Final

Sampling Plan

Duke Energy Carolinas’

Allen Steam Station

Belmont, NC

Sampling Episode 6561

Prepared for:

U.S. Environmental Protection Agency

Engineering and Analysis Division

Office of Water

1200 Pennsylvania Avenue, NW

Washington, D.C. 20460

Prepared by:

Eastern Research Group, Inc.

14555 Avion Parkway 

Suite 200

Chantilly, VA 20151

July 1, 2010

EPA Contract No. 68-C-02-095

Work Assignment 7-29
i

TABLE OF CONTENTS

Page

1. INTRODUCTION .................................................................................................................1-1

1.1 Background..........................................................................................................1-1

1.2 Objectives and Scope...........................................................................................1-1

1.3 Plant Selection .....................................................................................................1-2

2. FACILITY OVERVIEW ........................................................................................................2-1

2.1 FGD Scrubber Systems........................................................................................2-1

2.2 FGD Wastewater Treatment System ...................................................................2-2

3. SAMPLING PROCEDURES ...................................................................................................3-1

3.1 Sampling Point Selection.....................................................................................3-1

3.2 Analyte Selection.................................................................................................3-1

3.3 Sample Collection Procedures.............................................................................3-2

3.3.1 Influent to FGD Wastewater Treatment System (SP-1) ..........................3-3

3.3.2 Influent to Bioreactor System (SP-2).......................................................3-8

3.3.3 Effluent from Bioreactor System (SP-3)................................................3-16

3.4 Sample Preservation, Shipping, and Analysis ...................................................3-23

3.5 Field Measurements and Engineering Data Collection .....................................3-24

3.6 Sample Labeling ................................................................................................3-25

3.7 Traffic Reports...................................................................................................3-25

3.8 Quality Assurance/Quality Control....................................................................3-26

3.9 Sample Splitting.................................................................................................3-28

4. SAMPLING ACTIVITIES ......................................................................................................4-1

4.1 Sampling Team Organization ..............................................................................4-1

4.2 Presampling Preparation ......................................................................................4-1

4.3 Field Sampling Activities ....................................................................................4-1

4.4 Logistics...............................................................................................................4-2

4.4.1 Allen Steam Station Contacts ..................................................................4-2

4.4.2 EPA Contacts...........................................................................................4-2

4.4.3 Analytical Laboratories............................................................................4-3

4.4.4 ERG Contacts...........................................................................................4-3

4.4.5 Freight Forwarders...................................................................................4-3

5. SAMPLE SHIPMENT ...........................................................................................................5-1

5.1 Sample Set Preparation........................................................................................5-1

5.2 Sample Packing....................................................................................................5-1

6. SITE-SPECIFIC HEALTH AND SAFETY PROCEDURES ..........................................................6-1

6.1 Emergency/Medical Procedures ..........................................................................6-1

6.1.1 First Aid 6-1

6.1.2 Site Evacuation/Emergency Response Plan.............................................6-1

6.1.3 Emergency Showers and Eye Washes.....................................................6-1

6.1.4 Local Hospital..........................................................................................6-1

6.2 ERG Health and Safety Responsibilities and Authority......................................6-1
TABLE OF CONTENTS (Continued)

Page

ii

6.2.1 Work Assignment Manager.....................................................................6-2

6.2.2 Crew Chief...............................................................................................6-2

6.2.3 Sampling Team Members........................................................................6-2

6.3 Briefings...............................................................................................................6-2

6.3.1 Off-Site Briefings.....................................................................................6-2

6.3.2 On-Site Briefings.....................................................................................6-3

6.4 Safety Procedures.................................................................................................6-3

6.4.1 Personal Protective Equipment (PPE) .....................................................6-3

6.4.2 Safety Practices........................................................................................6-3

6.4.3 Safe Work Practices.................................................................................6-4

6.5 Sampling-Point-Specific Safety Procedures........................................................6-4

6.5.1 Physical Hazards......................................................................................6-4

6.5.2 Thermal Hazards......................................................................................6-4

6.5.3 Chemical Hazards....................................................................................6-5

6.6 Temperature Extremes.........................................................................................6-5

6.6.1 Heat Stress ...............................................................................................6-5

6.6.2 Heat Stress Monitoring ............................................................................6-6

6.7 First Aid ...............................................................................................................6-7

6.8 Sample Preservation and Safety Considerations..................................................6-7

6.9 Training and Medical Monitoring Requirements ................................................6-8

6.10 Shift Work Protocol.............................................................................................6-9

7. REFERENCES .....................................................................................................................7-1
iii

LIST OF TABLES

Page

3-1 Sample Collection at Allen Steam Station.........................Error! Bookmark not defined.

3-2 Analytical Methods ....................................................................................................... 3-30

3-3 Summary of Sample Container and Planned Preservation ............................................ 3-31

3-4 Sampling Point Field Measurements............................................................................. 3-32

6-1 Sample-Point-Specific PPE and Potential Hazards ....................................................... 6-10

LIST OF FIGURES

Page

2-1 Simplified Diagram of the FGD Wastewater Treatment System, Allen Steam 

Station .............................................................................................................................. 2-6

2-2 Physical/Chemical Separation and Biological Reactor Portion of FGD Wastewater 

Treatment System, Allen Steam Station .......................................................................... 2-7

3-1 Sample Preservation Log Sheet ..................................................................................... 3-33

3-2 Field Sampling Log Sheet.............................................................................................. 3-34

3-3 Engineering Data Collection Sheet (Page 1 of 4).......................................................... 3-35

3-4 Engineering Data Collection Sheet (Page 2 of 4).......................................................... 3-36

3-5 Engineering Data Collection Sheet (Page 3 of 4).......................................................... 3-37

3-6 Engineering Data Collection Sheet (Page 4 of 4).......................................................... 3-38

3-7 Example Traffic Report ................................................................................................. 3-39
1-1

1. INTRODUCTION

The Engineering and Analysis Division (EAD) of the U.S. Environmental Protection 

Agency (EPA) is currently conducting a sampling program at steam electric power plants. The 

sampling program will characterize raw wastewaters generated by coal-fired steam electric 

power plants, as well as evaluate treatment technologies and best management practices used to 

reduce pollutant discharges. This sampling plan, developed for the Duke Energy Carolinas’

Allen Steam Station (Allen), located in Belmont, North Carolina, provides plant-specific 

sampling procedures and methods EPA and its contractors will follow when conducting 

sampling activities. Sampling will be performed by EPA’s technical contractor, Eastern Research 

Group, Inc. (ERG), under Contract No. 68-C-02-095. This document, in combination with the 

Generic Sampling and Analysis Plan for Coal-Fired Steam Electric Power Plants [1], is intended 

to serve as a guide to the ERG field sampling crew, a review mechanism for EPA personnel, and 

a source of procedural information for plant personnel. 

1.1

During EPA’s recently completed detailed study of the steam electric industry, EPA 

identified metals and certain other constituents present in the wastewater discharges from steam 

electric power plants that are contributing the majority of the toxic loadings for the industry.

Additionally, EPA determined that one of the waste streams contributing most of these toxic 

loadings are associated with wet flue gas desulfurization (FGD) systems present at coal-fired 

power plants.

Background

This sampling plan will focus on characterizing wastewaters and treatment system 

discharges at Allen. For a general description of the steam electric process and the wastewaters 

generated during the operation of a coal-fired steam electric power plant, see Chapters 3 and 4 of 

the Steam Electric Power Generating Point Source Category: Final Detailed Study Report [2].

1.2

EPA is preparing to collect and analyze samples to characterize wastewater streams 

generated at coal-fired steam electric power plants. This sampling plan describes the approach 

EPA will use to collect and analyze samples to characterize untreated FGD scrubber purge and

treated FGD wastewater from the following types of FGD wastewater treatment systems:

Objectives and Scope

• Chemical precipitation: Physical/chemical treatment for heavy metals removal 

using hydroxide or a combination of hydroxide and sulfide precipitation; and

• Biological: Biological treatment specifically designed for metals removal.

Generally, the analytical results collected during this sampling program will support EPA 

in answering the following key questions:

• What are the characteristics (i.e., pollutants present, pollutant concentrations, flow 

rate/volume) of untreated FGD scrubber purge wastewater?
1-2

• What are the effluent concentrations for pollutants present in treated FGD 

wastewater?

• What are the pollutant loadings associated with discharges of FGD wastewater 

following treatment?

EPA conducted a one-day presampling site visit at Allen on October 22, 2009 and 

collected the following information:

• Information about the plant’s operations, including existing sampling data and 

results;

• Process-specific information;

• Information on pollution prevention and wastewater treatment/operations;

• Plant-specific information to tailor sampling plans; and

• Information on potential sampling points.

The sampling program will consist of four-day sampling episodes at selected plants. The 

sampling will characterize the wastewaters generated by wet FGD scrubbers and the treatment 

performance of the systems used to treat the FGD scrubber purge wastewaters. EPA will also 

collect field quality control (QC) samples consisting of bottle blanks, field blanks, equipment 

blanks, and duplicate samples, and laboratory QC samples used for matrix spike/matrix spike 

duplicate analyses.

EPA’s sampling program will provide data to perform an engineering assessment of the 

design, operation, and performance of treatment systems at steam electric power plants. In 

addition to sampling the wastewater, EPA will collect information regarding system design and 

day-to-day operation. 

1.3

EPA expects to select up to seven coal-fired steam electric plants for FGD wastewater 

sampling, basing the plant selection on the process configurations and characteristics of the 

plants.

Plant Selection

Allen was selected by EPA for sampling based on the following site characteristics:

• The plant is a coal-fired power plant that burns bituminous coal in each of its five

generating units;

• The plant operates two limestone forced oxidation wet FGD systems that service 

all five generating units;

• The plant operates a segregated FGD wastewater treatment system, which 

includes the following steps:

— Equalization,

— pH adjustment (lime addition),

— Ferric chloride addition,
1-3

— Polymer addition,

— Clarification,

— Filtration, and

— Biological treatment (nitrogen and metals);

• The plant operates a SNCR on all five generating units; and

• The plant produces a commercial-grade gypsum by-product.
2-1

2. FACILITY OVERVIEW

Allen operates five steam electric units and each has a coal-fired boiler. Units 1 and 2 

came on line in 1957, and each has a capacity of 165 megawatts (MW). Units 3, 4, and 5 came 

on line in 1959, 1960, and 1961, respectively, and each has a capacity of 275 MW. All five 

generating units burn bituminous coal. The electric generating units at Allen are operated on a 

cycling basis and are not baseload units. The plant is located on 1,000 acres adjacent to the 

Catawba River.

Allen recently retrofitted all five units with two FGD scrubber systems (Absorbers 1 and 

3) to control the sulfur dioxide (SO2) releases from the plant. Units 1, 2, and 5 exhaust to FGD 

Absorber 1 (which began operation in February 2009), and Units 3 and 4 exhaust to FGD 

Absorber 3 (which began operation in May 2009). The wet FGD scrubbers are designed to 

remove more than 95 percent of SO2 from the flue gas. With the recent addition of the FGD 

scrubber systems, Allen also installed an FGD wastewater treatment system to control the 

discharges of the wastewater generated during the operation of the FGD scrubbers. Sections 2.1 

and 2.2 further discuss the FGD scrubber systems and the FGD wastewater treatment system, 

respectively.

Allen operates electrostatic precipitators (ESPs) to control fly ash and particulate 

emissions from the plant. Allen also operates SNCR systems year-round to control nitrogen

oxide (NOx) emissions from the plant. Additionally, the boilers are operated with low-NOx

burners and a separated overfire air system.

The ESPs at Allen are particulate control devices that are designed to remove 99.9 

percent of the fly ash and other particulates from the flue gas. Allen utilizes ESPs to remove the 

fly ash from all five generating units. The fly ash and other particulates are collected in hoppers 

and usually pneumatically transferred to fly ash silos. However, Allen also has the capability of 

handling the fly ash wet by sluicing the fly ash in the hoppers and transferring the fly ash 

transport water to the ash basin. Allen uses the wet fly ash handling system during start ups for 

the generating units until the units are burning 100 percent coal. Allen also uses the wet fly ash 

handling system if there are issues with the dry fly ash handling system. 

All five generating units have the following configuration:

• Boiler (SNCR system contained in boiler);

• Air preheater;

• ESP; and

• FGD scrubber system.

2.1

Allen operates two wet FGD scrubber systems that treat the flue gas from all five electric 

generating units. The plant uses limestone slurry as the sorbent for sulfur dioxide absorption.

Limestone and service water are fed to on-site ball mills, which pulverize the limestone to create 

the slurry. From the ball mills, the slurry is transferred to hydroclones to collect limestone 

particles that are too large for use in the FGD system. The underflow from the hydrocyclones is 

transferred to the reject tank and then sent back to the ball mill for additional processing. The 

FGD Scrubber Systems
2-2

overflow from the hydroclones, which is approximately 30 percent solids, is transferred to the 

reagent tank for storage and then used as fresh limestone slurry in the absorber.

The fresh limestone slurry is fed to the reaction tank of the FGD system and the recycle 

pumps pump the slurry to the various levels of the FGD scrubber. Both absorbers have four 

spray levels; however, the plant typically operates only three levels at one time. The slurry is 

pressurized and sprayed downward into the scrubber vessel through spray nozzles. As the slurry 

falls downward and the flue gas flows countercurrent to the slurry, the spray droplets of the 

limestone slurry contact the flue gas and absorb the SO2, which reacts with the limestone 

particles and produces calcium sulfite. The spray droplets continue to flow downward in the 

scrubber until they reach the reaction tank. Allen bubbles air through the reaction tank to oxidize 

the calcium sulfite to calcium sulfate (i.e., gypsum).

Allen intermittently blows down the gypsum slurry from the reaction tank to control the 

solids and/or chlorides concentration in the scrubbers. The chlorides concentration in the 

scrubbers is maintained between 3,000 and 10,000 ppm (parts per million), with a design 

maximum chlorides concentration of 12,000 ppm. The typical percentage of solids within the 

scrubber is 14 to 16.

The gypsum slurry is pumped to the primary hydrocyclones where the solid gypsum is 

separated from the water by centrifugal force. The solid gypsum is forced outward to the walls of 

the hydrocyclones and falls downward, while the water exits the top of the hydrocyclones. The 

gypsum from the primary hydrocyclones is transferred to the filter feed tank, which is then 

transferred to the vacuum filter belts. The overflow from the primary hydrocyclones is 

transferred to a holding tank and then pumped to the secondary hydrocyclones. The underflow 

from the secondary hydrocyclones is returned to the scrubber. The overflow from the secondary 

hydrocyclones is sent to the FGD wastewater treatment system. This FGD purge stream contains 

0.5 to 0.8 percent solids.

Allen washes the gypsum sent to the vacuum filter belts with service water as it is applied 

to the belts to reduce the chlorides in the gypsum to typically less than 20 ppm. The vacuum 

filter belts dry the gypsum to a moisture content of approximately four percent. The gypsum 

produced at the plant must have a chloride content of less than 120 ppm and a moisture content 

of less than 10 percent to be sold to a wallboard manufacturer. Allen transfers the dry gypsum to 

a storage area and then trucks the gypsum to a wallboard manufacturer in Mount Holly, North 

Carolina.

2.2

The FGD wastewater treatment system is designed to receive intermittent transfers of 

FGD wastewater from the FGD system, which consists of secondary hydrocyclone overflow, at a 

flow rate of approximately 400 gallons per minute (gpm). The FGD wastewater treatment system 

consists of chemical precipitation and biological treatment technologies. Allen installed the 

wastewater treatment system to treat the FGD scrubber purge wastewater to meet its permit 

limits, which include limits for total suspended solids (TSS) and selenium. The Allen FGD 

wastewater treatment system contains the following treatment operations:

FGD Wastewater Treatment System
2-3

• Physical/Chemical Separation:

— Equalization,

— pH adjustment (lime addition),

— Ferric chloride addition,

— Polymer addition,

— Clarification, and

— Filtration; and

• Biological Reactors:

— Cooling (heat extraction),

— Nutrient addition,

— First-stage biological reaction,

— Nutrient addition, and

— Second-stage biological reaction.

Figures 2-1 and 2-2, located at the end of this section, present process flow diagrams of 

the FGD wastewater treatment system, as well as the planned sampling locations for EPA’s 

sampling episode. Figure 2-1 is a simplified diagram of the FGD wastewater treatment system, 

showing different portions of the system. Figure 2-2 is a diagram of the chemical precipitation 

and biological reactor portions of the treatment system.

The secondary hydrocyclone overflow from the scrubbers is transferred to the 

equalization tank at the beginning of the wastewater treatment system. Allen also has a

maintenance tank that is used as either a spare equalization tank or a spare sludge holding tank. 

The equalization tank also receives water from the filtrate sump (which includes filter press 

filtrate), gravity filter backwash reject, backflush waste from the biological treatment system, 

and off-specification biological treatment effluent. The wastewater entering the equalization tank 

has a pH of 6.7-6.9 S.U. and a temperature of 105-115o F. 

From the equalization tank, the wastewater enters three reaction tanks in series: reaction 

tank 1, in which lime is added to increase the pH to between 8.6 and 9.2 S.U.; reaction tank 2, 

formerly used for organosulfide addition, but which is now used to provide additional mixing; 

and reaction tank 3, in which ferric chloride is added.

The overflow from reaction tank 3 flows through a flow splitter, which distributes the 

flow evenly to two clarifiers. Allen operates the two clarifiers in parallel, each capable of 

handling 100 percent of the waste stream flow. A polymer is added to the wastewater just before 

it enters the clarifiers. Hydrochloric acid is added to the wastewater at a point between the 

clarifiers and the sand filters to ensure that the pH is adjusted closer to neutral prior to the 

biological treatment system. After the hydrochloric acid addition, the overflow from the two 

clarifiers is split and sent through three sand filters in parallel, each of which can handle 75 

percent of the waste stream capacity. The sand filters are continuous backwash gravity filters and 

produce an effluent with a TSS concentration of approximately 1 to 2 ppm. The filter backwash 

is sent to a sump and then transferred to the equalization tank.

The sludge collected in the clarifier is transferred to a sludge holding tank. A portion of 

the clarifier sludge is recycled from the sludge holding tank to reaction tank 1, while the majority 

is pumped to a filter press for dewatering. The filter press uses hydraulic power from 
2-4

compressors to remove water. The solids are transferred to an off-site landfill and the filtrate is 

recycled to the equalization tank. 

Prior to entering the biological portion of the wastewater treatment system, the 

wastewater is cooled by heat exchangers to 95o F, the optimal temperature for the biological 

treatment system. The heat exchangers were constructed with a titanium alloy that can withstand 

the high levels of chlorides and suspended solids in the FGD wastewater entering the biological 

treatment system. The heat exchanger requires 300 to 350 gpm of cooling water. Allen adds 

nutrients (in the form of molasses) to the wastewater as it flows from the heat exchanger to the 

biological treatment system. The nutrients provide a source of carbon to feed the bacteria.

In the bioreactor portion of the treatment, Allen treats the wastewater in two stages. Each

stage contains eight bioreactor cells, which are operated in parallel. Each cell contains 20 feet of 

activated carbon media. Within the activated carbon bed, specialized microbes fill the voided 

areas and reduce selenium to its elemental form, while other metals are precipitated as sulfide 

complexes. The microbes also reduce the concentration of nitrogen present in the wastewater. 

The wastewater is divided evenly among the first stage of eight cells. The flow to each cell is 

sent to 16 distribution pipes to create an even distribution of flow into the top of the cell. The 

water level in the cell is designed to be approximately six inches above the activated carbon bed; 

however, at the time of the site visit, the water level was below the top of the carbon bed.

Allen operates the bioreactors to achieve a negative oxidation reduction potential within 

the system, which provides the optimum environment to reduce selenium to its elemental form. 

This reduction potential is controlled by the amount of nutrient that is fed to the system. The 

plant also controls the pH in the bioreactor cells to between 6.0 and 9.0 S.U. because extreme 

high or low pH levels could affect the performance of the microbes and potentially allow 

nondesirable microbes to propagate.

The effluent from the first-stage bioreactor cells is transferred to the first-stage effluent 

storage area, where it is commingled with the other wastewater in the area. The wastewater is 

then transferred to the eight second-stage bioreactor cells, which are operated in parallel. 

Nutrients are added to the wastewater as feed for the microbes as the wastewater is transferred. 

As in the first stage, the wastewater is divided evenly among the eight second-stage cells and 

each cell has 16 distributor pipes to evenly distribute the flow into the cell.

Occasionally the bioreactor cells must be backflushed to remove accumulated solids. The 

plant pumps the effluent from the first-stage bioreactor cells backwards through each cell and it 

overflows into a spillover chamber. The plant then returns the backwash overflow to the 

equalization tank at the start of the FGD wastewater treatment system.

Because the first-stage bioreactor cells denitrify the waste stream, they produce nitrogen 

and carbon dioxide gas. To remove the gas from the cells, the plant occasionally performs a 

degassing operation where water is sent backwards through the cells, like a backflush, but the 

flush is only long enough for the gas to “burp” out of the system. The second-stage bioreactor 

cells are primarily anoxic and do not produce as much gas as the first-stage cells, requiring less 

frequent degassing than the first-stage cells. The TSS concentration within the first- and secondstage bioreactor cells is approximately 40 ppm. The solids in the cells are mostly biological 

materials.
2-5

From the second stage of the bioreactor treatment system, the wastewater is commingled 

with the heat exchanger cooling water and transferred to the ash basin. The effluent from the ash 

basin is discharged to the Catawba River via Outfall 002.

Because the steam electric generating units at Allen are operated on a cycling basis and 

are not baseload units, there are times when the units are shut down for a few days. During these 

shut-down periods, the wastewater treatment system does not receive any scrubber purge 

wastewater and, therefore, the plant has to find a way to feed the microbes to keep them alive. If

Allen knows ahead of time that all units will be shut down for a couple of days, they can build up 

additional scrubber purge in the equalization and maintenance tanks and then operate the FGD 

wastewater treatment system at a reduced flow rate until they begin operating again. If the plant 

is down for several days without advanced knowledge, the plant can run service water through 

the system and feed nutrients to the bioreactors to sustain biological growth.

Figure 2-2 shows the planned sampling points for the sampling episode at Allen. The 

influent sampling point at Allen’s FGD wastewater treatment system is located upstream of the 

equalization tank. Thus, the influent sampling point is upstream of any chemical addition. The 

in-process sampling point within Allen’s FGD wastewater treatment system is located 

downstream of the sand filters and the holding tank. The biological reactor effluent sampling 

point at Allen’s FGD wastewater treatment system is located downstream of the second-stage 

effluent storage area and upstream of where the FGD wastewater treatment effluent is 

commingled with the heat exchanger cooling water. 
2-6

Phys/Chem 

Separation

Bioreactor 

System Ash Basin FGD Scrubber Purge

Internal 

Outfall 005 Outfall 002

Bottom ash sluice, runoff 

(stormwater, coal pile, limestone 

handling), and plant sumps

Catawba 

River

Figure 2-1. Simplified Diagram of the FGD Wastewater Treatment System, Allen Steam Station
2-7

FGD Scrubber Purge 

(from Purge Tank)

Lime

Polymer

Equalization 

Tanks (2) Reaction Tank 1 Reaction 

Tank 2

Reaction 

Tank 3

SP-1

SP-2

Indicates a Sampling Point

Ferric 

Chloride

Filter

2

Biological 

System 

Feed Tank Clarifier 1

Sludge 

Storage 

Tank

Filter Press

Sump

Filter 

Backwash

Filter

1

Solids to OffWastewater Flow Site Landfill

Sludge Flow

Intermittent Wastewater Flow

Clarifier 

Sludge

Mix 

Chamber

Clarifier 2

Filter

3

Cooling Water

Nutrient

First-Stage 

Bioreactors 

(8)

First-Stage 

Effluent 

Storage

Second-Stage 

Bioreactors 

(8)

Second-Stage 

Effluent 

Storage

To Ash Basin via 

Internal Outfall 005

Bio Reactor Backflush

Hydrochloric 

Acid

SP-3

Figure 2-2. Physical/Chemical Separation and Biological Reactor Portion of FGD Wastewater Treatment System, Allen Steam 

Station
3-1

3. SAMPLING PROCEDURES

This section discusses the planned sampling procedures to be followed during the 

sampling episode at Allen. This section also provides the necessary information to plan for the 

logistics of this sampling episode. All tables and figures in this section are presented at the end of 

the section.

3.1

EPA selected the following eight sampling points for this plant (the three proposed 

sampling locations for Allen’s FGD wastewater treatment system as well as the related Quality 

Assurance/Quality Control (QA/QC) samples):

Sampling Point Selection

• SP-1 Influent to FGD Wastewater Treatment System;

• SP-2 Influent to Bioreactor System;

• SP-3 Effluent from Bioreactor System;

• SP-4 Duplicate of Influent to Bioreactor System (same location as SP-2);

• SP-5 Duplicate of Effluent from Bioreactor System (same location as SP-3);

• SP-6 Field Blank for Influent to FGD Wastewater Treatment System (same 

location as SP-1);

• SP-7 Field Blank for Influent to Bioreactor System (same location as SP-2); and

• SP-8 Field Blank for Effluent from Bioreactor System (same location as SP-3).

3.2

Analytes that will be included in EPA’s Allen sampling episode include those in the 

following classes of pollutants:

Analyte Selection

• Classicals:

— Biochemical oxygen demand, 5-day (BOD5),

— Chemical oxygen demand (COD),

— Total suspended solids (TSS),

— Total dissolved solids (TDS),

— Sulfate,

— Chloride,

— Total Kjeldahl nitrogen (TKN),

— Ammonia as nitrogen,

— Nitrate/nitrite as nitrogen,

— Total phosphorus,

— Total cyanide;
3-2

• Total metals:

— Aluminum, antimony, arsenic, barium, beryllium, boron, cadmium, 

calcium, chromium, cobalt, copper, iron, lead, magnesium, manganese, 

mercury, molybdenum, nickel, selenium, silver, sodium, thallium, tin, 

titanium, vanadium, and zinc.

• Dissolved metals:

— Same parameters as listed for total metals, plus hexavalent chromium.

The analytes selected for analysis reflect the current understanding of coal-fired power 

plant FGD wastewaters, including contributions from coal, scrubber sorbents, treatment 

chemicals, and other sources. Table 3-1 lists the potential analytes for each sampling point, Table 

3-2 lists the analytical methods that will be used, and Table 3-3 lists the sample container and 

volume and planned on-site preservation for each parameter or parameter group. 

3.3

To characterize the influent to FGD wastewater treatment system (SP-1), the influent to 

bioreactor system (SP-2), and the effluent from bioreactor system (SP-3) at Allen, the sampling 

team will use varying methods to collect the samples depending on the sampling point and 

pollutant parameters. This section describes in detail the sample collection techniques. 

Sample Collection Procedures

Samples are collected as a series of “fractions,” or bottles designated for particular 

analyses requiring the same preservation. The comprehensive sample set consists of sample

fractions for all pollutant classes listed in Section 3.2. Note that some sample fractions will be 

collected in the same sample bottle, such as Group I analytes (TSS, TDS, sulfate, and chloride) 

and Group II analytes (ammonia as nitrogen, COD, nitrate/nitrite as nitrogen, TKN, and total 

phosphorus). 

In general, samplers will work in teams of two to ensure that proper sampling techniques 

are followed and adequate notes are taken at each sampling location. Samplers will wear 

disposable gloves, Tyvek® suits, masks (when sampling for mercury by EPA Method 1631E), 

steel-toed boots, hard hats, and safety eyewear, and will observe precautions while collecting 

samples, remaining aware of their surroundings. Note that the use of masks is to prevent 

contamination of the mercury samples and not for respiratory protection.

Sample containers and bottles will be purchased precleaned and certified and will not 

require rinsing with sample. The sample bottles for the metals analyses will be cleaned according 

to EPA Method 1669. For this sampling episode, ERG will collect 24-hour composite samples at 

the influent to and the effluent from the bioreactor sampling points for most analytes; however, 

cyanide will be collected as a single grab sample and mercury will be collected as four grab 

samples. ERG will collect individual grab samples at the influent to the FGD wastewater 

treatment system sampling point for all analytes. ERG will collect one sample at each sampling 

point each day over four consecutive 24-hour periods (mercury will be collected as four grab 

samples each day for the influent to and effluent from the bioreactor sampling points). ERG will 

follow protocols described in EPA Method 1669 to collect metal sample fractions. All sampling 
3-3

equipment (e.g., tubing) and sample bottles will be cleaned according to the procedures 

described in EPA Method 1669. Samplers will use “clean hands / dirty hands” sample collection 

techniques when collecting metal sample fractions, as described in EPA Method 1669. 

Samplers will take care not to touch the insides of bottles or lids/caps during sampling. 

Samples that require cooling to ≤6°C for preservation will be cooled immediately in an ice-water 

bath and then placed into coolers containing bagged ice throughout sample storage, shipment, 

and receipt at the analytical laboratories. The Crew Chief will confirm that samples are actually 

≤6°C before being packed for shipment to the laboratory and the temperature reading will be 

documented in the traffic report for the samples. Samples that require cooling to ≤6°C shall not 

be shipped until that temperature is reached. In addition, the length of time required for the 

samples to reach ≤6°C shall be documented in the field log sheet.

3.3.1 Influent to FGD Wastewater Treatment System (SP-1)

The influent to FGD wastewater treatment system (SP-1) has a sample tap located on the 

wastewater piping downstream of the purge tank and upstream of the equalization tank. ERG

will collect the sample prior to the wastewater entering the equalization tank because the FGD 

scrubber purge is commingled with other waste streams in the equalization tank and, therefore, 

the sampling point upstream of the tank provides the best representation of the FGD scrubber 

purge from the Allen FGD system. Because the flow from the purge tank to the equalization tank 

is not continuous, ERG will need to coordinate closely with Allen personnel during the sampling 

episode to determine when grab samples can be collected (i.e., when wastewater is being 

transferred to the FGD wastewater treatment system). ERG will follow protocols described in 

EPA Method 1669 to collect metal sample fractions from SP-1.

ERG plans to collect split samples with Allen (or its representative), where possible; 

therefore, ERG plans to attach a piece of silicone tubing to the sample tap with a “Y” splitter at 

the other end of the tubing to allow ERG and Allen (or its representative) to collect samples 

simultaneously. If problems occur during the collection of split samples (e.g., the splitters 

become clogged and the flow is split unevenly between the sampling crews), then EPA may stop 

the split sample collection and offer instead to collect duplicate samples with Allen or its 

representative. For all analyses (except dissolved metals and hexavalent chromium), the samplers 

will collect samples through the tubing directly into the specified containers. For the dissolved 

metals (excluding mercury) and hexavalent chromium samples, the samplers will fill one 10-L 

container, allow the solids to settle for one hour, and then pump the aqueous portion of the 

sample through a 0.45-μm filter and then through a “Y” splitter into the specified containers; 

therefore, the dissolved metals and hexavalent chromium samples will be collected as split 

samples. 

Due to the high suspended solids content (typically 0.5 to 0.8 percent at Allen, but has 

been observed on the order of 1 to 5 percent at other plants) of the samples collected at the 

influent to the FGD wastewater treatment system, EPA may analyze the samples as bi-phasic 

samples. If the TSS content of the sample is greater than one percent, then the laboratory will 

separate the aqueous and solid portions of the sample and analyze both for the analyte of interest. 

In this instance, Group I (chloride and sulfate only), Group II (ammonia as nitrogen, 

nitrate/nitrite as nitrogen, and total phosphorus only), and total metals (including mercury, but 
3-4

not hexavalent chromium because it is filtered in the field during sample collection) samples will 

be analyzed as bi-phasic samples. Group I (TSS, and TDS only), Group II (COD only), BOD5, 

hexavalent chromium, and dissolved metals (including mercury) samples will not be analyzed as 

bi-phasic samples. Scrubber purge samples with less than one percent TSS will not require biphasic separation and analysis.

The samples for the influent to the FGD wastewater treatment system (SP-1) will be 

collected from a sample tap. The sampling equipment will consist of the following:

• Colorless, electronic-grade, non-nitrile gloves;

• Silicone tubing with “Y” splitter;

• 10-L containers;

• Teflon® tubing;

• Silicone tubing;

• 0.45-um filter;

• Funnel;

• Peristaltic pump;

• Small table;

• Cleanbox;

• Tyvek® suits (for metals samples); 

• Masks (for mercury samples); and

• Sample containers.

All metals sampling equipment will be specially-cleaned according to the procedures 

described in EPA Method 1669. ERG will follow protocols described in EPA Method 1669 to 

collect metal sample fractions. Two or more ERG samplers (“clean hands” and “dirty hands”) 

will follow the protocols described in the steps below to set up the sampling point, collect the 

field blank samples, and collect wastewater samples. This section describes the set-up of the 

sample point and collection of the EPA samples1.

1. Samplers remove the bags containing the gloves and HDPE plastic wrap from the 

coolers or storage containers in which they are packed. Samplers identify which 

coolers or boxes contain the double-bagged sample bottles, precleaned tubing, 

blank water, and cleanbox. Depending on the condition of the sample tap, 

samplers may need to wipe the tap with a clean paper towel to remove any 

buildup on the tap that could potentially fall in the sample bottles during sample 

collection.

2. Both samplers put on Tyvek® suits, masks, and gloves. “Dirty hands” covers 

work surfaces (ground or table) with HDPE plastic wrap and places the doublebagged sample bottles within easy access on the covered surface.

 1 For the sample collection, the samples will be split with the plant (or the plant’s representative) and, therefore, the 

sample set-up describes equipment needed for split samples. However, EPA is not responsible for the collection of 

the split samples collected by the plant and, therefore, the collection of their samples is not described in this plan.
3-5

3. “Dirty hands” opens the outer bag of the cleanbox and “clean hands” opens the 

inner bag. “Clean hands” places the cleanbox at the point of sample collection and 

secures it open with the clips located inside the box.

4. “Dirty hands” opens the outer bag containing a length of precleaned silicone 

tubing. “Clean hands” opens the inner bag inside of the cleanbox, removes the 

tubing, and places clean plastic bags over the ends of the silicone tubing.

5. “Dirty hands” opens the outer bag of the funnel and “clean hands” opens the inner 

bag inside of the cleanbox and attaches the funnel to the tubing.

6. “Dirty hands” opens the outer bags of the mercury field blank water and total 

mercury field blank sample bottles. “Clean hands” opens the inner bag for the 

field blank water, unscrews the lid and places it in the inner bag. “Clean hands” 

passes the funnel end of the tubing with a plastic bag shrouding the funnel to 

another “clean hands” person to hold outside the cleanbox. “Clean hands” 

removes the inner bag for the total mercury field blank sample bottle and places it 

in the cleanbox. “Clean hands” holds the end of the silicone tubing outside the 

cleanbox over a bucket, with the plastic bag still covering the end of the tubing. 

“Dirty hands” pours field blank water through the funnel and tubing. After the 

tubing has been purged with sufficient volume, “clean hands” places the silicone 

tubing back in the cleanbox. Working inside the cleanbox, “clean hands” 

unscrews the lid of the field blank sample bottle, removes the tubing from the 

plastic bag, and prepares to fill the field blank sample bottle. “Dirty hands” pours 

field blank water into the funnel and tubing, and “clean hands” fills the total 

mercury field blank sample bottle. “Clean hands” places the end of the silicone 

tubing into the plastic bag, replaces the lid on the sample bottle, and closes the 

inner bag. “Clean hands” removes the bottle from the cleanbox and places it in the 

outer bag. “Dirty hands” closes the outer bag. The samplers repeat this procedure 

for the total metals field blank samples2

.

7. “Dirty hands” opens the outer bag for a precleaned 10-L container. “Clean hands” 

opens the inner bag and loosens the lid. “Clean hands” holds the end of the 

silicone tubing at the mouth of the 10-L container and removes the lid. “Dirty 

hands” pours field blank water through the funnel and tubing, and “clean hands” 

fills the 10-L container with enough field blank water to collect the dissolved 

metals field blank samples. “Clean hands” places the lid back on the 10-L 

container, places the plastic bag over the end of the silicone tubing, and places the 

tubing in the cleanbox. “Clean hands” screws the lid on the 10-L container and 

closes the inner bag. “Dirty hands” closes the outer bag of the 10-L container.

 2 ERG will collect field blank samples at the influent to the FGD wastewater treatment system on Day 1 of the 

sampling episode. Additionally, ERG will collect the dissolved mercury sample using the same technique as the 

total mercury sample, but the dissolved sample will be filtered at the laboratory. A dissolved mercury field blank 

sample will be analyzed by the laboratory to assess any mercury contamination from the filtering performed at the 

laboratory. Therefore, ERG does not need to collect a dissolved mercury field blank sample in the field.
3-6

8. After collecting the field blank samples, “clean hands” removes the funnel from 

the tubing. “Clean hands” and “dirty hands” work to attach the end of the silicone 

tubing to the sample tap. 

9. “Clean hands” holds the opposite end of the silicone tubing outside the cleanbox 

over a bucket, with the plastic bag covering the end of the tubing. “Dirty hands” 

opens the valve to the sample tap to purge the piping for a minimum of 2 minutes. 

“Clean hands” places the end of the silicone tubing back in the cleanbox.

10. “Dirty hands” opens the outer bag for a precleaned 10-L container. “Clean hands” 

opens the inner bag and loosens the lid. “Clean hands” holds the end of the 

silicone tubing at the mouth of the 10-L container and removes the lid. “Dirty 

hands” opens the sample valve to allow sample to flow into the 10-L container. 

Samplers fill the 10-L container with sample to be analyzed for dissolved metals 

and hexavalent chromium, which is required to be filtered for these analyses. The 

samplers will allow the solids to settle for one hour while collecting the remaining 

samples. “Clean hands” places the lid back on the 10-L container, places the 

plastic bag over the end of the silicone tubing, and places the tubing into the 

cleanbox. ”Clean hands” screws the lid on the 10-L container and closes the inner 

bag. “Dirty hands” closes the outer bag of the 10-Liter container. Both samplers 

change their gloves.

11. “Dirty hands” opens the outer bag for the total mercury sample bottle. “Clean 

hands” removes the inner bag and bottle and places it in the cleanbox. “Clean 

hands” opens the inner bag and bottle lid. “Clean hands” removes the plastic bag 

from the tubing and fills the sample bottle. “Clean hands” places the tubing back 

in the plastic bag, replaces the lid on the sample bottle and closes the inner bag. 

“Clean hands” removes the sample bottle from the cleanbox and places it in the 

outer bag. “Dirty hands” closes the outer bag. The samplers repeat this procedure 

for the dissolved mercury and total metals samples.

12. “Dirty hands” places an ERG label on the outer bags of the sample bottles.

13. Samplers fill a 1-L jar for the field measurements. The samplers will give the jar 

to another sampling team member to measure the temperature and pH. 

14. Both samplers collect the BOD5, Group I, Group II, and total cyanide samples 

from the sample location. The samplers need to test the total cyanide samples for 

sulfides and oxidants and preserve the samples immediately after sample 

collection, according to the preservation protocols outlined in Section 3.4.

Dissolved Metals Sample Collection

15. Samplers allow the 10-L sample container to continue to settle if one hour has not 

elapsed since the sample was collected.
3-7

16. “Dirty hands” covers the work surfaces (ground or table) with HDPE plastic wrap 

and places the double-bagged sample bottles within easy access on the covered 

surface.

17. “Dirty hands” opens the outer bag of the clean box and “Clean hands” opens the 

inner bag. “Clean hands” places the cleanbox at the point of sample collection. 

“Clean hands” secures the cleanbox open with the clips located inside the box.

18. “Dirty hands” opens the opening on the peristaltic pump head so the tubing can be 

placed in the pump head. “Dirty hands” opens the outer bag containing a length of 

precleaned Teflon® tubing attached to a 5-foot length of precleaned silicone 

tubing, a “Y” splitter, and two additional pieces of precleaned silicone tubing. 

“Clean hands” moves the tubing into the cleanbox, opens the inner bag, and 

removes the tubing. “Clean hands” places a clean plastic bag over the ends of the 

Teflon® and silicone tubing.

19. “Dirty hands” threads the silicone tubing into the peristaltic pump head.

20. Both samplers change gloves.

21. “Dirty hands” opens the outer bag of a capsule filter. “Clean hands” opens the 

inner bag and removes the capsule filter. “Clean hands” attaches the capsule filter 

to the silicone tubing just before the “Y” splitter.

22. “Dirty hands” opens the outer bag of the 10-L container that was used to collect 

the field blank water for the dissolved metals fractions. “Clean hands” opens the 

inner bag of the 10-L container. “Clean hands” removes the Teflon® tubing from 

the cleanbox, opens the lid of the 10-L plastic container, removes the plastic bag 

from the Teflon® tubing, and places the Teflon® into the 10-L container. “Dirty 

hands” opens the dissolved metals field blank sample bottle. “Clean hands” 

removes the dissolved metals field blank sample bottle and places it in the 

cleanbox. “Clean hands” holds the end of the silicone tubing outside the cleanbox 

over a bucket, with the plastic bag still covering the end of the tubing and “dirty 

hands” operates the pump to pump about 750 mL of blank water from the field 

blank water bottle. “Clean hands” places the end of the silicone tubing in the 

cleanbox, opens the inner bag of the dissolved metals field blank sample bottle, 

and removes the lid. “Dirty hands” operates the pump to collect the dissolved 

metals field blank sample and then stops the pump. The samplers repeat the 

procedure for the dissolved metals and hexavalent chromium field blank samples.

If a new filter is needed, “clean hands” removes the used filter and samplers 

following step 21 to replace the filter3

.

23. Both samplers change gloves.

 3 ERG will collect field blank samples only at the influent to the FGD wastewater treatment system during one day 

of the sampling episode.
3-8

24. “Dirty hands” opens the outer bag of one of the 10-L containers. “Clean hands” 

opens the inner bag, removes the lid, and places the end of the Teflon® tubing 

into the container. “Clean hands” holds the end of the silicone tubing outside the 

cleanbox, with the plastic bag still covering the end of the tubing. “Dirty hands” 

starts the pump and passes approximately 750 mL through the tubing and filter

and then stops the pump.

25. “Dirty hands” opens the outer bag of the dissolved metals sample bottle. “Clean 

hands” removes the inner bag and bottle and places it in the cleanbox. “Clean 

hands” opens the inner bag and removes the lid. “Dirty hands” operates the pump 

to collect the dissolved metals sample and then stops the pump. “Clean hands” 

closes the lid on the sample bottle and closes the inner bag. “Clean hands” places 

the inner bag and bottle in the outer bag and “dirty hands” closes the outer bag. 

The samplers repeat this procedure for the dissolved metals and hexavalent 

chromium samples. 

26. “Dirty hands” places an ERG label on the outer bags of the sample bottles.

EPA plans to collect samples at the influent to the FGD wastewater treatment system 

(SP-1) on four consecutive days. The sample collection setup and sampling technique for each

day of sampling will be the same.

3.3.2 Influent to Bioreactor System (SP-2)

The influent to the bioreactor system (SP-2) will be collected downstream of the sand 

filters after the wastewater from the three filters is commingled. Allen has a sample tap located 

on the wastewater piping after the three sand filter effluent streams are commingled, downstream 

of the holding tank and upstream of the heat exchanger. Allen has agreed to install a three-way 

splitter on the sample tap that will have three separate taps to collect samples from the sampling 

point. ERG will follow protocols described in EPA Method 1669 to collect metal sample 

fractions at SP-2. 

ERG will collect the influent from the bioreactor system composite samples using two 

automatic compositors, which will be programmed to collect individual sample volumes into two 

large containers (e.g., two 20-liter containers). To collect sufficient sample volume, ERG will 

calculate the total volume required for ERG sample collection as well as plant split sample 

collection and also add additional volume for purging tubing and contingencies. The volume will 

then be programmed to be collected in one-hour intervals during the 24-hour composite period.

Following the composite period, ERG will pump off the specific sample volumes into the 

individual sample containers.

ERG will use one automatic compositor to collect sample volume for the metals analyses 

(excluding mercury) and another automatic compositor to collect sample volume for all classical 

analytes (i.e., BOD5, Group I, and Group II). In addition to collecting automatic composite 

samples for the analytes listed above, ERG will collect total and dissolved mercury grab samples 

every six hours during each compositing period. ERG will also collect one grab sample for 

cyanide during each compositing period.
3-9

ERG plans to collect split samples with Allen (or its representative), where possible; 

therefore, when pumping off the composite samples, a “Y” splitter will be used with two pieces 

of silicone tubing attached to the “Y” splitter to allow ERG and Allen (or its representative) to 

collect samples simultaneously. If problems occur during the collection of split samples (e.g., the 

splitters become clogged and the flow is split unevenly between the sampling crews), then EPA 

may stop the split sample collection and offer instead to collect duplicate samples with Allen (or 

its representative). 

ERG will collect the total and dissolved mercury grab samples by shrouding one of the 

three taps on the three-way splitter (the other two taps are used for the two compositors) and 

collecting the samples directly from the tap. Because the samples are collected directly from the 

tap, ERG will not be able to collect split samples with Allen (or its representative); therefore, 

duplicate samples will be collected.

For all analytes, ERG will collect QC samples at the influent to the bioreactor system 

(SP-2) on Day 4 of the sampling episode. In addition, for all analytes, ERG will collect a 

duplicate sample of the influent from bioreactor system (SP-4) on Day 3 of the sampling episode.

The samples for the influent to the bioreactor system (SP-2) will be collected from a 

sample tap. The sampling equipment will consist of the following:

• Colorless, electronic-grade, non-nitrile gloves;

• Peristaltic pump (automatic compositor – battery powered);

• Large composite containers (e.g., 20-liter containers);

• Funnel;

• “Y” splitter;

• “T” splitter;

• Teflon® tubing;

• Silicone tubing;

• 0.45-um filter;

• Cleanbox;

• Tyvek® suits (for metals samples); 

• Masks (for mercury samples); and

• Sample containers.

All metals sampling equipment will be specially cleaned according to the procedures 

described in EPA Method 1669. The supplier of the cleaned bottles, tubing, and composite 

containers will prepare and analyze bottle blanks and equipment blanks to evaluate possible 

contamination. ERG will follow protocols described in EPA Method 1669 to collect metal 

sample fractions. Two or more ERG samplers (“clean hands” and “dirty hands”) will follow the 

protocols described in the steps below to set up the sampling point, collect the field blank 
3-10

samples, and collect wastewater samples. This section describes the set-up of the sample point 

and collection of the EPA samples4

.

1. Samplers remove the bags containing the gloves and HDPE plastic wrap from the 

coolers or storage containers in which they are packed. Samplers identify which 

coolers or boxes contain the double-bagged composite containers, precleaned

tubing, blank water, and cleanbox.

2. Both samplers put on Tyvek® suits, masks, and gloves. “Dirty hands” covers 

work surfaces (ground or table) with HDPE plastic wrap and places the doublebagged composite containers within easy access on the covered surface.

3. “Dirty hands” opens the outer bag of the cleanbox and “clean hands” opens the 

clear inner bag. “Clean hands” places the cleanbox at the point of sample 

collection. “Clean hands” opens the cleanbox and secures it open with the clips 

located inside the box.

4. “Dirty hands” opens up the peristaltic pump portion of the automatic compositor 

so the tubing can be added. “Dirty hands” opens the outer bag containing a length 

of precleaned silicone tubing, a “T” splitter, and two additional pieces of silicone 

tubing. “Clean hands” takes the inner bag containing the tubing and moves it into 

the cleanbox. “Clean hands” opens the inner bag and removes the tubing. “Clean 

hands” places a clean plastic bag over each end of the silicone tubing. The tubing 

configuration will be set up such that one end will be connected to the sample tap, 

one end will be threaded through the automatic compositor and connected to the 

large composite container, and one end will be placed next to a sump/drain near 

the sampling point. To collect the samples, the sample tap will be left open during 

the entire sample collection time period and will flow directly to the sump/drain; 

however, the automatic compositor will pull sample from the flowing stream as 

dictated by the sampling program. Additionally, the automatic compositor will be 

capable of purging the line back to the flowing stream between each individual 

sample aliquot.

5. “Dirty hands” threads one portion of the silicone tubing through the peristaltic 

pump portion of the automatic compositor.

6. Both samplers change gloves.

7. “Dirty hands” opens the outer bag of the metals field blank water and the field 

blank composite container. “Clean hands” opens the inner bag for the field blank 

water, unscrews the lid and places it in the inner bag. “Clean hands” then places 

one end of the silicone tubing into the blank water. “Clean hands” also opens the 

inner bag for the field blank composite container and loosens the lid. “Clean 

 4 For the sample collection, the samples will be split with the plant (or the plant’s representative) and, therefore, the 

sample set-up describes equipment needed for split samples. However, EPA is not responsible for the collection of 

the split samples collected by the plant and, therefore, the collection of their samples is not described in this plan.
3-11

hands” holds the silicone tubing with the plastic bag covering the end out of the 

cleanbox and over a bucket and “dirty hands” operates the pump to pump blank 

water through the tubing. After the tubing has been purged with sufficient 

volume, “clean hands” holds the silicone tubing at the mouth of the field blank 

composite container and fills the composite container with sufficient volume to 

collect the total and dissolved metals field blank samples at the pump-off location.

“Dirty hands” stops the pump. During the purging of the tubing and collection of 

the field blank sample volume, “dirty hands” holds the end of the silicone tubing 

placed by the sump/drain above the composite container to prevent this portion of 

the tubing configuration from filling with blank water during the pumping 

process. “Clean hands” places the plastic bag over the end of the silicone tubing, 

replaces the lid on the field blank composite container, places the silicone tubing 

back in the cleanbox, and closes the inner bag of the field blank composite 

container. “Dirty hands” closes the outer bag of the field blank composite 

container5.

8. Both samplers work together to move the sampling tubing, automatic compositor, 

and composite containers into position for the sample collection. Samplers will 

ensure that the tubing will stay in place during the 24-hour sample collection 

period.

9. “Dirty hands” changes gloves.

10. “Clean hands” holds the end of the silicone tubing outside the cleanbox over a 

bucket, with the plastic bag still covering the end of the tubing. “Dirty hands” 

places the end of the silicone tubing near the sump/drain and opens the sample tap 

valve to allow the wastewater to flow through the tubing. “Dirty hands” operates 

the pump to purge the pump portion of the tubing for a minimum of 2 minutes.

11. “Dirty hands” programs the automatic compositor to collect 20 liters of sample 

over a 24-hour time period in one-hour intervals (i.e., collect 830 mL of sample 

every hour). “Dirty hands” calibrates the compositor to ensure that 830 mL is 

being collected for each individual grab.

12. “Dirty hands” opens the outer bag of the large composite container. “Clean 

hands” opens the inner bag and connects the silicone tubing to the port on the 

composite container, securing the connection with a cable tie. “Clean hands” 

closes the inner bag around the composite bottle, and “dirty hands” closes the 

outer bag. The samplers put ice around the composite container to keep the 

samples cold during the compositing time period.

13. Samplers repeat steps 1-12 to set up the automatic compositor for the classical

analytes (skipping step 7). Samplers will use another composite container.

 5 ERG will only collect field blank samples for all metals at the influent to the bioreactor system during Day 1 of the 

sampling episode. Additionally, ERG will collect a total mercury field blank sample during one of the grab samples 

for each day of sample collection at the influent to the bioreactor system.
3-12

14. “Dirty hands” and “Clean hands” then work to collect the total mercury field 

blank sample. “Dirty hands” shrouds the sample tap with a clear plastic bag that 

covers the end of the sample tap and provides enough room for samplers to work 

in with their hands. “Dirty hands” then opens the outer bag of the mercury field 

blank water and the total mercury field blank sample bottle. “Clean hands” opens 

the inner bag for the field blank water and the total mercury field blank sample 

bottle, unscrews the lids and places each in their inner bags. “Clean hands” pours 

the field blank water into the field blank sample bottle, closes the lids, and closes 

the inner bags. “Clean hands” places the total mercury sample bottle in the outer 

bag and “Dirty hands” closes the outer bag.

15. “Dirty hands” positions a bucket under the sample tap, opens the valve and purges 

the sample tap for at least two minutes, then keeps the valve open until mercury 

samples have been collected. Dirty hands” then opens the outer bag of the total 

mercury sample bottle. “Clean hands” takes the bottles and positions 

himself/herself at the tap with the bottle under the shrouding and opens the inner 

bag. “Clean hands” open the lid of the total mercury sample bottle and places the 

bottle under the flowing stream to fill the bottle. “Clean hands” then closes the lid 

on the bottle and closes the inner bag. “Clean hands” places the bottle in the outer 

bag and “dirty hands” closes the outer bag. The samplers repeat this procedure for 

the collection of the dissolved mercury sample.

The samplers will fill the bottle directly from the sample tap; therefore, the total 

and dissolved mercury samples will not be collected as split samples with Allen

(or its representative), but will be collected as duplicate samples.

16. The samplers will collect total and dissolved mercury grab samples every six 

hours during the compositing time period.

17. Samplers collect a total cyanide grab sample from the same sample tap used for 

the mercury sample collection. The samplers will fill the bottle directly from the 

tap; therefore, the cyanide sample will not be collected as a split sample with 

Allen (or its representative). Immediately after collection, the samplers test for 

sulfides and oxidants and preserve the sample according to the preservation 

protocols outlined in Section 3.4.

18. Samplers fill a 1-L jar for the field measurements. The samplers will give the jar 

to another sampling team member to measure the temperature and pH.

19. The samplers will collect field measurement samples every six hours during the 

compositing time period. The field measurement samples will be collected from 

the tubing that is discharging into the sump/drain at the sample location.

20. At the end of the composite sampling period, “dirty hands” stops each of the 

automatic compositors and opens the outer bag of each composite container. For 

each container, “clean hands” opens the inner bag and detaches the used tubing 
3-13

from the composite container and covers the port with a closed lid or small plastic 

bag. The samplers transport each of the composite containers, including the field 

blank composite container, to the pump–off area to pump off the samples into the 

specified containers.

21. The samplers then repeat steps 1 through 20 to collect the composite samples for 

the next day of sample collection. 

After the composite samples have been collected, the sampling team will then transfer the 

sample into the individual sample containers at the pump-off area. For this sampling point, ERG

will use a sample pump-off approach to transfer the composite samples to the individual sample 

bottles, because the samples are expected to have a low solids content. For this sample pump-off 

procedure, the dissolved metals samples will be collected before the total metals and classical 

samples to prevent cross-contamination within the tubing, which could lead to greater 

concentrations in the dissolved metals fractions.

Sample Pump-Off Procedures

22. Samplers remove the bags containing the gloves and HDPE plastic wrap from the 

coolers or storage containers in which they are packed. Samplers identify which 

coolers or boxes contain the double-bagged sample bottles, precleaned tubing, and 

cleanbox.

23. Both samplers put on Tyvek® suits and gloves. “Dirty hands” covers work 

surfaces with HDPE plastic wrap and places the double-bagged sample bottles 

and precleaned tubing within easy access on the covered surface.

24. “Dirty hands” opens the outer bag of the cleanbox and “clean hands” opens the 

clear inner bag. “Clean hands” places the cleanbox at the point of sample 

collection. “Clean hands” opens the cleanbox and secures it open with the clips 

located inside the box. 

25. “Dirty hands” opens the opening on the peristaltic pump head so the tubing can be 

placed in the pump head. “Dirty hands” opens the outer bag containing a length of 

precleaned Teflon® tubing connected to a length of precleaned silicone tubing, a 

“Y” splitter, and two additional pieces of silicone tubing. “Clean hands” moves 

the tubing into the cleanbox and opens the inner bag and removes the tubing.

“Clean hands” places a clean plastic bag over the end of the Teflon® and silicone 

tubing.

26. “Dirty hands” threads the silicone tubing into the peristaltic pump head.

27. Both samplers change gloves.

28. “Dirty hands” opens the outer bag of the field blank composite container and total

metals field blank sample bottle. “Clean hands” removes the total metals field 
3-14

blank sample bottle and places it in the cleanbox. “Clean hands” opens the inner 

bag of the field blank composite container. “Clean hands” removes the lid from 

the field blank composite container and places the end of the Teflon® tubing in 

the blank water. “Clean hands” holds the end of the silicone tubing outside the 

cleanbox over a bucket, with the plastic bag still covering the end of the tubing 

and “dirty hands” operates the pump to pump about 750 mL of blank water from 

the field blank composite container. “Clean hands” places the end of the silicone 

tubing in the cleanbox, opens the inner bag of the total metals field blank sample 

bottle, and removes the lid. “Dirty hands” operates the pump to collect the total 

metals field blank sample. “Dirty hands” stops the pump. “Clean hands” closes 

the lid on the sample bottle and closes the inner bag. “Clean hands” places the 

inner bag and bottle in the outer bag and “dirty hands” closes the outer bag.

29. “Dirty hands” opens the outer bag of a capsule filter. “Clean hands” opens the 

inner bag and removes the capsule filter. “Clean hands” attaches the capsule filter 

to the silicone tubing just before the “Y” splitter.

30. “Dirty hands” opens the outer bag of the dissolved metals field blank sample 

bottle. “Clean hands” removes the dissolved metals field blank sample bottle and 

places it in the cleanbox. “Clean hands” holds the end of the silicone tubing 

outside the cleanbox over a bucket, with the plastic bag still covering the end of 

the tubing and “dirty hands” operates the pump to pump about 750 mL of blank 

water from the field blank field blank composite container. “Clean hands” places 

the end of the silicone tubing in the cleanbox, opens the inner bag of the dissolved 

metals field blank sample bottle, and removes the lid. “Dirty hands” operates the 

pump to collect the dissolved metals field blank sample. “Dirty hands” stops the 

pump. “Clean hands” closes the lid on the sample bottle and closes the inner bag.

“Clean hands” places the inner bag and bottle in the outer bag and “dirty hands” 

closes the outer bag. The samplers repeat this procedure for the dissolved metals 

and hexavalent chromium field blank samples6

. “Clean hands” closes the inner 

bag of the field blank composite container and “dirty hands” closes the outer bag.

Note: 750 mL of blank water does not need to be purged for each sample, just at 

the beginning of each new filter. If a new filter is needed, “clean hands” removes 

the used filter and samplers follow step 29 to replace the filter. 

31. “Dirty hands” opens the outer bag of the large composite container for the metals 

samples and “clean hands” opens the inner bag. “Clean hands” transfers the 

Teflon® tubing from the field blank composite container to the metals sample 

composite container. “Clean hands” holds the end of the silicone tubing outside 

the cleanbox over a bucket, with the plastic bag still covering the end of the 

tubing and “dirty hands” operates the pump to pump about one liter of sample 

through the tubing and filter. “Dirty hands” stops the pump.

 6 ERG will collect field blank samples for all metals samples at the influent to the bioreactor system during Day 1 

of the sampling episode. ERG will collect the dissolved mercury sample using the same technique as the total 

mercury sample, but the dissolved sample will be filtered at the laboratory. A dissolved mercury field blank will be 

analyzed by the laboratory to assess any mercury contamination from the filtering performed at the laboratory. 

Therefore, ERG does not need to collect a dissolved mercury field blank sample in the field.
3-15

32. “Dirty hands” opens the outer bag of the dissolved metals sample bottle. “Clean 

hands” removes the inner bag and bottle and places it in the cleanbox. “Clean 

hands” opens the inner bag and removes the lid. “Dirty hands” operates the pump 

to collect the dissolved metals sample. “Dirty hands” stops the pump. “Clean 

hands” closes the lid on the sample bottle and closes the inner bag. “Clean hands” 

places the inner bag and bottle in the outer bag and “dirty hands” closes the outer 

bag. The samplers repeat this procedure for the dissolved metals and hexavalent 

chromium samples. During Day 3 of the sampling episode, the samplers will 

collect additional sample volume for the duplicate samples and during Day 4 of 

the sampling episode, the samplers will collect additional sample volume for the 

laboratory QC analyses. 

33. “Clean hands” removes the capsule filter from the sample tubing configuration 

and reconnects the two pieces of tubing together.

34. “Clean hands” holds the silicone tubing outside the cleanbox over a bucket, with 

the plastic bag covering the end of the tubing. “Dirty hands” pumps about one 

liter of sample through the tubing. “Dirty hands” stops the pump. “Clean hands” 

places the end of the silicone tubing back in the cleanbox.

35. “Dirty hands” opens the outer bag of the total metals sample bottle. “Clean hands” 

removes the inner bag and bottle and places it in the cleanbox. “Clean hands” 

opens the inner bag and removes the lid. “Dirty hands” operates the pump to 

collect the total metals sample and then stops the pump. “Clean hands” closes the 

lid on the sample bottle and closes the inner bag. “Clean hands” places the inner 

bag and bottle in the outer bag and “dirty hands” closes the outer bag. During Day 

3 of the sampling episode, the samplers will collect additional sample volume for 

the duplicate samples and during Day 4 of the sampling episode, the samplers will 

collect additional sample volume for the laboratory QC analyses. 

36. “Dirty hands” places an ERG label on the outer bags of the sample bottles.

37. “Dirty hands” shakes the large composite containers for the classical analytes to 

mix the sample. “Dirty hands” opens the outer bag for the composite container.

“Clean hands” opens the inner bag and transfers the Teflon® tubing from the 

metals composite container to the composite container for the classical analytes.

38. “Clean hands” holds the silicone tubing outside the cleanbox over a bucket, with 

the plastic bag covering the end of the tubing. “Dirty hands” pumps about one 

liter of sample through the tubing. “Dirty hands” stops the pump. 

39. Both samplers collect the BOD5, Group I, and Group II samples. During Day 3 of 

the sampling episode, the samplers will collect additional sample volume for the 

duplicate samples and during Day 4 of the sampling episode the samplers will

collect additional sample volume for the laboratory QC analyses.
3-16

EPA plans to collect samples at the influent to the bioreactor system (SP-2) on four

consecutive days. The sample collection setup and sampling technique for each day of sampling 

will be the same.

3.3.3 Effluent from Bioreactor System (SP-3)

The effluent from bioreactor system (SP-3) will be collected downstream of the secondstage effluent storage tank from the second-stage bioreactor cells. Allen has a sample tap located 

on the wastewater piping downstream of the second-stage effluent storage tank. Allen has agreed 

to install a three-way splitter on the sample tap that will have three separate taps to collect 

samples from the sampling point. ERG will follow protocols described in EPA Method 1669 to 

collect metal sample fractions from SP-3.

ERG will collect the effluent from the bioreactor system composite samples using two 

automatic compositors that will be programmed to collect individual sample volumes into two 

large containers (e.g., two 20-liter HPDE containers). To collect sufficient sample volume, ERG 

will calculate the total volume required for ERG sample collection as well as plant split sample 

collection and also add additional volume for purging tubing and contingencies. The volume will 

then be programmed to be collected in one-hour intervals during the 24-hour composite period.

Following the composite period, ERG will pump off the specific sample volumes into the 

individual sample containers.

ERG will use one automatic compositor to collect sample volume for the metals analyses

(excluding mercury) and another automatic compositor to collect sample volume for all classical 

analytes (i.e., BOD5, Group I, and Group II). In addition to collecting automatic composite 

samples for the analytes listed above, ERG will collect total and dissolved mercury grab samples 

every six hours during each compositing period. ERG will also collect one grab sample for 

cyanide during each compositing period.

ERG plans to collect split samples with Allen (or its representative), where possible; 

therefore, when pumping off of the composite samples, a “Y” splitter will be used with two 

pieces of silicone tubing attached to the “Y” splitter to allow ERG and Allen (or its 

representative) to collect samples simultaneously. If problems occur during the collection of split 

samples (e.g., the splitters become clogged and the flow is split unevenly between the sampling 

crews), then EPA may stop the split sample collection and offer instead to collect duplicate 

samples with Allen (or its representative). 

ERG will collect the total and dissolved mercury grab samples by shrouding one of the 

three taps on the three-way splitter (the other two taps are used for the two compositors) and 

collecting the samples directly from the tap. Because the samples are collected directly from the 

tap, ERG will not be able to collect split samples with Allen (or its representative); therefore, 

duplicate samples will be collected.

For all analytes, ERG will collect QC samples at the effluent from the bioreactor system 

(SP-3) on Day 3 of the sampling episode. In addition, for all analytes, ERG will collect a 

duplicate sample of the effluent from bioreactor system (SP-5) on Day 2 of the sampling episode.
3-17

The sample of the effluent from the bioreactor system (SP-3) will be collected from a 

sample tap. The sampling equipment will consist of the following:

• Colorless, electronic-grade, non-nitrile gloves;

• Peristaltic pump (automatic compositor – battery powered);

• Large composite containers (e.g., 20-liter containers);

• Funnel;

• “Y” splitter;

• “T” splitter;

• Teflon® tubing;

• Silicone tubing;

• 0.45-um filter;

• Cleanbox;

• Tyvek® suits (for metals samples); 

• Masks (for mercury samples); and

• Sample containers.

All metals sampling equipment will be specially cleaned according to the procedures 

described in EPA Method 1669. The supplier of the cleaned bottles, tubing, and composite 

containers will prepare and analyze bottle blanks and equipment blanks to evaluate possible 

contamination. ERG will follow protocols described in EPA Method 1669 to collect metal 

sample fractions. Two or more ERG samplers (“clean hands” and “dirty hands”) will follow the 

protocols described in the steps below to set up the sampling point, collect the field blank 

samples, and collect wastewater samples. This section describes the set up of the sample point 

and collection of the EPA samples7.

1. Samplers remove the bags containing the gloves and HDPE plastic wrap from the 

coolers or storage containers in which they are packed. Samplers identify which 

coolers or boxes contain the double-bagged composite containers, precleaned

tubing, blank water, and cleanbox.

2. Both samplers put on Tyvek® suits, masks, and gloves. “Dirty hands” covers 

work surfaces (ground or table) with HDPE plastic wrap and places the doublebagged composite containers within easy access on the covered surface.

3. “Dirty hands” opens the outer bag of the cleanbox and “clean hands” opens the 

clear inner bag. “Clean hands” places the cleanbox at the point of sample 

collection. “Clean hands” opens the cleanbox and secures it open with the clips 

located inside the box.

4. “Dirty hands” opens up the peristaltic pump portion of the automatic compositor 

so the tubing can be added. “Dirty hands” opens the outer bag containing a length 

of precleaned silicone tubing, a “T” splitter, and two additional pieces of silicone 

 7 For the sample collection, the samples will be split with the plant (or the plant’s representative) and therefore, the 

sample set-up describes equipment needed for split samples. However, EPA is not responsible for the collection of 

the split samples collected by the plant and therefore, the collection of their samples is not described.
3-18

tubing. “Clean hands” takes the inner bag containing the tubing and moves it into 

the cleanbox. “Clean hands” opens the inner bag and removes the tubing. “Clean 

hands” places a clean plastic bag over each end of the silicone tubing. The tubing 

configuration will be set up such that one end will be connected to the sample tap, 

one end will be threaded through the automatic compositor and connected to the 

large composite container, and one end will be placed next to a sump/drain near 

the sampling point. To collect the samples, the sample tap will be left open during 

the entire sample collection time period and will flow directly to the sump/drain; 

however, the automatic compositor will pull sample from the flowing stream as 

dictated by the sampling program. Additionally, the automatic compositor will be 

capable of purging the line back to the flowing stream between each individual 

sample aliquot.

5. “Dirty hands” threads one portion of the silicone tubing through the peristaltic 

pump portion of the automatic compositor.

6. Both samplers change gloves.

7. “Dirty hands” opens the outer bag of the metals field blank water and the field 

blank composite container. “Clean hands” opens the inner bag for the field blank 

water, unscrews the lid and places it in the inner bag. “Clean hands” then places 

the one end of the silicone tubing into the blank water. “Clean hands” also opens 

the inner bag for the field blank composite container and loosens the lid. “Clean 

hands” holds the silicone tubing with the plastic bag covering the end out of the 

cleanbox and over a bucket and “dirty hands” operates the pump to pump blank 

water through the tubing. After the tubing has been purged with sufficient 

volume, “clean hands” holds the silicone tubing at the mouth of the field blank 

composite container and fills the composite container with sufficient volume to 

the collect the total and dissolved metals field blank samples at the pump-off 

location. “Dirty hands” stops the pump. During the purging of the tubing and 

collection of the field blank sample volume, “dirty hands” holds the end of the 

silicone tubing that will be placed by the sump/drain above the composite 

container to prevent this portion of the tubing configuration from filling with 

blank water during the pumping process. “Clean hands” places the plastic bag 

over the end of the silicone tubing, replaces the lid on the field blank composite 

container, places the silicone tubing back in the cleanbox, and closes the inner bag 

of the field blank composite container. “Dirty hands” closes the outer bag of the 

field blank composite container8

.

8. Both samplers work together to move the sampling tubing, automatic compositor, 

and composite containers into position for the sample collection. Samplers will 

ensure that the tubing will stay in place during the 24-hour sample collection 

period.

 8 ERG will only collect field blank samples at the effluent from the bioreactor system during one day of the 

sampling episode.
3-19

9. “Dirty hands” changes gloves.

10. “Clean hands” holds the end of the silicone tubing outside the cleanbox over a 

bucket, with the plastic bag still covering the end of the tubing. “Dirty hands”

places the end of the silicone tubing near the sump/drain and opens the sample tap 

valve to allow the wastewater to flow through the tubing. “Dirty hands” operates 

the pump to purge the pump portion of the tubing for a minimum of 2 minutes.

11. “Dirty hands” programs the automatic compositor to collect the 20 liters of 

sample over a 24-hour time period in one-hour intervals (i.e., collect 830 mL of 

sample every hour). “Dirty hands” calibrates the compositor to ensure that

approximately 830 mL is being collected for each individual grab.

12. “Dirty hands” opens the outer bag of the large composite container. “Clean 

hands” opens the inner bag and connects the silicone tubing to the port on the 

composite container, securing the connection with a cable tie. “Clean hands” 

closes the inner bag around the composite bottle, and “dirty hands” closes the 

outer bag. The samplers put ice around the composite container to keep the 

samples cold during the compositing time period.

13. Samplers repeat steps 1-12 to set up the automatic compositor for the classical

analytes (skipping step 7). Samplers will use another composite container. The 

samplers will put the classicals composite container in ice to keep the samples 

cold during the compositing time period.

14. “Dirty hands” and “clean hands” then work to collect the total mercury field blank 

sample. “Dirty hands” shrouds the sample tap with a clear plastic bag that covers 

the end of the sample tap and provides enough room for samplers to work in with 

their hands. “Dirty hands” then opens the outer bag of the mercury field blank 

water and the total mercury field blank sample bottle. “Clean hands” opens the 

inner bag for the field blank water and the total mercury field blank sample bottle, 

unscrews the lids and places each in their inner bags. “Clean hands” pours the 

field blank water into the field blank sample bottle, closes the lids, and closes the 

inner bags. “Clean hands” places the total mercury sample bottle in the outer bag 

and “Dirty hands” closes the outer bag. 

15. “Dirty hands” positions a bucket under the sample tap, opens the valve and purges 

the sample tap for at least two minutes, then keeps the valve open until mercury 

samples have been collected. Dirty hands” then opens the outer bag of the total 

mercury sample bottle. “Clean hands” takes the bottles and positions 

himself/herself at the tap with the bottle under the shrouding and opens the inner 

bag. “Clean hands” open the lid of the total mercury sample bottle and places the 

bottle under the flowing stream to fill the bottle. “Clean hands” then closes the lid 

on the bottle and closes the inner bag. “Clean hands” places the bottle in the outer 

bag and “dirty hands” closes the outer bag. The samplers repeat this procedure for 

the collection of the dissolved mercury sample.
3-20

The samplers will fill the bottle directly from the sample tap; therefore, the total 

and dissolved mercury samples will not be collected as split samples with Allen 

(or its representative), but will be collected as duplicate samples.

16. The samplers will collect total and dissolved mercury grab samples every six 

hours during the compositing time period. 

17. Samplers collect a total cyanide grab sample from the same sample tap used for 

the mercury sample collection. The samplers will fill the bottle directly from the 

tap; therefore, the cyanide sample will not be collected as a split sample with 

Allen (or its representative). Immediately after collection, the samplers need to 

test for sulfides and oxidants and preserve the sample according to the 

preservation protocols outlined in Section 3.4.

18. Samplers fill a 1-L jar for the field measurements. The samplers will give the jar 

to another sampling team member to measure the temperature and pH.

19. The samplers will collect field measurements samples every six hours during the 

compositing time period. The field measurement samples will be collected from 

the sample tap used for the mercury collection.

20. At the end of the composite sampling period, “dirty hands” stops each of the 

automatic compositors and opens the outer bag of each composite container. For 

each container, “clean hands” opens the inner bag and detaches the used tubing 

from the composite container and covers the port with a closed lid or small plastic 

bag. The samplers transport each of the composite containers, including the field 

blank composite container, to the pump-off area to pump off the samples into the 

specified containers.

21. The samplers then repeat steps 1 through 20 to collect the composite samples for 

the next day of sample collection.

After the composite samples have been collected, the sampling team will then transfer the 

sample into the individual sample containers at the pump-off area. For this sampling point, ERG

will use a sample pump-off approach to transfer the composite samples to the individual sample 

bottles, because the samples are expected to have a low solids content. For this sample pump-off 

procedure, the dissolved metals samples will be collected before the total metals and classical 

samples to prevent cross-contamination within the tubing, which could lead to greater 

concentrations in the dissolved metals fractions.

Sample Pump-Off Procedures

22. Samplers remove the bags containing the gloves and HDPE plastic wrap from the 

coolers or storage containers in which they are packed. Samplers identify which 

coolers or boxes contain the double-bagged sample bottles, precleaned tubing, and 

cleanbox.
3-21

23. Both samplers put on Tyvek® suits and gloves. “Dirty hands” covers work 

surfaces with HDPE plastic wrap and places the double-bagged sample bottles 

and precleaned tubing within easy access on the covered surface.

24. “Dirty hands” opens the outer bag of the cleanbox and “clean hands” opens the 

clear inner bag. “Clean hands” places the cleanbox at the point of sample 

collection. “Clean hands” opens the cleanbox and secures it open with the clips 

located inside the box.

25. “Dirty hands” opens the opening on the peristaltic pump head so the tubing can be 

placed in the pump head. “Dirty hands” opens the outer bag containing a length of 

precleaned Teflon® tubing connected to a length of precleaned silicone tubing, a 

“Y” splitter, and two additional pieces of silicone tubing. “Clean hands” moves 

the tubing into the cleanbox and opens the inner bag and removes the tubing.

“Clean hands” places a clean plastic bag over the end of the Teflon® and silicone 

tubing.

26. “Dirty hands” threads the silicone tubing into the peristaltic pump head.

27. Both samplers change gloves.

28. “Dirty hands” opens the outer bag of the field blank composite container and total

metals field blank sample bottle. “Clean hands” removes the total metals field 

blank sample bottle and places it in the cleanbox. “Clean hands” opens the inner 

bag of the field blank composite container. “Clean hands” removes the lid from 

the field blank composite container and places the end of the Teflon® tubing in 

the blank water. “Clean hands” holds the end of the silicone tubing outside the 

cleanbox over a bucket, with the plastic bag still covering the end of the tubing 

and “dirty hands” operates the pump to pump about 750 mL of blank water from 

the field blank composite container. “Clean hands” places the end of the silicone 

tubing in the cleanbox, opens the inner bag of the total metals field blank sample 

bottle, and removes the lid. “Dirty hands” operates the pump to collect the total 

metals field blank sample. “Dirty hands” stops the pump. “Clean hands” closes 

the lid on the sample bottle and closes the inner bag. “Clean hands” places the 

inner bag and bottle in the outer bag and “dirty hands” closes the outer bag.

29. “Dirty hands” opens the outer bag of a capsule filter. “Clean hands” opens the 

inner bag and removes the capsule filter. “Clean hands” attaches the capsule filter 

to the silicone tubing just before the “Y” splitter.

30. “Dirty hands” opens the outer bag of the dissolved metals field blank sample 

bottle. “Clean hands” removes the dissolved metals field blank sample bottle and 

places it in the cleanbox. “Clean hands” holds the end of the silicone tubing 

outside the cleanbox over a bucket, with the plastic bag still covering the end of 

the tubing and “dirty hands” operates the pump to pump about 750 mL of blank 

water from the field blank field blank composite container. “Clean hands” places 

the end of the silicone tubing in the cleanbox, opens the inner bag of the dissolved 
3-22

metals field blank sample bottle, and removes the lid. “Dirty hands” operates the 

pump to collect the dissolved metals field blank sample. “Dirty hands” stops the 

pump. “Clean hands” closes the lid on the sample bottle and closes the inner bag.

“Clean hands” places the inner bag and bottle in the outer bag and “dirty hands” 

closes the outer bag. The samplers repeat this procedure for the dissolved metals 

and hexavalent chromium field blank samples9. “Clean hands” closes the inner 

bag of the field blank composite container and “dirty hands” closes the outer bag.

Note: 750 mL of blank water does not need to be purged for each sample, just at 

the beginning of each new filter. If a new filter is needed, “clean hands” removes 

the used filter and samplers follow step 29 to replace the filter.

31. “Dirty hands” opens the outer bag of the large composite container for the metals 

samples and “clean hands” opens the inner bag. “Clean hands” transfers the 

Teflon® tubing from the field blank composite container to the metals sample 

composite container. “Clean hands” holds the end of the silicone tubing outside

the cleanbox over a bucket, with the plastic bag still covering the end of the 

tubing and “dirty hands” operates the pump to pump about one liter of sample 

through the tubing and filter. “Dirty hands” stops the pump.

32. “Dirty hands” opens the outer bag of the dissolved metals sample bottle. “Clean 

hands” removes the inner bag and bottle and places it in the cleanbox. “Clean 

hands” opens the inner bag and removes the lid. “Dirty hands” operates the pump 

to collect the dissolved metals sample. “Dirty hands” stops the pump. “Clean 

hands” closes the lid on the sample bottle and closes the inner bag. “Clean hands” 

places the inner bag and bottle in the outer bag and “dirty hands” closes the outer 

bag. The samplers repeat this procedure for the dissolved metals and hexavalent 

chromium samples. During Day 2 of the sampling episode, the samplers will 

collect additional sample volume for the duplicate samples and during Day 3 of 

the sampling episode, the samplers will collect additional sample volume for the 

laboratory QC analyses.

33. “Clean hands” removes the capsule filter from the sample tubing configuration 

and reconnects the two pieces of tubing together.

34. “Clean hands” holds the silicone tubing outside the cleanbox over a bucket, with 

the plastic bag covering the end of the tubing. “Dirty hands” pumps about one 

liter of sample through the tubing. “Dirty hands” stops the pump. “Clean hands” 

places the end of the silicone tubing back in the cleanbox.

35. “Dirty hands” opens the outer bag of the total metals sample bottle. “Clean hands” 

removes the inner bag and bottle and places it in the cleanbox. “Clean hands” 

opens the inner bag and removes the lid. “Dirty hands” operates the pump to 

 9 ERG will collect field blank samples for all metals samples at the effluent from the bioreactor system during Day 1 

of the sampling episode. ERG will collect the dissolved mercury sample using the same technique as the total 

mercury sample, but the dissolved sample will be filtered at the laboratory. A dissolved mercury field blank will be 

performed by the laboratory to assess any mercury contamination from the filtering performed at the laboratory. 

Therefore, ERG does not need to collect a dissolved mercury field blank sample in the field.
3-23

collect the total metals sample and then stops the pump. “Clean hands” closes the 

lid on the sample bottle and closes the inner bag. “Clean hands” places the inner 

bag and bottle in the outer bag and “dirty hands” closes the outer bag. During Day 

2 of the sampling episode, the samplers will collect additional sample volume for 

the duplicate samples and during Day 3 of the sampling episode, the samplers will 

collect additional sample volume for the laboratory QC analyses.

36. “Dirty hands” places an ERG label on the outer bags of the sample bottles.

37. “Dirty hands” shakes the large composite containers for the classical analytes to 

mix the sample. “Dirty hands” opens the outer bag for the composite container.

“Clean hands” opens the inner bag and transfers the Teflon® tubing from the 

metals composite container to the composite container for the classical analytes.

38. “Clean hands” holds the silicone tubing outside the cleanbox over a bucket, with 

the plastic bag covering the end of the tubing. “Dirty hands” pumps about one 

liter of sample through the tubing. “Dirty hands” stops the pump.

39. Both samplers collect the BOD5, Group I, and Group II samples. During Day 2 of 

the sampling episode, the samplers will collect additional sample volume for the 

duplicate samples and during Day 3 of the sampling episode, the samplers will 

collect additional sample volume for the laboratory QC analyses.

EPA plans to collect samples at the effluent from the bioreactor system (SP-3) on four

consecutive days. The sample collection setup and sampling technique for each day of sampling 

will be the same.

3.4

All samples will be maintained on ice immediately upon collection (except metals 

samples that do not require cooling). Because the classical and hexavalent chromium samples are 

required to be cooled, all composite containers will be maintained on ice. After pumping off the 

composite samples into the individual sample containers, the classical and hexavalent chromium 

samples will be put in an ice-water bath; however, the other metals samples, which do not 

require cooling, will 

Sample Preservation, Shipping, and Analysis 

not be placed on ice. The classical and hexavalent chromium grab samples 

collected at the FGD influent sampling point will also be placed on ice immediately after 

collection. 

The dissolved metals (excluding mercury) and hexavalent chromium samples will be 

filtered in the field. The dissolved mercury samples will be filtered upon receipt at the 

laboratory. All metals samples, except hexavalent chromium, will be acid-preserved prior to 

extraction at the laboratory. Hexavalent chromium samples will be preserved on site, according 

to the method-specified protocols. Samplers will filter samples within 15 minutes after the 

compositing period ends (or as soon thereafter as possible). The dissolved samples of the FGD 

influent will be filtered approximately one hour after they are collected to allow for solids 

settling because the samples’ high solids content that would clog the filter.
3-24

The total cyanide grab samples will be preserved according to the method-specific 

protocols immediately following collection. Prior to sample collection, the samplers will test the 

wastewater at each sampling point for sulfide using lead acetate test strips. If sulfide is present, 

the samplers will use the procedure identified in Section 3.5 to determine the minimal amount of 

dilution necessary to reduce sulfide to a nondetectable concentration. After determining this 

minimal dilution factor for the sampling point, the samplers will dilute all samples collected at 

this sampling point using blank water. After dilution, the samplers will retest the sample for 

sulfides. If sulfides are still detected, the sample will be diluted further using the same technique 

as identified in Section 3.5 to ensure that the sample is not over-diluted. The samplers will then 

test the diluted sample for the presence of oxidants (i.e., chlorine) using potassium-iodide starch 

paper. If total chlorine is present, the samplers will add sodium arsenite in small increments until 

the oxidants are at nondetectable concentrations in the sample. The samplers will then carefully 

adjust the pH to >10 S.U. using sodium hydroxide and place the sample on ice. The preservation, 

including the amount of dilution, will be reported to the laboratory on the traffic reports.

Table 3-3 lists the parameters, bottle types, sample volume, and on-site preservation 

requirements for each type of analysis. The type and amount of preservation used will be 

recorded on sample preservation log sheets (Figure 3-1).With the exception of total cyanide 

samples, if 10 percent of the sample volume is added and the required pH is not achieved, ERG 

will stop diluting the samples by discontinuing preservation and noting it on the traffic report. 

The wastewater samples, except metals samples that do not require cooling, will be packed in ice 

chests with a sufficient quantity of ice to maintain a temperature of ≤6°C. All samples will be 

prepared for overnight shipment via Federal Express to laboratories.

3.5

Temperature, pH, sulfide, and oxidants will be measured and recorded by the sampling 

crew at each sampling point (SP-1, SP-2, and SP-3). The samplers will measure temperature and 

pH when the automatic composite samplers are initially set up and every six hours during the 

compositing period. The samplers will test the wastewater for sulfide and oxidants at the time the 

total cyanide grab sample is collected. For temperature and pH, the samplers will fill a 1-liter 

glass jar with sample and test the wastewater immediately after collecting the aliquot. For sulfide 

and oxidants, the samplers will fill the cyanide sample bottle directly and test for sulfide and 

oxidants using test strips immediately after sample collection.

Field Measurements and Engineering Data Collection

During a presampling set-up day (i.e., the day before the sampling episode begins), the

samplers will test the wastewater at each sampling point for sulfide using lead acetate test strips 

to determine if preservation is needed for cyanide. If sulfide is present, the samplers should 

determine the minimal amount of dilution necessary to reduce the sulfide concentration to below 

detection by the lead acetate test strips. To identify the minimal amount of dilution, the samplers 

will dilute the sample by a factor of two (1:1) and retest for sulfide. If sulfide is still detected, the 

samplers will dilute the original sample by a factor of 3 (2:1). This process will be continued 

until sulfide is not detected in the sample. After this minimal dilution factor is determined for the 

sampling point, the samplers will use this minimal dilution factor to dilute all samples collected 

at the sampling point. The samplers will also test both the original (i.e., nondiluted) and diluted 

sample for the presence of oxidants (e.g., chlorine) during the presampling set-up day using 

potassium-iodide starch paper.
3-25

Samplers will follow applicable test kit calibration procedures specified by the 

manufacturer. Table 3-4 summarizes the field measurements, the method to be used for the 

measurement, and the detection range of each field test instrument. In addition, EPA will collect 

flow rate data for each sampled waste stream. The flow rates for all the sampling points will be 

collected from the plant’s existing flow recorders. 

Field sampling log sheets (Figure 3-2) will be completed at each sampling point. This 

sheet will record the sampling methodology, names of the samplers, sample collection time, field 

measurements, and any notes and observations.

Samplers will also collect engineering information with regard to design and operation of 

the plant. For example, they will collect information such as coal usage, plant capacity, 

wastewater flow rates, sludge generation rates (if applicable), and retention times in wastewater 

treatment process stages. Engineering data collection sheets (Figures 3-3, 3-4, and 3-5) will be 

completed for the plant. This information will be used to determine if the specific design or 

operational criteria of the steam electric operations affect the wastewater characteristics.

3.6

Each sample will be coded with a unique sample number and labeled at the time of 

collection. Typically, labels are printed prior to arrival in the field, although they may also be 

completed by hand. Each self-adhesive label is completed in indelible ink and contains the 

following information:

Sample Labeling

• Sample number;

• Sampling episode number;

• Sampling point/description;

• Date of sample collection;

• Analysis to be performed;

• Sample bottle type; and

• Required preservation.

If any of the preprinted information is incorrect, it will be revised using indelible ink. In 

particular, if a required preservation is not used, it will be marked out (additional preservation 

details will be noted on the traffic report). Once applied to the sample container, labels are 

covered with clear tape to prevent tampering, abrasion, smearing, or loss during transit. For 

metal samples, the samplers will not label the sample bottles, but will label the outer plastic bag 

of the sample bottle.

3.7

To maintain a record of sample collection, transfer between personnel, shipment, and 

receipt by the laboratory, samplers will complete a traffic report for each sample set at each 

sampling location. These forms are used to document sample custody transfer from the field to 

the laboratory. Traffic report forms will be completed for all samples sent to all laboratories. 

Figure 3-6 includes an example of a traffic report. At the time of sample shipment, a copy of the 

Traffic Reports
3-26

traffic report will be sent to ERG, another copy will be kept by sampling personnel, and two 

copies will be transmitted with the samples to the analytical laboratory.

In addition to the transfer of custody, the traffic report provides information to the 

analytical laboratory on the sample number, type of water sample (in-line process, untreated 

wastewater, treated effluent), sample description, whether the sample is preserved, pH of the 

sample after preservation, type of sample (grab, composite), sample collection date and time, and 

the analyses requested. Samplers will use the comment section to provide special notes or 

instructions to the laboratory, such as whether samples have been filtered on site or how to 

composite separate samples prior to analysis. The sampling team will also comment if sample 

bottles are not completely filled (i.e., less than 75 percent full). In addition, the comments section 

will be used to note deviations from standard sampling protocols (for example, if a sample could 

not be acid-preserved because of excessive buffering).

3.8

The QA/QC program for sample collection at Allen will include the following:

Quality Assurance/Quality Control

• Documentation for samples through laboratory traffic reports;

• Collection of duplicate samples for all analytes;

• Collection of bottle blank(s) for metals;

• Collection of field blank(s) for metals;

• Collection of equipment blank(s) for metals; and

• Collection of laboratory QC samples for matrix spike/matrix spike duplicate 

analyses.

Duplicate sample sets will be collected as part of the quality assurance program for 

sampling. During Day 3 of the sampling episode, ERG will collect one duplicate sample (SP-4) 

of the influent to the bioreactor system (SP-2) and during Day 2 of the sampling episode, ERG 

will collect one duplicate sample (SP-5) of the effluent from the bioreactor system (SP-3). The 

duplicate samples will be collected as separate aliquots in the field. Results of the duplicate 

analyses will be used to evaluate precision, including variability in sample collection, handling, 

preparation, and analysis. 

Bottle blanks will be used to evaluate possible contamination from the sample bottles. 

The bottle blank will consist of an analyte-free matrix (Ultra Pure Blank Water DI+TM) poured 

into the appropriate sample bottles (e.g., 250-mL plastic bottle for metals) and stored for several 

days prior to shipment to the laboratory. The supplier of the cleaned metals bottles will prepare 

and analyze the bottle blanks prior to shipping the equipment to the sampling episode.

Field blanks will be used to evaluate possible contamination caused by sampling 

equipment or by sampling equipment decontamination procedures. Field blanks will be prepared 
3-27

in the field prior to sample collection and analyzed for all sampling equipment, other than sample 

bottles, that come into direct contact with samples (e.g., tubing or filters). 

ERG will prepare field blanks for each of the total and dissolved metals analyses at each 

of the three sampling points during Day 1 of the sampling episode10. Additionally, ERG will 

collect total mercury field blanks at the influent to the bioreactor and the effluent from the 

bioreactor sampling points during the collection of one of the grab samples each day of the 

sampling episode. ERG samplers will use “clean hands / dirty hands” sampling techniques to 

prepare the metals field blanks, as discussed in more detail in Section 3.3. The total metals field 

blanks (including mercury) at the influent to the FGD wastewater treatment system will be 

prepared by gravity-feeding ASTM Type 1 water through the silicone tubing into the sample 

bottles. The total metals field blanks (excluding mercury) at the influent to and effluent from the 

bioreactor system sampling points will be prepared by pumping ASTM Type 1 water through the 

composite tubing set into a large composite container where it will be held for the 24-hour 

compositing period, then pumping the ASTM Type 1 water from the large composite container 

through the Teflon® and silicone tubing and into the sample bottles. The total mercury field 

blanks at the influent to and effluent from the bioreactor sampling points will be prepared by 

pouring ASTM Type 1 water directly into the sample bottles. The dissolved metals field blanks 

at the influent to the FGD wastewater treatment system will be prepared by gravity-feeding the 

ASTM Type 1 water through the silicone tubing into a 10-L composite container and then

pumping the ASTM Type 1 water from the 10-L container through the Teflon® and silicone 

tubing, through a 0.45-um filter, and into the sample bottles. The dissolved metals field blanks at 

the influent to and effluent from the bioreactor system sampling points will be prepared by 

pumping ASTM Type 1 water through the composite tubing set into a large composite container 

where it will be held for the 24-hour compositing period, then pumping the ASTM Type 1 water 

from the large composite container through the Teflon® and silicone tubing, through a 0.45-um 

filter, and into the sample bottles. The field blanks will determine if there is any contamination 

from the sampling equipment, atmospheric contamination, or other contamination from the 

surroundings.

EPA Method 1669 requires that equipment blanks also be prepared and analyzed for 

metals to evaluate possible contamination of metals caused by the sampling equipment. The 

supplier of the tubing and composite containers will prepare and analyze these equipment blanks 

and provide a report certifying the equipment as clean.

As part of standard laboratory quality control, matrix effects on analytical performance 

are assessed through the analysis of matrix spikes and laboratory duplicates. Consequently, 

additional sample volume must be collected for these QC analyses. The sampling team will 

collect, label, and ship the necessary laboratory QC volumes. Laboratory QC volumes (i.e., 

MS/MSD sample) will be collected for every 10 samples collected at a sampling event, 

excluding field blank samples. For all analytes requiring laboratory QC volumes, the sampling 

team will collect QC sample volume from the influent to the bioreactor system (SP-2) during 

Day 4 of the sampling episode and from the effluent from the bioreactor system (SP-3) during 

Day 3 of the sampling episode. 

 10 ERG will not collect a field blank for dissolved mercury because a filter blank will be prepared and analyzed for 

by the laboratory. 
3-28

3.9

Allen or its representative has elected to collect split samples at each of the sampling 

points. Allen or its representative will supply all of the personnel, equipment, glassware, and 

reagents required to collect the split samples and to coordinate the analysis of samples. For each 

of the sampling points, the sampling crew will attempt to collect split samples with Allen or its 

representative as described in this plan; however, if problems occur (e.g., the splitters become 

clogged and the flow is split unevenly between the sampling crews), then EPA may stop the split 

sample collection and offer instead to collect duplicate samples with Allen or its representative. 

Sample Splitting
3-29

Table 3-1. Sample Collection at Allen Steam Station

Sampling 

Point 

Number Sampling Point Name

Total Metals(EPA Method 200.8 with collision cell,) Total Metals(EPA Method 200.7Dissolved Metals (EPA Method 200.8 with collision cell,)Dissolved Metals (EPA Method 200.7ision cell,)Total Mercury Dissolved MercuryHexavalent Chromium BOD5Group I aGroup II bTotal Cyanide

SP-1 Influent to FGD Wastewater 

Treatment System

4 4 4 4 4 4 4 4 4 4 4

SP-2 Influent to Bioreactor System 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC

SP-3 Effluent from Bioreactor System 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC 4+1QC

SP-4 Duplicate of Influent to Bioreactor 

System

1 1 1 1 1 1 1 1 1 1 1

SP-5 Duplicate of Effluent from Bioreactor 

System

1 1 1 1 1 1 1 1 1 1 1

SP-6 Influent to FGD Wastewater 

Treatment System Field Blank

1 1 1 1 1 1

SP-7 Field Blank for Influent to Bioreactor 

System

1 1 1 1 4 1

SP-8 Field Blank for Effluent from 

Bioreactor System

1 1 1 1 4 1

Total Number of Samples 17+2QC 17+2QC 17+2QC 17+2QC 23+2QC 14+2QC 17+2QC 14+2QC 14+2QC 14+2QC 14+2QC

a – Group I includes total suspended solids (TSS), total dissolved solids (TDS), sulfate, and chloride.

b – Group II includes ammonia as nitrogen, nitrate/nitrite as nitrogen, total Kjeldahl nitrogen (TKN), chemical oxygen demand (COD), and total phosphorus.
3-30

Table 3-2. Analytical Methods 

Parameter Method Number

Classicals

Biochemical oxygen demand (BOD5) SM 5210 B 

Chemical oxygen demand (COD) EPA 410.4

Total suspended solids (TSS) SM 2540 D

Total dissolved solids (TDS) SM 2540 C 

Sulfate EPA 300.0

Chloride EPA 300.0

Ammonia as nitrogen EPA 350.1

Nitrate/nitrate as nitrogen EPA 353.2

Total Kjeldahl nitrogen (TKN) EPA 351.2

Total phosphorus EPA 365.1

Total cyanide SM 4500 CN E

Total and Dissolved Metals

Mercury EPA 1631E

Hexavalent chromium (dissolved only) EPA 218.6 

Antimony, arsenic, cadmium, chromium, copper, lead, manganese, 

nickel, selenium, silver, thallium, vanadium, and zinc

EPA 200.8 with collision cell 

Aluminum, barium, beryllium, boron, calcium, cobalt, iron, magnesium, 

molybdenum, sodium, tin, and titanium 

EPA 200.7
3-31

Table 3-3. Summary of Sample Container and Planned Preservation

Parameter

Sample 

Container and 

Volume

QC Sample 

Container and 

Volume On-Site Preservation

Classicals

BOD5 One 1-L plastic 

bottle

One 1-L plastic 

bottle

≤6°C

Group I a One 1-L plastic 

bottles

One 1-L plastic 

bottles

≤6°C

Group II b Two 1-L plastic 

bottles

Two 1-L plastic 

bottles

H2SO4 to pH <2, ≤6°C

Total cyanide One 1-L plastic 

bottle

One 1-L plastic 

bottles

Dilution until sulfide is not present, 

NaAsO2 until total chlorine is not 

present, NaOH to pH >10, ≤6°C

Metals

Total metals (EPA Method 200.8 with 

collision cell)

One 500-mL 

plastic bottle

No additional 

volume needed

None

(acid preserve at laboratory)

Total metals (EPA Method 200.7) One 500-mL 

plastic bottle

No additional 

volume needed

None

(acid preserve at laboratory)

Dissolved metals (EPA Method 200.8 

with collision cell)

One 500-mL 

plastic bottle

No additional 

volume needed

0.45-μm filter (performed in field)

(acid preserve at laboratory)

Dissolved metals (EPA Method 200.7) One 500-mL 

plastic bottle

No additional 

volume needed

0.45-μm filter (performed in field)

(acid preserve at laboratory)

Total mercury: None

Manual composite grab samples (acid preserve at laboratory) Four 125-mL 

glass bottle

No additional 

volume needed

Influent samples and field blank 

samples

Two 250-mL 

glass bottle

No additional 

volume needed

Dissolved mercury: None

(filter and acid preserve at 

laboratory) Manual composite grab samples Four 125-mL 

glass bottle

No additional 

volume needed

Influent samples One 250-mL 

glass bottle

No additional 

volume needed

Hexavalent chromium One 250-mL 

plastic bottle

No additional 

volume needed

0.45-μm filter (performed in field)

Ammonium sulfate buffer to 

pH 9.3 – 9.7, ≤6°C

a – Group I includes TSS, TDS, sulfate, and chloride.

b – Group II includes ammonia as nitrogen, COD, nitrate/nitrite as nitrogen, TKN, and total phosphorus.
3-32

Table 3-4. Sampling Point Field Measurements

Field Measurements Method Detection Range (or Gradation of Scale)

Temperature Thermometer -20 to 150 ± 1oC

pH (Standard Units) Four-color indicator strip

pH meter

0 to 12 ± 1 pH S.U.

-1.0 to 15.0 ± 0.1 pH S.U.

Sulfide Lead acetate test strip >50 mg/L sulfide (S2-)

Oxidants (i.e., chlorine) Potassium-iodide starch paper >1 mg/L free chlorine (Cl2)
3-33

Sampling Episode ____________

Preservation Chemicals – List Strength of Solution from Bottle and Lot Number 

H2SO4 _____________________ NH4SO4 ________________________

NaOH _____________________

Sample

Number

Analysis Date Time Name Chemical Initial 

pH

Final pH Number of 

Drops

Figure 3-1. Sample Preservation Log Sheet
3-34

Sampling Episode: __________________________________

Sampling Point: ____________________________________

Sample Numbers: __________________________________

Date:

Manual Composite □ Grab □

Automatic Composite □

Time of Grab Sample Collection:

Start Time □ AM □ PM

End Time □ AM □ PM

Time of Automatic Sample Collection:

Start Time □ AM □ PM

End Time □ AM □ PM

Equipment Used: _________________________________________________

Samplers’ Names: ________________________________________________

Grab Sample Time

Temp

°C

pH

(S.U.)

meter / strips

Waste Stream Flow Rate 

(MGD)

1

2

3

4

Notes: (include observations of odor and color of each aliquot, take pictures if necessary)

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Figure 3-2. Field Sampling Log Sheet
3-35

Plant Name: ________________________________________________________________________________

Plant Contact: ______________________________________________________________________________

Dates of Sample Collection: ___________________________________________________________________

Data Collected by: ___________________________________________________________________________

Instructions: In the tables below, fill out information on the generating units and FGD systems operating at the plant based on all four days of the sampling 

episode. Note any changes in operation that occur during the four-day period. Provide actual data if possible. If actual data are not available, provide estimates 

for the specific information. Some of the data requested may not be susceptible to estimation. Enter “URE” for “unable to reasonably estimate.” Otherwise, 

specify whether data provided are actual or estimated by writing in “ACT” or EST” wherever appropriate.

Generating Unit Operating Characteristics During Sample Collection

Unit 

ID Boiler Type

Capacity 

(MW)

Electricity 

Production

(MW)

(or Percent 

Capacity %)

a

SCR

(No, On, 

Off)

Particulate 

Control System 

(HS/CS ESP, or 

BH)

a The electricity production should be measured on a daily basis from midnight of the 1st day of sample collection to 

midnight of the last day of sample collection. 

FGD System Operating Characteristics During Sample Collection

Unit 

ID

Wet FGD 

System 

(Yes/No)

Type of 

Scrubber

Forced 

Oxidation 

(Yes/No) Sorbent

Additives 

(DBA, formic 

acid, etc.)

FGD Makeup Water 

Source

SO2

Removal 

Percentage

Type of 

Solids 

Separation

Note changes in operation over the past month (e.g., turned off SCRs on October 1 or burned 5percent petroleum coke previous week);

Figure 3-3. Engineering Data Collection Sheet (Page 1 of 4)
3-36

Plant Name: ________________________________________________________________________________

Plant Contact: ______________________________________________________________________________

Dates of Sample Collection: ___________________________________________________________________

Data Collected by: ___________________________________________________________________________

Instructions: In the tables below, provide information on the coal burned and FGD scrubber slurry at the plant for 

each day of the sampling episode. Provide actual data if possible. If actual data are not available, provide estimates 

for the specific information. Some of the data requested may not be susceptible to estimation. Enter “URE” for 

“unable to reasonably estimate.” Otherwise, specify whether data provided are actual or estimated by writing in 

“ACT” or EST” wherever appropriate.

Coal Information

Day of 

Sampling Unit ID Coal Type

Amount of

Coal Used 

During 

Day of 

Sampling

Source of 

Coal (Coal 

Region 

and/or 

State)

Percent 

Sulfur in 

Coal

Chlorine 

Content of 

Coal

1

2

3

4

Note changes in operation over the past month (e.g., turned off SCRs on October 1 or burned 5% petroleum coke 

previous week) as well as conditions and changes during the sampling episode:

Figure 3-4. Engineering Data Collection Sheet (Page 2 of 4)
3-37

Scrubber Slurry Information

Day of 

Sampling

FGD 

System ID

Associated 

Unit IDs

Scrubber Slurry

Blowdown Flow Rate

Scrubber 

Slurry 

Percent 

Solids 

Time of 

Dewatering 

During 

Sampling Day 

Percent 

Filtrate 

Recycled 

Back to 

Scrubber

Flow Rate

(gpm) Duration

1

2

3

4

Figure 3-5. Engineering Data Collection Sheet (Page 3 of 4)
3-38

Plant Name: ________________________________________________________________________________

Plant Contact: ______________________________________________________________________________

Dates of Sample Collection: ___________________________________________________________________

Data Collected by: ___________________________________________________________________________

Instructions: In the table below, provide information on the FGD wastewater treatment system for each day of the sampling episode and the volumes of the FGD 

wastewater treatment system tanks and reactors. If possible, provide the name of the acid and polymer used during the sampling episode. Provide actual data if 

possible. If actual data are not available, provide estimates for the specific information. Some of the data requested may not be susceptible to estimation. Enter 

“URE” for “unable to reasonably estimate.” Otherwise, specify whether data provided are actual or estimated by writing in “ACT” or EST” wherever 

appropriate.

FGD Wastewater Treatment System Operation Information

Day of 

Sampling

Scrubber Purge 

Chemical Usage

(specify units)

Flow Rate

(gpm) Duration Lime

Ferric 

Chloride

Organo-sulfide

_________

(specify product)

Polymer:

_________

(specify product)

Acid:

_________

(specify product)

1

2

3

4

Volume of equalization tank: ________________

Volume of reaction tanks: 1) ________________ 2) ________________ 3) ________________ 

Volume of clarifiers: 1) ________________ 2) ________________

Volume of first-stage bioreactors: ________________

Volume of second-stage bioreactors: ________________

Figure 3-6. Engineering Data Collection Sheet (Page 4 of 4)
3-39

EPISODE NO:

RANGE OF SAMPLE NOS:

Return completed form to:

FOR LAB USE ONLY

NAME: SHIP TO: DATE REC'D:

CITY: ATTN: REC'D BY:

STATE: CARRIER: SAMPLE CONDITION ON RECEIPT:

INDUSTRIAL CATEGORY: AIRBILL:

DATE SHIPPED:

CONFIDENTIAL (Y/N): SAMPLING OFFICE/SAMPLER:

SAMPLE 

NUMBER

SOURCE WATER (city, river, well)IN LINE PROCESSUNREATED EFFLUENT (raw wastewater)TREATED EFFLUENTOTHER (specify)

ADDITIONAL 

SAMPLE 

DESCRIPTION

PH LEVELPRESERVED (Y/N)G=GRAB / C=COMPOSITESAMPLE COLLECTION TIME / DATE

Comments:

United States

EPA Environmental Protection Agency

Washington, DC 20460

TRAFFIC REPORT P.O. BOX 1407

USEPA ENGINEERING AND ANALYSIS DIVISION ALEXANDRIA, VA 22313

SAMPLE CONTROL CENTER (703) 519-1140

INDUSTRIAL FIRM SAMPLED SHIPPING & INFORMATION

SAMPLE POINT DESCRIPTION SAMPLE ANALYSES

Eastern Research Group, Inc.

14555 Avion Parkway, Suite 200

Chantilly, VA 20151

Figure 3-7. Example Traffic Report
4-1

4. SAMPLING ACTIVITIES

This section discusses the sampling team organization, sampling preparation, and 

sampling activities.

4.1

The sampling crew will consist of a crew chief and four crew members from ERG and 

two EPA representatives. The crew chief will be responsible for all health and safety, sample 

collection, preservation, and shipping activities while at Allen. Following the sampling episode,

ERG will collate the analytical results from each laboratory and summarize and transmit this 

information in a trip report to EPA. After EPA review, the report will be forwarded to Allen for 

review.

Sampling Team Organization

4.2

On October 22, 2009, ERG and EPA conducted a site visit at Allen. The site visit and 

subsequent follow-up telephone calls to Allen representatives provided ERG and EPA the 

necessary information to prepare for the sampling episode and to create this sampling plan. 

Presampling Preparation

As part of preparing the team for the sampling episode at Allen, the ERG crew chief will 

distribute this sampling plan to each team member and ensure they are completely familiar with 

the sampling plan and the health and safety requirements specific to Allen. The crew chief will 

also give copies of this sampling plan to Allen personnel before sampling begins. 

The ERG crew chief will also coordinate the procurement and shipment of all necessary 

sampling and health and safety equipment. 

4.3

Upon arrival at Allen, the ERG crew chief, in conjunction with the EPA representatives,

will meet with Allen personnel to determine whether samples can be collected as planned at each 

of the planned sampling points. Upon confirming the methods to collect samples, the ERG crew 

chief will update the descriptions of the proposed sampling points, if necessary, in consultation 

with EPA and Allen personnel. If necessary, the crew chief will obtain additional equipment. 

The revised sampling description will include:

Field Sampling Activities

• A sampling point description and collection procedure for each sampling point;

• A list of the sample fractions to be collected at each point;

• A list of potential physical hazards (e.g., pH, temperature, and potentially 

hazardous equipment);

• A list of potential chemical hazards associated with each sampling point; and

• A list of proposed health and safety procedures. 

Prior to sampling, the ERG crew chief will notify the ERG Health and Safety 

Coordinator (HSC) of any revised sampling activity descriptions along with recommended 

revisions to the proposed health and safety procedures. Together, the crew chief and HSC will 

review the proposed health and safety procedures. The crew chief will incorporate any plant-
4-2

specific changes indicated by the HSC and receive approval for sampling from the HSC before 

proceeding with sampling activities.

All sample bottles will be labeled, collected, and preserved, according to method 

protocols. Sample fractions requiring ≤6oC preservation will be placed on ice. Sample fractions 

will then be sealed, and placed in coolers for shipment to the laboratory. The Traffic Report 

forms will be completed and placed in plastic sleeves inside the coolers. The coolers will then be 

taken to the nearest Federal Express office and shipped to the analytical laboratories. At the 

conclusion of the sampling episode, the sampling equipment will be prepared for return shipping.

4.4

This subsection summarizes Allen contacts, analytical laboratory contacts and addresses, 

and sampling team personnel and support functions.

Logistics

4.4.1 Allen Steam Station Contacts

Robert Wylie

Duke Energy Carolinas

526 S. Church Street

Charlotte, NC 28201

(704) 382-4669

Don Scruggs

Duke Energy Carolinas

Allen Steam Station

253 Plant Allen Road

Belmont, NC 28012

(704) 829-2350

4.4.2 EPA Contacts

Ron Jordan

Engineering and Analysis Division

U.S. Environmental Protection Agency

1200 Pennsylvania Avenue, NW (4303T)

Washington, D.C. 20460

(202) 566-1003

Jezebele Alicea

Engineering and Analysis Division

U.S. Environmental Protection Agency

1200 Pennsylvania Avenue, NW (4303T)

Washington, D.C. 20460

(202) 566-1755
4-3

4.4.3 Analytical Laboratories

Classicals and Metals by 200.7 and 200.8 with Collision Cell

TestAmerica, Inc.

:

4955 Yarrow Street

Arvada, CO 80002

Phone: (303) 736-0138

Contact: Elizabeth Eichelberger

Frontier GeoSciences, Inc.

Mercury and Dissolved Hexavalent Chromium:

414 Pontius Ave. North

Seattle, WA 98109

Phone: (206) 957-1428

Contact: Patrick Garcia-Strickland

4.4.4 ERG Contacts

TJ Finseth (Crew Chief)

Eastern Research Group, Inc.

14555 Avion Parkway, Suite 200

Chantilly, VA 20151

(703) 633-1698

Deborah Bartram (Work Assignment Manager)

Eastern Research Group, Inc.

14555 Avion Parkway, Suite 200

Chantilly, VA 20151

(703) 633-1669

4.4.5 Freight Forwarders

Federal Express (FedEx)

General Information (800) 463-3339

FedEx Office Print & Ship Center (5 miles from plant)

2908 Oak Lake Blvd, Suite 107 

Charlotte, NC 28208 

Hours of Operation: Mon. – Fri.: 7:30 a.m. to 9:00 p.m.

Last Express Drop-off: Mon. – Fri.: 7:30 p.m.

FedEx Express Airport Facility (6 miles from plant)

4831/4850 Express Dr 

Charlotte, NC 28208 

Hours of Operation: Mon. – Fri.: 8:30 a.m. to 9:30 p.m.

Last Express Drop-off: Mon. – Fri.: 9:30 p.m.
5-1

5. SAMPLE SHIPMENT

All sample containers will be labeled with ERG's standard address labels. All samples 

will be tracked using Traffic Report forms. Custody will be maintained by the sampling crew 

chief from sample collection until samples are delivered to Federal Express.

All samples will be packaged and shipped in accordance with Department of 

Transportation (DOT) or International Air Transport Association (IATA) regulations. The 

general IATA packaging requirements for air shipment are as follows:

• “Inner packaging must be so packed, secured or cushioned as to prevent their 

breakage or leakage and so as to control their movement within the outer 

packaging during normal conditions of transport. Cushioning material must not 

react dangerously with the contents of the inner packaging. Any leakage of the 

contents must not substantially impair the protective properties of the cushioning 

material. Unless otherwise provided in this paragraph or in the Packing 

Instructions, liquids in Classes, 3, 4, 5, 6, or 8 of Packing Groups I or II in glass or 

earthenware inner packaging, must be packaged using material capable of 

absorbing the liquid. Absorbent material must not react dangerously with the 

liquid. Absorbent material is not required...” (IATA Dangerous Goods 

Regulations, 5.0.16).

• “When filling receptacles for liquids, sufficient ullage (outage) must be left to 

ensure that neither leakage nor permanent distortion of the receptacle will occur 

as a result of an expansion of the liquid caused by temperatures likely to prevail 

during transport. Liquids must not completely fill a receptacle at a temperature of 

55°C (130°F).” (IATA Dangerous Goods Regulations, 5.0.12).

The packing and labeling procedures in the following subsections may be used for 

nonhazardous samples. Hazardous samples will be identified based on consultation with the 

hazardous shipments contact, and appropriate hazardous shipping procedures will be followed. 

Based on process considerations, samples collected at Allen will not be classified as IATA 

dangerous goods.

5.1

Samples are collected as a series of “fractions,” or bottles designated for particular 

analyses requiring the same preservation. The comprehensive water sample set consists of 

sample fractions for all pollutants listed in Section 3.2, collected as grab samples directly into the 

individual sample containers or composite samples that are transferred to individual sample 

containers using a pump-off approach.

Sample Set Preparation

5.2

All dilute samples from the plant will be packed according to the following guidelines 

(there is no limit on the amount of liquid each sample container may contain):

Sample Packing
5-2

1. Label each sample bottle. If a required preservation is not used, cross it off with 

indelible ink. Cover the label with clear tape to protect this information. Do not 

label metal sample bottles, but the outer plastic bag for each bottle instead.

2. Tighten the lid on each filled sample bottle, being careful not to overtighten the 

lid. If bottle threads are dirty to where the lid is impeded from closing, clean the 

threads on the bottle being careful to not introduce contamination into the sample. 

Clean the sample bottle with a cloth rag or paper towel. Do not clean the bottle 

threads for the metals sample bottles.

3. Prior to packaging, place each sample bottle requiring ≤6°C preservation into an 

ice chest with wet ice to cool.

4. When each sample requiring ≤6°C preservation has reached the desired 

temperature, wrap each glass sample bottle with two layers of “bubble wrap” (or 

place bottle in two “bubble bags”). The bubble wrap must fit snugly and 

completely cover the sample bottle. Enclose each “bubble-wrapped” container 

and plastic container in an individual sealable plastic freezer bag. Place VOA 

vials in VOA bricks in a freezer bag.

5. Place two garbage bags inside each other in the cooler.

6. Place sample bottles in garbage bags in the cooler with proper end up, close the 

interior garbage bag by tying or with a twist-tie.

7. Add ice to cooler to keep samples cold during shipment. Arrange blue ice or 

sealed plastic freezer bags filled with wet ice on top of the sample bottles (if 

samples require ≤6°C preservation). If using wet ice, place the ice inside two onegallon sealable freezer bags. Put at least 4 × 1⁄2 gallons of ice (4 × 2.5 pounds of 

ice) in each large cooler and 2 × 1⁄2 gallons of ice (2 × 2.5 pounds of ice) in each 

small cooler. Use more ice when ambient temperatures are very high. Place the 

ice inside the second garbage bag and close the second garbage bag with a twisttie.

8. Fill in around the bottles and any free space with additional cushioning material. 

Use sufficient packing material so that the sample containers will not shift during 

shipment. 

9. Seal the Traffic Report form in a plastic zip-lock bag and tape it securely to the 

inside of the cooler lid.

10. Place a "Return to ..." label on the inside of the cooler lid.

11. Close cooler.

12. Make several wraps with tape around the cooler perpendicular to the seal to 

ensure that the lid will remain closed if the latch is accidentally released or 

damaged.
5-3

13. Tape the cooler drain plug so it will not open.

14. Place a completed address label on the lid of the cooler including name, address, 

and telephone number of the receiving laboratory and the return address and 

telephone number of the shipper.
6-1

6. SITE-SPECIFIC HEALTH AND SAFETY PROCEDURES

This section specifies the health and safety procedures and practices to be used by the 

sampling team during sampling at Allen. This section provides general health and safety 

information for this sampling episode. The sampling team is obligated to follow all safety

procedures specified in this section.

6.1

The following procedures will be followed in the event of a medical or other emergency 

situation. 

Emergency/Medical Procedures

6.1.1 First Aid

Allen has first aid kits available throughout the plant. In addition, ERG will also bring a 

first aid kit. Plant personnel stated that the plant’s first responder team would be available to 

ERG/EPA personnel, if needed. 

6.1.2 Site Evacuation/Emergency Response Plan

The sampling team will be informed of the Allen evacuation procedures and routes by 

plant personnel. 

6.1.3 Emergency Showers and Eye Washes

Emergency showers and eye wash stations are located throughout the plant. Before 

collecting samples at any point, sampling team members will locate the nearest operating safety 

shower and eye wash station.

6.1.4 Local Hospital

The nearest hospital is Gaston Memorial Hospital, located in Gastonia, NC, and is 

approximately 12 miles from Allen Steam Station. The hospital address is:

Gaston Memorial Hospital

2525 Court Drive

Gastonia, NC 28054

The local emergency phone number in Belmont, NC is 911.

6.2

The ERG Work Assignment Manager (WAM), crew chief, and sampling team members 

have different responsibilities to maintain a safe sampling environment. These responsibilities 

are described below.

ERG Health and Safety Responsibilities and Authority
6-2

6.2.1 Work Assignment Manager

The ERG WAM, Deborah Bartram, has the overall responsibility to ensure that these

health and safety procedures are developed and implemented in accordance with regulations and 

corporate guidelines, that proper health and safety procedures have been initiated, and that all 

ERG activities are conducted in accordance with the health and safety plan. The ERG WAM will 

also ensure that proper resources are allocated so that the project is conducted in a safe manner, 

and that the crew chief is competent in his ability to oversee health and safety during the 

sampling episode.

6.2.2 Crew Chief

The ERG crew chief, TJ Finseth, is responsible for ensuring that ERG sampling team 

members adhere to this plan. The ERG crew chief and ERG night crew chief are responsible for 

overseeing all activities. The crew chiefs must report any accident, near miss, or injury to any 

sampling team member to the ERG Chantilly Office Health and Safety Coordinator (HSC), 

Kevin Sikora, verbally within eight hours, or sooner. The HSC will investigate the incident to 

identify the cause of the accident, near miss, or injury. If sufficient cause exists, ERG’s general 

health and safety plan and in-house training program will be modified to avoid similar accidents 

in the future.

At the start of the sampling visit, the crew chiefs will inspect all sampling points and 

review sample collection procedures with the Allen personnel to ensure that all potential hazards 

have been identified.

The crew chiefs have the authority to enforce ERG’s health and safety requirements 

contained in this plan, and any facility-specific requirements. Changes to this plan can be made if 

the crew chiefs, the Chantilly HSC, and EPA representative agree that the changes are 

appropriate.

6.2.3 Sampling Team Members

All field personnel are responsible for following the requirements of this plan, adhering 

to plant-specific health and safety procedures, and donning required/recommended personal 

protective equipment (PPE). They are also responsible for bringing health and safety issues to 

the attention of the crew chiefs.

6.3

ERG sampling team personnel will attend on- and off-site health and safety briefings.

Briefings

6.3.1 Off-Site Briefings

Prior to arriving on site, all members of the sampling team will receive a copy of this 

sampling plan and attend a presampling meeting to review the sampling plan and the proposed 

sample collection activities. All ERG employees will be required to sign a health and safety signoff sheet stating that they have read, understood, and agree with this health and safety plan prior 

to participating in field sampling activities.
6-3

6.3.2 On-Site Briefings

ERG sampling team personnel must attend a one- to two-hour safety course given by 

Allen personnel prior to conducting sampling activities at Allen. This safety course will review 

plant-specific health and safety procedures, including:

• Locating on-site first aid/emergency medical procedures;

• Required PPE;

• High hazard areas and other specific areas or hazards of concern;

• Emergency alarms and evacuation procedures; and 

• Other site safety requirements and procedures that ERG personnel must follow.

6.4

ERG personnel will follow general safety procedures, which include wearing PPE and 

engaging in safe work practices.

Safety Procedures

6.4.1 Personal Protective Equipment (PPE)

The PPE listed below will be worn by ERG personnel at all times while inside the 

premises of Allen:

• Steel-toed safety shoes;

• Long sleeves (when sampling) and pants;

• Hard hat, where required by Allen;

• Hearing protection, where needed;

• Nitrile or noncolored, electronic grade gloves, when collecting or preserving; and

• Safety glasses with side shields or chemical splash goggles, when collecting or 

preserving samples.

For all phases of sample collection, disposal PPE will be used, so decontamination of the 

PPE may not be necessary. If gloves become torn or degraded, they will be thrown away and 

replaced with a new pair. Disposable PPE, including gloves, will be removed, bagged, and left at 

the site in a controlled manner.

6.4.2 Safety Practices

ERG personnel will conduct themselves at all times in a manner judged to be safe by site 

supervisors. 

All sample collection will be scheduled so that no ERG employee collects samples alone. 

Each worker will maintain visual contact with at least one other worker at all times. This buddy 

system will ensure against an employee becoming injured or contaminated with chemicals 

without a coworker being aware of his or her condition. Workers should “watch out” for each 

other while working close to potential chemical and physical hazards. An Allen or EPA 

employee may be used as a buddy by ERG personnel. This arrangement will be agreed to and 

acknowledged by the employee. 
6-4

ERG employees will not enter any permit-required confined space areas. 

6.4.3 Safe Work Practices

ERG samplers will obey the following safety rules while working in the facility:

• Wearing PPE, where required;

• Staying within designated areas;

• Not wearing loose clothing or jewelry; 

• Keeping long hair in hard hat or tied back; 

• Not eating in the sampling or staging areas; and

• Not smoking in the sampling or staging areas.

6.5

All sampling team members will be advised of any sampling-point-specific safety 

protocols during the on-site health and safety briefing. Table 6-1 summarizes all potential 

sampling-point-specific safety hazards as well as the PPE required at each sampling point. 

During the day shift, the sampling team health and safety officer (HSO) for this sampling 

episode is the crew chief, TJ Finseth (ERG). During the night shift, the HSO for this sampling 

episode is the ERG night crew chief (to be determined at a later date). The HSO and the 

sampling team will inspect each sampling point area to identify unique or additional hazards not 

already covered in this plan or during the formal health and safety briefing. If additional hazards 

are found, the sampling team will be informed of each hazard and required control measures 

prior to the start of work. Where identified hazards may affect the plant’s personnel, the HSO 

will notify the appropriate Allen personnel.

Sampling-Point-Specific Safety Procedures

6.5.1 Physical Hazards

ERG personnel will be alert for all physical hazards present while on site. Physical 

hazards may arise from using catwalks, hitting low-hanging overhead piping, and working 

around moving equipment or vehicles. ERG personnel will be aware of the potential splash 

hazards at SP-1, SP-2, and SP-3 due to the location of the sample taps. To prevent splashing, 

ERG personnel will ensure that the sample tubing is connected securely to the sample tap and 

will open the sample valve slowly when collecting samples. Other potential hazards may include 

falling hazards during sample collection, tripping on metal grates, or operation of large trucks 

and machinery in the vicinity of the sample collection area. See Table 6-1 for potential hazards 

that may be associated with specific sampling points.

Noise may be a hazard in certain areas of the facility. The sampling team will use hearing 

protection where required by the plant, when they are having trouble hearing or being heard 

when standing three feet or less away from another person, or when deemed necessary by the 

Allen personnel or ERG crew chief. 

6.5.2 Thermal Hazards

Heat stress may be a concern during the sampling episode. Samplers may be suited in 

Tyvek® and temperatures could reach extremes. Of particular concern is SP-1, which is located 
6-5

outside. The sampling team members will consume plenty of fluids prior to the start of sampling, 

and will monitor each other for symptoms of heat stress. 

Wastewater sampling points are not expected to be too hot for safe handling using typical 

PPE. Thicker nitrile gloves may be used during sampling if sample bottles are too hot to hold. 

Samplers will handle extremely hot samples with heat-resistant gloves.

6.5.3 Chemical Hazards

The only chemical hazards expected are chemicals used to preserve samples. All 

sampling team members will be advised of any potential chemical hazards at each sampling 

point as well as any special PPE recommendations during the formal health and safety briefing. 

If the sample tap (i.e., the point from which the wastewater flows) is above waist height, a face 

shield or goggles must be worn during sample collection. To avoid ingesting chemicals, 

sampling team members will be required to wash hands thoroughly before eating or drinking. 

ERG personnel will not be permitted to enter areas where the facility has determined that 

respiratory protection equipment is necessary to protect against inhalation hazards. 

6.6

Extremely hot temperatures can be a health and safety hazard for this sampling episode. 

ERG personnel will take precautions to avoid injuries due to extreme temperatures.

Temperature Extremes

6.6.1 Heat Stress

Heat stress is not only a concern in hot/humid outdoor environments, it is a concern due 

to the thermal or radiant heat generated by equipment and/or processes. Sampling team personnel 

will monitor each other for the following symptoms:

• Heat rash that may result from continuous exposure to heat or humid air. 

Treatment: Wear cotton clothing under coveralls or Tyvek®.

• Heat cramps that are caused by heavy sweating and inadequate electrolyte 

replacement. Many times, cramps may not occur until after work or until the 

worker is sleeping. Signs and symptoms include muscle spasms and pain in the 

hands, feet, and abdomen:

Treatment: Gently stretch and massage muscles and replace fluids. Have worker 

rest in a cool shaded area.

• Heat exhaustion that occurs from increased stress on various body organs 

including inadequate blood circulation due to cardiovascular insufficiency or 

dehydration. Signs and symptoms include:

— Pale, cool, moist, clammy skin

— Heavy sweating

— Headache and dizziness

— Nausea
6-6

— Fainting or fatigue

— Elevated pulse rate (above 150)

Treatment: Replace fluids, pour cool water over face, neck, hands, arms, and legs. 

Place worker in cool air and seek medical care.

• Heat stroke is the most serious form of heat stress. Temperature regulation fails 

and the body temperature rises to critical levels. Immediate action must be taken 

to cool the body before serious injury and death occur. Competent medical help 

must be obtained. Signs and symptoms are:

— Red, hot, usually dry skin, body core temperature 108°F (oral)

— Lack of or reduced perspiration

— Nausea

— Headache, dizziness, and confusion

— Strong, rapid pulse

— Coma

Treatment: Remove worker to cool area, saturate clothes with cold water, wrap 

worker in wet cold sheets (if possible), monitor ABC (airway, breathing, 

circulation), treat for shock, and call emergency services for basic life support 

(BLS) or advanced life support (ALS).

6.6.2 Heat Stress Monitoring

A worker who exhibits any of the above symptoms will be immediately relieved of 

responsibilities and requested to consume electrolyte fluid or cool water while resting in a shaded 

area. The individual should not return to work until symptoms are no longer recognizable. If 

symptoms appear critical, persist, or get worse, the crew chief will seek immediate medical 

attention for the employee. If the individual does resume work, he/she will be monitored for any 

increase in heart rate for the remainder of his/her shift. In addition, the worker will be requested 

to consume electrolyte fluid or cool water every hour.

The crew chief will visually monitor workers hourly when:

• Symptoms of heat stress are reported or observed;

• Ambient temperatures exceed 70°F and workers are dressed in impervious 

clothing; or

• Ambient temperatures exceed 90°F and workers are dressed in normal clothing.

For sampling on this project, work periods will be considered to be approximately two 

hours in length.

At ambient temperatures of 87°F and above, workers will be monitored for heat stress 

conditions by measuring the heart rate (HR) by radial (wrist) pulse for 30 seconds after one 

minute of rest. The HR after one minute of rest should not exceed 110 beats per minute. If the 
6-7

heart beat is higher, the next work period will be shortened by 33 percent, while the length of rest 

period remains the same. If the pulse rate is still higher than 110 beats per minute after one 

minute of rest in the next rest period, the following work cycle will be shortened by another 33 

percent. This shortening of the work period must continue until the worker's HR is no greater 

than 110 beats per minute.

6.7

First aid procedures in response to chemical exposures will be conducted in accordance 

with the appropriate MSDS for the chemical involved. If an incident occurs and MSDSs are not 

available for a particular hazardous chemical (e.g., wastewater), the following general first aid 

procedures will be performed:

First Aid

• Skin Contact – Rinse the affected area thoroughly and copiously with clean water. 

Seek medical attention if irritation is experienced after cleaning.

• Eye Contact – Flush the eyes thoroughly at the nearest eyewash station for 15 

minutes. Follow up with medical attention.

• Ingestion – Notify the hospital and carry out any procedures recommended. 

The first aid kit will be maintained on each site in the equipment staging area. The 

contents of the first aid kit will include at a minimum:

• Adhesive bandages;

• Antiseptic wipes;

• A compress;

• An eyewash solution;

• Gauze pads;

• A cold pack; and 

• A triangular bandage.

The injuries most likely to be encountered at Allen are cuts and bruises; the first aid kit 

will be maintained and stocked accordingly.

6.8

Water samples to be analyzed for various contaminants may be preserved with sulfuric 

acid (H2SO4), hydrochloric acid (HCl), sodium hydroxide (NaOH), an ammonium sulfate buffer 

solution (NH4SO4), and/or sodium arsenite (NaAsO2) before shipment to the analytical 

laboratory. Nitrile gloves and splash goggles must be worn when handling these corrosive 

chemicals to prevent chemical burns. Sample preservation must be performed in a wellventilated area (preferably an operational lab hood) to avoid potential accumulation and 

inhalation of any toxic vapors. When pouring samples, skin protection must also be worn (longsleeved cotton coveralls or uncoated Tyvek®, safety glasses with side shields or splash goggles, 

and nitrile gloves). Sodium arsenite is a known carcinogen and toxic so extra care should be 

taken when handling any solutions containing sodium arsenite.

Sample Preservation and Safety Considerations
6-8

In some instances, the use of these preservation chemicals could create a chemical 

reaction (i.e., generation of heat or release of toxic vapors). For instance, if acids are added to a 

wastewater sample containing cyanide or sulfides, dangerous and toxic vapors will be emitted. If 

the sample reacts violently, notify the crew chief and stop preserving the sample immediately.

In the case of a chemical spill, the following procedures must be followed:

• Don protective clothing (nitrile gloves as a minimum).

• Ventilate area (open doors, windows, or turn on ventilation).

• Use spill control pillows or prepared neutralizers to contain/clean up spill. Do not 

add water to acid.

• Place spilled material in a heavy plastic container, label the container, and contact 

site for disposal information.

• Notify the crew chief of the spill and the procedures used.

At any time, if personnel do not feel comfortable about cleaning up the spilled material or 

if a large quantity has been spilled, notify site personnel. The site may have an emergency 

response team who will respond to the chemical spill. 

In the case of fire, notify the site contact. If the fire can be easily extinguished using a 

portable fire extinguisher, and personnel have received fire extinguisher training, extinguish the 

fire using the portable extinguisher.

6.9

All ERG sampling crew personnel have participated in ERG's annual eight-hour health 

and safety training program as specified by ERG's Corporate Health and Safety Policy. 

Training and Medical Monitoring Requirements

This training includes:

• Toxicology;

• Exposure limits;

• Chemical, biological, and physical hazards;

• Heat and cold stress;

• Confined spaces;

• PPE;

• Decontamination; and

• Emergency plans and procedures.

All ERG personnel involved with sample collection and preservation are active 

participants in the Medical Monitoring Program. Field sampling personnel have received a 

baseline medical information review.
6-9

6.10

This subsection provides guidance for field personnel project schedules and field work, 

particularly overtime. It is important to remember extended work schedules will contribute to 

poor production and motivation. All field teams will rotate to ensure that sampling team 

members receive sufficient rest to avoid injuries resulting from fatigue or inattention.

Shift Work Protocol

It is common practice to perform 12-hour work days under project management direction. 

If this work schedule is exceeded, the following guidelines will be recognized:

1. A maximum work day will be 15 hours, provided that it does not occur on 

consecutive days, or more than three times in ANY SEVEN-DAY PERIOD.

2. Each shift will be followed by nine hours off per 24-hour period, excluding 

driving time to and from the hotel.

3. No more than seven consecutive days of work will be allowed without a 

minimum of 24 hours off.

4. Each work day will be reviewed as a 24-hour cycle to assure all field workers 

receive adequate time off.
6-10

Table 6-1. Sample-Point-Specific PPE and Potential Hazards

Sampling 

Point Number Sampling Point Description PPE Required a Potential Physical Hazards b

SP-1 Influent to FGD Wastewater 

Treatment System

Steel-toed boots, hard hats, 

gloves and safety glasses

Splash hazard: Potential for 

splashing from the sample tap. 

Sample tap will be below waist 

level.

SP-2/SP-4 Influent to Bioreactor System Steel-toed boots, hard hats, 

gloves, and safety glasses

Splash hazard: Potential for

splashing from the sample tap. 

Sample tap will be below waist 

level.

SP-3/SP-5 Effluent from Bioreactor System Steel-toed boots, hard hats, 

gloves, and safety glasses

Splash hazard: Potential for 

splashing from the sample tap. 

Sample tap will be below waist 

level.

a – Splash protection (face shield) required if sampling port is waist high or above. Hearing protection (ear plugs) 

will be worn if needed.

b – Additional physical hazards, if any, will be identified during the formal on-site health and safety briefing. 

Updates to this table will be made as needed.
7-1

7. REFERENCES

1. Eastern Research Group, Inc. 2009. Generic Sampling and Analysis Plan for Coal-Fired 

Steam Electric Power Plants. (February).

2. U.S. EPA. 2009. Steam Electric Power Generating Point Source Category: Final 

Detailed Study Report. EPA 821-R-09-008. Washington, DC. (October). Available online 

at: http://www.epa.gov/guide/steam/finalreport.pdf. DCN SE00003.