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Sludge Management Plan CALTRANS, C V Kane Safety Roadside Rest Area (SRRA)

Sewage Pond Rehabilitation Project

Board Order No: 6-94-100 WDID No: 6B369405003

Date: June 10, 2011

Prepared for: California Regional Water Quality Control Board

Lahontan Region 14440 Civic Drive, Suite 200

Victorville, CA 92392

Prepared by: California Department of Transportation (CALTRANS)

1801, 30th Street, MS9-3/11H Sacramento, CA 95816 Phone: 916-227-8350

Caltrans C V Kane SRRA Sewage Pond Rehabilitation Project Sludge Management Plan (Revised June 10, 2011)

CONTENTS

1.0 PURPOSE

2.0 BACKGROUND

3.0 SAMPLING ACTIVITIES

Sludge Depth Sampling Sludge Depth Estimates Sludge Analytical Sampling Sludge Analytical Results

4.0 PROPOSED WORK

Sewage Transfer Sludge Dewatering and Disposal Options

5.0 REPORTING REQUIREMENTS

LIST OF FIGURES

Figure 1 - Site Location Figure 2 - Approximate Sludge Depth Measurement Locations Figure 3 - Approximate Sludge Sampling Locations

APPENDIXES

Appendix A - Laboratory Analytical Results

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1.0 PURPOSE

The California Department of Transportation (CALTRANS) owns and maintains the C V Kane Safety Roadside Rest Area (SRRA) located on Interstate 15 in San Bernardino County, 30 miles east of Barstow, California. A location map is attached as Figure 1. The wastewater from the SRRA is being treated by a three pond system. The first pond is a lined primary stabilization pond.. The second and third ponds are for infiltration and evaporation of the wastewater. The CV Kane SRRA wastewater treatment facility is currently operated by Caltrans District 8 personnel under Lahontan Regional Water Quality Control Board (LRWQCB) Waste Discharge Requirements (WDR) Order No. 6-94-100.

CALTRANS is proposing to repair the ponds as a maintenance activity under their existing Waste Discharge Requirements (WDRs) issued by the LRWQCB.

This sludge management plan (SMP) has been prepared to fulfill the requirements of Board Order No. 6-94-100 Revised Waste Discharge Requirements, Monitoring and Reporting Program requirement Sludge Monitoring, which states that:

“The discharger will submit an SMP 90 days prior to any planned pond cleaning operation. The Plan will outline actions necessary for the Discharger to be in compliance with all state laws and regulations. Copies of reports submitted to other agencies regarding sludge disposal operations will be included in the Plan.”

This SMP includes the following information:

� A description of the Sampling Activities

� A description of the proposed work

2.0 BACKGROUND

The C V Kane SRRA wastewater treatment system was constructed in 1997 and consists of a collection system, lift station with grinder pumps and a three pond system being regulated by the LRWQCB Board Order No: 6-94-100 (WDID No: 6B369405003).

The first pond (Pond 1) is 0.75 acres, fully lined with a 36 mil Chlorosulfonated polyethylene liner and serves as an aerated lagoon designed to provide both primary and secondary treatment of wastewater flows. Pond 1 has a constructed depth of 10-feet and an operating depth of 8-feet.

The second pond (Pond 2) is 1.39 acres, unlined and serves as an infiltration/evaporation pond with a constructed depth of 9-feet and an operating depth of 5-feet.

The third pond (Pond 3) is 1.17 acres, is unlined, serves as an overflow from pond 2 and is a secondary infiltration/evaporation pond. Pond 3 has a constructed depth of 8.0-feet and an operating depth of 4-feet.

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3.0 SAMPLING ACTIVITIES

In June 2010, CALTRANS hired a consultant to measure the depth of the sludge, perform sludge sampling for Pond 1 and pond 2. The samples were analyzed by a California Certified Laboratory. During this sampling activity, Pond 1 was operating at its full capacity, Pond 2 operating depth was measured to be approximately 3.5 feet and Pond 3 was empty.

Sludge Depth Sampling

The consultant measured the depth of accumulated sludge at thirty-two locations in Pond 1 and twenty-six locations in Pond 2. Sludge depths were measured using a Sludge Judge II sampling device.

The depth of sludge recorded at each location was transferred into AutoCAD where a virtual surface of the sludge was created. This surface was compared to a surface derived from the as built drawings of each pond. The difference between the two surfaces was measured and an estimated volume of sludge calculated.

The approximate location of sludge measurement points and depths are shown on Figure 2.

Sludge Depth Estimates

Pond 1: Based on the sludge depth measurements from Pond 1, the overall average sludge depth is approximately 9-inches with elevated sludge depths near the aerator and outlet structure of up to 16-inches. Based on the depth of sludge measured in Pond 1, a sludge volume of approximately 470 cubic yards was calculated. Laboratory analysis determined a solids concentration to be approximately 3% solids.

Pond 2: Based on the sludge depth measurements from Pond 2, the average depth of sludge is approximately 3-inches. Distribution of sludge in Pond 2 was relatively uniform with the exception of the southwest corner where an elevated average sludge depth of approximately 6inches was observed. Based on the depth of sludge measured in Pond 2, a sludge volume of approximately 400 cubic yards was calculated. Laboratory analysis determined a solids concentration to be approximately 2.6% solids.

Sludge Analytical Sampling

The consultant collected sludge samples from Pond 1 and Pond 2 following California approved standard sampling techniques required for analytical analysis. A list of testing methods and constituents tested are shown below. A Sludge Judge II sampling tube was used to collect sludge samples. The approximate locations of discrete sampling points are shown on Figure 3.

Wastewater from the sampling tube was excluded from the sample in order to collect a representative sample of in-situ sludge for solids concentration analysis. . Samples were placed into 8 ounce glass jars provided by the laboratory and stored in a cooler at 4°C or less. Discrete

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samples were delivered within 24-hours to a state-certified laboratory under standard chain-ofcustody documentation for analysis. The following constituents were tested;

• pH by method SM 4500H+B

• Nitrate as N by EPA method 353.2

• Total Kjedahl Nitrogen by EPA method 351.2

• Ammonia by EPA method 350.1

• Phosphorus by SM 4500P-BE

• Percent solids by SM 2540G

• CAM 17 metals by EPA methods (6010B & 7470A)

• Chromium VI by method SM3500-Cr

• VOCs by EPA method 8260B

• TPH (Gas & BTEX) by EPA method 8260B

• TPH (Diesel & Motor oil) by EPA method 8015 MOD

• SVOCs by EPA method 8270

• Pesticides by EPA method 8081

• PCB by EPA method 8082

The consultant collected four discrete sludge samples (see Figure 3) from Pond 1 (1-1 through 14). The four samples were combined in the laboratory to form a composite sample for Pond 1.

The consultant collected four discrete sludge samples (see Figure 3) from Pond 2 (2-1 through 24). The four samples were combined in the laboratory to form a composite sample for Pond 2.

Sludge Analytical Results

A summary of the analytical results for Pond 1 and Pond 2 is presented in Table 1.

Table 1: Sludge Sampling Results and Disposal Options

Analyte Units Pond 1 Results

Pond 2 Results

Sludge Disposal Options

Compost Land Application

pH 7.68 8.5 Permitted Permitted

Nitrate as N mg/l 0.28 0.25 NR Permitted

Total Kjeldahl Nitrogen mg/l 670 278 NR Permitted (at agronomic rates)

Ammonia as N mg/l 99.2 35.8 NR Permitted (at agronomic rates)

Total Phosphorus as P mg/l 171 245 NR Permitted (at agronomic rates)

% Solids % 3 2.6 >20% 15 to 50%

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Analyte Units Pond 1 Results

Pond 2 Results

Sludge Disposal Options

Compost Land Application

CAM17 Metals

Antimony µg/l ND ND Permitted Permitted

Arsenic µg/l 2120 1080 Permitted Permitted

Barium µg/l 4240 2490 Permitted Permitted

Beryllium µg/l ND ND Permitted Permitted

Cadmium µg/l ND ND Permitted Permitted

Chromium µg/l 1160 588 Permitted Permitted

Cobalt µg/l 47 49 Permitted Permitted

Copper µg/l 2450 370 Permitted Permitted

Lead µg/l 298 90 Permitted Permitted

Mercury µg/l 7.3 0.7 Permitted Permitted

Molybdenum µg/l 12500 4810 Permitted Permitted

Nickel µg/l 174 96 Permitted Permitted

Selenium µg/l 182 ND Permitted Permitted

Silver µg/l ND ND Permitted Permitted

Thallium µg/l ND ND Permitted Permitted

Vanadium µg/l 13600 2080 Permitted Permitted

Zinc µg/l 16800 1810 Permitted Permitted

Chromium VI µg/l ND ND Permitted Permitted

VOCs

Acetone µg/l ND 18.6 Permitted Permitted

Dichloromethane µg/l 6.6 3.8 Permitted Permitted

Toluene µg/l 5.4 ND Permitted Permitted

TPHg µg/l 149 68.7 Permitted NR

TPHd µg/l 10500 2370 Permitted NR

TPHmo µg/l 23700 7060 Permitted NR

BTEX µg/l 5.4 ND Permitted NR

SVOCs

Bis(2-ethylhexyl)phthalate µg/l 15 14 Permitted NR

Butyl benzyl phthalate µg/l 4 6 Permitted NR

Diethyl phthalate µg/l 1 1 Permitted NR

Di-n-butyl phthalate µg/l 13 12 Permitted NR

3&4-Methylphenol µg/l 2 2 Permitted NR

Pesticides µg/l ND ND Permitted Permitted

PCBs µg/l ND ND Permitted Permitted Notes: Compost as disposal was based on processed sludge meeting EPA ‘Class A’ criteria. NR – Not Reportable as part of acceptance.

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In general, constituents of concern (COCs) for biosolids disposal via composting or land application were below acceptance criteria. The Laboratory analytical report is provided in Appendix A.

4.0 PROPOSED WORK

The proposed work will be done by the contractor. As part of the contract, the contractor will submit a Sewage, Sludge Handling and Disposal plan, (SSHDP) which will meet the requirements of this SMP and the LRWQCB Waste Discharge Requirement Board Order 6-94100. The SSHDP will be submitted to the LRWQCB for their review and approval.

CALTRANS Engineer will oversee the contractor's work. The contractor is expected to be selected in July 2011. Construction work is expected to begin in September 2011.

This SMP specifically addresses the methods of sewage transfer and sludge removal for the proposed Sewage Pond Rehabilitation project. The sewage and sludge maintenance aspects of the project include:

• Sewage Transfer • Sludge Dewatering and Disposal Options

Sewage Transfer

The sewage effluent liquid overlying the sludge in pond 1 will be transferred to the empty pond 3. This will enable the contractor to dewater and dispose of the sludge from pond 1. The sewage effluent will percolate and evaporate in pond 3. Sewage effluent liquid in pond 2 will be left to evaporate and percolate in pond 2. The loose sludge remaining in pond 2 will then be dewatered and disposed.

The piping and pumps required for this sewage transfer shall be contained and anchored appropriately on the surface and protected from traffic, and maintained in good operation without breaks, leaks, blockages etc.

The contractor will include the sewage transfer equipment to be used for this work in the SSHDP.

Sludge Dewatering and Disposal Options

This work will consist of dewatering, removing and transporting the sludge to a facility permitted for the disposal of sludge. The piping and pumps required for this work shall be contained and anchored appropriately on the surface and protected from traffic, and maintained in good operation without breaks, leaks, blockages etc.

Dewatering devices must be fully contained and are not permitted to drip supernate, sewage or decant water onto the ground. Sludge removed from the ponds by any method, will be

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stockpiled in a container which will not drip onto the ground. The contractor shall include the measures for containment of stockpiled dewatered sludge in the SSHDP.

The dewatered sludge will be loaded into trucks for transport to a permitted facility. Trucks transporting the sludge will not drip during transport. The contractor will determine sludge transport methods prior to project implementation and describe in detail in the SSHDP. The contractor shall perform any odor control arising from this work and will include the method of odor control in the SSHDP.

The contractor will properly manifest and transport sludge utilizing a US Department of Transportation licensed transporter. If sludge is dripped during transport, the contractor will immediately stop the transport of sludge, reevaluate and modify the transportation methods to prevent sludge from dripping during transport. The contractor will clean up sludge dripped/spilled during transportation. The contractor will follow all applicable county, state and federal requirements for the handling, transporting and disposing of sewage sludge.

The decant water from the sludge dewatering procedure will be disposed into the existing pond 3. The contractor will submit the charactareziation of the decant (recovered) water from the sludge dewatering opeartion to the RWQCB. The decant water will be sampled for:

• Total BOD (5 day carbonaceous), mg/L • Filtered BOD (5 day carbonaceous), mg/L • Total Suspended Solids, mg/L • Kjeldahl-Nitrogen, mg/L • Ammonia-Nitrogen, mg/L • Nitrite-Nitrogen, mg/L • Nitrate-Nitrogen, mg/L • Total Disolved Solids,mg/L

The contractor will pick one of the following options or provide an economical option for the sludge dewatering and disposal. The option selected will be submitted in the SSHDP.

Option 1- Passive Dewatering (i.e. Evaporation): One of the oldest and the most reliable methods of sludge dewatering is solar evaporation. This method involves removing any free standing water and allowing the remaining sludge to simply dry out. When the sludge is sufficiently dry, greater than 20% solids by volume, an excavator can be used to remove for disposal.

Option 2 - Mechanical Dewatering (i.e. Rotary Press): A rotary press is one of the most efficient methods of mechanical dewatering available. This method involves feeding a sludge/polymer blend into a rectangular channel which is then passed between two parallel revolving screens. The frictional force of the slow moving screens, coupled with the controlled outlet restriction, results in the extrusion of a very dry cake. A rotary press can obtain a solids concentration of 45% or greater depending on characteristics of the feed sludge. The press is easy to operate and maintain because of its robust construction and limited number of

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mechanical parts. It is entirely enclosed, runs quietly, takes up little space and consumes little energy. Filter cake is easily transported to approved disposal facilities.

The contractor shall include the average and maximum time between dewatering completion and offsite shipment of dewatered sludge in the SSHDP.

Option 3 - Chemical Dewatering (i.e. Polymer Injection Combined with Geotextile Dewatering Tubes): Dewatering tubes are generally an economical and cost effective means of dewatering sludge. Geotextile tubes come in a variety of fabrics and pore sizes for optimum performance. Geotextile tubes are normally filled to approximately 80% capacity with the sludge mixture and then allowed to drain. Once consolidation has taken place the dewatering tubes are refilled, and the cycle continues, until the tube has reached approximately 85% capacity with consolidated materials. Better consolidation of sludge can be achieved when using polymers and when allowing tubes to ‘rest’ for longer periods of time. Once consolidated the geotextile tube can be trucked to an off-site location for disposal.

5.0 REPORTING REQUIREMENTS

The contractor will immediately inform the Caltrans engineer of a spill of sewage; or any other adverse condition that results in a discharge outside the work area limits that could affect compliance with the WDRs. The Caltrans engineer will immediately notify the LRWQCB of the discharge. The Engineer will provide written report to the LRWQCB within two weeks of the discharge. Reporting will be required, if the contractor identifies discharge from the project site into surface waters or drainage systems, or if the project receives a written notice or order from a regulatory agency.

The report will include the date, time, location, nature of the operation, and type of discharge, including the cause or nature of the notice or order.

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FIGURE 1 – SITE LOCATION

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FIGURE 2 – APPROXIMATE SLUDGE DEPTH MEASUREMENT LOCATIONS - POND 1 AND POND 2

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FIGURE 3 – APPROXIMATE ANALYTICAL SAMPLING LOCATIONS - POND 1 AND POND 2

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APPENDIX A – ANALYTICAL LABORATORY REPORT

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