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Ash Transportation Information Plan
Dan River Steam Station
900 Edgewood Road, Eden-North Carolina
Rockingham County
Created by: CCP Ash Basin Closure Team
November 22, 2016 – Revision 6
Duke Energy
Dan River Ash Transportation Plan
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1.0 Dan River Steam Station Ash Transportation Information
The scope of work in this ash transportation plan (Plan) outlines information for the
support of excavation and transportation activities from Ash Stacks 1 and 2, and the
Primary/Secondary Ash Basins (see Figure 1) located at the Duke Energy Dan River
Steam Station (facility) to the Waste Management Maplewood Landfill in Amelia County
Virginia along with Roanoke Cement Company in Troutville,VA.
Excavation, loading, transportation and disposal services will be performed by Waste
Management (WM). The work area utilizes existing and newly constructed Ash Basin
and Ash Stack haul roads incorporated with a newly constructed concrete load-out pad.
Ash from the facility will be hauled by rail to the Maplewood Landfill, trucked to Roanoke
Cement in Troutville, VA or placed in the newly constructed on-site landfill, as outlined
in the Coal Ash Excavation Plan acknowledged by the North Carolina Department of
Environmental Quality (NCDEQ) on February 2,2015.
Figure 1 – Dan River Steam Station General Site Plan
Duke Energy
Dan River Ash Transportation Plan
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2.0 Excavation and Loading
Excavation, loading, and hauling activities at the facility will occur in accordance with
required regulatory permits. General activities include but are not limited to:
Erosion and Sediment Control (E&SC) measures will be maintained throughout the
project.
Storm water run-off from the Ash Basins, Ash Stacks, haul roads, and concrete load-
out pad are contained within the ash basin system and flows to the Secondary Ash
Basin.
Waste Management will conduct work in accordance with their Health and Safety
Plan (HASP), including the Material Transport Job Hazard Analysis (JHAs). The
HASP and JHAs have detailed procedures to mitigate potential hazards anticipated
for the project.
Excavation of material from Ash Stacks will be conducted with an excavator and
loaded in off-road dump trucks for transport the rail load-out pad.
Off-road dump trucks will enter the load-out pad via the entrance ramp, deposit the
ash, leave the pad using the exit ramp and proceed back to the ash stack area.
Operators will use spotters, horn signals, and 3 part radio communications when
staging off-road dump trucks in the ash excavation area and the load-out pad. If
communication is unclear, employees are instructed to call an all-stop until absolute
clarity can be obtained.
3.0 On-Site Rail Operations
Railcars will be lined with a HDPE liner. Liner crews will be trained on rail liner
installation.
The ash will be loaded into the rail car by a Wheel Loader.
Visual inspection of the ash is performed by the loading operator to ensure
consistency.
Material will be loaded and kept below the top of the rail car to ensure the liner
system remains secure.
When the rail car is fully loaded, the liner will be folded over and closed in
accordance with the rail liner guidelines and specifications.
The weight of each rail car will be measured after loading using a Norfolk-Southern
certified weight-in-motion rail scale.
A final inspection of each train will be documented and signed-off prior to the train
being released to Norfolk-Southern for transportation to Maplewood Landfill.
Inspection will include verification of: liner closure, no ash is outside of the liner, and
no ash is outside of the rail car. Incidental amounts of ash present in areas outside
of the liner or rail car will be removed by hand using a broom or other equipment
appropriate for the task.
3.1 Off-Site Truck Operations
Ash will be excavated from the Primary Basin. Ash will be removed from the existing
internal Dredge Pool constructed within the Primary Basin. Note: The Dredge Pool
Duke Energy
Dan River Ash Transportation Plan
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will be decommissioned and breached in accordance with Duke Engineering
requirements. (The Dredge Pool will be breached as drawn out by Will and Rusty
and approved by Sharat.)
No excavation will be performed within 30-ft of the inside edge of the earthen dam
embankment.
If ash excavation operation reveals non-ash material (visually different in
color or consistency from usual ponded ash appearance) - stop and notify
Project Manager.
Trucks will be coordinated in a staging area prior to loading. Trucks will be moved
to the loading area (one at a time) to be loaded.
Ash will be loaded into the trucks by an Excavator or Wheel Loader.
Visual inspection of the ash is performed by the loading operator to ensure
consistency.
Material will be loaded and kept below the top of the truck trailer to ensure the
protective tarp system remains secure.
Once each truck is fully loaded, an inspection will be conducted to ensure that no
ash material is left on the top of the truck trailer.
Trucks will proceed to the tarp closing area where the protective tarp system will be
placed over the ash.
Trucks will proceed to the wheel-wash area for cleaning and inspection to ensure
that no ash is present on the truck before exiting the Primary Basin area.
Trucks will proceed along Edgewood Road to the Truck Scale house.
The weight of each truck will be measured after loading using the Duke Energy
certified truck scale.
Once weighing process is complete and confirmed, trucks will depart the Dan River
property and proceed to Roanoke Cement, (6071 Catawba Road, Troutville, VA
24175).
4.0 Environmental Controls
4.1 Dust Control
Water will be the primary method of dust suppression at the facility with
application via water truck. Polymer based alternate cover material may
be utilized for dust suppression if conditions dictate need.
A street cleaner will be utilized for clearing ash from the loading pad.
Water will be applied to gravel haul roads and work areas via water truck
as needed to mitigate fugitive dust.
4.2 Spill prevention and clean-up
Routine inspections occur during hours of operation to identify spills or
areas of potential spills.
Displaced ash will be removed within 24 hours.
Duke Energy
Dan River Ash Transportation Plan
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5.0 Haul to Maplewood Landfill
Rail hauling operations from the facility to the Maplewood Landfill is anticipated to occur
with a maximum train length of 60-car units per train with transportation averaging 2.5-3
trips per week. Rail hauling activities will include but is not limited to:
NS will conduct work in accordance with all regulatory requirements.
NS train crews will perform a Class I Brake Inspections (air and mechanical) prior to
pulling the train offsite.
NS will perform mechanical inspections every 1000 miles (i.e., every 2 round trips).
Trains will follow the route on Figure 2.
In the event of an accident or incident resulting in displaced ash once off Duke
Energy property, NS is responsible for cleanup, and has emergency responders on
call.
If a spill occurs, train crews will notify NS OSS dispatch. NS OSS dispatch will alert
HAZMAT crews for assessment and removal of material. NS OSS will make all
required regulatory notifications. NS OSS dispatch will notify Duke Energy in the
event of a release.
If an emergency or spill occurs, notifications will be made according to NS
emergency response plan which is summarized in the call tree included as Figure 3.
NS is responsible for removal of any ash displaced from rail cars during transport.
Figure 2 – Rail Haul Plan
Maplewood Landfill
Dan River Steam Station
Duke Energy
Dan River Ash Transportation Plan
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Figure 3 – Emergency Response Call Tree
5.1 Haul to Roanoke Cement
Truck hauling operations from the facility to the Roanoke Cement facility in Troutville,
VA is anticipated to occur with a maximum number of 10 trucks per day with
transportation averaging 5 trips per week (50 trucks total). Truck hauling operations will
be conducted by AJ Transport Company from South Boston, VA. This will include but is
not limited to:
AJ Transport will conduct work in accordance with all regulatory requirements.
AJ Transport drivers will perform inspections of their trucks (air and mechanical)
prior to arriving at the Dan River site for loading.
In the event of an accident or incident resulting in displaced ash once off Duke
Energy property, AJ Transport is responsible for cleanup, and has emergency
responders on call.
If a spill occurs, truck drivers will notify AJ Transport dispatch. AJ Transport
dispatch will alert HAZMAT crews for assessment and removal of material. AJ
Duke Energy
Dan River Ash Transportation Plan
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Transport dispatch will make all required regulatory notifications. AJ Transport
dispatch will notify Duke Energy in the event of a release.
If an emergency or spill occurs, notifications will be made according to AJ Transport
dispatch emergency response plan which is summarized in the call tree included as
Figure 5.
AJ Transport is responsible for removal of any ash displaced from trucks during
transport.
Figure 4 – Truck Haul Plan to Roanoke Cement
Roanoke Cement
Duke Energy
Dan River Ash Transportation Plan
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Figure 5 – Dan River Truck Traffic Plan