20090139 Ver 1_More Info Received_20090306

EPCQR

EPCOR
Power L.P.

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EPCOR USA Ventures LLC
2000 York Road, Suite 129
Oak Brook, IL 60523

Tel: [phone]

February 27, 2009

VIA CERTIFIED MAIL / RETURN RECEIPT REQUESTED

Ms. Cyndi Karoly
40 I Oversight/Express Review Permitting Unit
-DWQ
1650 Mail Service Center
2321 Crabtree Blvd
Raleigh, NC 27604

Mr. Ian McMillan
40 I Oversight/Express Review Permitting Unit
-DWQ
1650 Mail Service Center
2321 Crabtree Blvd
Raleigh, NC 27604

Re: EPCOR USA North Carolina - Roxboro Plant
Mitchell Creek [ 030205, 22-58-12-6-3, C ]
DWQ Project # 09-0139 Person County
Pre-Construction Notification Submittal
Response to Agency Request for Additional Information

Ms. Karoly and Mr. McMillan:

The following responses are provided in response to your request for additional information
regarding the referenced Roxboro PCN Application as provided by Cyndi Karoly on February
17,2009.

The information submitted below is believed to be complete and should fully address the
questions you posed.

We are interested in completing this review as soon as possible as our construction schedule is
approaching. Your timely attention to the initial submittal was very much appreciated. If we
can respectively ask you for your timely review of this response as well, that also would be very
helpful.

Thank you in advance for your time and assistance.

Regards,

',~-'~
J~~ C. ~oo~

Corporate Director, Environmental Health & Safety
Suite #129
2000 York Road
Oak Brook, IL 60523
Office Phone: [phone]
Cell Phone: [phone]
Email: jmoore(a!epcorusa.com

Attachment: ROXBORO RESPONSE TO REQUEST FOR MORE INFORMATION

Subject Property:

EPCOR, USA, NC, Roxboro Plant
Mitchell Creek [030205, 22-58-12-6-3, C]
DWQ Project # 09-0139 Person County

ROXBORO RESPONSE TO REQUEST FOR MORE INFORMATION

1. Please locate the project boundaries on the most recent bound and published
Person County soil survey and the USGS 1 :24,000 topographic map for the project.
Those documents were ordered and received from the USGS February 23,2009. We
have also retrieved the Person County soil survey maps. We are locating the Plant
Boundaries onto the USGS Map. We will send these maps to Mr. Ian McMillan no later
than next week.

2. Please re-submit your site plans on full plan sheets at a scale of no smaller than
1 "=50' with topographic contours shown.
Mr. McMillan, per our discussion, we will submit Roxboro site plan drawings to you
that are on a scale of 1"= 80 ft. If, following your review, this drawing size does not
provide sufficient detail, we will then have I "=50 ft. scale drawing produced and sent.
have reviewed the 1 "=80 ft plans and the detail appears clear and discernable.

3. Please locate all isolated or non-isolated wetlands, streams, and other waters of the
State as overlays on the site plan.
Mr. Eric Alsmeyer, Project Manager, Army Corp. of Engineers, visited the Roxboro site
on December 10t\ 2008. Mr. Alsmeyer indicated that there were no on-site wetlands or
other site impacted streams. Mr. Alsmeyer informed me February 24, 2009 that he
called your office to discuss and indicate the above to you (Ian McMillan).

Please inform me if you need any further input on this point.

4. Please indicate all stream impacts including all fill slopes, dissipaters, and bank
stabilization on the site plan.
Per Mr. Eric Alsmeyer's December 10th 2008 assessment of the Roxboro Plant site, the
subject stream is classified as jurisdictional at the point of the Plant NPDES Outfall and
north to the facility property boundary.

The Project is planning the installation of a Truck Dumper ("TO") located in the
northeast comer of the Roxboro Plant property. The selected location is east of the
stream. Access to the TO equipment will require a short span of roadway. In order to
provide access to the TO, the roadway will traverse over the jurisdictional stream.

Per the Army Corp of Engineers 40 I /404 stream/wetlands assessment completed
December 10 of2008, the drainage area (referred to as the Channel #1 area containing 3-
crossings) is not classified as a stream and is not subject to any Pre-Construction
Notification (PCN) submittal. The ACOE's review determined that the stream requires

a Pre Construction Notification (PCN) at the Plant outfall to the off-site location
(referred to as stream Channel #2 area containing I-crossing).

Modifications to the Channel # I area receiving drainage from Contributory Areas A and
B include the following:
Culvert Position # I - 2 X 30" CHDPE Pipe
Culvert Position #2 - 2 X 30" CHDPE Pipe
Culvert Position #3 - 2 X 30" CHDPE Pipe

Maximum flow calculations for the Channel #1 section of the stream are provided for
both flow paths from contributory areas are provided in the PCN submittal application
for:

Existing Flow Path A
Existing Flow Path B
Proposed Stream Relocation Design

Upstream "ditch checks" (rock lenses to settle entrained solids) are located in the
Channel # I area to prevent entrained solids from entering the Channel #2 jurisdictional
section of the stream.

The impacts to the stream from the point of jurisdiction (as described above) are as
follows:

Modifications to the Channel #2 section of the stream receiving plant
NPDES outfall discharge and drainage from Contributory Areas C include
the installation of Culverts in position #4 - 60" Reinforced Concrete Pipe
(RCP) Pipe
Two segments of 60" culvert will be installed in position #4:
I. P-l is 119 ft long at a 2% grade tieing into Manhole # I
2. P-2 is 78 ft long at a 4.5% grade tieing into Manhole #2
Manhole #2 ties into the existing 60" culvert exiting the property
A rock bed (approximately 3"-6" diameter rock) is place at the entrance to
the 60" culvert to further control solids laydown within the culvert.

Project design for the culverts size and flow calculations for the above stream non-
jurisdictional and jurisdictional culvert locations were provided in the Worley Parsons
engineering report provided with the PCN submittal:
Appendix B - Roxboro Rainfall Intensity-Duration Curve
Appendix D - Existing Channel Cross Sections
Appendix E - Proposed Culvert and Channel Data
Appendix F - Storm Sewer Design Report

5. Please quantify your stream impacts in Section C, No. 3a of your PCN application.
Quantification ofthe jurisdictional stream impact involves two segments of 60" diameter
culvert installed in position #4 as follows:
P-l is 119 ft long at a 2% grade tying into Manhole # I
P-2 is 78 ft long at a 4.5% grade tying into Manhole #2
Refer to the site plan drawings submitted

-2-

6. Please clarify how many culverts are being installed.
Stream Culvert Installations:
Channel #1 (non-jurisdictional stream) = 6 culverts to be installed
Channel #2 (jurisdictional stream) = 2 culverts to be installed

7. Please provide an inventory of imperviousness surfaces in each drainage area. The
inventory should include all proposed building footprints, roads, driveways,
sidewalks, gravel-surfaced areas, amenity areas, etc.
The Roxboro Plant has two Stormwater Outfalls, Nos. #1 and #2. The inventory of
proposed new impervious areas for each area are provided below.

Outfall # I Area Proiect Proposed Inventory of Proposed Construction:
a. On-site Buildings (sq. ft.)
New Bldgs Proposed for Addition to the Roxboro Site:
Motor Control Centers (I) at 12 ft X 20 ft = 240 ft2 = 0.006 Acres
Office Bldg at 60 ft X 144 ft = 7800 ft2 = 0.18 Acres
b. On-site Streets (sq. ft.)
New Roadways Proposed for Addition to the site:
Truck roadway - Entrance to Scale = 455 ft X 24 ft wide = 10,920 ft2
Truck Roadway - Truck Return Roadway = 372 ft X 24 ft = 8,928 ft2
TOTAL ROADWAY Surface Area = 19,848 ft2 = 0.46 Acres
c. On-site Parking (sq. ft.)
Gravel Parking Lot at 225 X 225 ft = 44, I 00 ft2 = 1.16 Acres
d. On-site Sidewalks (sq. ft.) - None
No on-site sidewalks existing / planned at Roxboro
e. Other on-site (sq. ft.)
No other on-site impervious surfaces planned on-site

PROJECT GENERATED NEW IMPERVIOUS AREAs For Drainage Area #1
Total NEW Area = 1.81 Acres (0.006 + 0.18 + 0.46 + 1.16 )
Total Area contributing Stormwater flow to Outfall #2 = 1.81 Acres

An Erosion & Sedimentation Plan for the Office Bldg and new Parking lot has been
submitted to the NCDENR for approval on a fast-track basis.

Outfall #2 Area Proiect Proposed Inventory of Proposed Construction:
a. On-site Buildings (sq. ft.)
New Bldgs Proposed for Addition to the South port Site:
Motor Control Centers (2 ) at 12 ft X 10ft = 240 ft2
Truck Dumper at 15 ft X 70 ft = 16,000 ft2
New Wood Storage Pad = 28,000 ft2 ( Stormwater flows will go to the Plant
Wastewater System)
TDF Storage Pad = 16,000 ft2 located over inactive coal pile ( Stormwater
flows will go to the Plant Wastewater System)
TOTAL for NEW Construction = 60,240 ft2 = 1.4 acres
Total Area Impacting Stormwater Runoff ( subtracting Fuel Pads area directed
to wastewater system) = 16,240 ft2 = 0.38 acre

-3-

b. On-site Streets (sq. ft.)
New Roadways Proposed for Addition to the Southport Site:
Truck roadway - Scale to Truck Dump = 496 ft X 24 ft wide = 11,904 ft2
TOTAL ROADWAY Surface Area = 0.28 acres
c. On-site Parking (sq. ft.)
No parking in Drainage Area #2
d. On-site Sidewalks (sq. ft.) - None
No sidewalks in Drainage Area #2
e. Other on-site (sq. ft.)
No other on-site impervious surfaces planned in Drainage Area #2

PROJECT GENERA TED NEW IMPERVIOUS AREAs For Drainage Area #2
Total NEW Area = 2.06 Acres
Total Area contributing Stormwater flow to Outfall #2 = 0.66 Acres

All stormwater from the Wood and TDF Storage Pads will be directed to the Plant
Wastewater Basins and discharged from the plant under the Plant NPDES Permit.
There will be no discharge of pad stormwater to the #2 Stormwater Outfall.

A Stormwater Management Plan (SMP) must be provided for any drainage areas
that exceed 24 percent imperviousness.
The Project proposed new construction area is less than 24% of the total area for each
drainage area:

Outfall # 1 Drainage Area:
Total Outfall Drainage Area = 10.54 acres
Total Proposed New Impervious Area = 2.06 Acres
Percent of Proposed New Area to Total Area = 19.5%

Outfall #2 Drainage Area:
Total Outfall Drainage Area = 8.00 acres
Total Proposed New Impervious Area = 1.7 Acres
Percent of Proposed New Area to Total Area = 21.2%
Percent of Proposed New Area Contributing to Area #2 Stormwater
0.66 Acres divided by 8.0 Acres = 8.3 %

For each BMP, provide a completed BMP Supplement Form with all the required
items (see http://h2o.enr.state.nc.us/su/bmpforms.htm). Per NCAC 2B 15A:
02H.1000, a "drainage area" is defined as "the entire area contributing surface
runoff to a single point."

Based on the proposed construction at less than 24% of the total drainage drainage area
for Drainage areas NOx. 1 and 2, no additional BMP Supplemental forms are required.
The existing BMP's submitted in the October 2006 Stormwater Permit renewal
application should adequately address the Proposed new construction.

-4-

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U.S. DEPARTMENT OF AGRICULTURE
SOIL CONSERV ATION SERVICE

SHEET NUMBER 7
SOIL SURVEY OF PERSON COUNTY. NORTH CAROLINA

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