Morocco - Jorf Lasfar Power Project : environmental impact assessment (Vol. 2 of 6)

JORF LASFAR POWER PLANT ASH DISPOSAL SITE DEVELOPMENT RItIB XI. -, i Ft I~~~~~ K- _; -, t ' - r i : - > t'r_2IL wt< OPRA IS NAL PLAN LA . _ _ , ,.,-_ KKL PHS 2Ai -^ INTERMS DSOSL IEDIATELSITEN v ia K-st ,e C, K15k :. I .; -E S ai_s tW DECEMBER 1996 J96291 B  I  . DO.CUMENT CONTROL SHEET PROJECT: Jorf Lasfar Power Plant JOB NO: J96291B Ash Disposal Site Development TITLE: Phase 2A, Intermediate Site, Operational Plan Preared by Reviewed by Approved by ORIGINAL -- -- S.D. Clamp R.M. Wingfield J E. Crosfield mmi maw uSw _S 18 November 1996 REVISION I 16 December 1996 REVISION ptm | REVISION K I K- dm.inm _ md iAob oai m i, s _d byG y im _am dhbln __ dG u debri - m -I' miurt. A remon pam m r I mpatd be d mmd _d waa U nm t I _tr a ~~- . em.tE~m pim _ 0ms dm dtmapi ghind ddaytkmam3 aamt_ GUc 1mm no _arohg.medyd ~ i. on I mnms bmaadvigmmmm.0bdmarkdnsifnadvim pe~avd U d.inus fldipurt haasohmprepmapmdby GOSi mm m I mdaima ym C.dag ~mkmaas. Te mm.dd .pud. wng. myno. pupaI lo-ai wmymmmirlesdIgaaoapmu.1d iaptpapurt d. in accomea maha mm -mmdmam. dSU' eofonuamOmm Cbmmt NAg - md ahd amm mmnmm aas .a mmdab . mddor piada any snasme an mmk pat.Shauid U. VAt ihamimame 3d puhalbaPMtyhadmg putfnhwmem.GUS ny. dtiw agieetoamdh vaimm thaddt (a) GUfwmumdam ipummsa n inuamoich l. and (b) nuImamee3muptdamTk Pt.UdaIuy anmdpu iymiia w. lm ImIe I ~a ag omd Goa WA GM y. mm- s duMs hbdamem o babimID OM Tal1bd Party. md (4) GUSin m mpam I atIyfo any bains ormm iau by am Camt or~ -rwy guildW of GUB. outwkn ofd mm Coimt mimasectld. mpamtim mlbad Pamly.   CMS GENERATION CO. & ABB ENERGY VENTURES INC. JORF LASFAR POWER PLANT ASH DISPOSAL SITE DEVELOPMENT PHASE 2A INTERMEDIATE SITE FINAL REPORT OPERATIONAL PLAN DECEMBER 1996 J96291 B Revision 1 ---m---lPAWDoWOC  I  JORF LASFAR POWER PLANT ASH DISPOSAL SITE DEVELOPMENT PHASE 2A INTERMEDIATE SITE -FINAL REPORT OPERATIONAL PLAN CONTENTS Chapter Description Page I DESIGN AND DEVELOPMENT 1-2 1.1 General 1-2 1.2 Preparatory Works Contract 1-2 1.3 Drawings 1-2 1.4 Stages of Operation 1-2 1.5 Site Formation 1-3 1.6 Seting Out 1-3 1.7 Slope Stability 1-4 1.8 Management of Surface and Groundwater 1-4 1.9 Site lnfrastnucture 1-5 2 SITE OPERATION 2-1 2.1 General 2-1 2.2 Health and Safety 2-1 2.3 Emergency Procedures 2-1 2.4 Earh-moving Equipment and Manpower Resources 2-1 2.5 Ash Conditioning 2-2 2.6 Reception Procedures 2-2 2.7 Ash Placement 2-1 2.8 Dust Control 2-1 2.9 Cover Placemenit 2-2 2.10 Monitoring 2-2 3 LANDSCAPING, AFTER-USE AND LONG-TERM CARE 3-1 3.1 Landscaping 3-1 3.2 After-Use 3-1 3.3 Long TerTn Care 3-1 APPENDICES A Drawings 1-1  I  DESIGN AND DEVELOPMENT 1.1 General The Intermediate Ash Disposal Site (the Site) is located immediately south of the Jorf Lasfar Power Plant. Access to the Site from the Power Plant will be via the asphalt access road, * over the cooling water canal bridge and immediately right onto the gravelled road which leads directly to the Site. The Site is intended to be operated for a period of three to four years. The Site operation vwil be the responsibility of CMS Morocco Operating Company, SCA, referred to below as the Operator. This Operational Plan defines the requirements for routine setting out of cells, ash filling, cover placement, dust control and monitoring. Complete copies of the Operational Plan and Drawings should be maintained in the site office and at the Power Plant offices. 1.2 Preparatory Works Contract Site preparation work and initial ash placement will be performed under a Preparatory Works Contract. This work will be undertaken by a Contractor under contract to Jorf Lasfar Energy Company (JLEC). Provision has also been made for the Operator to place ash on the Site during the Preparatory works ContracL The Operator wil fully operate the site thereafter. 1.3 Drawings The Drawings listed below form part of this Operational Plan and are included in a reduced format in Appendix A. Drawina No. rTle 96291BI2AI;201 Cell Layout and Final Landform 96291 202 Cross-sections through the Landform 96291 B12A203 Stages of Operation 1.4 Stages of Operation This Operational Plan specifies the requirements for the placement of ash and cover material to create the final landforn shown on Drawing 201. The Site is designed to enable a potential future eastem extension to the landform as descnbed in the Design ReporL Cross-sections through the final landform are shown on Drawing 202. 1-2  The ash disposal operation is designed to be undertaken in a seuies of five separate cells as shown on Drawing 201. Each cell will be operated and covered in sequence in order to minimise the area of unprotected ash exposed to wind and rain. Cell 1 will be filled and restored under the Preparatory Works ContracL Works canied out by the Operator, will commence in Cell 2. The situation in each stage of site operation is shown in Drawing 203. The stages are as follows: STAGE OPERATION IN CELL SHOWN Restoration PFA Placement FBA Placement Preparation PWC V Temporary area Temporary area, then 2' 2 I - 2 3 3&4 if 2 3 4 5 III 3 4 5 IV 4 5 Stockpile/Re-use Long Term Site PWC - PrewamoryWmts ConUad (PFA) - PLOF'i. Fuel Ash (FBA) - Fsmune Bdkm Ash * W 3Wk wider PrputayWade C"*W 1.5 Site Formfaton Sie formation work for Cell 2 is wthin the scope of the Preparatory Works Contract Preparation of the forTnation to Cells 3, 4 and 5 will be catried out by the Operator pnor to the placement of ash in these cells. Preparation will comprise removal of foundation materials which are required for use as a cover material. Material comprising gravelly sand and sandy silt should be excavated in accordance with the site fomiation levels shown on Preparatory Works Contract Drawing 96291 B/2101. The excavation requirements and levels should be regularly reviewed by the Operator to ensure sufficient quantties of suitable cover material are obtained to allow the Site to be restored in a staged manner without leaving a shortfall. 1.6 Setting Out Four pemanent sure stations wil be provided under the Preparatory Works Contract on the norh-west side of the Site close to the cooling water canal. These are for use as necessary during the operation of the Site. The control points have the following NGM Coordinates: 1-3  Reference Eastina Northing Elevation C1 C2 * C3 C4 NoW Ths bbkit e tobe wooned by Fe OperMorafteresbshmert of the co posit. Markers showing the site boundary will also be provided under the Preparatory Works ContracL Each cell should be set out with pegs and batter boards prior to its filling with ash. In setting out, consideration should be given to the future placement of cover material. At the commencement of each cell, consideration must be given to the position and gradient of temporary access ramps. Drawing 203 shows a recommended sequence with two access ramps which should be sufficient to serve the entire operation. Some variation from the specified landform is acceptable provided that sufficient clearance is maintained to the adjacent drainage channels; the required direction of crss-fall is maintained; and side-slopes are not over-steepened. Acceptable tolerances for ash and cover placement are 300 mm in plan and 50 mm in elevation. When ash placement in any cell is estimated to be nearing completion, the surface should be surveyed at a number of points and the final surface profile set out with pegs and batter boards. 1.7 Slope Stability Side-opes for both the final and temporary slopes to the ash disposal site should be constructed as I Verical: 2.5 Horizontal and subject to the tolerances referred to in 1.6 above. These slopes are based upon the assumed worst case of firm to stiff clay being locally present in the foundations. Should weaker material be encountered during site formation work this matter should be referred to JLEC for a design review. 1.8 Management of Surface and Groundwater There are no pernanent water courses crossing the Site. Rainfall in areas away from the placed ash is generally expected to percolate rapidly into the ground except during heavy rainfall. Permanent surface water drainage channels will be constructed and lined to control emsion during heavy rain. These channels are designed both to intercept surface water entering the Site and to collect rainwater run-off from the temporary ash surfaces and final cover. The sequence and covering of cells is designed to minimise the area of uncovered ash exposed to rainfall at any one time. A portion of the drainage channel and its outfall into the cooring water canal will be constructed under the PWC to protect the Works during Stages I and I. The Operator will complete the construction of the drainage channel in stages. 14  - The Operator should minimise the area of exposed ash in the wet season by the placement of sections of final cover material as soon as is practical. Regular maintenance should be carried out during the operation of the Site to clean out the drainage channels and repair any gullying of exposed ash after heavy rainfall. Adequate cross-fall should be maintained on all exposed ash surfaces in order to prevent ponding and limit infiltration. Temporary drainage ditches associated with temporary access ramps and sloping ash surfaces should be constructed as necessary for the operating cell during ash placement in the wet season. Groundwater is not expected to be encountered and no groundwater control measures are required during operation of the Site. 1.9 Site Infrastructure Generally, the Site is serviced by the facilities available at the Power Plant. Basic facilities are provided on site comprnsing: * a fenced compound for securing the earth-moving equipment outside of operational hours * a Site Office with one room for use by equipmrent operators and one office for use by the Site Supervisor * a pumped system for supplying sea-water ftroU the existing cooling water canal for use in the dust control system Minor servidng of site-based earth-moving equipment should be undertaken in the compound. Refuelling will be by a small mobile fuel tanker based at the Power Plant No potentially polluting or flammable substances should be stored at the Site. The unsealed roads giving access to the site will require regular maintenance, and a stockpile of suitable granular material should be established for this purpose. A mobile phone should be maintained in the Site Office at all times together with a list of relevant phone numbers necessary for operational and emergency purposes. 1-5  2 SITE OPERATION 2.1 General Ash will be delivered by truck from the Power Plant. The Site will be open for the receipt of ash during daylight hours or as scheduled by the Operator. The Site will be controlled by a Site Supervisor and the operations overseen by the Operator's Director of Engineering. The Site Supervisor will be responsible for the day to day operation of the Site and for maintaining site records. 2.2 Health and Safety The Site Supervisor or a named deputy should be present at the Site during all operational hours. The primary hazard at the Site is movement of trucks and other equipment A secondary hazard is wind blown dust arising from Pulverised Fuel Ash (PFA). All personnel should be iformned of the hazards associated with inhalation and eye contact with PFA dusL Primary control should be by limitation of the hazard by covering or wetting down of the material. These controls should be applied both to materials being transported and to placed material. Personnel working at the Site involved with transportation and placement of PFA should be provided with suitable respiratory protection equipment. A first-aid cabinet and eyewash facilites should be maintained at the Site Office. The phone numbers of emergency services should be clearly displayed in the Site Office. The Operator's heatth and safety standards in force shall also apply. 2.3 Emergency Procedures If the Site is unable to accept ash due to unforeseen circumstances, the Power Plant should be informed by telephone. An emergency tipping area should be provided for temporary use and should be cleared to the cuffntiy operating cell as soon as is practical after any use. This area should be located within the area enclosed by the lined drainage channel. 2.4 Earth-moving Equipment and Manpower Resources Mobile earth-moving equipment supplied on site should include a bulldozer, water truck, self propelled vibraing compactor and front-end loader. A hand-held hose spray system should be supplied. An equipment operator and work crew should deal with the tipping, spreading and compacting work. A separate equipment operator should be responsible for operation of the water truck and spray system. .2-1  Trucks for delivery of the ash should be capable of off-road operation including travelling over semi-compacted ash and climbing gradients as steep as 1 in 8 while loaded. 2.5 Ash Conditioning 2.5.1 General PFA should be conditioned by the addition of water at the Power Plant prior to transportation. Conditioning should be undertaken using the wet unloader at the PFA silo. Conditioning should be controlled to achieve a moisture content in the range 14 percent to 25 percent at the point of depositon in the ash cell. This is necessary to reduce the dust hazard and to achieve the required semi-compaction. Moisture content for these purposes is defined as the mass of water expressed as a percentage of the mass of dry ash. It is acceptable to use fresh water or sea water for dust.control at the site, except in the uppermost 0.5 m of PFA and the cover layer (0.5 m thick) overlying it for which only fresh water shall be used because of the need to create satisfactory conditions for plant growth. No special conditioning is expected to be necessary for FBA which is discharged in a wetted state from the bottom ash silo. Ash relocated from the exsting ash piles on the Site or the emergency tipping area will be conditioned by the addition of water from a tanker or other means. 2.5.2 Ash for Upper Layers PFA to be placed within 1 m of the outer ash surface should be conditioned as in Section 2-5.1 above but in the moisture content range 20 percent to 25 percent 2.6 Reception Procedures Trucks arriving at the Site will be logged by the Site Supervisor who will record the type and capacity of truck, the type of ash and the btme of each delivery. The Site Supervisor Will be responsible for ensuring that the trucks deliver PFA and FBA to the appropriate areas of separate deposition. Ash ariving at the Site should be deposited immediately and loaded trucks should not be permitted to stand for extended periods prior to deposition. No wastes other than PFA and FBA should be deposited at the Site. Any other wastes arriving at the Site should be turned away by the Site Supervisor. 2-2  2.7 Ash Placement 2.7.1 General The spacing of the tipped ash piles should be controlled such that a minimum amount of spreading effort is required by the bulldozer to achieve the required placed thickness. 2.7.2 Fumace Bottom Ash As far as is practical within the operational constraints, FBA should be placed at the base of all cells and not co-placed with PFA. The following minimum requirements should be applied for the location of FBA as shown in the typical section on Drawing 202: * FBA should be placed as a blanket of 300 mm minimum thickness on the base of all cells and at least to a distance of 60 m from the toe of all permanent outer slopes * no FBA should be placed within I m of the outer ash surface, i.e. within I m of the cover material - FBA should be tipped in individual truck loads and spread with a bulldozer to a thickness no greater than 500 mm. The spread material should be tracked with the bulldozer to achieve a reasonable running surface for ash delivery trucks. L7.3 Pulverised Fuel Ash PFA should be placed in its conditioned state by tipping in adjacent individual truck loads. The placed material should be i'mmediately spread with a bulldozer to a thickness of approximately 500 mm and semi-compacted by tracking with the bulldozer. If the PFA dries out after placement it should be wetted up immediately prior to compacfion. PFA within 3 m measured horizontally from the outer permanent edges of the PFA layer and PFA within 1 m measured vertically from its final top profile, should be compacted by sufficient passes of the vibrating compactor to attain approximately 95 percent of its maximum dry density. Localised compaction of PFA ramps and access routes by vibrating compactor should also be undertaken as necessary to improve tafficking. 2.8 Dust Control Areas of exposed PFA should be wetted down by the use of the water truck In addftion PFA on exposed slopes should be wetted by hand-operated spray hoses. During the summer, it may be necessary to wet the entire area of exposed PFA in rotation. it is acceptable to use sea-water pumped from the cooling water canal for dust suppression. 2-3  2.9 Cover Placement Cover material should be gravelly sand selectively obtained from excavation dunng site formation work. This material should be transported directly from its point of excavation or hauled from the stockpile as appropriate at any stage of operation. The material should be placed as soon as is practical to areas of ash which have been filled to their final profile. The cover material to the upper surface should be placed in a single layer of 500 mm compacted thickness. Cover material to permanent outer slopes of the landform should be placed and compacted with the vibrating roler in parallel with ash placement Additional cover should be placed if necessary to temporary slopes in the event of maintenance or monitoring showing this to be desirable. 2.10 Monitoring 2.10.1 Ash Moisture Content PFA moisture content should be determnined by testing samples of material immediately after placement at the Site. The moisture content should be determined using standard sampling and testing procedures. Sampling and testing frequencies should be as folws: In semi-compacted PFA on commencement of Cell 2 Set of 6 tests In semricompacted PFA at three-monthly intervals or as found necessary Set of 6 tests Inthe compacted I mthickash top layerto each cell Set of 6 tests In the event of a change to the fuel source burnt at the Power Plant Set of 6 tests In the case of a set of tests showing several results outside of the range specified in Section 2.5 above, adjustments should be mnade to the conditioning operations and a further set of testing undertaken. 2.10.2 Ash Density In situ testing should be undertaken to determine the as-placed densities of the ash in its semi-compacted and compacted condition using standard testing procedures. This testing is required in order to optimise the applied compacting effort and to imprve estimates of the expected lifetime of the site. The frequency of testing should be as for the moisture content tests indicated above. 2-4  A topographical survey of placed ash, in conjunction with record keeping of tonnage of ash production, should be undertaken periodically in order to monitor void use and adjust the expected lifetime of the site. 2.10.3 Groundwater Monitoring Groundwater levels and quality should be monitored at quarterly intervals in order to determine the extent of any environmental impact from ash filling activities on the groundwater. The monitoring should be undertaken in Piezometers SI, S2 and S3 and should comprise recording of piezometric level followed by sampling and laboratory testing. The first round of monitoring should be undertaken at the start of ash deliveries to the Site. Sampling and testing should be undertaken by an approved and suitably accredited laboratory using standard sampling protocols. Prior to obtaining water samples the piezometer should be developed by removing at least five times the volume of the well and allowing the water to stabilise. Monitoring in Piezometers S2 and S3 should continue until such time as they are buried by the proceeding disposal operation. Prior to being buried these piezometers should be permanently sealed with grout. The samples should be tested in the field at the time of sampling for: salinidy, pH, conductivity and temperature. The samples should be tested in the laboratory for the following parameters: Dissolved metals (filtered) Arsenic, Cadmium, Boron, Chromium, Copper, Lead, Selenium, Zinc, AJuminium, Merury, Potassium, Magnesium, Calcium, and Sodium Com2ounds Nitrate, Nitrnte, Bicarbonate, Sulphate, Chloride and Silicate 2.10A Surface Water Monitoring Surface water should be sampled and tested at monthly intervals during the rainy season in order to determine the extent of any contamination from ash filling activities. The samples should be collected as grab samples from the point of discharge during periods of flow. The location of sampling should be recorded. Sampling and testing should be undertaken by an approved and suitably accredited laboratory using standard sampling protocols. The samples should be tested as described in Section 2.10.3 above. 2.10.5 Reporting of Information Records of monitoring and test results should be kept by the Operator. 2-5  The information obtained from the monitoring will provide a measure of the impact of the operations at the Site. The data should be reviewed as it is obtained and again on a cell by cell basis. The infornation should then be used to confirm or otherwise the need to make modifications to the operations. The data obtained from the monitoring described above will also provide essential input into the confirmation of the design of the Long Term Site. 2-6  3 LANDSCAPING, AFTER-USE AND LONG-TERM CARE 3.1 Landscaping After completion of Cells I to 5, the Site should be finally restored by the placement of stockpiled sandy silt overburden material to a thickness of between 150 mm and 200 mm and grading the surface. It is anticipated that some vegetation may then naturally establish such that the finished site will have a similar appearance to the surrounding ground. If the extension to the landform is intended to be constructed in the future then the final landscaping should be delayed until later. 3.2 After-Use The Site is intended to be left as unfenced open space. No access restrictions to the restored site are required other than for reasons of preventing unauthorised tipping of waste materials. 3.3 Long Term Care Monitoring of ground and surface water should continue as required during operation for a period of 12 months after completion. Thereafter, monitoring should be undertaken on an annual basis for 5 years or until a time established by JLEC. Initially, after heavy rainstorns an inspection should be made for erosion of the cover material and repairs made if needed. Periodic cleaning out of the drainage channels should be undertaken. 3-1  I  I APPENDIX A DRAWINGS The Drawi listed ian Sub-secton L3 It_ o c  I 4  C Cr;VLL ACCESS ROAD ELL 3 / x --C~cc.Ss POA") CELL LAYOUT X C L DNI OWN[9SHIP r~~ ~ ~ ~ ~ ~~ ~ ~~~~~~~~~~~~~ Xc Xi, Ail GRiE ACCESS OtI FINAL LANDFORM ,D='~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ IN' I:I I1:,II / t t)~~~pul :D.' ; ,e ,,, , " Q ,_