System Performance Annual Report Fiscal Year 2014

I. General Information Facility name - Metropolitan Sewerage District of Buncombe County 2028 Riverside Drive, William H. Mull Building Asheville, North Carolina 28804

General Manager Thomas E. Hartye, P.E. (828) 254-9646

Director of Wastewater Treatment (WRF) Peter Weed (ORC) (828) 225-8204

Operations Manager (WRF) Roger Edwards (ORC-Backup) (828) 225-8224

Director of Technical Services (Collection System) Ken Stines (ORC) (828) 255-0061

Director of System Services Construction (Collection System) Mike Stamey (ORC-Backup) (828) 255-0061

Permit Numbers:

• NPDES Permit # NC0024911 • Marketing & Distribution Permit # WQ0007174 (class A residuals) • General Storm water Permit # NCG110003 • Air Quality (WNCRAPCA) Permit # 11-0772 • Collection System # WQCS00004

II. Description of Facilities

A. Collection System- System Services Division The Metropolitan Sewerage District covers approximately 180 square miles serving over 51,000 billed customers and an estimated population of 125,000 people. Within this area, MSD service extends along the French Broad River and Swannanoa River Valleys. The collection system or pipes include 1,000 miles of public sanitary sewer line, 32 public pump stations and approximately 28,000 manhole access points. In this large network of sewer lines less than 65 miles of sewer lines are large interceptors with diameters ranging from 24" to 66". One third of the balance is comprised of smaller 6" lines and rest made up of lines ranging from 8" up to 24" in size. Most all of this pipe is between 50 and 100 years old, and is in continual need of rehabilitation or replacement. In FY 2014, over 8 billion gallons of wastewater was treated at the Districts Wastewater Reclamation Facility with an estimated 49% of this water classified as Infiltration (groundwater seeping in from

cracks in pipes and manholes) and Inflow (rainwater entering through manhole lids and unauthorized Storm Water connections). The District has been aggressively working to abate this problem which plagues all wastewater treatment systems.

B. Wastewater Reclamation Facility (WRF) The present Wastewater Reclamation Facility (WFR) is a 40MGD secondary treatment plant serving Buncombe County (specifically Asheville, Biltmore Forest, Black Mountain, Montreat, Weaverville, Woodfin and Buncombe County at large). Overall the MSD treatment facility serves over 51,000 residential and commercial customers and over 22 significant industries. In FY 2014 the facility treated an average daily flow of 22.9 million gallons per day. The WRF is an attached growth design, comprised of 152 rotating biological contactors (RBC’s), which provide full secondary treatment. These RBC’s provide 450-500 acres (about 3 acres each unit) of surface area for biological growth. It has been said that MSD’s facility is the largest RBC plant in the world. The plant consists of:

Preliminary Treatment Components • IDI Barscreens (2 units) w/screenings compactor and screw conveyer • Influent Pumps (3 units) – 35 MGD rated capacity each • Aerated Grit Chambers (3 units) w/associated grease removal

Primary Treatment Components • Primary Microscreens (7 units) – decommissioned

Secondary Treatment Components • 1st Stage RBC’s (44 units) • 2nd Stage RBC’s (72 units) • 3rd Stage RBC’s ( 36 units) • Intermediate Pumps (3 units) – pump water to clarifier from 3rd RBC stage • Intermediate Clarifier (4 cells – total volume 2 MG) • Microfiltration with Aqua Aerobics Systems AquaDisk system (16 Units)

Disinfection Components • Sodium Hypochlorite solution – average feed 1,000 gallons/day at 8% solution strength with

dechlorination of effluent prior to exiting the treatment facility Residuals Handling Components

• Gravity Thickeners (2 units) – 100 foot diameter each • 2.5 Meter Belt Filter Presses (2 units) • Anaerobic Digesters (decommissioned) – 100 foot diameter each (2) • Fluidized Bed Incinerator (40DT/day rated) • Alkaline Stabilization Facility (40DT/day rated - decommissioned)

Energy Management Components • 4 Megawatts in Diesel Generators (full back-up/emergency power supply) • 850 Kilowatt Hydro Turbines (3 units) – induction units (French Broad River source)

Automation Components • SCADA systems employed throughout facility – full automated control of WWTP

Sludge Management Plan • MSD utilizes its fluidized bed incinerator as its primary residual management option, with alkaline

stabilization as a reserved management option – as well as maintains an arrangement with the Buncombe County landfill (lined) for emergencies. Presently the facility is managing 15-16 DT’s per day of residuals, however the designed capacity is 40DT’s per day. Due to the lack of true primary clarifiers, most of the sludge generated at the facility is secondary in nature (i.e. sloughings from

the RBC’s). Sludge is thickened in on-site gravity thickeners to a consistency of normally 3-5% solids at which time it is then pumped to the 2 1/2-meter belt presses. These units dewater the sludge to over 24% solids and then it is pumped to the incinerator. The facility maintains gravity belt thickeners and anaerobic digesters; however these units are presently not being utilized. Air emissions from the incinerator are of excellent quality. Recent air emissions testing place removal efficiency of the air scrubbers at 99+% for regulated parameters. Incinerator ash is thickened on-site via a gravity ash thickener and then pumped to an on-site lagoon. Groundwater is monitored in accordance with NCDENR requirements (up & down gradient). When alkaline stabilization operations are activated, a class “A” product is produced and distributed to the public. The alkaline add-mixtures utilized in the process are fly ash, cement kiln dust (CKD) and lime kiln dust (LKD). The process incorporates the use of the "N-Viro" process when these alkaline products are utilized in accordance with the patented mix recipe. Due to the fact that the incinerator operations provide much more cost-effective management, it is utilized as the primary option. Supplementary fuel of natural gas is required due to the 24% solids content. MSD maintains an "agreement" with the local county landfill (lined) to dispose of dewatered sludge during emergency and/or maintenance/breakdown instances; this provides a 3rd residuals management alternative.

III. Improvements to Facilities A. Collection System Improvements MSD assumed ownership and maintenance of the various local public collection systems in 1990, and since that time MSD has undertaken an aggressive program to correct existing known collection system problems. Between 1990 and 2014, over 1,028,000 linear feet of pipe have been replaced and over $309 million has been re-invested in plant and collection system rehabilitation projects. However, due to the large size of the MSD system, there is much work still to be done. From FY 2015 to FY 2024, the District expects to rehabilitate or replace an additional 500,000 linear feet. Approximately $184 million will be spent for the Districts Capital Improvement Program (CIP) over the next 10 years. Of this, 9% will be spent on rehabilitating medium to large interceptors, 78% on rehabilitating or replacing small collection lines, and 13% on the treatment plant and pump station projects. The total estimated cost to rehabilitate the District’s aged collection system and WRF facilities over the next twenty year period is estimated at over $300 million. MSD has updated its “Pipe Rating” program to include new rating criteria in addition to the structural condition of pipes. This award winning program helps to objectively prioritize rehabilitation projects by using a combination of pipe-defect ratings, maintenance history, risk criteria, and the Geographic Information System (GIS) to generate a priority rating for all MSD rehabilitation projects. MSD maintains an aggressive Preventative Maintenance Program whereby approximately 698,000 lineal feet of sewer lines were cleaned by high pressure water jetting equipment. In addition, over 71,000 linear feet of sewer lines are mechanically or chemically treated to remove tree roots and blockages. MSD also maintains its Rights-of-Way to ensure access to the system for cleaning and maintenance activities. During FY 2014 over 58,000 ft. were cleared.

B. Wastewater Reclamation Facility Improvements Recently completed or underway facility projects include the following;

• Plant Electrical Improvements: This multi-year is now complete. It has greatly improved the plant’s aged electrical supply system. A second main power source has been added, and additional backup power capacity has been added in order that full treatment will be maintained during a power outage.

• Facilities Plan Update: This significant, comprehensive study will examine the various unit processes within the plant, with a focus on headwork’s, biological treatment alternatives, and the future regulatory climate. Completion of the study is expected in Spring 2015, and it will serve as a guide for planning future capital projects at the plant.

IV. Performance Measures A. Collection System, System Services Division • The District has an aggressive Preventative Maintenance program of high pressure cleaning and

root control. This year over 769,000 lineal feet of pipeline was treated by MSD in this way; more than 14.5% of the 1,000 miles of the system.

• System Services division completed and submitted to NCDNR-DWQ two six-month High Priority Line Inspection Reports and one Increased Inspection and Maintenance Report as required. The High Priority Line report documents inspection of aerial lines, siphons and lines in proximity to vulnerable creeks and streams. The Increased Inspection Report documents oversight of problem sewer lines in the 10 year CIP, all of which must be inspected once every three years until replaced.

• The collection system recorded 36 sanitary sewer overflows (SSO’s). All SSO’s were remediated according to the District’s standard operating procedures for sanitary sewer overflow cleanup and no severe environmental impact occurred.

Attachments (These documents are in Adobe Acrobat format. To download a free Acrobat Reader CLICK HERE)

• Customer Service response times • Pipeline Maintenance totals • SSO Report - monthly • Construction totals (In System Services Division) • NOV Report • SSO’s chart for FY14

B.Wastewater Reclamation Facility (WRF) During the FY14 annual reporting period, performance measures were again achieved. The WRF continues to provide effective/efficient treatment services to the community averaging CBOD & TSS removal efficiencies of 92% and 96% respectively. Flow to the WRF continues to remain well below hydraulic capacity for the plant, with an average flow of 22.9 million gallons per day. The WRF remained in compliance for all permitted parameters and received a favorable review by NC Department of Environment and Natural Resources and the WNC Regional Air Quality Agency regional office staff with respect to the annual facility inspections. MSD maintained its service contract agreement with Pace Analytical, Inc. (NC certified lab). This agreement incorporates the exchange of full laboratory testing services for use of the existing laboratory space. This progressive opportunity continues to yield significant long-term savings to MSD. The WRF successfully participated in a surveillance audits regarding ISO14001 certification – coming through with zero (0) non-conformances. This program, also referred to as an Environmental Management System, continues to provide significant benefits to MSD both in the short & long-term. Some of the significant WRF Division accomplishments this fiscal year were:

• Maintaining full compliance with NPDES and WNC Air Quality permits and standards • Achieving greater reduction in Total Suspended Solids (TSS) due to AquaDisk Filtration

operations. • SCADA – continued improvements to WRF, remote pump stations & flow monitoring sites for

faster response. • Elevating Preventative Maintenance schedule on RBC's and reducing loads as Basins are drained. • Began process of updating the 2007 WRF Facilities Plan with consultant. • Revamping of Grit & Grease process area for extreme wind and cold weather protection. • Successful replacing of #3 Raw Pump and repacking of all troublesome knife gates. • Working with contractor to replace all faulty slide gates located within RBC Basins I & II (31 slide gates in total). • Establishing additional Bioxide dosing station on S. French Broad Interceptor for H2S & odor

control. • Assisting in installation, testing and training of two new 1-meg generators and redundant feed-

loop electrical system. • Adding safe work platforms and several patch repairs to Incinerator ductwork & relining of

Venturi. • Complete rehab of key biosolids pumps after seven continuous years of hard service • Reconfiguration of CCTV security system for treatment plant, septage receiving, hydro power

plant and flume. • Installation of new HVAC controls and major replacements for Mull Administration building • Replacement of Incinerator, Blower building, and several pump station roofs maintaining 15-year

service life. • Completing over 1500 work orders; Motor Fleet, WRF Maintenance, and Facilities Maintenance

Combined.

Performance Measures

Task FY12 FY13 FY14 1. Daily (average) flow, treated MGD 18.7 21.9 22.9 2. Maximum daily flow treated, MGD 50.2 62.1 74.6 3. Dry tons of bio-solids processed 4,416 5,788 5,665 4. Cost per million gallons (MG), treated $722 $617 $614 5. Energy costs per MG, treated $162 $119 $101 6. Carbonaceous biochemical oxygen demand (CBOD) removal, % 93% 93% 92% 7. Total suspended solids (TSS) removal efficiency, % 93% 93% 96% 8. Number of NPDES permit non-compliance 0 0 0 9. Preventative to corrective maintenance ratio 70:30 70:30 70:30 10. Equipment availability percentage >95% >95% >95%

Attachments (These documents are in Adobe Acrobat format. To download a free Acrobat Reader CLICK HERE)

• Plant location map with contours ( This is a large file)

• Schematic of Wastewater Reclamation Facility • Wastewater Reclamation Facility site • WRF performance chart • WRF pollutant removals • Biosolids production • Air emissions

V. Certification I certify under penalty of law that this report is complete and accurate to the best of my knowledge. I further certify that this report has been made available to the users and customers of the MSD system and that those users have been notified of its availability.

____________________________________________ Thomas E. Hartye, P.E. August 29, 2014 General Manager Metropolitan Sewerage District of Buncombe County, NC If you would like a hard copy or more information... Write to webmaster@msdbc.org

FY00 FY01 FY02 FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14SSO's 289 221 137 114 78 78 55 52 41 23 34 24 25 37 36

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300

350

Fiscal Year July 1 thru June 30

Sanitary Sewer Overflows

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Wastewater Reclamation FacilityPerformance in FY14

CBOD (wastewater strength) CBOD LIMITTSS (total suspended solids) TSS LIMIT

Month INF CBOD EFF CBOD % Removal Req'd % RemovalJuly 108.5 8.6 92% 85%

August 120.6 8.7 93% 85%September 154.2 7.9 95% 85%

October 177.4 10.6 94% 85%November 180.3 10.3 94% 85%December 158.0 12.5 92% 85%

January 158.4 12.0 92% 85%February 143.4 13.5 91% 85%

March 177.2 12.5 93% 85%April 157.1 13.4 91% 85%May 144.4 16.7 88% 85%

June 194.8 15.8 92% 85%

Average 156.2 11.9

% Removal 92%

Month INF TSS EFF TSS % Removal Req'd % RemovalJuly 169.4 12.0 93% 85%

August 187.5 8.7 95% 85%September 210.4 7.5 96% 85%

October 328.1 9.5 97% 85%November 238.9 8.9 96% 85%December 261.5 9.0 97% 85%

January 206.0 6.8 97% 85%February 233.8 8.4 96% 85%

March 274.7 8.7 97% 85%April 224.1 13.4 94% 85%May 270.6 12.1 96% 85%

June 249.0 10.7 96% 85%

Average 237.8 9.6

% Removal 96%

80%82%84%86%88%90%92%94%96%

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May

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WWTP CBOD% Removal FY14% Removal

Req'd % Removal

78%80%82%84%86%88%90%92%94%96%98%

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WWTP TSS % Removal FY14 % Removal

Req'd % Removal

BIOSOLIDS PRODUCTION TOTAL

FY14 JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN FY14

DRY TONS BURNED 131 528 360 416 404.6 534.5 411 607 613 622.5 549.9 430.3 5,608

POUNDS POLYMER 1398 2271 1874 1639 1705 1805 1870 2365 2348 2090 1980 2685 24,030

LBS/PER TON POLYMER 3.2 4.3 5.2 3.9 4.1 3.4 4.5 3.9 3.8 4.1 4.5 6.2 4.3

B.F.P. FEED SOLIDS % 4.6 2.6 2.8 2.9 3.7 4.6 4.4 4.6 4.6 4.9 4.2 2.6 3.9

B.F.P. CAKE SOLIDS % 25.6 23.6 23.7 23.7 24.9 25.4 26.2 25.4 24.7 26.2 26.0 23.4 24.9

LANDFILL GAS (MCF) 0 0 0 0 0 0 0 0 0 0 0 0 0

NATURAL GAS (MCF) 1.64 2.05 1.73 1.69 1.06 1.12 1.04 1.53 1.61 1.15 1.12 1.47 1.43

FUEL OIL (GAL) 0 0 0 0 0 0 0 0 0 0 0 0 0

Dry Tons Sludge - Truck 57 0 0 0 0 0 0 0 0 0 0 0 57

Dry Tons Sludge - Nutri-Lime 0 0 0 0 0 0 0 0 0 0 0 0 0

Dry Tons - Alkaline AdMix 0 0 0 0 0 0 0 0 0 0 0 0 0

Wet Tons Nutri-Lime 0 0 0 0 0 0 0 0 0 0 0 0 0

Final Product Distr. - (DT) 0 0 0 0 0 0 0 0 0 0 0 0 0

Dry Tons Sludge - Landfill 57 0 0 0 0 0 63.7 0 0 0 0 0 121

Wet Tons Sludge - (scales) 245.5 0 0 0 0 0 214.32 0 0 0 0 0 460

METROPOLITAN SEWERAGE DISTRICT AIR EMISSIONS DATA FY 14

B.F.P. SLUDGE Removal RSC LIMITS dispersion factor = 245

METALS DATA Efficiency ug/M3 Mg/Kg JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN

ARSENIC 99.83% 0.023 298 ND ND ND ND ND ND ND ND ND ND ND ND

BERYLLIUM 99.83% 0.25 ND ND ND ND ND 0.32 ND ND ND ND ND

CADMIUM 99.89% 0.057 1,142 0.66 1.40 1.30 1.10 0.45 0.91 0.80 0.94 ND 0.75 0.97 1.10

CHROME 99.85% 0.65 9,551 17.5 27.2 23.7 28.9 25.7 35.1 25.6 35.7 35.7 40.2 46.2 33.8

COPPER 99.99% 145 238 278 265 259 263 207 204 197 214 232 265

NICKEL 99.83% 2.0 23,201 22.8 23.6 28.4 40.3 24.1 36 29.3 26.3 24.9 21.6 28.9 29.1

LEAD 99.81% 0.015 3,306 33.5 39.5 39.4 32.5 35 38.2 26.5 26.6 25.0 26.8 34.3 29.2

ZINC 99.99% 543 1220 1250 1310 1270 1190 1070 1000 968 801 1080 1270

MERCURY 25% 0.20 ND 0.010 0.16 0.06 0.06 ND ND 0.052 0.024 ND 0.05

PRESSURE DROP Venturi & Tray Scrubber 21/6 21/6 20/6 21/6 21/6 20/6 21/5 21/5 22/6 21/6 21/6 21/6

OXYGEN In Stack Gas 11.8 12.0 12.1 11.0 11.6 11.8 12.4 11.6 11.3 11.1 11.3 11.6

CARBON MONOXIDE In Stack Gas 4.9 4.4 5.1 3.6 4.9 4.3 2.7 2.3 3.0 3.0 3.5 4.4

COMBUSTION TEMP. 1502 1503 1493 1498 1503 1501 1501 1509 1516 1520 1510 1491

TONS BURNED 431 528 360 416 405 534.5 411 607 613 622.5 549.9 430

HOURS OPERATED 380 597 476 510 456 476 579 513 592 570 522 527

note - Lead limit is derived from NAAQS of 1.5ug/M3

note - dispersion factor & limits changed per 2009 emission testing & associated dispersion modeling (cooler exhaust gas temperature)