NC0005363_Permit (Modification)_20080916

h*o�, Pro ess Energy MAR 0 5 2008 '� �� ,� J I
March 5, 2008
Mar
Mr. Gil Vinzani MAR - 6 2008
Supervisor, Eastern NPDES Program
North Carolina Department of Environment and Natural Resources
Division of Water Quality - 1
1617 Mail Service Center
Raleigh, NC 27699 -1617
Subject: Carolina Power & Light Company d/b /a Progress Energy Carolinas, Inc.
Weatherspoon Ste t
NPDES Permit No Saion Request for Permit
Dear Mr. Vinzani:
Progress Energy Carolinas, Inc., requests an NPDES permit modification to incorporate the new
storm water activity described herein. Enclosed is the completed EPA Form 2F, Application for
Permit to Discharge Storm Water Discharges Associated with Industrial Activity, and the
amended Form 2C Attachment 3 (bolded areas indicate change). As indicated in the current
Form 2C, storm water from the industrial activity areas associated with the power plant
operations flows into the cooling pond and, thus, is not considered part of this request. We
understand that this request is a minor modification with no associated fee but could be a major
modification and therefore a check for the associated fee of $1,030 is enclosed.
The Weatherspoon Steam Electric Plant plans to pursue ash reclamation activities previously
authorized in the latest NPDES permit application. These events will not alter the chemical
character of the ash pond content and thus, no change in the nature of the discharge to the
cooling pond is anticipated. Further, no additional discharges are expected. During ash removal
projects, trucks are filled with moistened ash (about 15 -18 %) within the confines of the ash pond
boundary and covered. The trucks are washed down prior to leaving the area and travel along a
graveled on -site roadway before exiting the site via the existing plant access road. The
approximately 0.6 mile long access road becomes a new source of industrial activity when this
power plant by- product is transported along its route.
Along the access road, there are three discrete conveyances of storm water runoff which
ultimately discharges into the Lumber River. In section one, roadside ditches direct runoff into
an unnamed tributary which flows to the river. Roadway runoff in sections two and three is
collected in catch basins before being discharged to the river. Ash reclamation activities will not
increase or change the quantity of storm water currently associated with the plant access road.
Given that the drainage from all three sections of the roadway has the same characteristics, the
three outfalls should have substantially identical storm water discharges. Thus, we request
Progress Energy Carolinas,lnc.
Weatherspoon Steam Plant
491 Power Plant Road
Lumberton, NC 28358

Mr. Gil Vinzani, NCDENR 2 March 5, 2008
representative outfall status for any required analytical monitoring during ash reclamation
projects. We propose to sample SW -1 because its receiving stream has the lowest flow.
The currently proposed as reclamation project is scheduled to take about three years. Only on
days without significant precipitation, twenty trucks per day carrying approximately 24 tons of
ash per truck are planned. Specific quantities and timeframes may vary between projects.
Progress Energy Carolinas, Inc., requests that the NPDES Permit for Weatherspoon Steam
Electric Plant be modified to authorize the storm water discharges along the egress route for coal
ash reclamation projects. We ask that if any requirements are imposed, they be required only for
the time periods when an active ash reclamation project is ongoing.
If there are any questions regarding the enclosed information, please contact Robin Bryson at
(919) 546 -3962.
I 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. I am aware that there are significant penalties for submitting false information,
including the possibility of fines and imprisonment for knowing violations.
Sincerely,
C/ /�%" -azz�
J. Mark Frederick
Plant Manager
JMF /rb
Enclosures
c: Mr. L. Baxley
Ms. R. Bryson
Mr. D. Mottola

Carolina Power &,Light Company d /b /a WeathePspoon Steam Electric Plant
Progress Energy Carolinas, Inc NPDES Permit Number NC0005363
Attachment 1. Site Drainage Maps
The enclosed topographic map (Map 1) highlights the Weatherspoon Steam Electric Plant access road
which will', become a new source of industrial activity when trucks begin to transport coal ash offsite.
The enclosed drawn maps (Maps 2 and 3) detail the storm water drainage patterns and show the
sections of roadway from which storm water is conveyed to either the Lumber River or an, unnamed
tributary to the Lumber River. Storm water that drains from a small grassy area-adjacent to the power
plant and from one of the administration area parking lots also flows into this drainage system. Storm
water that falls on the power plant site is conveyed to the cooling pond, 'which discharges to the
Lumber River through an NPDES -permitted outfall, and is not included in this'permit request.
There are three distinct drainage areas along the access road The first storm water outfall (SW-1) is
about 675 feet from the Power Plant Road' entrance and receives runoff -from ,approximately 1,640 feet
of roadway. The road is sloped slightly such that most of the runoff flows towards the western edge -of
the road which then drains along a grass - lined trough into a low area of an unnamed tributary,. An
under -road culvert connects an offsite pond adjacent to an automobile parts business to this area also.
l
The second storm water outfall (SW-2) empties into the ,Lumber River near the power plant and
receives drainage from approximately 1,720 feet of roadway A short concrete -lined ditch directs water
from the eastern edge of the road into one of the drain junction boxes. Runoff from a side road drains
into catch basins and flows below ground to the drain junction boxes. This outfall also receives
drainage from the ditches alongside an abandoned rail line, a small grassy area udJacent to the power
plant, and an administrative building parking lot. Two pipes from these junction boxes direct the storm
water to the outfall.
The third storm water outfall (SW -3) primarily discharges rainwater collected from the picnic area
adjacent to -the power plant and- the runoff from the western, edge of the road which is funneled through
an open collection pipe. Catch basins divert the water to the outfall.
Al-1 03/04/2008

Carolina Power & Light Company d /b /a Weatherspoon Steam Electric Plant
Progress Energy Carolinas Inc. NPDES Permit Number NC0005363
0 0.09 0.18 0.27 0.36 0.45 mi
Map 1. Topographical map highlighting the access road to the Weatherspoon Plant.
A1-2 03/04/2008

Carolina Power & Light Company d /b /a Weatherspoon Steam Electric Plant
Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
—765 ft to top
of grade
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Map 3. Drainage pattern for storm water discharge at outfalls SW -2 and SW -3.
A1-4 03/04/ 0008
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Map 3. Drainage pattern for storm water discharge at outfalls SW -2 and SW -3.
A1-4 03/04/ 0008

Progress Eneegy,,Carolinasjnc.
Weatherspoon Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0005363
Attachment 3
Form 2C - Item II- B,Flows, Sources of Pollution, and Treatment Technologies
The Weatherspoon Plant is a coal -fired steam cycle electric generating plant with three units Four
Internal Combustion, (IC) Turbines are also located on the plant, site The plant has a 225 -acre off stream
cooling pond on the north side of the Lumber River in 'Robeson County, North Carolina Water is
withdrawn from the Lumber River as required to make up evaporative and seepage losses from the
cooling pond Water for plant use is also withdrawn from wells Makeup pumping rates from the rnverare
highly variable depending upon, natural weather conditions, generation. load, plant operations, and cooling
pond water level
Chemical constituent's contained in both of these discharges will, in part, be 'representative of the,naturally
occurring chemical quality of the intake water and will also have chemical constituents of such quality and
quantity associated with similar discharges for fossil generating facilities of this size, type, and in this
geographical location Eitherall,or part of the elements, enumerated in the Periodic Table, either singularly
or in any combination, may from time' to time be contained 'in this discharge Each component of the
discharges is described below
OUTFAL'L 001 - DISCHARGE FROM`COOLING POND
Plant waste streams are ,routed directly or, indirectly to the cooling pond and thereby recycled Releases
from the cooling pond (Outfall 0011) are rare, occurring usually when a major storm is expected and
additional freeboard is needed to prevent overtopping of the pond dikes On other occasions, the pond
may need to be drawn down for maintenance purposes The cooling pond last discharged to the Lumber
River in September of 1999 The permit required analyses were performed on, the discharge and
submitted in the September 1999 Discharge Monitoring Report (DMR) The pH of -the cooling pond is
neutralized when needed by adding acid or caustic at the discharge of the circulation water pumps A
description of the waste streams -that discharge into the, cooling pond follows
RECIRCULATED COOLINGWATER
This flow provides condenser,cooling water for the three generating units The flow is discharged
into the pond and routed through the pond° "by baffle dikes to achieve maximum surface cooling
efficiency before reaching the•condenser cooling water intake,structure to be used again Cooling
of the pond is achieved primarily by evaporation from the pond surface, which is estimated to
consume a ,maximum of approximately 16 MGD above natural, evaporation rates, during times the
units are in full operation_ Control of biological fouling on condenser surfaces is accomplished by
chlorinating as required
COAL PILE RUNOFF
Rainfall runoff from the coal pile (approximately 6 acres) is routed to the cooling pond, which
provides treatment by neutralization and sedimentation
STORMWATER RUNOFF
Rainfall runoff from the industrial portion of the site is ultimately routed to the cooling pond
Sludges /sediments collected in sumps, catchment basins, etc are disposed of in the, ash pond ,or
by other appropriate methods
ASH SLUICE WATER
Fly ash and bottom, ash from all three units is hydraulically conveyed by an ash sluice pipeline to
the ash pond In addition, water from washing the interior of the precipitators is sent to the ash
pond via the ash sluice pipeline A stand pipe allows for overflow release to a small secondary
settling basin containing another.stand pipe,for release to the cooling pond'

Progress Energy Carolinas, Inc.
Weatherspoon Steam Electric Plant
National Pollutant Discharge Elimination S stem Permit, Number NC0005363
'DOMESTIC WASTES
Sanitary wastes are treated on -site by a septic tank and a sand and gravel drainage field which
discharges to the cooling pond Flow from ,the system is dependent upon fluctuating demand due
to variations ,in the number of personnel ,on site When needed, residuals are disposed of off-site
by a licensed contract disposal firm
CHEMICAL METAL CLEANING WASTES
'Wastes from the chemical cleaning of °the boiler1ubes are normally disposed of by evaporation in
boilers, either onsite or at another Progress Energy facility Boiler cleaning is usually performed
evey 10 years Units 1 and 3 boiler cleanings are currently scheduled for spring 2008 and 2004,
respectfully , Should boiler cleaning wastes not be evaporated, they will be treated by
neutralization and precipitation in portable holding tanks The liquid fraction of the metal cleaning
wastes will be discharged to the ash pond The sludge fraction of the metal cleaning wastes will
be disposed of in either, the ash pond or by other appropriate methods In addition, wastes, from
the, chemical cleaning of the condenser tubes and,;heat exchangers are normally disposed' of in
the ash pond Should condenser and heat exchanger cleaning wastes not be discharged into the
ash pond, they will be evaporated At, this time it is unclear as to how often condenser and heat
exchanger cleaning may be ,performed , Currently, Unit 3 heat `exchanger cleaning is scheduled
for Aprd,2004 ,
IC TURBINE SITE
There are four Internal Combustion (IC) Turbines located at the, Weatherspoon Plant All drains
from the IC turbine site, including drains collecting rainfall,, are routed through an oil -water
separator which discharges to the cooling pond Sludges /sediments collected in sumps,
catchment basins, etc are disposed of in the ash pond or by other,appropnate methods
AIR PREHEATER'WASHES
The air preheaters are water washed infrequently When the air preheaters are washed
approximately 50,000 gallons of wastewater,is produced and discharged to the ash pond via the
ash sluice pipelines
SPENT SANDBLAST MATERIAL
Periodically, sections of boilers, turbines and miscellaneous parts require sandblasting The
sandblasting process produces approximately 500 to 700 pounds of spent material annually This
material is discharged to the ash pond via the ash sluice lines or by other suitable methods
depending on work location
LOW- VOLUME WASTES
Waste streams not identified above fall in the category of low volume wastes All low volume
Wastes described below are routed by gravity flow to the cooling pond Sumps convey
miscellaneous equipment leakage, equipment drainage for maintenance; equipment wash down
water, sampling streams, and closed cooling water system blowdown Water treatment wastes
consist of solutions of sodium chloride, used for water softener regeneration, and sodium
hydroxide and sulfuric acid which are used in the regeneration of demineralizers Demmeralizer
regeneration wastes Are routed to the ash, pond via the ash sluice line Water softener
regeneration wastes are routed directly to the cooling pond Blowdown of boiler water to control
boiler °chemistry is routed to a flash ,tank, which discharges to the cooling pond Drains from areas
likely to contain oil filled equipment or storage are routed through an oil -water separator
Sludges /sediments from sumps, catchment basins,, etc are disposed of "in the ash pond or by
other appropriate methods A summary of process chemicals is provided in Attachment 4
In many cases, chemicals added during the plant processes are consumed or chemically altered
Only trace amounts might be recoverable in water entering the cooling pond Because the,coolmg
2'

Progress Energy Carolinas, Inc.
Weatherspoon Steam Electric Plant
National Pollutant Discharge Elimination System, Permit Number NC0005363
pond serves as a final treatment basin and receives significantly greater volumes of water from
other inflows, detectable levels of,these chemicals should not occur in the cooling pond discharge
ASH MANAGEMENT AND RECLAMATION
From time to time fly and bottom ash in the ash pond may be stacked or relocated within the diked
boundary of the ash pond system As this pond management activity does not alter the chemical
character of the pond contents, no change in the nature of the discharge to the cooling pond is
anticipated
In the event a practicable market becomes available,, Progress Energy may exercise the option of
reclaiming ash from the ash pond system In consideration of the scope of such an operation, no
additional discharges are expected to result from ash reclamation efforts Best management
practices are established for these activities. During ash removal projects, trucks are filled
within the confines of the ash pond boundary and the load covered. The trucks are washed
down prior -to leaving ,the, area ,and travel along a graveled on -site roadway before exiting
the site via the plant access road.
HERBICIDE'AND PESTICIDE USAGE IN THE TREATMENT SYSTEM' PONDS
Herbicides may be used as needed to control nuisance aquatic vegetation These herbicides are
applied by licensed applicators, or persons under the immediate supervision of a licensed,
applicator, in accordance with the,manufacfurer's instructions
Pesticides may be used as needed to perform biological assessments These Pesticides are
applied by licensed' applicators, or persons under the immediate supervision of a licensed
applicator, in accordance with the manufacturer's instructions
OUTFALL 002 - SERVICE WATER
NON - CONTACT COOLING' WATER
Non - contact cooling water is withdrawn from the Lumber River and passed through heat
exchangers, to provide non - contact ;cooling for the Plant's closed cooling water system After
passing through the heat exchanger, non - contact cooling water is routed 'either to the cooling
pond or to the Lumber River via outfall 002 depending on the need for cooling pond makeup
water
Sodium hypochlonte (chlorine) is added at the non - contact cooling water pump intake, as
required, 'to control biological fouling of the heat exchanger surfaces As established by written
plant procedure, chlorine is only added during times where non - contact cooling water is routed to
the cooling pond Upon completion of chlorine addition, the non - contact cooling water system as
operated with discharge to the cooling pond for, a period of at least one hour prior to any
redirection to outfall 002 This procedure has been implemented to prevent the discharge of
chlorine to the, river via outfall 002
STORM WATER OUTFALLS ALONG ACCESS ROAD
During periods when coal ash removal projects are conducted, and the access road to the
power plant becomes part of an industrial activity, three storm water outfalls along the
road are addressed in EPA,Form 2F. Storm water fromAhese three discrete,conveyances'is
ultimately discharged into the Lumber River.

'Carolina Power &'Light Company d /b /a 'Weatherspoon Steam Electric Plant
Progress Energy Carolinas, Inc NPDES Permit Number NC0005363.
N
Scale 1approximated)
V7 ='270'
NC 72
Power Plant Road
Used auto parts
business
.�.,. Small pond
offsite
S -1
Unnamed
tributary to the
Lumber River
Top of grade
Map 2. Drainage pattern for storm water discharge at outfall SW -1.
A1-3 03/04/2008

Progress Energy
BIOCIDE CONDITION
"The permittee shall not discharge any biocides that have not been previously
approved in conjunction with the permit application. For biocides not
previously approved by the Division of Water Quality, the permittee shall notify
the Director in writing prior to use of these biocides. Completion of Biocide
Worksheet Form 101 is not necessary for those outfalls with toxicity testing
requirements."
Progress Energy Carolinas also requests that Footnote 3 on the Section A(2) page be amended to read
"Monitoring requirements apply only if chlorine is discharged through outfall 002." Sodium
hypochlorite (chlorine) is added at the non - contact cooling water pump intake, as needed, to control
biological fouling of the heat exchanger surfaces. As established by written plant procedure, if chlorine is
added for biofouling control, this chlorinated non - contact cooling water discharge is routed to the cooling
pond. Upon completion of chlorine addition, the non - contact cooling water system is operated with
discharge to the cooling pond for a period of at least one hour prior to any redirection to Outfall 002. This
procedure has been implemented to prevent the discharge of chlorine to the river.
Thank you in advance for your consideration of the above requested items. If there are any questions
regarding our requests or the enclosed application information, please contact Ms. Robin Bryson at (919)
362 -3962.
I 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. I am aware that there are significant penalties for submitting false information,
including the possibility of fines and imprisonment for knowing violations.
Sincerely,
(�;/PL_,ie z� �
J. Mark Frederick
Manager - Weatherspoon Plant
JF /rb
Enclosures: EPA Form 1 — General Information
EPA Form 2C — Wastewater Discharge Information
EPA Form 2F — Storm Water Discharges Associated with Industrial Activity
c: NCDENR -DWQ Fayetteville Regional Office
Robin Bryson, Progress Energy Carolinas, Inc.
Progress Energy Carolinas, Inc.
Weatherspoon Steam Plant
491 Power Plant Road
Lumberton, NC 28358

`� Progress Energy
Progress Energy
Weatherspoon Steam Electric Plant
491 Power Plant Rd.
Lumberton, NC 28358
Mrs. Dina Sprinkle
NCDENR Division of Water Quality
Point Source Branch
1617 Mail Service Center
Raleigh, N. C. 27699 -1617
RECEIVED
January 26, 2009
JAN 2 8 2009
DENR - WATER QUALITY
File No: WSPN — 12520 -13-01 POINT SOURCE BRANCH
Subject: Carolina Power & Light Company d/b /a Progress Energy Carolinas, Inc.
Weatherspoon Steam Electric Plant, Robeson County, Lumberton, North Carolina
National Pollutant Discharge Elimination System ( NPDES) Permit No. NC0005363
Renewal Application
Dear Mrs. Sprinkle:
The current NPDES permit for the Progress Energy Carolina's Weatherspoon Steam Electric Plant expires
on July 31, 2009. By this correspondence, Progress Energy Carolinas respectfully requests that the
NPDES permit for the facility be reissued. Enclosed are the completed application forms with
attachments, one signed original and two copies.
Progress Energy Carolinas has submitted five amendments to the last NPDES permit application. There
were two amendments to add coal freeze conditioning agents to Form 2C, Attachment 4 (November 2004
and December 2008); an amendment to incorporate the reverse osmosis water treatment system into full
operation (March 2005); an amendment to add three storm water outfalls along the access road to allow for
coal ash reclamation activities (March 2008); and an amendment to increase the predicted number of
trucks leaving the site with reclaimed ash (September 2008). The enclosed Form 2F includes sampling
data results from the new storm water outfalls as required by regulation. Some of the analyses have not
been conducted but the results will be submitted by the March 2010 due date under another transmittal.
The description of the management of solids generated during wastewater treatment at the Weatherspoon
Steam Electric Plant is described in Form 2C, Attachment 3.
Progress Energy Carolinas requests that the following condition be added to the renewed NPDES permit.
The purpose of this condition is to formally recognize the guidance and understanding we have received
from the Division in the past.
Progress Energy Carolinas, Inc.
Weatherspoon Steam Plant
491 Power Plant Road
Lumberton, NC 28358

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 1
Form 1 Item XI Maps
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1 -1

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 1 continued
0 0.1 0.2 0.3 0.4 05 mile
1 -2

Progress Energy Carolinas, Inc. NPDES Permit Number,, NCO005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 2
Form 2C Item II -A Flows, Sources of Pollution, and Treatment Technologies
- Source
Estimated
Average Flow
Comments
A
4 -16 MGD
Make up waterfrom Lumber River, Maximum rate is 9 12 MGD
B
4 03 MGD
Non - contact cooling water discharge, Maximum rate is 9 12 MGD
C
0 7 MGD
Make up for cooling pond, Maximum rate is 9.12 MGD
D
193 MGD
Condenser cooling water - all three units operating
E
2,400 GPM
Maximum make -up rate for fire water system
F
1`00 GPD
Low volume wastes to the ash pond
G
21 MGD
Ash pond discharge to cooling pond
H
191 MGD
Condenser discharge to cooling pond
1
120 GPM
Intermittent flow as required
J
0 14 MGD
Discharge to cooling pond from oil /water separator
K
0 024 MGD
Estimated using average daily rainfall
L
0 14 MGD
Variable due to intermittent processes and runoff
M
0.7 MGD
Maximum estimated rate is 1 6.MGD
N
0 MGD
Pond does not normally discharge See Attachment 3 for details
O
0 00125 MGD
Sanitary wastes
P
50,000 gal /event -
Units 1 & 2
42,000 gal /event -
Unit.3
Amounts estimated, Usually evaporated in boiler
Q
0 19 MGD
,Estimated using average daily rainfall
R
0 011 MGD
Estimated using average daily rainfall
S
4,000 GPD
Low volume waste (reverse osmosis reject water)
2 -1

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 2 continued
Combustion
Turbine Site
2 -2
Evaporation
Potable Water -
Sanitary Waste Septic
Sand & Q
System
System Tank
Gravel
P
Bed
Metal Cleaning
Wastes
Wells
i
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Low Volume L
Wastes
Plant Drains
Lumber River
i
F
A
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River Intake
i
' NV
Structure
s
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Condenser
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Exchancier
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Fire "Water
Internal Intake
Separator
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Structure
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Ash
Water Runoff
Pond
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Wastes
Coal Pile
Runoff
Secondary
Settling
K
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Basin
Seepage
M
G
C
Cooling
-
Pond
B
7Separator
N
Storm Water
Lumber River
NV
Outfalls
Outfa11002
Vater
Outfa11001
Combustion
Turbine Site
2 -2

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 3
Form 2C Item II -B Flows, Sources of Pollution, and Treatment Technologies
The Weatherspoon Steam Electric Plant is a steam cycle electric generating plant with three coal - burning
units and four internal combustion turbines Source water is withdrawn from the Lumber River as,
required to make up evaporative and seepage losses from the power plant's cooling pond Makeup
pumping rates from the river are, highly variable depending upon natural weather conditions, generation
load, plant operations, and cooling pond water level Water for,power plant' use is also'withdrawn from
groundwater wells
Chemical constituents of the power plant discharges will, in part, be representative of the naturally
occurring chemical quality of the intake water and will also have chemical constituents of such quality and
quantity associated with similar discharges,for fossil generating facilities of'this size, type, and in this
geographical location Either all or part of the elements enumerated in the Periodic Table, either
singularly or in any combination, may from time to time be contained,m this discharge,
There are-five permitted outfalls at the Weatherspoon Steam Electric Plant, three of which are for storm
water along the access road Components of the discharges are described below
OUTFALL 001 - DISCHARGE FROM COOLING POND
Most of the power,plant waste streams are routed directly or indirectly to the 225 -acre off - stream cooling
pond located on the north side, of the Lumber'River in Robeson County, North Carolina, and thereby
recycled Releases from the cooling pond are rare, occurring usually when a mayor storm is expected
and additional freeboard is needed to prevent °overtopping of the,pond -dikes On other occasions, the,
pond may need to be drawn down for maintenance purposes The cooling pond last discharged to the
Lumber River in September of 1999 There are also incidental seepages and leaks through the dikes and
retaining wall (sheet pilings) to ifie Lumber River from the cooling pond The pH of the cooling pond is
neutralized when needed by adding acid or caustic at the circulation water pumps A description of the
waste streams that discharge info the - cooling ipond follows
Recirculated Cooling Water
This flow provides condenser cooling water for,the three generating units The`flow is,discharged into
the cooling pond and routed through the cooling pond by baffle dikes to achieve maximum surface
cooling efficiency before reaching the condenser cooling water circulating water'pumps to be used
again Cooling of the water is achieved primarily by evaporation from the pond surface, which'is
estimated to consume a maximum of approximately 1 6 MGD above natural evaporation rates during
times the units' are in full operation Control of'biolog'ical fouling on condenser surfaces is
accomplished by chlorination, as needed
Coal Pile Runoff
Rainfall runoff from the coal pile (approximately 6 acres) is routed to the cooling, pond, which provides
treatment by sedimentation Freeze conditioning agents may be applied to coal shipped via trains to
the power plant typically between November 15 and March 15
Storm Water Runoff
Rainfall runoff from power plant areas is ultimately routed ,to the cooling pond Sludges /sediments
collected `in sumps, catchment basins, etc are disposed of'in the ash pond or by,other appropriate
methods
Ash Sluice Water
Fly ash and bottom ash'from all three units is hydraulically conveyed by a ash sluice pipeline system
to the ash pond In addition, water from washing the interior of the precipitators is sent to the ash
3 -1

Progress'Energy Carolinas, Inc. 'NPDES, Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
pond via the-ash sluice pipeline In the ash pond,,a stand pipe allows for overflow release to a small
secondary settling basin containing another stand pipe for release, to the cooling pond
Sanitary Waste
`Sanitary waste is treated on -site by a septic tank and a sand and' gravel drainage field which
discharges to the cooling pond Flow from the system is dependent upon fluctuating demand due to
variations in the number of personnel on site When needed, residuals are,disposed of off -site by'a
licensed contract disposal firm
Metal Cleaning Waste
Wastes from the chemical cleaning of the boiler,tubes are normally disposed of by evaporation in
boilers, either onsite or at another Progress Energy facility Boiler cleaning is usually performed
every 10 years Should boiler cleaning wastes not be evaporated, they will be treated by
neutralization and precipitation in portable holding tanks The liquid fraction of °the metal cleaning
wastes will be discharged to the ash pond The sludge fraction of the metal cleaning wastes will be
disposed of in either the ash pond or by other,appropnate methods
Internal Combustion Turbine (CT)-Site
There are four internal combustion turbines located at the Weatherspoon Plant' All drains from the
CT site, including drains collecting rainfall, are routed through an oil -water separator which
discharges to the cooling pond Sludges /sediments collected in sumps, catchment basins; etc are
disposed of in the ash pond or by other appropriate methods
Low - Volume Waste
All low volume wastes are routed by gravity flow to the cooling pond Sumps collect °and convey
miscellaneous equipment, leakage, .equipment drainage for maintenance, equipment wash down
water, sampling streams, and closed cooling water system blowdown Water treatment wastes
consist of solutions of sodium chloride, used for water softener regeneration, and sodium hydroxide
and sulfuric acid which are used in the regeneration of'derniineralizers Demineraliier regeneration
wastes are routed to the ash pond via the ash sluice line Reverse osmosis reject water and cleaning
solutions, and water'softener regeneration wastes are routed directly to the cooling pond Blowdown
of boilervater to control boiler chemistry is routed to a flash tank, which discharges to the cooling
pond Drains from areas likely to contain oil filled equipment or storage are routed through an oil -
water separator Sludges /sediments from sumps, catchment basins, etc are disposed of in the ash
pond ,or by other appropriate methods The air preheaters are water washed infrequently, When the
air preheaters are Washed, approximately 50,000 gallons of wastewater is produced and discharged
to the ash pond via1he ash sluice pipelines In addition, wastes from the chemical cleaning of the
condenser tubes and heat exchangers are normal ly,disposed , of,in the ash pond' Should condenser
and heat exchanger cleaning wastes not be discharged into the -ash pond, they will be evaporated At
this -time it is unclear as to how often condenser and heat exchanger cleaning may be performed
In, many cases, chemicals added during,the, plant processes are consumed or chemically altered
Only trace amounts might be discernable in water entering the cooling pond Because the cooling
pond serves as a final treatment basin and receives significantly ,greater volumes,of water from other
inflows, detectable levels,of these chemicals should not occur in the infrequent cooling pond
discharge
Non- contact Cooling Water
Non - contact cooling water withdrawn from, the Lumber River passes through heat exchangers to
provide non - contact cooling for the power plant's closed cooling water system which is typically
discharged to Outfall 002 As necessary, however, the non- contact cooling water may be routed
temporarily to the cooling pond depending on the need for cooling pond makeup water Sodium
hypochlonte (chlorine) is added at the non - contact cooling water pump intake, as needed, to control
biological fouling of the heat exchanger surfaces
3 -2

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weathers'noon Steam Electric Plant 2009' Renewal Application
Miscellaneous Waste Streams to the Cooling Pond
`Coal Ash Management
From time to time fly and bottom ash in the ash pond may be stacked or relocated within the diked
boundary of the,ash pond system As this pond management activity does not alter the chemical
character of the pond contents, no change in the nature of,the discharge to the cooling pond is
anticipated
Coal Ash Reclamation
In the event a practicable market becomes available, Progress Energy may exercise the option of
reclaiming coal ash from the ash pond system In consideration of the scope of such an operation, no
additional discharges are expected to result from coal ash reclamation efforts Bestmanagement
practices are established for these activities During ash removal projects, trucks are filled within the
confines of the ash pond boundary and the load covered The trucks are washed down prior, to
leaving the area and travel along a graveled on -site roadway before exiting the site via the plant
access road
Herbicide and Pesticide Usage in the Treatment System Ponds
Herbicides may be used as, needed to control nuisance aquatic vegetation These herbicides are
applied by licensed applicators, or persons under the immediate supervision of a licensed applicator,
in accordance with the manufacturer's instructions Pesticides may be used as needed to, perform
biological assessments These Pesticides are applied by licensed applicators, or persons under the
immediate supervision of a licensed applicator, in accordance with the manufacturer's instructions
OUTFALL 002 — NON - CONTACT COOLING WATER
Non - contact cooling water is withdrawn from the. Lumber River and passed - through heat exchangers to
provide non - contact cooling for the plant's closed cooling water,system After passing through the heat
exchanger, non - contact cooling water is routed to the Lumber River via Outfall 002 Depending-on _ the
need forcooling pond ,makeup water, the non- contact cooling water may be directed to the cooling pond
Sodium hypochlonte (chlonne),is,added at the non - contact cooling water pump intake,, as needed, to
control biological fouling of the heat exchanger surfaces As established by written plant procedure,
chlorine is only added during times where non - contact cooling water is. routed to the cooling pond Upon
completiori of chlorine addition, the non - contact cooling water system is operated with discharge to the
cooling pond for a period of at least one hour prior to any redirection to Outfall 002 This procedure has
been'implernented to prevent the discharge of chlorine to the river
OUTPAL' LS SW-1, SW -1, AND SW -3 — STORM WATER
During periods when coal ash removal prolects,are,conducted, the access road'to,the power plant
becomes part of an industrial activity with three storm water outfalls along the road which are addressed
in EPA Form 2F Storm water from these three discrete,conveyances is ultimately discharged into the
Lumber River
3 -3

Progress Energy Carolinas, Inc: NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 4
Form 2C Item VI Potential Discharges Not Covered by Analysis
Chemical
Quantity
Frequency
Purpose
(used /yr)
Hydrazine
165 gal
Continuous - when
units are operational
Oxygen scavenger in boiler
TrisodiUm phosphate
1,000 lb
As needed
pH control in boiler
Disodium phosphate
5001b
As needed
pH, control in boiler
Morpholine
275 gal
Continuous - when
pH control in boiler
units are operational
Sodium hypochlorite
12,950 gal
As, needed
Condenser and heat
exchanger biofouling control
Sodium hydroxide
9,000 gal
As needed
Deminerahzer regeneration
Sodium hydroxide
As needed
As needed
Cooling pond neutralization
Sulfuric acid
2,000 gal
As needed
Demrneralizer regeneration
Sulfuric acid
19,000 gal,
As needed
Cooling pond neutralization
Molybdenum trioxide
330 gal
As needed
Corrosion control in,boder
Sodium chloride
8,000 lb
Twice per month
Water softener regeneration
Sulfur, elemental
75 ton
Continuous - when
Flue gas, conditioning
Unit 3 is operational
Citric acid, 50%
1,460 gal /event
Approximately once
Boiler cleaning
per 10 years per unit
Citric acid, dry
3,500 lb/unit/event
Approximately once
Boiler cleaning
per 10 ears er,unit
_
Ammonium hydroxide
1,560 gal /event
Approximately once
goiler,cleaning
er 10 years per unit
1,775 lb/event -
'Sodium Nitrite
Units 1 & 2
Approximately once
Boiler cleaning
1,450 lb/event -
per 10 years per unit
_ Unit 3 -
Corrosion Inhibitor
55 gal`` /,'unit/event
Approximately once
Boiler cleaning
per 10 years per unit
475 lb/event —
Amm`onium bicarbonate
Units 1 & 2
Approximately once
375 lb/event —
per 10 years per unit
Boiler cleaning
Unit 3
EDTA, 39%
6,000
Approximately once
Boiler cleaning
al /unit/event
per 10 years per unit
Hydrochloric,acid
1,000 gal /event
As,needed
Condenser cleaning
Rodine 213
5 gal /event
As needed
Condenser cleaning
Ammonium bifluonde
100 lb/event
As needed
Condenser cleaning
4 -1

Progress Energy Carolinas, Inc. NPDES Permit Number N00005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Chemical
Quantity
(used'' /yr)
Frequency
Purpose
,FAF -10 foam agent
110 gal /,event
As needed
Condenser cleaning
FAF -20 anti -foam agent
20 gal /event
As needed
Condenser cleaning
Sodium carbonate
500 'lb /event
As needed
Condenser cleaning
Sodium hydroxide
400 gal /event
As needed
Condenser cleaning
Sandb►ast,Media
500 -700 Ib
As needed
Equipment cleaning
Rhodamine liquid dye
0 01 -0 03
al /event
As needed
Performance testing
Hypersperse MDC120
25 lb/MG
Duping operation
'Reverse osmosis anti - scalent
Solisep MPT150
17 lb/MG
During operation
'Reverse osmosis coagulant
Kleen MCT403
-
48 lb/event
Quarterly or as
needed
Reverse osmosis membrane
cleaning
Kleen MCT411
24 lb/event
Quarterly or as
needed
Reverse osmosis membrane
cleaning
O'B Freezetrol 60
Variable
As needed
Coal freeze conditioning agent
O'B Freezetrol 62
Variable
As needed
Coal freeze conditioning agent
O'B Freezetrol 76 -T
Variable
As needed
Coal freeze conditioning agent
FCA- 1'000
Variable
As needed
" Coal freeze conditioning agent
,FCA -1010
Variable
As needed
Coal freeze conditioning agent
'FCA -2000
Variable
As needed
Coal freeze conditioning agent
FCA -2500
Variable
As needed
Coal freeze conditioning agent
FCA -3070
Variable
As,needed
Coal freeze conditioning agent,
SRA -6000
Variable
As needed
Coal °freeze conditioning agent
SRA -7000
Variable,
As needed
Coal freeze conditioning agent
Flomin ST- Geomelt55
Variable
As needed
Coal freeze conditioning agent
Flomin ST -944
Variable
As needed
Coal freeze conditioning agent
AKJ FC =504
Variable
As needed
Coal freeze'conditioning agent
BT 910
Variable
As, needed
Coal freeze conditioning agent
NALCO 8880
Variable
As needed
ent
Coal freeze conditioning agent
1310 -PRO 55
Variable
As needed
Coal freeze conditioning agent
FreeFlow SR -300
Variable
As needed
Coal freeze conditioning agent
4 -2

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 6
Form 2F Item III Site Drainage Maps
1
-4 AO7;0�-
Imo"
i I I W. Ll M �!
0 0.1 0.2 03 0.4 0.5 miles
6 -1

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 6 continued
—765 ft to top
of grade
Open
Drainage from
drain
abandoned rail line
pipe
ditches and fields
i
cuardC.,®
�,��Drain junction ba
Underground pips
•. '• Catch
°y'�
•'• ••
1'
SW -2
basin
•' '.. '•.;�,
SW -3
;h.• .A�� �..• ''•..
•.
Od
G d
Old
fQStroams •.
Parking
Lot
N
1 Scale (approximated) covered
I111 = $O, picnic table
Approximated
6-2
\`c�Q
o°
vo
a`
a�
��A
ao
a�
Jy
`ca

Progress Energy Carolinas, Inc. NPDES Permit Number NC0005363
Weatherspoon Steam Electric Plant 2009 Renewal Application
Attachment 6 continued
N
1 Scale (approximated)
I 1" = 270'
NC 72
Power Plant Road
Used auto parts
business
Small pond
offsite
SW-1
Unnamed
tributary to the
Lumber River
Top of grade
6 -3

Coal Fired plants in NC
Progress Energy
Weatherspoon.— NC0005363 — East
Issued Modification 5/13/32008, (original issued 9/27/2004)
Expire: 7/31/2009
There is no FGD process. There is one ash pond that discharges to, the main cooling pond. The,
cooling pond_ has a designated outfall with limits Modification was to address storm water
management requirements. There is no special condition for Dike inspection In the last-renewal
there was no pursuit of an RPA since—no changes or reduction in limits /monitonng lwere
considered valid. Fact Sheet supports last permit renewal. Narrative reviewed, no problems
noted:
Reviewed,By. Ron Berry
Review'Date '1/16/09

Cv Progress Energy
December 1, 2008
Mr. Gil Vinzani, Supervisor, Eastern NPDES Program
Division of Water Quality
North Carolina Department of Environment and Natural Resources
1617 Mail Service Center
Raleigh, NC 27699 -1617
Subject: Carolina Power & Light Company dba Progress Energy Carolinas, Inc.
Asheville Steam Electric Plant NPDES Permit Number NC0000396
Cape Fear Steam Electric Plant NPDES Permit Number NC0003433
Lee Steam Electric Plant NPDES Permit Number NC0003417
Mayo Steam Electric Plant NPDES Permit Number NCO038377
Roxboro Steam Electric Plant NPDES Permit Number NC0003425
Sutton Steam Electric Plant NPDES Permit Number NC0001422
Weatherspoon Steam Electric Plant NPDES Permit Number NC0005363
NPDES Permit Application Amendment
Dear Mr. Vinzani:
Progress Energy Carolinas, Inc. (PEC) proposes to amend the NPDES Permit application for the
subject facilities to add three additional freeze conditioning agents.
These facilities expect to receive shipments of coal treated with freeze conditioning agents
during the winter months (November 15 through March 15). Freeze conditioning agents, needed
depending upon expected weather conditions during transport to ensure coal does not freeze in
railcars, will be applied at an approximate rate of 2 pints per ton of coal. The product names
used by the various coal mines which supply fuel to Progress Energy Carolinas power plants
could include one or more of the additional following products (MSDSs enclosed):
Product Name Primary Composition
FreeFlow SR -300 30 -50% glycerin
Flomin ST -944 SRA > 50% diethylene glycol mixture and polymer /surfactant blend
Bio -Pro 55 55% glycerin
Coal pile runoff at each of these facilities flows to a treatment system (e.g., ash pond, cooling
pond, settling basin). However, since there is a slight potential that these chemicals could be
present in the wastewater that is ultimately discharged via a permitted outfall, PEC requests that
these products be appended to the NPDES permit application. Note that toxicity testing is a
permit requirement at each power plant outfall which contains the coal pile runoff waste stream.

`f� Progress Energy
eptember T5, 2008
Mr. Gil Vinzani
S E P 15 2008
Supervisor, Eastern NPDES Program
North Carolina Department of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699 -1617
ii r
L�
SEP �' g 2008 '
/6 i
DE %'R - WATER GJALITY I
- •-- _.-- -` �1'tiT SOU? �_�_?�.DN - ___._. �._
Subject: Carolina Power & Light Company d/b /a Progress Energy Carolinas, Inc.
Weatherspoon Steam Electric Plant
NPDES Permit No. NC0005363
Permit Application Amendment
Dear Mr. Vinzani:
Progress Energy Carolinas, Inc., is amending our NPDES permit application to reflect an
increase in the planned number of trucks per day to transport coal ash off site as part of the ash
reclamation activity at the Weatherspoon Steam Electric Plant.
The ash reclamation activity currently conducted by the Weatherspoon Steam Electric Plant was
described in the latest NPDES permit application. In the cover letter, we indicated that twenty
trucks per day were planned. Due to changing market conditions, we are planning to increase the
number of trucks per day to approximately forty. We will continue to follow our Best
Management Practices (BMPs) and thus we do not expect any increased discharges into the three
permitted storm water outfalls.
Please amend your files accordingly. If there are any questions, please contact Robin Bryson at
(919) 546 -3962.
I 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 of fines and imprisonment for knowing violations.
Sincerely,
/- 17 1 e— i -; �A-.' �
Mark Frederick, Plant Manager
JMF /rb
Enclosures
c: Mr. L. Baxley
Ms. R. Bryson
A I PAYrpgAts,Inc.
491 Power Plant Road
Lumberton, NC 26358