HomeMy WebLinkAbout7906_Duke_DanRiver_LeachateTanks_DIN26123_20160523
Amec Foster Wheeler Environment & Infrastructure Inc.
2801 Yorkmont Road, Suite 100
Charlotte, North Carolina 28208 704-357-8600
amecfw.com
Registered in North Carolina
Engineering and Land Surveying License No. F-1253 Geology License No. C-247
May 17, 2016
Duke Energy
526 South Church Street
Charlotte, North Carolina 28202
Attention: Ms. Kimberlee Witt, P.E.
Subject: Leachate Tank and Secondary Containment Plan
Proposed Dan River Landfill
Duke Energy – Dan River Steam Station
Eden, North Carolina
Amec Foster Wheeler Project No. 7810140065
Dear Ms. Witt:
Amec Foster Wheeler is pleased to provide this Leachate Tank and Secondary Containment
Plan to Duke Energy (Duke) for the proposed Dan River Landfill at Duke’s Dan River Steam
Station. Amec Foster Wheeler is also attaching the Dan River Steam Station legal property
description which was prepared for Duke by ESP Associates, P.A. We understand that Duke
will provide these documents to the North Carolina Department of Environmental Quality
(NCDEQ) Solid Waste Section (SWS).
The Leachate Tank and Secondary Containment Plan drawings included with this submittal
address the design of the leachate storage tank, secondary containment facility, leachate force
main piping, and tie-in into the City of Eden sanitary sewer system. Development of a leachate
discharge agreement between Duke and the City of Eden is in progress. Additional information
regarding the proposed leachate tank and secondary containment is provided as follows.
Leachate Tank
The proposed leachate tank will consist of a ModuTank MS110-17 modular-style galvanized steel
uncovered tank, or equivalent as approved by the Engineer. Containment will be provided by a
geomembrane within the tank. The geomembrane will be anchored at the top of the tank and
ballasted at the bottom of the tank; therefore, there is no minimum required depth of water needed
to maintain the tank. The tank will have a capacity of 1,000,000 gallons at the service elevation,
with an additional two feet of freeboard in accordance with North Carolina solid waste rules for
uncovered storage tanks at municipal landfills generally referred to as the .1600 rules.
Leachate Tank and Secondary Containment Plan Dan River Landfill
Duke Energy – Dan River Steam Station Eden, North Carolina
Amec Foster Wheeler Project No. 7810140065 May 17, 2016
2
Modular Tank Anticipated Service
A typical landfill is designed, permitted, and constructed to serve as a facility to contain a
consistently generated waste stream; therefore, a typical landfill may have an active lifespan on
the order of several decades. The proposed Dan River Landfill modular tank is anticipated to have
a relatively short service life on the order of ten years due to the following factors:
The Dan River Landfill will not accept waste materials from other steam stations or other
off-site sources.
The Dan River Landfill will contain waste materials due to closure of the existing inactive
on-site coal combustion residual (CCR) units.
The Dan River Station no longer produces energy by burning coal; therefore, the waste
stream is of a finite quantity and no new CCR waste is being generated.
North Carolina’s Coal Ash Management Act (CAMA) requires closure and remediation of
the Dan River Station CCR surface impoundments by August 1, 2019.
The Dan River Landfill will be closed upon closure and remediation of on-site CCR units.
Leachate generation is anticipated to decrease following closure of the Dan River Landfill
as shown in the “Leachate Generation Calculation” provided in the “Engineering and
Facility Plan – Dan River Landfill”, Amec Foster Wheeler, December 24, 2015.
The proposed modular storage tank will be replaced by a smaller storage device with
secondary containment upon a demonstration of a sustained decrease in leachate
generation and approval by the NCDEQ-SWS.
The proposed modular storage tank will be disassembled upon incorporation of the smaller
storage device.
Modular Tank Liner
The proposed ModuTank MS110-17 modular tank will incorporate a 45-mil reinforced
polypropylene geomembrane liner, or as proposed by the tank Manufacturer and approved by the
Engineer. As previously discussed, the modular tank and tank liner is anticipated to be in service
on the order of ten years. During service, the proposed geomembrane tank liner will be inspected,
repaired, and replaced in accordance with the Manufacturer’s recommendations.
Modular Tank Performance History
ModuTank Inc. has been manufacturing above-ground modular storage tanks since 1970 for a
variety of applications, and has sold more than 30 modular storage tanks in North Carolina since
1987. Modular storage tanks have been successfully used at the following municipal solid waste
(MSW) landfill facilities:
CSS Landfill, Republic Services, Avalon, TX, installed December 2010.
Arlington Landfill, Republic Services, Evless, TX, installed December 2010.
Galveston Landfill, Republic Services, Santa Fe, TX, installed March 2012.
Ellis County Landfill, Republic Services, Ennis, TX, installed May 2013.
Itaska Landfill, Republic Services, Taska, TX, installed May 2013.
McCarty Road Landfill, Republic Services, Houston, TX, installed September 2014.
Leachate Tank and Secondary Containment Plan Dan River Landfill
Duke Energy – Dan River Steam Station Eden, North Carolina
Amec Foster Wheeler Project No. 7810140065 May 17, 2016
3
Secondary Containment
A soil berm will provide storage capacity for the leachate tank secondary containment area. The
secondary containment area storage volume was designed to be in excess of 1,100,000 gallons,
or 110 percent of the leachate tank storage volume as required by the .1600 rules.
Containment will be provided by a 60-mil high density polyethylene (HDPE) geomembrane with an
anchor trench at the top of the soil berm. The geomembrane will be overlain by an 8 oz/sy non-
woven geotextile and at least 12 inches of aggregate to protect the geomembrane.
The secondary containment area will be graded to drain to a sump in the southern portion of the
containment area. Liquids collected in the sump will either drain to the landfill perimeter channel
by gravity via an HDPE pipe if leachate is not present or will be pumped back to the storage tank if
leachate is present. Gravity flow through the HDPE pipe will be controlled by a butterfly valve
which will be maintained in the closed condition until it can be determined via visual observation
that leachate is not present in liquids collected in the secondary containment area sump.
Force Main
The proposed leachate force main will be located on Duke property and will consist of
approximately 2,269 linear feet of dual-contained solid-walled HDPE pipe. The force main will
begin at the pump pad on the northeast side of the secondary containment facility. Approximate
Stations 0+00 to 2+00 will be located along the outside edge of the proposed landfill perimeter
access road. Approximate Stations 2+00 to 5+00 will be located through a wooded area west of
the proposed Dan River Landfill. Approximate Stations 5+00 to 20+00 will be located along an
existing dirt road near the northern boundary of the Dan River Station property. The proposed
leachate force main will cross Edgewood Road between approximate stations 20+00 to 20+50.
The force main will cross Edgewood Road on Duke property beyond the limits of the North
Carolina Department of Transportation (NCDOT) right-of-way (ROW). Approximate Stations
20+50 to 22+69 will be located along the western side of Edgewood Road on Duke property
outside of the NCDOT ROW. The proposed tie-in to the City of Eden sanitary sewer system will
be at approximate station 22+69. The force main will include at least one air release valve at a
high point along the alignment and one witness manhole at a low point along the alignment.
Tie-In to City of Eden Sanitary Sewer System
The proposed leachate force main will tie in to the City of Eden sanitary sewer system on Duke
property near an existing air release valve on the west side of Edgewood Road approximately 375
feet north of the gated entrance to the Dan River Station. A check valve, gate valve, and flanged
outlet tapping sleeve will be utilized at the tie-in between the proposed leachate pipe and the
existing City of Eden sanitary sewer force main. The location and configuration of the tie-in was
discussed with the City of Eden and their consultants. A manhole will facilitate access, inspection,
and maintenance of the tie-in.
Leachate Tank and Secondary Containment Plan Dan River Landfill
Duke Energy – Dan River Steam Station Eden, North Carolina
Amec Foster Wheeler Project No. 7810140065 May 17, 2016
4
Closing
Amec Foster Wheeler appreciates the opportunity to provide these reports to Duke. Please
contact us at your convenience with questions.
Sincerely,
Amec Foster Wheeler
Cedric H. Ruhl Chris Jordan
Senior Engineer Technical Professional
Attachments:
Technical Specification Section 221363 – Leachate Storage Tank
Leachate Tank and Secondary Containment Plan drawings
Legal Property Description
TECHNICAL SPECIFICATION
Dan River Landfill Issued for Permit
Amec Foster Wheeler Project No. 7810140065 May 17, 2016
Leachate Storage Tank 22 13 63 - 1
SECTION 221363 – LEACHATE STORAGE TANK
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes leachate storage tank and sight tube.
1. Leachate storage tank shall be Modutank MS110-17 or approved equivalent.
2. Leachate storage tank shall have a minimum operating capacity of 1,000,000 gallons as
measured at the High elevation.
3. The top of the leachate storage tank shall be a minimum of two feet above the High
elevation.
4. Sight tube shall be Varec 6700 liquid level indicator or approved equivalent.
B. Related Sections.
1. Section 033000 “Cast-in-Place Concrete.”
2. Section 334110 “HDPE Pipe and Pipe Fittings.”
1.2 REFERENCES
A. American Welding Society (AWS):
1. AWS D1.1 – Structural Welding Code – Steel.
2. AWS D1.3 – Structural Welding Code – Sheet Steel.
3. AWS D1.4 – Structural Welding Code – Reinforced Steel.
B. American Water Works Association (AWWA):
1. AWWA D100 – Welded Carbon Steel Tanks for Water Storage.
1.3 SUBMITTALS
A. Product Data: For each type of product.
1. Include construction details, material descriptions, dimensions of individual components
and profiles, and finishes for storage tanks and sight tubes.
2. Include rated capacities, operating characteristics, and furnished specialties and
accessories.
B. Shop Drawings:
1. Include plans, elevations, sections, and mounting details.
2. Include details of equipment assemblies. Indicate dimensions, weights, loads, required
clearances, method of field assembly, components, and location and size of each field
connection.
Dan River Landfill Issued for Permit
Amec Foster Wheeler Project No. 7810140065 May 17, 2016
Leachate Storage Tank 22 13 63 - 2
3. Detail fabrication and assembly of tank and components.
C. Welding certificates.
D. Maintenance Data: For storage tanks to include in maintenance manuals.
E. Manufacturer’s tank warranty to be free from defects and material workmanship. Warranty shall
be valid for a minimum one year from date of shipment.
1.4 QUALITY ASSURANCE
A. Fabricator Qualifications: Employ a qualified structural engineer to prepare calculations, Shop
Drawings, and other structural data for fabrication and erection of surface water-storage tanks.
1. Engineering Responsibility: Preparation of data for surface water-storage tanks,
accessories, specified appurtenances, and concrete supports and foundations, including
Shop Drawings, based on testing and engineering analysis of manufacturer's standard units
in assemblies similar to those indicated for this Project.
B. Welding Qualifications: Qualify procedures and personnel according to the following:
1. AWS D1.1/D1.1M, "Structural Welding Code - Steel."
2. AWS D1.3/D1.3M, "Structural Welding Code - Sheet Steel."
3. AWS D1.4/D1.4M, "Structural Welding Code - Reinforced Steel."
PART 2 - PRODUCTS
2.1 PERFORMANCE REQUIREMENTS
A. Structural Performance: Surface water-storage tank, including structural reinforcement and
foundation, shall be capable of withstanding the effects of dead and live gravity loads and winds
of 100 mph.
2.2 MODULAR, NONPRESSURE, STORAGE TANKS
A. Description: Modular, vertical, nonpressure-rated tank with cylindrical sidewalls.
B. Construction: Steel or as otherwise approved by the Engineer, constructed with nontoxic welded
joints.
C. Liners
1. 45 mil reinforced polypropylene liner, shop fabricated in one piece for drop in installation
2. As specified by the Manufacturer and approved by the Engineer.
D. Inlet and Outlet connections: Factory-fabricated, as indicated on the Drawings.
E. Vertical Tank Supports: Factory-fabricated steel legs or steel skirt, welded to tank.
Dan River Landfill Issued for Permit
Amec Foster Wheeler Project No. 7810140065 May 17, 2016
Leachate Storage Tank 22 13 63 - 3
F. Exterior Coating: As specified by the Manufacturer and approved by the Engineer.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install water storage tanks on concrete bases, level and plumb, firmly anchored. Arrange so
devices needing servicing are accessible.
B. Vertical Water Storage Tanks:
1. Install on cast-in-place concrete equipment base(s).
C. Install the following devices on tanks:
1. Inlet and outlet connections to appurtenances and for over-the-wall and through-wall
piping.
2. OSHA approved galvanized steel or aluminum ladder with cage
D. After installing tanks with factory finish, inspect finishes and repair damages to finishes.
3.2 FIELD QUALITY CONTROL
A. Perform the following tests and inspections:
1. Tank Weld Test: Use radiographic method according to AWWA D100. Repair failures and
retest.
2. Leak Test: Comply with AWWA D100 or as approved by the Engineer. Fill tanks with
water and test for leaks after installation. Repair leaks and retest until no leaks exist.
a. Water will be furnished by Owner.
3. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and
equipment.
B. Water storage tanks will be considered defective if they do not pass test and inspections.
C. Prepare test and inspection reports.
D. Obtain and submit tank manufacturer warranty to Owner.
END OF SECTION 221363
LEGAL PROPERTY DESCRIPTION
DRAWINGS
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PREPARED FOR:
DUKE ENERGY CAROLINAS, LLC
LEACHATE TANK AND SECONDARY CONTAINMENT
DAN RIVER LANDFILL
DUKE ENERGY - DAN RIVER STEAM STATION
ROCKINGHAM COUNTY, NORTH CAROLINA
DAN RIVER STEAM STATION
ROCKINGHAM COUNTY
LANDFILL LIMIT
OF WASTE
ASH FILL 2
PRIMARY ASH BASIN
SECONDARY
ASH BASIN
LANDFILL LIMIT OF WASTE
ASH FILL 2
PRIMARY ASH BASIN
SECONDARY ASH BASIN
ASH FILL 1
ASH FILL 1
SITE AERIAL IMAGE
1"=1000'
SITE VICINITY MAP
NOT TO SCALE
NC GEOLOGY: C-247
NC ENG: F-1253
LICENSURE:
FAX: (704) 357-8638
TEL: (704) 357-8600
CHARLOTTE, NC 28208
SUITE 100
2801 YORKMONT ROAD
5/17/2016
7810-14-0065
DWG
AS SHOWN
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ISSUED FOR PERMITTING - NOT RELEASED FOR CONSTRUCTION
COVER SHEET
DAN RIVER STEAM STATION
LEACHATE TANK AND SECONDARY CONTAINMENT
Sheet List Table
Sheet Number Sheet Title
C-0.0 COVER SHEET
C-1.1 LEACHATE FORCE MAIN ALIGNMENT
C-1.2 LEACHATE STORAGE AREA GRADING PLAN
C-1.3 LEACHATE STORAGE TANK LAYOUT
C-1.4 LEACHATE FORCE MAIN PROFILE
D-1.1 LCRS DETAILS
D-2.1 LEACHATE STORAGE FACILITY DETAILS 1
D-2.2 LEACHATE STORAGE FACILITY DETAILS 2
D-2.3 LEACHATE STORAGE FACILITY DETAILS 3
D-2.4 LEACHATE STORAGE FACILITY DETAILS 4
D-2.5 LEACHATE STORAGE FACILITY DETAILS 5
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REV DATE JOB NO.PROJECT TYPE DES DFTR CHKD ENGR APPD DESCRIPTIONABSAT ISSUE #DATE DESIGN
5/17/20160 LEACHATE TANK AND SECONDARY CONTAINMENTCHRCHRAAJCSJCSJLANDFILL7810-14-0065
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REFERENCES1.EXISTING TOPOGRAPHIC INFORMATION WAS PRODUCED FROM PHOTOGRAMMETRICMETHODS FROM AERIAL PHOTOGRAPHY OBTAINED ON FEBRUARY 7, 2014 BY LDSI, INC.2.EXISTING TOPOGRAPHIC INFORMATION WAS PRODUCED FROM LIGHT DETECTION ANDRANGING (LIDAR) OBTAINED FROM NCDOT WEBSITE ON AUGUST 7, 2015.
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REFERENCES1.EXISTING TOPOGRAPHIC INFORMATION WAS PRODUCED FROM PHOTOGRAMMETRICMETHODS FROM AERIAL PHOTOGRAPHY OBTAINED ON FEBRUARY 7, 2014 BY LDSI, INC.
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REFERENCES1.EXISTING TOPOGRAPHIC INFORMATION WAS PRODUCED FROM PHOTOGRAMMETRICMETHODS FROM AERIAL PHOTOGRAPHY OBTAINED ON FEBRUARY 7, 2014 BY LDSI, INC.2.EXISTING TOPOGRAPHIC INFORMATION WAS PRODUCED FROM LIGHT DETECTION ANDRANGING (LIDAR) OBTAINED FROM NCDOT WEBSITE ON AUGUST 7, 2015.3.FORCE MAIN SIZE AND LOCATION PROVIDED BY CITY OF EDEN.
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2
B1UP-GRADIENTDIRECTION B2B2UP-GRADIENTDIRECTION 2'(MIN.)1.0'6" BUTTERFLY VALVEPVC BODY AND DISCEPDM SEATSUNISTRUTS PLACED AS NEEDED EXTRUSION WELD TO UNISTRUT (TYP.)END TERMINATION WITHLOW POINT DRAIN END TERMINATION WITHLOW POINT DRAIN9-IN. COMPACTED A
B
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MIRAFI RS58
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LOCALLY INCREASEAGGREGATE DEPTHAND GRADE TO DRAINAWAY FROM MANHOLE EXTRUSION WELD THE CONTAINMENTPIPE TO THE INSIDE AND OUTSIDE OFTHE VAULTEXTRUSION WELD THE CONTAINMENTPIPE TO THE INSIDE AND OUTSIDE OFTHE VAULT
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REFERENCES1.EXISTING TOPOGRAPHIC INFORMATION WAS PRODUCED FROM PHOTOGRAMMETRICMETHODS FROM AERIAL PHOTOGRAPHY OBTAINED ON FEBRUARY 7, 2014 BY LDSI, INC.
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