Wastewater Treatment Gloversville - Johnstown Joint Wastewater Treatment Facilities
191 Union Avenue - Johnstown, New York  12095-3399
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 (518) 762-3101
 (518) 762-3921
E-Mail: gjwwtf@frontiernet.net
NYSPDES # 0026042
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Annual Report  - Also available to download (PDF 880kbs)

The Gloversville-Johnstown Wastewater Facility
Gloversville - Johnstown Joint Wastewater Treatment Facilities
 

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.

Total Wastewater Flow

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.

Industrial TSS

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 BOD

Industrial samples were analyzed to determine Total Kjeldahl Nitrogen (TKN). A review of the data indicates 2007 results were 6.9% higher than 2006.

Industrial TKN

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.

Industrial Index.

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.
Truck Waste Revenue

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.

Industrial Top Ten

The $80 million FAGE USA Dairy, Inc. yogurt manufacturing facility was nearly completed in 2007.

$80 million FAGE USA Dairy, Inc.

   

Cogeneration Engine No. 1

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.

35’ long conveyor

   

February 2007 storm that delivered 30” of snow

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.

Bobcat Skid Steer

   

 Rriser Section

Extensive trunk line maintenance was completed by staff, including this riser section and several manhole frames and covers.

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?2006 Gloversville - Johnstown Joint Wastewater Treatment Facilities. All rights reserved. This web site was designed by Empire Web Pages on December 02, 1999. This page was most recently updated on February 27, 2006.
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