annual report - poughkeepsie poughkeepsie annual... · adam van tassel mathew deangelo andret hart...

annual reportSUEZ and Town of Poughkeepsie Partnership

2018-2019

Overview 1

Staffing 1

Operational Overview 2

Facility Overview 4

Weather 4

Arlington 4

Flows 4

Removal Efficiencies 4

Sludge, Grit and Screenings 4

Cake Sludge 4

Liquid Sludge 4

Compliance Overview 5

Toxicity Testing 5

Odor and Customer Issues 6

Environment, Health, Safety & Security 7

EHSS “Doing It Right” Recogntion Program 8

Safety Awards 8

Environmental Compliance 8

Inspections & Calibrations 9

Regulatory Inspections 9

Facility Improvements Overview 10

Arlington 10

Arlington WWTP Facility Upgrade Project 11

Upcoming Projects 12

Preventive Maintenance Overview 13

Capital and Corrective Maintenance Overview 13

Community Relations 14

table of contents

1PB

SUEZ and Town of Poughkeepsie Partnership 2018-2019 ANNUAL REPORT

SUEZ has performed Operations and Maintenance at the Arlington wastewater treatment facility for the Town of Poughkeepsie during the contracted year of July 5, 2018 thru July 4, 2019.

StaffingWe are fully staffed at the project level, and the SUEZ technical support and operational staff for the Poughkeepsie project this year includes:

Regional General ManagerJason O’Brien

Area ManagerMichael Burke

Project ManagerSteve Segna

Assistant Project ManagerRobert Eichler

O&M TechniciansMarcus ParoliJoseph Gilroy

Nicholas CrispiAdam Van Tassel

Mathew DeAngeloAndret Hart

Technical Services ManagerDon Goodroe

Engineer, Capital Asset/Planning

Anthony Park

Director, Environment, Health, Safety & Security

Cornelius Morgan

Manager, Environment, Health, Safety & Security

Michael Coon

Overview

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During the 2018-2019 operating period, on behalf of the Town of Poughkeepsie, SUEZ operated and maintained the Arlington Water Pollution Control Faciltiy, an activated sludge plant that treats an average of 4 million gallons of wastewater per day (MGD).During this period, SUEZ provided the following operations and maintenance services:• Process control of sludge processing system

including sludge cake and feed % solids testing. This includes thickener performance

• Maintained laboratory sampling plan and the Quality Assurance/Quality Control (QA/QC) plan including verifying sampling schedules

• Maintained all laboratory instruments and equipment• Continued with calibrations of all laboratory

equipment, plant flow meters, and sensors• Maintained and implemented wet weather plan

including adding extra operators during overnight wet weather events

• Automatic samplers have operated properly and are upgraded and maintained throughout period

• Cleaned clarifier weirs, channels and walls; influent channel, thickener weirs and channels; and sludge mixing box on a weekly basis

• Maintained and improved disinfection system including chlorine pumps with crocks, bulk storage tank and piping and analyzers throughout period

• Maintained and improved operations of centrifuge sludge dewatering system including polymer system and conveyors

• Maintained and improved all of the upgrade dequipment including the influent building and its equipment, primary clarifier equipment, emergency generator, sludge feed and primary sludge pumps, secondary sludge pumps and all of the electrical equipment throughout the facility

• Maintained Spill Prevention Control and Countermeasure (SPCC) Plan including monthly oil spill prevention plan inspections, containment area inspection, draining of rain water and any necessary changes

• Performed bi-monthly safety audits and continued operator safety training including risk assessment and Personal Protective Equipment (PPE) audits. Completed monthly safety inspections for fire extinguishers, eyewash stations, emergency lighting, first aid kits, hoists & rigging, and fork lift

• Updated SUEZ Environment, Health, Safety & Security (EHSS) policies, which included implementation, verification, audits and training for 21 different safety policies

• Maintained Storm Water Plan with quarterly inspections, annual operator training and annual sampling

• Maintained Emergency Action Plan (EAP) including annual training

• Maintained Spill Prevention Plan including daily tank inspection and annual operator training. This included the five year tank inspection performed in June of 2018 and passed successfully

• Maintained all other required plans including SPCC plan, Design Flow Management Plan, Frosi report, DMR-QA laboratory study, Bulk Storage permits and the EPA 503 Sludge report.

• Maintained all regulatory permits and certifications including required inspections

• Monitored and improved the new aeration blowers, controls and valves to ensure consistent dissolved oxygen levels throughout the aeration system

• Performed preventive maintenance on all operating equipment on a manufacturer’s recommended schedule. Implemented new computerized maintenance management system (CMMS)covering more than 500 assets throughout facility

Operational Overview

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• Continued to maintain and improve the grounds at the facility• Maintained and monitored the odor control system including the new process room system• Maintained the security of the facility via the front gate, CC cameras, door locks and operator involvement• Maintaiedn the aeration flow control system including valves, actuators and controls• Maintained all the facility grounds equipment including mowers, snow blowers, tractors, weed whackers and

leaf blowers• Performanced maintenance on all facility vehicles, trailer and fork lift• Maintained and operated the emergency generator• Performed daily operator rounds which is stored in the CMMS • Continue to monitor and guide all outside contractors performing upgrade work at the facility

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WEATHERThe weather over the past year was normal. The annual rainfall total was 53.2 inches plus 37.5 inches of snow. The highest single day of rainfall of 2.75 inches occurred on November 3, 2018.

ARLINGTONFlows

The highest daily average flow of 5.7 million gallons a day (mgd) was recorded on November 3, 2018. The daily average flow for the past year was 2.63 mgd. The minimum daily average flow of 1.5 mgd was recorded on July 4, 2018. The flow meters were last calibrated on May 10, 2019. Total flow processed for the year was 959,950,000 gallons.

Removal EfficienciesThe annual average plant efficiency was 96% removal for Biochemical Oxygen Demand (BOD) and 96% removal for Total Suspended Solids (TSS). The State Pollutant Discharge Elimination System (SPDES) permit requirement is a minimum of 85% removal for both BOD and TSS.

Sludge, Grit and ScreeningsThe wasting schedule was maintained seven days per week throughout the year. The wasting rate varied between 17,000 gallons per day and 101,000 gallons per day depending on the mixed liquor suspended solids (MLSS) concentration and sludge settleability. The grit removal from the headworks was performed every other day and screenings removal was performed daily. These items are stored at the facility in a small dumpster and hauled out every week by Royal Carting to the Dutchess County Resource Recovery site.

Cake SludgeStaff processed 7,536,797 gallons of sludge at an average of 2.9% solids producing 712.5 dry metric tons of sludge at an average of 31.3% dry cake. The sludge is hauled by trailer by Casella Organics for disposal.

Liquid SludgeEarth Care Inc. hauled out no liquid sludge over the past year. This is due to the new dewatering system and no major breakdowns of the sludge processing system.

Facility Overview

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All required sampling was conducted for the year. Results are summarized in the chart below and show compliance for all parameters tested. In addition, final effluent settleable solids readings were all <0.1 ml/l for the year. Laboratory reports and log sheets are available for review. There were no permit expeedences or non-compliances during the past year.

TOXICITY TESTINGToxicity WET testing was conducted as mandated in the year 2018. This testing is required every five years on years ending with 3 and 8. Tests were done quarterly and all samples passed regulatory limits by the NYSDEC. The next round of WET testing will be done in 2023.

Annual Testing Result Averages

Parameter BOD (mg/l)

TSS (mg/l)

Flow (mgd)

BOD (lbs/day)

TSS (lbs/day)

Coliform (#/100 ml)

Arlington WWTPInfluent 152 183 2.6 3,602 4,411Effluent 6.0 6.7 2.6 151.5 134.1 18

Compliance Overview

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There were no odor complaints during the 2018-2019 operating period. The odor control program continued throughout the past year. We continue to follow Standard Operating Procedures (SOPs) and perform weekly air monitoring for H2S, an odor control chemical (Calcium Nitrate) is added to the thickened sludge and procedures for obtaining information from residents or business owners who report odor issues. In addition, the odor control system for the sludge garage and centrifuge run continuously.

Odor and Customer Issues

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ENVIRONMENT, HEALTH, SAFETY & SECURITY

SUEZ is committed to providing its employees with a comprehensive, job-specific environment, health, safety and security (EHSS) training program. This training program is based on individual training needs of each employee, with input from the EHSS Manager. Applicable training courses are assigned to the individual employees based on individual job responsibilities.

Additionally, based on latest industrial research, SUEZ continues to offer other critical high value training programs. For example, research has indicated that there is no direct correlation in improving recordable injury rates and preventing fatal accidents, and specific and targeted interventions are required for preventing fatal industrial accidents. While SUEZ North America has never experienced a fatal accident by any employees, the 10 Life Saving Rules were implemented at all projects in 2013. All SUEZ employees at the Poughkeepsie, NY project were trained in this initiative during May and June of 2015, and this initiative continues to play an integral role in the project’s safety culture.

Some examples of key EHSS initiatives implemented at the Poughkeepsie, NY project during the 2018-2019 operating period include:• Routine training sessions, seminars and

compliance workshops. EHSS training was completed throughout the past year. All employees have continued online safety training covering a wide variety of safety topics. Plant staff also participated in weekly “tailgate” safety sessions to discuss safety needs of the facility. In addition, awareness training for the following plans were completed for 2018 and continues throughout 2019: SPR; SPCC; EAP; Sampling; Laboratory Hygiene; Universal Wastes; Slips, Trips & Falls; Fork Lift Safety; Confined Space; Lockout/Tagout; Hazard Communications; Electrical Safety; Fire Safety; and Storm Water Pollution Prevention. Facility staff also complete an operator led training class once per year.

• Safe Work Plan: All routine work procedures performed by the operational staff have a Safe Work Plan. The plan identifies the Hazards and Controls to safely perform their duties.

• Unsafe Conditions/Near Miss Program: All Unsafe Conditions or Near Miss incidents are recorded and corrected. A corrective action plan is developed for each incident and completed by a set completion date.

• Improvements to EHSS contractor orientation program. Before beginning work, each contractor authorized to perform work at the Poughkeepsie project is required to complete the EHSS orientation and is issued an orientation card. The program is aimed at prevention of injuries and environmental incidents.

Four of the plant staff are NYSDEC 3A Certified wastewater operators. They include Project Manager Steve Segna, Assistant Project Manager Robert Eichler, Marcus Paroli and Adam Vantassel. Andret Hart and Nicholas Crispi are grade 2A certified. The staff continue to complete recertification training on a regular basis.

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EHSS “Doing It Right” Recognition ProgramTo promote innovation and good safety practices in the workplace, the SUEZ EHSS team developed a recognition program that highlights innovative safety practices in the workplace. Whether it’s a new procedure, a new tool to make the job easier or employees demonstrating good work practices, we want to share that experience across the organization to recognize their effort and provide ideas to help make every workplace safer.During the 2018-2019 operating period, the Poughkeepsie team was recognized for the following safety improvements.• Installing new base plate next to each clarifier in the

plant. New personnel retrieval system will utilize these base plates during tank maintenance

• Installing safety gates through the railings for each clarifier tank. This eliminates the need to climb over the railings when entering tanks for maintenance

• Installed new safety railings around the skylights • Installed new panel locks on all electrical panels

that have unprotected power sources inside• Painted outside steps and walkways safety yellow

to eliminate trip and fall hazards• Replaced all of the electrical panels and transformer

in the chlorination room. These electrical components were badly corroded and had water dripping on them. New panels were located outside of the Chlorine room in weather proof enclosures.

•

Safety AwardsSUEZ staff has completed seven years without an OSHA reportable incident.

Environmental Compliance

SUEZ has an equally good environmental compliance record which is reflected in a high level of compliance at all projects including Poughkeepsie, NY. One of the highest priorities is complete transparency in all environmental matters at all projects. To accomplish this, the state-of-the-art Water Information Management System (Hach WIMS™) is used to monitor and track all compliance data. This data is reviewed daily, weekly and monthly, and any issues are immediately reported, investigated for root causes, and appropriate corrective and preventive measures are implemented. This data is also automatically transferred into the monthly report format for the State, thus eliminating the potential for any data transcription/calculation errors. Due to these and other compliance initiatives, the Poughkeepsie project did not experience missed samples or reporting deadlines during the period ending July 4, 2019. There were zero non-compliance events during this period. SUEZ also participates in its parent company’s (Paris-based SUEZ) annual reporting campaign. Pertinent data from all projects is reported to Paris and is benchmarked against water and wastewater treatment facilities across the world. Any deviations are noted and shared with the management team and are used to optimize plant operations for the clients we serve. This is a high-value service which SUEZ provides to all its clients at no cost to them.

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The following regulatory reports and plans were completed during the 2018-2019 operating period:• Monthly BMW and DMR reports – due the 28th and

15th of the following month• Annual EPA 503 Sludge Report – submitted

2/5/2019• Annual Tier II Report – 1/28/2019• Annual Design, Planning and Flow Management

Certification Report – 2/21/2019• Annual Storm Water Certification Report – 2/6/2019• Annual Status Report on Mercury Minimization

Program – 6/1/2019• Annual FROSI Report – Submitted 7/12/2019• Annual DMR QA Study – results submitted 7/9/2019

and final report due 8/11/2019• NYSDEC Hazardous Chemical Bulk Storage

Permit – submitted 4/4/2019 due 7/5/20• NYSDEC Hazardous Chemical Bulk Storage tank

five-year inspection passed on 5/21/19• NYSDEC Waste Transporter Permit – submitted by

collection system manager• NYSDEC Petroleum Storage Permit – expires

11/7/2021• Spill Prevention Plan – For Hazardous Chemicals,

Annual Certification 3/20/2019• Emergency Action Plan – Annual Review 7/8/2019• Oil Spill Prevention Control and Countermeasure

Plan – Annual Review 2/27/2019• Laboratory and Sampling Plan – reviewed

4/18/2019

Inspections & Calibrations• Flow meters – quarterly by ABB – 2/22/19 & 5/10/19• Annual fire extinguishers – 4/9/19• Bi annual gas detector calibrations – 4/19/19• Annual laboratory equipment calibrations – 1/16/19• Annual back flow inspection – 2/15/19• Annual Arc flash Personal Protective Equipment

(PPE) inspection – 2/1/19• Annual hoists inspections – 5/14/19

Regulatory InspectionsA facility inspection was completed by the NYSDEC on April 24, 2019 by Arthur Crawford. There were zero verbal deficiencies at the time of the inspection. We have not received an official written report at this time.

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Arlington

• Electrical improvements- Replaced and adjusted all primary clarifier drive

controllers and alarms- Replaced secondary clarifier #3 drive controls

and #2 control panels- New LED lighting throughout the plant was

completed in 2019- Replaced breakers for the thickener buildings

vent fans and front gate- Replaced wiring for secondary clarifier #3 drives- Atlas Copco and Revere upgraded the new

blower control program- Repair the #1 primary clarifier drive controls- Repaired wires for Secondary clarifier drive #1- Installed new control board for the front gate- Made repairs to old aeration flow control floats- Installed new outlet for the backup sump pump

in the effluent water pump room- Installed new conduit and outlets for the

emergency lights in the pipe tunnel, which eliminates the use of extension cords

- Replaced two of the Eaton VFD units for the sludge pumps in the thickener building

- Removed the old breaker panel and transformer from the chlorine room. Installed new panels and transformer on the outside wall of the room eliminating corrosion issues

• Installed three new AC vents in the control building and painted the hallways, laboratory and office areas

• Performed maintenance on the plant plow truck• Installed new shelving in the storage cage and moved

all spare parts to this area• Continued to repair or replace pipe supports in pipe

tunnel• Installed new safety pinch guards on the primary

clarifier drives• Installed new safety railings around the Skylights over

the RAS room.• Removed fuel oil (in the 8,000 gallon tank) and used

oil from the site• Replaced valve and pipe for RAS sampling port• Replaced sump and check valves for RAS area sump• Installed metal extension on the top of the thickener

scum pits to prevent overflows• Annual maintenance completed on SCADA system

alarm• Purchased a backup pump for domestic pit and

centrate tank. as well as a spare transducer for these two pump stations

• Replaced batteries in all UPS units• Installed a new window A/C unit for the tool room and

centrifuge control room• Installed new safety gate on all seven clarifier tanks• Installed new base plates at all clarifier tanks for the

retrieval system• Purchased a new personnel retrieval system for fall

protection entering the tanks• Made repairs to the walls, painted and added shelving

to the centrifuge control room• Completed painting on pipe supports, walkways,

thickener building, secondary building and clarifier walls

• Performed annual maintenance on Fork lift• Performed bi-annual maintenance on the generator• SUEZ performed a laboratory review which included a

new QA/QC plan and an update to the sampling plan

Facility Improvements Overview

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• Made extensive repairs to the heating system; replaced all old valves, circulator pump and valve, and performed maintenance on the boilers

• Rebuilt chlorine analyzer and feed pump• Completed maintenance and cleaning of thickener

tanks and equipment• Made repairs to the steps by the secondary tanks• Replaced thermal sensor and packing on the polymer

system for the centrifuge• Completed maintenance and repairs on the auto

samplers and chlorine analyzer• Removed old packing gland and had new glands

fabricated and installed for the aeration flow control valves prior to the installation of the new control actuators and control panel

• Completed maintenance and made repairs to all grounds equipment including snow blowers, mowers, tractors and weed wackers

• Purchased new drives for the Sludge pumps• Installed new cabinets and counters in the break room• Completed calibrations and repairs on the aeration

tank dissolved oxygen sensors and controls• Replaced carbon cans on both odor control systems• Installed dehumidifier and drain piping in the main

electrical room• Installed and reconfigured the piping in the sludge

mixing box to get a better mix• Maintenance and cleaning completed on secondary

clarifiers• All facility equipment has been inventoried and ID tags

have been placed for the new CMMS• Performed maintenance on the grit and rag hoppers in

the Influent building• Removed old ceiling heaters and piping due to leaking

from the process room; capped all pipes

Arlington WWTP Facility Upgrade ProjectThis project began in late 2016 and continues through 2019. The following areas of the upgrade have been completed:• Completely new headworks building with automatic

screening and grit removal, overhead crane, influent and DCRR influent flow meters, DCRR PH probe and meter, gas detection system and automatic venting fans, louvers and water booster station

• Sewer, effluent water and domestic water piping throughout facility

• New primary influent chamber flow valves • Upgrade of primary clarifiers, piping and gates• Upgrade of sludge pumps (primary sludge, RAS,

and sludge feed)• Electrical upgrades including a new generator,

control panels, conduit and wiring• New aeration blowers, piping, auto valves, dissolved

oxygen sensor system, fine bubble diffusers and controls for the biological treatment tanks

• New OSHA approved railings, kick plates and grating throughout facility

• Driveway paving, sidewalks and curbing• Landscaping and reseeding the grounds• New sludge dewatering system includes centrifuge,

screw style conveyors, controls and centrate tank with pumps

• All old skylights have been sealed up with concrete and new skylight covers installed over the secondary pump station

• 12-inch stainless steel wall extensions, new effluent water intake piping and valves, and a new valve platform were installed in the chlorine contact tanks

• Completed influent building overhead hoist, which is working

• Completed aeration flow control system, which has been working well

SUEZ staff has worked with Morris Engineering, Blue Heron Construction and SASS Electrical to complete all aspects of this project while maintaining a safe work environment.The facility met all regulatory compliance limits and standards throughout the project. This project has been completed.

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Upcoming Projects• Primary Scum Pit: This project is mostly complete. Waiting on a control panel for the primary scum pump

and a hoist for the secondary scum pump.• Effluent Spray Water Pumps: This project has been completed except for some painting, new hose and

valve and cleanup.• Computerized Maintenance Management System including preventive, predictive and corrective

maintenance, and spare part inventory and tracking of all equipment within the facility.• SCADA control system is in the bid process at this time.• Pipe support repairs: SUEZ has taken on this project with a goal of completing three to five supports per

month under the repair budget. Approximately 50 supports have been completed. • Expansion joints and ground water control: This project is in the planning stage at this time.• Upgrade of the chlorine room electrical system: All of the old breaker panels, switches and transformer

are to be removed. New units will be installed outside of the chlorine room in weather proof enclosures. This will eliminate the corrosion and water leakage issues that have affected this area. This project is in progress and should be completed by the end of July.

PREVENTIVE MAINTENANCE OVERVIEW

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We have continued asset management of all equipment and we are adding in all preventive maintenance schedules as we identify new items. The following data is provided as a record of maintenance work order activities during the year.

Type Total for YearPreventive Maintenance 1,147Corrective Maintenance 78Emergency Maintenance 26

The following data is provided as a record of maintenance financial activities during the year:

Item $ Spent/Yr.SUEZ Preventive, Corrective and Capital Maintenance

$140,976.75

Town of Poughkeepsie Capital Repair and Replacement

$81,519.26

Capital and Corrective Maintenance OverviewThe following is a list of recommended projects from July 5, 2018 to July 4, 2019 that are greater than $5,000.00:

Suggested Recommendations

Recommended Purpose or Use Status

Arlington Plant SCADA system

SCADA system to be installed after new equipment is installed

This goes out to bid in July

Arlington Plant Pipe Support Replacement

Replace rusted pipe rack supports in pipe tunnel

SUEZ has taken on this project with a goal of completing three to five supports per month

Arlington Plant Primary Scum Pit Upgrade

Install new pump system and controls and repair concrete

Waiting for control panel and hoist to complete this project

Suggested Recommendations

Recommended Purpose or Use Status

Arlington Plant Effluent Spray Pump System

Replace existing system with dual pump system, controls and strainers

Complete other than some painting and cleanup

Arlington Plant Aeration/Secondary clarifier flow control system

Replace older controls and valve actuators

This final portion of the upgrade project is complete and working well

Arlington Plant Chlorine Room Electrical Panel Upgrade

Replace and move breaker panel, transformer and switches that are rusted and unsafe

Completed panels are located outside Chlorine room in weather proof enclosures

Arlington Plant Odor Control System in Lower Process Room

Install a carbon odor control system for the centrate tank in lower process room; to remove high H2S levels in the area

Completed. H2S levels within acceptable limits

PREVENTIVE MAINTENANCE OVERVIEW

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SUEZ recognizes that its role in the community is as critical a part of its presence in Poughkeepsie as managing its wastewater facilities. SUEZ sustains good corporate citizenship through the support of many community outreach programs. Over the past year, the company has donated money to various local organizations throughout the Town of Poughkeepsie. The primary focus is to support nonprofit organizations dedicated to the environment, education, diversity and humanitarian services.Some of our outreach activities included: • Annual donation to the local volunteer fire department• Annual donation to Northeast Parent & Child Society’s Holiday Hope Fund, which raises money to purchase

food and gift cards for children and families the organization serves• Plant tours for students of Oakwood High School and Vassar College, all within the Town of Poughkeepsie• Worked with students at Marist College and SUNY Stony Brook in sampling and testing the plant effluent.

Testing is for personal care products and pharmaceuticals traveling through the plant and into the environment

Community Relations

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