GLOVERSVILLE-JOHNSTOWN
Joint Wastewater Treatment Facilities

2009 Joint Sewer Board
  Frank Malagisi, Chairman
Sal Giarrizzo
Robert Abel
Richard A. Handy
Lee A. Mitchell
David Thum

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 2009. 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 2009 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 2009 to make the wastewater treatment facility function properly for all of our customers. The names of employees, (as of 12/31/09), are as follows:

Once again, all employees exhibited a great effort during the past year.

Long tenured Industrial Waste Monitoring Technician Brian Jennings retired September 26, 2009 after twenty-five (25) years of service.

Long tenured Lead WTP Operator Richard Wager retired October 24, 2009 after thirty-four (34) years of service.

Robert Yaggle successfully obtained his NYSDEC Grade 3A WTP Operator Certification on April 3, 2009.

Scott Miller was promoted to Working Supervisor effective June 1, 2009.

Robert Yaggle was promoted to WTP Operator effective June 1, 2009.

Chris VanAuken was appointed to a vacant WTP Attendant position effective July 27, 2009.

Thomas Ambrosino was promoted to Lead WTP Operator effective December 14, 2009.

Several staff members obtained Wastewater Treatment Plant Operator Renewal Certification from New York State Department of Environmental Conservation (NYSDEC). The total number of NYSDEC Grade 3A and 4A license holders at this facility totals seven (7).

Ten (10) employees utilized less than three (3) sick days during 2009. The names of those employees are as follows:

Joseph Cellary
Bruce Gardner
Matt Handy
Robert Henze
David Malagisi
James McMillan (zero hours used)
Scott Miller (zero hours used)
Richard Pedrick
Bill Ratajczak
Hilary Ruzycky

During 2009 there were thirteen (13) injuries reported with no lost time.

Maintenance Department employees (with Operations assistance) completed several improvement projects this year and completed a total of 242 work orders repairing equipment.

1. Rebuilt a 30 HP pump and relocated to the Pump Gallery to be used as a more energy efficient Return Sludge Pump.

2. Rebuilt two (2) primary and two (2) Screening Sludge Pumps (20 year old units) and reinstalled. All pumps now have mechanical seals.

3. Performed a major rebuild on Cogeneration Engine No. 1. Overhaul by Milton Cat, removal and installation by staff.

4. Installed several variable frequency drives throughout the facility (Return and Wasting Pumps).

5. Performed 18,000-hour service on aeration system Turblex Blower with assistance from Turblex. Impeller sent to machine shop for balancing and cleaning.

6. Installed a new Godwin self-priming pump in Recirculation basement to pump leachate.

7. A new rooftop heater was installed on the Recirculation Building by Adirondack Mechanical with staff assistance.

8. All four (4) Aeration Tanks were pumped and cleaned during 2009. Grit was removed and all 5,000 ceramic stones were acid cleaned by staff.

9. Rebuilt Screening Horizontal Conveyor with stainless steel tops and sides. Installed new drive and idler rollers.

10. Removed old carbon steel weir boxes from Primary Tanks No. 2 and 3. Installed new stainless steel boxes and reused fiberglass weirs.

11. Administration Building parking lot repaving was completed by Cobleskill Stone Products at a total cost of $44,710.

12. Installed remanufactured heads for Cogeneration Engine No. 2.

13. Fabricated cold climate insulated stainless steel covers for both grit channels. Units replace wooden units.

14. Extended chain and relocated sprockets on both grit channels to prevent damage during wet weather events.

15. Performed numerous SCADA improvements during the year, including problems with process drain submersible pumps and elimination of “false” SCADA alarms.

16. Constructed a sand/salt storage shed near Day Tank.

Grants and Loans

Grant Management by the Administrative staff was a major part of office activities during 2009.

Required reports were prepared for the previously acquired $2.2 million Economic Development Administration (EDA) grant and the $1.4 million New York State Energy Research and Development Authority (NYSERDA) grant.

Actual construction activity started for the Capital Project designed to accommodate anticipated growth in the food-processing sector in the Industrial Park. The overall Capital Project now totals $10.3 million. In order to assist in payment of the required improvements, the cities of Johnstown and Gloversville were successful obtaining a $6.0 million Green Innovation Grant from NYS Environmental Facilities Corporation. This grant, along with previously obtained grants, will result in grant money totaling all but $0.7 million of the project costs.

During the course of 2009, several variable frequency drives were installed to operate pumps throughout the facility. These energy efficient drives are NYSERDA grant eligible. A total of $13,200 revenue was realized from this grant program.

COMPLIANCE MONITORING AND TESTING

LEGAL/MISCELLANEOUS

The GJJSB authorized a contract for 2009 legal services from the Glens Falls based firm MILLER, MANNIX, SCHACHNER & HAFNER, LLC. All legal services required by the GJJSB during 2009 were provided by MILLER, MANNIX, SCHACHNER & HAFNER, LLC.

The GJJSB settled a legal matter with the Euphrates Cheese Company to resolve a billing dispute. A Consent Order was signed by both parties resulting in a $985,000 payment for sewer charges and fines.

Construction work commenced in June of 2009 for the $9.5 million upgrade project. Ten (10) contracts were executed with various contractors and equipment vendors to complete the required work. By the end of 2009, the new Belt Press was operational, solids handling improvements were 75% complete, Dissolved Air Floatation Building foundation was installed, a Whey Tank was erected and electrical work has started for the generator portion of the project. Overall, the project is approximately 35% complete.

ENVIRONMENTAL

2009 was the tenth 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 one exceedance of nickel in July 2009 and one exceedance of Tetrachloroethylene in February 2009. The two (2) excursions, while unfortunate, were the only exceedances out of hundreds of required monitoring results obtained during the course of 2009. 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 2009. 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 2009 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 a 3.9% decrease from 2008.

Laboratory data compiled to determine the quantity of Biochemical Oxygen Demand (BOD) that arrived in the plant influent from industrial sources resulted in a 1.8% increase compared to 2008.

Industrial samples were analyzed to determine Total Kjeldahl Nitrogen (TKN). A review of the data indicates 2009 results were 7.6% lower than 2008.

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.

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Overall Industrial use at the facility via the sanitary sewer system remained relatively constant and was only 1.4% lower than 2008.

OPERATIONS

Removal efficiency rates for the facility are as follows:

Parameters	2004	2005	2006	2007	2008	2009
Total Suspended Solids	97%	98%	96%	98%	97%	98%
Biochemical Oxygen Demand	98%	99%	99%	98%	99%	99%
Total Kjeldahl Nitrogen	85%	89%	88%	89%	90%	92%

These removal efficiency rates have resulted in the continuation of discharging clean effluent to the Cayadutta Creek. The result was that the cleanest effluent in the 38-year history of the facility was discharged in 2009.

The Belt Presses ran a total of 7,648 hours and produced 14,133 wet tons of sludge. The quantity of sludge dewatered increased 20.5% compared to 2008 due to increased industrial activity.

The Belt Presses utilized 34,320 pounds of polymer, representing a 9% increase in chemical usage from 2008 due to sludge quantities.

During 2009, 24,144 gallons of Ferrous Chloride was used to control sulfides in the digested sludge.

A total of 2.8 million kilowatt hours of electricity were purchased during 2009. The total kilowatt- hours purchased decreased 7.6% during 2009. Overall the purchase of electrical power was minimized due to the exclusive use of the energy saving Turblex Blower and continuation of on-site generation of electrical power.

The Anaerobic Digester System produced an average of 5.9 million cubic feet of biogas per month, representing similar quantities from the previous year. A portion of the biogas powered the facility’s cogeneration system that produced on average 142,820 kilowatt-hours each month, representing 38% of the total electrical power consumed and resulting in over $225,150 of energy savings for the year.

Natural gas usage at the facility averaged 4,386 therms per month.

A total of 13.6 million gallons of leachate was received at the facility in 2009. Significantly less than the 16.2 million gallons received the previous year. The landfill leachate force main was operational all of 2009, eliminating truck traffic on the roads and at the facility.

Required monthly Discharge Monitoring Reports submitted to the New York State Department of Environmental Conservation (NYSDEC) were 100% computer generated in 2009. These more accurate and readable reports continue to provide the required information to NYSDEC in an efficient manner.

FINANCE OFFICE

O&M revenue totaled $3.53 million during 2009. The Industrial contribution was 43.1%, Residential 39.8%, Trucked/Pumped waste and miscellaneous revenue totaled 17.1%.

Continued marketing to make surrounding communities and entities aware of what our facility has to offer proved beneficial during 2009. Contracts were renewed with several customers during the year. For 2009, trucked & pumped waste receipts totaled $655,262.

The single largest trucked waste contract was Adirondack Septic. FAGE USA Dairy had their first full year of production during 2009 and pumped 9,555,223 gallons of whey directly to the facility via a separate pipeline resulting in 44% of the revenue in this category.

The total quantity of whey from the dairy sector increased 60% from 2008 resulting in $160,649 more revenue for facility operations.

Sewer rates were adopted after a public hearing in April 2009. For the third year in a row, the Red Oak consulting model was utilized to establish sewer rates. This new model provides more appropriate charges for residents and industry. The average industrial sewer bill decreased 2% while the residential rate decreased 1% for 2009, the second year in a row that rates have decreased.

Sewer law changes authorized the continued use of fund balance at the facility. The 2008 Fund Balance was $714,667, distributed by providing $200,294 each to the City of Johnstown and the City of Gloversville to fully pay back both cities for previous cash flow assistance. In addition, $225,000 was utilized for rate stabilization and the balance of $89,079 was transferred to a GJJWTF reserve account.

INDUSTRIAL USE

O&M revenue from industrial users increased to the highest level in a decade. The number one user of the facility was FAGE USA Dairy Industry, Inc. while Euphrates, Inc. was number two. Together with Cappiello, these three food processors combined was the largest category discharger to the facility representing nearly one quarter of the overall revenue collected.

Three leather industries, (Tradition Leather, Simco Leather and Colonial Tanning) and three trucked waste accounts (Landfill, Municipal Sludge contract, and Septage) were in the top ten.

One governmental agency, Hale Creek ASATCA and National Grid remediation site rounds out the top ten largest customers of the facility.

Maintenance staff reconstructed a Horizontal Conveyor located in the Screening Building. New rollers were installed, stainless steel decking added, and frame metal was painted.
	Staff removed old Weir Boxes from Primary Tank No. 2 and No. 3 and installed stainless steel units.
Insulated stainless steel covers were designed, fabricated and installed by maintenance staff to eliminate ice buildup on grit channel chains. Sprocket modifications were also accomplished to eliminate breakdowns during high flow events.
	Worked commenced in June 2009 on a $10.3 million wastewater upgrade project. Grant funds were secured from EDA, NYSERDA, and NYS EFC to pay for the majority of project costs.
The upgrade project is comprehensive, including the construction of a 200,000 gallon whey storage tank.
	A 2.5-meter sludge dewatering press was installed in the Solids Handing Building. The unit became operational in December of 2009.
Lead WTP Operator Richard Wager retired after 34 years of service.
Monitoring Technician Brian Jennings retired after 25 years of service.

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