NC0025453_Historical information_20131231

Romanski, Autumn
Ms. Gore and Mr. Smith,
1
From: Tim Broome [mailto:[e-mail] ]
Sent: Friday, March 08, 2013 9:04 AM
To: Gore, Deborah; Smith, Danny
Cc: Hassan, Monti; Rick Hester; Steve Biggs; Chandra Coats; Dan Wall; James Warren; Tim Simpson; Hayes, Mitch; Mary
Sadler; 'Rohrbacher, Joe'
Subject: Industrial Wastewater Treatability Study
From:
Sent:
To:
Cc:
Subject:
Cheng, Barry, and Autumn
Please review the below listed email.. I would like us to meet/discuss this on Monday. I want your input prior to
responding to Tim Broome.
Thanks!
Danny
As you are aware, the Town of Clayton receives pretreated industrial wastewater from Grifols Biotherapeutics and other
industrial and commercial customers in the industrial park on US 70 Business east of Clayton. The Town administers an
industrial pretreatment program and regulates the quality of effluent it receives.
The wastewater pump station that serves the industrial park is designed with dual pumping facilities, and the
wastewater flow stream is currently split with a larger portion pumped to the Town's Little Creek Water Reclamation
System and a smaller portion to the Central Johnston County Regional Wastewater Treatment Plant in Smithfield.
Grifols is expanding its manufacturing operation and projects its wastewater flow to increase from the current 0.45 MGD
daily average to approximately 0.85 MGD over a 4 year period. Grifols' pretreatment facilities consist of fine screening,
flow equalization, pH adjustment, suspended growth aerobic treatment by moving bed biological reactors (MBBR's),
activated sludge aeration, and solids separation by dissolved air flotation. Waste solids are transported off site for
disposal by either composting or land filling.
Smith, Danny
Friday, March 08, 2013 1:56 PM
Zhang. Cheng; Herzberg, Barry; Romanski, Autumn
Bolich, Rick; Gore, Deborah
FW: Industrial Wastewater Treatability Study
Danny Smith
Regional Supervisor
Raleigh Regional Office
Division of Water Quality
Surface Water Protection Section
3800 Barrett Drive
Raleigh, NC 27609
[phone]
Danny.Smithtgncdenr.gov
Email correspondence to and from this address may be subject to the North Carolina Public Records Law and may be
disclosed to third parties unless the content is exempt by statute or other regulation.
I
Please contact me and/or James Warren, Clayton Wastewater Manager, with questions and comments.
Sincerely,
Tim Broome, P.E.
2
Accordingly, the County with the assistance of its engineering consultant, Hazen and Sawyer, has conducted a due
diligence investigation to determine if the County's Central Regional wastewater treatment plant can accommodate
from 0.50 to 0.85 MGD of MBBR effluent and maintain compliance with its NPDES and reclaimed water effluent limits.
The results of process modeling and bench scale testing indicate the wastewater can probably be accommodated;
however, solids separation issues which could affect effluent quality are a possibility.
The cooperation and involvement of your sections will be appreciated. We invite you to meet with the County and
Town wastewater management staffs to discuss the detailed plan and protocol for the treatability study.
Process additions to insure permit compliance are prohibitively costly for the short term period of operation. The County
and Town believe it is in the best interest of all stakeholders to conduct a 30 to 45 day full scale treatability study. During
the trial period, MBBR effluent (from 0.45 to 0.50 MGD) will be diverted to the County's wwtp for treatment. Grifols
effluent quality and the County's plant operational performance will be carefully monitored. Arrangements will be in
place for Grifols to immediately return its pretreatment facility to full operation (i.e. return the aeration basin and DAF
units to service) in event of upsets in, or unsatisfactory effluent quality from the County's wwtp.
Timothy G. Broome, P.E.
Director of Utilities
Johnston County
919.209.8333
Grifols has requested the Town ^^ceive and treat flow equalized, pH adjus^^effluent from the MBBR process as the
industry desires to discontinue operation of the aeration basin and DAF process and to discontinue solids handling and
disposal. The Town of Clayton has requested the assistance of the County to receive and treat the MBBR effluent for a
period of 3 to 5 years, beginning in early 2014. During this interim period, the Town will plan, design, permit, and
construct its own facilities for treatment of the Grifols wastewater.
I
Romanski, Autumn
i
This came up just about a year ago. At that time it seemed that they were only going to pH adjust and the BOD would
have been around 3,000 mg/l. Now it sounds like there will be at least partial treatment by the SIU. Not sure what that
brings the BOD down to. It also sounds like the wastewater from Grifols will be going straight to the WWTP and not
through the landfill EQ.
Johnston County's HWA was approved in December 2012. They have an allowable load for BOD of 19,808 pounds/day
based on their influent design BOD of 350 mg/l and a permitted flow of 9.5 MGD. Their allocation table has 2,254
pounds allocated to Clayton SIUs and I'm not sure how much of that is Grifols, but for this quick analysis I will assume
zero. At 0.5 MGD the Grifols discharge could contain up to 2,100 mg/l of BOD.
A few years ago we started making Towns use their design values for BOD, TSS and NH3. The HWA spreadsheet would
often calculate allowable loads that would equal 1,000 mg/l at the influent which we didn't think was realistic. We go
some push back and we came to some compromises one of which is to allow the town to multiply their influent design
values by 1.5 if they could demonstrate consistent compliance. If Johnston County did this the influent at 375 mg/l and
9.5 MGD would be 29,711 Ibs/day and they could accept 0.5 mGD at 3,000 mg/l and still have 21% of their allowable
load remaining.
I would still urge a lot of caution, but these numbers make me feel a little better about their ability to accept the
wastewater.
Just a reminder, Grifols still has to meet categorical standards.
Let me know if you want to discuss further,
Deborah
From: Gore, Deborah
Sent: Tuesday, April 24, 2012 9:11 AM
To: Poupart, Jeff
Cc: Belnick, Tom
Subject: Griffles - heads up
Johnston County has a 4.2 MG aerated EQ basin at the landfill. They have about 0.8 MGD gong through it right now
from some residential areas - could be up to 1.95 MGD in 10 years. Johnston County wants to have Griffles discharge
their untreated wastewater (Griffles will continue to do pH adjustment) to the EQ basin. They will look at upgrading the
aeration at the landfill EQ basin so it can knock the BOD down to acceptable levels to be treated at the Johnston County
WWTP. They plan to take some more samples prior to Griffles' treatment at different times of the day to confirm
From:
Sent:
To:
Cc:
Subject:
Right now most of their flow goes to Clayton. They have biological treatment because of high BOD. They would like to
get out of the treatment business and are looking at expanding, more jobs and flow from 0.55 MGD to 0.91 MGD. The
BOD runs about 3,000 mg/l into the SIU's treatment system. Clayton has agreed to up to 0.65 MGD, but cannot take the
BOD without the treatment. They took a few samples going into the treatment system, which show compliance with
categorical standards - one exception on acetone, due to a cleaning operation that they have modified to prevent in the
future.
Monti and I met with an engineer from Hazen & Sawyer last Thursday. She is working with Johnston County on this
project. Griffles is a company in Clayton that bought out Telecris. They are a pharmaceutical company. Griffles plans to
request a meeting with the Secretary's office, which is why I am giving you this heads up.
Gore, Deborah
Monday, March 11,2013 7:53 AM
Smith, Danny; Zhang, Cheng; Romanski, Autumn; Herzberg, Barry
Hassan, Monti; Poupart, Jeff
FW: Griffles - heads up
!
2
Based on our meeting with the engineer and no road blocks for the project from pretreatment, I'm not sure if they will
still request the meeting, but wanted to let you know just in case something came down the pipe.
Deborah
E-mail correspondence to and from this address may be subject to the North Carolina Public Records Law and may be
disclosed to third parties.
Deborah Gore
PERCS Unit Supervisor
919-807-6383
categorical compliance. I told tn^engineer that as long as the wastewater leaving the Griffles property met the
categorical standards we in Pretreatment did not have a problem with it. They would still have a permit with limits and
monitoring requirements. I did advise her to contact NPDES to see if the EQ basin at the landfill would have to be
included in the NPDES permit - I didn't think so, but since it is providing treatment, I wasn't sure.
Permittee Owncr/Officer Name:
P c TIPMailing Address:
_ Phone #: ( e/fC( ) ■> 53 - .5 C'C‘2State: A€ Zin: 3
Email address:
Signature;
Permit#: Facility Name:
Facility Tvpe/Grade:
Signature: Date:
Print Full Name:1
Date:Signature:
Fax: [phone]
Revised 02-2013
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-Biological WWTP
Physical/Chemical
Collection System
Surface Irrigation
Land Application
WPCSOCC, 1618 Mail Service Center, Raleigh, NC 27699-1618
Email: certadmm-^ncdenr.gov
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“1 certify that 1 agree to my designation as (he Operator in Responsible Charge tor the facility noted I understand and will abide by the rules
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Water Pollution Control System Operator Designation Form
WPCSOCC
NCAC ISA 8G .0201
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"I certify that I agree to my designation as a Back-up Operator in Responsible Charge for the facility noted 1 understand and will abide by the
nilcs and regulations pertaining lo the responsibilities of (he Bl: ORC as set forth in 1 5A NC AC 08G .0205 and failing to do so can result in
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........................................................
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Print Full Name:
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6 ~l 38nr-Work Phone H: (IV ) 5 S' ? - 33
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Back-Up Operator in Responsible Charge (BU ORC)
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Revised 02-2C13
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“I certify that I agree to my designation as a Back-up Operator in Responsible Charge for the facility noted, i understand and will abide by the
rules and regulations pertaining to the responsibilities of the Bl; ORC as set forth in I 5A NCAC 08G .0205 and failing to do so can result in
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Facility Name: C ttT/c Ct ckeV j( pa---/ C: L/fr/i.
-I certify that I agree to my designation as a Back-up Operator in Responsible Charge for the facility noted. I understand and will abide by the
rules and regulations pertaining to the responsibilities of the Bl. ORC as set forth in 15A NCAC 08G .0205 and failing to do so can result in
Disciplinary Actions by the Water Pollution Control System Operators Certification Commission."
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Certificate Type / Grade / Number: _
Signature: fizz Dale :_3 / H/! 3
“1 certify that I agree to my designation as a Back-up Operator in Responsible Charge for the facility noted. 1 understand and will abide bv the
rules and regulations pertaining to the responsibilities of the Bl1 ORC as set forth in 15A NCAC 08C. .0205 and failing to do so can result in
Disciplinary Actions by (he Water Pollution Control System Operators Certification Commission."
Back-Up Operator in Responsible Charge (BU ORC)
L3/ <y A H r i^c oft
Certificate Type / Grade / Number: tULf?
"I certify that 1 agree to my designation as a Back-up Operator in Responsible Charge for the facility noted. 1 understand and will abide by the
rules and regulations pertaining to the responsibilities of the Bl! ORC as set forth in I 5A NCAC 08G .0205 and failing to do so can result in
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STATE OF NORTH CAROLINA
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Raleigh Regional Office
SECTION
NAME
FACILITY NAME
Cc.
luTP - he co ^37 Ql
?Ope cAuStre, 0^05^6
lorP - /^Co ft po!
Permittee: Town of Clayton Permit Number: NC0025453
Facility Name: Little Creek Water Reclamation County: Johnston
Level of Treatment:
None Primary TreatmentX Secondary Treatment Chlorination/Disinfection Only
Estimated Volume of Spill/Bypass: 232,350 gallons (must be given even if it is a rough estimate)
Did the Spill/Bypass reach the Surface Waters?X Yes No
If yes, please list the following:
Volume Reaching Surface Waters: 232,350 gallons Surface Water Name: Little Creek
Did the Spill/Bypass result in a Fish Kill? Yes X No
Was WWTP compliant with permit reguirements? X Yes No
Were samples taken during event? Yes X No
Spill/Bypass Reporting Form (August 1997)
Incident Started:
Incident Ended:
WWTP Upset, Spill, or Bypass 5-Day Reporting Form
(Please Print or Type Use Attachments if Needed)
Time: 1045
Time: 1830
Date: 06/07/2013
Date: 06/07/2013
Source of the Upset/Spill/Bypass (Location or Treatment Unit):
Effluent pump station.
Cause or Reason for the Upset/Spill/Bypass:
Effluent pump station overflowed due to excessive flow generated from Tropical Storm Andrea. The area
received 4.74 inches of rain in an eight hour period that triggered flash flooding and excessive inflow.
Describe the Repairs Made or Actions Taken:
N/A
I) r
■ x-
North Carolina D^artment of Environment ana Natural Resources
Division of Water Quality
op ZrAI I
Action Taken to Contain Spill, Clean Up and Remediate the Site (if applicable):
N/A
24-Hour Report Made To:Division of Water Quality X Emergency Management
Contact Name: Danny Smith Date: 06/07/2013 Time:1630
Other Agencies Notified (Health Dept, etc):
Person Reporting Event: James O. Warren Phone Number: 919-553-1536
Did DWQ Request an Additional Written Report?Yes X No
If Yes, What Additional Information is Needed:
Spill/Bypass Reporting Form (August 1997)
WWTP Upset, Spill, or By
Page 2
5-Day Reporting Form
Additional Comments About the Event:
Act of nature.
Action Taken or Proposed to be Taken to Prevent Occurrences:
A report will be prepared for management proposing additional effluent pumping capacity.