NC0024406_Permit Application_20110830

° Duke
r ' Energy.,
August 29, 2011
Mr. Charles H. Weaver, Jr.
State of North Carolina
Department of Environment and Natural Resources
Division of Water Quality
Point Source Branch
1617 Mail Service Center
Raleigh, North Carolina 27699 -1617
CORPORATE EHS SERVICES
Duke Energy
526 South Church St.
Charlotte, NC 28202
Mailing Address:
EC13K / PO Box 1006
Charlotte, NC 28201 -1006
Subject: Duke Energy Carolinas, LLC — NPDES Permit Application
Belews Creek Steam Station - #NC0024406
Dear Mr. Weaver:
Duke Energy requests the subject permit be renewed and reissued. The above
referenced permit expires February 28, 2012 As mandated by North Carolina
Administrative Code 15A NCAC 2H.0105 (e), this permit application for renewal is
being submitted at least 180 days prior to expiration of the current permit.
Please find enclosed in triplicate, the renewal application, which includes the
following items:
EPA Form 1
EPA Form 2C
Site Map
Water Flow Diagram
Supplemental Information
g -u, Lp
D
1 AUG 3 0 2011
D TER ri�Al.l'FY J
- POINT SC1t iurc n'.., —.. t
Duke Energy requests notification that this application is complete.
Additionally, the attached report, "Assessment of Balanced and Indigenous
Populations in Belews Lake," continues to indicate recovery of aquatic populations
and includes a request to approve recommended monitoring program modifications
going forward. Therefore, this report also supports renewal of the current thermal
monitoring requirements of outfall #001.
www.duke-energy.com

Duke Energy requests that all temperature limits for outfall #001 be expressed
solely in degrees Fahrenheit or Celcius to eliminate confusion.
The following monitoring reductions and /or eliminations at outfalls 002 and 003 are
requested based on historical monitoring data,
Outfall 002 (Internal)
• Eliminate total suspended solids, arsenic, cadmium, chromium, nickel, silver,
zinc and mercury monitoring
• Reduce chloride and selenium from monthly to quarterly
Outfall_003 (Ash Basin Discharge)
• Reduce oil -& grease, total suspended solids, zinc, arsenic; phosphorous,
and nitrogen from quarterly to semi - annually
• Eliminate cadmium, chromium, nickel,, silver„ and fluoride monitoring
• Monitor iron and copper only during boiler chemical cleanings
• Reduce chloride, selenium, and sulfate from monthly to quarterly
• Reduce discharge flow measurement from weekly'to monthly
Thank you in advance for your assistance on this matter. Should, you have
questions regarding this application, please contact me at (704) 3824309
Sincerely,
Allen Stowe
Water Management
Attachments
cc w/ Mr Mike Thomas - NCDENR' Winston -Salem R.O.
Ms.,'Tri'sh MacPherson — ,NCDENR, Raleigh, N.C. ,(BIP Report 3 copies)

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NOTES v
1) USGS 7.5 Minute Series Topographic Quadrangle. Belews Lake (NC) DISCHARGE LOCATION MAP FIGURE
[Source: ftp: //ftp.nconemapcom /outgoing /raster /drg/J
NPDES Permit No: NC0024406
2) Property line information provided by Duke Energy and is approximate.
• Indicates approximate location of home assumed to be supplied by private drinking water well
[Source : Stokes County GIS Aerial (2008)] DUKE ENERGY
Drawn By: Chad Hearn SCALE BELEWS CREEK STEAM STATION
Project Manager: Bill Miller STOKES COUNTY, NORTH CAROLINA
Client: Duke Energy o o.tzs o zs o Miles
Date: 05/23/2011

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Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
General Information
Belews Creek (BC) Steam Station is a coal -fired electric generating plant operated by Duke
Energy Carolinas, LL- C. BC is located on Belews Lake at NC County Road 1908 approximately
eight miles northeast of Walnut Cove in Stokes County near Winston- Salem, North Carolina.
System descriptions and a line drawing showing the water flow through, BC follow; indicating
sources of intake water, operations contributing to the effluent, and treatment provided. Other
flows on the line drawing and in a brief narrative description of sources contributing to each
outfall effluent that follows are an approximation,of average daily station operation by operators.
OUTFALL 001— CONDENSER COOLING WATER (CCW)
Raw water from Belews Lake is passed through condensers and auxiliary equipment on a "once -
through'•' basis,to cool equipment and condense exhaust steam from the turbines. Cooling water
passes through a network of tubes in the condenser and selected heat exchangers (e.g. turbine
lube oil coolers, condensate coolers, miscellaneous closedosystem coolers). This raw water in the
condenser tubes absorbs heat from a closed system of highly purified exhaust steam from the
turbines and converts it back to water. The condensed exhaust steam is returned to the boilers
and recycled in this loop a number•of times. The raw cooling water is returned to the lake. No
chemicals are added and only heat rejected from the condensers and auxiliary equipment is
absorbed, hence the term "once through, non - contact cooling water" is applied.
The condensers at BC are cleaned mechanically. Normally, amertap balls clean the tubes on a
continuous basis while the plant is operating. Periodically., metal scrapers, plastic scrapers or
rubber plugs are forced through the tubes to rid them of,scale or other deposits.
Each unit at BC has four condenser cooling water (CCW) pumps Pump capacities are listed in
the table below. Normal plant operation of the CCW pumps is based on intake and discharge
temperatures and unit load. The maximum pumping capacity is 1457.28 MGD and the average
CCW flow for 2009 - 2011 was 1'278 MGD. To avoid a system trip that would suddenly reduce
the discharge flow at outfall 001, each unit is on an independent system. This practice'leads to
higher reliability factor for the units and protection of aquatic,life taking refuge in the discharge
canal during cold weather
1
No. of Pumps
Total Flow
(gpm)
Intake Temperature
°F
1
184M00
2
3331000
<61
3
44400
61 -69
4
506,000
>69
1

Belews Creek Steam Station, Stokes County
NPDES Permit #N00022406
Intake Screen Backwash
Each unit has 4 stationary intake screens (18 ft x 23 ft) which are removed forcleaning. The
intake screens are backwashed as needed at a rate of 500 gpm for approximately five minutes
each. The total volume of water used is 0.02 MOD This intake screen backwash is discharged
back into the station intake. The debris, is collected within a cleaning basin and consists mainly
of twigs, leaves, and other material indigenous to Belews Lake. The collected debris is removed
and composted.
Recirculated Cooling Water (RCW) System
The Recirculated Cooling Water (RCW) system is a closed.loop cooling water system.
Depending on the tempefature,of the raw lake water and the operation of BC, once through non -
contact- condenser cooling water is passed through the RCW coolers to maintain the closed loop
cooling waterwithin the RCW,system at <95 °F. The RCW system supplies cooling water to
various equipment and is composed of a storage tank, three 50% capacity RCW pumps, two
100% capacity heat exchangers (RCW coolers), and associated piping and valves for the two
units. Recirculated cooling watevis supplied from the CCW system to the RCW storage tank
(capacity of 19,000 gallons) and makeup water is added, as required per tank level and
temperature controls. The maximum flow of CCW through each of the two RCW coolers is'
5360 gpm or 7.72 MGD. Non - contact cooling water discharged from the RCW coolers
combines with the condenser cooling water and is discharged from outfall 001.
The RCW system contains maintenance chemicals in order to prevent corrosion. The primary
chemical used in the RCW system is- sodium nitrite. Microbiocides are also used.at very low
concentrations. The potential exists for the RCW system to have minor tube leaks; due to
material corrosion. Tube leaks from the'RCW system discharge'into the CCW system, which
discharges into Belews Lake through outfall 001. Routine monitoring, of the RCW system for
nitrite concentrations and the inventory of make -up water provides input that assists in
determining a tube leak. Once a leak is identified, corrective•measures are implemented to
minimize and repaired the leak. During routine maintenance the process water from the RCW
system drains to floor- drains where it is, pumped to the ash basin (outfall 003.) During a leak
and/or routine maintenance, the concentration of the maintenance chemicals will not exceed the
No Observed Effect Concentration (NOEL) at either outfall 001 or 003.
2

Belews Creek; Steam Station, Stokes County
NPDES Permit #NC0022406
Hydrogen and Oil Coolers
Once through non - contact cooling water is supplied' from the Low Pressure Service Water
System that draws water from the CCW system to hydrogen and oil coolers. The system consists
of two High Pressure Generator Hydrogen Coolers (maximum combined flow of 3,990 gpm),
four Low Pressure Generator Hydrogen, Coolers (maximum combined flow, of-3520 gprr), and
two Turbine Lube Oil Coolers (maximum combined flow of 7400 gpm) for each unit. A
maximum of 43.0 MGD of cooling watercan flow'through these coolers, when both BC units are
operated at full load Discharge from these coolers combines with the condenser cooling, water
flow and discharged at out'fall 001.
Station Equipment Cooling Water
Once through non - contact cooling water is supplied from the Low and High Pressure Service
Water System to the bearings of the induced draft (ID) fans to remove excess heat. No
chemicals are added to the once through raw lake water discharged to Belews Lake. The rate of
flow through the control equipment is approkimately 0.86 MGD when both BC units are
operated at full load. This effluent also includes chiller once through water.
Outfall 002 — Treated FGD Wet Scrubber Waste_ water to Ash Settling Basin
(Internal NPDES Outfall)
The Wet Flue Gas Desulfurization (FGD) system was installed at Belews Creek in 2008 for the
reduction of Sulfur Dioxide (S02) from the stack gas. The FGD system follows the electrostatic
precipitators (which removes fly ash) and also the, Selective Catalytic Reduction (SCR) systems
(which uses anhydrous ammonia for nitrogen oxide (NQ,) control). The use of this equipment
entails the use of or production of. calcium sulfite, vanadium pentoxide, calcium carbonate and
sulfur.
Sulfur Dioxide is produced from the coal combustion process. The FGD system removes S02 by
a reaction using a limestone -water slurry The FGD system will collect the flue gas after it
passes through the electrostatic precipitator and route the gas to the absorber tank. As the gas
rises through the tank to the outlet•at the top, the gas passes through.a spray header. An
atomized slurry of water and limestone droplets is continually sprayed through this header into
the stream of flue gas. The S'02 in the flue gas reacts with the calcium in the limestone and
produces calcium sulfite (CaS03). This CaS03 slurry falls to the ,bottom of the tank where a
stream of air is injected to oxidize the slurry to form gypsum (CaSO4 H20). The gypsum slurry
is drawn off the absorber tank,and pumped to a hydrocyclone where solids are removed and part
of the slurry is sent to a vacuum belt filter for dewatering The solids (gypsum) may then be
used in making - wallboard.
Part of the slurry is blown down to primarily keep the FGD chloride concentration below 12,000
ppm. This water is sent to a wastewater treatment system in order to remove solids, metals and
reduce the temperature Initially the wastewater is sent to an equalization tank to allow`for a
3

Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
more constant flow and solid loading to the next treatment steps. The waste water from the
equalization tank is pumped through three reaction tanks where pH is adjusted, metal treatment
and coagulation occurs. After the treatment occurs in the reaction tanks, the wastewater is sent
to two clarifiers in order to reduce the solid loading. Once the wastewater leaves the clarifiers
the pH is readjusted and the wastewater is cooled by a heat exchanger. The treated wastewater is
then pumped to a two stage biological treatment system in order to reduce the selenium
concentrations. Leaving the biological treatment system the treated wastewater is mixed with the
cooling water from the heat exchanger in order to reduce the chloride concentration. This treated
wastewater is then discharged to the ash basin via outfall 002.
The following chemicals are utilized in the FGD wastewater treatment system: hydrated lime,
ferric chloride, polymer. hydrochloric acid, nutrients
OUTFALL 003 - ASH BASIN
The ash basin accommodates flows from the power house sumps, yard holding sump, ash sluice
lines, the chemical holding pond, the coal yard sumps, rainfall run -off ft'IQiM &a watP, bcd of s
thalwAim., Seepage from the toe - drains at the base of the ash basin dikes goes to the Dan River.
e toe - drains are needed to allow, as designed, seepage to occur from the earthen dikes. This
design ensures the structural integrity of the dikes.
Yard Holding Sump
Wastewater can accumulate in the yard holding sump from the power house sumps, the
condenser feedwater system, and the coal yard sumps.
Power House Sumps
The Power House Sumps discharge to the yard holding sump and include wastewater from water
treatment equipment, floor wash water, equipment cooling water, and miscellaneous leaks. The
Power House Sump receives wastes from the following systems:
❑ Water Treatment System
The water treatment system consists of one retention tank, three pressure filters, two activated
carbon filters, one Reverse Osmosis (RO) system, and one set of makeup demineralizers. The
pressure filters each have a capacity of 250 gpm. Filters are backwashed twice daily. The
pressure filter media is composed of rock and sand, therefore all backwash discharge is organic
buildup from the service water.
Make up demineralizers are operated in sequence (one cell at a time). Regeneration of these
cells is required approximately every 40 days. Each regeneration requires 120 gallons of 66°
Be sulfuric acid and 600 gallons of 50% sodium hydroxide. An average dilute waste chemical
and rinse flow of 0.34 MGD is realized (for two hours per regeneration). The diluted acid and
caustic are discharged to the yard holding sump and then pumped to the ash basin. The useful
rd

Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
life of the resin varies and when replacement is needed the spent resin is sluiced to the ash
basin. ,
The RO system is cleaned on an as needed basis using Osmonics AD -20 (275 lbs), Biomate
MBC 781 (2.5 gal`), sodium, laurylsulfate (10� lbs) and sodium hydroxide (4 L)
'❑ Condensate Feedwater System
The condensate feedwater system provides continuous flow- through boiler feedwater to BC
supercritical pressure boilers. Condensate polishing demineralizers of the powdered resin type
are used to filter feedwater. The, mixed anion - cation powdered resin provides filtering and ion
exchange. Spent resins and associated wastes are pumped to the ash basin for treatment and
disposal.
❑ Evaporative Losses, Soot 'Blowing
Exhaust steam from the turbine is used periodically`to blow soot off the outside of the boiler
tubes. Thus, some of the condensate feedwater is evaporated in the boiler,.
❑ Turbine and Boiler Room Drain 'System
Turbine ,and' boiler room drains receive flow from once through non - contact cooling water of
the Station air conditioning system, the fire protection system, washdown, and,miscellaneous
Station uses
❑ Station Air Conditioning
Once through non - contact §cooling water is supplied,from the Low Pressure Service Water
System to cool the Station air conditioning equipment. A maximum combined flow of 3.46
MGD of cooling, water can,flow through two chiller units. No chemicals are added to, the
once through raw lake water that drains to the Station sumps where it is pumped'to the ash
basin.
❑ Fire Protection, Washdown, and Miscellaneous Station uses
The fire protection system, washdown, and miscellaneous station uses from closed system
drainage, cleaning, and testing can.contain-
Corrosion inhibitors, e.g. Calgon CS and Betz, Powerline 3201
Biocides, e.g. Calgon H -300 and H -5,10
Laboratory wastes
Cleanings (e.g small heat exchangers) Dispersant, e.g polyacrylamide
Wetting agent, e.g. sodium lauryl sulfate
Detergent, e.g. tri= sodium phosphate.
Leak testing, e.g. disodium fluorescing dye
5

Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
Miscellaneous system leakage's (small leaks from pump packings and seals, valve seals, pipe
connections)
Moisture separators on air compressor precipitators
Floor wash water
Emergency fire fighting water
Ash sluice system overflow
Low Volume Wastewater.
❑ Fly and Bottom Ash Sluicing
Electrostatic precipitators are used to remove fly ash from the stack gases. The ash is treated in
thet flue gas ductwork with SO3 conditioning to improve removal efficiency. Typically, the dry -
fly ash captured in these precipitators is collected in temporary storage silos for subsequent
disposal in a permitted,on -site landfill or for recycling in,off -site ash utilization projects If the
system that collects the dry -fly ash is `not operating, then the fly ash can be sluiced to the ash
basin. Bottom ash from the boilemis usually water sluiced to holding cells for°recycling
activities per reuse permit #WQ0007211. In the case of equipment failure or immediately
following an outage, service water is used to sluice the ash to the, ash basin.
Electrostatic precipitators are normally cleaned by mechanically rapping the wires and'the plates
inside the precipitator-. Before major,precipitatof work is performed they are cleaned by a wash
down. The wash water is pumped to the ash basin from the yard drain sumps
As contingency measures, if the levels of regulated parameters are increasing one option,that
may be periodically implemented is to sluice service water (from Belews Lake) to the ash basin
to co -manage the various waste streams that are discharging to the ash basin.
Coal Yard Sumps
The coal yard covers approximately 51.5 acres. The average rainfall fun -off is 0.08 MGD. This
run -off is based on 40 inches of rain per year with 50% run -off During winter, freeze
conditioning agents (i.e. diethylene glycol) may be added to coal by 'a vendor °prior to shipment
or sprayed on the coal pile to prevent freezing Based on an application rate of two pints of 50
ppm di-ethylene glycol per ton of coal and 10,000 tons of coal per train load, the addition of
freezing agents will not significantly alter,the coal pile run -off waste stream and the discharge of
the ash basin at ouffall 003.

Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
Most of the coal yard drains into the ash basin near the point of ash influent. Floor wash water
from equipment in the coal handling area and the remaining drainage from the coal yard flows to
the coal yard sumps where it is then pumped to the ash basin.
Consolidated Sump
The consolidated sump includes wastewater from the sanitary waste system, the storm water
'wndS the limestone unloading facility sump and wastewater from the dry fly ash and
gypsum landfills.
The sanitary waste from the plant receives primary treatment in a 600,000 gallon capacity
aerated lagoon. The lagoon discharges to a concrete chlorine contact chamber. To polish the
effluent, the sanitary waste system routes a circuit of water treated with chlorine to the
consolidated sump which is routed to the ash basin. The expected flow from the sanitary
treatment system is less than 10,000 gpd.
The storm water collection pond collects storm water runoff from the gypsum and limestone
stockpiles as well as some of the limestone track area around the unloading facility. If the pumps
for the sump fail, there is an overflow to Belews Lake, possibly resulting in intermittent
discharge.
There are two on -site landfills at Belews Creek, the FGD Residue landfill and the Craig Road
Ash landfill. These landfills are located south east of the power station. The leachate and the
contact stormwater from these landfills is collected and pumped to the ash basin. The FGD
Residue landfill accepts gypsum and treatment residues. The Craig Road Ash landfill stores
flyash, gypsum that is not suitable for beneficial use and clarifier sludge from the FGD
wastewater treatment system. This material is filter pressed before it is placed in the landfill.
Both landfills began operation in 2008.
Ash Basin Run -Off
Non -point sources of storm water to the ash basin include coal pile runoff. Based on forty inches
of rain per year with fifty percent run -off, and the watershed area of the ash basin, the yearly
average rainfall run -off to the ash basin is approximately 0.47 MGD.
Boiler and Filter Cleaning Wastes
BC has two supercritical boilers that are cleaned on an as needed basis. Tube inspections are
done during outages to determine when cleaning is needed. The chemical cleaning wastes are
pumped to the chemical holding pond. After proper treatment, the pond effluent is discharged
into the ash basin at a controlled rate to provide further treatment. The chemicals and
approximate amounts for one boiler cleaning are as follows:
7

Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
BOILER CLEANING CHEMICALS & AMOUNTS USED PER UNIT
Chemical' Amount
Hydroxyacetic acid 50,312' lbs
Formic Acid* 20,598, lbs
Ammonium Hydroxide *(26 °Be') 2,063 gal
Ammonium Bifluoride* 4249 lbs
Hydrazine 718 lbs
Corrosion Inhibitor (Proprietary) 500 lbs
The Reverse Osmosis (RO) system is used treat raw water from Belews Lake. The RO system is
cleaned approximately 4 -6 times per year. The RO cleaning wastes are pumped to the ash basin
Chemicals and approximate, quantities for one RO cleaning are listed below;
REVERSE OSMOSIS (RO) SYSTEM
Chemical Amount
Osmonics AD -20
275 lbs
Biomate MBC 781
2.5 gal
Sodium Laurylsulfate
10 Ibs,
Sodium Hydroxide*
15 gal
The condensate polisher filters are cleaned with sodium hydrosulfite, approximately once every
five years. The chemical and approximate quantity used per year for this cleaning'is listed
below-
,Chemical Amount
Sodium Hydrosulfite 3000 lbs
* These chemicals are pre "sent in amounts greater than the reportable ,quantity as identified
under the Comprehensive Environmental Response, Compensation, and Liability Act
(CERCLA). If a spill of any-these chemicals were to occur, in most cases, the spill
would be routed to the ash basin for treatment. These chemicals are being identified to
qualify for the spill reportability exemption provided under 40 CER 117 and
CERCLA.
Spill Prevention
BC has one large above ground oil storage tank (260,000 gals). A concrete dike designed to
contain the entire contents of the tank in the event, of an accidental, rupture surrounds this tank.
All oil storage facilities are covered under the BC Spill Prevention Control and Countermeasure
Plan.

Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
Hazardous and Toxic, Substances Table 2c- 3:
At Belews Creek Steam Station, the potential for toxic and hazardous substances being
discharged is very low. In reference to Item V -D of Form 2 -C, the substances identified under
Table 2c -3 that may be in the discharge are as follows:
Acetaldehyde, Asbestos, Benzoyl Chloride, Butyl Acetate, Cresol, Cyclohexane,
Cyclohexanone, Epichlorohydrin, Formaldehyde, Furfural, Monoethyatnine, Naphthenic Acid,
Pyethrins, Stryrene, Triethanolamine, Vanadium, Vinyl,acetate, Xylene, and Zirconimum and
also during the, course of the year products such as commercial cleaners and laboratory reagents
may be purchased which contain very low levels of a substance found-in Table 2c -3. It is not
anticipated that these products will impact the ash basin's capacity to comply with its toxicity
limits,, since their concentrations are extremely low.
40 CFR 117 and CERCLA Hazardous Substances:
The table below identifies hazardous substances located on -site that,may be released to the ash
basin during a spill in quantities equal to or greater -than the reportable quantity (RQ) levels as
referenced in 40 CFR 117, 302 and 355. This list is being provided in order to qualify for the
spill reportability exemption provided under 40' CFR 117 and the Comprehensive Environmental
Response Compensation and Liability Act (CERCLA) These values below represent the
maximum quantities on -site that could be released at one time and sent to the ash basin. They do
not reflect quantities that a"re discharged through typical use.
CHEMICAL AMOUNT Obs) SOURCE
Ammonia 4,055,000 General Site
Sodium 10 Warehouse
Sodium Hydroxide 25,520 Water Treatment Room
Sulfuric Acid 61,228 Water Treatment Room
Belews Lake Balanced and Indigenous Populations
The attached report entitled, "Assessment of Balanced Indigenous Populations in Belews Lake
Near Belews Creek Steam Station ", indicates balanced and indigenous populations are
recovering. Recovery of populations in Belews Lake is associated with a decrease of selenium
bioaccumulation in populations of Belews Lake, following installation of a system to collect and
landfill dry -fly ash in 1984 and reroute of the ash basin discharge from Belews Lake to the Dan
River in 1985. The fish eating advisory on Belews Lake was recently revised by the North
Carolina Department of Environment, Health and Natural Resources from all fish species to only
three species (common carp, crappie, and redear sunfish). Duke Energy continues to maintain an
environmental monitoring program on Belews Lake and the Dan River to assess populations.
Annual summary reports of environmental monitoring of the Dan River per Part III.S of the
present NPDES permit- indicates that reroute of the ash basin discharge from Belews Lake to the
E

II
• Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
Dan River has had no adverse impact on the balanced and indigenous populations in the, Dan
River,
Duke Energy's operating experience during the past five years under the thermal limitations
imposed in NPDES Permit No. NC #0024406 substantiates for Belews Creek Steam Station that
the "thermal component of the discharge assures the protection and propagation of shellfish, fish
and wildlife in and on the receiving body of-water.
Ash Basin Capacity
Part III Section R of 'the existing NPDER, permit -for BC requires the permittee to provide ands
maintain at all times a minimum free water volume (between the top of the sediment level and
the minimum discharge elevation) equivalent'to the sum of the maximum 24 hour plant
discharges plus all direct rainfall and all runoff flows to the pond resulting from a 10 year, 24
hour rainfall event, when using a runoff coefficient of 1.0.
Estimate Runoff to the Ash Basin from a 10 -yr 24 -hr storm
Natural Drainage Area of Ash Basin =
Station Yard Drainage Area Pumped to Ash Basin =
Total-
2 Precipitation from 10 -yr 24 -hr storm =
3 FGD, System Sumps Discharge to Ash Basin
(2,100 gpm capacity for 24 hrs) =
4 Total Stormwater Runoff to Ash Basin =
(Assuming 100% runoff)
Estimated Maximum 24 -hr Dry Weather Waste Stream Discharging to Ash Basin
Maximum recorded Ash Basin Discharge =
2 Increase maximum daily discharge by 10% for
conservatism and convert units to acre -feet =
10
6550
Acres
876
Acres
7426
Acres
5 1 Inches
93 Acre -feet
327491 Acre -feet
17,900,000 Gallons /day
60 42 Acre -feet

c Belews Creek Steam Station, Stokes County
,• NPDES Permit• #NC0022406
1.
I11' WevWeather Detention Volume
Sum of Parts' I and 11 =
385 33 Acre -feet
V. Estimated Quantity of Solids (Bottom Ash) to be discharged to Ash Basiri through December 31, 2017
Note NPDES Permit expiration date 1s' 2/28/12
Time Period
Actual or Estimated Coal
Consumption (1000's tons)
%Ash
Estimated Total
Ash Production
(1000 s tons)
Estimated
Bottom Ash
Production
(1000's tons)
Estimated
Bottom
Ash
Utilization
(,1000's
tons)
Estimate
Bottom
Ash to
Ash bass
(1000's
tons)
July- December 2004
2,793 00
12 10%
35680
3925
7 10
32 15
2005
5,65360
12,110%
68520
75 37
1850
5687
2006,
5,771 10
1226%
70400
77 -44
1930
58 14
2007
5,55920
1240%
691 00
7601
1770
5831
2008
6,37080
1180%
74920
8241
14 10
6831
2009
5,58200
1134%
64760
7124
1730
5394
2010
5,54890
1157%
65680
7225
250
6975
2011
6,00490
1276%
78390
8623
500
8123,
2012
6,01140
1174%
12200
7042
15,00
6442
2013
5,701 50
1071%,
62470
6872
1,500
53 72
2014
5,733 80
940%
55140
6065
1500
4565
2015
5,962 10
940%
57340
6307
1500
4807
2016
5,64540
940%
54290
5972
1'5 00
4472
2017
5,628 10' 1940%
1 54130
5954
1-500
4454
Total
779,65 80 1
-15632%
1 8830`20
971 -32
1.91 50
77982
* Calculation assumes an in -place ash Aensity of 55 lbs per cubic foot.
Estimated Total Storage Volume Required through 2017
Wet Weather Detention Volume =
Required Storage Volume Through 12/31'/2015 =
Results
'I Ash Basin @ Pond Elevation 750 0' +0"
Estimated Solids,to Basin July 2004 - Dec 2017
Total
11
385 3 Acre -feet
385 3 Acre -feet
34060
Acre -feet
7798
Acre -feet
26262
Acre -feet

T
Note Available Storage based on basin survey dated 07/16/04
Available Storage,> Required Storage
Belews Creek Steam Station, Stokes County
NPDES Permit #NC0022406
Based on these calculations, there is sufficient capacity in the ash basin to provide the
retention volume specified in the permit through the year 2017
12

Please Dnnt or tvoe in the unshaded areas only
Form Approved OMB No 2040 -0086
FORM
US ENVIRONMENTAL PROTECTION AGENCY
I EPA I D NUMBER
1
e* GENERAL INFORMATION
6
T,A
F
D
e°.EPi4 Consolidated Permits Program
NC 0 0 2 4 4 0 6
GENERAL
(Read the 'General Instructions" before starting')
2 3
td 15
GENERAL INSTRUCTIONS
LABEL ITEMS
If a preprinted label has been provitled affix it in the
"
designated space Review'the information carefully, if any of it
is incorrect, cross through i and enter the correct datasin the
appropnate,fll- imarea below Also,,if any, of the preprinted data
is' absent (the area to the ileft of'the label space lists the
_
I EPA I D ,NUMBER
III FACILITY NAME
,PLEASE,PLACE1ABELJN THIS SPACE
n6rmahon that should appear), please provide Win the7 proper
fill -in area(s) below If the label is complete and correct, you
need not complete Item "s I -III, V, and VI (except VI -B which
V FACILITY°MAIL'ING
ADDRESS
must be completed regardless) Complete all items if no label
-
has been provided Refer to the instructions for detailed item
descriptions and for the legal authorizations under which this
VI FACILITY LOCATION , '
data+ is collected
II POLLUTANT CHARACTERISTICS
INSTRUCTIONS Complete A through J to determine whether you need to submit any permit, application forms to the EPA If you answer "yes" to any questions, you must
submit this form and the supplemental form listed in the parenthesis following the question Mark "X" in the box in the third column f the supplemental form is attached If
you answer "no" to each question, you need not submit any of these forms You may answer "no" if your activity is excluded from permit requirements,, see Section C of the
instructions See also, Section D of the instructions for definitions,of bold -faced terms
Mark
"X"
'Mark
"X"
SPECIFIC QUESTIONS
SPECIFIC QUESTIONS
L
YES
NO
'FORM
ATTACHED
YES
NO
_
FORM
_ATTACHED
A Is, this facility a publicly owned treatment works mhich
B Does or will this facility, (either existing or proposed)
results mra discharge to'waters of the U S ? (FORM 2A)
X
include a concentrated animal feeding operation or
aquatic animal production facility which results in a
/2B)
16
17
16
16
20
21
discharge to waters of the U S9 (FORM
C Is this a facility which currently results in discharges to
�/
X
D Is this a proposed,facility (other than those described in A
waters of the U S other than those described in A or B
or B above) which will�result,in a discharge to waters of
above? (FORM 2C)
the U S ? (FORM 2D)
22
20
25
26
27
E Does or will this facility treat, store, or dispose of
F Do you or will you inject at this facility industrial or
hazardous wastes? (FORM 3)
X
municipal effluent below the lowermost stratum
X
containing, within one quarter mile of the well bore,
underground sources of drinking water? (FORM 4)
26
m
30
31
32
33
G Do you or will you inject at'this facility any produced water
H Do you or will'you inject at this facility fluids for special
or other fluids which are brought to the surface in
processes such as mjning of sulfur by the Frasch process,
connection, with conventional oil or natural gas production;
X
solution mining of minerals, in� situ combustion of'fossd
X
inject fluids used, for enhanced recovery of oil or natural
fuel, or recovery'of geothermal energy ?'(FORM 4)
gas, or inject fluids for storage of liquid hydrocarbons?
(FORM 4)
34
35
36
37
W
39
I Isithis facility a proposed stationary source which is one
J Is this facility a proposed stationary source which is
of the 28'industnal categories listed in the instructions and
�/
X
NOT one of the 28 industrial categories listed in the
X
which will potentially emit 100 tons per year of any air
instructions and which will potentially emit 250 tons per
pollutant regulated under the Clean Air Act and may affect
year of any air pollutant regulated under the Clean Air,Act
40
61
92
or be located in an attainment area? (FORM 5)
and may affect or be located in an attainment area?
(FORM 5)
III NAME OF FACILITY'
1 SKIP Belews Creek Steam Station
-,
IV FACILITY CONTACT
A NAME & TITLE (last, first, &wide)
B PHONE (area code,& no) '
z
3 -4" 0 "
Stowe, J Allen enior Environmental Specialist ( 0 ') 2
15
18
45 s6 de d9 51 52 55
V FACILTY MAILING ADDRESS
A STREET OR P O BOX
`
3 5 6 South C urc Street Inter? face Mail -
EC13K
5 16
45
B CITY OR TOWN
C STATE D rZIP CODE p �/r `g.0 20'1'
U c9
a
Charlotte,
C' 2. ,
41 a2 4] 51
15
16
40
VI FACILITY LOCATION
A STREET, ROUTE NO OR'OTHER SPECIFIC IDENTIFIER "
5 e Hall Roa
3 9 in
5 16
45
B COUNTY NAME
-
4 <
Stokes
46
]0
C CITY OR TOWN
D 'STATE
I E ZIP CODE
F COUNTY CODE (ifknown)
„
6
B 1 w Ad
C I
2, 0 9 11
3
15
1X16
40
41 d2
4] 51
i2 34 -
EPA Form,3510 -1 (8 -90) CONTINUE ON REVERSE

1"IIKITIMI ICrI CGrIAA TI-IF FRrIMT
EPA Form 3510 -1 (8 -90)
VII SIC CODES 4{h n,, in order of non
A FIRST B SECOND
(sped) °
7
(specify)
7491'1'
15
18 1B
electric services
15
16 19
C THIRD D FOURTH
c
(,Pe fy)
(sped),
7
15
18 19
15
16 19
VIII OPERATOR INFORMATION
A NAME B Is the name Ilsted'In Item
c
VII -A also the owner
8
Duke Power" IC © YES ❑ NO
5,
16 55 66
C STATUS OF OPERATOR (/inter the appropriate letter into the answer box if "Other, spec)
D PHONE, (area code & no)'
F'= FEDERAL
M = PUBLIC (other than federal or state)
P
(sped)
A
(7 0 4) 382-4.30,9
S = STATE
O =OTHER (specify)
P = PRIVATE
%
15
6 18 19 21 22 26
E STREET OR P O BOX
- r• -
412'1 South 1Ch7ur-ch Street
F CITY OR TOWN _
G STATE H ZIP CODE
JIX INDIAN LAND
I s °the facility located on Indian lands
JB
Charlotte
NC
28242
C] YES 121 NO
52
15
16 40
41
12 4] 51
X ,EXISTING ENVIRONMENTAL PERMITS
D PSD Air Emrslions romPro osedSources
^ a
_ --
A -NPDES Drschar es to Surace.Wafer
c_
g
T
1 N
I
N00024406
C
g
T
1 p
I
0 Air
B UIC Under round In ecnon o Fluids
_ E OTHER s ecr _
C
r
I
c
T
8 -03, 8 -04, 85 -05
(Inspecr)
dustrial Landfill
9
U
g
151
161
17118
30
15
i6
1] 18
30N
C RCRA, Hazardous Waller
E OTHER (s )ecr
C
T
=CJ T r ecr
g
R
NCDO`00856591
g WQ0000452 str b ut ion of Residual solids
15
16
117
1 16 30
15 16 i] 18 26
XI MAP
Attach to this application a topographic map of the area extending to.at least one mile beyond property boundaries The map must shoWtfie outline +of the facility, the
location, ofe each of Its existing and proposeddntake and discharge s$uctures, eachrof its,haiardods waste treatment, storage, orldlsposal facilities, and eachlwell where It
Injects fluids underground Include,all,spnngs, rivers, and other surtaceiwater bodies in the map area ,See InstructionsJorlpreclse requirements
Al NATURE OF BUSINESS,(providva bnefdescnphon)
Coal Fired Electric Generation
XIII CERTIFICATION (see instructions)
I certify under penalty of law that hhave personally examined,and am,famihar with'the information submitted in this apphcahon, and =all attachments and,that, based on my
inquiry of those persons immediately responsible for obtatrnng,the information contained in the application, I believe that the information is4rue, accurate, and complete I
am aware -that there are significant penalhesrfor submitting, false information, including the, possib!hty of fine and imprisonment'
A NAMEWOFFICIAL TITLE (type or p
SIGNATURE
C DATE SIGNED
Jesse E. Huntley II General Mgr
C1
III Regulated Fossil Stations
mv,
COMMENTS FOR OFFICIAL USE ONLY
C
1s,
16
EPA Form 3510 -1 (8 -90)

EPA I D NUMBER (copyfrom Item l afForm (') Form Approved
OMB No 2040 -0086
Please onnt or Noe in the unshaded areas onlv NCO0244 06 Approval, expires 3 -31 -98
FORM
2CA
NPDES
US ENVIRONMENTAL PROTECTION AGENCY
APPLICATION FOR PERMIT TO DISCHARGE WASTEWATER
,CfEPA EXISTING MANUFACTURING, COMMERCIAL, MINING AND'SILVICULTU RE! OPERATIONS
Consolidated Permits Program
I OUTFALL LOCATION
For each outfall, list the latitude and longitude of its location to the nearest 15,seconds and the name of the receiving water
A OUTFALL NUMBER,
B LATITUDE
C LONGITUDE
D RECEIVING WATER (name)
1 DEG
2 MIN
3 SEC
1 DEG
2 MIN
3 SEC
001
36
16
49 5
80
03
39 8
Belews Lake
003
36
18
22 0
80
04
50 7
Dan River
002
36
13
18 0
80
03f
53 '8
.Ash Basin(Internal Outfall)
II FLOWS, SOURCES OF POLLUTION, AND TREATMENT TECHNOLOGIES
A Attach a line drawing showing the water flow through the facility Indicate sources of,lntake water, operations contributing wastewater to the effluent, and treatment units
labeled to correspond to the more detailed descriptions in Item B Construct a water balance on thedine drawing by showing average flows between intakes, operations,
treatmentlurnts, and outfalls If a water balance cannot be determined (e g, for certain mtmng•ac'hv_thes), provide a pictonal,description ofAhe nature and amount of any
sources of water and any, collection or treatment measures
IB For each outfall, provide a descnption�of a(,) All operations contributing wastewater to the effluent, including process' wastewater, sanitary wastewater; cooling water,
and storm water runoff, (2) The average flow contributed by each operation, and (3) The treatment, received by the wastewater Continue on addlt(onat sheets If
necessary`
1 OUT-
2 OPERATION(S) CONTRIBUTING FLOW
3 TREATMENT
FALL
NO (hit)
a OPERATION (list)
b AVERAGE FLOW
(include units)
a DESCRIPTION
b LIST CODES FROM
TABLE'2C -1
001
once Thru Cooling water,
Miscellaneous Equipment,
1278 MGD
Discharge to Surface water -
4A
Non = Contract Cooling Water
003
Ash'Settling Pond,
9 MGD
Coagulation, Sedimentation, Neutralization,
2D
1V
Discharge with Storm Dzairi
Ion Exchange, Surface water Discharge
2K
.2J
4A
002'
Flue Gas Desulfurization� wastewater
0 7 MGD
Sedimentation,
-
1V,
2K
"(Internal outfall)
_
Coaugulation, Chemical Precipitation
2L,
Reduction, Neutralization
3C
Belt Filtration
5C
Landfill'
SQ
OFFICIAL USE ONLY (effluent guidelines sub - categories)
EPA Form,3510 -2C (8 -90) PAGE 1, of 4 CONTINUE,bWREVERSE

rr1NTINIIIFr 1PPr)M THP FRONT
C Except for storm runoff, leaks,,or spills, are any of the discharges described In Items II -A or B'Intermittent'or seasonal?
❑ YES (complete the following table) Z NO (go to Section III)
3 FREQUENCY
4 FLOW
a DAYS;PER
`B TOTAL VOLUME
2 OPERATION(s)
WEEK
b MONTHS
a_ FLOW RATE (in mgo
(specify with unus)
LONGTERM
2 MAXIMUM
1 LONGTERM
2 MAXIMUM
'1 OUTFALL
CONTRIBUTING FLOW
(spec)
PER YEAR
'(spec
C DURATION
(in days)
NUMBER(hst)
(list)
average)
average)
AVERAGE
DAILY
AVERAGE
DAILY
III PRODUCTION
A Does an effluent guideline limitation promulgated by EPA'under'Section 304,of,the Clean Water Act apply to your facility?
m YES (complete Item 111 -B) ❑ NO (go to Section It7
B Are the,limdati- ons in the applicable effluent guideline, expressed in terms of production (or other measure of operation)?
7
11 YES (complete,liem 111 -C) ,m NO'(go to Section 117
Clfiyowanswered' "yes° to Item III -B, list the quantity which'represents an actual measurement of your level of production, expressed In the terms and units used In the
applicable effluent guideline, and Indicate the affected outfal(s
1 AVERAGE DAILY'PRODUCTION
2 ,AFFECTED OUTFALLS
(list ou(all numbers)
a QUANTITY, PER DAY
b UNITS OF MEASURE
c OPERATION, PRODUCT, MATERIAL „ETC-
(specify)
N/A
N/A
N/A
N/A
,IV IMPROVEMENTS
A Aie,you now required by any Federal, State or local authority to meet any Implementation schedule for the construction, upgrading or operations of wastewater
'treatment equipment or practices or any other environmental programs which may affect the discharges described in this application? This Includes, but is not limited to,
permit conditions, administrative or enforcement orders, enforcement compliance schedule letters, stipulations, court orders, and grant or loan conditions
❑ YES (complete the following - sable) NO (goito'hemilV -R)
1 IDENTIFICATION OF CONDITION,
2 AFFECTED OUTFALLS
3 BRIEF DESCRIPTION OF PROJECT
4 FINAL COMPLIANCE DATE
AGREEMENT, ETC
a NO
b SOURCE OF DISCHARGE
a REQUIRED
b PROJECTED
N/A
N/A
i
N/A
N/A
N/A
N/A
B OPTIONAL You, may attach additional sheets describing any additional water pollution control programs (oi other e`nvir`onmental projects which may affect your
discharges) you now have underway or which you plan Indicate whether each program is now underway or planned, and indicate your actual or planned schedules for
construction
❑ MARK "X7 IF DESCRIPTION OF ADDITIONAL CONTROL PROGRAMS IS ATTACHED
EPA Form 3510- 2C,(8 -90) PAGE,2 of '4 CONTINUE ON PAGE 3

nnwTimi IFrVFRr1M�THF FRr1NT
EPA,FL4 3510 -2C (8 -90) V PAGE 4 of 4
VII BIOLOGICAL TOXICITY TESTING DATA
Do you have any knowledge or reason to believe that any biological test for acute or chronic toxicity'has been made on any of your discharges,or on a receiving water_in
relation to your discharge within the last 3 years?
© YES (identify the ieyt(s) and describe their purposes below) ❑ NO (go to Section Vill)
ToxYcity testing is performed as required by the current station NPDES permit 'The chronic toxicity testliis
conducted and reported quarterly for the ash basin discharge(Outfali 0031
VIII CONTRACT ANALYSIS INFORMATION
Were any of the analyses reported in Item V performed by a contract laboratory or consulting firm?
® YES (list the name, address, and telephone number of, and pollutants analyzed by, ❑ NO (go to Section IX)
each such laboratory orfirm,below)
TELEPHONE
D,POLLUTANTS ANALYZED
A NAME
B ADDRESS
(area code &.no)
(
(hst)
Shealy Environmental Services,
106 Vantage,Point Drive
(828)791 -9700
EPA 8260 /8270,Metals
Inc (NC Cert #329)
West Columbia, SC 29172,
Coloi,Cyanide TOtal,MBAS,
Sulflde,Sulfate,BOD,COD,O &G
Nitrates /Nitrites,TSS,TOC,
Phenolics Total
Recoverable,Bromide,TKN^,
Fluoride, Total
Phosphorous,
Ammonia,Sulfite,
Prism Laboratories
449 Springbrook Road
(800)529 -6364
Fecal Coliform
(NC Cert #402)
Charlotte,NC 28224 -0543
SGS Laboratory
5500 Business Drive
(910)350 -1903,
Dioxins
(NC Cert #`481)
Wilmington, NC 28405
GEL Laboratories
2040 Salvage Road
(843)556 -8171
Total Radium „Gross Alpha,
(NC Cert #233)
Charleston, SC 29407
Gross Beta
IX CERTIFICATION
I certify under penalty of law, that this document and,all attachments were prepared under my direction or supennston 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 l,am aware that,there
are significant penalties for submitting false mformahon, including the possibility of fine and, imprisonment, for,knowmg violations
A NAME & OFFICIAL TITLE (type or prmt)
IiB PHONE NO (area code & no)
Jesse _E Huntley I-IIJO/ General Manager III, Reg Fossil Stat
`(336) 445 -05011
C SI ATURE
D DATE SIGNED
_
. AA- � �' 11
8 --?-q - ( t
EPA,FL4 3510 -2C (8 -90) V PAGE 4 of 4

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EPA I D NUMBER,(copyfromItem I ofform I)
CONTINUED'FROM PAGE 2 NCO024406
EPA Form 3510 -2C (8 -90) PAGE,3,of 4 CONTINUE ON REVERSE
V INTAKE AND EFFLUENT CHARACTERISTICS
A, B, & C See instructions before proceeding — Complete,one,set,of'tables,for eacri outfall = Annotate theioutfall number m�the space provided
NOTE ,Tables V -A, V -B; and V -C are included on separate sheets numbered V -1 through V -9
D Use the space below to list'any of the pollutants listed in Table 2c-3 of the instructions, which you know or have reason to believe is discharged or may be discharged
from any_outfall For every pollutant you list, briefly describe the reason&you believe It to�be present and report any analytical data in your possession
1 POLLUTANT
2 SOURCE
t 1 POLLUTANT
- 2 SOURCE
Asbestos
Cleanup of Containment Areas
Involved with Asbestos Removal
and Handling Operations
Discharge is to Ash Basin
(Outfall 003)
Hazardous arid,Toxic Substances'
See Supplemental Information
VI POTENTIAL DISCHARGES,NOT COVERED BY ANALYSIS
Is, any +pollutant Iisted,In Item V-C a substance or a component'of a substance � which)you currently'use or manufacture i as, an, intermediate or,final product onbypr6duct?
❑ YES'(hst all such pollutants below) NO'(go to Item VI -B)
EPA Form 3510 -2C (8 -90) PAGE,3,of 4 CONTINUE ON REVERSE

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