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GLOVERSVILLE-JOHNSTOWN
Joint Wastewater Treatment Facilities
2007 Joint Sewer Board
David Thum, Chairman
Lee A. Mitchell
Richard A. Handy
John Blackmon
Frank Malagisi
Sal Giarrizzo
INTRODUCTION
This report has been
prepared by the staff of the Gloversville-Johnstown Joint Wastewater
Treatment Facility (GJJWTF) to highlight significant projects
completed at the facility during 2007.
Routine assignments such as tank cleaning, instrument calibration,
laboratory analysis, sample collection,
general maintenance and upkeep, while important, are not identified
in this report. Some general statistics
have also been included to illustrate the facility’s activities.
The success of the facility
in 2007 is because of the continued support of the
Gloversville-Johnstown Joint Sewer Board
(GJJSB) and the hard work of all twenty-five (25) employees.
Without the effort of the workers needed during the day, on nights, on
weekends, on holidays, during severe weather
and typically in an inhospitable environment, this facility would not be
able to function or meet its wastewater discharge SPDES permit. I
wish to thank all employees for their efforts
in 2007 to make the wastewater treatment facility function properly for
all of our customers. The names of employees,
(as of 12/31/07), are as follows:
|
Victor Acquilla |
Stephen Craig |
William
Ratajczak |
|
Michael Albanese |
Jim Davis |
Donna Renda |
|
Barb Allen |
Robert Henze |
William Rowback |
|
Tom Ambrosino |
Tim Hutchinson |
Hilary Ruzycky |
|
Ricky Barnett |
Brian Jennings |
Sandra Tallon |
|
Rick Barnholt |
Jason Kohout |
Rich VanNostrand |
|
Ken Bray |
Dave Malagisi |
Richard Wager |
|
Joe Cellary |
Richard Pedrick |
|
|
Paul Christman |
Richard Praetorius |
|
Once again, all employees
exhibited a great effort during the past year.
PERSONNEL
Stephen Craig was
appointed to a vacant WTP Attendant position effective January 2, 2007.
Ricky Barnett was
promoted to Sr. WTP Maintenance Mechanic on December 3, 2007 to fill the
vacancy created by a previous resignation.
Several staff members
obtained Wastewater Treatment Plant Operator Renewal Certification from
New York State Department of Environmental Conservation (NYSDEC). The
total number of NYSDEC license holders at this facility totals ten (10).
A union contract
effective from January 2007 through December 2010 was successfully
negotiated with employees.
Eight (8) employees
utilized less than three (3) sick days during 2007. The names of those
employees are as follows:
Ricky Barnett (zero hours
used)
Richard Barnholt
Joseph Cellary
Paul Christman
Robert Henze
David Malagisi
Richard Pedrick
Donna Renda
Refresher courses were provided to applicable personnel for Hazardous
Conditions, Permit
Required Confined Space Entry, Respiratory Usage and Automatic External
Defibrillator (AED) operation.
During 2007 there were
two (2) reported injuries. Lost time was reported for one (1) of the
injuries.
MAINTENANCE
The Maintenance Department
employees (with Operations assistance) completed several
improvement projects this year:
1. No. 2 Caterpillar
Cogeneration Engine upper end was rebuilt.
2. A 30,000 hour class two
overhaul of the 450 hp Turblex Air Blower was completed.
3. No. 1 Caterpillar
Cogeneration Engine received a major overhaul by Milton Cat Inc.
4. Plant Maintenance fabricated
an auger style grit classifier to replace costly mechanical
rake style classifier. If purchased new, the cost from a manufacturer
would have been
$50,000; cost for fabricating in-house was $12,500.
5. Final Settling Tank weirs
were purchased from Barber Welding for the sum of $39,492.
The original carbon steel units were removed and replaced with stainless
steel weir
troughs by staff.
6. A new Peerless boiler was
installed by Adirondack Mechanical in the Sludge Handling
Complex, replacing original 1970 boiler. Cost of the new boiler was
$18,270.
7. A Bobcat Skid Steer was
purchased for snow and dirt removal.
8. Updated monitoring fleet with
the purchase of a new 2007 Chevrolet Van.
9. Six (6) concrete manhole
frames and covers were installed on incoming trunk line. Trunk
line maintenance from the plant to West Main St. in Johnstown was
completed.
10. Replaced rusted window
frames and glass in the Thickener Building.
11. The sampler building was
relocated near the primary tanks to accommodate influent and south side
samples.
12. A return sludge pump was
relocated and installed by staff resulting in $6,044 of annual
electrical savings.
13. A 35’ long sludge conveyor
was fabricated by plant personnel to convey sludge from the belt presses
to the truck dock.
14. A leachate pump was
purchased from Godwin Pumps of America at a cost of $14,478
and installed by maintenance staff.
15. Five hundred-thirteen (513)
Work Orders were completed in 2007.
GRANTS & LOANS
A New York State Energy
Research and Development Authority (NYSERDA) grant was
obtained to evaluate biogas options. This grant paid for approximately
50% of the cost to
conduct the necessary engineering analysis. The report was completed in
2007.
An Economic Development
Administration (EDA) grant application was prepared requesting financial
assistance for a future upgrade. The Capital Project will be to
accommodate anticipated growth in the food-processing sector in the
Industrial Park. Total requested grant was $3.5 million.
A NYSERDA grant
application was prepared requesting $1 million of grant funds to replace
the aging 20-year old cogeneration engines with new equipment.
COMPLIANCE MONITORING
AND TESTING
Annual reviews of the
Laboratory Quality Assurance, Test Method Standard Operating
Procedures (SOP), Administrative/Quality Procedures, and Laboratory
Chemical Hygiene
Manuals were all completed as scheduled.
In 2007, the
laboratory received satisfactory scores for all proficiency testing
performed for state and federal regulating agencies.
A total of
twenty-five (25) Industrial Wastewater Discharge Permits were issued
at the
beginning of 2007. Robison & Smith Textile Services was added June
1, 2007, and FAGE USA Dairy, Inc. was added December 1, 2007.
Industrial loadings
for 2007 were up compared with 2006:
|
Industrial Flow: |
Up
8.7% |
|
Industrial Solids: |
Up 8.5% |
|
Industrial BOD: |
Up
18.4% |
|
Industrial TKN: |
Up 6.9% |
HydroQual continued
to test ultraviolet disinfecting units in 2007, using nearly 18
million gallons of potable water. HydroQual tested both potable and
non-potable units. In addition, some Research & Development work
involving fluorescent micro spheres was done. HydroQual’s contract
is in force through 2009.
A total of sixty-two
(62) industrial pretreatment violations were detected in 2007. By
comparison, there were forty (40) violations detected in 2006.
The Environmental
Protection Agency (EPA) performed their five (5) year audit on
November 27-29, 2007. Only four (4) areas of concern requiring a
response from the wastewater treatment facility were discovered.
LEGAL/MISCELLANEOUS
FAGE USA Dairy, Inc., a
Greek food manufacturer, has almost completed construction of their
$80 million facility in the Johnstown Industrial Park. FAGE will be
a significant wastewater customer once operation commences in early
2008.
The
Gloversville-Johnstown Joint Sewer Board received the 2007 NYS
Environmental
Excellence Award. The award was presented by the NYSDEC Commissioner in
recognition for the innovative Digester Improvement Project.
The 1985 Rules and
Regulations of the Gloversville-Johnstown Joint Sewer Board were
successfully updated during 2007.
The
Gloversville-Johnstown Joint Sewer Board contracted with Malcolm Pirnie
to commence preliminary design for a required upgrade at the wastewater
treatment plant at a total cost of $69,850.
ENVIRONMENTAL
2007
was the eighth full year of enforcement of the modified New York State
Department of
Environmental Conservation (NYSDEC) State Pollutant Discharge
Elimination System (SPDES) permit. This stringent effluent permit
regulates discharge limits of a multitude of parameters measured on a
daily and/or monthly basis.
The
GJJWTF was in full compliance with all SPDES permit conditions during
the entire year with the exception of a single exceedance of cyanide in
February of 2007. Success complying with this stringent SPDES permit is
a direct result of the dedication of personnel who operate, maintain and
monitor the facility efficiently to protect the environment.
The
NYSDEC inspected the facility on a few occasions during 2007. The result
of each
inspection was the facility was operating within the SPDES permit
conditions. The facility
continues to work closely with NYSDEC on various environmental matters
and concerns.
USAGE
Influent data compiled
at the facility indicates that during 2007 average wastewater flows
were realized at the facility.
Laboratory data compiled to determine the quantity of Total Suspended Solids (TSS) that
arrived in the plant influent from industrial customers indicates an 8.5% increase from 2006.
Laboratory data compiled to determine the quantity of Biochemical Oxygen Demand (BOD) that
arrived in the plant influent from industrial sources resulted in an 18.4% increase compared to 2006.
Industrial samples were analyzed to determine Total Kjeldahl Nitrogen (TKN). A review of the
data indicates 2007 results were 6.9% higher than 2006.
Finally, in order to
measure the relative strength of industrial waste, staff developed a
formula that combines BOD, TKN, and TSS data. The resulting value,
Industrial Index, provides a single numeric number. Data indicates that
2007 was 13.1% higher than 2006.
 .
Overall Industrial use at the facility
was the highest values realized during the past five (5) years.
OPERATIONS
Removal efficiency rates for the facility are as follows:
|
Parameters |
2003 |
2004 |
2005 |
2006 |
2007 |
|
Total Suspended Solids |
97% |
97% |
98% |
96% |
98% |
|
Biochemical Oxygen Demand |
99% |
98% |
99% |
99% |
99% |
|
Total Kjeldahl Nitrogen |
82% |
85% |
89% |
88% |
89% |
These
removal efficiency rates have resulted in the continuation of
discharging clean effluent to the Cayadutta Creek.
The Belt Presses ran a total of
4,450 hours and produced 10,206 wet tons of sludge. The
quantity of sludge dewatered increased 400 tons compared to 2006 due to
increased industrial activity.
Rotary Drum Thickener (RDT) ran
a total of 1,900 hours and produced an average cake of
4.9%. The Belt Presses and RDT combined utilized 23,980 pounds of
polymer.
During 2007, 21,754 gallons of
Ferrous Chloride was used to control sulfides in the digested sludge.
A total of 2.7 million kilowatt
hours of electricity were purchased during 2007. The continued reduction
of electrical use is due to the exclusive use of the energy saving
Turblex Blower and improved on-site generation of electrical power.
The Anaerobic Digester System
produced an average of 4.0 million cubic feet of biogas per
month. The biogas powered the facility’s cogeneration system that
produced on average
149,320 kilowatt-hours each month, representing 40% of the total
electrical power consumed and resulting in over $233,000 of energy
savings for the year.
Natural gas usage at the
facility averaged 4,842 therms per month.
A total of 12.7 million gallons
of leachate was received at the facility in 2007.
Required monthly Discharge
Monitoring Reports submitted to the New York State Department of
Environmental Conservation (NYSDEC) were 100% computer generated in
2007. These more accurate and readable reports continue to provide the
required information to NYSDEC in an efficient manner.
FINANCE OFFICE
O&M revenue totaled $3.46 million during
2007. Industrial contribution was 44.0%, Residential 43.0%, Trucked
Waste 11.4% and Miscellaneous revenue totaled 1.6%. Industrial O&M
revenue received during 2007 increased for the first time in seven
(7) years.
Continued marketing to make surrounding
communities and entities aware of what our facility has to offer
proved beneficial during 2007. Contracts were renewed with several
customers during the year. For 2007, trucked waste receipts totaled
$394,446.
The single largest
trucked waste contract continues to be Cappiello’s of Schenectady.
Cappiello transports cheese whey that is accepted at $0.03 per
gallon representing 22% of revenue in this category.
Sewer rates were adopted
after a public hearing in April 2007. The rate model was modified
after Red Oak Consulting completed a comprehensive analysis. This
new model provides more appropriate charges for residents and
industry. The average industrial sewer bill increased 2-3% while the
residential increase was 1.5% in 2007.
Sewer law changes
authorized the continued use of fund balance at the facility. The
2006 Fund Balance of $103,800 was distributed 25% each to the City
of Johnstown and the City of Gloversville. In addition, 26% was
deposited to a reserve account and 24% was used for rate
stabilization.
At the National Grid
Hill Street groundwater remediation site, a pretreatment system
cleans the wastewater prior to discharge to the sewer system. Almost
19 million gallons were discharged in 2007 resulting in $201,963 of
revenue for the wastewater treatment facility.
INDUSTRIAL USE
O&M revenue from major users
increased for the first time in five (5) years. The number one user
of the facility is Euphrates, Inc. This is the first time in the
thirty-five (35) year history of the facility that a food processor
was the number one discharger to the facility.
Another new customer, National Grid,
was the number two revenue generator from wastewater discharged from
their Hill Street remediation site.
Three leather industries, (Tradition
Leather, Simco Leather and Colonial Tanning) and four trucked waste
accounts (Landfill, Municipal Sludge, Septage and Cappiello) were in
the top ten.
One governmental agency, Hale Creek
ASATCA rounds out the top ten large customers of the facility.
| The $80 million FAGE USA Dairy, Inc.
yogurt manufacturing facility was nearly completed in 2007. |
 |
| |
|
|
 |
Cogeneration Engine No. 1 was
rebuilt for continued electricity generation |
| |
|
| Staff designed and fabricated a
35’ long conveyor to replace a defective sludge conveyor for the
belt presses. |
 |
| |
|
|
 |
Staff promptly cleared almost
all of the snow from a February 2007 storm that delivered 30” of
snow. |
| |
|
| A Bobcat Skid Steer was
purchased for snow and dirt removal. |
 |
| |
|
|
 |
Extensive trunk line maintenance
was completed by staff, including this riser section and several
manhole frames and covers. |
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