DRC-2009-004582 - 0901a0688014310f

Page 1 of 1
Dave Rupp - Cell 1 Liner Repair 5t6-5^^/^!i/5^>
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From: Steve Landau <[e-mail]>
To: "D^^[e-mail]" <[e-mail]>
Date: 6/26/2009 4:22 PM
Subject: Cell 1 Liner Repair
CC: Dave Rupp <[e-mail]>, Harold Roberts <HRoberts@denison,mines.com>, David Frydenlund
<[e-mail]>
Attachments: Scan0014173.PDF
Dear Mr. Finerfrock,
Please find attached the Liner Repair Report documenting the repairs that were made and the testing that was conducted in.
relation to Cell 1 liner damage that was "Noticed" to the Division on 5-19-09. The document has been prepared in "text
searchable" format as per the regulations.
If you should have any questions regarding this Report, please contact either Harold Roberts or me. A hard copy of thisreport
will be transmitted via regular mail as well.
Yours Truly,
Steven D. Landau
Steve Landau
Manager. Environmental Affairs
t: [phone] | f: [phone]
1050 17th Street, Suite 950, Denver, CO 80265
DENISON MINES (USA) CORP
www.denisonmines.com
Ttiis e-mail is intended for exclusive use the person(s) mentioned as the recipient(s). This message and any attached files v^ith it are confidential and may contain privileged or
proprietary information. If you are not the intended recipient(s) please delete this message and notify the sender. You may not use, distribute print or copy this message if you are not
the intended recipient(s).
file://C:\Documents and Settings\Drupp\Local Settings\Temp\XPgrpwise\4A44F5D3EQDOMAINEQRA... ,7/20/2009
Memorandum
To: Steve Landau
From: Harold R. Roberts, P.E.
Date: June 25, 2009
Re: Cell 1 Liner Repairs
cc:
Denison MinH (USA) Corp.
1050 17th St ...... Suite 950
Denver. CO 80285
USA
Tel: [phone]
Fax: 303 311"125
denisonmln.s.com
On June 10 and 11, 2009 I visited the White mesa Mill site for the purpose of observing the repair activity on the
PVC lining material in the Cell 1 Evaporation Pond. The area of damage was along the east side of the Cell,
toward the northeast corner, and above the solution level of the Cell. The liner damage was caused by a
sudden, unexpected flow of water during routine maintenance on one of the tailings pipelines. The flow of
solution washed the soil cover off the liner and damaged the liner such that the underlying soil was eroded,
resulting in further damage to the liner.
An area of liner approximately 15 feet by 50 feet was totally replaced after the foundation materials were
replaced and compacted into place. The liner was replaced with 30 mil PVC roll stock supplied by Colorado
Lining, Inc. In order to reduce the amount of field seam the liner was replaced entirely in to the anchor trench
along the area of damage.
Prior to placement of the new lining material, the soil surface was compacted and swept clean of any protruding
rocks that might damage the lining material. Prior to seaming, the lining material was cleaned with methyl ethyl
ketone (MEK) as recommended by Colorado Lining, Inc. The liner was then seamed using an adhesive
supplied by Colorado Lining, Inc. The repaired seams were then 100% vacuum box tested according to the
procedures in the attached report. Testing results are included in the attached daily reports of the repair
activities. The final repair activities involved the replacement of the soil cover in order to protect the lining
material from exposure to UV degradation.
During my 2 day site visit I personally witnessed foundation preparation activities, liner placement, cleaning and
seaming of the liner, and vacuum box testing of the repaired seams. I also reviewed the records and
documentation of the work beginning on June 5, 2009. Photo documentation is included for each day's
activities. Weather conditions and repair activities for each day are documented in the daily reports. All of the
work was being performed in good workman like manner, and the repairs I observed were completed in
accordance with industry standard practices. The vacuum box testing was being conducted in accordance with
the manufactures recommendations and in general agreement the ASTM D 5641. The regulated pressure to
the vacuum box was maintained at 15 psig during the test process and vacuum pressure within the box was
recorded in inches of mercury, thus documenting the integrity of the seam. Photos taken on the days of my
inspection are attached to this memorandum.
The attached report documents the repairs in accordance with the White Mesa Mill's Discharge Minimization
Plan, revision 06, dated September 2008, and more specifically the procedure "Liner Maintenance Provisions-
Cells 1, 2, 3 and Roberts Pond", da2
~Harold R. Roberts, Utah Registered Professional Engineer No. 165838
Maintenance
Evaporation Cell #1
~ The Success'ful Completion of Cell #1 was taken place
on 12th of June 2009.
}> Proper Training and detailed explanation of the repairs
conducted were evaluated and documented.
~ Date, Time and Weather conditions were recorded.
Maintenance Department
Evaporation Cell # 1
IN THIS SECTION:
~ Repairs
~ Repair Report
~ Inspections
~ Training
'.
Inspections
Revision: O-Original
Approved: October 6, 2008
Liner Maintenance Provisions-Cells I, 2, 3 and Roberts Pond
Tailings cells 1. 2, and 3 are the subject of comprehensive daily inspections which are
conducted by either the Environmen1lll Technician or the Radiation TeChnician, as well
as once per shift Daily Operations Inspections which are conducted by the Mill Shift
Foreman or other trained personnel designated by the Shift Foreman. The details of these
daily inspections are outlined in Sections 2.1 and 2.2 of the White Mesa Mill Tailings
Management System and Discharge Minimization Technology (OMT) Monitoring Plan.
In each case, these inspections are recorded on inspection forms (Daily Inspection Data
Form and Operating Foreman 's Daily Inspection Form, respectively). In addition, non-
recorded Daily Operations Patrols are conducted twice per shift by operations personnel.
With regard to Roberts Pond, this facility is observed on a weekly basis when the
Environmental or Radiation Technician visits the facility for the recording of water levels
al that location.
Training
All individuals performing inspections described in Sections 2.1 and 2.2 of the DMT
Monitoring Plan must have Tailings Management System Training as described in
Appendix C to the OMT Monitoring Plan (Tailings Inspection Training). A$ and element
of the "Operational Systems" inspection. inspectors are trained and required to observe
the conditions of the PVC liner. Because the PVC liners in Tailings Cells I, 2 and 3 are
sensitive to sunlight and can degrade as It result of prolonged exposure. inspectors are
cautioned to observe any situation where the liner is exposed. These exposure situations
are considered serious and require immediate attention. Inspectors are trained to cover
small areas of exposure immediately. whereas, larger areas are reported to the radiation
Safety Officer to prompt the issuance of a work order to the Maintenance Departl'\lent. In
keeping with this inspection requirement, inspectors are trained to observe any
degradation of exposed liners. Such degradation can be that caused by exposure to
sunlight, abrasion due to erosive wave action andlor any rips or tears in the liner material.
Given the fact that the liner material is provided with an earthen cover, erosive damage
and/or rips and tears are unlikely. Inspectors are trained to reeord all obser"lltions of
liner exposure or disrepair on the inspection report, as well as the date and nature of any
repair activity.
Roberts Pond is lined with Hi Density Polyethylene (HOPE) material which is not
sensitive to sun damage and, as such. is not covered with earthen material. In this case
the inspector observes the conditions of the liner to the extent that visual observation is
possible (i.e. above the water level and any visually observable near surtiM:e condition).
As is the case for the tailing cell inspections, the liner will be observed for any abrasion
due to erosive wave action andlor any rips or tears in the liner material.
1
Revision: O-OriginaJ
Approved: October 6, 2008
(. Repairs
(
Repairs to PVC liners in Cells I, 2 and 2 and to the HDPE liner in Roberts Pond are made
on a case by case basis and usually involves the installation of a repair patch over the
damaged location. PVC patches require the use of glues or adhesive solvents to fuse the
patch to the repair location. HDPE repairs are accomplished by use of an extrusion
weIdc:r. Subsequent to any repair of a liner, the repair location will be tested using a
"vacuum box" and soapy water to assure that the repair is acceptable. The observation of
bubbles through the repair seam while vacuum is being applied to the seam constitutes
seam failure and the repair must be redone until all seams are acceptable. In the case of
Cells I, 2, and 3, after a patch has been applied, the repair location must be covered with
earthen material, again to avoid exposure to sunlight. Adequate supplies of PVC and
HDPE liner material, repair material and vacuum lest equipment ate maintained either in
the Mill warehouse or the maintenance depeibne4t. The continued aV811ability of these
supplies will be verified as an element of the Quarterly Tailings Inspection conducted by
the Radiation Safety Officer or his designee.
Any leak, hole or other damage to the liners in Cells I, 2, 3 and the Roberts Pond will be
reported orally to the Executive Secretary within 24 hours of the discovery and in writing
within 5 days of the discovery. The oral and written notifications will include a
notification and description of the failure in accordance with Part 1.G.3.(a) of the GWDP
and be in accordance with R317.6-6.16.C(I) of the regulations. In addition to the
descriptive information about the failure, a plan and schedule for the FML repair will be
included with the notification to the Executive Secretary (in accordance with Part
I.GJ.(c) of the Permit).
Repair Report
Each report will be signed by a Utah licensed professional engineer and will address the
following elements as they apply to the case·by-case repairs which are implemented:
• Repair narrative describing the nature of the damage and the repair work
completed to repair the damage.
• Repair material type used to complete the repair
• Repair material description
• Post repairs test specifications
• Test Methods (ASTM or other)
• Daily reports during the repair work
• Repair test results
• Quality Assurance/Quality Control Information
2
~
OPERATION OF TSP VACUUM LEAK TESTING
BOX
L \\.'~ar Saict~ '.tla~Xl·S
2. Install Yo"(enclosed) ball valve
3. Remove paper masking from top of Vacuum Box.
4. Connect 40 to 60 Ibs of air to quick coupler, (Yo" Hose is ideal for this procedure).
5. Be sure surface to be tested is reasonably smooth and clean.
6. Apply diluted ~I..eak Test Concentrate" solution to weld to be tested.
7. Place box over area to be tested. press down and tum on air at ball valve. 10 seconds of
Vacuum is enough time to reveal bubbles in area tested. Do not exceed I S inches (Ibs) of
Hg. Tum off vacuum and move to next area to be tested.
8. Do not stand near evacuator exhaust
9. Store Vacuum box on clean flat surface (shipping container) so gasket will not be damaged
10. Clean glass with solution of dishwashing detergent and rinse with clear clean water. Dry
II. with soft cloth to prevent scratching
12. To obtain replacement gaskets call 1·800-734-9266 or email: [e-mail]
J J. 11 is the r~sponsibilily of the U3er to establish appropria/e safety and health practice., and
determine the application ofregula/Qry limitations prior to U3t
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Maintenance
Evaporation Cell #1
IN THIS SECTION:
» Job Site
» Earth Work
» Liner
» Wrap-up
Cell #1 Repairs
June 5th of 2009.
7am-2pm.
Personnel: Devin, Kendall, Johnson, Kenneth and Casey.
Please read: Small Brief and training on all Personnel working on the tailings pond.
Weather: 66 degrees F. 7:35am.
Cell # 1
Material: PVC liner, PVC to PVC adhesive, MEK(Cleaner), Wire brush and paint brushes.
8:00 a.m. -10:00 a.m. Job site.
10am.-noon.
noon -lpm.
1:00 p.m. -2:00 p.m.
Additional Information:
Repair work need's done do to extreme tares on the
liner. 35'x18' section is exposed and replacement of old
liner will be repaired. We have 1500 sq.ft. of liner and
10 gal. of PVC to PVC adhesive. I did a small training
on Devin Mitchell and Kendall Benally on how to repair
liner. We also have a vacuum box that will check joints
for potential leaks. Re routed Pond Return line and
Shortened old tails line in order to perform work.
Earth Work.
Removed a section of the old liner. Graded and
removed any potential obstruction that would damage
liner. Compacted and smoothed area being lined.
Liner.
Cleaned old liner with MEK (Methyl Ethyl Ketone),
Ruffed up 8"-12" of the existing liner in order create a
bond with the new liner. Using new PVC liner and PVC
to PVC adhesive. We were able to glue the upper
section of the liner. We will conduct a Vacuum box test
after section of liner is cured.
Ryan Palmer came out and visited and took pictures of
the area being worked on. Spoke to him what we got
done and said we will continue Monday.
Wrap-up
The weather did not permit us to work on the liner do
to high winds. Covered the area and will begin on the
project on Monday 8th of June. 2009.
We were able to glue the first upper section of the liner. Due to high winds we were not able to set the first
section of liner. We will continue to make repairs Monday 8'" of June. 2009.
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Maintenance
Evaporation Cell #1
IN THIS SECTION:
» Job Site
» Earth Work
» Liner
» Wrap-up
Cell #1 Repairs
June 8th of 2009.
7am-3:30pm.
Personnel: Devin, Kendall and Johnson.
Please read: Small Brief and training on all Personnel working on the tailings pond.
Weather: 60 degrees F. 7:35am.
Cell # 1
Material: PVC liner, PVC to PVC adhesive, MEK(Cleaner), Wire brush and paint brushes.
7:00 a.m. -10:00 a.m. Job site.
10am.-noon.
noon-1pm.
1:00 p.m. -2:00 p.m.
Additional Information:
Repair work was conducted today. The Maintenance
department was able to get 2 sections of PVC liner
glued down.
Earth Work.
Removed a section of the old liner. Graded and
removed any potential obstruction that would damage
liner. Added 2nd liner and glued the north, east and
west side of liners.
Liner.
Cleaned old liner with MEK (Methyl Ethyl Ketone),
Ruffed up 8"-12" of the existing liner in order create a
bond with the new liner. Using new PVC liner and PVC
to PVC adhesive. We were able to glue the upper
section of the liner. We will conduct a Vacuum box test
after section of liner is cured.
David Turk went to the site.
Wrap-up
There were some winds from the south at about 5mph.
Pictures were taken on the finished 2nd PVC liner
section. We made 14 tests not to exceed 15psl on the
Pressure regulator. All tests passed using a small
amount of soap water. Test: 1) 2Hg. 2) 5Hg. 3) 4Hg. 4)
2Hg. 5) 2Hg. 6) 2Hg. 7) 2 Hg. 8) 4Hg. 9) 4Hg. 10) 5Hg.
11) 4Hg. 12) 2Hg. 13) 4Hg. 14) 4Hg.
We were able glue all 4 sides of the first liner section. We also glued the west and east of the 2nd section of
liners.
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Maintenance
Evaporation Cell #1
IN THIS SECTION:
» Job Site
» Earth Work
» liner
» Wrap-up
Cell #1 Repairs
June 9th of 2009.
7am-3:30pm.
Personnel:
Please read:
Weather:
Devin, Kendall, Casey and Johnson.
N/A
54 degrees F. 7:35am.
Cell # 1
Material: PVC liner, PVC to PVC adhesive, MEK(Cleaner}, Wire brush and paint brushes.
7:00 a.m. -10:00 a.m. Job site.
10am.-noon.
noon -1pm.
1:00 p.m. -3:30 p.m.
Additional Information:
Repair work was conducted today. The Maintenance
department was able to get 3 sections of PVC liner
glued down.
Earth Work.
Removed a section of the old liner. Graded and
removed any potential obstruction that would damage
liner. Added 3rd, 4th and 5th liners.
Liner.
Cleaned old liner with MEK (Methyl Ethyl Ketone),
Ruffed up 8"-12" of the existing liner in order create a
bond with the new liner. Using new PVC liner and PVC
to PVC adhesive. We were able to glue the upper
section of the liner. We will conduct a Vacuum box test
after section of liner is cured.
David Turk went to the site.
Wrap-up
It started to rain at about 1 :30pm had stop progress for
a while and then continued. Pictures were taken by
Wade Hancock on the finished PVC liner sections. We
made 2 tests not to exceed 15psi. All tests passed using
a small amount of soap water. Test: 1) 4Hg. 2) 5 Hg.
We were able to glue all the sides of the 3'd and 4th liner and the 5th on all three Sides.
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Maintenance
Evaporation Cell #1
IN THIS SECTION:
» Job Site
}o> Earth Work
}o> Liner
» Wrap-up
Cell #1 Repairs
June 10th of 2009.
7am-3:30pm.
Personnel: Devin, Kendall, Casey and Johnson.
Please read: N/ A
Weather: 47 degrees F. 7am.
Cell # 1
Material: PVC liner, PVC to PVC adhesive, MEK(Cleaner), Sand bags, Wire brush and paint brushes.
8:30 a.m. -10:00 a.m. Job site.
10am.-noon.
noon -2pm.
2:00 p.m. -3:30 p.m.
Additional Infonnation:
We had some light showers last night and this
moming. We will continue to make repairs on the liner.
Earth Work.
The maintenance department will dig back towards the
East and replace the liner going into the trench. We
come to point where the break or crack of the liner has
stopped on the south side.
Liner.
Did not lay any liner down. The maintenance
department mainly concentrated on removing dirt and
grading the surface for preparation of the liner. Mr.
Bartlett, Mr. Roberts and Mr. Turk were at the site.
Wrap-up
No tests were conducted. Found the end of the break of
the liner. We will continue to uncover the existing liner
and prep the area to lay new PVC liner.
We started at 8:30am. It was a little cool and we had some moisture that morning.
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Maintenance
Evaporation Cell #1
IN THIS SECTION:
> Job Site
> EarthWork
> Liner
> Wrap-up
Cell #1 Repairs
June 11th of 2009.
7am-3:30pm.
Personnel: Devin, Kendall, Casey and Johnson.
Please read: Nt A
Weather: 55 degrees F. 7am.
Cell # 1
Material: PVC liner, PVC to PVC adhesive, MEK(Cleaner), Sand bags, Wire brush and paint brushes.
7:30 a.m. -10:00 a.m. Job site.
10am.-noon.
noon-2pm.
2:00 p.m. -3:30 p.m.
Additional Information:
Continued with repairs. Uttle sunny and cool.
Earth Work.
Graded and cleaned up the last area. Dug the rest of
the trench.
Liner.
Set the rest of the liners. aeaned and glued them
down.
Wrap-up
It stayed sunny throughout the day. Finished adding all
the liners and conducted 55 tests. #3 Liner Bottom: 1)
3Hg.2)3Hg.3)3Hg. Top: 4)3Hg. 5) 3Hg. 6) 3Hg.Top
to Bottom: 7) 3Hg. 8) 3 Hg. 9) 3 Hg. 10) 3Hg. 11) 3Hg.
12) 3 Hg. 13) 3 Hg. 14) 3 Hg. #4 Uner Top: 15)3 Hg.
16)3 Hg. 17)3 Hg. Top to Bottom: 18) 4 Hg. 19) 4 Hg.
20) 4 Hg. 21)4 Hg. 22) 3 Hg. 23) 4 Hg. 24) 4 Hg.
Bottom: 25) 3 Hg. 26) 3 Hg. 27) 2 Hg. #5 liner Top:
28)3 Hg. 29)4 Hg. 30)4 Hg. Top to Bottom: 31) 4 Hg.
32) 3 Hg. 33) 3 Hg. 34)3 Hg 35) 2 Hg. 36) 3 Hg. 37) 3
Hg. 38) 3 Hg. Bottom: 39) 3 Hg. 40) 3 Hg. 41)3 Hg.
#6 Uner Top: 42)4 Hg. 43)3 Hg. 44) 3 Hg. Top: 45) 3
Hg. 46) 3 Hg. 47)3 Hg. 48) 3 Hg. 49) 3 Hg.50) 3 Hg.
51) 3 Hg. 52) 2 Hg. 53) 3 Hg. 54) 3 Hg. 55) 3 Hg.
We started at 7:30am. It was a little cool and Sunny. Finished Installing all the PVC liner. Conducted 55 tests. Will
finish tomorrow and with the earth work and testing.
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Maintenance
Evaporation Cell #1
IN THIS SECTION:
). Job Site
). Earth Work
). Liner
). Wrap-up
Cell #1 Repairs
lune 12th of 2009.
7am-3:30pm.
Personnel: Devin, Kendall, Casey and Johnson.
Please read: Documents attached.
Weather: 47 degrees F. 7:20am.
Cell # 1
Material: PVC liner, PVC to PVC adhesive, MEK(Cleaner), Sand bags, Wire brush and paint brushes.
7:25 a.m. -8:45 a.m. lob site.
8:45am.-10am.
lOam. -llam.
llam. -3:30 p.m.
Additional Information:
The Maintenance department will test the rest of the
seams and cover liner with dirt.
Earth Work.
David Turk, Ryan Palmer and Tanner Holiday inspected
and took pictures. David asked me to cover the liner
with dirt 6"-12".
Liner.
Tests were conducted made the last tests and they all
passed. Mr. Bartlett inspected and took pictures and
said go ahead and cover it.
Wrap-up
Oean up and back filled 6"-12" of dirt. Conducted 50
tests. #7 Liner Top: 1)3Hg. 2)3Hg. 3)3Hg. Top to
Bottom: 4) 3Hg. 5) 3Hg. 6) 3Hg. Top to Bottom: 7)3
Hg. 8) 3Hg. 9) 3Hg. 10) 2Hg. Bottom: 11) 3Hg. 12) 3
Hg. #8 LIner: 13) 4Hg. 14) 5Hg. 15)4Hg. 16)5Hg.
17)5Hg. 18) 4Hg. 19) 5Hg. Bottom: 20) 5Hg. 21)5Hg.
22) 4Hg. #9 LIner: 23) 4Hg. 24) 5Hg. 25) 4Hg. 26) 4
Hg. 27) 4Hg. 28)4Hg. 29)4Hg. 30)4Hg. 31) 3Hg . 32) 3
Hg. 33) 3Hg. 34)3Hg. 35) 3Hg. 36) 3Hg. 37) 2Hg. 38) 3
Hg . 39) 3Hg. 40) 2Hg. 41) 3Hg. 42) 3Hg. #10 Liner:
43) 3Hg. 44) 3Hg. 45) 3Hg. 46) 3Hg. 47) 3Hg. 48) 3
Hg. 49) 3 Hg.50) 3 Hg.
We started at 7:20am. It was a little cool and Sunny. Finished Installing all the PVC liner. Conducted 50 tests.
Everything is completed installing liners and Vacuum tests. We added 6-12 inches of dirt.
All documentation of training is provided on this file. Vacuum test procedures are logged in and photographs
were taken to keep track of evidence and progress of the job. Completion status 100%.
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