NC0003417_Renewal (Application)_20071127

X*,2 Progress Energy
File #12520B -1
Gil Vinzani November 27, 2007
NC Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699 -1617
Subject: Carolina Power & Light Company d/b /a Progress v-; er or _ `l
Lee Steam Electric Plant `� r t
Fi
NPDES Permit No. NC0003417
Permit renewal request] DEC 5 2007
Dear Mr. Vinzani:
OFNR - WATER QUALITY
POINT SQUPCE KAKI ^h i
The current NPDES permit for Carolina Power & Light Company dT /aFrogess�Eriergy-
Carolinas, Inc. (PEC) Lee Steam Electric Plant located in Wayne County expires on
May 31, 2008. 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.
With re- issuance of the NPDES permit, PEC requests the following:
First, PEC appreciates you and other Division staff's time and efforts in meeting to
discuss the issues surrounding nitrogen discharge from the plant. As you know this
discharge is associated with the operation of the Rotamix NOx emissions control unit at
the plant. PEC is actively working on means to identify ways to reduce the nitrogen
discharge to the Neuse River. As representatives from PEC and the DWQ have discussed
previously, PEC requests sufficient time to evaluate, optimize and reduce the nitrogen
discharge associated with the operation of the NOx control unit. Our intent is to
significantly reduce the amount of nitrogen discharged from this site rather than to simply
purchase allocation for and permit it. We request a timeframe be recognized in our
renewed permit that would allow for this work to be accomplished.
Second, PEC requests the following language regarding usage of biocides and the
completion of the Biocide Form 101 be added to the permit:
The permittee shall not use any biocides except those approved in conjunction with the
permit application. The permittee shall notify the Director in writing not later than
ninety (90) days prior to instituting use of any additional biocide used in cooling systems
which may be toxic to aquatic life other than those previously reported to the Division of
Water Quality. Such notification shall include completion of Biocide /Chemical
Treatment Worksheet - -Form 101. Division of Water Quality approval is not necessary for
the introduction of new biocides into outfalls that are tested for whole effluent toxicity.
Completion of the Biocide Worksheet is thus, not necessary for those outfalls with toxicity
testing requirements.
Progress Energy Carolinas, Inc.
Lee Steam Plant
1677 Old Smithfield Road
Goldsboro, NC 27530

Finally, PEC is in,the,process,of adding a fifth umt "to the Wayne County Combustion
Turbine Site. That is reflected in this permit application. The wastewater from the new
unit will be blended with the flow from the existing, units which is sent to a collection
system, sump and pumped to the Lee Plant cooling pond Some wastewater, mostly from
secondary containments, is collected and transported to the Lee Plant ash pond. We are
not adding any new "wastewater treatment" units associated with this new combustion
turbine unit and therefore believe an Authorization to Construct is not needed. P,EC staff
are currently discussing this requirement with Construction Grants and Loans staff.
If you have any questions please contact Mr. Ricky Miller at (9.19) 580 -3983 or Mr.
Shannon Lan g ley at (919) 546 -2439.
I certify, under penalty of law, that this document and all attachments'were prepared under my
dzrectzon.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 f nes and imprisonment for knowing violations
Enclosures
TH/esl
,cc: Ricky Miller
Shannon Langley
Respectful)y sub tted,
Tim Hill
Plant Manager, Lee Plant

Carolina Power & Light Company d /b /a
j Progress Energy Carolinas, Inc.
Attachment 1. (continued)
/Aj
1; '
a
I _
H. F. Lee Steam Electric Plant
NPDES Permit Number NCO03417
Ash Pond
n..�u nnd
-$j
Ji
i
14�36831d�p + Y uA� k .
0 0,2 0.4 0.6 0.8 1 mi
USGS Northwest Goldsboro (NC) Quadrangle
Plant location 35 "22'43 "N, 78`04'31 "W (NAD27)
1:24K/25K topo map Scale 1:50,000
A11-2 08/23/2007

J $ Carolina Power & Light Company d /b /a
j Proaress Energv Carolinas. Inc.
H. F. Lee Steam Electric Plant
NPDES Permit Number NCO03417
Attachment 1. Topographical Maps of the H. F. Lee Steam Electric Plant Area
Way
Combu
r, ion Turbine
T
ite Area
_ T _
. •♦ I i T
1 �•, r
� l K
_i
0 0.4 0.3 1.2 1.6 2 ni
USGS Northwest Goldsboro (NC) Quadrangle
Plant location 35 °22'43 "N, 78 °04'31 "W (NAD27)
1:24K/25K topo map Scale 1:100,000
agegn -r�cra ante a r a� t►
Al-1 08/23/2007

- Carolina Power & LIgHt Company d /b /a
..j Progress Energy Carolinas, Inc
Attachment 2. Water Flow Line Drawing
Collection Tanks
Wayne Co CT,Site and Dram Tanks
Plant Processes
Collection Sump
H F Lee Steam Electric Plant
NPDES Permlt,Number NCO03417
Wayne Ca CT Site Units 1 &2 Equipment
RO S stem Plant Cooling Water F- Service Water
Coolm Tower Blowdown
Processes
T
Storfn'Water Runoff S
Collection Sumps
Domestic Waste &
Potable Water Drains Sewage
Treatment
Residuals,sent off site 'System
CRetention
Residuals to Ash Pond F-
K
Filter Plant
Incineration R
,(Normal)
L
Chemical Metal
Cleaning
L (alt )
Storm Water, from
Ash Line Trench
Residuals from
Retention, Basins
(Retention Other Low Volume
Basin Wastes
It
Infiltration &
Evaporation
Residuals,to Ash pond
_30 Low Volume Waste
Retention Basin
Waste oil sent off site
)oration Neuse River
eepage H Outfall002
M
P Neuse,River
A
Cooling Pond
B River Make -up Intake - (alt )
C
E,
D
N
Plant Intake Structure Condensers
halt }
F Unit 3 Equipment
Cooling Water <
(closed Cycle)
O
Ash_ Transport;System
Precipitator and Air
Preheater" Wash Water
O (alt )
Y
Coohng�Pond
(rarely)
Q
Ash Pond
G
Neuse River
Outfall 001
A2 -1 08/29/2007

i Ifarolina Power & Light Company d /b /a H F Lee Steam Electric Plant
Progress Energy Cairblinas jnc NPDES Permit Number NC000341,7
Attachment 2. (continued)
Stream
Estimated Average
Flow
Comments
A
12.7 MGD
Make -up water from.Neuse River
B
12.7 MGD
Make -up water to cooling pond
" C
0.02 MGD
Coal pile runoff — estimate based on 5" rainfall/month, 50% runoff
D
372 MGD
Plant withdrawal from cooling-pond
E'
369 MGD
Condenser cooling Water and Unit 3 equipment coolingw,ater
F
2 5` MGD
Ash transport ,system' water
G
2.5 MGD
Ash pond discharge, to , Neuse River (Outfall 001)
H
0 07 MGD
Low volume basin wastewater- (estimated)
I
11.3 MGD
Cooling pond evaporation & seepage (estimated)
J
0.004 MGD
Sewage treatment - system
K
0.16'MGD
Treated water to revefse osmosis system °and plant processes
L-
100,000 gal/event
Chemical metal cleaning (usually incinerated)
M
Rare Occurrence
Cooling pond discharge to Neuse River (Outfall 002)
N
0 3 MGD
Raw water to filter °plant
O
0.5'MG /event
Precipitator & air preheater wash water
P
580 gpm/event
Wayne County CT Site wastewaters from sump lift station
Q
2,400 gal/event
Wayne County CT Site wastewaters from collection & drain tanks
R
0 14 MGD
Wastewater from filter °plant
S
12,250 gal/event
Storm water runoff -- estimate based on 0.5" rainfall event
T
25 gpm /unit
Units, 1 &2 equipment,coolmg water ,cooling tower blowdown
A2 -2 08/29/2007

44-arolina Power & LightlCompany d /b /a H F Lee Steam Electric Plant
;< Progress Energy Carolinas Inc NPDES Permit Number NC0003417
Attachment 3. Description of Operations Contributing to Wastewaters
The H F. Lee Plant is a three -unit, coal -fired steam cycle electric generating plant with four additional
oil -fired Combustion Turbme,(CT) units and four adjacent oil/gas -fired CT units (aka Wayne County
Combustion Turbine Site). The plant has 'a 545 acre off- stream closed -cycle cooling pond on the west
side of the Neuse River near Goldsboro, North Carolina, in Wayne County. Water is withdrawn from
the Neuse River as required to make up evaporative, seepage, and discharge losses from the cooling
pond. Makeup pumping rates are highly variable depending upon natural weather conditions,
generation load and plant operations, quantity of water available iri the river, and pond water levels.
The Lee Plant has two permitted outfalls to the Neuse River: Outfall 001 from the ash pond and
Outfall 002, from the cooling pond. The maximum normal operating level of the cooling pond is
maintained at approximately 1.2 feei (weather dependent) below the crest of -the spillway gates.
Discharges from the cooling pond are rarely made, usually only during an extremely heavy rainfall
event or hurricane. The cooling pond last discharged in April 1994. Chemical constituents contained in
the cooling pond discharge are, for the most part, representative of the naturally - occurring chemical
quality and quantity of the intake water.
In addition to these outfalls, backwash from intake screening devices is discharged into the Neuse
River bypass canal associated with the Neuse Riverpursuant to NCAC 15A 2H .0106 (f) (2).
The following is a description of wastewater streams produced at the plant:
Contributing Flows into the Ash, Pond
Ash Transport System Wastewater
Fly ash and bottom ash from all three units are hydraulically conveyed by ash sluice pipelines to ,the
Lee Plant ash pond.
Precipitator and Air Preheater Wash Water
Water from washing the interior of the precipitators and air heaters is typically routed to the ash pond
via the ash transport system but could, be routed directly or indirectly to the cooling pond. The
wastewater from the Rotamix@ treatment system added to Unit 3 for NOx removal is also routed to the
ash pond.
Filter Plant Wastewater
Blowdown and filter backwash wastewater generated in the filter plant is discharged into the ash sluice
transport system which flows to the ash pond.
Wayne County Combustion Turbine Site Wastewaters
The containments around 'the accessory module, liquid fuel, and atomizing air modules and the wash
water drain empty into collection tanks. Once there is a quantity of liquid collected in the tanks, the
wastewater -is removed by pumper truck and transported and released into the Lee Plant ash pond. The
wash water drain tanks collect the water and detergent used to clean the CT compressors.
A3 -1 08/23/2007

,t
�learolina Power & Light Company d /b /a H F Lee Steam Electric Plant
Progress Energy Carolinas Inc NPDES Permit Number NC0003417
Micellaneous Wastes
Cooling tower basin sludge, circulating water-' tunnel sediment, and boiler vacuuming sediments are
sent to the ash pond. Other residuals from the low volume wastes retention basin and the coal pile
runoff' retention basin and other miscellaneous low volume wastes from plant processes are also
transported to the ash pond. Storm water from the ash line trench flows 'into the' ash pond.
Contributing Flows into the Cooling Pond '(Closed Cycle)
Recirculated Condenser Cooling_ Water
This flow provides, condenser cooling water for generating Units 1, 2, and 3. The total flow is
recirculated 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 3 -5 MGD above natural evaporation rates during times the units are in,full
operation.
Equipment Cooling Water
Circulating water for Unit 3 is withdrawn from cooling water makeup and/or the cooling pond and
passed through two heat exchangers to provide non- contact cooling for the plant's closed - cooling water
system. After passing through the heat exchangers, the circulating water is routed to the cooling,pond.
Units 1 and 2 use a cooling tower for heat removal for their equipment closed - cooling water system.
Cooling tower blowdown is routed to the low-voMme waste,retention basin.
Coal Pile Runoff
The coal pile area is, surrounded by a drainage ditch that is routed to a clay- bottomed, asphalt and
concrete -sided settling pond. The basin is sized so as to adequately store runoff and allow the
suspended solids to,�settle before the supernate is discharged by overflow to the cooling pond. During
routine maintenance of the,pond, ay solids removed will be disposed of in the active ash pond.
Sewage Treatment System
Domestic waste is treated in a septic tank and sand filter bed system. Flow from the system is
dependent upon fluctuating demand due to variations in the number of personnel on site. Residuals are
disposed of off -site by a licensed contract disposal firm. The sand 'm the system is penodically,changed
to ensure system effectiveness is maintained. The spent sand is disinfected and then used as _fill and
stabilization matenal.
Low Volume Wastewaters
A low volume waste, retention basin receives wastewaters from three sumps located throughout the Lee
Plant. The sumps collect waste from floor and equipment drains, the fuel oil unloading area,, boiler
blowdown, cooling tower overflow, sampling streams, and rainfall from the immediate plant area.
Water ,treatment wastes including filter backwash water and settling basin drains also goes to a sump.
In addition, the low, volume basin receives discharges from equipment washings, boiler and condenser
drains, and closed - cooling system blowdowns and. drains, greywater from contractor washing stations,
and Units 1 and 2 cooling tower blowdown. Oily waste collectors .remove, oil and grease and a holding
chamber allows the solids to settle out before the effluent is discharged into the cooling pond. To
A3 -2 08/23/2007

iCrolina Power & Light Company d /b /a H F Lee Steam Electric Plant
Z� Progress Energy Carolinas Inc NPDES Permit Number NC0003417
maintain the efficiency of the basin and allow adequate freeboard, the settled sludge from the basin and
from the three sumps will penodically`be removed and disposed of 'in the ash pond.
Precipitator and Air Pre - Heater Wash Water
Under normal operations, water from washing the interior of the precipitators and air heaters are routed
to the ash pond via the ash transport system. However, these wastewaters could be routed directly or
indirectly to the cooling pond in unusual situations.
Wayne County Combustion Turbine Site Wastewater
The wastewater collection system sump receives wastewaters from the filter plant, Reverse Osmosis
(RO) water treatment system (reject water), excess evaporative cooling°water, process drains, and from
the oil water separator. Two pumps (rated at 580 pgm each), one for operation and one for a back up,
transfer the wastewater to the Lee Plant cooling pond.
In the RO water treatment system, water from the Lee Plant cooling pond passes through dual ,media
sand filters then through a five - micron cartridge pre -filter before entering either of the two RO units
The two RO units may be operated in parallel or series depending on operational needs The treated
water is stored in a tank until needed Reject wastewater is sent to the sump.
The oil water separator treats water from the containment areas around the two fuel oil storage tanks,
the fuel forwarding pumps, and the fuel oil unloading area. Storm water collection containment areas
around transformers and substations are examined for the presence of any oily substance; if oily
substances are present in the containment, nothing will be drained from the containments until that
substance is properly removed.
In many cases added chemicals are consumed or chemically altered during the plant processes
(Attachment 4). Only trace elements might be recoverable in water entering the cooling pond. Since
the cooling pond serves as a final treatment basin and receives significantly ,greater volumes of water
from other inflows, detectable levels of these chemicals should not occur in the cooling pond
discharge.
A3 -3 0843/2007

0
Progress Energy
October 5, 2010
Mr. Jeff Poupart
NC Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699 -1617
Subject: Amendment of NPDES application
Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
H.F. Lee Steam Plant
Permit #: NC0003417
Wayne County
Dear Mr. Poupart:
By submittal of this letter, Carolina Power & Light Company d /b /a Progress Energy Carolinas, Inc.
(Progress Energy) is modifying the subject permit's NPDES application to detail the relocation of a spare
parts lay down yard being moved to facilitate construction of the new combined cycle power plant on
site. The plant's spare parts lay down area is being relocated to a point adjacent to the site's coal pile. A
map showing the new area is attached for reference. Any storm water runoff from this area of industrial
activity will, like other site storm water runoff, be directed to the site's cooling reservoir. This manmade
reservoir is a permitted wastewater structure with discreet outfall to the Neuse River (outfall 002 in the
sites NPDES permit). There will be no new runoff from this area to the Neuse River or any waters of the
State. For reference, the last discharge from outfall 002 to the Neuse River was in 1999 during
Hurricane Floyd. As part of this relocation, amendment to the site's Sediment and Erosion Control plan
will be obtained prior to the land disturbance of the new lay down area.
This correspondence is being sent to update the current application on file and we do not anticipate any
permit modifications or further authorizations to be necessary. We will gladly assist should additional
questions arise. If you have further questions, please feel free to contact Shannon Langley at (919) 546-
2439 or Ricky miller at (919) 580 -3983.
Progress Energy Carolinas, Inc.
Lee Steam Plant
1677 Old Smithfield Road
Goldsboro, NC 27530
o [R@ffl0dC� p
D
7T nr 82010
DENR -WATER QUALITY
POINT SOURCE BRANCH

9
Tcert►fy, under,penalty-of law, that this documerit and a// attachments were prepared under my direction
or superv►s►on do accordance, with d system designed to fissure that quol►fled personnel properly gather
and evaluate the information submitted_ Based on -my inquiry of the person or persons who manage the'
system, or those persons d►re'ctly'respons►ble for gather►ng'the,►nformation, the'►nformation submitted is;
to the best of'my knowledge ond,bel►ef, true„ accurate; ,and'comp/ete 1 am aware thot there ore
signif icant penalties for submitting false�mforrri t►on „including t_he poss►brhty,of fines and vmpnsonment
for knowing violations:
C° Shannon Langley PE64 w /attachment
Ricky Miller w/ attachment
Teresa Williams PEB8 w /,attachment
Mr. Al`Hodge,'Supervisoe
NC'Divisiomof Water Quality
943' Wash mgton'Square„Mall
Washington,, NC 27889
Sinterely;
Kns . Edmondson, `P,la,nt Manager
H.F' Lee,,-Stearn Electric Plant

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K, Progress Energy
November 11, 2011
Tom Belnick, Supervisor
NC Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699 -1617
Subject: Administrative Update to NPDES Application
H.F. Lee Steam Electric Plant
NC0003417
Wayne County
Dear Mr. Belnick:
,x
This letter is intended to provide additional information for the NPDES permit file and
application of record for the subject facility. In order to facilitate work necessary to fully
commission the new combined cycle plant at the H.F. Lee Energy Complex, Progress Energy
Carolinas, Inc. hereby adds the following information to the previously submitted "Description
of Operations Contributing to wastewaters" of the facility's NPDES application:
Outfall 001
The facility may transfer coal mill rejects and pyrites to the ash pond for disposal. Coal Mill
rejects and/or pyrites will be buried within existing dry ash deposits within the pond.
Additionally, non - contaminated soil from the construction site may be used in the dry area of the
ash pond as a top dressing for dust control.
Outfall 002
Hydrostatic tests waters and initial boiler blow down waters from the facility's new Boilers will
be captured in frac tanks and then sent to the site's 545 acre cooling pond. Approximately
107,708 gallons of water and 70 lbs Ammonium Benzoate (used as a rust inhibitor) per unit will
be generated and sent to the cooling reservoir for each of these start up activities. As the permit
reflects, any infrequent discharge from this outfall is limited by technology- based and WET
limits.
Herbicide and Pesticide Usage in the Treatment System Ponds and on plant property (OutEtg
001, 002 and 003)
Herbicides may be used as needed to control nuisance aquatic vegetation. These herbicides are
applied by licensed applicators, or persons under the immediate supervision of a licensed
applicator, in accordance with the manufacturer's instructions. Pesticides may be used as
needed to perform biological assessments. These Pesticides are applied by licensed applicators,
or persons under the immediate supervision of a li licator, in accordance with the
manufacturer's instructions. 1 11 M1�
Progress Energy Carolinas, Inc.
Lee Steam Plant
1677 Old Smithfield Road
Goldsboro, NC 27530

Various brands of commercaal,her�bacides may be used to control'weeds and other unwanted
plant growth on the plant property These herbicides will be carefully applied by licensed
.applicators, or persons under, the immediate supervision of a licensed applicator, an accordance
vi,ilh, the manufactur er's ins Ii ucttons
We are making this amendment to the facility's official NPDES application to support the start-
up of the plant's, Combined Cycle Plant and the beginning stages of closure of the HY Lee coal-
fired steam plant site. We do not believe this notification and file amendment will result in the
need for, not are we seeking, amendment to the facility's NPDES permit for this activity as
neither the discharge characteristics nor permit limits will be altered
Please' contact Mr Shannon Langley at (919) 546 -2439 or Mr. Ricky Miller at (919 580 -3983, if
you have any questions.
I certify, under penalty of law, that this document and all attachments were prepared under my
dar, ection ,or supervision an 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 as, 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
R ectfully submitted,
tj
F3, 3., ►L ��
Julie Turner, Plant Manager
H F Lee Steam Electric Plant
Cc: Ricky Miller
Shannon Langley (PE134)