HomeMy WebLinkAboutNCD980602163_20010422_Warren County PCB Landfill_SERB C_No. 110 - Site Operating Plan-OCR•
TRANSMITTAL COVER PAGE
WARREN COUNTY PCB LANDFILL DETOXIFICATION PROJECT
IT Corp. Project #823851
Submitted By: IT Corporation -200 Horizon Center Boulevard. Trenton. New Jersey 08691
Transmittal Number (chronological sequence): 003
Transmittal Date: 04/22/01
Submittal Register Item Number: 110
Resubmittal : No__x_ _ Yes
Specification Section: H&SP - 3 .1 .1
Description: Site Operations Plan
Drawing/Detail Number: NIA
Subcontractor/Supplier: NI A
Comments: NIA_
Number of Copies Submitted: _i__
Number of Copies to be Returned to Contractor 1
Earth Tech Engineer's Receipt Signature: ___________________ _
Comments:
Receipt Date:
Engineer's Approval
Comments:
Reviewer's Signature
Project Manager's Signature
D A. "Reviewed and approved, no exceptions taken"
D B. "Reviewed and approved with comments
D C. "Revise and Resubmit"
Date -----------------------
Date ---------------· ---------
Warren County PCB Landfill Detoxification
Site Operations Work Plan
Rev. 0
April 16, 2001
Table of Contents
1.0 Introduction ................................................................................................................... 1
2.0 Premobilization Activities ............................................................................................ 2
2.1 Plans .......................................................................................................................... 2
2.2 Drawings ................................................................................................................... 2
2.3 Permits and Notifications .......................................................................................... 3
2.4 Subcontracts .............................................................................................................. 4
2.5 Sampling and Analysis ............................................................................................. 4
3.0 Initial Mobilization ....................................................................................................... 5
3 .1 Initial Site Survey ..................................................................................................... 5
3.2 Two Temporary Office Trailer ................................................................................. 5
3.3 Monitoring Well Abandonment.. .............................................................................. 5
4.0 Civil Construction Mobilization ................................................................................... 6
4.1 Initial Site work ......................................................................................................... 6
4.2 Concrete Slab and Utilities .............................................................. _ ......................... 6
4.3 Post Concrete Cure Construction Activities ............................................................. 7
5.0 Soil Treatment Equipment Mobilization ...................................................................... 8
6.0 Demonstration ·BCD Operation ..................................................................................... 9
6.1 Material Handling ..................................................................................................... 9
6.2 Haul Road Construction .......................................................................................... 10
6.3 Water Treatment System ......................................................................................... 10
7.0 Period between Demonstration and Full Scale Operations ......................................... 11
8.0 Full Scale Operation ................................................................................................... 12
9.0 Post Processing Activities ........................................................................................... 13
1.0 Introduction
_This plan summarizes the work that will be required to perform the remediation of
approximately 70,000 tons of PCB contaminated material in the Warren County Landfill.
The work will be accomplished by excavating the contaminated material, detoxifying the
material using the BCD process, then returning the clean material to the landfill. The
work is being performed for the state of North Carolina.
IT Corporation (IT) is the prime contractor. · The major subcontractor is Midwest Soil
Remediation, Inc. (MSR) who will operate the BCD process. IT will perform the civil
construction at the site. During operations IT will supply contaminated material to
MSR's battery limits and handle clean material when it leaves the battery limits. IT will
utilize local construction subcontractors during the site set up.
This plan discusses the major items of work. The submittal register and schedule for this
project provides additional details.
April 16, 2001 1 Rev.O
2.0 Premobilization Activities
2.1 Plans
The following plans, supplied by the State, will be modified as necessary to reflect the
specific job requirements:
1. Community Involvement Plan.
2. Project Health and Safety Plan.
3. Per{ormance Demonstration Plan.
4. Air Monitoring Plan.
5. Site Operations Work Plan.
6. Construction Quality Assurance Plan.
7. Final Verification/Confirmation Sampling Plan.
8. Emergency Response Plan.
2.2 Drawings
The following drawings, supplied by the State, will be modified as necessary to reflect
the specific job requirements:
SHT. NO. DWG.NO.
1 G-1
2 G-2
3 C-1
4 C-2
5 C-3
6 C-4
7 C-5
8 C-6
9 C-7
10 C-8
11 C-9
12 C-10
13 C-11
14 C-12
15 C-13
16 C-14
17 C-15
18 C-16
19 C-17
April 16, 2001
DESCRIPTION
Project Cover Sheet
Overall Project Map and Air Monitoring Location Map
Existing Condition Survey Plan
Demolition Plan
Site Plan
Site Grading & Drainage Plan
Site Grading & Drainage Sections
New Lined Ponds -Sections and Details -Storm Sewer
Profile
Project Details -Existing Leachate Treatment System
Site Fencing Details
Site Construction Details
Storm Water Management Plan Schematic
Storm water Pumping Station and Drainage Details
Typical Existing Landfill Section-(East and West)
Excavation Section -Exist. Landfill Profile (North -South)
and Material Quantities
Excavation Section -Profile Line "A" Excavation Area No. 1
Excavation Section -Profile Line "A" Excavation Area No. 2
Excavation Section -Profile Line "A" Excavation Area No. 3
-Backfill Area No. 1
Excavation Section -Profile Line "A" Excavation Area No. 4
-Backfill Area No. 2
2 Rev. 0
20 C-18
21 C-19
22 C-20
23 C-21
24 C-22
25 C-23
26&27 W-1 & W-2
28 W-3
29 ER-I
30-32 ER-2-ER-4
33 R-1
34 S-1
35 S-2
36 S-3
37 E-1
38 E-2
39 PFD-200
40 PFD-201
41 PFD-202
42 PFD-203
43 PFD-204
44 PFD-205
45 PFD-206
2.3 Permits and Notifications
Excavation Section -Profile Line "A" Excavation Area No. 5
-Backfill Area No. 3
Excavation Section -Profile Line "A" Excavation Area No. 6
-Backfill Area No. 4
Excavation Section -Profile Line "A" Excavation Area No. 7
-Backfill Area No. 5
Excavation Section -Profile Line "A" Excavation Area No. 8
-Backfill Area No. 6
Excavation Section -Profile Line "A" Backfill Area No. 7
Excavation Section -Profile Line "A" Backfill Area No. 8
New Water Main-Plans
Water Main Details
Erosion Control Plan
Sedimentation & Erosion Control Details
Post Detoxification -Site Demolition and Restoration Plan
Structural -Plan, Sections, and Details
Structural -PCSAPT Process -Pre-Engineered Metal Bldg. -
Plan and Elevations
Structural -Working Area Pre-Engineered Barn Plan and
Elevations
Electrical -Plan Details
Electrical -Power Riser
BCD Detoxification Equipment Layout
Material Preparation Process Flow Diagram
CBCD Process Flow Diagram
BBCD Process Flow Diagram
Process Condensate Separation and Aqueous Phase Treatment
Process Flow Diagram
LBCD Process Flow Diagram
Common System Process Flow Diagram
IT will obtain the following permits and notifications
1. TSCA permit from the U.S. EPA.
2. NPDES permit for treated storm water discharge (The State has offered to
work with IT to modify their existing NPDES permit).
3. File an erosion control and sedimentation plan with the NC Department of
Environment.
4. Electrical trailer inspection for each trailer on site.
5. County water line connection permit.
April 16, 2001 3 Rev. 0
6. Notify the Warren County fire department of the presence of flammable and
hazardous materials that will be stored at the site.
7. Air permit from the NC Department of Air Quality.
2.4 Subcontracts
Place subcontracts for the following construction activities:
1. Clearing, Grubbing, Grading (including new pond), and Erosion and Sediment
Control
2. Electrical work
3. Fencing
4. Surveying
5. Concrete work
6. Water line
2.5 Sampling and Analysis
The specification, Section 0 1010, C, v. requires IT to sample the existing storm water
pond for PCB contamination. To prevent potential worker exposure to PCBs and allow
for analytical lead time these samples should be taken prior to mobilization following
procedures described in EPA SW-846, Chapter 9 or EPA-560/5-85-025, Verification of
PCB Spill Clean Up by Sampling and Analysis. If PCBs are present they should be in the
top 6 inches of soil.
April 16, 2001 4 Rev.0
3.0 Initial Mobilization
The superintendent will mobilize initially to locate housing accommodations, finalize any
local permits, install the project sign, and coordinate the initial site survey and monitoring
well abandonment. Meetings will also be held with the selected subcontractors to review
any final issues and coordinate their work.
3.1 Initial Site Survey
Relocate the benchmark on the east side of the landfill, Station "PCB" N942447.1670,
E2245359.0490,NAD 83 to a location approved by Owner's Consultant.
Establish a minimum of two (2) permanent benchmarks on site, referenced to data
established by survey control points. These benchmarks will be in a location that will not
be disturbed and where direct instrument sights may be taken from the construction areas.
The surveyor will also mark the eight comers for the fence ( one comer is on the existing
fence), the four comers of the concrete slab, and the four comers of the landfill. Where
necessary the surveyor will place temporary markers outside the fence line or on the edge
of the landfill to be used to reconfirm the fence and slab locations after the clearing and
grubbing activities.
3.2 Two Temporary Office Trailer
Two temporary office trailers with phone and electrical service and two portable toilets
will be located near the fence line just inside the main gate area in an area not requiring
earthwork. One trailer will be used by IT and IT subcontractors and the other trailer will
be furnished per the contract for the Owner's Consultant. The trailers will be used for the
duration of the project but may need to be moved at the completion of the site work.
3.3 Monitoring Well Abandonment
All monitoring wells except for MW-2 will be abandoned in accordance with contract
specification section 02221.
April 16, 2001 5 Rev.0
4.0 Civil Construction Mobilization
The Field Engineer, Project Business Associate (PBA), and Health and Safety (H&S)
person will mobilize just prior the start of construction activities.
4.1 Initial Site work
The initial site work will prepare the area for the concrete slab construction.
Clearing and grubbing will initially be concentrated in the area that the fence will be
installed. The fencing work will start as soon as possible to provide additional site
security.
The site will be graded to the final contours immediately following the clearing and
grubbing. Grading work will include restoring the existing storm water pond to the
dimensions shown in the design (after receipt of analysis showing the pond to be free of
PCBs) and excavation for the new lined pond. As shown on the schedule, the following
activities will start with the grading:
a. Water main
b. Drain from west side of slab to new swell area
c. Treated water line from the concrete slab to the existing pond
d. Parking lot and access road into site and along the west side of the concrete
slab
e. Storm water retention pond
f. Force main from the slab to the treated water pond
g. Installation of permanent erosion control systems
One subcontractor will perform the site work described above and details of the work will
be finalized after the subcontract is in place.
4.2 Concrete Slab and Utilities
After completion of the initial site work the concrete subcontractor will form and pour the
four slabs. The following activities will occur during the slab construction:
a. Electrical work, including site lighting
b. Guard shack construction
c. Install electrical and support structures for the perimeter monitoring
stations in a location specified by the owner's consultant.
Concrete pours will occur over four days during the slab construction. Other activities
will be scheduled so as not to interfere with the concrete pouring.
While the concrete slab is curing and the sealer is being applied the following trailers will
be brought on site, set up, and furnished:
a. Lunch/break trailer
b. Decon trailer
c. Second office trailer for IT and IT subcontractors
April 16, 2001 6 Rev. 0
If necessary, the IT office trailer will be relocated during this period. IT will also install
the liner in the new lined pond. If necessary, accumulated storm water will be pumped to
the clean water pond.
4.3 Post Concrete Cure Construction Activities
After the concrete is cured and sealed IT subcontractors will install the pole barn
SCHEDULE NOTE: The remaining items will start after TSCA permit application
approval. It may be necessary to stop fieldwork at this point.
There is also the possibility that the work will not proceed unless the State has
assurances that they will receive funding for phase II of the contract. This issue is not
discussed in the contract documents and will be decided at the time.
April 16, 2001 7 Rev.0
5.0 Soil Treatment Equipment Mobilization
These activities will occur after the TSCA permit is received.
The security service will be started during hours that the site is not occupied and two
additional portable toilets will be moved on site.
IT will mobilize personnel to install the slab sump storm water pumps and piping.
IT will mobilize two equipment operators and the following earth moving equipment:
a. Screening plant
b. Two wheel loaders
c. One dozer
d. One excavator
e. Two articulated dump trucks
f. One Compactor
g. Three gasoline powered centrifugal pumps ( one spare)
MSR will mobilize the soil treatment equipment and the personnel necessary to install the
equipment.
IT construction activities will continue on site while MSR installs the treatment
equipment as described and approved in their TSCA permit.
While the crane is on site to move the treatment equipment into place the water treatment
system dual sand filters and carbon units will be set in place. The following construction
activities will occur while the treatment equipment is installed:
a. The storm water treatment plant piping
b. The concrete barriers on the slab
c. The pump and interconnecting piping in the new lined pond
d. The meteorological station
April 16, 2001 8 Rev.0
--.:~---
6.0 Demonstration BCD Operation
The demonstration processing provides the operating data necessary for the EPA to
determine that the process operates as described in the TSCA permit application. The
quantity of soil processed will be determined by MSR. As much as 20,000 tons ofsoil
could be processed.
6.1 Material Handling
The landfill will be opened at the south end as shown on the project drawings. The dozer
will be used to remove clean topsoil, fill material, and clay from the landfill cap. This
material will be stored at the north end of the landfill. The topsoil will be segregated and
the clay and fill material will be mixed in the stockpile. The 10 mil PVC liner between
the fill material and clay will be removed, cleaned, and disposed in a class I landfill.
There is 2 feet of clay below the liner. This material will also be removed and placed in
the clay and fill stockpile. Between this 2 feet of clay and the contaminated material is
one foot of fill material. This fill material will be considered contaminated. A filter
fabric is located at the bottom of the fill material. This fabric will be removed, sampled,
and disposed in a Class I landfill if under 50 ppm. A 9 inch sand layer below the filter
fabric will be excavated for treatment.
The landfill is approximately 476 feet long. Fifty feet of the landfill cap will be removed
at a time. When the contaminated material under the removed cap portion is removed an
additional 50 feet of the cap will be removed. These 50 foot increments may be altered
during the demonstration depending on the quantity of material that will be processed
during those runs.
While the landfill is open rainwater that accumulates in the landfill will be pumped to the
new lined pond with a gasoline powered portable centrifugal pump. Much of the initial
excavation will be over the sloped bottom end of the landfill and initially water will flow
into the lower portions of the landfill. After clean soil backfill is started a clay berm will
be constructed on the floor of the landfill to separate the clean and contaminated soil.
Separate pumps and suction hoses will be used to insure that there is no cross
contamination between the contaminated and uncontaminated material. The pumps and
hoses will be clearly labeled "CLEAN" and "CONTAMINATED".
After the landfill cap is removed the excavator will be used to load contaminated material
into the dirty side dump truck which will haul the material to the north end of the slab and
dump it on the concrete slab. To the extent possible material will be excavated when the
soil is dry.
The dirty side loader will move the material to the screening plant. From the screening
plant a conveyor belt will move the material to the MSR feed hopper. A weigh belt on
this conveyor will record the amount of material processed.
The processed (clean) material will be deposited in segregated clean soil bins. Each bin
will hold approximately 24 hours of production. Samples of the treated material will be
taken as specified in the Quality Control Plan. When a bin is filled the product conveyor
moves to an empty bin and the samples from the full bin are sent off site for analysis.
When analysis confirms that the material in the full bin meets the treatment specification
the clean side wheel loader moves the material from the bin to the clean side dump truck.
The first approximately 17,000 tons of soil treated will be used to build the stockpile area
south of the landfill. This soil will be left in place and returned to the landfill after all the
April 16, 2001 9 Rev. 0
remaining soil is treated. The stockpile will be approximately 282 feet by 135 feet by 20
feet high. The side slope will be 2: 1.
The stockpile together with the treated storage capacity on the slab will be sufficient for
the demonstration run and no treated soil will be returned to the landfill during this phase.
The soil treatment plant will operate 24 hours per day 6 days a week. The expected
throughput rate is 20 tons per hour. Depending on the conditions the plant may be able
to achieve rates as high as 30 tons per hour.
6.2 Haul Road Construction
Contingent on the material being suitable, the clean and contaminated haul roads will be
constructed using gravel from the treated soil stockpile. Otherwise material will be
purchased. This decision will be made after the landfill is opened. The contaminated
haul road will be constructed first followed by construction of the treated material haul
road. The treated material haul road can be completed after the demonstration run if
necessary since this road will not be used during the demonstration run. The
contaminated haul road will be built with clean side equipment, so extra care will be
taken not to spill any contaminated material on the road until the road is completed.
6.3 Water Treatment System
Storm water that falls on the concrete slab and into open areas of the landfill will be
pumped to the lined pond. The lined pond will be used as a clarifier. A well will be built
around the discharge pump to maintain a constant water level in the pond. The clarified
water discharge will be pumped through the dual sand filters and dual carbon units. The
carbon unit discharge will go to the clean water pond.
The sand filters will be backwashed into the lined pond.
When the sludge buildup becomes significant prior to the end of processing a Lamella
clarifier and plate and frame filter will be obtained to dewater the sludge. The well
around the pump in the lined pond will be removed, and the sludge will be dewatered. .
The filter cake will be added to the feed soil and processed with the excavated material.
April 16, 2001 Rev.0
7.0 Period between Demonstration and Full Scale Operations
EPA is expected to grant an interim operating permit within two weeks of the completion
of the demonstration run. During this period any rainfall will be pwnped out of the
landfill and treated.
The exposed face of the landfill will be covered with tarps during this period to minimize
washout of contaminated material during a rain or dusting during dry windy weather.
The dozer will enter the south end of the landfill and push 6 inches of the exposed clay
layer towards the north end of the landfill to build a two foot high berm separating the
contaminated soil from the excavated area. The berm will be about 15 feet from the
contaminated material remaining in the landfill and will extend up the walls of the
landfill at least as high as the lowest point on the top of the berm. The berm must be built
on a rain free day when there is no freestanding water on the clean side of the berm
location.
Confirmation samples will be taken from the clay on the clean side of the berm and
analyzed according to the sampling plan. If the material is still contaminated another six
inches of clay will be removed from the contaminated area and the area will be
resampled. This procedure will be repeated until the requirements of the sampling plan
are satisfied.
The security service will be onsite anytime workers are not present.
April 16, 2001 11 Rev.O
8.0 Full Scale Operation
When EPA grants interim operating permission the plant will be started up again and soil
processing will continue in the same fashion as the demonstration run. While the plant is
starting up any clean soil remaining on the slab will be returned to the clean side of the
landfill. The tarp will be removed from the dirty face of the landfill and excavation of
contaminated material will resume. As before, the cap will be stripped off in 50 foot
lengths as required to support the excavation.
The clean material returned to the landfill will be compacted in 1 to 2 foot lifts with a
1: 1.5 side slope. When approximately 50 lineal feet of clean material has been replaced
(as measured along the top of the landfill) the material will be capped. The cap will be
installed so that the final elevations approximate the starting elevations. The first layer of
the cap will consist of blended clay and fill material from the old cap. The topsoil
removed from the landfill will cover this blended material. The capped area will be
seeded and mulched.
When the backfilling operation has come within about 20 feet of the clay berm the berm
will be moved north. The dozer will enter the landfill south of the berm and push the
berm together with 6 inches of clay under the berm to reconstruct the berm about 15 feet
from the bottom edge of the contaminated material. If the amount of clay in the berm
becomes excessive the excavator can remove some clay on the contaminated side of the
berm and place it with the contaminated material.
As before, once the area between the old berm and new berm location has been tested and
found to meet the clean up criteria treated material backfill proceeds towards the new
berm.
When the last section of the landfill is excavated the gap between the clean and
contaminated soil will be increased because the landfill depth tapers off at the end. Some
stockpiled treated material can be moved into the landfill at this point.
The last material excavated and treated will be the haul roads and treated soil storage
area. These areas will be excavated in 6 inch lifts and tested until the area is shown to be
clean. When this material is treated and deposited in the landfill the new landfill cap will
be completed.
April 16, 2001 12 Rev. 0
9.0 Post Processing Activities
The water treatment system will remain in service during the decontamination.
Operation will be the same as before except that the filter cake will have to be drummed
for shipment to a hazardous waste incinerator. The slab section with the water treatment
system will be used as a decontamination pad. Contaminated Water from this pad will
continue to be pumped to the lined pond.
All the BCD soil treatment equipment will be decontaminated and removed from the site.
The rolling stock will be decontaminated with pressure washers as soon as processing
stops and if necessary can then be used to finish the work on the landfill. A front end
loader with a fork attachment may be required to complete the demobilization, but the
rest of the heavy equipment will be sent off site.
When all contaminated material has been treated and the final excavated area in the
landfill has tested clean the stockpiled treated soil can be backfilled. When backfilling is
completed and the entire landfill is capped a drill rig will be brought on site to punch
holes through the clay liner in the bottom of the landfill. The site will be hydro-seeded
with a mixture of native ground cover designed to return the area to a stabilized old field
environment.
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.
As each of the 4 concrete slabs is cleared of all equipment the slab section will be
pressure washed until it is verified clean. The curbs on the west side of the slab will be
removed to allow the slab to drain and the sump pumps will be removed. The sumps will
be filled with gravel or sand and concrete will be poured to close the sump opening at the
same level as the slab. The slab section with the water treatment equipment will be the
last slab section taken out of service.
The next to last area to be decontaminated will be the lined pond. Prior to starting this
decon the sand filters will be backwashed for the last time. The pond will be pumped
down to a low level and workers will enter the pond with low pressure washers to wash
down the liner into the pump sump. Wash water will go to the water treatment plant.
After the liner has been physically cleaned, the liner will be wipe tested for
contamination. If the liner is clean it will be removed, cut up, and shipped to a class 1
landfill and the pump and piping will be removed. If the liner is not clean enough for a
class 1 landfill the decision will be made to continue decontamination efforts or send the
liner to a hazard waste landfill.
The last area to be decontaminated is the area of the slab containing the water treatment
plant. The plate and frame filter filtrate will be piped directly to the sand filter and
carbon. The Lamella clarifier will be pumped out and the clarifier sump will be flushed
April 16, 2001 13 Rev. 0
and pumped into the plate and frame filter. The flushing will continue until the clarifier
tests clean.
Liquid remaining in the filter will be pushed out with compressed air and the filter will be
dried with compressed air. The plates will be disassembled and any filter cake along with
the filter fabric will be drummed for disposal as a TSCA waste.
The filter plates along with any remaining small equipment will be cleaned and the water
pumped to the sand filters. When all equipment is cleaned the water treatment slab will
be deconed.
The sand filters and carbon units will be drained into drums for disposal as a liquid TSCA
waste. The sand and carbon units will then be opened and their contents shoveled into
drums for disposal as a TSCA waste.
The pole barn, area lighting, process pad, perimeter fencing, 6-inch water main, lined
pond without liner and treated storm water pond will remain on site. All other
equipment, wiring, and materials will be removed.
April 16, 2001 14 Rev.0