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HomeMy WebLinkAboutNC0003433_Re-Issuance Application_20060123�� Progress Energy January 11, 2006 Mr. David Goodrich North Carolina Department of Environment and Natural Resources Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699 -1617 Subject: CP &L d/b /a Progress Energy Carolinas, Inc. Cape Fear Steam Electric Plant NPDES Permit No. NC0003433 Re- issuance Application Dear Mr. Goodrich: ,y r "1n The current NPDES permit for Cape Fear Steam Electric Plant located in Chatham County expires on July 31, 2006. Progress Energy hereby requests that the NPDES permit for the facility be reissued. Enclosed are EPA Application Form 1 — General Information and EPA Application Form 2C — Wastewater Discharge Information, all in triplicate. With re- issuance of the NPDES permit, Progress Energy requests the following: • Reduce the monitoring frequency for oil and grease and total suspended solids at internal Outfalls 001 and 005. Currently the permit required frequency for both is twice per month. Monthly mo itoring should be sufficient to demonstrate compliance with the effluent limitations. • Reduce the monitoring frequency for Chromium, Arsenic, Selenium, Mercury, Nickel, Copper, total nitrogen and phosphorus at Outfall 007. Currently, the permit required frequency for all these parameters is quarterly. Based on permit renewal sampling and monthly DMR data semi - annual monitoring should be sufficient to demonstrate compliance with the effluent limitations. • Reduce the monitoring frequency for Arsenic and Selenium at Outfall 005. Currently the permit required sampling frequency is quarterly. Based on permit renewal sampling, DMR data and its status as an internal outfall semi annual monitoring should be sufficient to demonstrate compliance with effluent guidelines. • Reduce the monitoring frequency for ammonia for Outfall 005. Currently the permit required monitoring frequency is monthly. Based on monthly DMR data quarterly sampling should be sufficient to demonstrate compliance with effluent guidelines. Progress Energy Carolinas, Inc. Cape Fear Steam Plant 500 CP &L Road Moncure, NC 27559 ��2. Progress Energy • Change the required monitoring frequencies for Arsenic, Selenium and Ammonia - Nitrogen at Outfall 001. Currently the permit monitoring frequency for Arsenic and selenium is quarterly, and monthly for ammonia. The plant only uses this outfall as a backup to Outfall 005, and suggests that there be a provision in the permit to allow for quarterly sampling only if there is a discharge made to the ash pond during the quarter. k With regard to 316(b), Progress Energy is in the midst of sampling and monitoring activities as described in the approved study plan. If there are any questions regarding the enclosed information, please contact Steve Cahoon at (919) 546 -7457. I certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fines and imprisonment for knowing violations. Sincerely, 4&�J� ;(" Victoria K. Will Plant Manager Attachments Progress Energy Carolinas, Inc. Cape Fear Steam Plant 500 CP &L Road Moncure, NC 27559 Cape Fear • Plant North Carolina Attachment I - Form I - Item XI - Map Progress Energy Carolinas, Inc. Cape Fear Steam Electric Plant Chatham County Page 2 of 3 s 1 o�9 �'° Riper Plant Site 003 001 n I_I Intake West Ash Pond Co T �d East Ash Pond 005 -qc-- 007 Discharge Canal IN 0 1000 2000 Meters 0 2000 4000 6000 Feet Cape Fear Steam Electric Plant I NORTH CAROLINA Buckhorn Dam �O 1.5 miles Attachment 1 — Form 1 — Item XI — Map Progress Energy Carolinas, Inc. Cape Fear Steam Electric Plant Chatham County Page 3 of 3 + �} \/ tm \} (E co 0 2 S G 0 0 z k tm o L j _ I § »� q m / 6 CL e £ tE 0 or- - I 7 f k ( )` 7 V E ` / k, / ( E � k! z k§ ` k k E, 0 / a± ± o < 4 § / 2 �,C t m _ k k ( « e ( & - 3 ) k \ \ 0 j / c c c c $ » > p # �0 )CL e \� a m �E 2 E \ .2 m ) )' co 0 2 2 £ �\ �/ �{ ƒ\ § E E E z. : )� «; )� e0 aw °o CL � 2 E CL \z }z. a_ C ,0 Ez z /{ )� E z '§ ,[ p T CL CL ui L---i c a .2 c - 2 0 Q )) _ CD _ Q C \ kE \/ -2 c _ - )® \\ U) 3¥ / ) \� /2 ƒ _ )$ _ 2 __ <$ -_ f/ \� �$ § \2 /@ e _ \ _ \ a E Q - M2 - � f _3 ¥ 2 - J a@ # % . « { 3 5 £ 2° � »} _ � �- \ /_ g ) d y /® 3 3 J A 2 l\ $ ± §, I I L -1 Ll Carolina Power & Light Company Cape Fear Steam Electric Plant National Pollutant Discharge Elimination System Permit Number NC0003433 Attachment 2 Form 2C - Item 11 -B Flows, Sources of Pollution, and Treatment Technologies Once - through Cooling Stream Estimated Average Flow Comments A, 0 58 MGD West,Ash Pond discharge to discharge canal B 0 51 MGD East Ash pond discharge to discharge canal C 182 8 MGD Cooling water °discharge to discharge canal D 0 001 MGD Evaporation E 0 MGD Evaporation H 0,51 MGD Provides water for ash sluicing I 50,000 gallons /event Electrostatic precipitator washing J 50,000 gallons /event Air preheater washing K 0 005-MGD County water supply L 0 140 MGD Boiler water makeup supply ,M 0 MGD Used only if cooling towers operate in closed cycle Valve is normally closed N' 183 4 MGD Intake from Cape Fear River O 183 4 MGD Discharge to Cape Fear River P 0 004 MGD Coal pile runoff, average rainfall — 50% runoff Q 0 002 MGD Sanitary Wastes R 0 052 MGD Storm water, average rainfall — 50 %, runoff S 0 001 MGD Evaporation T 0 34 MGD Ash Sluice water from East Ash Pond to West Ash Pond 2 0 Y m 16 Y y E c 2 m C E N m N L N Q 7 d d � E 0 0 CO W W c 0 3 'm CL 0 > C, W g U LL c m IL L N Q E- 0 m a W d O1 — lV m C m NU 0 L Q c C N O da O 2 N W V W Z O O Z F- 0 C7, Z Z w O m O � V Q Z O N _ d E c U rn � 0 c d m N O c N m .d. y > _C N LL d LL N N > 0 a O L 3 a _ aW Y U m E U Q W E ,? d, U y d T Z O F- V/ U m N r � - y U o w 0 Y m 16 Y y E c 2 m C E N m N L N Q 7 d d � E 0 0 CO W W c 0 3 'm CL 0 > C, W g U LL c m IL L N Q E- 0 m a W d O1 — lV m C m NU 0 L Q c C N O da O 2 N W V W Z O O Z F- 0 C7, Z Z w O m O � V Q Z O N _ d E c U rn � 0 c d m O c N m "� m p c _C N 0 4 J C CI C p O O O B'N N (O .m. O1 C C 'O O O CL no no EeZ %m mN Nn :3 n3 az a' Z EZ CZ d a a mllw� MALE v N C O p U O T T m m E c c N' N N 0 N d c m p c _C N N 0 2 O C 3 0) ° c 2 Y c E f0 T d m m y d 0 F- V/ m N , s U) y U w Z ) v N C O p U O T T m m E c c N' N 0 9v 0 CL c 0 c 0 CL (n O CO N OE z m ` ° Ez T a :3 a W'' loxf lox: af 0: (n N C N C y N C N C m N C C N -2 o E E N O O $ 0 00 E 7 N -g cu d 3 d 0 d d d C=am Ct 'O f0 m C° d D 3 �p v m c 0-6 IE v_ L w E N' m m CL L z O z 7" w c r dt N j r c p 7 10 W w C. 1-1 Li — — Carolina Power &, Light Company Cape Fear Steam Electric Plant National Pollutant.Discharge Elimination System Permit Number NCO 003433 Attachment 2 Form 2C - Item II -B Flows, Sources of Pollution, and Treatment Technologies Once - through Cooling Towers Stream Estimated Average Flow Comments A 0 58 MGD West' Ash Pond discharge to,discharge canal' B 0 51 MGD East Ash pond discharge to discharge canal C 269 0 MGD Cooling Tower discharge to discharge canal D 0 001 MGD Evaporation E 8 657 MGD Evaporation F 269 0 MGD Effluent from Cooling Tower G 277 8 MGD Influent'to'Coolmg Tower `H 0 51 MGD Provides water for ash sluicing I 50,000 gallons /event Electrostatic precipitator washing J 50,000 gallons /event Air preheaterwashing K 0 005 MGD County water supply L 0 140 MGD Boiler water makeup supply M 0 MGD Used only if,cooling towers operate in closed, cycle Valve is normally closed N 278 4 MGD' Intake from -Cape Fear River O 269 7 MGD Discharge to Cape Fear River P 0 004 MGD Coal pile runoff, average rainfall —50% runoff Q 0 002 MGD Sanitary Waste R 0 052 MGD Storm water, average rainfall —�50% runoff S 0 001 MGD Evaporation T 0 34 MGD Ash Sluice,water from East Ash Pond to West Ash Pond 4 Carolina Power & Light Company Cape Fear Steam Electric Plant National ,Pollutant Discharge Elimination System Permit, Number,NC0003433 Attachment 3 Form 2C - Item II -B Flows, Sources of Pollution, and Treatment Technologies The Cape Fear Steam Electric Plant is as coal -fated steam cycle electric generating plant with two units Two heat recovery boilers and 4 Internal Combustion (IC) Turbines are also located on the plant site Water is withdrawn from the Cape Fear River as required Chemical constituents contained in the discharges from this plant will, in part be representative of the naturally occurring chemical quality of the intake water and will also have chemical constituents of such quality and quantity associated with similar discharges for fossil generating facilities of this size, type, and'in the geographical location Either all or part of the elements listed on the Periodic Table, either singularly or in any combination, may from time,to time be contained in the discharge Outfall 007 Combined Wastewater Discharge,to Unnamed Tributary Canal to Cape Fear River This outfall is located in the discharge canal approximately 250 feet below the point where the East Ash Pond discharges into the canal This discharge contains all waste stream flows including once - through cooling water,. East Ash pond discharge, and West Ash pond discharge Internal Outfall 001 - West Ash Pond The West Ash Pond receives ash transport waters (bottom and fly ash), coal pile runoff, No 2 fuel oil tank runoff, settling basin drains, sand bed °filter backwash, parking lot drains, equipment cooling tower blowdown and drain, boiler, blowdown, oil unloading, area drains, derriineralizer regenerate, various yard and floor drains, and ash trench drain Detailed descriptions of the individual waste streams are below Coal Pile Runoff Storm water runoff from the coal pile is collected in drainage ditches that surround the coal pile The drainage ditches are routed to the west ash pond for treatment During maintenance activities, sludges "removed from catch basins, sumps, etc may be transported to the west and /or east ash pond for disposal Carolina Power & Light Company Cape Fear Steam ;Electric Plant National Pollutant Discharge Elimination System Permit' Number NC0003433 Low Volume Wastes Boiler water make up is withdrawn from the Cape Fear River and purified utilizing plant equipment or„ on rare occasions, vendor supplied equipment In February 2006 a Reverse Osmosis (RO) unit and Electrodeionization unit will be installed at the plant °to treat surface water withdrawn from the river and used for plant processes RO reject water and cleaning solutions wastes will be routed directly from low volume waste to the West Ash pond Boiler water is treated with morpholine,, trisodium phosphate, and sod ium'heptametaphosphate Boiler'blowdbwn and drainage is sent to the ash pond and may contain small quantities of the chemicals The equipment cooling tower and it's associated heat exchangers are treated with Spectrus OX103 and Dianodic DN2126 for corrosion and biofouling control Small amounts of cooling tower blowdown are produced and discharged to the low °volume retention basin Ash Sluice Water Fly ash and bottom ash from both units are hydraulically conveyed by an ash sluice pipeline to the ash pond A Rotamix system is used to inject urea into Units 5 and 6 In the boiler, the ammonia /urea will react with NOz to form water Vapor and nitrogen The system will be designed to minimize any ammonia,formation and ammonia slip Any unreacted ammonia adsorbed on the fly ash from this system will be carried to .the ash pond via ash sluice water Dry Ash Stacking From time to time fly ash and bottom ash from the East,Ash Pond (Outfall 005) will be excavated and transported and stacked or relocated into the diked boundary of the West Ash Pond The ash will be placed in the vegetated areas of the West Ash Pond No ash stacking or relocation will occur 1n areas of the pond that contain water No ichange in, the nature of the discharge to the discharge canal is anticipated Ash Sluice Water From East Ash Pond From time to time fly ash and bottom ash may be sluiced from the East Ash Pond to the West Ash Pond A floating dredge will be, placed in the, East Ash Pond and ash will be suctioned from the East Ash Pond and sent to the West Ash Pond via ash sluice lines Carolina Power & Light Company Cape Fear Steam Electric Plant National Pollutant Discharge Elimination System 'Permit Number NC0003433 Plant area floor and yard drains are routed "to the west ash pond and include equipment drainage, wash down water, and rainfall runoff Drains from areas likely to contain oil - filled equipment or storage are routed to the low volume retention basin which contains an oil /waterseparator, Waste oil is disposed of,according to'the appropriate regulations During maintenance activities sludges removed from the retention basin, ash trench, catch basins, sumps, etc may be transported to the east and /or west ash pond for disposal Internal Outfall 003 - Once - through Cooling Water Once - through condenser cooling water for the coal fired units and heat recovery units is withdrawn from the Cape Fear River, passed through the condenser, and discharged directly into the discharge canal Some cooling is accomplished in the discharge canal When the temperature at Outfall 007 approaches 32 °C, cooling towers are placed in service in once - through mode to keep the canal water at or below 32 °C If 32 °C or less cannot be maintained by orice- through cooling ,mode, operation is either`shifted to closed cycle cooling tower mode or the plant operation is modified such that the temperature remains below 32 °C Normally the cooling towers are placed in service in once - through mode during -the months of June through September The once - through flow may range from 58 8 MGD to 385 -4 MGD Internal Outfall 005- East Ash Pond The East Ash Pond receives ash transport waters (bottom and fly ash), runoff from yard drains, air preheater,washes, electrostatic precipitator washes, spent sandblast material, and sewage treatment plant effluent The ash pond provides treatment by sedimentation, oxidation, neutralization, equalization, and adsorption Domestic Wastes Domestic wastes are treated gat an extended aeration package plant priorto discharge to the east ash pond .which provides secondary treatment for the effluent Flow from the plant is dependent upon fluctuating demand due to variations in the number of personnel onsite The effluent from the plant is disinfected prior to discharge into the ash pond When needed, residuals are disposed of off-site by a licensed contract disposal firm '3 s s Carolina Power & Light Company Cape Fear Steam Electric Plant National Pollutant Discharge Elimination System Permit Number NC0003433 Air Pre - heater Washes The, air preheaters are water washed approxi °mately, once every 5 years Approximately 50,000 gallons of wastewater is produced and is discharged to the east ash pond via the ash sluice pipelines Electrostatic Precipitators The electrostatic precipitators are washed approximately once every 5 years Approximately, 50,000 gallons of wastewater is produced and is discharged, to the east ash pond via,the ash sluice pipelines Spent Sandblast Material Approximately every 5 years the interior of the boiler is sandblasted. Approximately 2000 pounds of spent sandblast material is produced This material is discharged to the east ash pond via the, ash sluice pipelines Other Wastes Chemical Metal Cleaning Wastes The boilers are chemically cleaned every 8 to 10 years using one of the following chemical processes. 1) citric acid, ammonium hydroxide, Cronox inhibitor, sodium nitrite, ammonium bicarbonate, or 2) Tetraammonium Ethylenediaminetetraacetic acid ,(EDTA) and A300 inhibitor, On occasion soda ash, ammonium persulfate, ammonium bifluonde, sodium bromate, and hydrochloric acid may also be used This cleaning solution and its rinses are stored on -site for disposal by evaporation in an operating unit's boiler Typical cleariings would result in a waste of approximately 60,000 gallons 4 f RO at CapeTear Plant - NC0003433 • � 7 y Subject: RO at Cape Fear Plant - NC0003433 From: Teresa' Rodriguez <teresa.rodnguez @ncmatl.net> Date: Tue, 13 Dec 2005 14.51.22 -0500 To: "Cahoon, Steve" < Steve Cahoon @pgnmatl com> CC: Gil Vinzani <gil.vtnzam @ncmail.net> Steve, we - received Progress Energy's letter regarding the replacement of the deminerali.zer for Reverse Osmosis and Electrodeionizati.on at the Cape Fear Plant,. The.wastewater flows generated by these units are considered low volume wastes. A permit modification,is not necesary since low volume wastes are cove-red under the permit. Teresa Teresa Rodriguez; P.E Division of Water Quality EAST NP,DES ,Program 9,19 -733 -5083 ext. 553 1 of 1 i2/13/2005 2 52 PM 4 `2,,,, Progress Energy November 14, 2005 Ms. Teresa Rodriguez I North Carolina Department of Environment and Natural Resources Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699 -1617 NOV 7 2005 ' OV Subject: CP &L dba Progress Energy Carolinas, Inc. Cape Fear Steam Electric Plant NPDES Permit No. NC0003433 NPDES Permit Application Amendment - Reverse Osmosis - Electrodeionization Water Purification System Cape Fear File Point: 12520B -1 Dear Teresa: CP &L dba Progress Energy Carolinas, Inc. will be utilizing a temporary portable Reverse Osmosis (RO) unit and Electrodeionization (EDI) unit to remove dissolved solids from filtered surface water (process water) at the Cape Fear Steam Electric Plant beginning December 15, 2005. The system is will be used on a rental basis until February 2006. At that time, the technology will be permanently installed. Reverse osmosis uses a membrane that is semi - permeable, allowing the fluid that is being purified to pass through it, while rejecting the contaminants that remain. Most reverse osmosis technology uses a process known as crossflow to allow the membrane to continually clean itself. As some of the fluid passes through the membrane the rest continues downstream, sweeping the rejected species away from the membrane. Electrodeionization is a process by which the demineralizer resin is regenerated by electric voltage. Acid and caustic solutions are not needed to regenerate this equipment. Previously, the Cape Fear Steam Electric Plant used a demineralizer to purify surface water for use in plant systems, the system will be removed and low volume waste from this process will cease. A RO unit followed by an EDI unit will be used to filter the surface water prior to entering package demineralizer units. The package demineralizer units used with both the temporary and permanent RO systems will be regenerated offsite. Low volume waste associated with the RO system is expected to be 24,000 GPD. Chemical reductions of sodium hydroxide (14,200 gals /yr to 0 gal /yr) and sulfuric acid (6,300 gals /yr to 0 gal /yr) will occur (See Attachment 4). Antiscalant, sodium hydroxide, and /or biocide may be added during the operation of the RO. The RO membrane will be cleaned approximately 12 times per year with 3 additional chemicals used at the time of cleaning (See Attachment 4). Also, the plant may use a biocide (See enclosed MSDS and Biocide Worksheet) to reduce biofouling in the RO membranes when the system is not in use, the biocide worksheet has been attached for your convenience, but not required since there is a toxicity monitoring requirement at Outfall 007. The EDI will be cleaned approximately 4 times per year with one additional chemical used only at the time of cleaning (See Attachment 4). In reverse osmosis treatment, the supply water is typically cycled up to four (4) times its normal concentration before being discharged from the unit. This water (Reverse Osmosis Progress Energy Carolinas, Inc. Cape Fear Steam Plant 500 CP &L Road Moncure, NC 27559 reject water) would then be sent to the Low Volume Retention Basin. Based on the proposed design for this system, this RO rejection water flow rate would be about 24,000 gallons per day. Because of the addition of the RO and EDI, the Cape Fear Plant wishes to amend the current NPDES Permit Application to include the RO and EDI as part of the low volume waste stream. Enclosed is an amended Attachment 3 and 4 of the NPDES permit application and the MSDS sheets for the water treatment additives. Previously, a similar system was constructed at the Weatherspoon Plant (NPDES Permit # NC 0005363); DWQ concluded this waste steam was considered to be a low volume waste and is currently addressed by the facilities NPDES permit (see attached letter from DWQ). Therefore, consistent with previous guidance from DWQ; we do not believe that a permit modification is needed for this activity. Progress Energy would appreciate a response from DWQ confirming that a permit modification is not needed for this activity. Also please note that Attachment 3 has been updated to reflect a change with the ROFA & Rotamix system for units 5 and 6. Currently, the plant uses ammonia in conjunction with the ROFA Rotomix system to reduce NOx emissions; in the coming ozone season (May through September) the ammonia will be replaced with urea. We do not expect any change in our discharge as a result of the change from ammonia to urea. If you have any questions regarding any information in this submittal please call Steve Cahoon at (919) 546 -7457. 1 certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fines and imprisonment for knowing violations. Sincerely, Mrz M Victoria K. Will Plant Manager Attachments M reject water) would then be sent to the Low Volume Retention Basin. Based on the proposed design for this system, this RO rejection water flow rate would be about 24,000 gallons per day. Because of the addition of the RO and EDI, the Cape Fear Plant wishes to amend the current NPDES Permit Application to include the RO and EDI as part of the low volume waste stream. Enclosed is an amended Attachment 3 and 4 of the NPDES permit application and the MSDS sheets for the water treatment additives. Previously, a similar system was constructed at the Weatherspoon Plant (NPDES Permit # NC 0005363); DWQ concluded this waste steam was considered to be a low volume waste and is currently addressed by the facilities NPDES permit (see attached letter from DWQ). Therefore, consistent with previous guidance from DWQ; we do not believe that a permit modification is needed for this activity. Progress Energy would appreciate a response from DWQ confirming that a permit modification is not needed for this activity. Also please note that Attachment 3 has been updated to reflect a change with the ROFA & Rotamix system for units 5 and 6. Currently, the plant uses ammonia in conjunction with the ROFA Rotomix system to reduce NOx emissions; in the coming ozone season (May through September) the ammonia will be replaced with urea. We do not expect any change in our discharge as a result of the change from ammonia to urea. If you have any questions regarding any information in this submittal please call Steve Cahoon at (919) 546 -7457. 1 certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fines and imprisonment for knowing violations. Sincerely, Mrz M Victoria K. Will Plant Manager Attachments