NC0003425_Reissue Permit_20061002

h4O Pro ress Ene � 9 �JY
File No.: 12520 B -0 1
Mr. Gil Vinzani
Q
OCT 2 2006
DENR - WATER QUALITY
North Carolina Department of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699 -1617
FPr� r T
IO�Z /O�o
October 2, 2006
Subject: Carolina Power & Light Company d/b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System ( NPDES)
Permit No. NC0003425
Dear Mr. Vinzani:
The current NPDES permit for Roxboro Steam Electric Plant located in Person County
expires on March 31, 2007. Progress Energy Carolinas, Inc. hereby requests that the
North Carolina Division of Water Quality reissue the Roxboro NPDES permit in
accordance with 15A NCAC 2H .0105.
Enclosed is EPA Application Form 1 — General Information, EPA Application Form 2C —
Wastewater Discharge Information, and EPA Application Form 2F — Stormwater
Discharges Associated with Industrial Activity, all in triplicate.
With reissuance of the NDPES permit Progress Energy requests the following:
Replace the name of the company from "Progress Energy Carolinas, Inc." with
"Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc." on the
permit cover sheet.
2. Replace the name of the company from "Progress Energy Carolinas, Inc." with
"Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc." on the
Supplement to Permit Cover Sheet.
3. Revise Note 3 in Part I A.(2) such that monitoring for Total Residual Chlorine is
required only when chlorine is added to the cooling water systems.
4. Revise Note 2 in Part I A.(3) such that monitoring for Free Available Chlorine is
required only if chlorine is used in the cooling water system.
Progress Energy Carolinas, Inc.
Roxboro Steam Plant
1700 Ounnaway Road
Semora, NC 27343

Mr. Gil Vinzani 2
NPDES Application
Permit No NC0003425
5 Revise the�final paragraph in Part I A.(3) so that total residual chlorine monitoring
is required prior to,a maintenance drain of the Unit 4 Cooling Tower only if
chlorine is added to the system.
6. Revise the sample type in Part I A.(5) for Biochemical Oxygen Demand and Total
Suspended Solids from Composite to Grab. This outfall receives only domestic
wastewater which does not vary significantly in composition over time therefore
,grab sampling is appropriate.
7. Revise the definition of Bypass on Part II Page 1 to reflect the definition stated -in
40' CFR 122.41 as the "intentional" diversion of waste streams
In order to facilitate compliance with,40 CFR Part 1'25 ySubpart J (Phase II Cooling
Water Intake Structures) the Roxboro Plant is considering,a barrier net in the intake
pond north of the intake forebay. The barrier net will be designed for a maximum
through - velocity of 0.5 feet per second or less Should we pursue this measure no
further Comprehensive Demonstration Study work would be required Progress
Energy further °proposes that the barrier net will be designed in 2006 with installation
in 2007.
1 certify, under penalty of law, that this document and all attachments were prepared
under my direction or supervision in accordance with a system designed to assure that
qualified personnel properly gather and evaluate the information submitted Based on
my inquiry of "the person or persons who manage the system, or,those persons directly
responsible for gathering the, information, the information submitted is, to the best of my
knowledge and belief, true, accurate, and complete 1 am, aware that there are significant
penalties for submitting false information, including the possibility offines and
imprisonment for,knowang violations
Sincerely,
)f
Cecil E. 'Rowland
Plant Manager
Roxboro Steam Electric Plant

Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Attachment 1
Form 1 — Item X,— Existing Environmental Permits
Issuing,Agency
Type of Permit
ID Number
Division of Water Quality
NPDES
NC0003425
NPDES — Authorization to
Division of Water Quality
NC0003425A02
Construct
Division of Water Quality
Ash, Reuse Program Permit
WQ00070020
Erosion and Sedimentation
Roxboro FGD Installation
Division of Land Quality
Control Plan
Rev. M
Construction and Operation
Division of Air Quality
01001R28
of Air Emission Sources
Solid Waste Permit
Division of Solid Waste
73 -02
(Ash Monofill)
Solid Waste Permit (Land
Division of Solid Waste
Clearing and Inert Debris with
73 -D
Asbestos )

0
Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National'Pollutant,Discharge Elimination System Permit Number NC0003425
. o Roxboro Stearn? G
Electric Plant
NORTH CAROLINA
u _ Afterbay
Reservoir,
Car►e,Creek,
' Auxiliary.
blscharge `take Main
(Outfall #006) Dam
Plant Site; Y
2
J®
_
- Intake Canal"
e.
Discharge
L/ Asti Settling' Pond'
)utfalll #003)
4 Y }
' 0
1,- 2" , 3.
Kilometers" _
0
1 ,,2'
I-
Miles. .7
-;
Cobbs Creek,
North Hyco Creeks
"
South Hyco Creek
2
J®
_
- Intake Canal"
Discharge
L/ Asti Settling' Pond'
)utfalll #003)
4 Y }
' 0
1,- 2" , 3.
Kilometers" _
0
1 ,,2'
I-
Miles. .7

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Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Attachment 3
Form 2C — Item II -A - Flow, Sources of Pollution, and Treatment Technologies
Stream
Estimate(NAGeD, age Flow
Comments
A
4
Make -up water for Water Treatment Systems
B
505
Unit 3 Cooling Water Intake
C
592
Units 1 & 2 Cooling Water Intake
D
7
Unit 4 Cooling Tower Blowdown
E
505
Unit 3 Cooling Water discharge
F
17.3
Unit 4 Cooling Tower Intake
G
505
Unit 3 Cooling Water Discharge
H
0.015
Sewage Treatment Plant discharge
I
3
Low Volume discharge into Ash Pond
J
19.25
Ash transport into Ash Pond
K
0.17
Silo wash water
L
12
Ash Pond discharge into Discharge Canal
M
1067
Discharge Canal flow into Hyco Lake
N
0.09
Coal Pile Runoff Pond discharge to Hyco Lake
O
1.92
Flue Gas Desulfurization discharge
P
5.81 (maximum)
Intake to Flue Gas Desulfurization
2

Carolina Power & Light Company d /b /a Progress Energy Carol inas,,,lnc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit'Number NC0003425
Attachment 4
Form 2C - Item II -B Flows, Sources of Pollution, and Treatment Technologies
The Roxboro Steam Electr`,ic Plant, located in Person ,County, North Carolina, consists of four
coal fired generating units with net dependable capacities of 385, 670, 707, and 700 MWe for
units 1, 2, 3, and 4 respectively. All plant waste streams are routed directly or indirectly to
the Hyco Reservoir. Chemical constituents contained in these discharges will, in part, be
representative of the naturally' occurring chemical quality and quantity of the intake water and
will also have chemical constituents of such ,quality associated with similar discharges for
fossil generating facilities of this isize, type, and in this, geographical location. Either all or
part of the elements in the Periodic Table, either singularly or in any combination, may from
time to, time be contained in the discharges. Each component -of the discharges is described
below.
Outfall 003 - Discharge Canal
At the point that the discharge canal enters the Hyco Reservoir, it contains the flows, from
several waste streams, including once- through cooling water.,-,, stormwater runoff, and the
effluent from the ash pond, which in turn receives and treats combined flows from the ash
transport system, the low volume waste system, the dry fly ash handling system, cooling
tower 'blowdow,n, stormwater runoff, drainage from the ash landfill and' from occasional
wastewater piping leakage.
Once - Through Cooling Water
Condenser Cooling Water (CCW) for Units 1, .2, and 3 is drawn from the Hyco
Reservoir via an intake canal and discharges to the Hyco Reservoir via a discharge
canal. Flows for Units 1, 2, and 3 are 249 MGD, 342 MGD„ and 505 MGD
respectively. Cooling is accomplished by evaporation from the surface of Hyco
Reservoir and mixing -and convection with the reservoir waters
1

Carolina °Power& Light Company d /b /,a Progress Energy 'Carolinas,.Jfc.
Roxboro Steam Electric- Plant
National Pollutant Discharge Elimination System Permit Number�NC0003425
During the, summer months, Unit 3' CCW' is routed through mechanical .draft,cooling
towers where Moist ,of the waste heat is removed by evaporation before the water is
discharged to,the reservoit'via the discharge canal along with the CCW of Units 1 and
2. Additionally,, once-through cooling water is used as component closed cooling
water, the flow of which is combined with the CCW prior to introduction ,into the
discharge canal
Ash Pond Discha -rge,
The ash, pond receives ;ash transport water, low volume wastes, runoff from "the ash
landfill, dry 'fly ash handling system wash water, blowdown from `Unit 4, cooling tower,
coal' mill rejects and pyrites, •and sewage treatri, ent plant effluent., The pond provides
treatment by sedimentation,, oxidation, neutralization, equalization, and adsorption.
Ash Transport Wafer
Water for sluicing ash to "the 'ash pond' is withdrawn from the COW system as
needed The plant will primarily supply ,ash sluice water from' Unit 2 However,
the facility, will ,continue 'to .maintain the ability to operate the unit 4 ash sluice
pumps The Unit 4 ash sluice pumps are and Will continue to 'be utilized for,the�
following i) during maintenanceAraining ,of the ,cooling tower,,'ii) back -up supply
for the fide suppressant system, and ',iii), ash sluicing pumps during operational
events, 'which regpire additional pumping Normally, only' bottom ash is.
conveyed to the ash pond by sluicing. Fly ,ash is ;handled dry by a, pneumatic
system and' is lartdfilled' on, site or- sold !.f the ;dry fly ash handling system is out
,of service during plant operating ',periods,, fly ash will be sent to, the ash pond via,
the ash sluicing,,,syste ms until the d'ry system is restored. Such occurrences are
expected 'to [be, infrequent and ,brief
Silos Wash Watef
Ash silo wash, water runoff' and dust suppressant spray runoff' from the dry 'fly
ash hand dling ,sysfemi�are� routed to the ash pond.
2

Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Low Volume Wastes
Boiler make =up water is withdrawn from the CCW system and filtered, softened,
and demineralizered for treatment. Boiler water is" treated with ammonia,
hydrazine, and occasionally sodium hydroxide. Boiler blowdown is sent to the
ash pond via the low volume wastes collection system (LVWS); these are
special drains, in the plant that flow by gravity to collection sumps and are
pumped to the ash, pond. Ethylene, glycol is,used for freeze protection of some
equipment and may be discharged to the LVWS,, as is some molybdate waste
from the closed cooling water system, during periods of maintenance The
plant's demineralizers are regenerated using sulfuric acid and sodium
hydroxide When this equipment is rinsed, small amounts of these chemicals
are discharged to the low volume system via `the neutralization basin
Essentially all plant equipment, floor drains, water'treatment filter backwashes,
clarifier and sedimentation basin sludge, and' ash hopper seal water overflow
also discharge to the LVWS In addition, a back -up domestic sewage system
can discharge to the LVWS. The back -up system consists of a septic tank with
a subsurface sand filter and a chlorine dosing chamber. The back -up system
can be used if the facility's extended ,aeration treatment system is temporarily
out �of'sertivice.
Cooling Tower,Blowdown
Unit 4 is the only unit that produces cooling tower blowdown A blowdown
stream is used to maintain concentrations of total dissolved solids in the cooling
tower to within proper operating limits. Make -up to the Unit 4 cooling tower is
from the Heated Water Discharge Canal
Domestic Sewage
Domestic sewage is treated by an extended aeration treatment plant consisting
of a screen, comminutor, surge tank, aeration tank, clarifier, chlorine contact
chamber, and a sludge holding tank.
3

Carolina Power & Light Company d /b /a Progress Energy Carolinas; Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Coal Pile Runoff
The solids settling, basin, which contains a portion of the'wastewater runoff from
the coal pile and other coal handling areas of the plant, is routed to the ash
pond.
Ash Landfill Drainage
Water for sluicing a minimum :amount of bottom ash to the ash landfill is
withdrawn from the ash transport system as needed. The bottom ash is used
to enhance'the subsurface drainage of the landfill.
Air Preheater Cleaning (Low Volume Waste)
The air preheater will be water washed once per year or more frequently as
needed. The wastewater from this activity will be discharged to the ash pond.
Chemical Metal Cleaning Wastes
The boilers'are chemically cleaned approximately every five -to -eight years as
required using Tetra-ammonia ethylene diamine tetraaccetic acid (EDTA)
solution or citric acid. This? cleaning solution and its rinses are stored on site for
disposal by evaporation in an operating unit's furnace. Should evaporation not
be used, the wastewater can'be treated by neutralization and precipitation prior
to being conveyed to the ash pond. Alternatively, the wastewater can be
disposed by other acceptable disposal methods. Cleaning of otherheat
exchanger surfaces may produce 5,000- 10,000 gallons of wastewater
approximately every three -to -five years.
Stormwater Runoff
The stormwater runoff, which flows into the ,ash pond 'includes, runoff from the
plant drainage area, landfill runoff (including silo area drainage), and the
drainage area from the ash pond (including roadways).
4

l
Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Flue Gas, Desulfurization (FGD) System Biow, down Emergency
Overflow /Pipeline Drain,
Emergency overflow from the FGD System blowdown will discharge to the ash
pond., This is expected to occur only in the event of extreme rainfall. If the
FGD 'System blowdown pipeline requires emergency draining, the contents of
the pipeline will be drained to a sump that is pumped to the ash pond.
Stormwater Runoff
The stormwater, which flows into the discharge canal includes "runoff from the plant
drainage area, the drainage area from the dry flyash handling system (including
roadways), Unit 4 cooling tower drainage area, the fuel oil storage containment area,
the switchyard drainage area, the anhydrous ammonia tank farm, and the gypsum
storage pile area.
Flue Gas Desulfurization Blowdown (Low Volume Waste)
The Flue Gas Desulfurization (FGD) system directs flue gas into an absorber where
limestone (calcium carbonate) slurry is sprayed. Sulfur dioxide in the flue gas reacts
with the limestone slurry, to produce calcium sulfate (gypsum). The system reclaims
any unreacted limestone slurry to be reused in the absorber. A small blowdown
stream is used to maintain the `chloride concentration in the reaction tank. The
blowdown stream will be discharged to a gypsum settling pond where suspended
solids will be reduced prior to entering a bioreactor The bioreactor utilizes microbes
to reduce soluble contaminants to insoluble forms that then precipitate from solution
The treated wastewater will enter the ash pond discharge canal prior to outfall 002
Outfall 006 — Coal Pile Runoff
Wastewater runoff from the coal pile, limestone pile,, and gypsum pile and other coal
handling areas of the plant is routed to a retention pond for treatment by neutralization,
sedimentation, ,and equalization. The pond is designed to store in excess of the 1,0- year /24-
hour storm event. Releases are controlled by a standpipe and skimmer discharge structure
5

Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System, Permit Number NC0003425
Attachment 5
Form 2C - Item VI Potential Discharges Not Covered By Analysis
Chemical
Quantity
(used per year)
Frequency
Purpose
Anhydrous Ammonia
14,000 gal /wk,
per unit
As required
(Seasonal)
Flue Gas Conditioning
Nalco 8338
385 gallons
As required
Corrosion Inhibitor
Nalclear 8173
(flocculant)
250 Ibs
As required
Water Treatment
H =130 (Microbiocide)
2300 gallons
As required
Unit 4 Cooling Tower
Algae Control
Nalco 71,D5 Plus
(Antifoam Agent)
630 gallons
As required
Unit 4 Cooling Tower
Foam Control
'Nalco 7396
(Polyphosphate)
110 gallons
Twice per day
Corrosion ,Inhibitor
Potable Water
Ice Free Conveyor
(Propylene glycol)
750 gallons
2100 Ibs
As required
Conveyer Belt Freeze
Protection
Aluminum Sulfate,
4000 gallons
As required
Water Treatment
Sodium Chloride
100,000 Ibs
As required
Softener Regeneration
Sulfuric Acid
1`3,000 gallons
Twice per week
Demmeralizer
Regeneration
'Sodium Hydroxide
15,000 gallons
Twice perweek
Demmeralizer
Regeneration
Ethylene Glycol
6,000 gallons
As required
Freeze Protection Hot
Water Coil System
Lime
2,500 Ibs
As required
Wastewater pH Control
Hydrazine
1,760 gallons
As required
Feedwater Oxygen
Ammonia Hydroxide
1,760 gallons
As required
Boiler Water pH 'Control
Chemical
Quantity
(used per year)
Frequency
Purpose
Rev 10/06

w. m
� ifw
Carolina Power & Light Company &b /a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Sodium Hydroxide
200 Ibs
As required
Boiler Water pH Control
Sodium Hypochlorite
400 gallons
Twice per day
Potable Water
Treatment
BT -210W'
40,,,000 Ibs
(estimated)
As required
Dust Suppressant
Coaltrol 35
40,000 Ibs
As required
Dust Suppressant
Sodium Bicarbonate
20,000 ,Ibs
As required
Wastewater pH Control
Caustic Soda (20 1/6)
110 gallons
Twice per,day
Potable Water pH
Control
Molten Sulfur
525,000 Ibs
As required
Flue Gas Conditioning
Sanuril Tablets
(Calcium Hypochlorite)
135 Ibs
As required
Biocide for Sewage
Treatment
Nalclean
200 Ibs
As required
Softened Water System
Sodium Carbonate
8,000 Ibs
As required
Air preheater wash
water neutralization
EDTA
69,000 Ibs /boiler
As required
Boiler Cleaning
A300
(Chelating Agent)
50 gallons /boiler
As required
Boiler Cleaning
M045 Silicone
Antifoam Agent
15 gallons /boiler
As required
Boiler Cleaning
GEOMELT
87,000 gallons
per month
Winter months
Anti -icing Fluid for Coal
,BT -930
87,000 gallons
per month
Winter months
Anti -icing Fluid for Coal
Limestone (calcium
carbonate)
492,000 tons
Continuous
Flue Gas
Desulfunzation
2
Rev 10/06

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PROGRESS ENERGY CAROLINAS, INC.
Roxboro Steam Electric Plant
National Pollutant, Discharge Elimination System Permit,Number NC0003425
Attachment 7
Form 2F - Item III — Site Drainage Map
The enclosed site drainage maps are for the section of rail lines from which
stormwater is conveyed to Hyco Lake and the plant area which discharges to
Hyco Lake. Stormwater from other sections of the rail line is conveyed to the coal
pile runoff pond which is permitted through 'the Plant's NPDES permit — Outfall
006.
Progress Energy has not treated, stored, or disposed of any significant materials
in the drainage area of this rail line and has no plans to treat, store, or dispose of
significant materials ;in these areas. No materials loading or unloading activities
will take place on these rail lines Drainage from areas where coal, limestone,
and gypsum' will be loaded or unloaded will drain to the coal pile runoff pond
which is a NPDES permitted (wastewater)' outfall to Hyco Lake. Various brands of
commercial herb'i'cides (i.e., roundup, Crossbow) might be used to control weeds
and other unwanted plant, growth for security reasons. These herbicides will be
carefully applied by licensed applicators, or persons under the immediate
supervision of a licensed applicator, in accordance with the manufacturer's
instructions. Fertilizers, pesticides, and /or soil conditioners will not be used in this
drainage area No hazardous waste treatment, storage, or disposal will occur in
any of the drainage areas.

') •,. 1
PROGRESS ENERGY CAROLINAS, INC.
Roxboro Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Attachment 8
Form 2F - Item IV B.
Progress Energy has not treated, stored or disposed of any significant materials in
a manner which allows exposure to stormwater in the drainage area of these
stormwater outfalls and has no plans to treat, store, or dispose of significant
materials in these areas No materials loading or unloading activities will take
place on these rail lines. Drainage from areas where coal, limestone, and
gypsum will be stored, loaded or unloaded will drain to the coal pile runoff pond, a
NPDES permitted (wastewater) outfall to Hyco Lake. Chemicals or process that
could potentially contaminate stormwater are located in buildings or covered by
shelters. Outside storage areas contain inert materials.
Various brands of commercial herbicides (i.e., Roundup, Crossbow) might be
used to control weeds and other unwanted plant growth for security reasons
These herbicides will be carefully applied' by licensed applicators, or persons
under the immediate supervision of a licensed applicator, in accordance with the
manufacturer's instructions Fertilizers, pesticides, and /or soil conditions will not
be used in this drainage area. No hazardous waste treatment, storage, or
disposal will occur in any of,the drainage areas.

PROGRESS ENERGY CAROLINAS, INC.
Roxboro Steam Electric 'Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Attachment 9
Item IV C - Narrative Description of Stormwater Outfalls
Outfall SW -A – North Loop of Plant
The drainage, area of this outfall' is 'located ,north ,of the plant and is enclosed by a
rail line. Stormwater will flow through a 24" diameter culvert under the rail line
through riprap into a vegetated swale approximately 150 feet to Hyco Lake. An
erosion and sediment control plan is in place for construction which is currently
taking place in the drainage area.
Outfall SW -B — Plant Area – Future Discharge
This outfall will be located northwest of the plant and will drain the industrial area
of ,the facility Stormwater will be routed through vegetated ditches to a 30"
diameter culvert under the rail line and will be discharged to Hyco Lake. The area
that will drain to Outfall SW -B is currently under construction and is monitored per
NPDES Permit No. NCG010000.
No conventional treatment will be provided for the stormwater drained from these
stormwater outfalls. Discharges from Outfall SW -A will flow over a vegetative
buffer which will provide some filtering, of sediment from the stormwater.

4 ` PROGRESS ENERGY CAROLINAS, INC.
Roxboro Steam Electric `Plant
National Pollutant Discharge Elimination System Permit Number NC0003425
Form 2F — Attachment 10
`Data in Item VII is provided from 'a similar discharge, Outfall `005, at`the Mayo
Steam Electric Plant ,(NPDES permit NC0038377). 'The storm event that
produced this data is documented in Item `VII 'Part D -. Samples from, a discharge
from SW -A will be collected and data will be submitted when available