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HomeMy WebLinkAbout4104_HighPoint_MSWLF_DIN22430_20141028.pdfSEABOARD  GROUP  II  AND  CITY  OF  HIGH  POINT   Page  1  of  7   October  28,  2014   Mr.  Larry  Stanley   North  Carolina  Department  of  Environment  and  Natural  Resources   Division  of  Waste  Management   1646  Mail  Service  Center   Raleigh,  North  Carolina  27699-­‐1646   Re:  Quarterly  Remedial  Action  Construction  Progress  Report,  3rd  Quarter  2014,   Seaboard  Chemical  Corp.  and  Riverdale  Drive  Landfill  Site,  Jamestown,  North   Carolina   Dear  Mr.  Stanley:   Seaboard  Group  II  and  the  City  of  High  Point,  NC  (hereinafter  the  “Parties”)  provides  this   Remedial  Action  Construction  Progress  Report  for  the  former  Seaboard  Chemical   Corporation  facility  (SCC)  and  closed  Riverdale  Drive  Landfill  (Landfill)  located  in  Jamestown,   NC  (collectively  hereinafter  referred  to  as  the  “Site”).  The  Remedial  Action  Pre-­‐Construction   Report  for  the  physical  treatment  systems  was  submitted  to  North  Carolina  Department  of   Environment  and  Natural  Resources  (NCDENR)1  on  December  28,  2009.  The  report  was   subsequently  approved  by  NCDENR  on  March  22,  2010.  Although  the  Natural  Treatment   Systems  Remedial  Action  Pre-­‐Construction  Report  has  not  been  formally  approved  by   NCDENR,  it  was  submitted  on  October  25,  2010,  and  the  Parties  have  included  comments   on  activities  associated  with  that  process  as  well.  Collectively  these  reports  are  referred  to   herein  as  the  “Pre-­‐construction  Report.”   Remedial  Construction  Work  Performed  since  the  Last  Progress  Report   A  quarterly  Remedial  Action  Construction  Progress  Report  was  submitted  to  NCDENR  in   January  2014  updating  progress  at  the  Site  through  the  end  of  December  2013.  The   activities  conducted  since  that  report  mainly  involve  the  initial  startup  and  testing  of  the   physical  and  phytoremediation  treatment  system  components.  Technical  Memoranda   numbers  E-­‐4,  E-­‐5,  E-­‐6,  E-­‐7,  E-­‐8,  and  E-­‐9  explain  in  some  detail  the  difficulties  that  have  been   experienced  in  the  construction  and  startup  of  this  system.    The  remedial  system  startup   has  fallen  behind  the  schedule  in  the  original  Scope  of  Work  included  in  Remedial  Action   Settlement  Agreement  (RASA).  As  previously  reported,  the  delays  were  caused  by  the  failure   of  the  physical  treatment  system  manufacturer,  Purifics  ES,  Inc.,  to  manufacture,  deliver   and  install  a  fully  tested  and  operational  system  without  defects  as  required  by  its  contract   with  the  Parties.    The  Parties  have  devoted  substantial  time,  resources  and  expenditures  to                                                                                                                   1  NCDENR  is  used  in  this  report  to  refer  to  the  North  Carolina  Department  of  Environment  and  Natural  Resources,  and  collectively   the  associated  Division  of  Waste  Management,  Solid  Waste  Section,  Hazardous  Waste  Section,  and  the  Inactive  Hazardous  Sites   Branch,  all  of  which  are  involved  in  the  regulatory  oversight  of  this  remedial  action.   Remedial  Action  Construction  Progress  Report   October  28,  2014   Page  2  of  7   correct  and  repair  the  numerous  deificiencies  in  the  Purifics’  treatment  system   components.   Initial  testing  prior  to  startup  began  during  April  2013  when  the  irrigation  network  control   software  was  incorporated  into  the  system  control  and  data  acquisition  programming   (SCADA),  and  the  automation  upgrade  was  completed.  Once  that  equipment  was  installed,   and  the  final  data  inputs  were  added  to  the  SCADA,  the  automation  contractor  tested  the   system,  and  both  the  automation  and  irrigation  system  upgrades  were  complete.  At  that   time,  the  system  was  tested  and  shown  to  be  able  to  operate  in  automatic  mode  for   sustained  periods  in  all  flow  paths  including  through  the  AOP+2  process.   During  the  initial  startup  attempt  it  was  determined  that  the  level  of  metals,  in  particular   iron,  calcium,  manganese,  and  magnesium  in  the  leachate  and  shallow  groundwater  were   significantly  higher  than  those  reported  during  earlier  testing.  At  first  this  was  thought  to  be   a  temporary  spike  in  metal  concentrations  due  to  initial  system  operations.  However,  it  was   subsequently  determined  to  be  an  indication  of  a  more  chronically  high  level  of  metals,   particularly  in  the  leachate.  As  a  result,  a  30’  by  30’  building  housing  a  new  filtration  system   (referred  to  as  the  “Filter  Building”)  was  installed  and  all  piping,  electrical  and  automation   work  is  complete  at  this  time.  The  system  startup  testing  recommenced  as  soon  as  those   modifications  were  complete.     During  January  2014,  the  system  resumed  operation,  and    a  series  of  required  pre-­‐ operational  tests  was  commenced.  Initially,  the  system  was  operated  on  a  limited  basis   processing  only  city  water  to  retest  all  of  the  alarms  and  interlocks,  leak  check  the  entire   system  and  prove  the  viability  of  automatic  operation  of  each  possible  flow  path.  The  Pre-­‐ construction  Report  proposed  that  the  initial  testing  would  also  include  a  30-­‐day  aquifer   drawdown  test,  an  AOP+  performance  test,  and  certain  other  tests  that  were  thought   necessary  prior  to  beginning  regular  operations  and  monitoring.  The  Project  Managers  felt   that  the  30-­‐day  drawdown  test  would  not  provide  useful  data  due  to  its  limited  scope,  and   submitted  TM-­‐E8.  TM-­‐E8  included  a  revised  Remedial  Monitoring  and  Effectiveness   Evaluation  Plan  (RMEEP),  which  specified  a  longer-­‐term  capture  zone  evaluation  period.   TM-­‐E8  and  the  new  RMEEP  were  approved  by  NCDENR  during  February  2014.     At  that  time,  the  contractors  had  finished  most  of  the  modification  of  the  remedial  system   thought  to  be  necessary  to  remove  the  additional  metals  and  the  associated  sludge  this   generated,  and  the  system  resumed  startup  testing.  During  the  initial  operating  period  in   the  first  quarter  of  2014,  the  startup  advanced  to  the  point  that  all  the  groundwater  and   leachate  sources  were  introduced  into  the  process,  and  the  entire  system  was  operated  in   various  configurations  to  test  the  automation  controls.  The  testing  progressed  fairly  well  to   that  point;  however,  the  management  of  the  solids  generated  by  the  process  made  it   necessary  to  evaluate  the  need  to  install  additional  solids  removal  equipment.                                                                                                                   2  The  term  AOP+  is  used  in  this  report  to  refer  to  a  photo  catalytic  ultraviolet  light  oxidation  process       Remedial  Action  Construction  Progress  Report   October  28,  2014   Page  3  of  7   The  solids  problem  was  present  in  two  locations.  The  most  serious  problem  occurred  when   the  new  filter  discharge  pump  impeller  (P-­‐605)  ceased,  causing  the  system  to  shutdown.   Upon  inspection  it  was  determined  that  solids  had  caused  deposits  to  buildup  between  the   impeller  and  the  backing  plate  on  the  pump  casing.  To  address  this  problem  the  Project   Managers  sent  a  sample  of  the  solids  and  sludge  from  the  system  to  a  NC  certified   laboratory  to  be  tested.  The  results  indicated  that  the  filter  media  being  used  in  the  new   filters  was  not  performing  as  efficiently  as  required.  To  address  this  problem,  it  was  decided   to  replace  the  existing  single  sand  bed  with  a  two-­‐layer  bed  comprised  of  a  bottom  layer  of   garnet  and  an  upper  layer  of  Filter  AD.  This  two-­‐layer  system  provides  the  requisite  solids   removal  and  eliminates  the  problem  in  the  P-­‐605  pump.  However,  it  became  apparent  that   the  sludge  generated  at  Lift  Station-­‐1  (LS-­‐1)  would  be  much  more  than  the  existing   equipment  could  properly  handle.   The  enhanced  filtration  in  the  filter  building  also  raised  the  concern  that  during  filter   backwash  the  amount  of  solids  being  removed  would  be  more  than  the  existing  bag-­‐filter   will  be  able  to  efficiently  remove.  Therefore,  the  Project  Managers  sent  a  sample  for  testing   to  determine  the  particle  size  distribution  in  the  sludge.  From  that  it  was  determined  that   about  98%  of  the  larger  particles  (above  74-­‐microns  in  size)  could  be  removed  using  a   hydrocyclone.  Therefore,  a  hydrocyclone  was  added  to  the  filter  backwash  line  before  the   bag-­‐filter  to  handle  the  increase  in  solids.  The  bag-­‐filter  was  then  operated  with  a  filter  bag   designed  to  capture  particles  greater  than  25-­‐micron  in  size3,  allowing  the  backwash  water   to  be  reused.  This  modification  was  installed  without  a  full  system  shutdown.  After   installation,  it  was  determined  that  the  hydrocyclone  alone  would  not  adequately  remove   the  solids,  and  the  bag  filter  was  plugging  frequently  during  each  backwash  cycle.  As  a   result,  the  Project  Managers  shutdown  and  installed  a  sand  bed  filter  at  the  back  of  the   filter  building.  They  then  had  the  piping  modified  to  send  all  of  the  backwash  water  to  the   lined  sand  bed  filter.  The  underflow  from  the  sand  bed  is  collected  and  returned  to  the   system  for  treatment.     The  other  concern  raised  by  the  amount  of  solids  generated  by  the  treatment  of  shallow   groundwater  and  leachate  was  the  possible  plugging  of  the  line  from  LS-­‐1  to  LS-­‐2  and  from   LS-­‐2  into  the  filter  building.  The  improvements  in  the  filter  media  will  address  the  concerns   in  all  locations  except  LS-­‐1.  This  line  raises  up-­‐hill  about  70-­‐feet  and  could  become  fouled   with  the  high  solids  content  of  the  mixed  groundwater  and  leachate.  Therefore,  it  was   decided  to  install  a  sand  bed  filter  at  LS-­‐1  and  direct  all  flow  from  the  T-­‐121  tank  into  that   sand  bed  filter.  The  underflow  from  the  sand  bed  filter  is  directed  through  a  second   hydrocyclone  installed  in  the  line  from  the  LS-­‐1  discharge  pump  (P-­‐120)  to  LS-­‐2.  Flow   entering  LS-­‐1  is  adjusted  to  a  pH  of  9.25  and  treated  with  polycarbonate  to  chelate  and   separate  the  metals.  This  should  remove  the  majority  of  the  solids  from  the  process  before   they  enter  the  line  feeding  LS-­‐2,  and  reduce  the  calcium  and  iron  content  to  a  level  the   treatment  system  can  tolerate.                                                                                                                   3  It  may  be  possible  to  use  a  filter  bag  as  fine  as  10-­‐microns..   Remedial  Action  Construction  Progress  Report   October  28,  2014   Page  4  of  7   In  addition,  during  full  operation  the  effluent  showed  signs  of  colloidal  iron  (or  something   that  caused  an  iron-­‐like  color)  remaining  after  all  treatment.  The  effluent  from  the  Settling   Tank  in  the  main  treatment  structure,  which  feeds  either  the  irrigation  process  or  the  AOP+   unit,  continued  to  show  a  significant  amount  of  color.  This  was  thought  to  be  colloidal  iron.   To  address  this,  the  Parties  retained  the  services  of  a  consulting  process  chemist  who   evaluated  methods  to  flocculate,  coagulate,  or  otherwise  remove  the  remaining  color  from   the  process  effluent.  Although  this  may  not  be  a  problem  for  the  irrigation  effluent,  it  would   not  be  suitable  for  processing  through  the  AOP+  unit.  This  unit  relies  on  the  transmissivity  of   light  to  operate  efficiently.  Therefore,  this  effluent  color  would  have  interfered  with  the   AOP+  operation,  reduced  its  effectiveness  and  increased  its  operating  costs.  After  the   modifications  mentioned,  and  some  modification  to  the  chemical  treatment,  the  iron   discoloration  was  removed.  However,  when  processing  in  the  AOP+  unit,  the  flow  is  filtered   through  a  1-­‐micron  filter  cartridge  that  cost  $450  each.  Tests  indicated  that  cartridge  was   plugging  off  after  approximately  15-­‐hours  of  use.  To  correct  this,  the  Project  Managers  have   installed  two  bag  filters  that  can  be  operated  in  series  or  as  a  spared  (parallel)  system.   When  discharging  to  the  irrigation  system,  the  filters  will  be  operated  as  a  spared  system   with  25-­‐micron  filter  bags  so  that  the  bags  can  be  changed  without  shutting  the  system   down.  During  this  operation,  the  1-­‐micron  filter  will  be  bypassed.  When  discharging  to  the   AOP+  unit,  the  filters  will  be  operated  in  series  as  pre-­‐filters  to  the  1-­‐micron  filter  unit.  The   inlet  filter  will  be  fitted  with  a  25-­‐micron  bag,  and  the  outlet  filter  will  be  filtered  with  a  5-­‐ micron  bag.  This  should  capture  the  majority  of  the  suspended  solids  and  extend  the   operating  life  of  the  1-­‐micron  filter.     Finally,  the  Project  Managers  determined  that  it  would  be  necessary  to  design  a  method  to   handle  and  dry  the  sludge  and  filter  backwash  solids  generated  by  the  two  new  sand  filter   beds.  To  determine  the  requirements,  a  sample  was  collected  and  sent  for  hazardous  waste   characteristic  testing,  including  a  full  TCLP  metals  and  organics.  That  testing  showed  that   sludge  did  not  exhibit  any  of  the  characteristics  of  hazardous  waste.  Therefore,  the  Parties   are  exploring  methods  to  thicken  the  sludge  and  release  entrained  water  more  quickly.  In   addition,  they  are  exploring  methods  to  dry  the  sludge  to  make  disposal  in  a  sanitary  landfill   possible.   Remedial  Construction  Work  Remaining   The  following  summarizes  the  status  of  the  treatment  system  components  and  the  activities   that  remain  to  complete  the  construction  and  start-­‐up  of  the  remedy:   1. Physical  Treatment  System   1.1. Lift  Station-­‐1   Complete  except  for  any  required  sludge  thickening  and/or  drying  equipment  needs,  as   well  as  an  update  of  the  SCADA  to  reflect  recent  changes.   1.2. Lift  Station-­‐2   Complete.  Except  for  an  update  of  the  SCADA  to  reflect  recent  changes   Remedial  Action  Construction  Progress  Report   October  28,  2014   Page  5  of  7   1.3. Main  Treatment  Structure   Complete,  except  for  an  update  of  the  SCADA  to  reflect  recent  changes.     1.4. Filter  Building   Complete  except  for  an  update  of  the  SCADA  to  reflect  recent  changes.   1.5. SCADA     Complete  except  for  an  update  of  the  SCADA  to  reflect  recent  changes   Phytoremediation  System   Complete.  Testing  for  leaks   Significant  Potential  Future  Requirements   Monitoring  Well  Abandonment   The  Project  Managers  submitted  Technical  Memorandum  E-­‐1  dated  January  4,  2011   identifying  a  portion  of  the  monitoring  wells  at  the  Site  that  are  no  longer  necessary  and   requested  permission  to  plug  and  abandon  them.  NCDENR  verbally  approved  the  well   abandonment  in  March  2011,  and  the  Project  Managers  originally  intended  to  perform  this   work  during  2013,  in  conjunction  with  the  annual  monitoring  work.  However,  because  of   the  effect  of  the  PW-­‐6I/PW-­‐6D  well  casing  problem  (see  below),  the  Project  Managers   elected  to  delay  the  monitoring  well  abandonment  until  after  that  problem  is  resolved.  In   addition,  there  are  several  additional  wells  at  the  Site  that  are  not  intended  to  be   monitored,  gauged,  or  maintained  and  have  not  been  an  active  part  of  the  Site  remedial   monitoring  program.  The  Project  Managers  are  in  the  process  of  identifying  those  wells  and,   once  complete,  will  submit  additional  wells  to  NCDENR  for  approval  to  abandon.  At  the   request  of  NCDENR,  the  potable  water  well  in  the  front  area  of  the  Landfill  will  also  be   plugged  and  abandoned  at  that  time.  This  work  can  now  proceed  with  the  replacement  of   the  PW-­‐6I/PW-­‐6D  wells.     Monitoring  Well  Transducers   In  the  revised  RMEEP,  the  Parties  proposed  to  install  level  transducers  in  seven  additional   monitoring  wells.  These  includes  OW-­‐DR-­‐2,  OW-­‐DR-­‐3,  OW-­‐DR-­‐4,  PW-­‐6D,  and  OW-­‐LFS-­‐2,   which  are  located  on  the  landfill,  and  PW-­‐15D  and  PW-­‐16D  located  across  the  Randleman   Reservoir  on  property  within  the  Randleman  Reservoir  buffer.  There  is  an  existing   transducer  in  PW-­‐DR-­‐1.  The  equipment  design  was  completed  in  the  second  quarter  of   2014  and  those  transducers  have  been  installed  at  this  time.  These  new  level  indications  are   recorded  by  the  SCADA  and  drawdown  is  indicated  in  all  of  the  wells  except  OWDR-­‐3.  After   review  of  the  historic  performance  of  OWDR-­‐3,  it  was  determined  that  the  well  has  never   shown  any  influence  from  pumping  PWDR-­‐1,  and  it  was  decided  to  relocate  that  transducer   to  PW-­‐6I  which  is  screened  into  the  hanging  wall  of  the  Deep  River  fault.  Water  level   monitoring  during  recent  testing  indicated  that  pumping  PWDR-­‐1  does  affect  the  level  in   Remedial  Action  Construction  Progress  Report   October  28,  2014   Page  6  of  7   PW-­‐6I  and  this  location  will  give  the  Parties  data  on  the  effect  of  the  capture  zone  on  the   upper  aquifer  at  the  site.   Summary   The  remedial  system  startup  has  fallen  behind  schedule  based  upon  the  original  Scope  of   Work  included  in  Remedial  Action  Settlement  Agreement  (RASA).  The  delays  were  caused  by   the  failure  of  the  AOP  system  manufacturer,  Purifics,  to  manufacture,  deliver  and  install  a   fully  tested  and  operational  system  without  defects  as  required  by  its  contract  with  the   Parties.  However,  significant  progress  has  been  made  at  this  time,  and  the  items  required   for  startup  are  complete.  Startup  resumed  during  September  2014,  and  testing  should  be   finished  by  December  31,  2014.     Please  contact  Mr.  Gary  D.  Babb,  P.G.  (919-­‐325-­‐0696)  or  James  C.  LaRue  (281-­‐431-­‐3571)  if   there  are  any  questions  or  comments.  Please  direct  correspondence  related  to  this  matter   to:   Gary  D.  Babb,  P.G.   Seaboard  Group  II  and  City  of  High  Point   c/o  Babb  &  Associates,  P.A.   P.O.  Box  37697   Raleigh,  NC  27627.   Communications  via  electronic  mail  should  be  directed  to  gbabb@nc.rr.com  and   jlarue@swenv.com.   Respectfully,   Seaboard  Group  II  and  City  of  High  Point       James  C.  LaRue   Seaboard  Group  II   Gary  D.  Babb,  P.G.   City  of  High  Point   Attachment  -­‐  Project  Schedule   cc  Amos  Dawson,  Esq.  Counsel    Terry  Hauk  -­‐  City  of  High  Point    Randy  Smith  -­‐  Seaboard  Remediation  Trust    Jackie  Drummond  –  NCDENR       Remedial  Action  Construction  Progress  Report   October  28,  2014   Page  7  of  7   PROJECT  SCHEDULE   2014   October  1  –  December  31  Commence  operation  of  the  AOP+  unit  to  test  performance,   operate  system  for  a  sustained  operating  period  and  address   any  programming  needs.  Complete  all  testing  including  the   AOP+  performance  test.  Design  procedure  and  install    solids   handling  upgrades,  if  required.   2015   January  1,  2015-­‐  Begin  to  operate  using  the  phytoremediation  system.  Operate   system  at  50-­‐GPM  sustained  flows  with  discharge  to  the   irrigation  network.   January  31  -­‐    Submit  Construction  Completion  Report.