NC0001422_Permit (Modification)_20060313

�0� WA Michael F.Easley,Governor
William G.Ross Jr.,Secretary
rNorth Carolina Department of Environment and Natural Resources
>_
17 Alan W.Klimek,P.E.Director
Division of Water Quality
March 13, 2006
Mr. Michael S. Longfellow
Progress Energy Carolinas, Inc.
Sutton Steam Electric Plant
801 Sutton Steam Plant Road
Wilmington,NC 28401
Subject: NPDES Permit Modification
Permit Number NC0001422
Sutton Steam Electric Plant
New Hanover County
Dear Mr.Longfellow:
Division personnel have reviewed and approved your application for minor modification of the subject
permit. Accordingly we are forwarding the attached modified permit pages. These pages should be
inserted into your permit and the old ones discarded. This modification changes the monitoring
requirements for ammonia to correspond with the facility's use of its Rotomix system(May through
September)during calendar year 2006 only. In subsequent years,the facility anticipates full time use of
the Rotomix system and therefore,beginning in January 2007,monitoring for ammonia will become a
year round requirement at the designated outfalls.
This modification is issued pursuant to the requirements of North Carolina General Statute 143-215.1
and the Memorandum of Agreement between North Carolina and the U.S. Environmental Protection
Agency dated May 9, 1994 (or as subsequently amended).
Please note that this permit is not transferable except after notice to the Division. The Division may
require modification or revocation and reissuance of the permit. This permit does not affect the legal
requirements to obtain other permits which may be required by the Division of Water Quality or permits
required by the Division of Land Resources,the Coastal Area Management Act or any other Federal or
Local governmental permit that may be required. If you have any questions concerning this permit,
please contact Bob Sledge at telephone number(919)733-5083,extension 547.
Sincerely,
/TAlan W. Klimek,P.E. ,
cc: Central Files
Wilmington Regional Office/Surface Water Protection Section
NPDES Unit
Steve Cahoon one
Nbi Carolina
)Vatura!!y
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh,NC 27699-1617 Phone[phone] Customer Service
Internet: www.ncwaterquality.org Location: 512 N.Salisbury St. Raleigh,NC 27604 Fax [phone]
An Equal Opportunity/Affirmative Action Employer—50%Recyded/l0%Post Consumer Paper

1
Permit NC0001422 '
A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (002)
During the period beginning on the effective date of the permit and lasting until expiration, the
Permittee is authorized to discharge to the Cooling Pond from Outfall 002 (Old Ash Pond- coal pile
runoff, low volume wastes, ash sluice water, chemical metal cleaning wastes (Outfall 003), and
stormwater runoff). Such discharges shall be limited and monitored by the Permittee as specified
below:
EFFLUENT LIMITS MONITORING REQUIREMENTS
CHARACTERISTICS
Monthly Daily Measurement Sample Sample Location
Average Maximum Frequency e
Flow Weekly Pump Logs Effluent
or similar
Oil and Grease 15 mg/L 20 mg/L 2/Month Grab Effluent
Total Suspended 30 mg/L 100 mg/L 2/Month Grab Effluent
Solids
Total Arsenic NL(µg/L) Quarterly Grab Effluent
Total Selenium NL (µg/L) Quarterly Grab Effluent
Ammonia-Nitrogen',2 Weekly Grab Effluent
1. Monitoring is only required when ash sluicing occurs.
2. Monitoring is required only during the months May through September during calendar year 2006.
The requirement will change to year-round monitoring in subsequent years.
Samples taken in compliance with the monitoring requirements specified above shall be taken prior to
mixing with other waste streams.
A. (3) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (003)
During the period beginning on the effective date of the permit and lasting until expiration, the
Permittee is authorized to discharge to the Old Ash Pond from Outfall 003 (Chemical metal cleaning
wastes). Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT LIMITS MONITORING REQUIREMENTS
CHARACTERISTICS
Monthly Daily Measurement Sample Type Sample
Avera a Maximum Frequency Location
Flow Weekly Pump Logs or Effluent
similar
Total Copper 1 mg/L 1 mg/L 2/Month Grab Effluent
Total Iron 1 mg/L 1 mg/L 2/Month Grab Effluent
i

Permit NC0001422
A. (4) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (004)
During the period beginning on the effective date of the permit and lasting until expiration, the
Permittee is authorized to discharge to the Cooling Pond and/or to Outfall 001 from Outfall 004(New
Ash Pond-ash sluice water, coal pile runoff, low volume wastes, chemical metal cleaning wastes
(Outfall 003), and stormwater runoff). Such discharges shall be limited and monitored by the
Permittee as specified below:
EFFLUENT LIMITS MONITORING REQUIREMENTS
CHARACTERISTICS
Monthly Daily Measurement Sample Sample
AverMe Maximum Frequency a Location
Flow Weekly Pump Logs Effluent
or similar
Oil and Grease 15 m /L 20 m /L 2/Month Grab Effluent
Total Suspended 30 mg/L 100 mg/L 2/Month Grab Effluent
Solids
Total Arsenic NL (, /L) Quarterly Grab Effluent
Total Selenium NL( /L) Monthly Grab Effluent
Ammonia-Nitrogen' Weekly Grab Effluent
1. Monitoring is required only during the months May through September during calendar year 2006.
The requirement will change to year-round monitoring in subsequent years.
Samples taken in compliance with the monitoring requirements specified above shall be taken prior to
mixing with other waste streams.
A. (5) ACUTE TOXICITY MONITORING (Monthly)
The permittee shall conduct acute toxicity tests on a monthly basis using protocols defined as
definitive in E.P.A. Document 600/4-85/013 entitled 'The Acute Toxicity of Effluents to Freshwater
and Marine Organisms." The monitoring shall be performed as a Fathead Minnow (Pimephales
promelas) 24-hour static test, using effluent collected as a grab sample. Effluent samples for self-
monitoring purposes must be obtained during representative effluent discharge below all waste
treatment. The test will be performed once per month in each month in which a discharge occurs.
The parameter code for this test is TAE6C. All toxicity testing results required as part of this permit
condition will be entered on the Effluent Discharge Form (MR-1) for the month in which it was
performed, using the appropriate parameter code. Additionally, DWQ Form AT-1 (original) is to be sent
to the following address:
Attention: NC DENR/ DWQ / Environmental Sciences Branch
1621 Mail Service Center
Raleigh, N.C. 27699-1621
Test data shall be complete and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity tests, as well as all dose/response data. Total residual
chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream.
Should test data from either these monitoring requirements or tests performed by the North Carolina
Division of Water Quality indicate that there is a reasonable potential for water quality standards
excursions in the receiving stream, this permit may be re-opened and modified to include alternate
monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival and appropriate environmental controls, shall constitute an invalid test and will

Progress Energy
9
Michael Shawn Longfellow
Plant Manager
File No.: SUT 12520-13-01
January 10,2006
Certified Mail#7004 0550 0000 5750 8066(1 copy) I JAN 1 2 2M
Mr.Gill Vinzani,PE i 1
North Carolina Division of Environment and Natural Resources
Division of Water Quality L'>_ .a - t'_t ER QUALITY
1617 Mail Service Center h`i+PJCH
Raleigh,NC 27699-1617
PERMIT APPLICATION AMENDMENT
Dear Mr.V inzani,
On March 10,2005,Progress Energy Carolinas Inc.,submitted a National Pollutant Discharge Elimination
System(NPDES)permit application amendment to install a Mobotec Rotating Over Fire Air-High Density
(ROFA-HD)system in association with a Rotomix Urea Injection System on Unit 3 at the L.V.Sutton
Plant, located in New Hanover County,North Carolina. On June 20,2005 Progress Energy Carolinas,Inc.,
received approval for the permit amendment from the NPDES Unit and was issued a minor permit
modification. The modified permit requires weekly monitoring of ammonia at Outfall 002(old Ash pond)
and Outfall 004(New ash Pond).
The company began operation of the above equipment for the 2005 ozone season(typically May through
September),and will only use the equipment during the 2006 ozone season. In 2007 the equipment will
operate all year. Therefore,Progress Energy Carolinas,Inc.,requests the NPDES Permit for the L.V.
Sutton Plant(NC0001422)be modified to reflect weekly ammonia sampling and analysis from Outfalls
002 and 004 only be required during the ozone season in 2006 when the equipment is in use and there is
potential for ammonia discharge from these outfalls. Then,in 2007,when the equipment is in use year
round,the requirement for sampling and analysis be adjusted to weekly sampling during the entire year.
If you have any questions please contact Mr. Steve Cahoon Environmental Specialist at our Corporate
Office(919)546-7457 or Mr.Kent Tyndall Environmental Specialist at the Sutton Plant(910)343-3244.
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.
Respectfully yours
Michael Shawn Longfellow
Progress Energy Carolinas,Inc.
Sutton Steam Plant
801 Sutton Steam Plant Road
Wilmington,NC 28401

OF WATF� Michael
North carol
QG William G.Ross,Jr.,secretary
rDepartment of Environment and Natural Resources
y Alan W.Klimek,P.E.,Director
Division of water Quality
June 20, 2005
Mr. Michael S. Longfellow
Progress Energy
Sutton Steam Plant
801 Sutton Steam Plant Road
Wilmington, North Carolina 28401
Subject: NPDES Permit Modification
Permit Number NC0001422
Sutton Steam Plant
New Hanover County
Dear Mr. Longfellow:
Division personnel have reviewed and approved your application for minor
modification of the subject permit. Accordingly, we are forwarding the attached modified
permit pages. These pages should be inserted into your permit and the old ones discarded.
This modification incorporates monitoring requirements for ammonia in conjunction with the
installation of the Rotomix system at the above referenced facility. This modification is issued
pursuant to the requirements of North Carolina General Statute 143-215.1 and the
Memorandum of Agreement between North Carolina and the U.S. Environmental Protection
Agency dated May 9, 1994 (or as subsequently amended).
Please take notice that this permit is not transferable. This permit does not affect the
legal requirements to obtain other permits which may be required by the Division of Water
Quality or permits required by the Division of Land Resources, Coastal Area Management Act,
or any other Federal or Local governmental permits which may be required.
If you have any questions or need additional information, please do not hesitate to
contact Mark McIntire of my staff at(919) 733-5083, extension 508.
Sincerely,
Za�n . Klimek, P.E.
cc: Central Files
NPDES Unit Files
Wilmington Regional Office
1617 MAIL SERVICE CENTER,RALEIGH,NORTH CAROLINA 27699-1617-TELEPHONE [phone]/FAX [phone]
VISIT US ON THE WEB AT http://h2o.enr.state.nc.us/NPDES

SUPPLEMENT TO PERMIT COVER SHEET
Carolina Power&Light Company is hereby authorized to:
1. Continue to discharge cooling pond blowdown, recirculated cooling
water, noncontact cooling water, and treated wastewater from internal
outfalls 002, 003, and 004 (via external Outfall 001); coal pile runoff,
low volume wastes, ash sluice water (including wastewater generated
from the Rotomix system), and stormwater runoff (Outfall 002);
chemical metal cleaning waste (Outfall 003); and ash sluice water
(including wastewater generated from the Rotomix system), coal pile
runoff, low volume wastes, and stormwater runoff (Outfall 004) at a
facility located at Sutton Steam Electric Plant, 801 Sutton Steam
Plant Road, Wilmington, New Hanover County, and
2. Discharge wastewater (via Outfall 001) from said treatment works at
the location specified on the attached map into the Cape Fear River,
classified C-Swamp waters in the Cape Fear River Basin.
Permit NC0001422

A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (002)
During the period beginning on the-effective date of the permit and lasting until expiration, the
Permittee is authorized to discharge to the Cooling Pond from Outfall 002 (Old Ash Pond — coal pile
runoff, loan volume wastes, ash sluice water, chemical metal cleaning wastes (Outfall 003). and
stormwater runoffl. Such discharges shall be limited and monitored by the Permittee as specified
below:
EFFLUENT LIMITS MONITORING REQUIREMENTS
CHARACTERISTICS
Monthly Daily Measurement Sample Sample Location
Average.. Maximum Fre uenc
Flow Weekly Pump Logs Effluent
or similar
Oil and Grease 15 mg/L 20 mg/L 2/Month Grab Effluent
Total Suspended 30 mg/L 100 mg/L 2/Month Grab Effluent
Solids
Total Arsenic NL(pg/L) Quarterly Grab Effluent
Total Selenium NL(pg/L) Quarterly Grab Effluent
Ammonia-Nitrogen' Weekly Grab Effluent
1. Monitoring is only required when ash sluicing occurs.
Samples taken in compliance with the monitoring requirements specified above shall be taken prior to
mixing with other waste streams.
A. (3) EFFLUENT LBOTATIONS AND MONITORING REQUIREMENTS (003)
During the period beginning on the effective date of the permit and lasting until expiration, the
Permittee is authorized to discharge to the Old Ash Pond from Outfall 003 (Chemical metal cleaning
wastes). Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT LIMITS MONITORING REQUIREMENTS
CHARACTERISTICS
Monthly Daily Measurement Sample Type Sample
Average Maximum FreQjt1enSZ Location
Flow Weekly Pump Logs or Effluent
similar
Total Copper 1 mg/L 1 mg/L 2/Month Grab Effluent
Total Iron 1 mg/L 1 mg/L 2/Month Grab Effluent
Permit NC0001422

A. (4) EFFLUENT LINIITATIONS AND MONITORING REQUIREMENTS (004)
During the period beginning on the effective date of the permit and lasting until expiration, the
Permittee is authorized to discharge to the Cooling Pond and/or to Outfall 001 from Outfall 004 (New
Ash Pond -ash sluice water, coal pile runoff, low volume wastes. chemical metal cleaning wastes
(Outfall 003), and stormwater runoff). Such discharges shall be limited and monitored by the
Permittee as specified below:
EFFLUENT LIMITS MONITORING REQUIREMENTS
CHARACTERISTICS
Monthly Daily Measurement Sample Sample
Average Maximum Fre uenc a Location
Flow Weekly Pump Logs Effluent
or similar
Oil and Grease 15 m /L 20 m /L 2/Month Grab Effluent
Total Suspended 30 mg/L 100 mg/L 2/Month Grab Effluent
Solids
Total Arsenic NL ( /L) Quarterl Grab Effluent
Total Selenium NL ( /L) Monthly Grab Effluent
Ammonia-Nitrogen I I I Weekly Grab Effluent
Samples taken in compliance with the monitoring requirements specified above shall be taken prior to
mixing with other waste streams.
A. (5) ACUTE TOXICITY MONITORING (Monthly)
The permittee shall conduct acute toxicity tests on a monthly basis using protocols defined as
definitive in E.P.A. Document 600/4-85/013 entitled 'The Acute Toxicity of Effluents to Freshwater
and Marine Organisms." The monitoring shall be performed as a Fathead Minnow (Pimephales
promelas) 24-hour static test, using effluent collected as a grab sample. Effluent samples for self-
monitoring purposes must be obtained during representative effluent discharge below all waste
treatment. The test will be performed once per month in each month in which a discharge occurs.
The parameter code for this test is TAE6C. All toxicity testing results required as part of this permit
condition will be entered on the Effluent Discharge Form (MR-1) for the month in which it was
performed, using the appropriate parameter code. Additionally, DWQ Form AT-1 (original) is to be sent
to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Branch
1621 Mail Service Center
Raleigh, N.C. 27699-1621
Test data shall be complete and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity tests, as well as all dose/response data. Total residual
chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream.
Should test data from either these monitoring requirements or tests performed by the North Carolina
Division of Water Quality indicate that there is a reasonable potential for water quality standards
excursions in the receiving stream, this permit may be re-opened and modified to include alternate
monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival and appropriate environmental controls, shall constitute an invalid test and will
require immediate retesting (within 30 days of initial monitoring event). Failure to submit suitable test
results will constitute noncompliance with monitoring requirements.
Permit NC0001422

RIMA
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F.Easley,Governor William G.Ross,Jr.,Secretary
Alan W.Klimek,P.E.,Director
April 11,2005
Mr.Michael Shawn Longfellow
Progress Energy Carolinas,Inc.Sutton Steam Plant
801 Sutton Steam Plant Road
Wilmington,NC 28401
Subject: Request for Modification of
NPDES Permit NCOOO1422
Sutton Steam Plant/WWTP
New Hanover County
Dear Mr.Longfellow:
Thank you for the letter of January 12,2005,requesting the Division of Water Quality to determine if the
Selenium Daily Maximum Limit of 56 ug/l,referenced in operating condition A(1)of your NPDES permit,could
be eliminated. The Division has reviewed your analytical effluent data reflecting Selenium levels and has
completed a Reasonable Potential Analysis(RPA)to address your request.
Results from the RPA indicate that your facility does have Reasonable Potential to exceed the Selenium
Daily Maximum effluent limit of 56 ug/1 currently in your NPDES penAit.Your request to remove the Daily
Maximum limit for Selenium cannot be granted at this time. Please be advised that the Selenium Daily Maximum
effluent limit of 56 ug/1 is in effect. The Division will review the Selenium data again at permit renewal in 2006
(or prior to that period at Progress'request.
All other terms and conditions contained in the original permit remain unchanged and in full effect. If
you have any questions concerning this letter,please contact Bob Guerra of the NPDES Unit at(919)733-5083,
extension 539.
Sincerely,
Robert Guerra
cc: Central Files
Wilmington Regional office/Surface Water Protection
NPDES Unit
1617 Mail Service Center,Raleigh,North Carolina 27699-1617
512 N.Salisbury St,Raleigh,North Carolina 27604 e
Phone: [phone]/FAX [phone]/Internet h2o.em stalanc.� o Carolina
An Equal gWtunity/Afirrmalin Action Employer-50%Recycle IO%Post Consumer Paper Xaturntly

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REASONABLE POTENTIAL ANALYSIS ,
Sutton Steam Electric Plant Outfall 001
NC0001422 Qw= 15 MGD
Time Pomd Feb 2003-Feb 2005
Qw(MGD) 15 WWFP Gass V
7Q10S(ds) 0 /WC(%)Q 7Q10S NIA
7QloW(cfs) 0 Tidally Influenced Q 7Q10W NIA
30Q2(ds) 0 3OQ2 NIA
Avg.Sbaam Flow,QA(Cfs) 0 0 QA NIA
RwWv Stream Cape Fear River(001) Stream Class C Swamp(001)
TAN AR
PARAMETER TYPE CRITERIA(2) POL Unl1s REASONABLE POTENTIAL RESULTS RECOMMENDED ACTION
h) NCWQS1 %FAY/ #Dst AhwPrdCw AAwslbCr
Clrook Awb
Acute: 58
Selsniwn NC 5.0 Se up1L 59 41 98.1
Chronic: SVALUEI
•Lepend.• "FnshwatarDischaMa
C-Cw*wparke
NC-Non•c�e
A-AsstheDe
Sutton Steam Plant RPA NC0001422(3-23-05),rpa
4/11/2005

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REASONABLE POTENTIAL ANALYSIS
Selenium
Date Data BDL=1/2DL Results
1 FEB 17 2003 < 5 2.5 Std Dev. 10.5556
2 MAR 3 2003 < 5 2 5 Mean 13.0508
3 MAR 11 2003 26 26.0 C.V. 0.8088
4 MAR 17 2003< 5 2.5 n 59
5 MAR 27 2003 42 42.0
6 APR 1 2003 38 38.0 Mult Factor= 1.8700
7 APR 7 2003 53 53.0 Max.Value 53.0 ug/L
8 JUL 22 2003 < 5 2.5 Max.Pred Cw 99.1 ug/L
9 AUG 4 2003 < 5 25
10 AUG 18 2003 < 5 2.5
11 SEP 4 2003 < 5 2.5
12 SEP 15 2003 < 5 2.5
13 OCT 13 2003 < 5 2.5
14 OCT 20 2003 < 5 2.5
15 OCT 27 2003 < 5 2.5
16 NOV 3 2003 6 6.0
17 NOV 10 2003 < 5 2.5
18 NOV 17 20039 9.0
19 NOV 24 2003 K, 5 2.5
20 DEC 1 2003 < 5 2.5
21 DEC 23 2003 10 10.0
22 DEC 29 2003 30 30.0
23 JAN 5 2004 14 14.0
24 JAN 12 2004 18 18.0
25 MAR 15 2004< 5 2.5
26 MAY 3 2004 7 7.0
27 MAY 9 2003 19 19.0
28 MAY 17 2004 10 10.0
29 JULY 13 2004 20 20.0
30 JULY 19 2004 22 22.0
31 JULY 26 2004 19 19.0
32 AUG 2 2003 22 22.0
33 AUG 9 2004 19 19.0
34 AUG 16 2004 13 13.0
35 AUG 23 2004 19 19.0
36 AUG 30 2004 15 15.0
37 SEP 7 2004 18 18.0
38 SEP 13 2004 18 18.0
39 SEP 20 2004 5 5.0
40 SEP 27 2004 10 10.0
41 OCT 4 2004 9 90
42 OCT 14 2004 < 5 2.5
43 OCT 25 2004 11 11.0
44 NOV 1 2004 14 14.0
45 NOV 8 2004 14 14.0
46 NOV 15 2004 17 170
47 NOV 22 2004 15 15.0
48 NOV 29 2004 12 12.0
49 DEC 6 2004 16 16.0
50 DEC 13 2004 23 23.0
51 DEC 2D 2004 21 21.0
52 DEC 28 2004 20 20.0
53 JAN 3 2005 < 5 2.5
54 JAN 10 2005 8 8.0
55 JAN 17 2005 17 17.0
56 JAN 24 2005 17 17.0
57 FEB 1 2005 15 15.0
58 FEB 7 2005 14 14.0
59 FEB 14 2005 < 5 2.5
60
199
200
Sutton Steam Plant RPA NC0001422(3-23-05),data
1" 4/11/2005

&4? Pro ress Ener Michael Shawn Longfellow
g 9Y Plant Manager
File No.: SUT 12520-13-01
March 10, 2005
Certifed Mail#7004 0550 0000 5750 7809
Mr. Mark McIntire
NCDENR-DWQ
1617 Mail Service Center
Raleigh,NC 27699-1617
PERMIT APPLICATION AMENDMENT
Dear Mr. McIntire,
Carolina Power&Light Company d/b/a Progress Energy Carolinas,Inc. hereby submits a National
Pollutant Discharge Elimination System(NPDES)permit NC0001422 application amendment to
install a Mobotec Rotating Over Fire Air-High Density(ROFA-HD)system and a Rotomix
Ammonia/Urea Injection System on Unit 3 at the L. V. Sutton Plant, located in New Hanover
County,North Carolina. The company desires to begin operation of the above equipment for the
2005 ozone season(typically May through September),and therefore requests the permitting
agency expedite permitting to support the construction schedule.
These systems are being added to Sutton Unit 3 to reduce nitrogen oxides(NOx)emissions from
the unit and to meet the requirements of state and federal clean air legislation and associated rules.
The Rotomix system will require approximately 31 injection points into the boiler staggered over
three elevations. The system will inject an ammonia/urea solution mixed with humidified air into
the boiler. In the boiler,the ammonia/urea will react with NOx to form water vapor and nitrogen.
The system will be designed to minimize any ammonia formation and ammonia slip.
The ROFA portion of the project will involve the construction of a supplemental air supply to the
upper portion of the boiler,intending to improve the combustion on this portion of the boiler.
Any ammonia that adheres to the ash will be sent to the ash pond along with an estimated 2.2
MGD of water. The waste stream is currently directed to the new ash pond. The new ash pond
may discharge directly to the Cape Fear River or may discharge to the cooling pond. There is a
monthly acute toxicity requirement for the cooling pond discharge. Because this waste stream
system involves a large amount of water from the plant,the amount of ammonia discharged from
the new Rotomix and ROFA-HD systems should not pose a concern for water quality in the river.
Similar systems have been installed at our Cape Fear and Asheville facilities. After reviewing
available ammonia data from the Asheville facility we expect the concentration_of.wnmonia in the
ash pond discharge from the Sutton Plant to be approximately 5 to 10 mg/L. - t
Progress Energy Carolinas,Inc. MAR 1 4 2005
Sutton Steam Plant
801 Sutton Steam Plant Road
Wilmington,NC 28401 DENR - WATER QUALITY
POINT SOURCE BRANCH---,
fi

Mr Mark McIntire
March 10,2005
Page 2
Enclosed please find an amended Attachment 3 of Form 2C—Item II-B Flows, Sources of
Pollution,and Treatment Technologies, describing the ROFA system and the discharge to the ash
pond,the MSDS for Urea, and several diagrams depicting the Rotomix system and the ROFA-HD
system.
If you have any questions please contact Mr. Steve Cahoon Environmental Specialist at our
Corporate Office(919)546-7457 or Mr. Kent Tyndall Environmental Specialist at the Sutton Plant
[phone].
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 qualifced 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.
Respectfully yours,
A4p(--
Michael Shawn Longfellow

Carolina Power& Light Co. d/b/a Progress Energy Carolinas, Inc.
L. V. Sutton Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0001422
Attachment 3
Form 2C -Item II-B Flow,Sources of Pollution,and Treatment Technologies
The Sutton Plant is a coal-fired steam cycle electric generating plant with three units. Three Internal
Combustion (IC)turbines are also on the plant site. The plant has an 1110-acre(6,900 acre-ft)off-stream
cooling pond on the east side of the Cape Fear River approximately twelve river miles upstream of
Wilmington. Water is withdrawn from the Cape Fear River as required to make up evaporative, seepage,
and blowdown losses from the cooling pond.
Chemical constituents contained in this discharge 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 size,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 discharge.
Recirculated Cooling Water
This flow provides condenser cooling water for generating units 1, 2, and 3. The total combined flow of
583 million gallons per day(MGD)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 approximately 5.5 MGD above natural evaporation rates during
times the units are in full operation. Control of biological fouling on heat exchanger surfaces is
accomplished by feeding a mixture of bromine and chlorine into the intake structure approximately one
hour once or twice a week with a residual oxidant concentration of 0.2 ppm or less.
Non-contact Cooling Water
Non-contact cooling water is withdrawn from and returned to the cooling pond. It provides indirect cooling
for various plant equipment by absorbing heat as it passes through a heat exchanger. No direct contact is
made with any other equipment or process. Control of biological fouling on heat exchanger surfaces is
accomplished by feeding a mixture of bromine and chlorine approximately one hour per week with a
residual oxidant concentration of 0.2 ppm or less.
Coal Pile Runoff
Stormwater runoff from the coal pile is routed to the old ash pond,which provides neutralization and
sedimentation treatment. During maintenance activities, sludges removed from catch basins, sumps, etc.
may be transported to the old and/or new ash pond for disposal.
1

Carolina Power& Light Co. d/b/a Progress Energy Carolinas, Inc.
L. V. Sutton Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0001422
Storm Water Runoff
Stormwater runoff from the plant area that includes parking lots, switchyard, and the IC Turbine area is
collected in yard drains which flow to the cooling pond. All other yard and plant drains,which may contain
pollutants from spills or leakage from plant processes are routed to one of two retention basins, and
pumped from there to the ash ponds for treatment. During maintenance activities, sludges removed from
catch basins, sumps, etc. may be transported to the old and/or new ash pond for disposal.
Ash Sluice Water
Fly ash and bottom ash from all three units is hydraulically conveyed by an ash sluice pipeline to the
plant's new ash pond,which provides sedimentation and oxidation treatment. Alternatively, fly and
bottom ash may be conveyed to the old ash pond for treatment while maintenance activities are performed
on the new ash pond. Rotomix Ammonia/Urea injection system and Rotating Over Fire Air(ROFA)
System will be installed on the Unit 3 boiler in the Spring of 2005. These systems will be used jointly to
use high velocity air injection and ammonia/urea to reduce nitrogen oxides(NOx)emissions during the
ozone season (approximately May through September). Any un-reacted ammonia will be absorbed into
the fly ash and will be carried to the ash pond via ash sluice water.
Ash Pond Discharge
Effluent from the new ash pond can be discharged to either the cooling pond or to the Cape Fear River.
When the effluent from the new ash pond is routed to the Cape Fear River, up to approximately 0.5 MGD
will still be discharged to the cooling pond. Effluent from the old ash pond discharges to the cooling pond.
Coolinq Pond Discharge
Discharges from the cooling pond to the Cape Fear River have occurred on a sporadic basis. Within the
next permit cycle it is expected to discharge on a more regular basis(e.g., from several times per week to
daily). On an intermittent(e.g., monthly)basis, the blowdown from the cooling pond to the river may reach
approximately 350 MGD for a duration of 1 to 2 days.
Domestic Wastes
Sanitary wastes are treated by an onsite septic tank and drainage field that is permitted by the New
Hanover County Health Department. The septage is exempt from the 40 CFR 503 standards. Progress
Energy will submit appropriate information to the EPA if required.
2

Carolina Power & Light Co. d/b/a Progress Energy Carolinas, Inc.
L. V. Sutton Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0001422
Low-Volume Wastes
All waste streams not identified above fall in the category of low-volume wastes. These wastes include
plant drains,which convey miscellaneous equipment leakage, equipment drainage for maintenance,
equipment washdown water, sampling streams, service water system blowdown, and water treatment
wastes. Plant process water is treated prior to use by an ion-exchange demineralizer which must be
periodically regenerated with solutions of sodium chloride, sodium hydroxide, and sulfuric acid.
Alternatively a vendor may be used to provide treatment of plant process water. Blowdown of boiler water
to control boiler chemistry is routed through low-volume prior to discharge in the ash pond. Boiler
vacuuming sediment is routed through low-volume prior to discharge to the ash ponds. The precipitators
are water washed as needed with the wastewater discharging to the ash pond. Drains from areas likely to
contain oil-filled equipment or storage are routed through an oil-water separator with the effluent routed
through low volume prior to discharge to the ash pond. Waste oil is disposed of according to the
appropriate regulations. During maintenance activities, sludges removed from catch basins, sumps, etc.
may be transported to the old and/or new ash pond for disposal.
All low volume wastes described above are routed by gravity flows to the retention basins at the plant and
then to the ash ponds for treatment by neutralization, sedimentation, oxidation, and absorption.
The air preheaters and electrostatic precipitators are water washed as needed with the wastewater
discharging to the ash pond via the ash sluice lines.
In many cases added chemicals are consumed or chemically altered during the plant processes. Only
trace amounts might be recoverable in water entering the ash ponds. Since the ash ponds serve as a
final treatment basin and receives significantly greater volumes of water from other inflows, detectable
levels of these chemicals should not occur in ash pond discharges.
Chemical Metal Cleaning Wastes
The boilers are chemically cleaned as needed using citric acid, ammonium hydroxide, sodium nitrite,
ammonium bicarbonate, and cronox 240, a corrosion inhibitor. In addition the following chemicals can be
used if needed: soda ash, ammonium persulfate, ammonium bifluoride, sodium bromide, and hydrochloric
acid. The cleaning solution and rinses are stored on site for disposal by evaporation in the boilers.
Typical cleanings would result in a waste of approximately 50,000 gallons for Unit 1, 70,000 gallons for
Unit 2, and 140,000 gallons for Unit 3. Should chemical metal cleaning wastes not be evaporated, they
will be treated by neutralization and precipitation in retention basins prior to discharge to the ash ponds.
3

Carolina Power& Light Co. d/b/a Progress Energy Carolinas, Inc.
L. V. Sutton Steam Electric Plant
National Pollutant Discharge Elimination System Permit Number NC0001422
Fire Water System
Several plant heat exchangers are cooled by the fire water system. Control of biological fouling on heat
exchanger surfaces is accomplished by brominating approximately one hour per week with a residual
bromine concentration of 0.2 ppm or less.
Ash Reclamation
In the event a practicable market becomes available, Progress Energy may exercise the option of
reclaiming ash from it's ash ponds. However, due to the limited scope of such an operation no additional
discharges would be expected.
Old Ash Pond
The old ash pond was listed as a potential Superfund site in the early 1980s during the initial development
of the State Superfund Program. The old ash pond is still listed on the State's Inactive Hazardous Waste
Sites List.
Pesticide Usage in Sutton Cooling Pond
Herbicides are used when 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 are used when needed to perform biological assessments of fish populations. These
pesticides are applied by licensed applicators, or persons under the immediate supervision of a licensed
applicator, in accordance with the manufacturer's instructions.
4

I
C
Progress Be
t� 9 r9Y
Michael Shawn Longfellow
Plant Manager
File: SUT 12520-B-01
January 21, 2005
Cer ged Mail#7004 0530 0000 5750 7939
NCDENR-DWQ
1617 Mail Service Center
Raleigh,NC 27699-1617
DATA SUBMISSION FOR REMOVAL OF SELENIUM MONITORING
REQUIREMENT
Dear Mark McIntire,
Section A. (1)Outfall 001 of the L. V. Sutton Electric Plant's National Pollutant
Discharge Elimination System(NPDES)permit NC0001422 requires that a 56 µg/L daily
maximum limit on the discharge be applied beginning February 1, 2005. At this time we
would like to request the NPDES Unit review the attached data collected from Outfall
001 over the last 22 months and consider removing the daily maximum limit for selenium
from the current NPDES permit.
If you have any further questions related to this request please contact Mr. Steve Cahoon,
Environmental Specialist in our Corporate Office at (919) 546-7457; or Mr. Kent
Tyndall, Sutton Plant Environmental Specialist at(910) 343-3244.
Respectfully yours,
Michael Shawn Longfellow
2 5 2005
Progress Energy Carolinas.Inc.
Sutton Steam Plant L f
P, u
801 Sutton Steam Plant Road
Wilmington,NC 28401
L:.

Sutton Plant Selenium Data
DATE 2003 RESULT
February 17 <5
March 3 <5
March 11 26
March 17 <5
March 27 42
Aril 1 38
April 7 53
May No Discharge
June No Discharge
July 22 <5
August 4 <5
August 18 <5
September 4 <5
September 15 <5
October 13 <5
October 20 <5
October 27 <5
November 3 6
November 10 <5
November 17 9
November 24 <5
December 1 <5
December 23 10
December 29 30

Sutton Plant Selenium Data
DATE 2004 RESULT
January 5 14
January 12 18
February No Discharge
March 15 <5
Aril No Discharge
May 3 7
May 9 19
May 17 10
June No Discharge
July 13 20
July 19 22
July 26 19
August 2 22
August 9 19
August 16 13
August 23 19
August 30 15
September 7 18
September 13 18
September 20 5
September 27 10
October 4 9
October 14 <5
October 25 11
November 1 14
November 8 14
November 15 17
November 22 15
November 29 12

i
�OF W AT49Q Michael F.Easley,Governor
William G.Ross Jr.,Secretary
1 (� North Carolina Department of Environment and Natural Resources
rAlan W.Klimek,P.E.Director
-� Division of Water Quality
O `C Coleen H.Sullins,Deputy Director
Division of Water Quality
d :.
3
March 17,2005
MAR 29 2005
Mr. Michael Shawn Longfellow DENR - WATER QUALITY
Plant Manager POINT SOURCE BRANCH
Sutton Steam Plant
801 Sutton Steam Plant Road
Wilmington,North Carolina 28401
Subject: 2004 Selenium Monitoring
Sutton Steam Plant Ash Pond Effluent
NPDES No.NC0001422
Dear Mr. Longfellow:
The Environmental Sciences Section(ESS)has received the 2004 selenium fish tissue
monitoring results for the Sutton Steam Plant submitted by your office on March 3, 2005. ESS
staff members have reviewed the report and concur with your staff's conclusions. During 2004,
no apparent bioaccumulation of selenium was observed between fish from different sampling
stations,nor is any trend apparent when 2004 results are compared with preoperational baseline
tissue data
Thank you for providing this information for review and for your cooperation. If you have any
further questions or comments please feel free to contact me at 919/733-9960.
Sincerely,
�
RD44--='.
I verton
Chief, Environmental Sciences Section
cc: Reid Garrett, Progress Energy ESS
Dave Goodrich,NPDES Unit
Rick Shiver,WiRO
Dr. Luanne Williams, DHHS Environmental Epidemiology Section
N.C.Division of Water Quality 1617 Mail Service Center Raleigh,North Carolina 27699-1617 [phone] Customer Service
1-877-623-6748