HomeMy WebLinkAboutNC0007064_Compliance Evaluation Inspection_20240625DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
ROr COOPER
covet at
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
Jay Ratliff, Plant Manager
Duke Energy Progress LLC
8470 River Road SE
Southport, NC 28461
NORTH CAROLINA
Environmental Quality
July 09, 2024
SUBJECT: Compliance Inspection Report
Brunswick Steam Electric Plant
NPDES WW Permit No. NC0007064
Brunswick County
Dear Permittee:
The North Carolina Division of Water Resources conducted an inspection of the Brunswick Steam Electric
Plant on 6/25/2024. This inspection was conducted to verify that the facility is operating in compliance
with the conditions and limitations specified in NPDES WW Permit No. NC0007064. The findings and
comments noted during this inspection are provided in the enclosed copy of the inspection report
entitled "Compliance Inspection Report".
There were no significant issues or findings noted during the inspection and therefore, a response to this
inspection report is not required. If you should have any questions, please do not hesitate to contact Bryan
Lievre with the Water Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215
or via email at bryan.lievre@deq.nc.gov.
ATTACHMENT
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Tom Tharrington, Assistant Regional Supervisor
Water Quality Regional Operations Section
Wilmington Regional Office
Division of Water Resources, NCDEQ
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DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 20460
OMB No. 2040-0057
Water Compliance Inspection Report
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 IN 1 2 IS I 3 I NC0007064 I11 121 24/06/25 I17 18 I,- I 19 I G I 201
21111111111111111111111111111111111111111111 f6
Inspection
Work Days Facility Self -Monitoring Evaluation Rating B1 CA ---------------------- Reserved -------------------
67
70 Lla J I 71 I tyI 72 I Ln, I 73 LLI74 71 I I I I I I I80
J
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
08:15AM 24/06/25
23/10/01
Brunswick Steam Electric Plant
8470 River Rd SE
Exit Time/Date
Permit Expiration Date
Southport NC 28461
12:15PM 24/06/25
28/09/30
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Charles K Wilson/ORC/910-457-3687/
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
John Krakuszski,PO Box 10429 Southport NC 28461/Plant Manager//
No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit 0 Flow Measurement 0 Operations & Maintenar 0 Records/Reports
Self -Monitoring Progran 0 Sludge Handling Dispos 0 Facility Site Review 0 Compliance Schedules
Effluent/Receiving Wate 0 Laboratory 0 Storm Water 0 Other
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Bryan Lievre Docusignedby: DWR/WIROWQ/910-796-7215/
7/9/2024 "u
BAF550231BDD428...
Signature of Management Q A Reviewer Agency/Office/Pho D���@dittitbers Date
�dn�` �^�%�� 7/9/2024
Tom Tharrington DWR/WIRO WQ/ - - /
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page#
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
NPDES yr/mo/day Inspection Type (Cont.)
31 NC0007064 I11 12I 24/06/25 117 18 ICI
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
A compliance inspection of the Brunswick Steam Electric Plant was performed on June 25, 2024. The
purpose of the inspection was to verify that the facility is operating in compliance with the conditions
and limitations specified within Permit NC0007064. Present during the inspection were Drew Petrusic
and Eric Caison with the system as well as William Wells and Joseph Babson (both BORCs) also with
the system but only present while at the Support Facilities Wastewater Treatment Plant (i.e., WWTP)
as well as Bryan Lievre with NCDEQ.
The permit provides for the following outfalls:
1. Outfall 001, which is generally plant cooling water but also includes flow from Internal Outfalls
003, 005, 006, 010, 011 and 012. For Outfall 001, from April 1, 2022 through May 30, 2024, the
maximum daily flows were equal to the permit limits for each period and an exceedance was not
reported. During the same period, the reported pH in Outfall 001 ranged from 7.1 to 8.1 with an
average of 7.82 which is also within the established permit limits. No detectable levels of total
residual chlorine were reported at this location during this period. Total Beta radioactivity sampling
results were 332 pCi/L on 11/16/2023, 101 pCi/L on 1/18/2024, 222 pCi/L on 3/25/24 and 258 pCi/L
on 5/22/24. Thermal Reports from 11/2/2022, 1/12/23, 11/08/2023 and 3/14/2024 were reviewed and
found to be in general conformance with permitted limits as described in permit condition A.(1).
2. Outfall 003 has three Radwaste Treatment Systems, although the waste from all is intermittent
and eventually flows from the same discharge line. Sampling conducted on November 12, 2022 and
November 26, 2023 indicates that results for this outfall are in compliance with established permit
limits and had an average flow of 0.023 mgd during the two sampling events;
3. Outfall 005 is a Drain Holding Facility (DHF) which has replaced a legacy Drain Stabilization Pond.
The primary input into the pond is surface water runoff and effluent drains into Outfall 011. The 4.2
acre, approximately 4 million gallon pond had been placed into operation following the previous
inspection performed on 5/26/2022. Sampling conducted from April 2022 through April 2024 indicates
that the system had four discharge events over this period and that results for this outfall are in
compliance with established permit limits. It should be noted that holes had been detected in one of
the two liners, so the pond had been drained and taken back out of service for anticipated repairs
prior to the recent inspection.
4. Outfall 006 is for the discharge of treated metal cleaning wastes and has not been utilized during
this permit cycle (i.e., since prior to April 6, 2018);
5. Outfall 010 is for the Support Facilities Wastewater Treatment Facility (WWTP). This is a 0.150
million gallon per day (mgd) system which includes 12 lift stations (only four of which pump directly to
the WWTF), three fine screens, four sequencing batch reactors, an effluent flow meter, two disc
filters and two UV disinfection units. The system also has two aerated sludge basins and a sludge
thickening system. All parameters during the period of 1/2022 through 5/2024 were all within
permitted levels, the average daily flow for Outfall 010 was 0.008 mgd, TSS averaged 3.7 mg/L and
BOD5 had an average of less than 5 mg/L.
6. Outfall 011 is for a Storm Drain Stabilization Pond (SDSP). There are eight intermittent and
routine sources which are routed to this outfall. Potential discharges include those from an Auxiliary
Boiler System, HVAC Cooling Towers, aDemineralized Water System, a Standby Liquid Control Test
Tank, Turbine Building Closed Cooling Water, Diesel Generator Cooling Water System, Maintenance
Activities and an Independent Spent Fuel Storage Installation (ISFI). Outfall 005 can receive the
same inputs described above when the SDSF is not available and Outfall 012 can also be routed to
the Storm Drain Stabilization Facility. Discharge from Outfall 011 is into the intake canal. From
1/2022 through 5/2024 all parameters were within permitted levels and the flow averaged 0.4613
mgd, TSS had an average concentration of 3.33 mg/L and oil and grease was typically
non -detectable (i.e., less than 5 mg/L) but had a maximum daily concentration of 5.56 mg/L.
7. Outfall 012 is for discharge of the Groundwater Well Extraction System. This system recovers
groundwater with tritium levels of concern from the area of the former Storm Drain Stabilization Pond.
The outfall is typically directed to the intake canal via Outfall 011, but can be directed to Outfall 005.
Although there was no flow reported in Outfall 012 during the period of 1/2022 through 5/2024, the
groundwater extraction system reportedly operated and flows were incorporated into Outfall 011.
Page#
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064 Owner - Facility: Brunswick Steam Electric Plant
Inspection Date: 06/25/2024 Inspection Type: Compliance Evaluation
A review of monitoring records indicates that the system has not had any violations since at least the
past 15 years. The staff were extremely knowledgeable of the facility and the facility seemed to be
well maintained and operated. The facility is compliant with the discharge Permit NC0007064.
Please review the comment sections of the inspection report for more details.
Page#
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064 Owner - Facility: Brunswick Steam Electric Plant
Inspection Date: 06/25/2024 Inspection Type: Compliance Evaluation
Permit
Yes
No
NA
NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new
❑
❑
0
❑
application?
Is the facility as described in the permit?
0
❑
❑
❑
# Are there any special conditions for the permit?
0
❑
❑
❑
Is access to the plant site restricted to the general public?
0
❑
❑
❑
Is the inspector granted access to all areas for inspection?
0
❑
❑
❑
Comment: The current permit was issued 9/6/2023, became effective 10/1/2023 and expires
9/30/2028. Permit conditions include varying discharge flow limits depending upon the
time of the year and electrical demand, annual reports of results to minimize organism
impingement and entrainment at a diversion fence, the number of fine mesh screens in
place to prevent high differential pressures at the Circulating Water Intake Pumps
(CWIPS), total residual chlorine at the Caswell Beach Pump Station and thermal plume
monitoring.
Record Keeping
Yes
No
NA
NE
Are records kept and maintained as required by the permit?
0
❑
❑
❑
Is all required information readily available, complete and current?
0
❑
❑
❑
Are all records maintained for 3 years (lab. reg. required 5 years)?
0
❑
❑
❑
Are analytical results consistent with data reported on DMRs?
0
❑
❑
❑
Is the chain -of -custody complete?
0
❑
❑
❑
Dates, times and location of sampling
Name of individual performing the sampling
Results of analysis and calibration
Dates of analysis
Name of person performing analyses
Transported COCs
Are DMRs complete: do they include all permit parameters?
❑
❑
❑
Has the facility submitted its annual compliance report to users and DWQ?
❑
❑
❑
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified
❑
❑
❑
operator on each shift?
Is the ORC visitation log available and current?
❑
❑
❑
Is the ORC certified at grade equal to or higher than the facility classification?
❑
❑
❑
Is the backup operator certified at one grade less or greater than the facility
❑
❑
❑
classification?
Is a copy of the current NPDES permit available on site?
0
❑
❑
❑
Facility has copy of previous year's Annual Report on file for review?
0
❑
❑
❑
Page# 4
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064
Inspection Date: 06/25/2024
Record Keeping
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Yes No NA NE
Comment: Greater than 10 years of records are maintained on -site either in hand written to
books or electronically. The system has classifications of PC-1 and WW-2. Charles
Wilson maintains a PC-1 and WW-2 certifications and the system has at least three
back-up operators with appropriate certifications. The system maintains lab certification
number 5052 for performing field test parameters and utilize Envirochem for most other
lab analyses.
Compliance Schedules
Yes
No
NA
NE
Is there a compliance schedule for this facility?
0
❑
❑
❑
Is the facility compliant with the permit and conditions for the review period?
0
❑
❑
❑
Comment: A review of monitoring records indicates that the system has not had any violations in
greater than 15 years.
Other
Yes No NA NE
Comment: The permit includes a diversion fence at the mouth of the intake canal as well as an
intake structure which includes coarse trash racks and effluent then flowing through
rotating 42 fine mesh screens and eight (8) coarse mesh screens for each of the four
(4) Circulating Water Intake Pumps (CWIPs). The intake system also includes lower
Pressure spray to wash organisms and higher pressure spray to wash remaining debris
off the screens and back into an estuarine area of the Lower Cape Fear River by a
gravity aqueduct system. The intake system appeared to be functioning properly
during the inspection. The facility is actively working on enhancements to the intake
canal walls with filter fabric and rio rao.
Lagoons
Yes
No
NA
NE
Type of lagoons?
# Number of lagoons in operation at time of visit?
2
Are lagoons operated in?
# Is a re -circulation line present?
❑
❑
0
❑
Is lagoon free of excessive floating materials?
❑
❑
0
❑
# Are baffles between ponds or effluent baffles adjustable?
❑
❑
0
❑
Are dike slopes clear of woody vegetation?
0
❑
❑
❑
Are weeds controlled around the edge of the lagoon?
0
❑
❑
❑
Are dikes free of seepage?
0
❑
❑
❑
Are dikes free of erosion?
0
❑
❑
❑
Are dikes free of burrowing animals?
0
❑
❑
❑
# Has the sludge blanket in the lagoon (s) been measured periodically in multiple
0
❑
❑
❑
locations?
# If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ 0 ❑
Page# 5
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064
Inspection Date: 06/25/2024
Lagoons
Is the lagoon surface free of weeds?
Is the lagoon free of short circuiting?
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Yes No NA NE
■ ❑ ❑ ❑
❑ ■ ❑ ❑
Comment: There are two laqoons which are associated with Outfalls 005 and 011. Both laqoons
are equipped with various types of black balls of various design, intended to inhibit
evaporation and prevent algal growth. The lagoon for Outfall 005 is called the Drain
Holding Facility (DHF) which is a low volume waste pond which has replaced the Storm
Drain Stabilization Pond. The lagoon has a capacity of approximately 4 million gallons,
was constructed with a double liner and discharges into Outfall 011. The sensors
between the liners had detected a leak and so the lagoon was drained and down for
impending repairs during the recent site visit. The lagoon associated with Outfall 011
is called the Storm Drain Stabilization Facility Pond (SDSF) and is approximately 6
millions gallons and discharges on a weekly basis during normal operation to the intake
canal. No exceedances of permit limits were documented from 1/1/2022 through
5/30/2024 for Outfalls 005 nor 011.
Pump Station - Influent
Yes
No
NA
NE
Is the pump wet well free of bypass lines or structures?
0
❑
❑
❑
Is the wet well free of excessive grease?
0
❑
❑
❑
Are all pumps present?
■
❑
❑
❑
Are all pumps operable?
■
❑
❑
❑
Are float controls operable?
0
❑
❑
❑
Is SCADA telemetry available and operational?
0
❑
❑
❑
Is audible and visual alarm available and operational?
0
❑
❑
❑
Comment: Above information is in regards to Lift Station 11, which was inspected during
recent
activities. Lift Station No. 11 is a duplex pump station that is located northwest of the
WWTF and is one of 12 lift stations that serve the Support Facilities WWTF,
althouqh
only four lift stations Ws 3, 6, 11 & 16) pump directly to the WWTF. At least one spare
pump is maintained, although other spare miscellaneous pumps are also available.
Bar Screens
Yes
No
NA
NE
Type of bar screen
a.Manual
❑
b.Mechanical
Are the bars adequately screening debris?
0
❑
❑
❑
Is the screen free of excessive debris?
0
❑
❑
❑
Is disposal of screening in compliance?
0
❑
❑
❑
Is the unit in good condition?
0
❑
❑
❑
Page# 6
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064
Inspection Date: 06/25/2024
Bar Screens
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Yes No NA NE
Comment: The WWTF has three fine screen units installed in parallel with overflow to each of the
subsequent SBR units. One of the screen system was (still) off-line, awaiting
replacement arts at the time of inspection. The units have internal brushes that push
solids to an auger and the solids then travel to a container and are disposed of as low
level radioactive waste (simply as a precaution).
Sequencing Batch Reactors
Type of operation:
Is the reactor effluent free of solids?
Does minimum fill time correspond to the peak hour flow rate of the facility?
Is aeration and mixing cycled on and off during fill?
The operator understands and can explain the process?
Yes No NA NE
Duplex
■
❑
❑
❑
❑
❑
■
❑
Comment: The WWTF has four (4) SBR units with two typically in operation at a time. The units
typically operate with 15 minutes of aeration and 15 minutes of settling with a DO of
between 8.1 to 8.8 mg/L. Train 1 which includes SBRs 1 and 2 was inoperative during
the visit as the system awaiting replacement parts. Although it is understood that an
overflow of one of the SBRs would be automatically diverted to one of the sludge
holding tanks, it is recommended that high liquid level alarms be installed to prevent
overflows from the SBRs.
Flow Measurement - Effluent
# Is flow meter used for reporting?
Is flow meter calibrated annually?
Is the flow meter operational?
(If units are separated) Does the chart recorder match the flow meter?
Yes
No
NA
NE
■
❑
❑
❑
•
❑
❑
❑
•
❑
❑
❑
❑
❑
■
❑
Comment: Effluent flowrates for Outfall 001 are determined based on influent pump data and
validated by measurements and associated calculations of liquid level over the weir at
the effluent channel at the facility. Flowrates for Outfall 003 are determined by using
the volume of tank contents released over time (as would Outfall 006, if utilized).
Flowrates for Outfalls 005 and 011 are determined with a Parshall Flume and
associated calibrated meter(s) (as would Outfall 012, if utilized). For the WWTP or
Outfall 010, the system has two influent flow meters for internal purposes and are not
utilized for reporting purposes. The effluent flow meter K' diam pipe maqmeter) is
located after the SBR units and is used for reporting purposes. The meter was last
calibrated 8/7/2023 by C. Wright Instruments, Inc.
Filtration (High Rate Tertiary)
Yes
No
NA
NE
Type of operation:
Is the filter media present?
❑
❑
❑
Is the filter surface free of clogging?
❑
❑
❑
Is the filter free of growth?
❑
❑
❑
Page# 7
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064 Owner - Facility: Brunswick Steam Electric Plant
Inspection Date: 06/25/2024 Inspection Type: Compliance Evaluation
Filtration (High Rate Tertiary)
Yes
No
NA
NE
Is the air scour operational?
0
❑
❑
❑
Is the scouring acceptable?
0
❑
❑
❑
Is the clear well free of excessive solids and filter media?
❑
❑
0
❑
Comment: The WWTF has two high -rate disc filters set up in parallel.
The filters have a stainless
steel filters and backwash is sent to Lift Station No.
11. 25% sodium hydroxide is
infected into the disc filters for pH control.
Disinfection - UV
Yes
No
NA
NE
Are extra UV bulbs available on site?
0
❑
❑
❑
Are UV bulbs clean?
❑
❑
❑
Is UV intensity adequate?
❑
❑
❑
Is transmittance at or above designed level?
❑
❑
❑
Is there a backup system on site?
❑
❑
❑
Is effluent clear and free of solids?
0
❑
❑
❑
Comment: The WWTF has two UV units, set up in parallel, and each unit has three bulbs. The
system tries to maintain 3 spare bulbs on -site.
Aerobic Digester
Yes
No
NA
NE
Is the capacity adequate?
0
❑
❑
❑
Is the mixing adequate?
0
❑
❑
❑
Is the site free of excessive foaming in the tank?
0
❑
❑
❑
# Is the odor acceptable?
0
❑
❑
❑
# Is tankage available for properly waste sludge?
0
❑
❑
❑
Comment: The WWTF has two aerated sludqe tanks, set up in parallel. The WWTF system is
also equipped with a sludge thickening system (currently inoperative) including a screw
press, an electric drier unit, and an auger assembly that conveys solids to a holding
container. Liquids from the drying process are discharged into Lift Station 11 and are
disposed as low-level radioactive waste (as a precaution). The system has not had to
dispose of sludge from the WWTP.
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: The WWTF is checked daily for PH, DO & settleability and mixed liquor is checked
weekly and sludge fudge measurements are taken as needed.
Page# 8
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064
Inspection Date: 06/25/2024
Effluent Sam plinq
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Owner - Facility: Brunswick Steam Electric Plant
Inspection Type: Compliance Evaluation
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0
degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
representative)?
Yes
No
NA
NE
❑
❑
■
❑
•
❑
❑
❑
•
❑
❑
❑
❑
❑
■
❑
❑
❑
■
❑
■
❑
❑
❑
Comment: Composite sampling is not required for any of the outfalls for the current permit.
Pump Station - Effluent
Yes
No
NA
NE
Is the pump wet well free of bypass lines or structures?
0
❑
❑
❑
Are all pumps present?
0
❑
❑
❑
Are all pumps operable?
0
❑
❑
❑
Are float controls operable?
❑
❑
0
❑
Is SCADA telemetry available and operational?
0
❑
❑
❑
Is audible and visual alarm available and operational?
❑
❑
0
❑
Comment: The WWTF qravitv discharqes into a storm drain that drains into the effluent channel
at the entrance to the plant. All combined effluent then flows through a 5.4 mile long
effluent channel to Caswell Beach. A siphon system allows the effluent to flow under
the Intracoastal Waterway and this structure is reportedly inspected by others with the
facility. The pump station at Caswell Beach is equipped with eight pumps with trash
racks to screen large debris. The pumps discharge the effluent into a submerged pipe
in the Atlantic Ocean, south of the Caswell Beach pump station. The trash racks are
manually cleaned and the facility monitors the level within the discharge canal.
Effluent Pipe
Yes
No
NA NE
Is right of way to the outfall properly maintained?
❑
❑
❑
Are the receiving water free of foam other than trace amounts and other debris?
0
❑
❑ ❑
If effluent (diffuser pipes are required) are they operating properly?
❑
❑
■ ❑
Comment: Some foam was visible along the discharge channel leaving the facility. According
to
system staff and verified during previous inspections, the foam dissipates by
the time it
reaches the end of the channel. As previously mwentioned the final effluent
pipe is
submersed in the Atlantic Ocean. aooroximatelv 2.000 feet off shore.
Standby Power
Yes
No
NA
NE
Is automatically activated standby power available?
0
❑
❑
❑
Is the generator tested by interrupting primary power source?
0
❑
❑
❑
Page# 9
DocuSign Envelope ID: DD52231E-F1A3-46AO-87BD-6C96FOF6D69F
Permit: NC0007064 Owner - Facility: Brunswick Steam Electric Plant
Inspection Date: 06/25/2024 Inspection Type: Compliance Evaluation
Standby Power
Yes
No
NA
NE
Is the generator tested under load?
0
❑
❑
❑
Was generator tested & operational during the inspection?
❑
0
❑
❑
Do the generator(s) have adequate capacity to operate the entire wastewater site?
0
❑
❑
❑
Is there an emergency agreement with a fuel vendor for extended run on back-up
0
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power?
Is the generator fuel level monitored?
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Comment: The propoane powered emergency generator is capable of powering the WWTF as
well as Lift Station 11. The unit is serviced by on -site staff (Site Services Department)
and runs weekly for 15 minutes.
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