NC0081957_Report_20021202

NPDES DOCIMENT SCANNING COVER :MEET
NPDES Permit:
NC0081957
Narrows Powerhouse
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Report
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
December 12, 2002
This document is printed on reuse paper - ignore any
content on the resrerse side

R L-6
ALCOA
December 05, 2002
Alcoa Primary Metals
Alcoa Power Generating Inc.
Yadkin Division
293 NC 740 Hwy
PO Box 576
Badin, NC 28009-0576 USA
N. C. Department of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
leigh, lC. 27699-1617
Atteon: T. Kerr Stevens
RE:
Gentlemen:
CERTIFIED MAIL
RETURN RECEIPT REQU
8368 8791
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(Rf's
0,4-C��
CORRECTIVE ACTION SCHEDULE STATUS REPORT b/!! 0p,?pp2
NARROWS POWERHOUSE - NPDES PERMIT # NC 0081957 �/R1, rSR n,
OP' l}-
Alcoa Power Generating, Inc. ("Alcoa") is providing the Division of Water Quality with
a status report regarding the corrective action schedule as specified in section A(3) of
NPDES Permit No. NC 0081957 (the "Permit") for the Narrows Powerhouse.
In accordance with Section A(3) of the Permit, in January 2001, Alcoa completed the
planned improvements to the Penstock sump area which involved capping the area
around the sumps with gunnite, installation of silt fencing around the perimeter, and
installation of a high pressure sump pump. In furtherance of its obligations under the
Permit, Alcoa has recently completed the monitoring to confirm that the improvements
have been effective in reducing the concentrations of target constituents in the storm
water which discharges through the Unit #4 penstock. Alcoa commenced this monitoring
in January 2002, and a total of 12 samples were collected through October 2002. The
monitoring results, which are attached, show that there were no detectable concentrations
of target constituents in any of the samples with the exception of the February 28, 2002
sample. The February 28, 2002 sample had detectable concentrations of metals, which we
believe were the result of maintenance personnel changing the sample tap from PVC to
galvanized pipe. The sample tap was subsequently changed back to PVC prior to
collecting the March 22 sample and the problem was eliminated.
As a follow-up to this notification, we will be contacting you in the near future to set-up a
meeting during January 2003 to discuss these results as they relate to the existing permit.
If you should have any questions or comments regarding this information, please don't
hesitate to contact me.
Very truly y
Mark J. Joss
Vice -President of Operations
Alcoa Power Generating, Inc.
P:\WINWORD\ENVIRON\WATER\YADKIN\CORRECTIVE ACTION SCHEDULE STATUS REPORT
11-21-02.DOC

Cc: email
Z. T. Gibson
W. L. McCaskill
B. A. Cox
J. A. Lease — PGH NAEHS
J. D. Morton - PGH NAEHS
M. A. Ross — PGH Legal
S. H. Myers - Knoxville
K. G. Hunsucker
P:IWINWORDIENVIRONIWATERIYADKINICORRECTIVE ACTION SCHEDULE STATUS REPORT
11-21-02.DOC

t
NARROWS PENSTOCK SAMPLING DATA (2002)
1/24 217 2128 3122 3/27 4/23 4/30 6131 6/28 7/31 8130 10131
LEAD (mgll) < 0.005 < 0.005 0.17 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005
CADMIUM < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005
(mg/1) < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005
CHROMIUM
(mg/I) <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
ZINC (mg/i) < 0.02 < 0.02 0.47 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02
COPPER < 0.02 < 0.02 < 0.02 < 0.02 < 0.02
(mgli) < 0.02 < 0.02 0.33 < 0.02 < 0.02 < 0.02 < 0.02
AROCHLOR
1016(ugl1) < 1.1 <1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0
AROCHLOR < 2.0 < 2.0 < 2.0 < 2.0 < 2.0
1221(ug11) <2.2 <2.0 <2.0 <2.0 <2.0 <2.0 <2.1
AROCHLOR
1232(ugA) < 1.1 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0
AROCHLOR <1.0 <1.0 <1.0 <i,p <1,p <1.0
1242(ugf) < 1.1 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0
AROCHLOR
1248(ug/i) < 1.1 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1,0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0
AROCHLOR
1254(ugll) < 1.1 < 1.0 <1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0
AROCHLOR
1260(ug11) < 1.1 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0
AROCHLOR
1268(ugl1) < 1.1 <1.0 <1.0 <1.0 < 1.0 <1.0
< 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0

r
2001 November 30
N. C. Department of Environment
and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27626-0535
Attn: Dave Goodrich
•
!j�
JU DEC -6 2001
DENR - WATER QUALITY
POINT SOURCE BRANCH
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
xxxx xxxx
RE: CORRECTIVE ACTION PLAN — NARROWS POWERHOUSE
NPDES PERMIT #NC0081957
Dear Mr. Goodrich:
As per condition A(3) in Alcoa Power Generating Inc's (APGI) NPDES permit issued on
1/26/01, we are hereby providing the Division of Water Quality with a status report as
required by the special conditions of the corrective action schedule. As of this report,
Yadkin has completed the concrete gunite of the sump pits at it's Narrows powerhouse
below the four penstocks, and the installation of a silt fence as scheduled.. This work
will keep sandy media from washing into the pits in the future, and the concrete gunite
will allow us to easily maintain the surrounding area. The sump pump for the final
installation is on order and is scheduled to be delivered the second week of December.
This 20hp pump will overcome the 180 foot head required to pump the runoff water into
the penstock. The pump is a custom built combination we ordered after determining the
exact specifications on shaft length upon completion of the gunite construction. In the
interim, we have installed a temporary pump to discharge any water which may runoff
the hill into the draft tube portion of the generator. As conveyed and agreed to in a phone
conversationl on 11/29/01 with Mike Myers of the Division of Water Quality office,
sampling of the discharge will begin following the permanent installation of the custom
sump pump
If you should have any questions regarding these matters, please don't hesitate to contact
me.
Yours Very Truly,
Gr
Vice1't nt Operations
Alcoa Power Generating, Inc.
C:\TEMPORARY INTERNET FILES \OLK1I\CORRECTIVE ACTION SCHEDULE 11-28-01 DRAFT.DOC

ALCOA
2001 October 17
N. C. Department of Environment
and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27626-0535
Attn: Michael J. Myers
Alcoa Primary Metals
Alcoa Power Generating Inc.
Yadkin Division
293 NC 740 Hwy
PO Box 576
Badin, NC 28009-0576 USA
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
9421 1174
RE: CORRECTIVE ACTION PLAN — NARROWS POWERHOUSE
NPDES PERMIT #NC0081957
Dear Mr. Myers:
As a follow-up to our conversation today regarding progress at the Narrows Powerhouse,
the construction is moving forward as planned, and weather permitting, should be
completed by the end of October. Once the construction is complete, we will begin
collecting samples to verify the concentrations of specific metals & PCB's in the
discharge utilizing approved methodologies as outlined in your 12/23/99 corrective action
letter. As we discussed, the currently approved analytical methods for PCB's are only
capable of detecting PCB's at concentrations above 100 ng/1 which is well above the
current water quality standards for PCB's, but hopefully the data will show that there are
no PCB's present above the 100 ng/1 practical quantitation limit.
As per the corrective action schedule, once the final construction is completed, Yadkin,
Inc will provide the Division of Water Quality with the next project update around the
end of November 2001.
If you should have any questions regarding these matters, please don't hesitate to contact
me.
Yours Very Truly,
William L. McCaskill
Senior Environmental Specialist
Alcoa - Badin Works
P:\WINWORD\ENVIRON\WATER\YADKIN\CORRECTIVE ACTION SCHEDULE 10-17-01.DOC

Cc:email
B. A. Cox
Z. T. Gibson
S. H. Myers
J. D. Morton - PGH - NAEHS
J. A. Lease — PGH - NAEHS
G. J. Ott - Yadkin
K. G. Hunsucker - Yadkin
M. A. Ross — PGH - Legal
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Alcoa Inc.
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ALCOA
2000 October 12
N. C. Department of Environment and Natural Resources
Division of Water Quality
P. O. Box 2953
Raleigh, N. C.
Attention: T. K
evens
CERTIFIED MAIL -
RETURN RECEIPT REQUESTED
0214 6218
RE: PROPOS$D CORRECTIVE ACTION SCHEDULE -NARROWS POWERHOUSE
NPDES PERMIT # NC 0081957
Gentlemen:
As a follow-up to the September 19, 2000, meeting between representatives of Alcoa
Inc., Yadkin, Inc. and the Division of Water Quality, Alcoa is submitting on behalf of
Yadkin, Inc, a proposed schedule of corrective action for the Narrows Powerhouse
Penstock Sump Drain. During our September 19 meeting with Dave Goodrich, Michael
Myers, and the states' legal counsel, it was agreed that Yadkin, Inc would plan corrective
actions for the Penstock Sump Drain and submit a corrective action schedule to the
Division of Water Quality for their review and approval.
If you should have questions or comments regarding the proposed schedule, please don't
hesitate to contact me.
Very truly yours,
t/de;,-
William L. McCaskill
Senior Environmental Specialist
Alcoa — Badin Works
Cc:email
B. A. Cox
G. J. Ott
B. J. Polk
S. H. Myers
J. A. Lease — PGH NAEHS
J. D. Morton — PGH NAEHS
M. A. Ross — PGH Legal
K. G. Hunsucker
P:\WINWORD\ENVIRON\WATER\YADKIN\CORRECTIVE ACTION SCHEDULE COVER
LETTER.DOC
JJ
P.O. Box 576 Badin, North Carolina 28009 USA

NARROWS POWERHOUSE/PENSTOCK WATER REMEDIATION TASK
PROPOSED REMEDIATION SCHEDULE
TASK START DATE END DATE
PREPARE GENERAL TASK PLAN — SCOPE OF WORK & INTERNAL REVIEW 10/10/00 12/15/00 Z "'`°"T``' r S. cl.7.
AGENCY TASK PLAN REVIEW 12/15/00 01/31/01 , 5 Krk
COST ESTIMATE & TASK FUNDING 01/31/01 03/31/01 c2. ,0°-4 11—
UPDATE TASK PLAN - INCORPORATE AGENCY COMMENTS 03/31/01 04/30/01 / )i l'rr`
PREPARE DETAILED ENGINEERING PLANS & SPECIFICATIONS 04/30/01 6/15/01 ' s �"``
PREPARE REQUEST FOR PROPOSAL 6/15/01 7/15/01 / 0-014,
BID CYCLE 7/15/01 8/15/01 % '''r&
AWARD CONTRACT 8/15/01 8/30/01 43-641O
IMPLEMENT TASK PLAN 8/30/01 10/30/01 Z A/to - -
DATA COLLECTION 11/01/01 11/01/02 / pt..
EVALUATE DATA & SUBMIT TO AGENCY 11/01/02 01/01/03 Z ''2v`"' `.
MEETING TO DISCUSS RESULTS 01/01/03 02/01/03 1 1-' c.,t,rc.
SUBMIT REQUEST FOR FINAL APPROVAL 02/01/03 04/30/03 .3 $ $ ice' `rt`"°
P:IWINWORDIENVIRONIWATERIYADKINICORRECTIVE ACTION SCHEDULE,doc 10/12/00

RE: Yadkin Status Report
Subject: RE: Yadkin Status Report
Date: Wed, 20 Dec 2000 15:34:41 -0500
From: "Ross, Marc A." <[e-mail]>
To: 'Mary Thompson' <[e-mail]>
CC: "Myers, Steve H." <[e-mail]>,
"McCaskill, William L." <[e-mail]>
Mary Penny --
Just so that there's no confusion ---
If the state is going to issue a new permit incorporating the work plan for
the Narrows Powerhouse (and the schedule for implementing that work plan),
we don't envision any numerical effluent limitation for PCBs until after 1
year of data collection. Furthermore, because we believe it will take us
approximately 1 year from now to get the work done on the powerhouse and
install the monitoring equipment, we don't envision even a monitoring and
reporting requirement in the new permit for PCBs to commence until the "data
collection period" specified in work plan schedule which has already been
submitted to the agency (on 10/18/00).
Please call me if you have further questions.
The contents of this e-mail may be confidential and may be protected by the
attorney -client or other privileges. If you have received this e-mail in
error, please contact:
Marc A. Ross
a Legal Department
phone: [phone]
fax: [phone]
e-mail: [e-mail]
1 of 1
12/21/00 10:23 AM

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ALCOA
2001 June 28
Alcoa Primary Metals
Badin Works
Highway 740
PO Box 576
Badin, NC 28009-0576 USA
Fax:[phone]
N. C. Department of Environment and Natural Resources
Division of Water Quality
1617 ail Service Center
Ralei � ►�. , ' i 99-1617
AttentioI. Kerr Stevens
RE: CORRECTIVE ACTION SCHEDULE STATUS REPORT
NARROWS POWERHOUSE - NPDES PERMIT # NC 0081957
Gentlemen:
CERTIFIED MAIL
RETURN RECEIPT REQUUTED
G v
9421 1310 0 �•
`�-r G '�
G O
-0 9
cIN
Alcoa Power Generating, Inc. is providing the Division of Water Quality with a status
report regarding the corrective action schedule as specified in section A(3) of NPDES
Permit No. NC 0081957 for the Narrows Powerhouse.
As of the date of this report, Alcoa Power Generating, Inc. has contracted with an outside
engineering firm and has completed the initial design for modifications to the sump pits.
Requests for bids have been released and on -site visits by prospective contractors have
been completed. Both contractors were made aware of the schedule and have confirmed
that they can complete the project by October 2001 weather permitting.
Following the site visits, detailed design for the installation began. Currently, final
engineered design drawings are being completed. These include Civil / Structural,
Electrical / Instrumentation, Piping / Mechanical. As per section A(3) of the NPDES
permit, Alcoa Power Generating, Inc. will provide the Division of Water Quality with
another update by November 30, 2001.
If you should have questions or comments regarding this project, please don't hesitate to
contact me.
Very truly yours,
4
10
GreC tt�
Vice-Pres e • • f Operations
Alcoa Power Generating, Inc.
P:\WINWORD\ENVIRON\WATER\YADKIN\CORRECTIVE ACTION SCHEDULE STATUS REPORT
6-28-01.DOC

Cc:email
B. A. Cox
Z. T. Gibson
B. J. Polk
W. L. McCaskill
J. A. Lease — PGH NAEHS
J. D. Morton — PGH NAEHS
M. A. Ross — PGH Legal
K. G. Hunsucker
S. H. Myers - Knoxville
C:ITEMPORARY INTERNET FILESIOLKDICORRECTIVE ACTION SCHEDULE STATUS REPORT
6-27-01.DOC

Alcoa Inc. ALCOA
2001 January 04
N. C. Department of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, N. C. 27626-0535 CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Attention: Dave Goodrich 0214 7628
RE: CORRECTIVE ACTION PLANS - NARROWS POWERHOUSE
NPDES PERMIT # NC 0081957
Gentlemen:
As a follow-up to our 12/19/00 meeting during which we discussed the corrective actions
planned for the Narrows Powerhouse, Alcoa is providing, on behalf of Yadkin, Inc. a
copy of the drawings which we reviewed during our meeting. Also, please find attached a
copy of the analytical report which we discussed regarding the recent discovery of PCB's
in the existing paint coatings on the Narrows Penstocks. Yadkin's current schedule for
repainting the Penstocks is tentatively within the next 1 — 2 years.
Please feel free to provide us with any comments you may have regarding the drawings
and planned corrective actions. If you should have questions or comments regarding
these matters, please don't hesitate to contact me.
Very truly yours,
44
William L. McCaskill
Senior Environmental Specialist
Alcoa — Badin Works
Cc:email
B. A. Cox
G. J. Ott
B. J. Polk
S. H. Myers
J. A. Lease — PGH NAEHS
J. D. Morton — PGH NAEHS
M. A. Ross — PGH Legal
K. G. Hunsucker
JAN 1 0 2001 I
i!EHR 4'f,;; "' QUALITY
PO":?,IT i+RA,`iCH
P.O. Box 576 Badin, North Carolina 28009 USA

SEVERN
TRENT
5102 LaRoche Avenue • Savannah, GA 31404 • Tel: [phone] • Fax: [phone] • www.stl-inc.com
Mr. Larry McCaskill
Aluminum Company of America
P.O. Box 576
Badin, NC 28009
REPORT OF RESULTS
LOG NO SAMPLE DESCRIPTION , SOLID OR SEMISOLID SAMPLES
SERVICES
STL Savannah
LOG NO: SO-07074
Received: 14 OCT 00
Reported: 24 OCT 00
Project: ALCOA
Sampled By: Client
Code: 145401026
Page 1
DATE/
TIME SAMPLED
07074-1
07074-2
07074-3
#1 PENSTOCK
#3 PENSTOCK
#16 #2 GROUND
10-12-00/14:30
10-12-00/14:30
10-12-00/14:30
PARAMETER
07074-1 07074-2 07074-3
PCB's (8082)
Aroclor-1016, ug/kg <35 <45 <33
Aroclor-1221, ug/kg <72 <91 <67
Aroclor-1232, ug/kg <35 <45 <33
Aroclor-1242, ug/kg <35 <45 <33
Aroclor-1248, ug/kg <35 <45 <33
Aroclor-1254, ug/kg <35 52 100
Aroclor-1260, ug/kg <35 120 65
Surrogate - TCX 26 Is 31 % 39 '
Surrogate - DCB 40 & 48 % 49 %
Dilution Factor 1 1 1
Prep Date 10.17.00 10.17.00 10.17.00
Analysis Date 10.19.00 10.19.00 10.19.00
Batch ID 10170 10170 10170
4,i vcie.gie_
savx- - AL(
JAN 1 0 2001
pDENR - w.AT Q
Py
Of SOURCE GRAN
STL Savannah is a part of Severn Trent Laboratories, Inc.

SEVERN
TRENT
5102 LaRoche Avenue • Savannah, GA 31404 • Tel: [phone] • Fax: [phone] • www.stl-inc.com
Mr. Larry McCaskill
Aluminum Company of America
P.O. Box 576
Badin, NC 28009
REPORT OF RESULTS
SERVICES
STL Savannah
LOG NO: SO-07074
Received: 14 OCT 00
Reported: 24 OCT 00
Project: ALCOA
Sampled By: Client
Code: 145401026
Page 2
DATE/
LOG NO SAMPLE DESCRIPTION , SOLID OR SEMISOLID SAMPLES TIME SAMPLED
07074-4 #36 #4 GROUND 10-12-00/14:30
PETER 07074-4
PCB's (8082)
Aroclor-1016, ug/kg dw <35
Aroclor-1221, ug/kg dw <72
Aroclor-1232, ug/kg dw <35
Aroclor-1242, ug/kg dw <35
Aroclor-1248, ug/kg dw <35
Aroclor-1254, ug/kg dw <35
Aroclor-1260, ug/kg dw <35
Surrogate - TCX 39 Is
Surrogate - DCB 58 Vs
Dilution Factor 1
Prep Date 10.17.00
Analysis Date 10.19.00
Batch ID 10170
Percent Solids 93
STL Savannah is a part of Severn Trent Laboratories, Inc.

SEVERN
TRENT
5102 LaRoche Avenue • Savannah, GA 31404 • Tel: [phone] • Fax: [phone] • www.stl-inc.com
Mr. Larry McCaskill
Aluminum Company of America
P.O. Box 576
Badin, NC 28009
REPORT OF RESULTS
SERVICES
STL Savannah
LOG NO: SO-07074
Received: 14 OCT 00
Reported: 24 OCT 00
Project: ALCOA
Sampled By: Client
Code: 145401026
Page 3
DATE/
LOG NO SAMPLE DESCRIPTION , QC REPORT FOR SOLID/SEMISOLID TIME SAMPLED
07074-5
07074-6
07074-7
07074-8
07074-9
Method Blank
Lab Control Standard * Recovery
LCS Accuracy Control Limit (%R)
Practical Quantitation Limit (PQL)
Method Detection Limit (MDL)
PARAMETER 07074-5 07074-6 07074-7 07074-8 07074-9
PCB's (8082)
Aroclor-1016, ug/kg dw <33 64 % 34-138 % 33 5.7
Aroclor-1221, ug/kg dw <67 67 7.6
Aroclor-1232, ug/kg dw <33 33 3.5
Aroclor-1242, ug/kg dw <33 33 6.5
Aroclor-1248, ug/kg dw <33 33 5.9
Aroclor-1254, ug/kg dw <33 --- --- 33 8.2
Aroclor-1260, ug/kg dw <33 58 % 39-138 % 33 8.0
Surrogate - TCX 55 % 39 % 30-150 ' --- ---
Surrogate - DCB 59 % 46 * 30-150
Dilution Factor 1 1 ---
Prep Date 10.17.00 10.17.00
Analysis Date 10.19.00 10.19.00
Batch ID 10170 10170
STL Savannah is a part of Severn Trent Laboratories, Inc.

SEVERN
TRENT
5102 LaRoche Avenue • Savannah, GA 31404 • Tel: [phone] • Fax: [phone] • www.stl-inc.com
Mr. Larry McCaskill
Aluminum Company of America
P.O. Box 576
Badin, NC 28009
REPORT OF RESULTS
SERVICES
STL Savannah
LOG NO: SO-07074
Received: 14 OCT 00
Reported: 24 OCT 00
Project: ALCOA
Sampled By: Client
Code: 145401026
Page 4
DATE/
LOG NO SAMPLE DESCRIPTION , QC REPORT FOR SOLID/SEMISOLID TIME SAMPLED
07074-10
07074-11
MS/MSD % RPD
RPD Limits
PARAMETER 07074-10 07074-11
PCB's (8082)
Aroclor-1016, 31 % <44
Aroclor-1260, 50 % <30
Batch ID 10170 ---
Methods: EPA 40 CFR Part 136
NC DEHNR Cert. #389
Angie
jl�i�un+z�
wart, Project Manager
Final Page Of Report
STL Savannah is a part of Severn Trent Laboratories, Inc.