2010 WATER POLLUTION CONTROL ANNUAL REPORT

“ Th e m issio n o f th e Wa ter Po l lu tio n Co n tro l P la n t is to p ro vid e th e m o st effec tive

cu sto m er o r ien ted wastewa ter co l lec tio n a n d trea tm en t to th e c i tizen s o f Pa in esvi l le” .

GRIT CLASSIFIER GENERATOR

CLARIFIER DRIVE AERATION SYSTEM

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WPCP SUMMARY

The Painesville Water Pollution Control Plant protects the health of the community and environment by reclaiming the community’s wastewater. During 2010 the plant treated an average of 2.75 million gallons per day of wastewater from residential, commercial and industrial sources. From this wastewater, two recycled products were produced, clean water discharged to the Grand River, and 3,581 wet tons of processed biosolids, which are landfilled at the Lake County Landfill.

Treatment of hauled septage by the WPCP completed its first full year of service in 2005. Twelve septage haulers are currently permitted by the WPCP. The revenue generated from these haulers totaled $163,336.00 for 2010.

Management and operations of plant biosolids dewatering and disposal are performed by plant staff. Determining the most economical approach to an environmentally approved disposal practice is critical to our financial feasibility. In 2010 the WPCP hauled 3,581 wet tons to the Lake County Landfill. The total cost to dispose of the plants biosolids was $112,885.00

The WPCP Safety operated successfully in 2010. The coordinator position was under the responsibility of Kevin Aiken. Kevin continued his involvement with the Lake County Safety Council and attended the monthly meetings. Fire extinguishers were inspected and certified.

SAFETY PROGRAM

The 2010 Ohio Water Environment Conference was held June 15 – 17 in Columbus, OH. The conference attracts water professionals from the state of Ohio and surrounding states to meet and share ideas and information on water pollution issues and research. Over 500 water professionals annually attend the OWEA conference.

OHIO WATER ENVIRONMENT ANNUAL CONFERENCE

COLUMBUS, OHIO

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LABORATORY Laboratory personnel Leslie Balata and Jeff Tressel completed the DMR-QA testing and evaluation required for laboratory facilities by the USEPA. The results of the testing were that the plants laboratory analyses were in complete 100% compliance, an outstanding achievement by both Leslie and Jeff.

1. Capital – Sewer Budget

CAPITAL IMPROVEMENT PROJECTS

a. Administration Building – New Roof b. SCADA Server Upgrade C. Sewage Pump Station – Wireless Communication

ACCOMPLISHMENTS OF THE 2010 DEPARTMENTAL BUDGET Water Pollution Control Loan Fund (WPCLF) Construction- completed construction of

major plant equipment and systems. Alum Sludge De-watering – in January of 2010 alum sludge was trucked to the WPCP

where plant personnel de-watered the alum sludge. De-watered alum sludge was then transported to the Lake County Landfill for disposal.

Computer’s – Purchased new computers to operate the WPCP SCADA system Standby Generator – Completed construction of new 2.2 megawatt generator. New

generator can provide power to the WPCP during power outages. Pump Station Communication – installed new pump controllers in 5 pump stations that will

allow communications via radio signals. SCADA – Keeping with the goal of plant automation, the SCADA system has the ability to

perform the following new functions: a. automatically waste sludge to the primary clarifiers b. automatically pump raw sludge to the anaerobic digesters c. backwash the tertiary filters d. control the airflow in the aeration process

Jeff and Leslie have over 40 years combined experience in laboratory sampling and analysis. Both have Bachelor Degree’s in Arts and Sciences.

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Vactor Truck Dump Station – Completed construction on new vactor truck dump station. New fiberglass wall extensions were installed to prevent station leaks during dumping. Two new pumps were purchased to de-water the dump station.

Computer Server Upgrade –Updated the SCADA system IFIX program. Administration Building Roof Replacement – replaced the existing rubber membrane on the

administration building with new. The new roof has been insulated and replaced with new white roof membrane.

Variable Frequency Drives – VFD’s that were salvaged from Lake East Hospital have been installed on the sludge press pump (No. 2). The new VFD allows the operator of the press to adjust the sludge flow to the belt filter press.

Senior Employment – The WPCP employs an employee who is a member of the SCSEP, Senior Community Employment Program. The overall goal of this program is to help build skills that improve the employee’s ability to find employment in the wastewater profession. The employee is provided a 20 hour work week that is funded by federal budget.

Harvey High School Salvage – Department personnel identified salvageable equipment in Harvey High School that was removed for use. Equipment included a 90 gallon hot water heater, welder, folding chairs, table saw, planer, sander, ceiling fans, water cooler, floor fan and other related items of value.

Lake East Hospital Salvage – Department personnel identified salvageable equipment in the hospital that was removed. Equipment included electrical panels, variable frequency drives, cabinets, dry erase boards, sinks, faucets, communication towers, security cameras, pumps and other related items of value.

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2010 TRAINING EVENTS Date Site Training

Event Staff Attendees

Cost

Jan. 28, 2010 Richfield, OH

NESOWEA Annual Operations Seminar

Randy Bruback Joe Jackson Joe Elliott James Davidson James Boykin David Sudbrook Leslie Balata Mike Darosy

$320.00

Feb. 25, 2010 Richfield, OH

NESOWEA Industrial Wastes Seminar

Jeff Tressel

$40.00

Mar. 23, 2010 Caldwell, OH Buckeye Hills RC&D & Ohio EPA Grant Writing

Randy Bruback $106.49

Apr. 13-14, 2010 Youngstown, OH Ohio BWC Confined Space Assessment

Kevin Aiken $102.54

May 7, 2010 Columbus, OH OH Warn Table Top Exercise

Randy Bruback $106.20

May 25, 2010 Lake Erie College

Painesville Electric Power Quality Workshop

Randy Bruback Joseph Jackson Terry Haffey Jeff Hannan

$200.00

May 27, 2010 Euclid, OH

NESOWEA Annual Awards Euclid WRF Tour & Technical Sessions

Randy Bruback Jeff Tressel Joe Jackson Leslie Balata Mike Darosy David Sudbrook Tim Leonard James Boykin James Davidson Kevin Aiken Terry Haffey Gerald Skaggs

$275.00

Jun.7, 2010 North Olmstead, OH

ITT Flygt Pump System Design

Joe Jackson Kevin Aiken Terry Haffey Jeff Hannan Gerald Skaggs

$0.00

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Jun. 15-17, 2010 Columbus, OH OWEA 2010 Annual Conference

Randy Bruback $703.48

Jun. 24, 2010 Painesville WPCP

American Red Cross CPR/AED Training

WPCP Plant Staff

$420.00

Nov. 3, 2010 Mentor, OH Lake County Safety Council OSHA/PERRP Recordkeeping

Randy Bruback Kevin Aiken

$100.00

Nov. 10, 2010 Galion, OH ITT Flygt Product Service Education

Joe Jackson Kevin Aiken

$0.00

Nov. 18, 2010 Wadsworth, OH NESOWEA Wadsworth WWTP Plant Tour & Technical Sessions

Joe Elliott James Davidson David Sudbrook Tim Leonard John Caldwell

$125.00

Nov. 18, 2010 Cincinnati, OH SWOWEA Plant Operations Seminar & Sectional Meeting

Randy Bruback

$210.45

Dec. 9, 2010 Columbus, OH OWEA 2010 Biosolids Specialty Workshop

Randy Bruback

$192.37

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WPCP HISTORY

The Painesville Sanitary Sewer System was first developed about 1887 as a combined sewer system discharging directly to the Grand River at six (6) different locations. As the Village of Painesville grew and expanded, the sewer system was expanded. At the present time there are approximately forty-five (45) miles of sanitary sewers in the Painesville Sanitary Sewer System. The service area for the Painesville Sanitary Sewer System is shown on the following page. On December 16, 1946, the Painesville City Council hired Havens & Emerson Consulting Engineers to prepare reports and plans for an Interceptor Sewer System and a Water Pollution Control Plant, which would eliminate the pollution of the Grand River.

The original Painesville Water Pollution Control Plant was built as a Primary type treatment plant in 1957 by Freeman and Jones of Cleveland. The thirty-six (36) inch and thirty (30) inch interceptor sewers were constructed in 1958. Two (2) Ejector Stations and one (1) pump station together with related sewers and force mains to complete the Interceptor Sewer System were also constructed. Two (2) miles of thirty (30) inch Interceptor sewers and appurtenances were constructed by Curro-Construction Company. The Koski Construction Company of Ashtabula, Ohio constructed two (2) ejector stations and (1) pump station together with related sewers and force mains to complete the Interceptor collection system. The primary type treatment plant was placed into operation on April 4, 1958. In August 1965, intermediate chemical treatment facilities were added to the original primary treatment units. The process of feeding chloride for phosphate removal was put into operation on June 2, 1970; this was accomplished on full plant scale.

In 1968, the firm of Glause, Pyle, Shomer, Burns, and Dehaven were hired as the Consulting Engineers for a plant expansion. Phase I of the expansion was completed in February 1973. This included the new Administration Building, which was attached to the old building. Phase II was never accomplished with the aforementioned engineering firm. Burgess & Niple, Ltd. was then hired on February 18, 1973, to plan and design the construction of an activated sludge plant, followed with tertiary filters.

On July 6, 1973, the City authorized the preparation of detailed plants and specifications for wastewater treatment facilities in accordance with the general plants that were approved by the Ohio EPA, February 7, 1973. These plans would provide additional grit removal and comminution, additional primary settling, first stage aeration tanks and settling for carbonaceous biochemical oxygen demand reduction, second stage aeration tanks and settling for ammonia-nitrogen reduction, tertiary filters, post aeration, hypo-chlorination, aerobic digesters, sludge dewatering, additional anaerobic capacity, and facilities for feeding chemicals for phosphorus reduction. The facilities would have an average daily capacity of six (6) million gallons per day for ultimate treatment, a daily peak capacity of fifteen (15) millions gallons per day and a maximum hydraulic capacity of twenty-eight (28) million gallons per day. The facility would be designed so the average daily treatment capacity can be expanded to twelve (12) million gallons per day with a peak flow of twenty-eight (28) million gallons per day. The facility, as designed would include the best available control technology economically available.

After development of a facilities plan for the Painesville-Fairport Harbor Area, federally funded construction contracts for the secondary and tertiary treatment facilities at the Painesville Water Pollution Control Plant were signed on June 24, 1976. Groundbreaking ceremonies were held on

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July 6, 1976.

Bay Con Construction Company of Sandusky, Ohio was the general contractor. Improvements were made to the grit facility, primary treatment, and anaerobic sludge facilities. New facilities include two-stage aeration secondary, tertiary filters, and post aeration/ hypo-chlorination facilities.

The firm of Burgess & Niple Ltd., was contracted on August 15, 1997 to prepare detailed plans to construct a new Sludge handling Facility at the Water Pollution Control Plant. This facility included a new 1.5 meter Filter Press and all the necessary appurtenances for the process of aerobic and anaerobic sludge’s.

Bids for this project were advertised on October 15, 1998, and the tabulation of bids were received and opened on October 29, 1998. The successful bidder was ABC Piping Company on November 13, 1998 in the amount of $817,390.00. The completion date of this project was 270 Days or September 13, 1999.

2009-2010 WPCP CONSTRUCTION AND EQUIPMENT UPGRADES In 1978 the WPCP increased its design flow capacity to 6.0 million gallons per day by way of a major construction expansion. New systems were added that included secondary and tertiary treatment processes. Over the course of the last 30 years these treatment systems have served the cities responsibility in meeting OEPA effluent discharge requirements.

The useful life of wastewater equipment and processes is estimated at 30 years. Since 2004 the annual capital budget submittals have included major process control upgrades to maintain the required level of treatment set forth by OEPA. The City decided in 2006’s capital budget process to combine the requested capital budget proposals and seek a funding source that would allow a construction project that included all the necessary upgrades.

Burgess & Niple Engineers were hired in August, 2007 to plan and design the new construction upgrades. Water Pollution Control plant staff worked with the engineers to correctly identify the specific processes that had deteriorated to the point of replacement. The plan developed included the following upgrades:

o Tertiary Control System Upgrade o Tertiary Filter Media Replacement/Tertiary Screw Pump Protection o Secondary clarifier tank collection mechanism replacement (3 tanks) o Primary clarifier tank collection mechanism replacement (2 tanks) o Aeration Control system upgrade o Grit removal system replacement o Polymer feed system replacement o Standby generator replacement o Aeration Basin Slide Gates o Odor Control

Funding for the project was investigated by the engineers and city staff. An OEPA “Water Pollution Control Loan Fund (WPCLF) was selected. The WPCLF provides financial and technical assistance for qualifying wastewater treatment works projects which are owned by

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public entities. The WPCLF offers below-market interest loans. In addition to low-interest loans, the WPCLF staff offered experience in planning, design review and project implementation.

The original treatment plant was built at a cost of $807,904.80 in 1957. The 1958 improvements to the Water Pollution Control System cost nearly $1,600,000.00. The 1973 expansion, at a cost of $530,000.00 brought the estimated value of the Painesville Wastewater Treatment System to $7,060,006.00. The cost of the 1976 expansion was $11,305,382.17 and the addition of the Sludge Handling Building in 1998 at a cost of $817,390.00, bringing the estimated value of the Painesville Water Pollution Control Plant, seven (7) pump stations, and collection system of $22,317,390.00.

VALUATION

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PLANT OPERATIONS & PERFORMANCE

In 2010, the City of Painesville Water Pollution Control Plant ran very efficiently treating 1.004 billion gallons of wastewater. The average daily flow of wastewater through the plant was 2.75 million gallons. The raw 5-day biochemical oxygen demand (B.O.D.) into the facility was 177 mg/l daily. The final daily average B.O.D. was 1 mg/l, which represents a 99.3% reduction.

The daily average influent concentration of suspended solids (S.S.) was 306 mg/l in 2010. The S.S. was reduced by 99.1% to 3 mg/l by treatment in the plant.

The average daily influent concentration of phosphates was 4.07 mg/l. This was reduced to 0.46 mg/l, which represents a 88.7% reduction. The daily average influent concentration of ammonia nitrogen into the facility was 16.6 mg/l. This was reduced to 0.14 mg/l, which represents a 99.2% removal rate.

During the period of January 1, 2010 through December 31, 2010, the WPCP processed and pressed 8,179,201 gallons of anaerobic sludge, and 392,716 gallons of Alum Sludge for a total of 8,572,917 gallons. This produced 3,581 wet tons and 767 tons of dry solids.

The Vulcan Step Screen which is used to remove debris and rags has performed as designed. During the year the plant removed 20.92 tons of screenings. The detritors removed 43.21 tons of grit. The screenings and grit were both disposed of at the Lake County Landfill.

PRIMARY TREATMENT

Chemical treatment for phosphorus removal using Liquid Aluminum Sulfate, required 231,500 pounds of Aluminum Sulfate at a cost of $.149 per pound or $34,505 for 2010.

The Annual Gallons of raw influent records for the past 10 years are presented below.

1.001.10

1.361.16

1.321.16 1.16 1.09

0.85 0.85

00.20.40.60.8

11.21.4

2010 2009 2008 2007 2006 2005 2004 2003 2002 2001

years

Treated Flow - Billion Gallons

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The cost of operation and maintenance for the Water Pollution Control Plant, collection system and administration total was $3,871,703 for 2010. This resulted in a unit cost of $3857 per million gallons treated.

The three (3) Primary Settling Tanks operated satisfactory during 2010 and recorded performance levels of 61.7% removal of suspended solids and 42.4% removal of 5-day B.O.D. A total of 6,961,881 gallons of sludge was removed from the primary settling tanks and transferred to the anaerobic digesters. Raw Sludge was pumped at an average concentration of 3.90% solids.

ANAEROBIC DIGESTERS

ANAEROBIC DIGESTERS

ANAEROBIC DIGESTERS

No.1 and No. 2 Primary Digester’s and the No. 1 Secondary Digester operated satisfactorily during the year. The primary digesters received sludge from the primary settling tanks. After digestion, the sludge is then pumped to the secondary digester. The main function of the secondary digester is to produce a settle sludge that is well stabilized. The liquid sludge is then removed from the secondary digester, pressed and sent to the landfill. The digesters received 6,961,881 gallons or 19,074 gallons per day of 3.9% solids during the year. The sludge contained an average fresh solids volatile matter of 68.1% and an average fresh solids fixed matter of 31.9%

Secondary treatment consists of the single stage aeration basins and the final settling tanks. The units of the secondary treatment process functioned properly during the year, single stage aeration now in its second full year of operation, performed very well.

SECONDARY TREATMENT

The purpose of secondary treatment is for the oxidation of carbonaceous B.O.D. and ammonia nitrogen. The nitrifying organisms oxidize the ammonia nitrogen into the nitrate form. The settling tanks are used for the removal of solids generated in the aeration process and the return sludge pumps are used to control the amount of solids, or food for the micro-organisms in the aeration basins.

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AERATION BASINS

AERATION BASINS

Return sludge is collected in the final tanks and returned to the aeration process. The average daily return sludge rate from the final settling tank was 2.61 MGD with 26,030 gallons of sludge wasted daily to the primary clarifiers.

SECONDARY SETTLING TANKS

SECONDARY CLARIFIER

Aerobic digestion is a sludge processing technique used to oxidize sludge organics to stable end products, reduce mass and volume of sludge, condition sludge and further solids handling. In aerobic digestion, the principal materials being oxidized include cellular organics and ammonia. Operation of the aerobic digesters was discontinued in May 2008. Aerobic digester tanks are being used to treat ammonia nitrogen from the belt filter press filtrate and to store alum sludge from the Water Plant prior to being mixed and pressed with plant solids.

AEROBIC DIGESTERS

AEROBIC DIGESTERS

AEROBIC DIGESTERS

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During the year, 48,179,201 gallons of anaerobic sludge and 392,716 gallons of Alum sludge were filter pressed and sent to the landfill for disposal. The sludge produced 3,581 tons of wet cake or 767 tons of dry solids. The cost of pressing and disposing of this year’s liquid sludge was $112,879.70 or $147.17 per dry ton.

FILTER PRESS

The Tertiary filtration or third level of treatment is provided by four gravity “mixed” media coal & sand filters. These filters are used to polish the secondary effluent by filtering suspended solids from the wastewater.

TERTIARY TREATMENT

TERTIARY FILTERS TERTIARY SCREW

During the year 10,519 pounds of evaporated salt was used in the production of 3,506 pounds of useable chlorine. The average chlorine residual in the effluent was 0.02 mg/l. The Hypo-Chlorination of wastewater was instituted only during the periods of our N.P.D.E.S Permit.

HYPO-CHLORINATION

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HYPO-CHLORINATION SYSTEM

Dechlorination of the plant’s effluent started on May 1, 2010 and ceased on October 31, 2010, as per our N.P.D.E.S. Permit. This process is accomplished by the addition of Sodium Bi-Sulfate to the effluent. During the year 4390 pounds of Sodium Bi-Sulfate was applied to the plant’s effluent to maintain a chlorine residual of 0.038 mg/l or less. Total chorination and dechlorination cost was $3261.00

DE-CHLORINATION

DE-CHLORINATION SYSTEM

During 2010 the average daily flow at the plant was 2.75 million gallons per day. The 2010 census recorded 19,563 residents in the City of Painesville. The Painesville Water Pollution Control Plant now serves an estimated 20,000 people.

TRIBUTARY POPULATION

The WPCP engineered, designed and installed a new SCADA system in 2004. The SCADA system is replacing the existing control panel with new computer technology that monitors and

SUPERVISORY CONTROL & DATA AQUISITON SYSTEM

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controls plant operations. Wireless Ethernet allows communications for the SCADA system vs. cable. In 2008 the SCADA system was programmed to pump raw sludge and waste activated sludge automatically, this new programming allows for a more efficient means of operation.

In 2010 the SCADA system was upgraded with the purchase of three new computers. The new computers have increased capacity and improved memory.

In 1962 no instruments were found to be adaptable to telemetering ejector and pump station information to the Water Pollution Control Plant. Accordingly, the plant personnel designed, built, and installed pilot telemetering equipment operated over leased phone lines. The telemetering system sends information indicating when the pumps are operating.

TELEMETERING

The latest plant improvements provided new transmitting equipment at each pump station. This equipment transmits information back to the plant where it is displayed on the display board and the SCADA System in the control room.

PLANT MONITORS AND SCADA SYSTEM

PUMP STATION OPERATIONS

Sanford Street Pump Station - is a dual non-clog submersible pump system, with two 250 GPM Flygt pumps. This station pumped 12,609,654 gallons of wastewater.

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Jackson Street Pump Station - The telemetering lines were connected to this station on January 25, 1964. This station has performed satisfactory during the year and pumped 13,834,400 gallons of wastewater. New construction for the Jackson Street Pump Station was completed in 2005. The new pump station is now located out of the street to prevent safety concerns. The new station was built using Issue II funding. The wet well has two new Flygt pumps, control system and dry pit valves.

Recreation Park Pump Station - is a dual pot centrifugal pump installed with a manually clean bar rack. The telemetering equipment was put into service on October 25, 1963. This pump station pumped 15,525,098 gallons of wastewater during the year.

Valleyview Pump Station - is a dual non-clog submersible pump system, with two 124 GPM Flygt pumps with a mix-flush system. This station pumped 2,469,556 gallons of wastewater.

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Erie Street Pump Station - the upgrading of this station includes two 100 gal/min. Flygt pumps, a wet well, valve box, and electrical equipment. This was completed on October 16, 1998, and returned to service. This station pumped 6,199,920 gallons of wastewater during the year.

Fern Drive Pump Station

- is a dual non-clog submersible pump system, with two 220 GPM Myers pumps. This station pumps wastewater under State Route 44. The instrumentation indicates this station pumped 6,630,048 gallons of wastewater during the year.

Poplar Lane Pump Station - was put into operation on April 2, 2004. This station is a dual non-clog submersible pump system with two 180 GPM Flygt Pumps with a mix flush system. This station pumped 43,561,440 gallons of wastewater.

Brookstone Meter - Brookstone Meter is located at Diamond Center. This meter recorded 11,739,358 gallons of flow.

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PUBLIC RELATIONS AND MEETINGS

January On January 6, Randy Bruback attended a Painesville City Image Committee meeting at city hall. On January 14, Randy met with Bill Carlson, Burgess & Niple Engineers, and Mike Kovach of North Bay Construction to discuss the Water Pollution Control Loan Fund project credits and deductions on change order #3. On January 28, plant staff attended the NESOWEA Annual Operations Seminar in Richfield, OH. February On February 5, Randy met with Rainbow Farms Produce in Perry, OH to discuss the land applications of biosolids. On February 5, Randy met with Bill Carlson, Burgess & Niple, to discuss the Water Pollution Control Loan Fund Project change order #3. On February 12, Randy met with Burgess & Niple Engineers and Richard Lesiecki, City Engineer, to discuss preliminary plans for the new sewage pump station in Heisley Park Development. Randy made a council presentation on February 16 that highlighted WPCP construction during 2010. Dmytryka Jacob Engineers were at the plant February 16-18 to set up the new tertiary filter control panels. On February 17, Randy met with the Painesville City Image Committee to discuss goals and objectives. On February 17, Randy and Jeff Tressel attended Leadership Training at Harvey High School. On February 23, Randy and Mark Mlachak, Fire Chief, met with James Fodor, City Council, to discuss the Painesville City Image Committee goals and objectives. On February 23, Randy met with Glen Ginesi, Engineered Process Systems to discuss the merits of a wind turbine at the WPCP. On February 24, Randy and Joe Elliott met with David Whitaker, Recreation Dept., to discuss a City steelhead fishing tournament.

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On February 25 the City Engagement Committee hosted a luncheon for city clergy at First Church Congregational. The meeting was held by the committee to engage a communication format with the local clergy to discuss new means of partnering. WPCP personnel served the luncheon to the clergy and city staff. On February 25, Jeff Tressel attended the NESOWEA Industrial Wastes Seminar in Richfield, OH. March On March 1, Randy met with Painesville City Image Committee members at Harvey High School. On March 2, Randy and Joe Jackson, traveled to Mason, OH to observe and evaluate a sludge paddle dryer used to remove moisture from belt pressed biosolids. On March 3, Randy and Joe Jackson met with Fowler Electric to discuss the project status of the new generator and fiber optic cabling. On March 4, Randy and Rita McMahon met with Engineered Process Systems to discuss wind turbine proposals. On March 8, The Bureau of Workers Compensation visited the WPCP to evaluate the ergonomics of plant personnel. On March 9, plant personnel removed equipment from the old Lake East Hospital. On March 9, Randy met with Painesville City Image Committee members at Harvey High School. On March 23, Randy attended the Buckeye Hills RC&D and Ohio EPA Grant Writing Seminar in Caldwell, OH. On March 29, the Community Engagement Committee met to discuss future plans. On March 29, Randy met with Rita McMahon, Joe Gurley, Law Director, to discuss the generator project and progress. On March 30, the Village of Hartville, OH WPCP plant personnel visited the Painesville WPCP. The village is entering the design phase of new construction and asked to tour our plant to get ideas and suggestions for new construction. On March 31, plant staff met with North Bay Construction and Burgess & Niple Engineers to discuss the construction progress and to establish a date of “substantial completion”.

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April On April 5, the Painesville City Image Committee met at the Painesville City School Board Building. On April 6-7, Mark Lyons of Dmytryka Jacobs Engineers was at the plant to program new plant process controls. On April 7, CAT and GPD Engineers were at the WPCP to perform power outage testing and determine the effectiveness of the new plant generator. On April 7, Burgess & Niple Engineers and North Bay Construction were at the WPCP to walk through the plant and review the punch list for completion of construction. On April 8, the Painesville City Image Committee met at the Painesville City School Board Building. On April 13, the Painesville City Image Committee met at the Painesville City School Board Building. On April 13-14, Kevin Aiken attended the Ohio Bureau of Workers Compensation Confined Space Assessment Course in Youngstown, OH. On April 15, the Painesville City Image Committee met at the Painesville City School Board Building. On April 20, Randy met with Mr. Chris Green, Harvey High School science teacher to discuss the idea of applying for an Environmental Education Grant from the Ohio EPA. On April 22, the Community Engagement Committee met at City Hall. On April 22, the Painesville City Image Committee met at Harvey High School. On April 26, Eric Rinninger, Applied Specialties, performed jar tests on aluminum chlorhydrate and plant influent to determine the effectiveness of phosphorus removal vs. alum. May On May 3, Randy met with Rita McMahon and Utility Department supervisors to discuss city utilites. On May 5, Mr. Green’s Harvey High School biology class toured the WPCP. On May 7, Randy attended the Ohio Warn Table Top Exercise in Columbus, OH. On May 18 Randy attended a Job Ready Sites Grant meeting at city hall.

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On May 25 Randy, Joe Jackson, Terry Haffey, and Jeff Hannan attended the Painesville Electric Power Quality Workshop. On May 27, plant staff attended the NESOWEA Annual Awards and Technical Sessions, and toured the Euclid Water Reclamation Facility. June On June 1, Randy attended a Public Relations Meeting at Harvey High School. On June 7, the WPCP Maintenance staff attended an ITT Flygt Pump Design System seminar. On June 15-17, Randy attended the OWEA 2010 Annual Conference in Columbus, OH. On June 22, Randy met with Rita McMahon to discuss Industrial Surcharges. On June 23, Utility Department supervisors met with Rita McMahon. On June 24, The WPCP staff received American Red Cross CPR/AED Training. On June 28, Randy attended a Community Engagement Committee meeting at Lake Erie College. July On July 1, Randy and Jeff Tressel met with Cintas to discuss local limits. On July 13, Paul Turner, GPD Group, was at the WPCP to discuss the generator project completion. On July 21, the WPCP hosted a Concerned Citizens of Painesville tour of the WPCP. On July 26, the Painesville City Image Committee held a meeting at city hall. On July 28, Utility Department supervisors met with Rita McMahon at city hall. On July 29, Randy, Joe Jackson, Joe Elliott, and Jeff Tressel attended an OWEA webinar at the WPCP. The webinar discussed Capital Asset Management in Government Utilities. August On August 3, Randy and Joe Jackson traveled to Clow Manufacturing in Coshocton, OH. On August 10, Randy met with a representative of the Painesville United Methodist Church to discuss the Community Engagement Committee’s breakfast on September 23rd. On August 10, Randy attended a Public Relations Committee meeting at city hall.

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On August 12, WPCP personnel attended a safety meeting presented by AMP Ohio at Electric Distribution. On August 24, Randy and Jeff Tressel met with Eckart America to discuss the WPCP effluent copper violations. On August 26, Randy attended a webinar on Innovative Local Government Marketing Strategies that Build Community & Trust hosted by ICMA at city hall. On August 31, Randy met with the Senior Employment Center project manager to discuss employment opportunities for senior citizens at the WPCP. September On September 8, Randy, Joe Jackson, Joe Elliott, and Jeff Tressel attended an OWEA webinar at the WPCP. The webinar was the second in a series discussing Capital Asset Management in Government Utilities. On September 16, Randy and Kevin Aiken attended an open house at CT Consultants. On September 20, Gordon McCollough, Senior Employment Center began employment (20 hrs/week) at the WPCP. On September 23, the Community Engagement Committee held a breakfast for the clergy in the City of Painesville at the United Methodist Church. WPCP personnel served the breakfast to the clergy and city staff On September 28, the 2011 Sewer Budget meeting was held at city hall. On September 29, Randy met with the Public relations Committee at Harvey High School. October On October 4, Randy met with Paul Turner, GPD Engineering to discuss outstanding electric invoices with Fowler Electric. On October 6, Randy and Rita McMahon met with Paul Turner and Fowler Electric to resolve payment of outstanding invoices. On October 13, WPCP personnel attended a safety seminar at Morse Ave. presented by AMP Ohio. On October 25, Randy and Joe Jackson met with Rita McMahon and Andy Unetic to discuss the wireless communications at the city’s sewage pump stations. On October 28, Randy and Joe Jackson met with Sung Pyo, Beta Group, to discuss the installation of the new wireless communication devices at the city’s sewage pump stations.

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On October 29, David Jenkins, who trains border collies to chase Canadian geese off of properties, gave a demonstration at the city park. November On November 3, Randy and Kevin Aiken attended the Lake County Safety Council OSHA/PERRP Recordkeeping seminar. On November 10, Joe Jackson and Kevin Aiken attended ITT Flygt Product Service Education in Galion, OH. On November 18, plant staff attended the NESOWEA Wadsworth WWTP Tour and Technical Sessions. On November 18, Randy attended the SWOEA Plant Operations Seminar & Sectional Meeting in Cincinnati, OH. On November 22-23, Mark Lyons of Dmytryka Jacobs Engineers was at the WPCP to update the new software for the IFIX program that controls the plant SCADA system. On November 23, Doug Lewis, Assistant City Manager gave a United way Presentation and also spoke on community development progress. Cathy Bieterman, Economic Development, also spoke to the plant staff about new development within the city. On November 24, Utility Department supervisors met with Rita McMahon at city hall. December On December 2, Randy met with Fosters McMasters, AECOM Engineers, to discuss his presentation for the NESOWEA Annual Operations Meeting. On December 9, Randy attended the OWEA 2010 Biosolids Specialty Workshop in Columbus, OH. On December 20, Randy attended a Painesville City Image Committee meeting. On December 21, the WPCP hosted the annual Christmas Party at the plant. Retirees in attendance included Smith Carson, Bob Remington, Greg Brown, and Gary Paine.

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OPERATOR’S CERTIFICATIONS

When the plant was put into operation in 1958, only one Class “C” certified operator was employed, with a 4-man crew 8-hour operation. We now have 18 people and operate 24 hours a day, Monday-Friday and 16 hours on Saturday and Sunday. The following men and women have received certification from the Ohio EPA after a very concentrated effort in school, night classes, sectional meetings & seminars. This not only helps the individuals, it also aids the City by having a well-operated & maintained Water Pollution Control Plant.

1. Randy Bruback Class IV Superintendent

2. Jeffrey Tressel Class III Lab Supervisor

3. Joseph Jackson Class I Maintenance Supervisor

4. Joseph Elliott Class III Operations Supervisor

5. Russ Thompson Class I Operator II

6. James Davidson Class III Operator II

7. Michael Darosy Class III Operator II

8. John Caldwell Class I Operator II

9. David Sudbrook Class I Operator II

10. James Boykin Class I Operator I

11. Gerald Skaggs Class II Operator I

12. Timothy Leonard Class I Operator I

13. Leslie Balata Class II Lab Technician I

14. Edward Prib Class I Maintenance Mechanic I

15. Terry Haffey **** Mechanic/Electrician

16. Jeffrey Hannan **** Maintenance Mechanic II

17. Kevin Aiken Class II Operator I

18. Carol Kappel **** Secretary I

Randy Bruback also has a Class I Laboratory Analyst Certificate and Jeffrey Tressel has a Class IV Laboratory Analyst Certificate.

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2010 ANNUAL REPORT – MAINTENANCE

January 2010 • An operational error resulted in the rupture of the digested sludge line in the tunnel. A North Bay

construction worker was down there when it happened and immediately reported the failure. It was isolated quickly and spillage was very minimal. It cracked in the wall thimble and buckled an expansion joint mid -tunnel. A new expansion joint had to be ordered and the pipe jacked back into the thimble to complete repairs.

• Sludge Heater #2 / purge fan failure. We took the unit off #1 since it was out of service and put on #2. A new motor was ordered and installed on #1 4 days later.

• We installed a pipe pressure switch on the Primary pumps discharge line to the digester's. This was done to monitor pressures, detect blockage, and protect piping and over-pressures, subsequently shutting the pump down. This was also wired to the SCADA to initiate an alarm.

• Tertiary Filters: surface-wash arms piping - ring groove couplings were replaced, arm bearings and nozzles replaced. While the filter beds were emptied of media. Piping brackets repaired and Tile Grout joints inspected and repaired. Bed Bleeder Piping was modified and shutoff valves added.

• Began replacing the venturi tubes with Mag - Meters in the filter Effluent lines. • New 2.2 Mw Caterpillar - Generator Training took place with the start up. • Overhead door # 1 failed to close due to a control transformer failure. A new one was ordered and

in the mean time we took one from #3 to keep 1 working. Eventually 3 were repaired. February 2010 • Tertiary filter control consoles dismantled for new construction replacement. • Continued installing new Mag-Meters in Tertiary. 16" diameter Pipe changes: Straight spool

sections, Reducing spools and MJ-Flanges were used to accommodate the new meters. Pipe supports were fabricated in house to support new meters and piping.

• A new ground bus cable was looped through lower mezzanine and lower level for electronic equipment protection.

• Filter Media replacement is under way and should be completed in a couple weeks • Fern Drive started having a lot of debris caught up in pumps, overloading pump and tripping

circuit. We found a lot of large "wipes" being entangled in pump suction. This required several "visits" to the station and pulling of pumps to correct.

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12” Mag Meter (1 of 4) Tertiary Filter Console (1 of 2) Installing Galvanized Screw Pump March 2010 • All four filter effluent flow meter modifications were completed. • A trip to Mason, Ohio - Wastewater plant to examine a new wastewater facility, located on a new

36 acre site. Construction included 40' deep influent pump station, screen and grit collecting building, two oxidation ditches with a capacity of 5.6 million gallons each, three 105' clarifiers, disinfection by a UV system, one sludge thickening tank, two sludge holding tanks, sludge pumping building, Bio-solids drying building including two centrifuges. The main intent of the visit was a Komline-Sanderson bio-solids dryer. A picture file has been created.

• Grit Mitt, seal modification to cyclone was done to prevent leakage. Wear bar inspection was performed on unit.

• The DO probes in tanks 2 and 4 where extended to mid tank positions for improved averaging for HIS blower control package.

• Repack #1 press sludge pump • Old wiring was pulled from conduits in lieu of all new equipment and wiring. This material was

monitored and all recycled at Painesville Recycling. All other demo material from construction was sorted, iron, aluminum, copper etc. and recycled.

• First Inspection and tuning by Caterpillar Service was done on new Generator. • A new gate was added to Perimeter fence by the Drying (Green) House. April 2010 • A new 24"mag meter was installed in the backwash piping, inspection of valve and afterwards a

new Rotork valve controller was installed replacing a 35 yr. old Pratt on the backwash valve. New conduits and 3 phase wiring and control wiring was installed to accommodate the new controller.

• Alum Holding Tank; Conduits wiring, control circuit installation. • Erie and Sanford Street; one Flygt pump from each station was sent out for rebuild, these where

done a weeks’ time and reinstalled. • Wash water holding tank, was completely cleaned out by Vac-Qua company from Youngstown. • Fiber pull is nearing completion by Fowler Electric personnel. • Sodium Hypochlorite Generator was prepped and started for making Hypo' for feed May 1st. • Vac-Qua Tank Cleaning was contracted to clean out the Wash-water Holding Tank. They removed

roughly250 yards of grit/sludge. This was 30+ years of accumulation.

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Wash Water Holding Tank 24” mag Meter, Spool and Controller Installation May 2010 • The Pumps at Fern drive had to be pulled again due to clogging. The same material was found

"large wipes” entangled and knotted in the suction opening. We decided to try and trace back thru the manholes for similar material and determine where it might have come from. We even stopped at some of the area businesses that could be using them. We could not pin point any clues. But, to jump ahead, since then we have not had any issues. Whether it was due to us asking questions or what the station has been fine.

• A new base was fabricated for a new Secondary Scum pump. This was sent out for Hot Dip Galvanizing. A procedure we hope will eliminate base plate rust-out. A common problem with painted steel. When the plain steel begins to rust the forces will shift the pump and cause coupling miss-alignments, resulting in coupling stress and ultimately bearing fatigue and failure.

• The new Secondary scum pump was installed along with new Roto-Meter, seal water solenoid and piping. The old pump was a rope packed pump the new has a mechanical which needs no attention until it wears out. The old setup had the flush water going across the floor, now it has been piped to a drain. The area has now been dry since installation, and is performing well. It should run for 2-4 years without any intervention other than a yearly oil change on the bearing housing. Packed pumps require weekly inspection and possibly adjustment of packing.

• Maintenance Personnel attended a Power Quality Workshop at Lake Erie College • An Unused air compressor was moved from Hypo and a shelf installed up on the wall in the

tractor bay to hold it. This will come in handy back there for the lawn equipment and the trucks. The only other air back there was the press unit and a small portable.

• A field trip to the Euclid Water Reclamation Facility and Workshop for contact hours was attended.

• The Fiber backbone was activated and tested by Skoda Minotti Personnel. A Fiber Switch was installed at each end, one here at the WPCP and the other at the Light Plant. It will serve 3 systems. 1.) Generator Status to Light Plant - 2.) WPCP SCADA Communications with Pump Stations - 3.) Internet/Mail service for City Computers.

June 2010 • New Multitrode Pump Station Controllers are being installed at Erie, Sanford to interface with

future radio links through city network back to the WPCP Meter room. Heisley Park and Jackson Street stations are already equipped with this device. We have another unit slated for Valley View,

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however the cabinet will have to be changed as it is too shallow to accommodate the unit. Also at Valley View the Main Disconnect, Emergency Transfer Switch and Emergency Power Hookup has taken some abuse/weathering. The standard steel enclosures are affected by the salt and should be replaced with Stainless enclosures. The same Cabinet issue is true with Fern Drive Station the existing box and support framework is weathered beyond repair.

• 2011 purchases should include another Multitrode, level probe for Fern Drive, two Enclosures and hardware along with new enclosures for Valley View.

• Joe Jackson, Brian Belfiore and Kevin Aiken attended an 8 hour Flygt Pump sponsored Pump Station Design Seminar in Beachwood.

• Splash wall extensions were ordered and factory installed to Decant Dump Pit. This was done to make sure material was contained when vactor truck dumps.

• DJE Programming of Filter Consoles. • More Surface wash Arms were disassembled and cleaned, some received new rotating bearing

assemblies, others just had the bearings replaced, and all units worked on got new nozzles. • Roto-Rooter came in and cleaned out the Press room floor drains. • Communications with New 2.2 Generator was established by DJE.

July 2010 • New UPS - Uninterruptable Power Supplies were purchased and either replaced older units and

added to SCADA nodes around plant. A few replacement batteries were also bought for some of the older but better units. SCADA Computers and all support PLCS will stay powered at all times, regardless of main power issues.

• Rec Park Station Multitrode Pump controller installation. • #2 Grit Chamber installed a new motor and motor adjustment base for the grit pump. We cleaned

everything out and started from base, treated base, new anchors, belts. Belt Guard modifications and painted. Sump pit cleaned out, sump pump cleaned and checked. Tested and ready for service.

August 2010 • Grit Mitt Wear Bar Inspection of all wear strip indicators, everything looks good. Next inspection

in January 2011. • Grit Pump locked up on large rock, smoked the belts. These were replaced as well as a new seal

solenoid replacing a leaking one, plus a valve was installed to isolate the solenoid. One was not there before so the water had to shut down to the area to facilitate repairs.

• Guide Rails for the pumps at Fern Drive Station had to be replaced, the old ones (20+ yrs.') were falling apart.

• Grit Chamber #1 needed the motor base replaced, we decided to raise the base from direct contact with the floor and gave it extra corrosion treatment. All adjusting and mounting hardware was replaced with stainless.

• Belt guard was modified for easier but secure mounting. The pit flushing system got modified repairs for ease of servicing.

• Removed Impellor from Septage Pump, sandblasted and it was coated with Belzona, a ceramic surface conditioner that resists abrasion. It was reinstalled and put back into service.

• A large hole in Truck #75 cake Hauler was welded closed. It was probably from when we were hauling all the scrap iron from the clarifiers.

• Plant Light poles, several lights were not operating and needed sensors replaced. This was done.

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• Began running new 220v circuits in preparation for new sumps in Tertiary and Blower Basements. The current 120v units just did not have enough power/capacity to efficiently take care of these deep basements.

• #3 RAS motor failed, it was pulled and shipped to Hannon, inspection was not good so a new motor was ordered and installed.

Decanting Pit - Splash Walls made with FRP material – (Fiber Reinforced Plastic) September 2010 • Roofers arrived to apply new membrane roofing material to Administration Bldg. The old roof

was completely removed, new insulation, parapet walls recapped and membrane. • Ceiling Fans were installed in the Tertiary to circulate air and help with condensation issues. • A mud valve was removed from Aerobic tank, it was rebuilt and reinstalled. • Laser Alignment of RAS pumps performed to correct coupling issues. We also lifted pumps and

repaired the bases to level pumps which have been shifting and failing the couplers. • We made a makeshift hood to set over press; this allowed a better collection of vapor/odor from

the press. • New Sump pump circuits were installed in the Tertiary and B&S basements in preparation to some

new higher voltage/HP pumps. The current ones have been inefficient for the application. • We changed both Non - Potable Pumps Discharge headers from Plastic to Stainless steel. We had

an incident earlier when one of the pipes broke overnight and filled the lower level with 3 and half feet of water.

• The Ground Detection Unit for the Main Electrical disconnect was rebuilt. This unit protects the plant from potential phase to ground shorts. It is capable of detecting the smallest circuit fault even on the far end of the plant.

October 2010 • Fern Drive Station Pump #2 was pulled to Replace Impellor and seal. • Weather tower was dismantled to allow roofers to install roofing. We took the opportunity to

permanently affix the tower base to the concrete roof panels, the roofers made the base water tight. We also made a roof penetration to add a new junction box for the tower and rewired it and re-erected after the roofers were done.

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• The Aerobic Digester #1 has been converted to accept Alum Sludge from the Water Plant. In preparation to this we had a wedge of concrete poured from 3 foot up the south wall and tapered north to 3.5 " thick about 10 feet from north end. The wedge has a compacted base with a 3.5" slab of concrete on top. We then took one of the course air diffusers, had a power plant welder come over and weld a 4 inch stainless pipe and elbows to extend and set the diffuser in the final 10 foot floor section. Between relocating the diffuser and the sloped bottom the mixing has been more consistent. This tank is now deemed the Alum Sludge Holding Tank.

• Grit Chamber #1 inlet piping had to be taken apart to pull a 2x4 and other material out of the pipe. It was stuck in a bend.

• The New computers, SCADA Software, Alarm and reporting Software came in and DJE will be here to start initializing. Meantime we rearranged the SCADA cabinet, wiring and cleaned. Eliminated the final components left over from the old meter panel. Media converters were installed in Tertiary and blower building PLC Cabinets to replace radio links to the Meter Room. We are now connected by Fiber between buildings.

• The Tertiary PLC started losing its program unexpectedly, unusual but when this happens the system has to be taken offline, shutdown and restarted, the backup program then has to be uploaded from the SCADA computers, verify and put online. This has happened 4 times over a 3 week period. It seems it’s a firmware problem, Rockwell was contacted and an upgrade is being furnished.

November 2010 • Fern Drive Pump #2 repaired and installation of new impellor and seal, Impellor was coated with

Belzona ceramic coatings for improved life. • The Digester #2 Mixer lower bearing assembly failed. New parts were ordered and a crane was

scheduled to pull the unit. The mixer was unbolted lifted out and set on cradles to work on. Repairs involved removing prop and lower bearing assembly, installing new double roller bearing, bearing keeper, mechanical seal and new gaskets. Indicator readings to confirm minimal run-out, then reassembled. Before installing back in the tank we filled the unit with oil and tested for leaks before reinstalling. It had to in a vertical position to fill and test. The unit is about 14 feet long and weighs 1800 lbs. It was re-installed, bolted, power hook-up and put on line. Total downtime = 7 hours.

• A large coupling in the Blower Basement had to be repaired do to a severe air leak. The system had to be shut down for repairs to be made. The reason is attributed to age and the rubber gasket was completely dried out and became brittle. During the recent construction project the adjoining piping was cut to install air flow meters. The piping may have been tweaked a fraction and disturbed the seal. All these similar components in the plant are in similar condition. Any rubber gasket expansion fittings are nearing 40 years and care or planned replacement if any of the adjacent piping is to be disturbed.

• Pump Repair, Hands on Flygt Pumps Training. Kevin Aiken and myself, Joe Jackson went to Buckeye Pumps in Galion, Ohio for a full day of class and shop to breakdown and assemble Flygt Submersible pumps.

• Old Hospital salvage - A crew of us went to Lake East roof top to retrieve Two Blower units and five VFD’s from top floor. The Blower Units were wrapped for protection from weather till a crane could retrieve them. The VFDs were brought back the same day. Work involved verifying power was off, and disconnecting g power and dismantling ductwork. The one blower we had to remove a section of the outer wall to get it out onto the roof.

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December 2010 • Plant Inventory and Inventory additions of spare parts included from construction project. • Press feed Pump #2 - The VFD controlling this unit failed. One of the units we got from the

hospital was checked out and installed is working perfectly. • Tertiary PLC - Program lost again. Deeper investigation found corrosion on memory board, due to

"cold solder joints". I cleaned the corrosion off, applied a protective electrical barrier coating. Re-assembled, re-upload the program and placed online. It has not malfunctioned now for over 3 full months.

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INDUSTRIAL PRETREATMENT

Findings and orders were received June 6, 1983 directing the City to begin development of their Industrial Pretreatment Program. Upon receipt of these findings and orders, Burgess & Niple Limited, began the Industrial Inventory portion of the program. One hundred and fifty-five (155) survey questionnaires were sent out to commercial and industrial establishments within the City of Painesville service area. By May 1984, 100 percent of the questionnaires were returned.

The questionnaires were reviewed and the industries were classified as Significant Major, Significant Minor, and Not Significant. These classifications were based upon definitions stated for each. The Standard Industrial Classifications (SIC) Codes were assigned to industries which did not list a SIC code on the questionnaire. Non-categorical industries were included to help Painesville establish a total Industrial monitoring program and surcharging program.

The Inventory data was presented in the Phase I, Volume I, Summary of Industrial Waste Survey Information. This report was approved by the Ohio EPA on March 12, 1984.

Technical data regarding the operation of the Painesville Water Pollution Control Plant were discussed in the Phase I, Volume II, and Technical Information Report. During this portion of the program development, Environmental Research Group, Inc. was used to perform Laboratory analysis with GC/MS. Their analysis and all analysis performed by Burgess & Niple, Limited and the personnel at the Water Pollution Control Plant were performed using U.S. EPA sampling and analytical procedures set forth in 40 CFR Part 136. The Technical information submittal received Ohio EPA approval on May 18, 1984.

The operational data of the Painesville Water Pollution Control Plant was used to determine maximum allowable influent limitations to the Water Pollution Control Plant. The limitation based upon N.P.D.E.S. Permit limitations; land application of sludge limitations; Grand River water quality limitations, and operational limitations for the Water Pollution Control Plant. These limitations were then compared with sampling results obtained during Phase II to determine maximum limitations for the Industrial discharges.

The legal evaluation of Phase I was presented in Phase I, Volume III, Legal Evaluation. This portion was a review of the existing Sewer Use Ordinance for the City. The existing ordinance was found to be adequate in areas of limitations of parameters to be discharged by industries, however, it was lacking in areas regarding the monitoring and enforcement of the proposed pretreatment program. Areas of concern, as addressed in the EPA model ordinance, were added by the Ohio EPA as per their letter of August 3, 1984, and City Council passed legislation on September 4, 1984, to accept the proposed Ordinance.

The monitoring/enforcement program was developed during Phase II of the Pretreatment Development Program. A program was developed and equipment listed to perform the required work for enforcement of the regulations. Non-Categorical Industries were included in the program to help the City develop a total sampling program. The monitoring program includes scheduled and demand monitoring procedures, a tracking and filing system, procedures to notify industries of existing and newly promulgated standards discharge limitations, and other requirements and self-monitoring procedures for industries.

An evaluation of financial programs, personnel, equipment, and laboratory needs were also performed during the preparation of the Phase II report. This portion of the report determined estimated costs that would be passed on to the industry for sampling required. It was determined additional personnel would not be required, however, additional equipment would be needed to perform the ongoing sampling.

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The final Program Report was submitted to the Ohio EPA for approval on October 10, 1984. Ohio EPA public noticed the Industrial Pretreatment Program on May 21, 1985, for comments. The Final Program received approval from the Ohio EPA on July 2, 1985.

Since the time of final approval, all industries have been notified of the requirements for their discharge. Agreements have been signed with Avery Dennison, Cintas, Eckart America, Kinedyne, Lubrizol Corporation, Meritec Plating, and Painesville Municipal Electric Plant.

The financial program, personnel, equipment, and laboratory needs are constantly evaluated to determine estimated costs that would be passed on to each industry to support the pretreatment budget and staffing levels. The total industry base that discharges to the treatment plant has changed very little since the incorporation of the pretreatment program. Therefore, the budget and staffing levels have remained unchanged throughout the past year.

The Painesville Water Pollution Control Plant has been very successful treating all Industrial wastes and has not experienced any major problems due to industrial effluent.

Meritec Plating, a company that produces circuit board connectors, is classified as a Categorical Industry because of their electroplating operation. Annual and semi-annual monitoring showed compliance with Local and Federal limitations.

The Painesville Municipal Electric Plant was changed to a Significant Industrial User classification. This was done when inspections and sampling revealed violations with the City’s Sewer Use Ordinance and newly discovered sewer lines. The engineering firm of Burgess & Niple, Limited, has been contracted to evaluate and design a pretreatment system to bring the Electric Plant into compliance. Routine compliance monitoring during 2009 showed sampling compliance.

Avery Dennison FFD and STD were determined to be non-categorical industries and were reclassified as a Significant Minor Industry. They will continue to be monitored for B.O.D., S.S., TKN, and phenols for the purpose of surcharges.

Eckart America is a Non-Categorical Industry; however, their discharge contains a high concentration of copper and zinc. They had redesigned and installed a pretreatment system to remove the excess pollutants. Periodic sampling showed noncompliance with copper. They submitted a probable cause and a plan of action to meet compliance in early 2009.

Lubrizol Corporation is a Categorical Industry and performs self-monitoring on a quarterly basis. They installed a 2.5 million dollar upgrade of their pretreatment system for their water management program and compliance with the newly promulgated rulings concerning organic chemical manufacturers.

Annual and quarterly monitoring showed compliance with Local and Federal limitations.

Kinedyne is a categorical industry. They manufacture and powder coat slotted steel rails which are used in semi-tractor trailers. Annual and semi-annual monitoring showed compliance. They are no longer in business due to the poor economy.

Cintas is a non-categorical industry, but due to their high volume of wastewater discharge, they are classified as a Significant Industrial User. Compliance sampling showed noncompliance with pH and not reporting results when required. They were issued a letter of violation and responded with corrective actions.

PCC Airfoils started up in 2009. They are a vacuum metal casting facility. This business is non-categorical but will be sampled and inspected due to the possibility of discharge of metals and suspended solids.

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INDUSTRIAL PRETREATMENT INSPECTIONS

Avery Dennison FFD Avery Dennison STD Cintas Eckart America Kinedyne Lubrizol Corporation Meritec Plating Painesville Municipal Electric Plant PCC Airfoils

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DISBURSEMENT COST COMPARISONS

The following table shows a cost comparison of the total disbursements for the Water Pollution Control Plant. The Sewer Collection System and Administration Cost over the past 10 years.

YEAR TOTAL COST

2010 $3,871,703.00

2009 $3,815,288.00

2008 $3,382,018.00

2007 $3,419,758.00

2006 $2,870,479.00

2005 $2,950,871.00

2004 $3,025,757.78

2003 $3,178,145.14

2002 $3,548,714.61

2001 $3,089,308.85

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UTILITY COST COMPARISONS

One of the major expenses in the Painesville Water Pollution Control Plant Budget on an annual basis is Electrical Costs. The following table shows the yearly cost for Electricity used over a ten year period.

YEAR TOTAL COST

2010 $196,047.00

2009 $163,032.00

2008 $168,698.00

2007 $177,454.00

2006 $164,251.00

2005 $189,192.00

2004 $246,459.00

2003 $274,009.07

2002 $287,382.79

2001 $173,664.85

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SLUDGE DISPOSAL COST COMPARISON

The following table shows the cost of removing liquid digested sludge from the plant over the last ten years. During the 2010 year the wastewater plant began pressing alum sludge from the water plant.

YEAR GALLONS TOTAL COST

2010 3,581 wet tons $112,879.70

2009 2,376 wet tons $71,693.09

2008 3,150 wet tons $91,203.00

2007 2,704 wet tons $78,109.00

2006 2,790 wet tons $80,696.00

2005 6,344,336 $99,451.00

2004 6,078,247 $194,423.68

2003 6,065,200 $168,081.20

2002 6,935,892 $155,758.30

2001 4,248,391 $101,461.30

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FLOW, COST/MG AND RAINFALL

The following table shows the annual flows treated by the Plant, the cost per million gallons for treatment and the Annual rainfall at the facility during the last ten (10) years.

YEAR FLOW TREATED COST/MG ANNUAL

RAINFALL

2010 1003.82 MG $3857.00 28.15 Inches

2009 1100.62 MG $3774.00 27.85 Inches

2008 1361.16 MG $2485.00 35.86 Inches

2007 1162.24 MG $2942.00 34.28 Inches

2006 1324.42 MG $2167.00 53.12 Inches

2005 1,156.37 MG $2553.00 30.40 Inches

2004 1,157.76 MG $2613.00 50.50 Inches

2003 1,091.43 MG $2913.00 58.90 Inches

2002 1,000.63 MG $3545.00 31.42 Inches

2001 847.32 MG $3647.00 36.98 Inches

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SEWER RATES AND SURCHARGES

A new service rate system was adopted on July 1, 2008. Due to the increase in the cost of equipment and materials, it is necessary to revise the sewer rates. This rate is based on water consumption and reads as follows: $4.15/100 cubic ft with a minimum usage of 400 cubic feet. The charge per 100 cubic feet includes $3.55 per 100 cubic ft for operation and maintenance and $0.60 per 100 cubic ft for debt service. The City Manager is obligated to review the sewer service charges annually and recommend appropriate changes thereto; to become effective on January 1st of each year.

SEWER SERVICE RATE

The Sewer use surcharge program was started by plant personnel as per the EPA Grant conditions to assist in recovery costs from dischargers who discharge higher than normal concentrations of pollutants. The surcharge program by definition is a means to recover the proportional share of the cost to treat pollutants.

SEWER USE SURCHARGE

Annually the plant personnel establish the normal domestic strength waste entering the plant and determine the cost to treat the pollutants. Presently, the surcharge pollutants are: Biological oxygen demand (BOD), Suspended Solids (SS), phenols, and total Kjeldahl Nitrogen (TKN). On May 1, 2009 the surcharge rates were established as follows: BOD, $0.320 per pound per day; S.S., $0.170 per pound per day; Phenols, $0.320 per pound per day; and TKN $0.294 per pound per day. Industries that choose to install and maintain meters to record their wastewater discharge are not charged for sewer service based on water consumption but on actual quantity discharged.

Industries sampled for surcharges during 2010 were: Eckart America, Cintas Corporation, Lubrizol Corporation, Avery Dennison FFD, and Avery Dennison STD and PCC Airfoils. The program generated $34,222.22 in extra revenues during 2010. A breakdown of the surcharges are as follows:

Eckart America $317.87

Cintas $19,891.35

Lubrizol $11,921.03

Avery Dennison FFD $270.71

Avery Dennison STD $78.80

PCC Airfoils $1,742.44

TOTAL $34,222.22

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2010 SEWER REVENUES & DISBURSEMENTS

Revenues: Sewer Service Charges (Reg.) $2,635,368 Service Charges (Contract) $448,452 Sewer Service Charges (Septic) $193,034 Sewer Tap-In Connections $9,900 Late Payment Fees $72,118 Interest $10 Refund/Reimbursements (Oper./Non-Oper.) $1630 Other-Miscellaneous-Scrap $4,103 Other-Miscellaneous $820 Juror – Witness Fees $0 Sale of Fixed Assets $651 Proceeds of Notes $73,880 Premium on sale of bonds/notes $35 Sales - Miscellaneous $12,419 Total Sewer Revenue Fund $3,452,420 Disbursements: Administration (721) - Personal Services $494,480 - Others $99,466 TOTAL $593,946 Utilities Office (722) - Personal Services $137,823 - Others $23,406 TOTAL $161,229 Supervision (Plant & System) (723) - Personal Services $43,308 - Others $3,975 TOTAL $48,724 Plant & Pumping Operations (724) - Personal Services $1,016,643 - Others $698,216 TOTAL $1,714,860 Collection & Transmission (725) - Personal Services $164,879 - Others $26,758 TOTAL $191,637 Sewer Equipment-O&M (726) $4,157 Total Insurance & Misc. Contracts (729) $102,852 Debt Services: Debt Service-Revenue Supported (803) $0 Debt Service-Other (805) $89,983 Other Non-Operating Expenses (902) $22,169 Transfers-Out (910) $530,900 TOTAL $643,052

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Workers Compensation $36,079 Hospitalization $368,465 TOTAL (970) $404,544 Reserves (999) $6,704 Grand Total Sewer Fund Disbursements $3,871,703

SEWER FUND CAPITAL IMPROVEMENTS SANITARY SEWER IMPROVEMENT (793) Architectural/Engineering $0 Infrastructure Improvements $14,033 TOTAL $14,033 WATER POLLUTION CONTROL IMPROVEMENTS (798) Infrastructure Improvements $97,135 Construction $64,716 Bldg. Improvement/Enhancement $120,000 Specialized/Technical $2,733 TOTAL $284,584 DEBT SERVICE-OTHER (805) Note Principal Retirement $731,500 Other Debt $2,049 Note Interest $28,736 TOTAL $762,285 EQUIPMENT/MACHINERY (902) Equipment/Machinery/Debt $14,647 TRANSFERS-OUT (910) Transfer To General Fund $0 Transfer To Storm Water $0 SEWER CONSTRUCTION FUND (722) GRAND TOTAL $1,802,860

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MAJOR DEPARTMENTAL GOALS & OBJECTIVES

Strategic Goal #1 Valve Exercising Program (Stewardship and Fiscal Responsibility)

A valve exercising program will be initiated and managed to improve the operation of plant valving. Preventative maintenance of valve repair and replacement by scheduling valve exercises will assure the useful life of plant valves.

Strategic Goal #2 Landscaping of Administration Building (Improving Painesville’s Environment and Image)

A new front entrance design for the Administration Building will enhance the image of the WPCP. Visitors to the WPCP will be presented with a new and improved image of the administration building front entrance.

Strategic Goal #3 Volunteer Program (Community Engagement)

Contact area high schools and colleges to promote a volunteer program for the WPCP. Present opportunities to encourage area students to consider a career in the wastewater industry.