HomeMy WebLinkAboutNC0002468_SARP_Rev0_Appx F_20161201December 2016Amec Foster Wheeler Environment & Infrastructure, Inc.
Duke Energy Coal Combustion Residuals Management Program
Dan River Steam Station Site Analysis and Removal Plan
Revision 0
APPENDIX F: CONSTRUCTION QUALITY ASSURANCE
PLAN - DAN RIVER DECOMMISSIONING PLAN
CONSTRUCTION QUALITY ASSURANCE
PLAN
DAN RIVER STEAM STATION
REVISION 0
Prepared for
Duke Energy
400 South Tryon Street
Charlotte, North Carolina 28202
December 2016
Prepared by
Amec Foster Wheeler Environment & Infrastructure, Inc.
Project 7810140065.09
Amec Foster Wheeler Environment & Infrastructure, Inc. December 2016
Construction Quality Assurance Plan
Dan River Steam Station Site Analysis and Removal Plan
Revision 0
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TABLE OF CONTENTS
1. INTRODUCTION .............................................................................................................1
2. BACKGROUND ..............................................................................................................1
3. PROJECT TEAM AND RESPONSIBILITIES ....... ERROR! BOOKMARK NOT DEFINED.
3.1. Owner .................................................................................................................................. 2
3.2. Design Engineer of Record (Engineer) ............................................................................... 2
3.3. Construction Quality Assurance Engineer .......................................................................... 2
3.4. Engineering Technicians ..................................................................................................... 3
3.5. Prime Contractor ................................................................................................................. 3
3.6. Regulatory Agency .............................................................................................................. 3
4. DOCUMENTATION .........................................................................................................3
4.1. Record Documentation ....................................................................................................... 4
4.2. Error! Bookmark not defined.
4.3. Design, Specification, and Drawing Changes ..................................................................... 4
4.4. Non-Conformances ............................................................................................................. 4
4.5. Record Drawings ................................................................................................................. 4
4.6. Certification Report ............................................................................................................. 5
5. QUALITY ASSURANCE PROGRAM ..............................................................................5
5.1. Fill Density Testing .............................................................................................................. 5
5.2. Instrumentation ................................................................................................................... 6
5.3. Verification of Ash Removal ................................................................................................ 7
5.4. Surveying ............................................................................................................................ 7
Figures
Figure 1 – Site Vicinity Map
Figure 2 – Instrumentation Locations
Tables
Table 1 – Instrumentation
Table 2 – Testing Frequency
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Construction Quality Assurance Plan
Dan River Steam Station Site Analysis and Removal Plan
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1. INTRODUCTION
This document presents the Construction Quality Assurance Plan (CQA) Plan for the Dan River
Steam Station Dam Decommissioning project in Rockingham County, North Carolina. The
purpose of the CQA Plan is to identify the quality assurance procedures, standards, and
methods that will be employed during the project to provide assurance that the requirements of
the drawings, specifications, regulatory permits, and owner specified health, safety and
environmental requirements are met. The CQA Plan is specific to the referenced project and is
prepared in compliance with the North Carolina Coal Ash Management Act of 2014.
The primary objective of the scope of work for the Dam Decommissioning project at Dan River
Steam Station (hereafter referred to as Dan River) includes excavation and removal of CCR
materials currently stored in the areas known as the Primary Ash Basin (RO CKI-237),
Secondary Ash Basin (ROCKI-238), Ash Fills 1 and 2, and ancillary areas. The scope of work
includes all ancillary activities such as erection and maintenance of erosion and sediment
control, dewatering, CCR removal, grading to design grades, permanent stabilization, and all
other activities required to achieve the primary objective. The scope of work also includes
obtaining and complying with regulatory permits required for performing the work. The project
will be performed with regard to safety and environmental standards in compliance with local,
state, and federal regulations as included in the site specific environmental, health and safety
program.
2. BACKGROUND
The Dan River Steam Station is located on the Dan River near Eden in Rockingham County,
North Carolina. Historically, the primary ash management facilities included the Primary and
Secondary Ash Basins which have served as the main ash storage component for plant
operations. The site has two regulated impoundment structures, the Primary Ash Basin Dam
(State ID ROCKI-237) and the Secondary Ash Basin Dam (ROCKI-238). Two additional ash
storage areas at the station include Ash Fills 1 and 2. Ancillary ash areas include an area
between Ash Fills 1 and 2 commonly called the dredge area. Power production at the plant was
discontinued in 2012. The closure of the ash management facilities at the station is a part of the
overall station decommissioning plan.
The CCR materials in the storage areas at Dan River will be excavated and removed using
conventional excavation equipment. A portion of the CCR material will be transported and
placed in the Maplewood Landfill in Amelia County, Jetersville, Virginia. The remaining CCR
material will be placed in a new on-site lined landfill. Construction of the on-site landfill is
anticipated to begin in 2016.
Upon establishing final grades, the site will be seeded to establish grassy ground cover per
approved grading plan drawings and specifications. Final grades have been designed such that
the footprint of the currently jurisdictional dams no longer impound water, allowing the dams to
be removed from the state dam inventory and jurisdiction of state dam safety regulations. In
addition to establishing vegetative ground cover, relatively gentle slopes will be established
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during final grading to control runoff velocities. Following completion of the ash removal, the
short term disposition of the site will be grading the site to drain, establishing the vegetative
cover and maintaining the site in an undeveloped state.
3. PROJECT TEAM AND RESPONSIBILITIES
The following identifies the roles and responsibilities for the primary parties associated with the
project, including the anticipated duties and expectations each party will fulfill in execution of the
work associated with implementation of the project.
3.1. Owner
The Owner of the site and project is Duke Energy Carolinas, LLC (Duke). The Owner is
ultimately responsible for oversight and authorization of the work and assuring that the work is
performed in general accordance with the specifications, drawings, permits, this CQA Plan, and
other contractual documents. The Owner has the right to delegate its oversight authority to third
parties contracted with the Owner but will maintain ultimate responsibility for the successful
implementation of the project. The Owner will maintain the authority to make final decisions
regarding all aspects of the project in compliance with local, state, and federal regulations. For
this project, the Owner will have sole authority to suspend or stop work if, in their opinion, the
work is being performed in an unsafe manner, the work is not meeting quality standards, or
changes to the scope of work must be enacted to comply with the spirit of the objectives of the
project.
3.2. Design Engineer of Record (Engineer)
The Design Engineer of Record (Engineer) is the Engineer of Record for the Project Drawings
and Specifications. The Engineer is delegated limited and selected authority at the discretion of
the Owner. The Engineer acts in a consultant role to the Owner on aspects of the project for
which the Owner seeks direction in the decision making process. The Engineer has no
authority to stop or suspend work at the site, only the authority to recommend remedial actions
for the Owner’s consideration.
3.3. Construction Quality Assurance Engineer
The Construction Quality Assurance Engineer (CQA Engineer) will be experienced in quality
assurance testing and monitoring. The CQA Engineer will report to the Owner and can be
employed by the same entity as the Design Engineer of Record. The CQA Engineer may be a
Duke employee. The CQA Engineer serves as the on-site representative of the Owner and is
responsible for the field implementation of the approved quality assurance program as follows:
Monitor the quality assurance activities of the field testing and document conformance
with test procedures and the Technical Specifications
Inform the Engineer of quality assurance activities and non-conformance to the
approved CQA program, if any
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Construction Quality Assurance Plan
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Observe that sample handling procedures are in accordance with the appropriate
guidelines for the testing to be conducted
Organize, assign, and direct engineering technicians
Maintain an awareness of the overall field testing operations to identify conditions that
may jeopardize the quality of testing
3.4. Engineering Technicians
The engineering technicians (technicians) are responsible for field observations and testing at
the direction of the CQA Engineer. Technicians will be assigned to the project as deemed
necessary by the CQA Engineer. The CQA Engineer may perform and conduct field
observations and testing himself. Technicians will be under the direct supervision of the CQA
Engineer.
3.5. Prime Contractor
The Prime Contractor will be responsible for performing and managing construction activities
required for completing the project. The Prime Contractor is responsible for performing the work
in compliance with the requirements and to the quality standards of the specifications, drawings,
permits, and this CQA Plan. The Prime Contractor is responsible for overseeing and managing
their personnel, including the personnel of their Subcontractors such that the work is performed
safely and effectively and in compliance with local, state, and federal safety and environmental
regulations to include the Owner’s site specific environmental, health, and safety rules.
3.6. Regulatory Agency
The Regulatory Agency having direct regulatory authority of the project is the North Carolina
Department of Environmental Quality, (NCDEQ). With respect to dam decommissioning the
lead agency is the NCDEQ, Division of Energy, Mineral, and Land Resources, Land Quality
Section, Dams Program. The Regulatory Agency has the authority to inspect the project at any
time during the course of the work, and has the authority to direct the Owner to suspend or stop
the work with appropriate cause. Upon direction to suspend or stop the work, the Regulatory
Agency should provide remedial measures to the Owner, that once implemented, should allow
for work to continue.
4. DOCUMENTATION
This section provides a description of project documentation and record keeping that will be
maintained during the course of the work as the project record.
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4.1. Record Documentation
Reports will be completed by designated Owner personnel to serve as a record of the project.
The reports are intended to summarize work activities, serve as a record of important
discussions and/or decisions, action items, or other information that the Owner deems important
or critical to the project record. The Owner, at their discretion, may require other entities, such
as the CQA Engineer, to maintain records as well.
The CQA Engineer and technicians will be responsible for documenting construction,
monitoring, and testing activities by taking photographs. Photographs should be organized and
documented in photo-logs and/or by including them in reports, monitoring logs, and test data
sheets. Photo-logs should include a unique identifying number corresponding to the photograph
file name, the date and location where the photograph was taken, and a description of the
photograph subject matter.
4.2. Design, Specification, and Drawing Changes
Design, specification and drawing changes may be required during construction. Proposed
changes may be initiated by the Design Engineer of Record, Contractor, CQA Engineer, or
Owner and submitted to the Design Engineer of Record for consideration. Design, specification
and drawing changes may be made only with the approval of the Design Engineer of Record
with consent from Owner. Changes that effect the design intent will require approval of that
agency.
4.3. Non-Conformances
Non-conformance reports are intended to serve as a record of nonconforming items during the
course of the work and as a record of the disposition of the non-conformance. Generally, the
Owner will initiate the non-conformance procedure based on the recommendation or findings of
a third party such as a CQA Engineer. The non-conformance will be evaluated and resolved
with the disposition recorded in the non-conformance report. Sample dispositions may include
rework of the nonconforming item, replacement of the nonconforming item, or accepting the
nonconforming item as installed based on engineering judgment. A record of all non-
conformance reports will be maintained at the site during the course of the work at all times for
review by requesting representatives of the Regulatory Agency.
4.4. Record Drawings
The Contractor shall retain a third-party surveyor registered in the state that the work is
performed. The Contractor shall be responsible for submitting to the Engineer the following:
Existing conditions survey (pre-construction, which may be a recent aerial survey not
specifically performed for this project)
Existing stormwater piping elevations and locations (including piping to be removed)
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Bottom of excavation grades Installed stormwater piping elevations and locations
Final conditions survey (which may be an aerial survey)
The excavation grades survey and any other ground surveys shall be performed on a 100-foot
grid with berms, toes, crests and breaks-in-slope also surveyed. Topographic ground surveys
shall be performed on the same grid such that survey point locations are consistent with the
survey points of the underlying layer. Surveys shall also show contours of the completed
surface at two-foot contour intervals.
As-built locations and details for existing and installed stormwater piping shall also be submitted
to the Engineer by the Contractor. Drawings shall include pipe locations at a spacing that is
adequate to identify the position of the pipe. Survey timing should be coordinated so as not to
impact the construction schedule of the geosynthetics and overlying materials.
4.5. Certification Report
The Engineer will prepare a certification report upon completion of dam decommissioning
activities. The certification report will include as-built and record documents that are intended to
serve as documentation of the project. For this project, the primary purpose of the record
drawings is to capture final grades at the site for use in future projects. A secondary purpose is
to fulfill regulatory requirements for developing as-built drawings for decommissioned ash
basins. The as-built and record documents will generally include:
Record drawings detailing final grades
Record of quality assurance/control testing including compacted fill, stormwater piping
information, instrumentation monitoring, and verification of CCR removal
Record of non-conformance reports
Other relevant information or data at the discretion of the Owner
5. QUALITY ASSURANCE PROGRAM
The intent of the Quality Assurance Program is to provide observations, test data, and other
recorded information at a sufficient frequency to assure that the work is completed in general
accordance with the requirements of the specifications, drawings, regulatory permits, and other
controlling documents. A list of the observations and testing requirements for the Quality
Assurance Program is included in Table 2.
5.1. Fill Density Testing
Final grades at the site will be established by placing and compacting soil materials excavated
from onsite sources. The requirements for fill placement are provided in the Technical
Specifications. The general requirements for fill density testing include establishing moisture-
density relationships for fill materials, visually observing placement of fill materials during
construction, performing fill density tests to assess the level of compaction achieved, and
Amec Foster Wheeler Environment & Infrastructure, Inc. December 2016
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recording the results of testing for project records. A specific list of the observations and testing
requirements for the Quality Assurance Program associated with fill placement is included in
Table 2.
5.2. Instrumentation
During dewatering of the ash basins, limitations on the drawdown rate within the basins will be
imposed to reduce the potential for detrimental conditions developing within the existing dams.
The primary concern with regard to the drawdown rate is lowering the water level within the
basin significantly faster than the embankment fill materials are able to drain, potentially
reducing the overall stability of the impoundment structures. In order to evaluate the initial
drawdown limitations, existing instrumentation in the embankments will be monitored to track
the drawdown occurring within the embankments compared to the changing water level within
the basin. The locations of the instruments to be monitored during the project are shown on
Figure 2. The frequency of readings to be performed as a part of the Quality Assurance
Program is included on Tables 1 and 2. The water level readings will be tracked in spreadsheet
format and plotted versus the dam profile such that the data can be evaluated by qualified
personnel.
In general, monthly readings of the instrumentation listed in Tables 1 and 2 will be performed
during the course of the work until the identified wells are dry or dewatering of the basins is
complete. A dry well will be defined as a well that returns a “dry” reading for three consecutive
readings. The frequency of reading a well that has been deemed dry may be reduced to either
monthly or discontinued subject to any changing condition or data from other wells that suggest
reading the dry wells should be reinstated. More frequent readings of the piezometers may be
deemed necessary during the course of the project and will be implemented based on the
discretion of the qualified person reviewing the data.
Amec Foster Wheeler Environment & Infrastructure, Inc. December 2016
Construction Quality Assurance Plan
Dan River Steam Station Site Analysis and Removal Plan
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Table 1. Instrumentation
Structure Piezometer
Screen
Interval
(ft bls)
Sreen Elevation
(ft, amsl)
Monitoring
Frequency
P-3 INA INA
P-4 INA INA
P-5 INA INA
P-6 INA INA
P-7 INA INA
P-11 INA INA
OW-10 25-45 514.6-494.6
OW-11 25-45 514.4-494.4
OW-12 25-45 514.5-494.5
OW-13 5-20 491.3-476.3
P-1 INA INA
P-2 INA INA
OW-7 15-35 514.0-494.0
OW-8 15-35 514.6-494.6
OW-9 15-35 514.5-494.5
Monthly
Monthly
Primary Ash
Basin Dam
(ROCKI-237)
Secondary Ash
Basin Dam
(ROCKI-238)
5.3. Verification of Ash Removal
Verification and documentation that CCRs have been removed will be required during ash basin
closure implementation. In order to meet the basin closure performance standard, Duke’s CCR
Removal Verification Procedure will be used to verify that primary source ash has been
removed from the basin. Subsequent to removal of the ash pursuant to the CCR Removal
Verification Procedure, Duke Energy will implement its Excavation Soil Sampling Plan, which
was developed for the purpose of closing the Ash Basins in a manner that meets the closure
performance standards set out in Part II, Section 3.(c) of the Coal Ash Act and 40 C.F.R. §
257.102(c). The Excavation Soil Sampling Plan is attached to the Dan River Steam Station Coal
Ash Excavation Plan (2016 Update).
5.4. Surveying
The Owner may, at their discretion, contract with a CQA Engineer to perform surveying services
for the project to validate or verify the surveys performed by others. A specific scope of work
and frequency or quantity of measurements for the CQA Engineer performing the surveying
services for the Owner will be developed if and when such services are contracted. The scope
of work for surveying to be performed by the Prime Contractor is contained in the Technical
Specifications.
Amec Foster Wheeler Environment & Infrastructure, Inc. December 2016
Construction Quality Assurance Plan
Dan River Steam Station Site Analysis and Removal Plan
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FIGURES
As
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Ramp
Ch
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Ram
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Ramp
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Ra
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Ashley
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Hill
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Early
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UV1700
UV700
UV1709
UV1700
UV2145
UV770
UV2203
UV65
UV1785
UV2066
UV1962
UV1733
UV770
UV1714
UV1716
UV2203
UV2203
UV2039
UV1747
UV14
UV87
PREPARED
BY JMS
DATE
11/11/15
CHECKED
BY KD
DATE
11/11/15
JOB NUMBER FIGURE 17810-14-0065
SITE VICINITY MAP
DUKE ENERGY DAN RIVER STEAM STATION
ROCKINGHAM COUNTY, NORTH CAROLINA
¯^_
NORTH CAROLINA
Project Location
0 6,000 12,000Feet Service Layer Credits: Sources: Esri, HERE, DeLorme, Intermpa, increment P Corp., GEBCO, USGS, FAO, NPS, NRCAN, GeoBase, IGN,
Kadaster NL, Ordnance Survey, Esri Japan, METI, Esri China (Hong Kong), swisstopo, MapmyIndia, OpenStreetMap contributors, and the
GIS User community Copyright: 2013 National Geogrpahic Society, i-cubed
Primary
Ash Basin
Secondary
Ash Basin
Ash Fill
1
Ash Fill
2
"J "J
"J"J
"J
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"J
!U
!U
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!U
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DAN RIVER FACILITY
Primary
Pond
Secondary
Pond
Ash
Fill 1
Ash
Fill 2
P1 P2
P3
P4
P5
P6
P7
P11
ROCKI-237-OW11
ROCKI-237-OW10
ROCKI-238-OW09
ROCKI-238-OW08
ROCKI-238-OW07
ROCKI-237-OW12
ROCKI-237-OW13
PREPARED
BY
DATE CHECKED
BY
DATE JOB NUMBER FIGURE
0 130 260
Feet 2
INSTRUMENTATION LOCATIONS
CQA PLAN FOR DAM DECOMMISSIONING
DAN RIVER STEAM STATION
NORTH CAROLINA¯
CHR KRD11/16/15 11/16/15
SOURCE: AERIAL PHOTOGRAPHY FLOWN MAY 5, 2014; TOPOGRAPHIC MAPPING FROM AERIAL PHOTOGRAPHY DATED FEBRUARY 7, 2014;
AS-BUILT PIEZOMETER LOCATIONS OBTAINED BY LDSI FIELD SURVEY, 10/30/14 AND 11/14/14.
7810-14-0065
INSTRUMENTATION
"J EXISTING DUKE PIEZOMETER (P)
!U EXISTING DUKE OBSERVATION WELL (OW)
TOPOGRAPHIC CONTOURS - 5 FT (2/7/14)
TOPOGRAPHIC CONTOURS - 1 FT (2/7/14)
Amec Foster Wheeler Environment & Infrastructure, Inc. December 2016
Construction Quality Assurance Plan
Dan River Steam Station Site Analysis and Removal Plan
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TABLES
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Table 2. Testing Frequency
Component Test Method Frequency
Fill Placement/Compaction Visual ● Daily
Soil Classification of Fill ASTM D 2488 ● Daily
Moisture Density Relationship ASTM D 698 ● 3 proctors prior to commencement of fill placement
● one per 20,000 cubic yards of fill placed or change of material classification
In-Place Density Testing
ASTM D 2937
ASTM D 6938
ASTM D 1556
● one per 8,000 cubic yards placed
● minimum of once daily
Index Testing ASTM D 6913 or D 422
ASTM D 4318 ● one each per 8,000 cubic yards placed
Moisture Content
ASTM D 2216
ASTM D 4643
ASTM D 4959
● one per 8,000 cubic yards placed (in conjunction with field density test)
● minimum once daily or as needed to monitor fill placement
Component Test Method Frequency
Aggregate Visual ● Per delivery
Aggregate Quarry Certification ● Once at beginning of project and at Owner's request thereafter
Rip Rap Visual ● Per delivery
Rip Rap Quarry Certification ● Once at beginning of project and at Owner's request thereafter
Component Test Method Frequency
Contractor - Project Controls N/A ● Initial site layout
● At Contractor's discretion thereafter
Owner - Record Survey N/A ● Per Owner's scope of work
CQA Engineer N/A ● Per Owner's scope of work
Component Test Method Frequency
Primary Ash Basin (ROCKI-237)
P-3, P-4, P-5, P-6, P-7, P-11, OW-10, OW-
11, OW-12, and OW-13
Water level meter
Tracking spreadsheet ● Monthly or until "dry"
Secondary Ash Basin (ROCKI-238)
P-1, P-2, OW-7, OW-8, and OW-9
Water level meter
Tracking spreadsheet ● Monthly or until "dry"
Component Test Method Frequency
Formal Inspection Visual
Inspection Form ● Weekly and within 24 hours after each 0.5-inch of rainfall
Rain Gauge Visual ● Daily
Informal Inspection Visual ● Daily
Field Density Testing
Earthwork
Surveying
Instrumentation
Erosion and Sediment Control