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HomeMy WebLinkAboutNC0001422_Re-Issuance Application_20060726i r \ ,1 Progress Energy File No.: SUT 12520 -B -01 July 26, 2006 NCDENR -D WQ 1617 Mail Service Center Raleigh, NC 27699 -1617 NPDES PERMIT NO. NC0001422 RE- ISSUANCE APPLICATION Dear Mr. Gil Vinzani: E C E � l! JUN 2 8 2006 DENR - WATER QUALITY SURFACE WATER PROTECTION SECTION Harry Sideris Plant Manager The current National Pollutant Discharge Elimination System ( NPDES) Permit No. NC0001422 for Progress Energy Carolinas, Inc (PEC) L. V. Sutton Electric Plant located in New Hanover County expires on December 31, 2006. PEC hereby requests that the NPDES permit for the facility be reissued. Enclosed is EPA Application Form 1 — General Information and EPA Application Form 2C — Wastewater Discharge Information, both in triplicate. The L. V. Sutton Electric Plant is expected to continue to operate over the next five years essentially as it has previously with the new ash pond discharging to the Cape Fear River via Outfall 001 on a more routine basis (i.e., several times per week to daily). When the effluent of the new ash pond is aligned to discharge to Outfall 001, there will continue to be anywhere from 0 to 0.5 MGD of new ash pond effluent discharging into the cooling pond. At times that the new ash pond ( Outfall 004) is not discharging to the Cape Fear River via Outfall 001, all of the new ash pond effluent will discharge to the cooling pond. Thus for our permit renewal, we conducted two sampling events. One sampling event consisted of cooling pond discharge only and the other was a combined sample of cooling pond discharge and new ash pond discharge. The samples were analyzed and the highest v_ ue of the two sample sets was used as the maximum dal y value for Form 2C V. Intake and Effluent Characteristics Part A, B, and C. The results of the two sample sets were averaged together to reflect the maximum 30 day value, and the results of the two sampling events along with DMR data were used to calculate long term average values, where appropriate. A value of 12.84 MGD (long term average value) was used to calculate mass for all values in Item V. Part A, B, and C. Progress Energy Carolinas, Inc. Sutton Steam Plant 801 Sutton Steam Plant Road Wilmington, NC 213401 f L. V. Sutton Electric Plant NPDES Permit No. NCOW1422 Reissuance Application June 26, 2006 With re- issuance of the NPDES permit, PEC requests the following: • Reduce the monitoring frequency for total residual chlorine from weekly to monthly at Outfall 001. Based on past DMR's (February 2003 through December 2005) the TRC concentration has been less than 1.2 pg/L in every test. Monthly monitoring should be sufficient to demonstrate compliance with the effluent limitations. • Reduce the monitoring frequency for copper from monthly to quarterly at Outfall 001. Based on past DMR's (February 2003 through December 2005) the average copper concentration of the discharge over that period of time has been 6.9 µg/L, with 10 of 28 tests below the detection limit. Quarterly monitoring should be sufficient to demonstrate compliance with the effluent limitations. • Reduce the monitoring frequency for selenium from weekly to monthly at Outfall 001. Based on past DMR's (February 2003 through December 2005) the selenium concentration in the discharge has averaged 11.9 pg/L over 82 sampling events. Monthly monitoring should be sufficient to demonstrate compliance with the effluent limitations. • Reduce the monitoring frequency for arsenic from monthly to quarterly at Outfall 001. Based on past DMR's (February 2003 through December 2005) the average arsenic discharge concentration at the outfall has averaged 11.8 pg/L over 27 sampling events. Quarterly monitoring should be sufficient to demonstrate compliance with the effluent limitations. • Reduce the monitoring frequency for toxicity from monthly to quarterly at Outfall 001. Based on past DMR's (February 2003 through December 2005) the average survival rate in every test over that period of time has been greater than 99 %. Quarterly monitoring should be sufficient to demonstrate compliance with the effluent limitations. • Reduce the monitoring frequency for total suspended solids and oil and grease at Outfall 002 and Outfall 004. Currently the permit required frequency for both is twice per month. Based on past DMR's (February 2003 through December 2005) the average TSS concentration of the discharge over that period of time from Outfall 002 is 2.8 mg/1 and at Outfall 004 4.3 mg/L. Oil and grease concentrations over the same period of time, has averaged 2.3 mg/L at Outfall 002 and 2.2 mg/1 at Outfall 004. Monthly monitoring should be sufficient to demonstrate compliance with the effluent limitations. L. V. Sutton Electric Plant NPDES Permit No. NC0001422 Reissuance Application June 26, 2006 Also Sutton Plant requests the Division consider suspending the requirements for Outfall 003, Y/ Metal Cleaning Wastes. The Plant's current method (in use for the last 15 years) of disposal of these chemicals is to incinerate them in the boiler, thus no discharge. However, the plant would like to reserve the option to discharge metal cleaning waste if necessary through Outfall 003, with 1 week's notice to the Division. If there are any questions regarding the enclosed information, please contact Steve Cahoon, Environmental Specialist at our Environmental Services Section, at (919) 546 -7457. Enclosures cc: Wilmington Regional Office — DWQ Respectfully yours, Harry Sideris '!ease print-0 type in the unshaded areas only Form Approved, OMB No. 2040 -0086. Approval expires 5- 31 -92. ?ill -in area3- are spaced for elite type, re, 12 charactersinch). FORM U.S. ENVIRONMENTAL PROTECTION AGENCY 1 EPA GENERAL INFORMATION Consolidated Permits Program - GENERAL (Read the "General Instructions" before starting) LABE ITEMS I I. EPA I.D. NUMBER III. FACILITY NAME FACILITY V. MAILING ADDRESS VI. FACILITY LOCATION II. POLLUTANT CHARACTERISTICS PLEASE PLACE LABEL IN THIS SPACE 1. EPA LID NUMBER F NCD000830646 I 1 2 T/A C 13 14 155 GENERAL INSTRUCTIONS If a preprinted label has been provided, affix it in the designated space. Review the information carefully. if any of it is incorrect, cross through it and enter the correct data in the appropriate fill - in area below. Also, if any of the preprinted data is absent (the area to the left of the label space lists the information that should appear) , please provide it in the proper fill -in area(s) below. If the label is complete and correct, you need not complete Items I, III, V, and VI (except VI -B which must be completed regardless). Complete all items if no label has been provided. Refer to the instructions for detailed item descriptions and forthe legal authorizations under which this data is collected. INSTRUCTIONS: Complete A through J to determine whether you need to submit any permit application forms to the EPA. If you answer "yes" to any questions, you must submit this form and the supplemental form listed in the parenthesis following the question. Mark "X" in the box in the third column if the supplemental form is attached. If you answer "no" to each question, you need not submit any of these forms. You may answer "no" if your activity is excluded from permit requirements; see Section C of the instructions. See also, Section D of the instructions for definitions of bold -faced terms. x SPECIFIC QUESTIONS MARK FURM SPECIFIC QUESTIONS (M'o FORM YES NO ATTACHED YESI NO ATTACHED A. Is this facility a publicly owned treatment works which results in a discharge to waters of the U.S.? X (FORM 2A) 16 17 18 C Is this a facility which currently results in discharges to waters of the U.S. other than those described in A or B X X above? (FORM 2C) 22 23 24 E. Does or will this facility treat, store, or dispose of hazardous wastes? (FORM 3) X 28 29 30 G. Do you or will you inject at this facility any produced water or other fluids which are brought to the surface in connection with conventional oil or natural gas production, inject fluids used for enhanced recovery of oil or natural X gas, or inject fluids for storage of liquid hydrocarbons? (FORM 4) 34 35 36 I. Is this facility a proposed stationary source which is one of the 28 industrial categories listed in the instructions and which will potentially emit 100 tons per year of any air pollutant regulated under the Clean Air Act and may affect or be located in an attainment area? X (FORM 5) 40 41 42 III. NAME OF FACILITY ISKIPIL. V. Sutton Electric Plant 1 15 16 - 29 30 IV. FACILITYCONTACT A. NAME & TITLE (last, first, & title) - (Harry Sideris - Plant Manager 1 15 16 V. FACILITY MAILING ADDRESS A. STREET OR P.O. BOX 801 Sutton Steam Plant Road 15 116 B. CITY OR TOWN B. Does or will this facility (either existing or proposed) include a concentrated animal feeding operation or aquatic animal production facility which results in a discharge to waters of the U.S.? (FORM 2B) D. Is this a proposed facility (other than those described in A or 8 above) which will result in a discharge to waters of the U.S.? (FORM 2D) F. Do you or will you inject at this facility industrial or municipal effluent below the lowermost stratum containing, within one quarter mile of the well bore, underground sources of drinking water? (FORM 4) H. Do you or will you inject at this facility fluids for special processes such as mining of sulfur by the Frasch process, solution mining of minerals, in situ combustion of fossil fuel, or recovery of geothermal energy? (FORM 4) J. Is this facility a proposed stationary source which is NOT one of the 28 industrial categories listed in the instructions and which will potentially emit 250 tons per year of any air pollutant regulated under the Clean Air Act and mayaffect or be located in an attainment areaP (FORM 5) H Wilmington II 15116 VI. FACILITY LOCATION A. STREET, ROUTE NO. OR OTHER SPECIFIC IDENTIFIER CJ 801 Sutton Steam Plant Road 16 B. COUNTY NAME I New Hanover 46 70 C. CITY OR TOWN 6 Wilmington E1P 1Form 3510 -1 (8 -90) B. PHONE (area code & no.) 910 343 13201 45146 - 48 49 51 1 52 - 55 IC. STAT D.1IP CODE I NC 1]28401 401 4 4 141 - 511 I 1 451 D. STAT E. ZIP CODE NC 28401 401 41 42 147 - 5' 19 I 20 21 X 25 26 27 1 X 31 32 33 I X 37 38 39 X 43 44 45 691 F. COUNTY CODE (if known. 52 54 CCrNTINUE ON REVERSE STF EW564F 1 rONTINUEU FROM THE FRONT VII. SIC LODES (4 digit in order of priority) A. FIRST 4 911 (specify) I (specify) Electric Power Services I ?5 16 19 15 16 - 191 1 C. THIRD 1(specify) 7 (specify) 16 1 9 175 16 191 VIII. OPERATOR INFORMATION A. NAME c B. SECOND 8 Carolina Power & Light d /b /a/ Progress Energy Carolinas, 15 16 C. STATUS OF OPERATOR (Enter the appropriate letter into the answer box; if "Other, " specify.) F= FEDERAL M = PUBLIC (other than federal or state) (specify) c S = STATE O = OTHER (specify) Public P= PRIVATE s6 Public Utility P. O. Box 1551 26 E. STREET OR P.O. BOX F. CITY OR TOWN B Raleigh 15 16 X. EXISTING ENVIRONMENTAL PERMITS A. NPDES (Discharges to Surface Water) c r I � NCO 001422 9 I sI 17 1t B. UIC (Underground Injection of Fluids) C I I 19s C. RCRA (Hazardous Wastes) 9 R 1 NCD000830646 15 16 1" 18 XI. MAP G. STAT T ZIP CODE N 40 41 42 47 - 51 B. Is the name listed in Item VIII -A also the Inc . owner? YES F NO �] 5s D. PHONE (area codee & no.) 910 343 13201 1 1 22 - z51 IX. INDIAN LAND I Is the facility located on Indian lands? YES ENO D. PSD (Air Emissions from Proposed Sources) C T I 30 195 P 17 1 1a - Sul E. OTHER (specify) c l 1 1 WQ 0 0 0 0 0 2 0 I (specify) 9 N. C. Ash Utilization 30 15 16 17 18 - 301 E. OTHER (specify) C 165-88 I (specify) 30 9 15 l 16 1 17 1 18 LAMA Permit for Intake Structure - 301 Attach to this application a topographic map of the area extending to at least one mile beyond property boundaries. The map must show the outline of the facility, the location of each of its existing and proposed intake and discharge structures, each of its hazardous waste treatment, storage, or disposal facilities, and each well where it injects fluids underground. Include all springs, rivers and other surface water bodies in the map area. See instructions for precise requirements. All. NATURE OF BUSINES1Jpmvlde a briefdescription) This is a steam elecric generating facility consisting of 3 coal fired units with a nominal net capacity of 613 MWe and three Internal Combustion (IC) Turbines with a nominal net capacity of 64 MWe. XIII. CERTIFICATION (see instructions) I certify under penalty of law that I have personally examined and am familiar with the information submitted in this application and all attachments and that, based on my inquiry of those persons immediately responsible for obtaining the information contained in the application, I believe that the information is true, accurate and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fine and imprisonment. A. NAME & OFFICIAL TITLE (typeorprint) Harry Sideris Plant Manager COMMENTS FOR OFFICIAL USE ONLY lg 1¢orm 3510 -1 (8 -90) B. SIG TURE C. DATE SIGNED ��� ss I STF ENJ5W 2 V Attachment 1 — Form 1 — Item XI — Map (j Sutton SteaM Electric Plant New Hanover County Page 1 of 2 t C> 0 500 1000 0 1000 2000 3000 Feet it7.✓ S fq y�v1w � Discharge Canal Plant Site Attachment 1 — Form 1 — Item XI — Map Sutton Steam Electric Plant New Hanover County Page 2 of 2 l Progress Energy Carolinas, Inc. L. V. Sutton Electric Plant National Pollutant Discharge Elimination System Permit Number NC0001422 Attachment 2 Form 2C - Item II -A Flow, Sources of Pollution, and Treatment Technologies Stream Averaqe Flow (MGD) Comments A 49 Pump Capacity - flow is intermittent B 589 Totals for Units 1, 2, & 3 C 2.5-3.0 Outfall 004 - Optionally routed to Outfall 001 or to the cooling pond D 583 Totals for Units 1, 2, & 3 E 1.5 (estimate) Net forced evaporation F 2.5-3.0 Totals for Units 1, 2, & 3 G 0.01 Maximum flow H 0.11 Maximum flow 1 0.17 Maximum flow J 0.01 K 2.5-3.0 Outfall 002 L Variable (0 - 380) Outfall 001 - Normally continuous 25 MGD (2.5 MGD ash pond effluent plus 12.5 MGD cooling pond blowdown) M 0.08 N 0.003 O 0.05 P 6.7 S 0.16 T 0.01 U 10 (estimate) V 0.145 Outfall 003 - Normally disposed of by evaporation in the boilers W 2.5-3.0 Ash sluice water for Units 1, 2, & 3 routed to old ash pond during maintenance on new ash pond X Variable (0-3.0) Discharge to the cooling pond Y Variable (0-3.0) Discharge to the Cape Fear River 1 County i Water I I Potable Water I I Sanitary Systems f Septic Tanks Drain Fields ; , Infiltration Wells 0 Plant Systems I Non - contact Cooling p Fire System Wells n Units 1 & 2 Bearing Cooling Water Heat Exchanger f (service water) .. W Units 1, 2, & 3 d Oily Waste South S Low Volume Units 1, 2, & 3 E— Circulating Treatment Retention Waste Sources Condensers Water Pumps Basin T Chemical Metal Oily Wastes I West Retention Cleaning Evaporation Yard Drains Basin Evaporation V Outfall 003 T � v G J F Units 1, 2, & 3 `— Intake Chemical Metal Old Ash Pond New Ash Pond .E-- Ash Sluice Structure Cleaning V H ., Outfall w Outfall 004 — W Coal Pile U & Tank Farm B Seepage Runoff D Screen Wash E Evaporation K X Q Outfall 002 Cooling Pond Y � 1 A M Yard Drains Cape Fear Makeup Intake L Runoff Attachment 2 Attachment River Structure n f L j;P1CL — L. V. Sutton Electric Plant C New Hanover County, NC Cape Fear River Schematic of Water Flows Outfall 001 Page 2 of 2 Carolina Power & Light Company L. V. Sutton Electric Plant National Pollutant Discharge Elimination Svstem Permit Number NC0001422 Attachment 3 Form 2C - Item II -13 Flow, Sources of Pollution, and Treatment Technologies The Sutton Plant is a coal -fired 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 ten 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 Coolinq 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 in the Outfall 001 discharge. 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 in the Outfall 001 discharge. i ) '. Carolina Power & Light Company L. V. Sutton Electric Plant National Pollutant Discharqe Elimination System Permit Number NC0001422 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, sludge removed from catch basins, sumps, etc. may be transported to the old and /or new ash pond for disposal. 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, sludge 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. A Rotamix Urea injection system and Rotating Over Fire Air (ROFA) System were installed on the Unit 3 boiler in the Spring of 2005. These systems are used jointly to employ high velocity air injection and urea to reduce nitrogen oxides (NOx) emissions during the ozone season 2006 (approximately May through September). After 2006 the ROFA Rotamix system will be used throughout the year. Any un- reacted ammonia will be absorbed into the fly ash and will be carried to the ash pond via ash sluice water. Currently, as part of our ash treatment system we have a drip that feeds either acid or caustic (depending on season and type of coal burned) into the ash sluice line to help with the pH adjustment of the ash sluice water before it is discharged to the ash pond. Ash Pond Discharqe 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 1.0 MGD will still be discharged to the cooling pond. Effluent from the old ash pond discharges to the cooling pond. Coolinq Pond Discharqe 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. E Carolina Power & Light Company L. V. Sutton Electric Plant National Pollutant Discharge Elimination Svstem Permit Number NCO001422 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 Carolinas, Inc. will submit appropriate information to the EPA if required. 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 approximately every 1 to 3 years 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 pre- heaters and electrostatic precipitators are water washed approximately every one to three years 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 would not occur in ash pond discharges. Chemical Metal Cleanina Wastes The boilers are chemically cleaned approximately every 5 to 10 years using one of the following chemical processes: 1) citric acid, ammonium hydroxide, Cronox inhibitor, sodium nitrite, ammonium bicarbonate, 3 ti r Carolina Power & Light Company L. V. Sutton Electric Plant National Pollutant Discharqe Elimination System Permit Number NC0001422 or 2) Tetraammonium Ethyl enediaminetetraacetic acid (EDTA) and A300 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, 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. Fire Water Svstem 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 Carolinas, Inc. may exercise the option of reclaiming ash from its ash ponds. However, due to the limited scope of such an operation no additional discharges would be expected. Former Ash Disposal Area 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 Coolinq 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. 0 Sutton Plant Location Map C Progress Energy r r i mom Wanks J r , 15 Makeup - i Intake - . structure Heated water to -t. Cooling Pond (Tan giant Site ���� — • r -� -'-" Recirculated ` Cooling Water -'41111111� back to PlantC�ol�` 0 0.6 1.2 1.8 2.4 3 km 0 0.4 0.8 1.2 1.6 2 mi Map center is UTM 18 224327E 3799059N (WGS84 /NAD83) Castle Hayne quadrangle M= -8.944 Projection is UTM Zone 18 NAD83 Datum G- -1.689