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TABLE OF CONTENTS PLANT SUMMARY 1 WPCP HISTORY PLANT OPERATIONS AND PERFORMANCE PRIMARY TREATMENT ANAEROBIC TREATMENT SECONDARY TREATMENT AEROBIC TREATMENT TERTIARY TREATMENT HYPO-CHLORINATION DE-CHLORINATION PLANT PERFORMANCE CHARTS RECEIVING STREAM TRIBUTARY POPULATION SUPERVISORY CONTROL & DATA ACQUISITION TELEMETERING PUMP STATION OPERATIONS PUBLIC RELATIONS AND MEETINGS OPERATORS CERTIFICATIONS INDUSTRIAL PRETREATMENT INDUSTRIAL PRETREATMENT INSPECTIONS DISBURSEMENT COST COMPARISON UTILITY COST COMPARISON SLUDGE DISPOSAL COST COMPARISON FLOW, COST/MG AND RAINFALL SEWER RATES AND SURCHARGES SEWER REVENUE AND DISBURSEMENTS FOR 2006 SEWER FUND CAPITAL IMPROVEMENTS DEPARTMENT GOALS AND OBJECTIVES WPCP SUMMARY The Painesville Water Pollution Control Plant protects the health of the community and environment by reclaiming the community’s wastewater. During 2006 the plant treated an average of 3.62 million gallons per day of wastewater from residential, commercial and industrial sources. From this wastewater, two recycled products were produced, clean water discharged to the Grand River and 2807 wet tons of processed biosolids, which are landfilled in the Lake County Landfill. We are proud to report that the WPCP did not report a single discharge violation for the year 2006. The WPCP has now gone two years without a discharge violation, this is a remarkable achievement when considering the requirements of analysis and reporting for the plants National Pollutant Discharge Elimination Permit (NPDES). The WPCP performs and reports nearly 4000 values that are required not to exceed permitted limits. Thanks go to a terrific staff, without which, this type of success would not be realized. Treatment of hauled septage by the WPCP completed its first full year of service in 2005. Septage haulers permitted by the WPCP, were expanded to twelve (12) in 2006. The revenue generated from these haulers totaled $117,109.00 for the year and early reports for 2007 have indicated that septage revenues will continue to increase. Management and operations of plant biosolids dewatering and disposal are performed by plant staff. Determining the most economical approach to an environmentally approved disposal practice is critical to our financial feasibility. In 2006 the WPCP hauled 2807 wet tons to the Lake County Landfill. The total cost to dispose of the plants biosolids was $80,696.00. SAFETY PROGRAM The WPCP was awarded the Burke Award which goes to one WPCP in the State of Ohio which displays a record of achievement in safety awareness. This award was presented to the plant by the Water Environment Association at the state conference in June in Columbus, OH. Water Environment Federation President, J. Michael Read presents the George W. Burke Award to Randy Bruback, WPCP Superintendent, City of Painesville. The award was presented at the OWEA 80th Annual Conference Banquet held on June 21, 2006 at the Hyatt Regency Hotel and Convention Center in Columbus, OH. The WPCP was presented two awards by the Lake County Safety Council. The first recognition was for Zero Loss Time for 2005 and additionally we were honored by the Safety Council for outstanding safety awareness programs. WPCP PERSONNEL Eric MacMichael took and passed his Wastewater III Operator’s License exam in 2006. Eric just recently left his position as an Operator I to become the new WPCP Superintendent for the City of Bellevue, OH. We wish Eric all the best in his new job. Eric MacMichael with Class III Operator’s License Going Away Party given by Plant Staff, Good Luck Eric! Craig Deakins, Operator II retired at the end of 2006. Craig had an Operator II Wastewater Operators license and had been employed with the City for 30 years. Craig was a valuable asset to the WPCP and his years of experience will be missed. Craig Deakins Retirement Party Criag with his wife Judy opening gift from plant staff. Jeff Hannan trained and passed his Commercial Drivers License exam in Willard, OH in 2006. Jeff Hannan practicing with the International 20 ton dump truck in preparation for his CDL exam. Laboratory personnel Leslie Balata and Jeff Tressel completed the DMR-QA testing and evaluation required for laboratory facilities by the USEPA. The results of the testing were that the plants laboratory analyses were in complete compliance, an outstanding achievement by both Leslie and Jeff. Jeff and Leslie have over 40 years combined experience in laboratory sampling and analysis. Both have Bachelor Degree’s in Arts and Sciences. CAPITAL IMPROVEMENT PROJECTS 1. GREENHOUSE In 2006 the construction of the new greenhouse was completed. The greenhouse now stores belt pressed biosolids, that are further dried using the solar heat generated with the design of the greenhouse. The solar heat and fans reduce the total weight of the biosolids by removing the trapped water from the solids. The WPCP staff along with employees from Public Works, Engineering, Electric Distribution and Electric Plant performed the entire construction of the greenhouse facility, including: 1. Natural Gas line installation: trenching, welding, metering and energizing 2. Electric installation: temporary, trenching, metering, conduit and energizing 3. Concrete: wall supports and floor 4. Surveying and layout 5. Building Erection 6. Site Preparation and grading 7. Heating and Ventilation 8. Computerization Future Site of Greenhouse Topsoil removed and forms set Main supports constructed Greenhouse Spans Erected Concrete Floor Completion Plastic Roof Installation Plastic Sidewalls Installed Polycarbonate End Walls, Doors, Fans Inside of Greenhouse Inside of Greenhouse 2. AERATION DIFFUSERS The replacement of existing aeration diffuser stones was completed and placed into operation. The early results of this retrofit have produced a reduction in the amount of energy required to supply air to the aeration biomass. A 300 hp motor and blower was needed to generate the required dissolved oxygen before the retrofit and after the diffusers were replaced a 200 hp motor and blower has been capable of the meeting the systems demands. Aeration Diffusers Installation of new aeration diffusers required confined space entry safety procedures. A total of over 2000 diffusers were removed and replaced by WPCP staff. 3. SODIUM HYPOCHLORINATION GENERATION REPLACEMENT Sodium Hypochlorination Generation equipment was engineering and bid in 2006. The new equipment was supplied by Severn Trent of Torrence, CA. The equipment has recently been installed by plant staff and will be ready for operation at the beginning of the chlorination season on May 1, 2007. The new system will be more energy efficient and requires less salt for the production of sodium hypochlorite. New Sodium Hypochlorination Generation Equipment 2006 FLOOD July flooding required a massive effort by plant personnel to maintain sewerage system operations and plant operations. Flooding of the Recreation Park Pump Station halted pumping operations for nearly two days. The overflow of a creek adjacent to the plant flooded the aeration basins and aerobic digester. The Grand River rose in elevation and flooded the Contact Chamber and Hypochlorination Tanks. Plant personnel worked around the clock to bring these systems back into operation and did so successfully. Training and experience played a critical role in performing these recovery tasks. Recreation Park Pump Post Aeration Tank/Grand River Station Flooding at Gristmill Apartments Grit Pumps Under Water Flooding at Gristmill Apartments Flood Debris at the WPCP Flooded Secondary Clarifiers Flooded Aeration Tanks WPCP HISTORY The Painesville Sanitary Sewer System was first developed about 1887 as a combined sewer system discharging directly to the Grand River at six (6) different locations. As the village of Painesville grew and expanded, the sewer system was expanded. At the present time there are approximately forty-five (45) miles of sanitary sewers in the Painesville Sanitary Sewer System. The service area for the Painesville Sanitary Sewer System is shown on the following page. On December 16, 1946, the Painesville City Council hired Havens & Emerson Consulting Engineers to prepare reports and plans for an Interceptor Sewer System and a Water Pollution Control Plant, which would eliminate the pollution of the Grand River. The original Painesville Water Pollution Control Plant was built as a Primary type treatment plant in 1957 by Freeman and Jones of Cleveland. The thirty-six (36) inch and thirty (30) inch interceptor sewers were constructed in 1958. Two (2) Ejector Stations and one (1) pump station together with related sewers and force mains to complete the Interceptor Sewer System were also constructed. Two (2) miles of thirty (30) inch Interceptor sewers and appurtenances were constructed by Curro-Construction Company. The Koski Construction Company of Ashtabula, Ohio constructed two (2) ejector stations and (1) pump station together with related sewers and force mains to complete the Interceptor collection system. The primary type treatment plant was placed into operation on April 4, 1958. In August 1965, intermediate chemical treatment facilities were added to the original primary treatment units. The process of feeding chloride for phosphate removal was put into operation on June 2, 1970; this was accomplished on full plant scale. In 1968, the firm of Glause, Pyle, Shomer, Burns, and Dehaven were hired as the Consulting Engineers for a plant expansion. Phase I of the expansion was completed in February 1973. This included the new Administration Building, which was attached to the old building. Phase II was never accomplished with the aforementioned engineering firm. Burgess & Niple, Ltd. was then hired on February 18, 1973, to plan and design the construction of an activated sludge plant, followed with tertiary filters. On July 6, 1973, the City authorized the preparation of detailed plants and specifications for wastewater treatment facilities in accordance with the general plants that were approved by the Ohio EPA, February 7, 1973. These plans would provide additional grit removal and comminution, additional primary settling, first stage aeration tanks and settling for carbonaceous biochemical oxygen demand reduction, second stage aeration tanks and settling for ammonia- nitrogen reduction, tertiary filters, post aeration, hypo-chlorination, aerobic digesters, sludge dewatering, additional anaerobic capacity, and facilities for feeding chemicals for phosphorus reduction. The facilities would have an average daily capacity of six (6) million gallons per day for ultimate treatment, a daily peak capacity of fifteen (15) millions gallons per day and a maximum hydraulic capacity of twenty-eight (28) million gallons per day. The facility would be designed so the average daily treatment capacity can be expanded to twelve (12) million gallons per day with a peak flow of twenty-eight (28) million gallons per day. The facility, as designed would include the best available control technology economically available. After development of a facilities plan for the Painesville-Fairport Harbor Area, federally funded construction contracts for the secondary and tertiary treatment facilities at the Painesville Water Pollution Control Plant were signed on June 24, 1976. Groundbreaking ceremonies were held on July 6, 1976. Bay Con Construction Company of Sandusky, Ohio was the general contractor. Improvements were made to the grit facility, primary treatment, and anaerobic sludge facilities. New facilities include two-stage aeration secondary, tertiary filters, and post aeration/ hypo-chlorination facilities. The firm of Burgess & Niple Ltd., was contracted on August 15, 1997 to prepare detailed plans to construct a new Sludge handling Facility at the Water Pollution Control Plant. This facility included a new 1.5 meter Filter Press and all the necessary appurtenances for the process of aerobic and anaerobic sludge’s. Bids for this project were advertised on October 15, 1998, and the tabulation of bids were received and opened on October 29, 1998. The successful bidder was ABC Piping Company on November 13, 1998 in the amount of $817,390.00. The completion date of this project was 270 Days or September 13, 1999. VALUATION The original treatment plant was built at a cost of $807,904.80 in 1957. The 1958 improvements to the Water Pollution Control System cost nearly $1,600,000.00. The 1973 expansion, at a cost of $530,000.00, bringing the estimated value of the Painesville Wastewater Treatment System to $7,060,006.00. The cost of the 1976 expansion was $11,305,382.17 and the addition of the Sludge Handling Building in 1998 at a cost of $817,390.00, bringing the estimated value of the Painesville Water Pollution Control Plant, seven (7) pump stations, and collection system of $22,317,390.00. WATER POLLUTION CONTROL PLANT SERVICE AREA PLANT OPERATIONS & PERFORMANCE In 2006, the City of Painesville Water Pollution Control Plant ran very efficiently treating 1.324 billion gallons of wastewater. The average daily flow of wastewater through the plant was 3.62 million gallons. The raw 5-day biochemical oxygen demand (B.O.D.) into the facility was 180 mg/l daily. The final daily average B.O.D. was 2 mg/l, which represents a 99.07% reduction. The daily average influent concentration of suspended solids (S.S.) was 256 mg/l in 2006. The S.S. was reduced by 98.86% to 3 mg/l by treatment in the plant. The average daily influent concentration of phosphates were 3.86 mg/l. This was reduced to 0.36 mg/l, which represents a _____% reduction. The daily average influent concentration of nitrogen into the facility was _____ mg/l. This was reduced to _____ mg/l. During the period of January 1, 2006 through December 31, 2006, the WPCP processed and pressed 580,832 gallons of Anaerobic Sludge, 3,981,907 gallons of Aerobic Sludge for a total of 4,486,978 gallons. This produced _____ wet tons and _____ tons of dry solids. PRIMARY TREATMENT The Vulcan Step Screen which is used to remove debris and rags has performed as designed. During the year the Plant removed _____ cubic yards of screenings. The detritors removed _____ tons of grit. The screenings and grit were both disposed of at the Lake County Landfill. Chemical treatment for phosphorus removal using Liquid Aluminum Sulfate, required 291,328 pounds of Aluminum Sulfate at a cost of $0.090 per pound or $26,152 for 2006. The Annual Gallons of raw influent records for the past 10 years are presented below. Treated Flow - Billion Gallons 2 1.61 1.5 1.32 1.16 1.16 1.09 1.16 1 0.85 0.85 0.99 0.96 0.5 0 2006 2004 2002 2000 1998 years The cost of operation and maintenance for the Water Pollution Control Plant, collection system and administration total was $______ for 2006. This results in a unit cost of $______ per million gallons treated. The three (3) Primary Settling Tanks operated satisfactory during 2006 and recorded performance levels of 98.86% removal of suspended solids and removal of 5-day B.O.D. A total of gallons of sludge was removed from the primary settling tanks and transferred to the anaerobic digesters. Raw Sludge was pumped at an average concentration of _____% solids. ANAEROBIC DIGESTERS ANAEROBIC DIGESTERS The No.1 Primary Digester and the No. 1 Secondary Digester operated satisfactorily during the year. The No. 2 Primary Digester was returned to service after a year of construction. The primary digester received sludge from the primary settling tanks. After digestion, the sludge is then pumped to the secondary digester. The main function of the secondary digester is to produce a settle sludge that is well stabilized. The liquid sludge is then removed from the secondary digester, pressed and sent to the landfill. The digesters received ________ gallons or ________ gallons per day of ________ solids during the year. The sludge contained an average ________% fresh solids volatile matter of ________% and an average fresh solids fixed matter of _______% The volatile matter reduction for the year was ________% The average temperature of the digester during the year was _____ degrees Fahrenheit and ________ gallons of anaerobic digested sludge was mixed with ________ gallons of aerobic sludge and sent to the landfill for disposal. SECONDARY TREATMENT Secondary treatment consists of the single stage aeration basins and the final settling tanks. The units of the secondary treatment process functioned properly during the year, single stage aeration now in its second full year of operation, performed very well. The purpose of secondary treatment is for the oxidation of carbonaceous B.O.D. and ammonia nitrogen. The nitrifying organisms oxidize the ammonia nitrogen into the nitrate form. The settling tanks are used for the removal of solids generated in the aeration process and the return sludge pumps are used to control the amount of solids, or food for the micro-organisms in the aeration basins. AERATION BASINS Return sludge is collected in the final tanks and returned to the aeration process. The average daily return sludge rate from the final settling tank was ________ MGD with ________ gallons of sludge wasted daily to the aerobic digesters. SECONDARY SETTLING TANKS AEROBIC DIGESTERS Aerobic digestion is a sludge processing technique used to oxidize sludge organics to stable end products, reduce mass and volume of sludge, condition sludge and further solids handling. In aerobic digestion, the principal materials being oxidized include cellular organics and ammonia. AEROBIC DIGESTERS During the year, the three aerobic digesters received ______ gallons of sludge from the final settling tanks. _____ gallons of liquid aerobic sludge, gallons of water plant sludge along with gallons of anaerobic sludge were filter pressed and sent to landfill disposal. The sludge produced tons of wet cake containing solids or tons of dry solids. The cost of pressing and disposing of this year’s liquid sludge was $ or $ per dry ton. FILTER PRESS TERTIARY TREATMENT The Tertiary filtration or third level of treatment is provided by four gravity “mixed” media coal & sand filters. These filters are used to polish the secondary effluent by filtering suspended solids from the waste-water. The tertiary filters boost the achieved treatment to an average treatment level of removal of B.O.D.; removal of suspended solids; and removal of phosphates. TERTIARY FILTERS TERTIARY SCREW HYPO-CHLORINATION During the year pounds of evaporated salt was used in the production of pounds of useable chlorine. The average chlorine residual in the effluent was mg/l The Hypo-Chlorination of wastewater was instituted only during the periods of our N.P.D.E.S Permit. HYPO-CHLORINATION SYSTEM DE-CHLORINATION Dechlorination of the plant’s effluent started on May 1, 2006 and ceased on October 31, 2006, as per our N.P.D.E.S. Permit. This process is accomplished by the addition of Sodium Bi-Sulfate to the effluent. During the year 8152 pounds of Sodium Bi-Sulfate was applied to the plant’s effluent to maintain a chlorine residual of 0.038mg/l or less. DE-CHLORINATION SYSTEM ADDITIONAL PLANT PERFORMANCE RECORDS The Bar graphs below illustrate the levels of suspended solids, biological oxygen demand, phosphates, and nitrogen present in the influent (raw) and the effluent (final) at the Painesville Water Pollution Control Plant for the previous ten years. RECEIVING STREAM The plant effluent is introduced into the Grand River about 2 miles from the mouth as it enters into Lake Erie. The average B.O.D. of the above plant stream was 1.6 mg/l for the year and the D.O. was 9.6 mg/l. The B.O.D. of the below plant stream was 1.3 mg/l and the D.O. was 9.9 mg/l. The average phosphorus of the above plant stream samples were 0.11 mg/l and the average phosphorus below stream was 0.09 mg/l. The drainage area of the mouth of the Grand River is 712 square miles. The annual rainfall at the plant during the year was 30.4 inches. The estimated annual flow of the Grand River is 336,448 million gallons, and the Painesville Water Pollution Control Plant’s annual flow was 1156.4 MG. This represents 1/291th of the Grand River’s flow on an annual basis. Receiving stream samples were taken from two locations on the Grand River during the year. They are taken once a month for the entire year at the St. Clair Street Bridge and the Main Street Bridge. Dissolved Oxygen tests, Biochemical Oxygen demand tests, and Phosphate tests were run along with temperatures. The results of the receiving stream sampling are presented in the following table: TRIBUTARY POPULATION During 2005 the average daily flow at the plant was 3.17 million gallons per day. The 2000 census recorded 17,603 residents in the City of Painesville. The Painesville Water Pollution Control Plant now serves an estimated 18,500 people. SUPERVISORY CONTROL & DATA AQUISITON SYSTEM The WPCP engineered, designed and installed a new SCADA system in 2004. The SCADA system is replacing the existing control panel with new computer technology that monitors and controls plant operations. Wireless Ethernet allows communications for the SCADA system vs. cable. Future plans will incorporate the control of plant systems from a single computer. TELEMETERING In 1962 no instruments were found to be adaptable to telemetering ejector and pump station information to the Water Pollution Control Plant. Accordingly, the plant personnel designed, built, and installed pilot telemetering equipment operated over leased phone lines. The telemetering system sends information indicating when the pumps are operating. The latest plant improvements provided new transmitting equipment at each pump station. This equipment transmits information back to the plant where it is displayed on the display board and the SCADA System in the control room. CONTROL PANEL FOR CENTRALIZED HEADING & ADJUSTMENTS PUMP STATION OPERATIONS Sanford Street Pump Station - is a dual non-clog submersible pump system, with two 250 GPM Flygt pumps. This station operated 790.4 hours during the year and pumped 11,856,000 Gallons of wastewater. Jackson Street Pump Station - is a single self-priming horizontal unit installed in a wet well. The telemetering lines were connected to this station on January 25, 1964. This station has performed satisfactory during the year, recording 386.7 hours and pumped 7,596,610 gallons of wastewater. New construction for the Jackson Street Pump Station was completed in 2005. The new pump station is now located out of the street to prevent safety concerns. The new station was built using Issue II funding. The wet well has two new Flygt pumps, control system and dry pit valves. Recreation Park Pump Station - is a dual pot centrifugal pump installed with a manually clean bar rack. The telemetering equipment was put into service on October 25, 1963. This pump recorded 1,315.8 hours and pumped 23,684,400 gallons of wastewater during the year. Valleyview Pump Station - is a dual non-clog submersible pump system, with two 124 GPM Flygt pumps with a mix-flush system. This station operated 245.5 hours during the year and pumped 2,651,400 gallons of wastewater. Erie Street Pump Station - the upgrading of this station includes two 100 gal/min. Flygt pumps, a wet well, valve box, and electrical equipment. This was completed on October 16, 1998, and returned to service. This station recorded 1,829.5 hours and pumped 9,977,600 gallons of wastewater during the year. Fern Drive Pump Station - is a dual non-clog submersible pump system, with two 220 GPM Myers pumps. This station pumps wastewater under State Route 44. The instrumentation indicates this station recorded 586.3 hours and pumped 7,739,160 gallons of wastewater during the year. Heisley Park Pump Station - was put into operation on April 2, 2004. This station is a dual non-clog submersible pump system with two 180 GPM Flygt Pumps with a mix flush system. This station operated 308.0 hours during the year and pumped 10,059,840 gallons of wastewater. Brookstone Meter PUBLIC RELATIONS AND MEETINGS January Jeff Hannan was hired on January 30th for the Mechanic/Mechanic position. Nine WPCP employees attended the NEOWEA Operator’s seminar in Canton, OH. An Automatic External Defibrillator was installed in the Administration building. All plant employees will be trained to use the equipment. A safety inspector from PERP was requested by Safety Coordinator, Russ Thompson ,to visit the plant to inspect for safety violations, so that the plant may address any potential violations. Randy Bruback met with Mike Murphy of Bergen & Assoc, to discuss the new sodium hypochlorination equipment. Randy, Tom Green, Bill Vargyas, and Paul Morton, met to discuss the Machinery Maintenance Committee direction for 2006. Supervisory staff at the WPCP met with Art Kimpton and Dan Moss of Burgess & Niple to discuss 2006 capital projects. Operational staff from the Caldwell, OH were at the plant at observe operation of the Vulcan Step Screen. Randy, Paul Morton, Bill Vargyas, and Tom Simko met to discuss residual processing and disposal options. February Metcalf & Eddy Engineering was hired for the sodium hypochlorite generation equipment replacement project. Randy met with Tina Wolff and Foster McMasters to discuss the project. Joe Jackson met with Tim Winegard, Fairbanks Morse Pumps, to discuss the pump replacement proposal for No. 4 Return Activated Sludge Pump. Randy and Joe Jackson attended a seminar on Asset Management hosted by Estabrook Inc. March CPR and First Aid Training was done by the American Red Cross for WPCP staff. Prime Solutions, a manufacturer of a Rotary Fan Press was at the WPCP for 3 days to determine the performance of their equipment design. Randy met with Malcolm Pirnie Engineers to discuss Capital Projects for the next 5 years. Randy met with Metcalf & Eddy engineers to discuss the sodium hypochlorination project. Randy and Joe Jackson met with Chris Buck of Estabrook to do discuss coating options for the tertiary screw pumps. Randy met with Ed Pelton and Bill Kolens to discuss the aeration diffuser’s replacement project. April Excavation of the site for the Greenhouse project began. The WPCP was the winner in the Public Works Category for its outstanding safety program at the Lake County Safety Council. The plant was also awarded the government safety award for zero lost time in in 2005. A training event was held for the new AED. Fire extinguisher training was done at the WPCP. WPCP staff met with Cabrera, Army Corps of Engineers, OEPA, and Lake County Utilities to determine the best possible solution in cleaning a radioactive contaminated site on the Diamond Shamrock property. Public Works and Engineering personnel met at the WPCP to discuss construction of the Greenhouse. May Randy met with Metcalf & Eddy engineers to discuss the sodium hypochlorination bid proposals. The WPCP and Electric Plant sponsored the Lake County Safety Council meeting at the LaMalfa Party Center in Mentor. Randy and Jeff Tressel met with the Army Corps of Engineers, OEPA, Lake County Utilities and Cabrerra to discuss remediation at the Diamond Shamrock site. Johnson Controls was at the WPCP to review the plant’s heating and air conditioning units. Harvey H.S. Environmental class was given a plant tour. June The greenhouse foundation has been set and the greenhouse framework has begun. Randy met with Randy Drazba, CH2M Hill, environmental engineer to discuss future capital projects. Joe Jackson and Terry Haffey met with Cuyahoga County officials to aid them in troubleshooting of their chlorine injection equipment. Severn Trent was awarded the bid for the new hypochlorination system. Eric MacMichael successfully passed his Class II Wastewater Operator’s license exam. Randy, Joe Jackson, and Joe Elliott attended the OWEA State Conference. The WPCP was awarded the Burke award from the OWEA for outstanding safety program awareness and application. The Operating Engineers and AFL-CIO contracts were approved. Estabrook held a workshop for WPCP and Lake Co. wastewater employees on pump packing and equipment coatings. Scott Aston was hired for temporary summer help. July On July 27-28 the city experienced a rainfall of 15 inches. Flooding occurred at the WPCP and throughout the city. The WPCP experienced flooding from the creek and Grand River. Aerobic Digesters, Aeration Basins, Chlorine Contact Tanks, the Blower Building Basement, and Recreation Park Pump Station all experienced flooding. WPCP plant personnel assisted city crews with cleanup and pumping operations throughout the city. Randy attended a BWC Bloodborne Pathogens training event in Cambridge, OH. Randy and Joe Jackson met with Estabrook to discuss the ceramic coating options for the tertiary screw pumps. August WPCP employees continued assisting city crews in the cleanup of the flood aftermath. The News-Herald interviewed Randy Bruback on the use of jail inmates to assist in the flood cleanup. Art Kimpton of Burgess & Niple visited the WPCP to observe the concrete cracks in the upper control chamber of the Anaerobic Digester building. Randy, Rita McMahon, Tom Green, and Lee Homyock, met with Johnson Controls to discuss energy conservation study results. Randy met with Paul Matraka of Komline-Sanderson to discuss sludge drying equipment and design. Randy and Joe Jackson met with Loy instruments to discuss metering options for the meter room. Randy met with Sean Aken, of CT Consultants to discuss the Lakeview Bluff’s Development. Randy and Joe Jackson had a conference call with METONE Weather Stations on the proposed new weather station for the 2007 budget. Randy and Joe Jackson met with Rita McMahon to discuss the Lakeview Bluffs Development and its impact on the City’s 208 plan for sewer service to the affected area. Thermograph testing was performed on plant electrical equipment. September Joe Jackson attended an Intellusion Seminar in Put-In-Bay, OH. A mock emergency evacuation drill was performed at the WPCP. A sound analysis was performed at the plant by a BWC safety rep. to evaluate the possible need for hearing protection in some buildings. Personnel from Cleveland’s Easterly WWTP visited the plant to observe our Vulcan Step Screen and Compactor. Heinz Goetz, a former technician at Roediger Press, was at the WPCP to service the plants belt press. Roediger Press is no longer in business. October Randy met with Rita McMahon to review the 2007 Annual Budget for the WPCP. Randy met with Johnson Controls to discuss energy conservation projects. WPCP personnel pumped out Gristmill basements. Randy met with Kevin Lynch to discuss FEMA flood forms to submitted for recovery of flood expenses. November Randy and Joe Jackson met with Glen Heitkamp and Tom Castro of Johnson Controls to discuss energy projects. Randy met with Jerry Livergood, of Orwell Gas to review gas well ideas for the WPCP. Light plant personnel assisted WPCP personnel with installation of the electrical and gas lines for the Greenhouse. Plant personnel attended a NESOWEA seminar at Westerly WWTP. Randy met with Rita McMahon to discuss long term debt options for future WPCP capital projects. Randy met with Mike Rustifo to discuss the possible training options for a Wastewater I license program. Eric MacMichael passed his Class III Wastewater Operators exam. December Randy met with Metcalf & Eddy Engineers to review the sodium hypochlorite equipment replacement project. Chris Moody, of the OEPA, performed an audit on the city’s Sludge Management Program. Johnson Controls visited the WPCP throughout December to perform evaluations of future energy saving projects. Randy met with Rita McMahon and Department Heads to discuss funding for repairs and replacement of damaged equipment due to the July 2006 flood. Craig Deakins, Operator II, retired after 30 years of service . OPERATOR’S CERTIFICATIONS When the plant was put into operation in 1958, only one Class “C” certified operator was employed, with a 4-man crew 8-hour operation. We now have 19 people and operate 24 hours a day, Monday-Friday and 16 hours on Saturday and Sunday. The following men and women have received certification from the Ohio EPA after a very concentrated effort in school, night classes, sectional meetings & seminars. This not only helps the individuals, it also aids the City by having a well-operated & maintained Water Pollution Control Plant. 1. Randy Bruback Class IV Superintendent 2. Jeffrey Tressel Class III Lab Supervisor 3. Joseph Jackson Class I Maintenance Supervisor 4. Joseph Elliott Class III Operations Supervisor 5. Craig Deakins Class II Operator II 6. Russ Thompson Class I Operator II 7. James Davidson Class III Operator II 8. Michael Darosy Class III Operator II 9. John Caldwell Class I Operator II 10. David Sudbrook Class I Operator I 11. James Boykin Class I Operator I 12. Gerald Skaggs Class II Operator I 13. Eric MacMichael Class III Operator I 14. Timothy Leonard Class I Operator I 15. Leslie Balata Class II Lab Technician I 16. Edward Prib Class I Maintenance Mechanic I 17. Terry Haffey **** Mechanic/Electrician 18. Jeffrey Hannan **** Maintenance Mechanic II 19. Carol Kappel **** Secretary I Randy Bruback also has a Class I Laboratory Analyst Certificate and Jeffrey Tressel has a Class IV Laboratory Analyst Certificate. INDUSTRIAL PRETREATMENT Findings and orders were received June 6, 1983 directing the City to begin development of their Industrial Pretreatment Program. Upon receipt of these findings and orders, Burgess & Niple Limited, began the Industrial Inventory portion of the program. One hundred and fifty-five (155) survey questionnaires were sent out to commercial and industrial establishments within the City of Painesville service area. By May 1984, 100 percent of the questionnaires were returned. The questionnaires were reviewed and the industries were classified as Significant Major, Significant Minor, and Not Significant. These classifications were based upon definitions stated for each. The Standard Industrial Classifications (SIC) Codes were assigned to industries which did not list a SIC code on the questionnaire. Non-categorical industries were included to help Painesville establish a total Industrial monitoring program and surcharging program. The Inventory data was presented in the Phase I, Volume I, Summary of Industrial Waste Survey Information. This report was approved by the Ohio EPA on March 12, 1984. Technical data regarding the operation of the Painesville Water Pollution Control Plant were discussed in the Phase I, Volume II, and Technical Information Report. During this portion of the program development, Environmental Research Group, Inc. was used to perform Laboratory analysis with GC/MS. Their analysis and all analysis performed by Burgess & Niple, Limited and the personnel at the Water Pollution Control Plant were performed using U.S. EPA sampling and analytical procedures set forth in 40 CFR Part 136. The Technical information submittal received Ohio EPA approval on May 18, 1984. The operational data of the Painesville Water Pollution Control Plant was used to determine maximum allowable influent limitations to the Water Pollution Control Plant. The limitation based upon N.P.D.E.S. Permit limitations; land application of sludge limitations; Grand River water quality limitations, and operational limitations for the Water Pollution Control Plant. These limitations were then compared with sampling results obtained during Phase II to determine maximum limitations for the Industrial discharges. The legal evaluation of Phase I was presented in Phase I, Volume III, Legal Evaluation. This portion was a review of the existing Sewer Use Ordinance for the City. The existing ordinance was found to be adequate in areas of limitations of parameters to be discharged by industries, however, it was lacking in areas regarding the monitoring and enforcement of the proposed pretreatment program. Areas of concern, as addressed in the EPA model ordinance, were added by the Ohio EPA as per their letter of August 3, 1984, and City Council passed legislation on September 4, 1984, to accept the proposed Ordinance. The monitoring/enforcement program was developed during Phase II of the Pretreatment Development Program. A program was developed and equipment listed to perform the required work for enforcement of the regulations. Non-Categorical Industries were included in the program to help the City develop a total sampling program. The monitoring program includes scheduled and demand monitoring procedures, a tracking and filing system, procedures to notify industries of existing and newly promulgated standards discharge limitations, and other requirements and self-monitoring procedures for industries. An evaluation of financial programs, personnel, equipment, and laboratory needs were also performed during the preparation of the Phase II report. This portion of the report determined estimated costs that would be passed on to the industry for sampling required. It was determined additional personnel would not be required, however, additional equipment would be needed to perform the ongoing sampling. The final Program Report was submitted to the Ohio EPA for approval on October 10, 1984. Ohio EPA public noticed the Industrial Pretreatment Program on May 21, 1985, for comments. The Final Program received approval from the Ohio EPA on July 2, 1985. Since the time of final approval, all industries have been notified of the requirements for their discharge. Agreements have been signed with Avery Dennison, Cintas, Eckart America, Kinedyne, Lubrizol Corporation, Meritec Plating, and Painesville Municipal Electric Plant. The financial program, personnel, equipment, and laboratory needs are constantly evaluated to determine estimated costs that would be passed on to each industry to support the pretreatment budget and staffing levels. The total industry base that discharges to the treatment plant has changed very little since the incorporation of the pretreatment program. Therefore, the budget and staffing levels have remained unchanged throughout the past year. The National Pollutant Discharge Elimination System (NPDES) Permit issued by the Ohio EPA required a Local Limit Evaluation. This evaluation is to ensure that the permittee can attain compliance with final table limits. A technical justification for revising local industrial user limitations, along with a pretreatment program modification request, was submitted to the Ohio EPA. This technical justification included: Domestic/background and industrial pollutant contributions Treatment plant removal efficiencies A comparison of maximum allowable headworks loading based on all applicable criteria; including sludge disposal, NPDES permit limits, interface with plant biological processes Method used for allocating available pollutant loads to industrial users Supporting data, assumptions and methodologies used in establishing the information above. The Ohio EPA reviewed the Pretreatment Program Modification—Local Industrial Discharge Limitations Technical Justification and gave final approval on August 31, 2004. The Painesville Water Pollution Control Plant has been very successful treating all Industrial wastes and has not experienced any major problems due to industrial effluent. Meritec Plating, a company that produces circuit board connectors, is classified as a Categorical Industry because of their electroplating operation. Annual and semi-annual monitoring showed compliance with Local and Federal limitations. The Painesville Municipal Electric Plant was changed to a Significant Industrial User classification. This was done when inspections and sampling revealed violations with the City’s Sewer Use Ordinance and newly discovered sewer lines. The engineering firm of Burgess & Niple, Limited, has been contracted to evaluate and design a pretreatment system to bring the Electric Plant into compliance. Routine compliance monitoring during 2006 showed sampling compliance. Avery Dennison Fasson FFD and STD were determined to be non-categorical industries and were reclassified as a Significant Minor Industry. They will continue to be monitored for B.O.D., S.S., TKN, and phenols for the purpose of surcharges. Eckart America is a Non-Categorical Industry, however, their discharge contains a high concentration of copper and zinc. They had redesigned and installed a pretreatment system to remove the excess pollutants. Periodic sampling showed compliance with copper and zinc. Lubrizol Corporation is a Categorical Industry and performs self-monitoring on a quarterly basis. They installed a 2.5 million dollar upgrade of their pretreatment system for their water management program and compliance with the newly promulgated rulings concerning organic chemical manufacturers. Annual and Quarterly monitoring showed compliance with Local and Federal limitations. Kinedyne is a categorical industry. They manufacture and powder coat slotted steel rails which are used in semi-tractor trailers. Annual and semi-annual monitoring showed compliance. Cintas is a non-categorical industry, but due to their high volume of wastewater discharge, they are classified as a Significant Industrial User. Compliance sampling showed numerous violations. They were issued a compliance schedule that included installation of a pretreatment system. The system has been installed and placed into operation on January 5, 2005. Sampling events still showed violations of pH and zinc. Several meetings took place with CINTAS and their pretreatment chemical supplier. Adjustments were made to the chemicals and dosage rates. The October sampling results displayed compliance with local limits. INDUSTRIAL PRETREATMENT INSPECTIONS Avery Dennison FFD Avery Dennison STD Cintas Eckart America Kinedyne Lubrizol Corporation Meritec Plating Painesville Municipal Electric Plant DISBURSEMENT COST COMPARISONS The following table and graph shows a cost comparison of the total disbursements for the Water Pollution Control Plant. The Sewer Collection System, and Administration Cost over the past 10 years. YEAR TOTAL COST 2006 $ 2005 $2,950,871.00 2004 $3,025,757.78 2003 $3,178,145.14 2002 $3,548,714.61 2001 $3,089,308.85 2000 $2,873,678.92 1999 $3,098,512.98 1998 $3,314,147.04 1997 $3,292,539.44 1996 $3,196,428.70 UTILITY COST COMPARISONS One of the major expenses in the Painesville Water Pollution Control Plant Budget on an annual basis is Electrical Costs. The following table and graph show the yearly cost for Electricity used over a ten year period. YEAR TOTAL COST 2006 $ 2005 $196,382.00 2004 $246,459.00 2003 $274,009.07 2002 $287,382.79 2001 $173,664.85 2000 $179,924.26 1999 $160,254,66 1998 $147,545.02 1997 $150,561.42 SLUDGE DISPOSAL COST COMPARISON The following table and graph shows the cost of removing liquid digested sludge from the plant over the last ten years. YEAR GALLONS TOTAL COST 2006 $ 2005 6,344,336 $99,451.00 2004 6,078,247 $194,423.68 2003 6,065,200 $168,081.20 2002 6,935,892 $155,758.30 2001 4,248,391 $101,461.30 2000 3,022,500 $ 94,014.14 1999 4,318,303 $134,731.00 1998 3,969,710 $121,097.88 1997 5,714,700 $169,159.77 FLOW, COST/MG AND RAINFALL The following table shows the annual flows treated by the Plant, the cost per million gallons for treatment and the Annual rainfall at the facility during the last ten (10) years. YEAR FLOW TREATED COST/MG ANNUAL RAINFALL 2006 MG $ Inches 2005 1,156.37 MG $2553.00 30.40 Inches 2004 1,157.76 MG $2613.00 50.50 Inches 2003 1,091.43 MG $2913.00 58.90 Inches 2002 1,000.63 MG $3545.00 31.42 Inches 2001 847.32 MG $3647.00 36.98 Inches 2000 989.29 MG $2906.00 37.77 Inches 1999 964.05 MG $3214.00 44.41 Inches 1998 1,161.00 MG $2855.00 37.99 Inches 1997 1,612.27 MG $2043.00 38.58 Inches SEWER RATES AND SURCHARGES SEWER SERVICE RATE A new service rate system was adopted on May 3, 1993. Due to the increase in the cost of equipment and materials, it was necessary to revise the sewer rates. This rate is based on water consumption and reads as follows: $3.69/100 cubic ft with a minimum usage of 400 cubic feet. The charge per 100 cubic feet includes $3.17 per 100 cubic ft for operation and maintenance and $0.52 per 100 cubic ft for debt service. The City Manager is obligated to review the sewer service charges annually and recommend appropriate changes thereto; to become effective on May 1st of each year. SEWER USE SURCHARGE The Sewer use surcharge program was started by plant personnel as per the EPA Grant conditions to assist in recovery costs from dischargers who discharge higher than normal concentrations of pollutants. The surcharge program by definition is a means to recover the proportional share of the cost to treat pollutants. Annually the plant personnel establish the normal domestic strength waste entering the plant and determine the cost to treat the pollutants. Presently, the surcharge pollutants are: Biological oxygen demand (BOD), Suspended Solids (SS), phenols, and total Kjeldahl Nitrogen (TKN) . On May 1, 2005 the surcharge rates were established as follows: BOD, $0.361 per pound per day; S.S., $0.263 per pound per day; phenols, $0.361 per pound per day; and TKN $0.430 per pound per day. Industries whom choose to install and maintain meters to record their wastewater discharge are not charged for sewer service based on water consumption but on actual quantity discharged. This rate is equal to the water consumption rate of $3.69 per 100 cubic feet or $4.92 per 1000 gallons. Industries sampled for surcharges during 2005 were: Cintas Corporation, Lubrizol Corporation, Fasson STD, and Fasson FSD and Lake East Hospital. The program generated $41,002.39 in extra revenues during 2005. A breakdown of the surcharges are as follows: Cintas $32,455.36 Lubrizol $3,094.06 Avery Dennison FFD $449.39 Avery Dennison FDS $352.43 Lake East Hospital $4651.15 TOTAL $41,002.39 2006 SEWER REVENUES AND DISBURSEMENTS Revenues: Sewer Service Charges (Reg.) $ Service Charges (Contract) $ Sewer Service Charges (Septic) $ Sewer Tap-In Connections $ Late Payment Fees $ Interest $ Refund/Reimbursements (Operating/Non-Operating) $ Other-Miscellaneous $ Proceeds from Capital Lease $ Total Sewer Revenue Fund $ Disbursements: Administration (721) - Personal Services $ - Others $ TOTAL $ Utilities Office (722) - Personal Services $ - Others $ TOTAL $ Supervision (Plant & System) (723) - Personal Services $ - Others $ TOTAL $ Plant & Pumping Operations (724) - Personal Services $ - Others $ TOTAL $ Collection & Transmission (725) - Personal Services $ - Others $ TOTAL $ Sewer Equipment-O&M (726) $ Total Insurance & Misc. Contracts (729) $ Debt Services: Debt Service-Revenue Supported (803) $ Debt Service-Other (805) $ Other Non-Operating Expenses (902) $ Transfers-Out (910) $ TOTAL $ Grand Total Sewer Fund Disbursements $ Reserves Reserve-Emergency/Contingency $ SEWER FUND CAPITAL IMPROVEMENTS UTILITIES OFFICE (151-722) Legal Services $ Others $ TOTAL $ SANITARY SEWER IMPROVEMENT (793) Architectural/Engineering $ Infrastructure Improvements $ TOTAL $ WATER POLLUTION CONTROL IMPROVEMENTS (798) Architectural/Engineering $ Infrastructure Improvements $ Motor Vehicles $ Other Equipment $ TOTAL $ DEBT SERVICE-OTHER (805) Note Principal Retirement $ Note Interest $ TOTAL $ EQUIPMENT/MACHINERY (902) Equipment/Machinery $ TRANSFERS-OUT (910) Transfer To General Fund $ Transfer To Storm Water $ SEWER CONSTRUCTION FUND (722) GRAND TOTAL $ DEPARTMENT GOALS AND OBJECTIVES Major Departmental Goals and Objectives Strategic Goal #1 Stewardship Departmental Objectives a. Greenhouse Operation Operate new greenhouse to remove trapped water through the process of evaporation. The new greenhouse will permit extended storage periods of time for pressed biosolids. In turn the design of the greenhouse will evaporate water from the biosolids, reducing the wet tonnage cost for landfilling. b. Aeration Blower Operation New aeration diffusers will improve the oxygen transfer efficiency within the aeration tank biomass. Reduced energy cost to operate the blowers, which supply air to the aeration diffusers. c. Natural Gas Well Natural gas prices have remained volatile and costs have increased over 40% in the last year. The Ohio Department of Natural Resources requires 20 acres of property to drill a natural gas well. The WPCP has 21+ acres and we will explore the feasibility of placing a natural gas well on plant properties. Strategic Goal #2 Communication Departmental Objectives a. Employee Evaluations Perform employee evaluations on department employees. b. Civic Organizations Become involved in a civic organization within the City of Painesville. Strategic Goal #3 Revitalization Departmental Objectives a. Image Enhancement Promote and publicize the WPCP’s effluent loadings to the Grand River. The design of Painesville’s WPCP, that includes tertiary treatment (sand filters), removes solids and metals far below OEPA effluent standards. The effluent discharged into the Grand River enhances the water quality biological assemblage.
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