NC0076775_Permit (Issuance)_20090820

NPDES DOCIMENT SCANNIN`: COVER :SHEET
NPDES Permit:
NC0076775
Falls Powerhouse
Document Type: (
Permit Issuance,
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Staff Report
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
August 20, 2009
This document is printed on reuse paper - ignore any
content on the remrerse side

ATA
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
August 20, 2009
Mr. Mark Gross
Alcoa Power Generating, Inc.
P.O. Box 576
Badin, North Carolina 28009
Subject:
n
4
Dear Mr. Gross:
Issuance of NPDES Permit NC0076775
Falls Powerhouse
Stanly County
Division personnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued pursuant to the
requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North
Carolina and the U.S. Environmental Protection Agency dated October 15, 2007 (or as subsequently, amended).
This final permit includes no major changes from the draft permit sent to you on July 1, 2009.
If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable
to you, you have the right to an adjudicatory hearing upon written request within thirty (30) days following receipt
of this letter. This request must be in the form of a written petition, conforming to Chapter 150B of the North
Carolina General Statutes, and filed with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh,
North Carolina 27699-6714). Unless such demand is made, this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division may
require modification or revocation and reissuancc of the permit. This permit does not affect the legal requirements
to obtain other permits which may be required by the Division of Water Quality or permits required by the
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity t Affirmative Action Employer
NorthCarolina
Naturally

Division of Land Resources, the Coastal Area Management Act or any other Federal or Local governmental permit
that may be required. If you have any questions concerning this permit, please contact Sergei Chernikov at
telephone number [phone].
Sincerely,
4'1j11C
oleen H. Sullins
cc: MRO-Surface Water Protection
NPDES File
Central Files
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity l Affirmative Action Employer
NorthCarolina
Naturally

Permit NC0076775
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and
the Federal Water Pollution Control Act, as amended,
Alcoa Power Generating, Inc.
is hereby authorized to discharge wastewater from a facility located at the
Falls Powerhouse
at the end of NCSR 1727
souteast of Badin, NC
Stanly County
to receiving waters designated as Yadkin River in the Yadkin -Pee Dee River Basin in accordance with
effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective October 1, 2009.
This permit and authorization to discharge shall expire at midnight on January 31, 2014
Signed this day August 20, 2009
0i11r
een H. Sullins, Director
vision of Water Quality
By Authority of the Environmental Management Commission

Permit NC0076775
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked. As of this
permit issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive
authority to operate and discharge from this facility arises under the permit conditions, requirements, terms, and
provisions included herein.
Alcoa Power Generating, Inc. is hereby authorized to:
1. Continue to discharge once -through cooling water from outfalls 001, 002, 003, 004, and 005 and
water from a sump drain (Outfall 007) located at the Falls Powerhouse, southeast of Badin at the
end of NCSR 1727 in Stanly County.
2. Stormwater Discharge System — The facility is permitted to periodically discharge stormwater from
secondary containment for transformers through a stormwater conveyance system, via outfall 008
located at the Falls Powerhouse.
3. Discharge from said treatment works at the location specified on the attached map into the Yadkin
River which is classified as class WS-IV & B CA waters in the Yadkin -Pee Dee River Basin.

NC0076775 — Falls Powerhouse
Latitude: 35°23'44"
Longitude: 80°04'34"
Quad #: F18NE
Stream Class: WS-IV &-B
Receiving Stream: Yadkin River
Sub -Basin:
03-07-08
Stanly County
Map not to scale

Permit NC0076775
A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [007]
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge stormwater from outfall 007 [Sump Drain]. Such discharges shall be limited and
monitored by the Permittee as specified below:
PARAMETER •
DISCHARGE LIMITATIONS
Monitoring Requirements -_
Monthly :
Avera'e
Daily'
Maximum
. , Measurement
Frequency
Sample • .
Type
Sample
Location
Flow
Annual
Estimate
Effluent
Oil and Grease1
15.0 mg/L
_ 20.0 mg/L
Annual
Grab
Effluent
pH2
Annual
Grab
Effluent
NOTES:
* Effluent or at the point closest to discharge where a representative sample of the discharge can
feasibly be obtained.
1 The tailrace shall be visually inspected for oil sheen attributed to facility operations on a weekly
basis in conjunction with inspections of the floor sump and rope skimmer. Confirmation that a
visual inspection was conducted shall be recorded in the operating log for the facility and provided
to the Division upon request.
2. The pH of the effluent shall not be less than 6.0 standard units or greater than 9.0 standard units,
unless ambient river conditions prevent compliance with this range.
Best Management Practices (BMPs) must be employed to ensure that excessive pollutants are not discharged
to the surface water of the state. These practices should include as a minimum, routine maintenance of the
rope skimmer type oillwater separator and cleaning accumulated sediment in the bottom of the sump
annually.
Chemical wheel pit cleaning is permitted on a monthly basis. When wheel pit cleaning occurs, the
tailrace shall be inspected visually for foam and oil. Cleaning shall be conducted only with pre -
approved solvents. Should the Permittee wish to change solvents, a written request should be made to
the Division including the MSDS for the proposed solvent.
Mechanical cleaning operations, which do not contribute any wastewater to the discharge are not
limited by this permit. Non -discharging cleaning operations may be conducted as often as necessary to
ensure safety and proper facility operation.
Monitoring results obtained during the calendar year shall be recorded and reported on a Discharge
Monitoring Report (DMR) form and postmarked no later than January 30th following the completed
reporting period. Samples obtained for monitoring purposes may be collected anytime during the
calendar year.
There shall be no discharge of floating solids or visible foam (other than trace amounts) in the effluent,
unless ambient river conditions prevent compliance.

Permit NC0076775 ,
•
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
[001 / 002 / 003 / 004 / 005]
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge once -through cooling water from outfalls 001, 002, 003, 004, and 005. Such
discharges shall be limited and monitored by the Permittee as specified below:
PARAMETER
• DISCHARGE LIMITATIONS`.:.
Monitoring Requirements
Monthly Average ,
: Daily Maximum
Effluent Measurement
Frequency.:
Sample Type
Sample
' Location*
Flow (MGD)
Annual
Estimate
Effluent
Temperature1
1
1
Annual
Grab
Effluent
pH2
Annual
Grab
Effluent
NOTES:
* Effluent or at the point closest to discharge where a representative sample of the discharge can
feasibly be obtained.
1 The temperature of the effluent will be regulated so that the temperature of the receiving stream
does not increase by more than 2.8 °C above the natural water temperature. In no case should the
receiving stream temperature exceed 32 °C due to the facility's operation. Temperature of the
effluent may be obtained anywhere downstream of the heat exchanger effluent that is representative
of the discharge.
2 The pH of the effluent shall not be less than 6.0 standard units nor greater than 9.0 standard units,
unless ambient river conditions prevent compliance with this range.
Monitoring results obtained during the calendar year shall be recorded and reported on a Discharge
Monitoring Report (DMR) form and postmarked no later than January 30th following the completed
reporting period. Samples obtained for monitoring purposes may be collected anytime during the calendar
year.
There shall be no discharge of floating solids or visible foam (other than trace amounts) in the effluent,
unless ambient river conditions prevent compliance.
A. (2) BIOCIDE CONDITION
There shall be no chromium, zinc or copper added to the treatment system except as
Pre -approved additives to biocidal compounds.
The permittee shall obtain approval from the Division's Aquatic Toxicology Unit prior to the use of any
biocide (not previously approved by the Division) in the effluent discharged under this permit. Approval for
use of any biocide not previously approved should be requested at least 90 days in advance of any planned
usage.
Contact the Aquatic Toxicology Unit for detailed instructions on requesting approval of biocides:
NC DENR / DWQ / Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621

Permit NC0076775
A. (3) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [008]
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge stormwater from outfall 008. Such discharges shall be limited and monitored by the
Permittee as specified below:
PARAMETER
DISCHARGE LIMITATIONS.
Monitoring Requirements
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample .
Type
Sample
Location
BMP1
NOTES:
1. SEE A. (4).
There shall be no discharge of floating solids or visible foam (other than trace amounts) in the effluent,
unless ambient river conditions prevent compliance.
A (4) BEST MANAGEMENT PRACTICES (BMP) FOR PERIODIC STORMWATER
DISCHARGE
The permittee is authorized by the Division to use Best Management Practices for the stormwater discharge
from the secondary containment around the transformers under the following conditions:
• Sumps shall be designed with underflow weirs/devices to prevent discharge of oily stormwater.
• Weekly inspections of the transformers shall be performed to detect leaks/drips of oil.
• Routine preventive maintenance procedures shall be conducted to address any leaks/drips of oil.
• Inspection of the sump for the presence of oil as indicated by a visible sheen shall be conducted prior to
the discharge.
• Logs of time, date, and volume of stormwater discharge per discharge event shall be maintained.
• All stormwater discharge events shall be reported along with the annual Discharge Monitoring Report
(DMR).

July 1, 2009
MEMORANDUM
To: Britt Setzer, Regional Engineer
NC DENR / DEH / Public Water Supply Section
Mooresville Regional Office
From: Sergei Chernikov, Environmental Engineer II, NPDES-West,
Division of Water Quality (fax-919-807-6495)
Subject: Review of the discharge locations for the following:
Falls Powerhouse
NC0076775
Stanly County
Please indicate below by August 3, 2009 your agency's position or viewpoint on the facility
listed above. We cannot issue the permit without your concurrence. Please return this form
at your earliest convenience.
RESPONSE:
cc: file
This agency has reviewed the draft permit and determined that the proposed
discharge will not be sufficiently close to any existing or known proposed
public water supply intake so as to create an adverse effect on water quality.
We concur with the issuance of this permit provided the facility is operated
and maintained properly, the stated effluent limits are met prior to discharge,
and the discharge does not contravene the designated water quality standards.
Concurs with issuance of the above permit, provided the following conditions
are met:
Opposes the issuance of the above permit, based on reasons stated below, or
attached:

North Carolina } ss
Mecklenburg County)
The Charlotte Observer Publishing Co.
Charlotte, NC
Affidavit of Publication
THE CHARLOTTE OBSERVER
DINA SPRINKLE
NCDENR/DWQ/POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH NC 27699
REFERENCE: 30063432
6361919 wastewater permit
Before the undersigned, a Notary Public of said
County and State, duly authorized to administer
oaths affirmations, etc., personally appeared,
being duly sworn or affirmed according to law,
doth depose and say that he/she is a
representative of The Charlotte Observer
Publishing Company, a corporation organized and
doing business under the laws of the State of
Delaware, and publishing a newspaper known as The
Charlotte Observer in the city of Charlotte,
County of MeckLenburg, and State of North Carolina
and that as such he/she is familiar with the
books, records, files, and business of said
Corporation and by reference to the files of said
publication, the attached advertisement was
inserted. The following is correctly copied from
the books and files of the aforesaid Corporation
and PubLication.
PUBLISHED ON: 07/04
AD SPACE: 90 LINE
FILED ON: 07/10/09
NAME: KW"`Lr` -
In Testimony Whereof I have hereunto set my hand and affixed my seal, the
day and ear aforesaid.
Public Notice '
North Carolina Enviro0mentarManagement-
Gommission/NPDES Unit •
1617 Mail Service Center r
Raleigh, NC 27699-1617 ,•
i Notice of Intent to Issue a NPDES Wastewater Peri1R_'.
on
pre North .Carolina NPDES wastewater discharge permrit tement o proposes to issue-..
person(s) listed below. Permit will be
Written comments regarding the proposed p,
accepted until 30 days atierthe publish date otitis notice.
Director of the NC Division of Water Quality (DWO) mayree of ho.puld
nterest. Please should
comments e be ansignificant
lor info tlrmation requests to
DWO at the above atRaleigh,
Interested
persons
at Salisbury Sreet; Ra eh1C'to review m ortion on
file. Additional information wNODES permits end this notice may
be found on our webstecww.ncwaterqualM.org, or by calling
[phone]. _ ,.
The Alcoa Power Generating,. Inc. ;requested renewal of permit
NC0081957 tar Narrows Powerhouse in Stanly County; this iacrittyo
discharge is once -through cooling water and sump dram wee
the Yadkin River, Yadkin River Basin., - -, .
The Alcoa Power Generating, Inc. requested renev
ial -of permit
NC0081949disc tore irs once -through gh cooling water owerhriuse in and sump drain.
wCounty; this
atety discharge ,: • - . " '
weer to Yadkin lver, Yadkin River Basin. •
renewal of permit
The 7677$ over Generating. Inc.. request .1h5 facility
discharge i for Fallse-h Power ooling in
Shinty
mwatteer. and sump
discharge is once -through •...
drain water to Yadkin -River, Yadkin River Basin.:.
The C00 931Ptorr High Rock Powerhduse requested
County: this
facility discharge is once -through cooling water and stormwater,to:
Yadkin River; Yadkin River Basin. rm3 i.,.; • ' fai
The,Tyson Foods, Inc requested renewal of discharge is treated
Harmony Plant in Iredell County; this facility
industrial wastewater to Yadkin River, Yadkin River Basin. .
LP6361919 •-
Nota
TITLE:
DATE:
JUL 1 0 ZOOS
Commission Expires: _/_/_
My Commission Expires May 27, 2011

DENRJDWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0076775
Facility Information
Applicant/Facility Name:
Alcoa Power Generating, Inc. /Falls Powerhouse
Applicant Address:
PO Box 576, Badin, NC 28009-0576
Facility Address:
End of NCSR 1727 southeast of Basin, NC
Permitted Flow
N/A — Monthly Average — 1,386,000 gpd
Type of Waste:
Once though cooling water, process water, stormwater and sump discharges.
Facility/Permit Status:
Renewal
County:
Stanly
Miscellaneous
Receiving Stream:
Yadkin River
Regional Office:
Mooresville
Stream Classification: .
WS-IV & B CA
USGS Topo Quad:
F 18 NE
303(d) Listed?:
NO
Permit Writer:
Sergei Chernikov
Subbasin:
03-07-08
Date:
June 3, 2009
Drainage Area (mi2):
4125
Summer 7Q10 (cfs)
1400
Winter 7Q10 (cfs):
1400
Average Flow (cfs):
IWC (%):
Primary SIC Code:
4911
SUMMARY
This facility maintains 7 outfalls (001, 002, 003, 004, 005 and 007) With the exception of outfall 007
(sump drain) the source of water for the other outfalls is once through cooling water. The permit
stipulates that outfalls 001 through 005 monitor (with no limits) flow, temperature and pH. For the
outfall 007 monitoring was required for oil and grease, flow and pH. The permit was recently modified
to include Outfall 008 for periodic discharges of stormwater from secondary containment around the
transformers. In order to prevent contamination of the receiving stream, the facility is required to use
Best Management Practices. Discharge Monitoring Reports have to be submitted annually.
The receiving stream, Yadkin River, is classified as WS-IV and B CA waters, from a point 0.6 mile
upstream of the High Rock Lake Dam to the Badin Dam. This reach is not listed on the 303(d) list as
impaired water.
COMPLIANCE SUMMARY:
The facility has an excellent compliance history. During the last 5 years, facility did not violate the
permit terms and conditions. Compliance Evaluation Inspection conducted on 11/21/2006 determined
that the facility is well maintained and operated.
PROPOSED CHANGES:
None
PROPOSED SCHEDULE FOR PERMIT ISSUANCE:
Draft Permit to Public Notice: July 1 (est.).
Permit Scheduled to Issue: August 24 (est.).
STATE CONTACT:
If you have any questions on any of the above information or on the attached permit, please contact
Sergei Chernikov at [phone].
Alcoa Power Generating, Inc. Falls Hydroelectric Powerhouse Fact Sheet
NPDES Renewal
Page 1

SOC Priority Project: No
To: Western NPDES Program Unit
Water Quality Section ' i (� �f I� �I ; �c , ,
Attention: Dina Sprinkle i i'
Date: September 8 2008 EF L00.
NPDES STAFF REPORT AND RECOMMENDATIONS DENR - WA — �1'tr� s:�uC;R U4J1rr
County: Stanly
NPDES Permit No.: NC0076775
PART I - GENERAL INFORMATION
1. Facility and address: Falls Powerhouse
Alcoa Power Generating Inc.
Yadkin Division
Post Office Box 576
Badin, N.C. 28009
2. Date of investigation: N/A
3. Report prepared by: Samar Bou-Ghazale, Environmental Engineer II
4. Person contacted and telephone number: Mr. Mark Gross, [phone]
5. Directions to site: From the jct. of Hwy. 740 and SR 1719 (Falls Road) in the Town of
Badin, travel east on SR 1719 to the end of the road (the road changes to SR 1727). The
Falls Powerhouse is located at the end of SR 1727.
6. Discharge point(s), list for all discharge points: -
Latitude: 35° 23' 44"
Longitude: 80° 04' 34"
Attach a USGS Map Extract and indicate treatment plant site and discharge point on map.
USGS Quad No.: E 18 NE
7. Size (land available for expansion and upgrading): There is little, if any, area available for
the construction of wastewater treatment facilities.
8. Topography (relationship to flood plain included): The Powerhouse is located on the main
segment of the Yadkin River; however, the hydroelectric generation facilities are not subject
to flooding.

Page Two
9. Location of nearest dwelling: The nearest dwelling is at least 1000 feet from the
Powerhouse site.
10. Receiving stream or affected surface waters: Yadkin River
a.
b.
c.
Classification: WS-IV and B
River basin and subbasin no.: Yadkin 03-07-08
Describe receiving stream features and pertinent downstream uses: The Yadkin
River is used for primary and secondary recreation and electricity generation. There
are no known water intakes several miles below this Powerhouse.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater: (MGD)
Outfalls 001, 003, and 005:
Outfalls 002 & 004:
Outfall: 007:
Outfall 001, 003, and 005:
Outfall 002 and 004:
Outfall 007:
0.432 MGD
0.0432 MGD
0.00072 MGD
Unit's 1, 2, & 3 generator cooling water.
Unit's 2 & 3 thrust bearing cooling water.
Powerhouse floor drains, wheelpit drains, oil & sludge
skimmer.
b. Current permitted capacity: The permit does not contain a permitted capacity.
c. Actual treatment capacity: Treatment is not provided at any of the six outfalls.
d. Description of existing or substantially constructed treatment works: There are no
existing treatment works nor are any proposed. For domestic wastewater disposal,
employees have an on -site subsurface disposal system.
e. Possible toxic impacts to surface waters: None. There are no biocides added to the
cooling water at this facility.
d. Pretreatment Program (POTWs only): N/A
2. Residuals handling and disposal scheme: There are no residuals generated.
3. Treatment Plant Classification: This facility does not meet the minimum criteria for a class I
rating.
4. SIC Code(s): 4911 Wastewater Code(s): 48 MTU Code(s): N/A

Page Three
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grants Funds (municipals only)? Public
monies were not used in the construction of this facility.
2. Special monitoring requests: None at this time.
3. Additional effluent limits requests: None at this time.
PART IV - EVALUATION AND RECOMMENDATIONS
The applicant, Alcoa Power Generating, Inc., operates a powerhouse (dam) on the Yadkin
River known as the Falls Powerhouse. There have been no changes and/or modifications to this
facility or the subject permit since the permit was last issued.
Pending review and approval by the Western NPDES Program Unit, it is recommended that
the permit be renewed as requested.
Signature of Report Preparer
Surface Water Quality Regional Supervisor
Date
?/J W
Date
SEP 1 1 2008
CuAufrr

ALCOA
August 1, 2008
N. C. Department of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, N. C. 27699-1617
Attention: Mr. Charles H. Weaver, Jr.
RE: NPDES PERMIT RENEWAL APPLICATIONS —
FALLS POWERHOUSE — NC0076775
NARROWS POWERHOUSE — NC0081957
TUCKERTOWN POWERHOUSE — NC0081949
HIGH ROCK POWERHOUSE — NC0081931
Mr. Weaver:
Alcoa Power Generating Inc.
Yadkin Division
293 NC 740 Hwy
PO Box 576
Badin, NC 28009-0576 USA
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
7005 3110 0003 6918 9935
ALCOA POWER GENERATING, INC
Attached, please find the NPDES permit renewal applications for Alcoa Power
Generating, Inc.'s four hydroelectric facilities. Alcoa Power Generating, Inc.'s present
NPDES permits are due to expire on January 31, 2009. The renewal application package
contains the following items:
• N. C. Short Form C - One signed original and two copies for each facility.
• Schematic of Water Flow - Three copies for each facility.
• Location Map - Three copies for each facility.
If you should have any questions or comments, please don't hesitate to contact me @
704-422-5701.
Yours Very Truly,
Tommy Gibson
Alcoa - Badin Works
cc: M. J. Gross - attachments
RECE IVED
2008
DENR - WATER QUALITY
POINT SOURCE BRANCH

NPDES PERMIT APPLICATION SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mailthe complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number
NC0076775
If you are completing this form in computer use the TAB key or the up - down. arrows to move from one
field to the next. To check the boxes, click your mouse on top of the box. Otherwise, please print or type.
1. Contact Information:
Owner Name
Facility Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
e-mail Address
Alcoa Power Generating, Inc
Falls Powerhouse
P.O. BOX 576
N.C. 28009
[phone]
[phone]
AUG - 2008
[e-mail]
2. Location of facility producing discharge:
Check here if same as above ❑
Street Address or State Road Falls Road
DFNR - WATFR Ol1AI ITY
POINT SOURCE BRANCH
City Badin
State / Zip Code N.C. 28127
County Stanly
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
Alcoa Power Generating, Inc
P.O. BOX 576
Badin
N.C. 28009
[phone]
[phone]
Page 1 of 4 C-MI 03105

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
4. Ownership Status:
Federal ❑ State 0 Private ® Public 0
5. Standard Industrial Classification (SIC) code(s): 4911
6. Number of employees: 4
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the processes that generate wastewaters. If the space provided is not sufficient attach a
separate sheet of paper with the system description.
See Attached Flow Diagram
8. Is facility covered under federal effluent limitation guidelines? No ® Yes 0
If yes, specify the category?
9. Principal product(s) produced: Electricity
Principal raw material(s) consumed: N A
Briefly describe the manufacturing process(es):
Hydroelectric Generation
Page 2 of 4 C-MI 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
10. Amount of principal product produced or raw material consumed
(List specific amounts consumed and/or units of production over the last three years
Product Produced or Raw Material
Consumed
(AVERAGE)
Product Produced or Raw Material
Consumed
(PEAK).
per Day
385 MW
806 MW
per Month
11,714 MW
24,528 MW
per Year
140,569 mw
294,336 MW
11. Frequency of discharge: Continuous 0 Intermittent El
If intermittent:
Days per week discharge occurs: ? Duration:
12. Types of wastewater discharged to surface waters only
Discharge
Flow
(GALLONS PER DAY)
Sanitary - monthly average
NA
Utility water, etc. - monthly average
NA
Process water - monthly average
2880
Stormwater - monthly average
NA
Other - monthly average
Explain: Cooling Water
1,383,120
Monthly Average
total discharge (all types)
1,386,000
13. Number of separate discharge points: 6
Outfall Identification number(s) 001, 002, 003, 004, 005, 007
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Yadkin River
Page 3 of 4
C-MI 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
15. Effluent Data
Provide data for the parameters listed. Temperature and pH shall be grab samples, for all other parameters 24-hour
composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly average.
If only one analysis is reported, report as daily maximum.
Parameter
Daily
Maximum
Monthly
Average
Units of
Measurement
Biochemical Oxygen Demand (BOD5)
NA
NA
NA
Chemical Oxygen Demand (COD)
NA
NA
NA
Total Organic Carbon
NA
NA
NA
Total Suspended Solids
NA
NA
NA
Ammonia as N
NA
NA
NA
Temperature (Summer)
NA
NA
NA
Temperature (Winter)
27
20
Celsius
pH
9.8
7.1
Units
Fecal Coliform (If sanitary waste is
present)
NA
NA
NA
Total Residual Chlorine (if chlorine is
used)
NA
NA
NA
16. List all permits, construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable):
Type
Hazardous Waste (RCRA)
UIC (SDWA)
NPDES
Permit Number Type
NA NESHAPS (CAA)
NA
Permit Number
NA
Ocean Dumping (MPRSA) NA
NC0076775 Dredge or fill (Section 404 or CWA) NA
PSD (CAA) NA Other NA
Non -attainment program (CAA) NA
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Oil & Grease
18. Is this facility located on Indian country? (check one)
Yes ❑ No El
Page 4 of 4 C-MI 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Mark J. Gross Facility Manager
Printed name of Person Signing Title
fl
North Carolina • l Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of nor more Than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Signature of Ap
Date
Page 5 of 4 C-MI 03/05

Powerhouse
Floor
Drains
FALLS POWERHOUSE
NPDES PERMIT NO. NC0076775
Yadkin River
v
FALLS
Unit One
Scroll Case
FALLS
Unit Two
Scroll Case
v
FALLS
Unit Three
Scroll Case
Units 1,2, and 3
Unit One
Unit Two
Unit Two
Unit Three
Unit Three
Wheelpits
Generator
Thrust Bearing
Generator
Thrust Bearing
Generator
Drainage
Cooling Water
Cooling Water
Cooling Water
Cooling Water
Cooling Water
432,000 Gal/Day
43,200 Gal/Day
432,000 GallDay
43,200 Gal/Day
432,000 Gal/Day
Oil and Sludge
Skimmer
720 GaUDay
Outfall # 007
Outfall # 005
Outfall # 004
Outfall # 003
Outfall # 002
Outfall # 001
Into Yadkin
Into Yadkin
Into Yadkin
Into Yadkin
Into Yadkin
Into Yadkin
River
River
River
River
River
River
Unit One Generator
Discharge per 24 Hrs.
1,551,226,600 Gals.
Unit Two Generator
Discharge per 24 Hrs.
1,712,880,000 Gals.
Unit Three Generator
Discharge per 24 Hrs.
1,712,880,000 Gals.

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• _ _
MAP TAKEN FROM USGS 7.5-MINUTE
QUADRANGLE BADIN. NC
-
GEL Engineering OF NC, Inc.
an Affiliate of THE GEL GROLIP,Ine.
GEL
Post Office Box 14262
Research Mangle Park. NC 27709
[phone]
PROJECT: aimx01608
Falls Powerhouse
Stanly County, North Carolina
SITE LOCATION
MAP
FIGURE
1
DATE: August 1. 2008
DRAWN BY: KDM
APPRV. BY: ADE

FACT SHEET FOR EXPEDITED PERMIT RENEWALS
Basic Information to determine Dotential for expedited Dermit renewal
Reviewer/Date
g on ej,e-ir L1, S- O 6
Permit Number
14 C_ p p . �(o q-4-. 5. ".
Facility Name
AL. CID 4 Pa w CA C r u ,aeA,,Ns rcr+z-t-
Basin Name/Sub-basin number
-O )4 to v4�'
ya_ 0 g'
Receiving Stream
Pep 14
Stream Classification in Permit
W S ---TU' I. C/4
Does permit need NH3 limits?
1-11
Does permit need TRC limits?
/.i o
Does permit have toxicity testing?
/40
Does permit have Special Conditions?
i1, 0
Does permit have instream monitoring?
1,1 0
Is the stream impaired (on 303(d) list)?
It--cew
Any compliance com liance concerns?
Any permit mods since last permit?
10g J J E---r Zv al --
Existing expiration date
j A1,.1 Si, 2009
New expiration date
J 4-,-. 31 201 `f
New permit effective date
- 1 a
Miscellaneous Comments
l' N ci % /-) PA t (7 ck- WA l"4-7S ✓n'1Uu-ri c
0- oc,A 'ru-ki1
D Ft-4.,,0p,r b
YES This is a SIMPLE EXPEDITED permit renewal (administrative
renewal with no changes, or only minor changes such as TRC, NH3,
name/ownership changes). Include conventional WTPs in this group.
YES ✓ This is a MORE COMPLEX EXPEDITED permit renewal (includes
Special Conditions (such as EAA, Wastewater Management Plan), 303(d)
listed, toxicity testing, instream monitoring, compliance concerns, phased
limits). Basin Coordinator to make case -by -case decision.
YES_ This permit CANNOT BE EXPEDITED for one of the following reasons:
• Major Facility (municipal/industrial)
• Minor Municipals with pretreatment program
• Minor Industrials subject to Fed Effluent Guidelines (lb/day limits for BOD, TSS,
etc)
• Limits based on reasonable potential analysis (metals, GW remediation organics)
• Permitted flow > 0.5 MGD (requires full Fact Sheet)
• Permits determined by Basin Coordinator to be outside expedited process
TB Version 8/18/2006 (NPDES Server/Current Versions/Expedited Fact Sheet)