REPRESENTATIVE, HA VE INSPECTED THE WORK PERFORMED THIS DAY BY
THE PRIME CONTRACTOR AND EACH SUBCONTRACTOR AND HA VE DETERMINED THAT
ALL MATERIALS, EQUIPMENT, AND WORKMANSHIP ARE IN STRICT COMPLIANCE WITH
THE CONTRACT DOCUMENTS EXCEPT AS NOTED ABOVE.
SIGNATURE PRINTED NAME DATE)
ETG Environmental, lnc./BFA Environmental, Inc. March 2000
Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill
I & i&ldJbJLd X&Ul
NOTICE OF NON-COMPLIANCE
2 kl IL . &i&Ld .. ~ 1 ill. 3 .. L J ,,. J @Uh L 1& & . .2& LEU§£ &.. . ..I
GENERAL INFORMATION
IDATE: PROJECT:
!NOTICE NUMBER: CONTRACTOR:
ISPECIFICA TION NUMBER(S): NOTICE ISSUED TO:
DESCRIPTION OF DEFICIENCY IN WORKMANSHIP AND/OR MATERIAL
·;
CORRECTIVE ACTION ACCOMPLISHED
SIGNATURES
CQAP TECHNICAN: DA TE ISSUED:
CONTRACTOR: DA TE ISSUED:
ETG Environmental, lncJBFA Environmental, Inc. March 2000