NC0007064_Inspection_20220609

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
ROY COOPER
Governor
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
John Krakuszski
Duke Energy Progress LLC
PO Box 10429
Southport, NC 28461
NORTH CAROLINA
Environmental Quality
June 08, 2022
SUBJECT: Compliance Inspection Report
Brunswick Steam Electric Plant
NPDES WW Permit No. NC0007064
Brunswick County
Dear Permittee:
The North Carolina Division of Water Resources conducted an inspection of the Brunswick Steam Electric
Plant on 5/26/2022. This inspection was conducted to verify that the facility is operating in compliance
with the conditions and limitations specified in NPDES WW Permit No. NC0007064. The findings and
comments noted during this inspection are provided in the enclosed copy of the inspection report
entitled "Compliance Inspection Report".
There were no significant issues or findings noted during the inspection and therefore, a response to this
inspection report is not required. If you should have any questions, please do not hesitate to contact Bryan
Lievre with the Water Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215
or via email at [e-mail].
Sincerely,
DocuSied by:
L8'L4U
E3ABA14AC7DC434...
Morella Sanchez -King, Regional Supervisor
Water Quality Regional Operations Section
Wilmington Regional Office
Division of Water Resources, NCDEQ
Attachment
Cc: Drew Petrusic (via email at Drew.Petrusic@duke-energy,com)
Laserfiche
£ D_E
NORTH CAROI
North Carolina Department of Environmental Quality I Division of Water Resources
Wilmington Regional Office 1127 Cardinal Drive Extension I Wilmington, North Carolina 28405
910.796,7215

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
United States Environmental Protection Agency
EPA Washington, D.C. 20460
Water Compliance Inspection Report
Form Approved.
OMB No. 2040-0057
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code
1 IN I 2 I5
21I I I I I I
NPDES yr/mo/day Inspection
I 3 I NC0007064 111 121 22/05/26 117
Type
18 I �, I
I I I I I
Inspector Fac Type
19 I S I 201
I I I I I I I I I I I I I I I I I I I I I I I
I I I
I I I 1 I P6
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved
671 I 7° I I 711 172 I N I 731 I 74 71
I I
1 1 1 1 1 1 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Brunswick Steam Electric Plant
8470 River Rd SE
Southport NC 28461
Entry Time/Date
08:30AM 22/05/26
Permit Effective Date
18/05/01
Exit Time/Date
02:OOPM 22/05/26
Permit Expiration Date
22/11/30
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Charles K Wilson/ORC/910-457-3687/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
John Krakuszski,PO Box 10429 Southport NC 28461/Plant Manager//
No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenar Records/Reports
Self -Monitoring Progran Sludge Handling Dispo: Facility Site Review Compliance Schedules
Effluent/Receiving Wate Laboratory Storm Water Other
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s)
Bryan Lievre
of Inspector(s) Agency/Office/Phone and Fax Numbers Date
�Docusignedby: DWR/WIRO WQ/910-796-7215/
6/8/2022
731,70n. liPN2Pi
'-74249ABED37443E...
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
Morella Sanchez -King DWR/WIRO WQ/910-796-7218/ DocuSigned by: 6/8/2022
I wt wdLt StUA,t ,t "- — tut
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
E3ABA14AC7DC434...
Page# 1

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
31
NPDES yr/mo/day
NC0007064 I11 121 22/05/26
117
Inspection Type
18LI
(Cont.)
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
A compliance inspection of the Brunswick Steam Electric Plant was performed on May 26, 2022. The
purpose of the inspection was to verify that the facility is operating in compliance with the conditions
and limitations specified within Permit NC0007064. Present during the inspection were Don Safrit,
Drew Petrusic, Charles Wilson (ORC), Eric Caison and Randy Hawkins with Progress Energy as well
as Bryan Lievre with NCDEQ.
The permit provides for the following outfalls:
1. Outfall 001, which is generally plant cooling water but also includes flow from Internal Outfalls
003, 005, 006, 010, 011 and 012. For Outfall 001, from December 1, 2019 through March 31, 2022,
the maximum daily flows were equal to the permit limits for each period. The average daily flows for
each period were very close to (i.e., within 7%) or at the maximum permitted flow, although an
exceedance was not reported. During the same period, the reported pH in Outfall 001 ranged from 7
to 8.1 with an average of 7.8 which is also within the established permit limits. No detectable levels of
total residual chlorine were reported at this location during this period. Thermal Reports from
11/24/2020, 2/4/2021, 11/10/2021 and 2/16/2022 were reviewed and found to be within permitted
limits as described in permit condition A.(1);
2. Outfall 003 has three Radwaste Treatment Systems, although the waste from all is intermittent
and eventually flows from the same discharge line. Sampling conducted in November 2020 and 2021
indicates that results for this outfall are in compliance with established permit limits;
3. Outfall 004 was for a wastewater treatment system which has been removed from the facility and
the effluent line has been filled with concrete. The current permit application has requested the
removal of this outfall from the future permit and the Wilmington Regional Office concurs with this
request;
4. Outfall 005 is a Drain Holding Facility (DHF) which has replaced a legacy Drain Stabilization Pond.
The primary input into the pond will be surface water runoff. The 4.2 acre, approximately 4 million
gallon pond was under construction during the recent inspection. The pond is being constructed with
various liners and will discharge into the intake canal;
5. Outfall 006 is for the discharge of treated metal cleaning wastes and has not been utilized during
this permit cycle (i.e., since prior to April 6, 2018);
6. Outfall 010 is for the Support Facilities WWTF. This is a 0.150 million gallon per day (mgd) which
includes 12 lift stations (only four of which pump directly to the WWTF), three fine screens, four
sequencing batch reactors, an effluent flow meter, two disc filters and two UV disinfection units. The
system also has two aerated sludge basins and a sludge thickening system. The average monthly
flow for Outfall 010 from 12/2019 through 3/2022 was 0.012 mgd with a maximum recorded monthly
flow of 0.028 mgd (permitted at 0.150 mgd). Outfall 010 had an average BODS of 4.76 mg/L with a
maximum of 18 mg/L and an average TSS of 6.35 mg/L with a maximum of 36 mg/L over the same
period;
7. Outfall 011 is for a Storm Drain Stabilization Pond (SDSP). There are eight intermittent and
routine sources which are routed to this outfall. Potential discharges include those from an Auxiliary
Boiler System, HVAC Cooling Towers, a Demineralized Water System, a Standby Liquid Control Test
Tank, Turbine Building Closed Cooling Water, Diesel Generator Cooling Water System, Maintenance
Activities and an Independent Spent Fuel Storage Installation (ISFI). Outfall 005 can receive the
same inputs described above when the SDSF is not available and Outfall 012 can also be routed to
the Storm Drain Stabilization Facility. Discharge from Outfall 011 is into the intake canal. From
12/2019 through 3/2022 was approximately 0.552 mgd (when discharging), total suspended solids
were 7.02 mg/L on average, and sampling results for oil and grease were typically non -detectable,
with a high of 5.7 mg/L; and,
Page# 2

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
Permit: NC0007064
Inspection Date: 05/26/2022
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
8. Outfall 012 is for discharge of the Groundwater Well Extraction System. This system recovers
groundwater with tritium levels of concern from the area of the former Storm Drain Stabilization Pond.
The outfall is typically directed to the intake canal, but can be directed to Outfall 005.
A review of monitoring records indicates that the system has not had any violations since the most
recent permit was issued on 4/6/2018. The staff were extremely knowledgeable of the facility and the
facility seemed to be well maintained and operated. The facility is compliant with the discharge Permit
NC0007064. Please review the comment sections of the inspection report for more details.
Page# 3

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
Permit: NC0007064
Inspection Date: 05/26/2022
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Permit Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new MODE
application?
Is the facility as described in the permit? ❑ ❑ ❑ ❑
# Are there any special conditions for the permit? ❑ ❑ ❑ ❑
Is access to the plant site restricted to the general public? • ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? • ❑ ❑ ❑
Comment: The current permit expires 11/30/2022 and staff have submitted a renewal application.
A copy of the application, dated 5/23/22, was provided for WiRO during the inspection.
Permit conditions include varying discarge flow limits depending upon the time of year
and electrical demand, annual reports of results to minimize organism impingment and
entrainment at a diversion fence, the number of fine mesh screens in place to prevent
high differential pressures at the Circulating Water Intake Pumps (CWIPs), total
residual chlorine at the Caswell Beach Pump Station and thermal plume monitoring.
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? • ❑ ❑ ❑
Is all required information readily available, complete and current? • ❑ ❑ ❑
Are all records maintained for 3 years (lab. reg. required 5 years)? • ❑ El El
Are analytical results consistent with data reported on DMRs? • El El El
Is the chain -of -custody complete? • El ❑ ❑
Dates, times and location of sampling ■
Name of individual performing the sampling •
Results of analysis and calibration •
Dates of analysis ■
Name of person performing analyses ■
Transported COCs ■
Are DMRs complete: do they include all permit parameters? • El El El
Has the facility submitted its annual compliance report to users and DWQ? ❑ El • ❑
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified ■ El El El
operator on each shift?
Is the ORC visitation log available and current? • El El El
Is the ORC certified at grade equal to or higher than the facility classification? • El El El
Is the backup operator certified at one grade less or greater than the facility • ❑ ❑ ❑
classification?
Is a copy of the current NPDES permit available on site? • El El El
Facility has copy of previous year's Annual Report on file for review? El El • El
Page# 4

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
Permit: NC0007064
Inspection Date: 05/26/2022
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Comment: Greater than 10 years worth of records are maintain on -site. The system has an ORC
and three back-up operators with the appropriate certification. The system maintains
lab certification number 5052 for performing field test parameters and utilize
Envirochem for most other lab analyses. A recommendation was made to include
additional information on COC to be sumbitted to Envirochem, including number of
containers, type of containers, preservatives, etc.
Compliance Schedules
Is there a compliance schedule for this facility?
Is the facility compliant with the permit and conditions for the review period?
Yes No NA NE
• ❑ ❑ ❑
Comment: A review of monitoring records indicates that the system has not had any violations
since the most recent permit was issued on 4/6/2018.
Other Yes No NA NE
Comment: The permit includes a diversion fence at the mouth of the intake canal as well as an
intake structure which includes coarse trash racks and effluent then flowing though
rotating 42 fine mesh screens and eight (8) coarse mesh screens for each of the four
(4) Circulating Water Intake Pumps (CWIPs). The intake system also includes lower
pressure spray to wash organisms and higher pressure spray to wash remaining debris
off the screens and back into an estuarine area of the Lower Cape Fear River by a
gravity aqueduct system. The intake system appeared to be functioning properly
during the inspection.
Lagoons Yes No NA NE
Type of lagoons?
# Number of lagoons in operation at time of visit? 2
Are lagoons operated in?
# Is a re -circulation line present? ❑ ❑ • ❑
Is lagoon free of excessive floating materials? ❑ ❑ • ❑
# Are baffles between ponds or effluent baffles adjustable? El El • El
Are dike slopes clear of woody vegetation? • El El El
Are weeds controlled around the edge of the lagoon? • ❑ ❑ ❑
Are dikes free of seepage? El El El •
Are dikes free of erosion? • El El El
Are dikes free of burrowing animals? El El El •
# Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ • ❑
locations?
# If excessive algae is present, has barley straw been used to help control the growth? El El El
Is the lagoon surface free of weeds? • El El El
Page# 5

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
Permit: NC0007064
Inspection Date: 05/26/2022
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Lagoons Yes No NA NE
Is the lagoon free of short circuiting?
• ❑ ❑ •
Comment: The two lagoons mentioned above refer to those associated with Outfalls 005 and 011.
The lagoon for Outfall 005 is called the Drain Holding Facilty (DHF) which is a low
volume waste pond which has replaced the Storm Drain Stabilization Pond. The
lagoon was under construction during the visit and is being constructed with liners and
will be approx. 4 million gallons and discharges into the intake canal, as needed. The
lagoon associated with Outfall 011 is called the Storm Drain Stabilization Facility Pond
(SDSF) and is approix. 6 millions gallons and discharges on a weekly basis during
normal operation to the intake canal. An average daily flow of approx. 0.552 mgd was
intermittently discharged from Outfall 011 from 12/1/2019 through 3/31/2022. The
SDSF is a lined pond with black plastic "balls" to prevent algal growth and inhibit
evaporation.
Pump Station - Influent Yes No NA NE
Is the pump wet well free of bypass lines or structures? ■ ❑ ❑ ❑
Is the wet well free of excessive grease? • ❑ ❑ ❑
Are all pumps present? • ❑ ❑ ❑
Are all pumps operable? ■ ❑ ❑ ❑
Are float controls operable? • ❑ ❑ ❑
Is SCADA telemetry available and operational? • ❑ ❑ ❑
Is audible and visual alarm available and operational? • ❑ ❑ ❑
Comment: Above information is in regards to Lift Station No 11, which was inspected during recent
activities. Lift Station No. 11 is a duplex pump station that is located northwest of the
WWTF and is one of 12 lift stations that serve the Support Facilities WWTF, although
only four lift stations (#'s 3, 6, 11 & 16) pump directly to the WWTF.
Bar Screens
Type of bar screen
a.Manual
b.Mechanical
Are the bars adequately screening debris?
Is the screen free of excessive debris?
Is disposal of screening in compliance?
Is the unit in good condition?
Yes No NA NE
•
• ❑ ❑ ❑
❑ ❑ ❑ •
• ❑ ❑ ❑
• ❑ ❑ ❑
Comment: The WWTF has three fine screen units installed in parallel with overflow to each of the
subsequent SBR units. One of the screen systems was off-line awaiting replacement
parts at the time of inspection. The units have internal brushes that push solids to an
auger and the solids then travel to a container and are disposed of as low level
radioactive waste (simply as a precaution).
Page# 6

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
Permit: NC0007064
Inspection Date: 05/26/2022
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Sequencing Batch Reactors
Type of operation:
Is the reactor effluent free of solids?
Does minimum fill time correspond to the peak hour flow rate of the facility?
Is aeration and mixing cycled on and off during fill?
The operator understands and can explain the process?
Yes No NA NE
Duplex
▪ El El El
• ❑ ❑ ❑
• ❑ ❑ ❑
Comment: The WWTF has four (4) SBR units with two typically in operation at a time. The units
typically operate with 15 minutes of aeration and 15 minutes of settling with a DO of
between 8.1 to 8.8 mg/L.
Flow Measurement - Effluent
# Is flow meter used for reporting?
Is flow meter calibrated annually?
Is the flow meter operational?
(If units are separated) Does the chart recorder match the flow meter?
Yes No NA NE
• ❑ ❑ ❑
• ❑ ❑ ❑
• ❑ • ❑
Comment: The system has two influent flow meters for internal purposes and are not utilized for
reporting purposes. The effluent flow meter (4" diam pipe magmeter) is located after
the SBR units and is used for reporting purposes. The meter was last calibrated
11/9/2021 by C. Wright Instruments, Inc.
Filtration (High Rate Tertiary) Yes No NA NE
Type of operation:
Is the filter media present? ■ ❑ ❑ ❑
Is the filter surface free of clogging? • ❑ El El
Is the filter free of growth? • El El El
Is the air scour operational? • El ❑ ❑
Is the scouring acceptable? ■ El El El
Is the clear well free of excessive solids and filter media? El El • El
Comment: The WWTF has two high -rate disc filters set up in parallel. The filters have a stainless
steel filters and backwash is sent to Lift Station No. 11. 25% sodium hydroxide is
injected into the disc filters for pH control.
Disinfection - UV
Are extra UV bulbs available on site?
Are UV bulbs clean?
Is UV intensity adequate?
Is transmittance at or above designed level?
Yes No NA NE
• ❑ ❑ ❑
❑ ❑ ❑ •
Page# 7

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
Permit: NC0007064
Inspection Date: 05/26/2022
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Disinfection - UV
Is there a backup system on site?
Is effluent clear and free of solids?
•
Yes No NA NE
❑ ❑ ❑
Comment: The WWTF has two UV units, set up in parallel, and each unit has three bulbs. The
system tries to maintain 3 spare bulbs on -site.
Aerobic Digester Yes No NA NE
Is the capacity adequate? ❑ ❑ El •
Is the mixing adequate? • ❑ ❑ ❑
Is the site free of excessive foaming in the tank? • ❑ ❑ ❑
# Is the odor acceptable? • ❑ ❑ ❑
# Is tankage available for properly waste sludge? • ❑ ❑ ❑
Comment: The WWTF has two aerated sludge tanks, set up in parallel. The WWTF system is
also equipped with a sludge thickening system including a screw press, an electric drier
unit, an auger assembly that conveys solids to a holding container. Liquids from the
drying process are discharged into Lift Station 11 and solids are disposed as low-level
radioactive waste (as a precaution).
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? • ❑ El El
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable El El El
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: The WWTF is checked daily for pH, DO & settleability and mixed liquor is checked
weekly.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? El ❑ • ❑
Is sample collected below all treatment units? • El El El
Is proper volume collected? • El El El
Is the tubing clean? ❑ ❑ • ❑
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 ❑ ❑ • ❑
degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type El El • El
representative)?
Comment: Composite sampling is not required for any of the outfalls for the current permit.
Pump Station - Effluent
Is the pump wet well free of bypass lines or structures?
•
Yes No NA NE
❑ ❑ ❑
Page# 8

DocuSign Envelope ID: C77B83C3-EBD3-4598-A331-E5813A301EC3
Permit: NC0007064
Inspection Date: 05/26/2022
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Pump Station - Effluent Yes No NA NE
Are all pumps present? • ❑ ❑ ❑
Are all pumps operable? ❑ ❑ El •
Are float controls operable? ❑ El • El
Is SCADA telemetry available and operational? • ❑ ❑ ❑
Is audible and visual alarm available and operational? ❑ ❑ • ❑
Comment: The WWTF discharges into a storm drain that drains into the effluent channel at the
entrance to the plant. All combined effluent then flows through a 5.4-mile long effluent
channel to Caswell Beach. I siphon system allows the effluent to flow under the
Intracoastal Waterway and this structure is reportedly inspected by others with the
facility. The pump station at Caswell Beach is equipped with eight pumps with large
trash racks to screen large debris. The pumps discharge the effluent into a
submerged pipe in the Atlantic Ocean, south of the Caswell Beach pump station. The
trash racks are manually cleaned and appeared in good condition during the
inspection. The facility montors the level within the discharge canal.
Effluent Pipe
Is right of way to the outfall properly maintained?
Are the receiving water free of foam other than trace amounts and other debris?
If effluent (diffuser pipes are required) are they operating properly?
Comment:
Standby Power
Is automatically activated standby power available?
Is the generator tested by interrupting primary power source?
Is the generator tested under load?
Was generator tested & operational during the inspection?
Do the generator(s) have adequate capacity to operate the entire wastewater site?
Is there an emergency agreement with a fuel vendor for extended run on back-up
power?
Is the generator fuel level monitored?
Yes No NA NE
• ❑ ❑ ❑
• ❑ • ❑
Yes No NA NE
• ❑ ❑ ❑
• ❑ ❑ ❑
• ❑ ❑ ❑
▪ El El El
• ❑ ❑ ❑
• ❑ ❑ ❑
Comment: The emergency generator is capable of powering the WWTF as well as Lift Station 11.
Page# 9