NC0005088_Renewal Application_20030128

Duke
� Pow er-
A Dukr Energy Company
January 27, 2003
Mr. David Goodrich
North Carolina Department of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699 -1617
Subject: Cliffside Steam Station
NPDES Permit Application for Renewal of
NPDES Permit No. NC0005088
Dear Mr. Goodrich:
Duke Power Company
Fossil and Hydro Generation Department
P.O. Box 1006
Charlotte, NC 28201 -1006
The subject NPDES permit is scheduled to expire on July 31, 2003. As required by the North Carolina
Administrative Code (15A NCAC 211.0105(e)), this permit application for renewal is being submitted at
least 180 days prior to the expiration date of the current permit. In accordance with this requirement,
please find enclosed in triplicate, the application for renewal. The following items are attached:
• EPA Form 1 — General Information
• EPA Form 2C — Application for Permit to Discharge Wastewater Existing Manufacturing,
Commercial, Mining and Silvicultural Operations
• Site Map
• Supplemental Information to the NPDES Application
o Characterization of NPDES related process and wastewater streams.
o Schematic water flow diagram.
• The Balanced Indigenous Population (BIP) Report
Duke Energy Corporation requests a continuation of the current thermal limits at outfall 001. The
attached Balanced Indigenous Population (BIP) Report concludes that the current NPDES permit's
thermal limits provide sufficient protection to the aquatic population in the Broad River. Additionally, it
should be noted that annual monitoring has been performed to support the NPDES permit thermal limits
since 1990. Duke Energy Corporation believes that data collected during the twelve years of annual
monitoring provides a sufficient baseline to characterize thermal considerations for the receiving water
body. Therefore, a reduction in the annual monitoring program is requested. Duke Energy Corporation
proposes to meet with your staff to discuss at a later date.
In review of monitoring data, oil & grease test results for outfall 002 are significantly below the NPDES
permit limit. For example, during the 12 month period of August 2001 to July 2002, the oil & grease
monthly test results were all below detection except for one month in which the results were 6.5 mg/1.
Thus, it is requested that the monitoring requirements for oil & grease be reduced from monthly to
quarterly.
Units 1 — 4 retired ash basin currently has a discharge tower that allows rainfall runoff to discharge to the
Broad River. In close proximity, the yard drainage basin collects wastewater and rainwater and pumps it
LL
JAN
28 20
i._ ` NMI
fi
The subject NPDES permit is scheduled to expire on July 31, 2003. As required by the North Carolina
Administrative Code (15A NCAC 211.0105(e)), this permit application for renewal is being submitted at
least 180 days prior to the expiration date of the current permit. In accordance with this requirement,
please find enclosed in triplicate, the application for renewal. The following items are attached:
• EPA Form 1 — General Information
• EPA Form 2C — Application for Permit to Discharge Wastewater Existing Manufacturing,
Commercial, Mining and Silvicultural Operations
• Site Map
• Supplemental Information to the NPDES Application
o Characterization of NPDES related process and wastewater streams.
o Schematic water flow diagram.
• The Balanced Indigenous Population (BIP) Report
Duke Energy Corporation requests a continuation of the current thermal limits at outfall 001. The
attached Balanced Indigenous Population (BIP) Report concludes that the current NPDES permit's
thermal limits provide sufficient protection to the aquatic population in the Broad River. Additionally, it
should be noted that annual monitoring has been performed to support the NPDES permit thermal limits
since 1990. Duke Energy Corporation believes that data collected during the twelve years of annual
monitoring provides a sufficient baseline to characterize thermal considerations for the receiving water
body. Therefore, a reduction in the annual monitoring program is requested. Duke Energy Corporation
proposes to meet with your staff to discuss at a later date.
In review of monitoring data, oil & grease test results for outfall 002 are significantly below the NPDES
permit limit. For example, during the 12 month period of August 2001 to July 2002, the oil & grease
monthly test results were all below detection except for one month in which the results were 6.5 mg/1.
Thus, it is requested that the monitoring requirements for oil & grease be reduced from monthly to
quarterly.
Units 1 — 4 retired ash basin currently has a discharge tower that allows rainfall runoff to discharge to the
Broad River. In close proximity, the yard drainage basin collects wastewater and rainwater and pumps it

to the present ash basin (outfall 002) for,additional treatment. The yard drainage basin presently has a
"blocked off' emergency overflow discharge line that connects to a ditch that directs waterflow to the
Units 1-4 retired ash basin's discharge tower. The potential exists for the yard drainage basin's pumps to
be•damaged if the pump motors were submerged in water due to a system malfunction. Therefore,
permission is requested unblock the emergency overflow discharge line and permit the retired, ash basin
discharge tower as outfall'002A. This outfall is sirmlar to emergency sump overflow outfalls that have
been permitted at other Duke Energy Corporation locations.
Outfall 003 no longer discharges process cooling water. Previously, once through non - contact cooling
water, from Units 1-4 transformers, was discharged through this outfall. These transformers have been
converted to an air cooling system and no longer use once through non-contact-cooling water as their
cooling source. Therefore, it is requesfe`d that outfall 003 be elimmated from the NPDES permit.
If additional'mformation is needed pleaseycontact Robert Wylie at (704) 382=4669.
Sincerely,
Michael A. Ruhe, Manager
Environmental, Health and Safety
Fossil/Hydro Operations
Attachments
cc: Ms. Tris,MacPherson — NCDENR (BIP Report only)

Cliffside Steam Station, Rutherford County
NPDES # NC0005088/
Page 2 of 17�
General Information
Cliffside Steam Station (CSS) is located at 573 Duke Power Road, off NC
State Road 1002 just south of Cliffside, North Carolina beside-the Broad-
River. The five unit coal fired steam electric generating station has a
combined rated capacity of 760 MW =net. Units 1 - 4 have a combined
capacity, of 1,98 MW -net and a once- through Condenser Cooling Water
(CCW) maximum flow rate of 4.17 cfs. Unit 5 has a capacity oU562 MW-
net and utilizes closed cycle, forced draft cooling towers for heat
dissipation. Unit '5 cooling tower make -up water is withdrawn at a
maximum rate of 14_cfs and the blowdown is discharged to the ash basin.
.CSS utilizes waters from the Broad River for the CCW and other service
water systems. The .service water required �by units 1 - 4 is initially pumped
to a, settling basin for sedimentation of sand and silt before it is taken into
the plant. 'Unit, 5 can acquire intake water from either; the unit 4 screen
room (normal operation) or from the condenser cooling water discharge of
unit's 3 and 4. The intake water for unit 5 flows to a storage tank before
entering the unit.
A schematic flow diagram of water use, treatment, and discharge is
attached. A discussion, of the individual waste streams follows._
EOutfaIII-U01 -Condenser Cooling Water ( M,Units 1- 4 s
Units 1 - 4 utilize raw river water for` once - through-- non- contact_conden`'ser -
cooling =water requirements. This water system removes heat from the
condensers and other selected heat exchangers. No biocides or other -
additives are used in the condenser cooling water.
There are two condenser circulating pumps per ,condense'r /unit for units 1 -
4. Rawiriver water is pumped through the condensers for cooling.
Annually, the condensers may be opened and cleaned by forcing plugs
through the tubes. The plugs are collected within the cooling water system
prior to being discharged into the Broad River.

Cliffside Steam Station, Rutherford County
NPDES # NC0005088
Page 3 of 17
Approximately twice per year, the condenser tubes may need to be tested
for leaks. This test is conducted using a tracer gas (i.e., sulfur
hexafluoride, helium, etc.). The levels of discharge will be well below any
levels of aquatic biological toxicity concern. If a leak was detected, any
release to the environment will only occur during short intervals
(approximately thirty seconds per injection, normally less than six injections
per condenser) as the tests are being conducted. The entire test period
per unit is normally conducted in two or three hours.
Units 1 - 4 CCW Pump Maximum Capacity
Unit # 1 -Pump Operation 2 -Pump Operation
gpm gpm
1 19,800 39,600
2 19,800 39,600
3 28,125 56,250
4 28,125 56,250
Operational schedule for these pumps is dependent upon the intake water
temperature and on the unit loads. Depending on the electrical demand,
pumps are operated to maximize CSS efficiency and to assure compliance
with its permitted NPDES thermal and flow limits. Flow recorded on the
monthly Discharge Monitoring Reports (DMR) is based on CCW pump run
times.
Closed Cooling Systems
Unit's 1-4 Recirculated Cooling Water (RCW) system is used for cooling
various station components. The CCW system is used to cool the RCW
system. The RCW system is a relatively small closed cooling system that
uses maintenance chemicals (microbiocides and corrosion inhibitors) in
order to prevent biofouling and system corrosion. The primary corrosion
inhibitor used in these systems is sodium nitrite. The potential exists for
minor plate leaks to occur. For units 1-4 if a plate leak occurs, the leak will
discharge into the CCW system. Routine system monitoring for nitrite
concentrations and make -up water, provides input that assists in
determining a tube leak. Once a leak is identified corrective measures will
be implemented to minimize and repair the leak. During a leak the
concentration of the maintenance chemicals will not exceed the No
Observed Effect Concentration (NOEC). The closed cooling water

Cliffside Steam Station, Rutherford County
NPDES # NC0005088
Page 4 of 17
systems for Unit 5 include the RCW and chiller systems. Both of these
systems use microbiocides and corrosion inhibitors.
The RCW and Chiller systems are required to be cleaned periodically. The
cleanings normally use a dispersant, wetting agent and detergent. In
addition leak detection is conducted using a fluorescing dye. While these
are closed systems, they are drained on a non - routine basis,, as necessary
for,maintenance, to the sump and pumped to the ash basin (outfall 002).
Intake Screen Backwash
The CSS intake screens are continuously backwashed during unit
operation. The wash water is taken from the service water system (raw
water). An average flow of 3000 gpm is utilized. The debris collected on
the screens consists of twigs, leaves and other material indigenous to the,
river, and is therefore flushed back to the river.
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 four Low Pressure Generator
Hydrogen Coolers and two Turbine Lube Oil Coolers for each unit=. `
Discharge from these coolers combines with the condenser cooling water
flow and discharged at outfall 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) ;
and forced draft (FD) fans to remove excess heat. No chemicals are
added to the once through raw lake water discharged to the -Broad River.
10Utfa11=002 -Ash Basin
The ash basin is the primary treatment system for waste water produced, at
Cliffside Steam Station. The ash basin treatment consists of
sedimentation,— _ion7exehange= andvpH =adjustments. The ash basin's pH is
adjusted using sulfuric acid. The additions of carbon dioxide and also
sodium hydroxide are under review for pH control. Additionally, aluminum

Cliffside,Steam Station, Rutherford County
MIMES # NC0005088
Page 5 of 17
sulfate is being reviewed for use as a coagulant in order to further settle
out solids.
Wastewater from Air Pollution Control Systems
At Cliffside Steam Station waste water streams that are generated from the
operation of air pollution control systems, are sent to the Lash --basin. The
following, provides a� brief, description of these waste stream's in addition, to
the .above mentioned fly ash sluicing system.
Continuous Emissions Monitors
Continuous Emissions Monitors, produce potassium permanganate
during normal operation at a ,rate of approximately 2 pints /month.
This waste stream is sluiced' to the ash basin.
Flue Gas Conditioning
For increased precipitator performance, anhydrous ammonia and
sulfur trioxide ($03) gases are injected into the gas stream prior to
Unit 5's precipitators- The injection of the gases increases the
efficiency of the precipitators and the injection rate varies to prevent
ammonia and SO3 slippage through the precipitator. The designed
maximum injection rate for ammonia is, 15 ppm and 12 ppm for the
sulfur trioxide. The ammonia and sulfur concentrations will not
significantly increase in the ash basin from this flue gas conditioning
system.
Selective. Catalytic Reduction (SCR)
'Unit 5 has a Selective Catalytic Reduction unit installed in the gas Y
path prior to the preheater. The SCR uses anhydrous ammonia and
a catalyst to convert nitrous oxides to nitrogen and water vapor. The
flow rate of anhydrous ammonia depends upon the level of reduction
on nitrogen oxides, the flue gas emission rate, and the slip through
the SCR. The slip rate for anhydrous ammonia through the SCR is
projected to be less than 2 ppm. The design injection rate of
ammonia is 400 Ibs /hour. During operation fly ash may absorb low
concentrations of ammonia. Fly ash for Unit 5 is primarily collected
and sent to a silo, for off -site use. iPeriodically the fly ash is sluiced
to the site's ash basin. The ammonia concentrations are not

Cliffside Steam Station, Rutherford County
NPDES # NC0005088
Page 6 of 17
expected to significantly increase in the- ash basin from the SCR
operation.
Selective Non — Catalytic Reduction (SNCR)
In the future, Units 1-4 may have SNCR systems installed to lower
Nitrogen Oxide (NOX) emissions. SNCR systems operate by
'injecting urea into the upper section ,of the boiler, where a chemical
reaction will occur, to reduce the NOX,to water and nitrogen. Some
residual ammonia may be collected onto the fly ash and sent to the
ash basin. However, the operation of the SNCR systems is not
expected to require additional treatment capabilities to ensure
compliance with NPDES permit limits.
,Flue Gas Desulphurization
In the future, 'Unit 5 plans to install a Flue Gas Desulphurization
(FGD) system to reduce the SO2 in the stack gas. The FGD system
will discharge blowdown waste water to the ash basin. Operation of
the FGD system will be evaluated to determine if additional, treatment
capabilities will b& required to ensure compliance with NPDES permit
limits. Notification of the proposed installation of a FG'D system will
be communicated to address any permitting concerns.
Cooling Towers
Unit 5 utilizes two cooling towers for its cooling water requirements. Unit 5
has four circulating pumps. Each circulating condenser pump has a
capacity of 62,500 gpm for a combined total of 250,000 gpm. The
circulating pumps on unit 5 operate continuously. Each tower has a
circulation rate of 125,000 gpm with a make -up rate of 2875 gpm per tower
and a blowdown rate of approximately 2500 gpm. The cooling tower
blowdown is pumped to the ash basin.
Cooling tower water is chlorinated to approximately 0.5 ppm, for,one half
hour, 3 times /wk during the winter and approximately 1.0 ppm, for one
hour,, 5 times /week during the summer months. Fifty gallons, of the
microbiocide iBu°lab 6002 are added approximately every 6 months, to each
tower. The towers are sprayed with, the microbiocide Bulab 6009 once
yearly. Mechanical means are employed for additional cleaning.,

Cliffside Steam Station, Rutherford County
NPDES #'NCooO5088
Page 7 of'17
Sanitary Wastes
The sanitary wastes from Units 1� 4 ,are treated Eby a,'2500 gpd -capacity,
septic tank. The Unit 5 sanitary wastes are treated by an activated, sludge
unit with a 3000 gpd capacity. An average of fifty people contribute for,the
,load oa the 2 systems. The effluent, from both systems, is ,pumped to ,the
yard' drainage basin and then to -the ash basin,:
The water "for the sanitary waste systems and the drin'ki'ng, water system ,is
supplied by the Grassy Pond 'Municipal water°system.
Storm Water
The ash basin ,at CSS, collects %receives flows from the yard drainage basin,
,ash removal lines, and` rainfall run -off from the basin "watershed area: The
average rainfall Arun-off flows are based on 49 inches of rain per year with
100% run -off, from thelpond, surfaces and 50% run -off from, other areas.. ,
The average rainfall run -off for the °ash basin watershed area ,is -0.640
MGD. The ,coal yard drainage at Cliffsi'de, Steam- Station drains to� the yard
drainage basin :and is then pumped ,to the ash basin. The, coal yard `has. an
averaged run -off'of 0:027 M'GD.,
Cliffside, Steam Station, has, several stor =m water outfalls, that ,discharge to
the,15road River. These storm drains do notcontain any process
wastewater discharges.. On the main entrance road to the site, �a,natural
spritig/dreek flows continuously in the road ditch. The water enters the
storm ,drainage system and flows directly to the Broad 'River.
Cliffside Steam, Station was included in the group application submitted, to
the,Envi'ronmental ,Protectio Agency in March 1991. CSS maintains a site
St'orrii 'Water �Pollu�tion, Prevention Plan (SWPPP) to minimize the discharge
of ,pollutants in the storm water discharges.
Boiler- Chemical Cleaniog
Boilers#1 and, #2 at ,CSS are not chemically cleaned. Boilers #3, #4; and
#5 are chemically cleaned as needed. The wastes 'produced from a boiler
dleaning are, pum,ped to the ash basin, The chemical's and approximate
amounts for leach cleaning are Ii'sted below.

Chffside Steam Station, Rutherford County
NPDES # NC0005088
Page.8 of 17
Cherni'cals
Unit 3 or4
Unit 5
Sodium bromate
- --
550 Ibs
Ammonium carbonate
- --
100014S
Ammonium hydroxide, 260 Be *
- --
1000 gal
Hydrochloric acid, 200 Be *
3300 gal
9000 gal
Thiourea *
1000 Ibs
2900 Ibs
Ammonium biflouride
1000 Ibs
2700 Ibs
Proprietary Inhibitor
24 gal
130 gal
Citric acid
200 Ibs
600 Ibs
Soda Ash
2000 Ibs
5600 Ibs
Sodium sulfite
- --
100 Ibs
Iodine 213
24 gal
130 gal
Approximately 220,000 gals of wash water are required for cleaning boilers
#3 or #4. Boiler #5 requires 950,000 gals of wash water per cleaning.
Immediately, prior to the beginning of a boiler chemical cleaning
procedure, additional ,stop logs are added to the ash basin discharge
structure. This assures longer retention time of the chemical, wastes for
proper treatment through dilution, neutralization, precipitation and ion -
exchange.
* During a chemical metals cleaning these chemicals are present 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,
it would be routed to the ash basin for treatment. Per 40 CFR 117 the
chemicals that are routed to the ash basin are exempt from reporting -•
requirements.
Floor Drains,
CSS floor drains contain boiler blowdown, leakage from seals, equipment
cooling water, condensates, regeneration wastes, miscellaneous plant
wastes and area wash down water. Effluents from these drains are
flushed to the, plant sumps and then to the yard drainage basin and are
then pumped to the ash 'basin.
The floor drains in the powerhouse connect to sumps where they are
pumped to the ash basin. These drains can receive inputs from spillage or
leakage, floor wash water, as well as flows from water treatment

Cliffside Steam Station, Rutherford County
NPDES # NC0005088
Page 9 of 17
processes. The following are examples of materials that are stored inside
the powerhouse:
sulfuric acid
sodium hydroxide
water treatment chemicals
ammonium, hydroxide .
industrial cleaning products used for general housekeeping
hydrazine
oil, lube oil (recycled)
Ash Basin Toe Drains
In order to assure the integrity of the ash basin's dike structure, the dikes
are designed with, a system that, allows for the water to seep through the
dike. This drainage system prevents the dikes from becoming overly
saturated'with water. This water is discharged out of the dikes via toe
drains. The volume of water is normally, at a nominal seeping rate. It
discharges to the ground and is ,ultimately routed' to Suck Creek and Broad
River.
Water Treatment System
The CSS make -up water treatment system (non- potable) is comprised of:
(a) a clarifier, (b) three gravity filters, (c) two activated carbon filters, (d)
chlorination, (e) two mixed bed demineralizers, (f) a polisher and (g) a
reverse osmosis process. Make -up water is supplied to the boilers to
generate steam to turn the turbines. On occasion a vendor may be used
with a mobile water treatment unit to augment the facility•water treatment
capacity. Any vendor will use traditional water-treatment methods,
chemicals; and disposal methods, generally described. below.
The water treatment wastes consist of (a) flocculants and' sedimentation,
(b) filter backwash, (c) demineralizer regeneration wastes, and (d) reverse
osmosis wastes. This waste is sent to the ash basin.
Clarifier
The clarifier currently utilizes a continuous feed of cationic water
treatment polymer and clay (Nalco 8105 and Nalco Coagulant AID 25,
respectively or, similar products) to remove suspended solids and

Cliffside Steam Station, Rutherford County
NPDES # NC0005088
Page 10 of 17
colloidal material. The flocculent and sedimentation collected by the
clarifier consists of solids that were suspended in the service water.
Approximately 1000 GPD of sedimentation wastes are pumped to the
yard drainage basin and then to the ash basin. The station may alter
this process to supply site clarified water by other traditional water
treatment methods and using traditional chemicals other than those
listed above. JUDv
Gravity Filters
There are three gravity filt`er's composed ofanthracite (coal) which
follow the clarifier in the water treatment process. Each of these
filters has a capacity of 360,000 GPD. One of these filters is
backwashed once per day with the backwash_ water going to the ash
basin. The gravity filters are changed out on an as- needed basis
with, the spent filter medium going to the ash basin:
Activated Carbon Filters
Two activated carbon filters are backwashed and steam cleaned
once per,month. The,wash water is pumped to the ash-basin. The
activated carbon filters are changed out approximately twice per year
with approximately 147 ft3 of activated carbon being pumped to the
ash basin.
Desrninerailiiers
Demineralized water, is used to supply the plant with its make -up
water requirements. Each demineralizer consists of two mixed bed
cells,. Only one demineralizer is in operation; at a time. A
demineralizer is regenerated once per week. A regeneration
requires 39.5 gallons of 66013e sulfuric acid and 150 gallons of 50%
sodium hydroxide. Approximately, 10,000 gal of rinse water is used
.per regeneration. Double regenerations are required for each
regeneration. The dilute acid and caustic are discharged to the floor
drains simultaneously through the same header for neutralization
purposes. The, demineralizer resin is changed out approximately
every seven years with the waste resin being pumped to the ash
basin. Approximately, two times- a year each d'emineralizer is brine
treated to clean the resin. This process uses approximately 3000 Ibs
of salt (sodium chloride) and filtered water for each demineralizer
treatment. All regeneration wastes are pumped to the ash basin.

Cliffside,Steam Station, Rutherford,County
°NPIDES4 NC0006088
` Page 11 of 17
Cooling water for the ,unit 5 stator ,cooler,goes through an additional
�dernineralize_r- The ,demineralizer resin is changed out approximately
every, 18 months with approximately 9 cubic feet being pumped to the
ash basin.
Polisher
A fifty cubic foot polisher (20 cubic Reef cation, 30 cubic feet anion
resin) ;is used to, popish d'ernineralizer effluents.- Th'i`s ;polisher will
minimize silica leak8ge. The resin will be, replaced anmally with
spent r-esi`n being pumped to the -ash basin. �-
Reverse ,Osmosis
A Reverse Osmosis (RO), unit is used at'`Clfffside Steam Station to
decrease the conductivityAn the de *ineralizer snake -utp water., 'The,
RO unit treats 400 ,gpm with 100 �gpm rinse water.. This rinse water
drains to the yard settling,,basin and then is, pumped to the ash basin.
The 'RO, unit increases the efficiency, of the demineralizers. Sulfuric
acid (25 %)' is injected, at approximately,5, gal %day. 'This controls ,the
unit's pH.' Sodiu.*hisulfite i5jhen injected downstream of the SRO
unit to remove any residual chlori'ne.- The concentration of sodium
bisulfite is maintained at 2 ppm. The RO unit is cleaned on a
quarterly, basis with the, rNaste going to the yard drains aqd eventually
the ash basin. During a cleaning, approximately,30 Ibs ,of the cleaner,
OSMO AD -20 containing °sulfarhic acid, citric acid anti •sodium lauryl
sulfate is, used_ Also, used is a generic cleaner consisting of tfi;
sodium ;phosphate, sodium laurylsulfate and sulfuric acid with
,approxirnately'40G gallons of waste water going to the ash` basin. JDd f
Boiler BloWdown
Boilers 1' - 4 each blowd`own at a rate of approximately 500 Ibs,. of
steam %hour. Most of the bl'owdoWh is vented to the atmosphere With
a minimal amount going to, the, boiler, room fl'gor draih& The
blowdown from unit 5, is vented to a bl`owdown tank, With 8 mini -mal
flow of condensate being, pumped, to the ash basin.
Hydrazine, is maintained at a concentration of <30, p0b, in the feed
water train for deoxygenation., Ammonium,'hydroxJde ,i's used for .pH
control in the units: A, minute arno`unt, of fh„ydra2ine ,( <10 ppb) may be

Cliffside Steam, Station, Rutherford County
NPDES # NC0005088
Page 12 of 17
present in the steam jet air ejector waste condensate flow to the floor
drains which are pumped to the ash basin.
Oil Storage Run -Off
CSS currently has 8 above ground oil storage tanks and one �und'erground
gas tank (1,000 gal). The total above ground storage capacity is 125,300
gal. All above ground tanks are surrounded by concrete dikes. Any spill
not contained by the dikes would be drain to the yard drainage sump
system. The spill will be cleaned up within the yard drainage sump system.
The yardisump system pumps wastewater to the ash, basin. If for some
reason a spill is not completely cleaned up within the yard sump system it
will be cleaned up in the ash basin. The underground gas tank ,is of
double- walled fiberglass construction.
All oil storage facilities and oil- filled equipment are presently covered under
the Spill Prevention Control and Countermeasure Plans (SPCC).
,Outfall 002A —Yard Drainage Basin Overflow
An overflow pipe directs flow from the yard drainage basin in the event that
the basin's pumps malfunction. _ This'is_a very rare- event. Routine
inspections and system alarms alert Cliffside operators when a high level
alarm is, reached. The operators' response will normally prevent an
overflow from occurring. However, this design is needed in order to protect,
the pump motors from being submerged and damaged.
Miscellaneous Waste Streams
Dredging
The intake at CSS is dredged on an as needed basis. All Hof the
dredge discharge, is pumped to the yard drainage basin.. The yard
drainage basin is dredged as needed with the dredge spoil going to
the ash basin.
In addition to this process, sand mining is, also permitted. The sand
mining operation is permitted under permit 23 -16. 'During this
operation sand material is pumped from the ,bottom of the river,and
settles out on land. The effluent from, this operation discharges back

Cliffside Steam Station, Rutherford County
NPDES #,NC0005088
Page 13 of 17
to the Broad River. This discharge is permitted under NPDES
general permit MG520000 (Certificate Number NCG520067):
'Laboratory Wastes
The chemistry lab on site performs a variety ,of water analyses and
routine sample collections. Therefore, several chemicals/reagents
are used in the lab in small quantities for sample preservation,
equipment calibration, analytical analyses, etc. The wastes, are
poured down the sink, flushed to the activated sludge unit and "then
pumped to the ash basin.
Boresonic Rotor Testing
Approximately once per year, one turbine is tested for cracks in the
generator shaft using an ultrasonic nondestructive test. During the
process a maximum of 400 gal of demineralized water mixed with 4
gal of corrosion inhibitor is used and is, pumped to, the ash basin.
Condenser Leakage, Testing
Occasionally, the condensers are tested for in leakage. This involves
filling the steam side of the condenser with demineralized water and
using a disodium fluorescing dye. The maximum yearly usage of the
dye would be 6 Ibs of dye in 90,000 gal of water. All wastes are
pumped to the ash basin.
Heat Exchanger Cleaning
On average, one heat exchanger per month is cleaned of mud fouling
with 40 gallons of tri- sodium phosphate (1 %) and sodium hydroxide
(5 %). The mixture is then discharged to the sump and pumped to
the ash basin.
Vacuum Trucks
Commercial vacuum trucks are used to remove sediment from
various pits and trenches. The material will be deposited in the yard
drainage basin or the ash basin. Vacuum trucks are also used to
vacuum areas of the plant that can not be washed with water, to the
plant sumps. This material is hauled to the ash basin for disposal.

Cliffside Steam Station, Rutherford County
NPDES # NC0005088
Page 14 of 17
Vehicle and Equipment Washing
The site vehicles are planned to be hand washed with mild detergent
once a month. The rinse water will be routed to the yard drainage
basin and pumped to the ash basin.
An employee vehicle rinse station is used by the site employees to
rinse their- cars. The employee drives their vehicle through a curtain
of water spraying through nozzles. No detergent is'used for the
employee's vehicles. The rinse water is routed to the yard settling
basin and pumped to the ash `basin.
During maintenance activities some plant equipment is washed with
a steam cleaner. If possible, this equipment is moved into the tractor
shed. This allows the rinse water to drain into an oil separator prior
to be discharged to the yard drainage basin.
Photographic Waste Streams
Periodically welding operations occur at Cliffside Steam Station. In
some situations the wel'dsl are x -rayed -to verify completion. During
this process, a low volume photographic waste stream is generated.
The waste stream is primarily composed of rinse water. This waste
stream is analytically characterized to ensure that it is not a
hazardous waste prior to be discharged 'into the ash, basin.
Hazardous ,and Toxic Substances Table 2c -3
At Cliffside, 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, Alkanolamine, Asbestos, Butyl Acetate, Cyclohexane,
Cyclohexanone, Epichlorohydrin, Formaldehyde, Monoethylamine,
Naphtentic Acid, Pyrethrins, Vanadium, Vinyl Acetate, Xylene and
Zirconium.

Cliffside Steam Station, Rutherford County
NPDES,# NC000508&
Page 15 of 17
40 CFR 117 and CERCLA.Hazard'ous Substances
The following table 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
reporting exemption provided in 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
necessarily reflect quantities that are discharged through typical use.
List of Hazardous Substances
SUBSTANCE APPROXIMATE SOURCE Reportable
QUANTITY Quahtity (Lbs.)
Two 45,000 gallon tanks of Anhydrous Ammonia are located, at Cliffside
Steam Station., This product is used in the SCR system. If a leak did
occur from these tanks an emergency fogging system would immediately
initiate. This would result in an ammonia water mixture which would be
captured into the containment system that surrounds the two tanks. The
discharge from the secondary containment system is ,normally closed by ,a
valve. When open the discharge drains into the yard drainage basin which
pumps to the ash basin. The adjacent unloading areas for these tanks
also drain to the yard drainage basin.
Balanced and Indigenous Populations
Attached is the report entitled "Assessment of Balanced and Indigenous
Populations in the Broad River near Cliffside Steam Station ". This report
concludes that the operation of Cliffside Steam Station did not have an
adverse impact on the balance indigenous aquatic communities in the

Cliffside Steam Station, Rutherford County
v NPDES # NC0005088
~ Page 16 of 17
e.
Broad River. Duke Energy Corporation therefore requests a continuation
of the current NPDES thermal limits for outfall 001.
Ash Basin Capacity
,Part CII B (1) of the existing NPDES permit for Cliffside requires the
permittee to provide and maintain at all times a minimum free water volume
(between the top of the sediment level and the minimum, discharge
elevation).
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 equals 213.1 acre -feet.
The ash basin was last surveyed for its level of sediment ;in December
19,92. The amount of sediment to accumulate in the ash basin since
December 1992 is based on coal consumption and ash content of the coal.,
It is estimated that from 1992 through 12/31/2008 the volume of solids to
the ash basin will be 1,069 acre -feet.
The required storage volume equals the summation of 1,069 and 213 or
1,283 `acre -feet. The available storage capacity based on the 1992 basin
survey is 1,458.0-acre-feet. Therefore, sufficient capacity 'is ,available
through December `31, 2008.-

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WASTE WATER FROM X -RAY OPERATION AT CLIFFSIDE STEAM STATION
.s
Subject: WASTE WATER FROM X -RAY OPERATION AT CLIFFSIDE STEAM STATION
Date: Tue, 3 Dec 2002 13.37.26 -0500
From: "Robert.R Wylie" <rrwylle @duke- energy com>
To::Natal'ie.Slerra @ncmall.net
CC: "Randolph W Price" <rwpnce @duke- energy.com>
Natalie„
At Belews Creek Steam Station the same process that was used a't Clif'fside
Steam Station of x- raying welds for boiler tube work is scheduled to begin
in January -2003. It will be conducted over approximately a 5 month period.
The process will not occur each day On th_e days that welding occurs it is
estimated that approximately 55 gallons of waste water may be generated
The current plans are to send this wastewater to the ash basin. The ash
basin has a long term average flowrate of 7.7 mgd with an estimated ash
basin capacity of 1„26,0 million gallons (at pond elevation of 752 +0 feet
msl). Thus based on the analysis below and the low volume of this waste
stream there should not be any significant Changes to the ash basin's waste
water
Your approval of this'process is requested If you need additional
information please feel free to contact Randy Price (336) 445 -:0324 or me
('704) 382 -4669
Thanks,
Robert
- - - -- Forwarded by Robert R Wylie /Gen /DukePower on 12/03,/2002 01:13 PM
Robert R Wylie
< Natalie Sierra @ncmail.net>
03/'27/2002 01:06
Hodges /Gen /DukePower @DukePower
PM
OPERATION AT CLIFFSIDE STEAM STATION
Natalie,
To: Natalie Sierra
CC: Steve D
Subject: WASTE WATER FROM X -RAY
As we discussed yesterday, at Cli.ffsi.de Steam Station (NPDES permit
0005088) the process of k- raying welds for boiler tube work, has generated
wastewater that needs to be disposed. During the process the wastewater
was /is being collected in,drums An analysis has been performed on the
waste already collected. The results of this analysis is below. Currently
there is approximately 500 gallons of wastewater and used developer from
this process that has been collected in drums It is estimated that up to
5,00 gallons more wastewater and used developer- will be generated from the
process for a total of 1,000 gallons Based on the analytical results
(below,) it is requested that this non - hazardous waste be disposed of in a
controlled amount into the station power house sump which, discharges
ultimately into the ash basin (permitted NPDES Outfall 002) available
capacity estimated > 100 mgal. The long term average flowrate from the ash
basin is 10 mgd,.
I wi -11 be out of my office from 3/28/02 until 4/8/02 Please feel free to
respond to Steve Hodges (,sdhodges @duke- energy,com or 828 - 657 - 233,9) once you
1219/02 4 05 PM

WASTE'W°ATER FROM' XLRAY'OPERATION AT CLIFFSIDE STEAM STATION
s -
,i
have'had a chance to determine an acceptable disposal rate.
Thanks,
Robert
-`------=---------+--------- =-------- +- -------- - - - --- _ --- '+-------- - - - - -- -----
Parameter (Waste Water (mg /l)jUsed Developer ITCLP Limit (mg /l)
1(mg /1)
------------------ +------------------ +--- - - - - -- +----- - - - - -- --
Silver 14 7 10.49 15
------------------ +----- - - - - -_---------------------------------------------
Barium 10.05 10.1 1100 _
------------------+------------------+-------------------+---_--------------
Cadmium 1 <0.3 1 <0.3 11
--- - - - - -- ----+------------------+------------------+------------------
Chromium 1<0 4
10.6
15
-----+------------ _=-------------------
- -- --+------------ - - - - --
Lead <0 9
14.4
15
---------- ------------------------ __-- +-------- - - -_
-- __- +----- - - - - -- -------
Arsenic 1' <0'.1
1<0 1
1'5,
- - - - - -- ----------+---------_-__-----+-----_-------

WASTE,*WATER FROM X -RAY OPERATION AT CLIFFSIDE STEAM STATION
.s
Subject: WASTE WATER FROM X -RAY OPERATION AT CLIFFSIDE STEAM STATION
Date: Wed, 27 Mar 2002 13:06:53 -0500
From: "Robert R Wylie" <rrwylie @duke- energy.com>
To: Natalie Sierra <Natalie.Sierra @ncmai1.net>
CC: "Steve D Hodges" < sdhodges @duke- energy.com>
Natalie,
As we discussed yesterday, at Cliffside Steam Station ( NPDES permit
0005088) the process of x- raying welds for boiler tube work, has generated
wastewater that needs to be disposed. During the process the wastewater
was /is being collected in drums. An analysis has been performed on the
waste already collected. The results of this analysis is below. Currently
there is approximately 500 gallons of wastewater and used developer from
this process that has been collected in drums. It is estimated that up to
500 gallons more wastewater and used developer will be generated from the
process for a total of 1,000 gallons. Based on the analytical results
(below) it is requested that this non - hazardous waste be disposed of in a
controlled amount into the station power house sump which, discharges
ultimately into the ash basin (permitted NPDES Outfall 002) available
capacity estimated > 100 mgal. The long term average flowrate from the ash
basin is 10 mgd.
I will be out of my office from 3/28/02 until 4/8/02. Please feel free to
respond to Steve Hodges (sdhodges @duke - energy.com or 828 - 657 -2339) once you
have had a chance to determine an acceptable disposal rate.
Thanks,
Robert
---------------+---------------+---------------+---------------
Parameter lWaste Water JUsed Developer JTCLP Limit
1(mg /1) 1(mg /1) 1(mg /1)
---------------+---------------+---------------+---------------
Silver 14.7 10.49 15
---------------+---------------+---------------+---------------
Barium 10.05 10.1 1100
---------------+---------------+---------------+---------------
Cadmium 1<0.3 1<0.3 11
---------------+---------------+---------------+---------------
Chromium 1<0.4 10.6 15
---------------+---------------+---------------+---------------
Lead <0.9 14.4 15
---------------+---------------+---------------+---------------
Arsenic <0.1 <0.1 15
---------------+---------------+---------------+---------------
Selenium 10.1 10.1 I1
---------------+---------------+---------------+---------------
Mercury <0.01ug /g 1<0.01 ug /g 10.2
---------------+---------------+---------------+---------------
% ash 10.11 1 1
---------------+---------------+---------------+---------------
BTU 10 1 1
---------------------------------------------------------------
Total Sulfur 1<0.01
---------------+---------------+---------------+---------------
Ignitibility >94 1 1
---------------+---------------+---------------+---------------
pH 19.1 1 1
---------------+---------------+---------------+---------------
% Water 177 1 1
1 of 2 4/2/02 4:31 PM

W,ASTE,WATER FROM X -RAY OPERATION AT CLIFFSIDE STEAM STATION
---------------i---------------i---------------i----------------
1 Total Halides <500
---=-----------+---------------+---------------- +---------- - - - - -�
COD 1831.1
1---------------+---------------+----------- _--- +-----=---- - - - - -�
2 of 2 4/2/02'4 31 PM