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: Wastewater@GJWastewater.com
NYSPDES # 0026042
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2016 Annual Report

GLOVERSVILLE-JOHNSTOWN
Joint Wastewater Treatment Facilities


2016 Joint Sewer Board
 
Helen Martin : Chairwoman
Wrandy Siarkowski
John Rizzo
Bobbi Trudel
Dale Trumbull
Christopher Vose


You can also Download the Annual Report

INTRODUCTION:

The 2016 Annual Report highlights the significant projects completed at the Gloversville-Johnstown Joint Wastewater Treatment Facility (GJJWTF). Routine assignments such as tank cleaning, instrument calibration, laboratory analysis, sample collection, general maintenance and upkeep, while important, are not identified in this report. General statistics are included to illustrate additional activities at the facility.

Electrically, GJJWTF generated 7.4 million kilowatt hours of electricity; purchased 195,382 kilowatt hours of electricity from National Grid; and sold back 1,427,083 kilowatt hours of electricity to National Grid for $37,418.59. GJJWTF saved users $874,050 (assuming $0.15/kwh) in direct electrical costs during 2016.

O & M revenues totaled $4.3 million during 2016. The Industrial contribution was 52.3%, Residential 29.3% and Trucked/Pumped waste and miscellaneous revenue totaled 18.4%. The average industrial sewer bill increased 6%, while the residential rate increased by 2.3%. Use of $355,000 from the rate stabilization reserve fund helped to minimize the rate increase.

Belt Filter Presses operated 4,450 hours producing 21,480 wet tons of sludge. Fulton County Department of Solid Waste received $731,339 to accept the sludge.

FAGE USA Dairy (FAGE) and Euphrates Inc. pumped over 28.6 million gallons of whey via a dedicated pipeline during 2016. FAGE’s 23.1 million gallons of whey constituted 37% of the revenue collected in the trucked and pumped waste category.

The foundation for success of GJJWTF is due to the support of the Gloversville-Johnstown Joint Sewer Board (GJJSB) and the work of its twenty-six (26) employees. As a result of the conscientious efforts by all GJJWTF employees days, nights, weekends, holidays, during severe weather, and often in an inhospitable environment; the facility continues to operate and meet its wastewater discharge SPDES permit requirements.

The employee names (as of 12/31/16) are as follows:

Barbara Allen

Alexander Isabella

Hilary Ruzycky

Thomas Ambrosino

Mark Levendusky

Christopher Stankes

Wallace Arnold

David Malagisi

Michael VanAlstyne

Ricky Barnett

Catherine Maragno

Christopher VanAuken

Steven Burns

James McMillan

Richard VanNostrand

Bruce Gardner

Scott Miller

Robert Yaggle

Erich Goodemote

Chad Oathout

 

Matthew Handy

Richard Pedrick

 

Robert Henze

William Ratajczak

 

Timothy Hutchinson

Donna Renda

 

PERSONNEL:

The total number of NYSDEC Grade 3A and 4A license holders at this facility totals seven (7). Two (2) employees are in the process of obtaining the necessary training and experience to obtain a wastewater operator license.

Seven (7) employees utilized three (3) sick days or less during 2016. The names of those employees are as follows:

Bruce Gardner
Alexander Isabella
Mark Levendusky
James McMillan
Donna Renda
Hilary Ruzycky
Christopher VanAuken

During 2016 there were four (4) injuries reported; one (1) of the injuries resulted in lost time.

Michal VanAlstyne promoted from Operator Trainee to Operator after passing his NYSDEC Grade 3A exam

Wallace Arnold appointed as the new Wastewater Programs Manager in April 2016.

Three new members appointed to the Gloversville-Johnstown Joint Sewer Board:

  1. Bobbi Trudel to represent the City of Gloversville;
  2. Dale Trumbull to represent the City of Gloversville;
  3. Christopher Vose to represent the City of Johnstown.

WEBSITE:

Minor updates were accomplished to the GJJWTF website (g-jwastewater.com) which included general revisions and new photos. The website was viewed by 2,425 visitors in 2016.

OPERATIONS AND MAINTENANCE:

Several improvement projects accomplished during 2016 with assistance from the Operations and Maintenance staff were:

  1. 1. Upgraded SCADA (Supervisory Control and Data Acquisition) from version 7.2 to 7.5, upgraded the SCADA Control Center, and added new screens.

  2. Moved feed breakers in Screening Building MCC panel to make room for bar screen panel and new grit classifier panel.

  3. Rehabbed both digester boilers. Installed new flame controller and gas valves on Boiler No. 2 to help control digester temperatures. Replaced both boiler safety valves.

  4. Assisted National Grid and Frontier Communications to repair the High Yard DTT safety switch to the cogen engines.

  5. Serviced High Yard via High Voltage Electric Service.

  6. Cleaned and inspected all transformers onsite.

  7. Assisted Milton CAT technician with warranty work to install a drive coupling between CAT Engine No. 3 and the generator.

  8. Removed old existing grit classifiers and installed two (2) new Lakeside grit classifiers. Ran new pipes and conduit, wired control panels, and refurbished wiring for SCADA monitoring.

  9. Ran conduit to influent pipe at the CAST Headworks Building for the pH probe.

  10. Assisted High Voltage Electric technician with work on the Hoffman control panel.

  11. Removed existing cross members, flight supports, and catwalk from Grit Channel No. 1 & No. 2. Refurbished both channels with new stainless steel framework/supports, and new plastic chain and flights.

  12. Replaced obsolete florescent and HID lighting with LED lights. National Grid assisted by offering 50% cost reduction to convert to LED. Lighting Phases II and III included all exterior tank lights, explosion and vapor proof lights, and the rest of the buildings throughout the facility.

  13. Addressed PESH inspection requirements such as replacing worn labels, cleaning wires and power supplies, and checking power cords.

  14. Installed new gravity belt, plows and drive motor on Belt Filter Press No. 1 and new plows on Belt Filter Press No. 3. Installed new gravity belt and plows on Gravity Belt Thickener No. 2.

  15. Installed an oil mist removal motor and replaced Head No. 4 on CAT No. 2. Installed new battery charger (under warranty) on CAT No. 3.

  16. Relocated Duperon level sensor for bar screens to the outside of the Screening Building to allow for the installation of a cold weather curtain. Fabricated a stainless steel cover over the level sensor.

  17. Removed and replaced H2S scrubber media.

  18. Installed outdoor lighting and handrail safety chains at the Gloversville Parshall Flume Building.

  19. Installed and wired a high-level float from the whey vault to MCC Room (Thickener Building) to the SCADA alarm panel.

  20. Installed a diaphragm and check ball on chemical pump of Siemen’s air scrubber. Installed new bearing and impeller in the main blower of scrubber.

  21. Pulled wires and programmed VFDs to automatically run emulsion polymer pump with the belt filter presses.

GRANTS & LOANS:

The H2S scrubber and CAT No. 3 generator QA/QC plan for the NYSERDA grant was completed and sent to NYSERDA for approval. A requirement of the QA/QC plan provided real-time data to NYSERDA for posting on their website which began in June.

Submitted a proposed work plan and budget on NYS grants portal system (Grants Gateway) for the Disinfection project whereby GJJWTF had received a 1.1 million dollar grant in 2015. The work plan and budget along with proof of insurance was submitted to NYSDEC for approval.

COMPLIANCE MONITORING AND TESTING:

Annual reviews of the Laboratory Quality Assurance, Test Method Standard Operating Procedures (SOP), Administrative/Quality Procedures, Monitoring and Field Activities, and Laboratory Chemical Hygiene manuals completed as scheduled.

Technical Director completed the annual internal audit of the laboratory in May of 2016.

NYS Department of Health’s Environmental Laboratory Accreditation Program (NYS DOH ELAP) conducted their bi-annual ELAP external audit on August 17, 2016. Seven (7) areas of concern were identified. ELAP concurred with all corrective actions implemented. In addition, Lab Director performed proficiency testing and found all reportable parameters within acceptable limits.

EPA conducted a three (3) day onsite assessment of GJJWTF on August 23-25, 2016. A full tour of the facility was provided and twenty-four (24) hour composite samples of GJWWTF’s influent and effluent were collected. Distributions of the industrial mass loadings were discussed. Consequently, all reviewed parameters were in compliance.

Laboratory Director conducted the annual ethics and data integrity training of all laboratory and monitoring personnel during December of 2016.

GJJWTF issued twenty-two (22) Industrial Wastewater Discharge Permits in December of 2015 for year 2016.

Recorded industrial loadings for 2016 compared to 2015:

Industrial Flow: Down 1%
Industrial Solids: UP 1%
Industrial BOD: Up 12%
Industrial TKN: Down 13%

No personnel changes in the monitoring crew or the laboratory staff occurred during 2016

2016 had eighteen (18) industrial violations as compared to thirty-five (35) reported in 2015.

GJJWTF issued two (2) consent orders to industries during 2016, one for a Chromium violation and the other for a flow violation. The chromium consent order is pending January’s test results. The flow violation consent order was fully executed in the amount of $10,000.

The Laboratory Director performed confined space entry and compressed air refresher training for employees in the Confined Space Entry Program. The in-house drill covered the set up and function of a new davit arm, safety harnesses, masks, regulators, air packs and air tanks.

Laboratory personnel continued additional analysis of CAST project samples.

USAGE:

Historically, Wastewater Influent flows are relatively constant.

Total Wastewater Flow

Industry: Total Suspended Solids (TSS) increased 1% in 2016

Industrial TSS lbs

Industry: Biochemical Oxygen Demand (BOD) increased 12% in 2016.

Industrial BOD Per Year

Industry: Total Kjeldahl Nitrogen (TKN) decreased 13% in 2016.

Industrial TKN lbs Per Year 

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. The Industrial Index increased 5.2% in 2016.

Average Monthly Industrial Index

Overall, Industrial wastewater conveyed to GJJWTF via the sanitary sewer continued to increase in 2016.

However, the industrial index system does not incorporate the following waste streams:

  1. Whey directly piped to the anaerobic digester;

  2. National Grid remediation;

  3. Fulton County Department of Solid Waste - Leachate.

As shown in the previous graphs, industrial loadings have increased over the past several years. During 2016, industrial loadings to GJJWTF accounted for 93% of the total BOD, 25% of the total TSS and 42% of total TKN. While total BOD and TKN loadings remain less than 50% of the GJJWTF’s design capacity, the total TSS is 70% of design capacity.

LEGAL/MISCELLANEOUS:

Enforcement of the New York State Department of Environmental Conservation (NYSDEC) State Pollutant Discharge Elimination System (SPDES) permit continues. This stringent effluent permit regulates the discharge limits of a multitude of parameters measured on a daily, weekly, monthly and/or annual basis.

The GJJWTF was in full compliance with most SPDES permit conditions during 2016. However, the facility was not in compliance due to an accidental release of industrial high strength waste which caused GJJWTF to violate settleable solids limits in September and October, six (6) times:

A NYSDEC reportable event occurred on May 11, 2016. GJJWTF had a gravity belt thickener belt failure which led to untreated sludge filling the solids handling building and eventually making it into the Cayadutta Creek via the storm sewer system. The facility notified NYS Alert as required by the Sewage Pollution Right to Know Act. NYSDEC inspected and requested the facility evaluate the SCADA (Supervisory Control and Data Acquisition) system. The evaluation was completed and the changes have been implemented to prevent future failures.

The NYSDEC performed a detailed site inspection on November 29, 2016. At the time of the inspection, GJJWTF was found to be in good operating condition and received a satisfactory rating. The facility continues to work closely with NYSDEC on various environmental matters and concerns.

The NYSDEC contacted GJJWTF in late 2016 for comments on an updated SPDES permit for the facility. A final draft permit was agreed upon between the facility and NYSDEC and is ready to go out for public comment before taking effect sometime in 2017.

OPERATIONS:

The year-to-year removal efficiency rates for the GJJWTF are as follows:

Parameters

2011 

2012 

2013 

2014 

2015  2016 

Total Suspended Solids

97% 

97% 

98% 

97% 

97%  98%

Biochemical Oxygen Demand

98% 

99% 

99% 

98% 

99%  99%

Total Kjeldahl Nitrogen

89% 

92% 

91% 

79% 

92% 92%

The above TSS and BOD removal efficiencies exceed the permitted removal rate of 85 percent prior to discharge to the Cayadutta Creek.

Belt Filter Presses (BFPs) operated 4,450 hours producing 21,480 wet tons of sludge. During 2016, sand and/or dried sludge was blended into the sludge cake to meet the minimum 20% solids landfill disposal requirement.

Together, the BFPs and Gravity Belt Thickeners (GBTs) utilized 42,452 pounds of polymer. In addition, the BFPs used another 5,050 gallons of an emulsion polymer to enhance sludge dewaterability. In 2016, due to a product change, emulsion usage declined 21%.

During 2016, the GJJWTF purchased 35,440 gallons of Ferrous Chloride to control sulfides at the anaerobic digesters. GJJWTF also purchased Natural gas at an average 4,557 therms per month to heat various buildings.

GJJWTF processed 12.3 million gallons of leachate in 2016. This represented an 18% increase over 2015. The Fulton County Landfill pumped leachate to the facility via a dedicated five (5) mile long force main.

ENERGY RECOVERY:

During 2016, GJJWTF generated 7.4 million kilowatt hours of electricity. The addition of CAT Generator No. 3 created the 32% increase in generated power in 2016.

The biogas generators (CAT1, CAT2 and CAT3) generated 97% of GJJWTF’s electrical needs in 2016.

Most of the purchased power occurred during the months of February and June. In February, the exhaust heat exchangers for CAT Generators No.1 & No. 2 failed. This resulted in one week of down time for repair. In June, the GJJWTF and National Grid safety transfer switch failed.

In 2016, the Anaerobic Digester System produced an average of 14.2 million cubic feet of biogas per month, representing a similar biogas production rate comparable to 2015. With CAT Generator No. 3 in service the facility was able to use more biogas toward power production and heat instead of flaring it.

KWH 

FINANCE OFFICE:

O&M revenues totaled $4.3 million during 2016. The Industrial contribution was 52.3%, Residential 29.3%, and Trucked/Pumped waste and miscellaneous revenue totaled 18.4%. Trucked/Pumped waste and miscellaneous revenue decreased by 1% from 2015 and the industrial contribution increased by 1.4%.

Continued marketing to make surrounding communities and entities aware of what our facility has to offer proved beneficial during 2016. All trucked/pumped high strength waste contracts were renewed with existing customers during the year. For 2016, trucked & pumped waste receipts totaled $727,369.

Truck Pumped Waste Revenue

The single largest trucked waste contract was Adirondack Septic. FAGE USA Dairy and Euphrates Inc. pumped over 28.6 million gallons of whey directly to the facility via a dedicated pipeline during 2016 resulting in slightly lower loadings compared to 2015 in gallons treated. The 23.1 million gallons of whey from FAGE resulted in 37% of the revenue collected in this category.

The total quantity of whey during 2016 from FAGE and Euphrates Inc. decreased 2%.

Sewer rates were adopted after a public hearing in April 2016. The average industrial sewer bill increased 6%, while the residential rate increased 2.3%. Rates remained relatively stable due to a variety of reasons including the use of $355,000 of rate stabilization reserve funds.

The 2015 Financial Audit Summary from Bollam, Sheedy, Torani & Co. disclosed no issues of noncompliance, and no alternative procedures or corrective actions were suggested.

INDUSTRIAL USE:

O&M revenue from industrial users increased 5.6% in 2016. The number one user of the facility was FAGE USA Dairy, and Euphrates Inc. was the second largest user.

One (1) trucked waste account, septic haulers, and three (3) leather industries (Colonial Tanning, Simco Leather, and Townsend Leather) were in the top ten.

Fulton County Landfill Leachate, Hale Creek ASATCA, National Grid remediation site and Johnstown’s Century Linen and Uniform round out the top ten largest customers of the facility in 2016.

Industrial O&M Revenue

     

High Voltage Electric and GJJWTF personnel panels  

High Yard preventative maintenance completed by outside contractor High Voltage Electric and GJJWTF personnel panels


 Parshall Flume.  

GJJWTF personnel installed a new roof and painted the exterior of the Gloversville Parshall Flume.


2017 International dump truck  

GJJWTF purchased a 2017 International dump truck for transporting sludge to the Fulton County Department of Solid Waste.


lights replaced with LEDs  

Tank lights replaced with LEDs to provide better lighting for personnel during the night shift.


replaced original steel supports for both grit channels with new stainless steel supports. 

Maintenance staff replaced original steel supports for both grit channels with new stainless steel supports.


Staff stabilized the SulfaTreat vessel

Staff stabilized the SulfaTreat vessel. A vacuum truck from NRC removed and replaced 25 ton of H2S scrubber media.


Two new Lakeside Grit Classifiers

GJJWTF purchased two new Lakeside Grit Classifiers as part of the Screening Building Upgrade and performed the installation. The classifiers replaced 1990 grit classifiers.


Duperon 1/2” bar screens and a washer compactor

Miller Construction installed three Duperon 1/2” bar screens and a washer compactor as part of the Screening Building Upgrade. The new bar screens remove finer debris that clogs downstream equipment.

 

Duperon 1/2” bar screens and a washer compactor

 


 
 

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