WQ0002523_Additional Information Received_20201023

Council Member
Barry Kaufman, Mayor
Jimmie Accardi, Vice
Mayor
Weidner Abernethy
Kelly Xlelang
Erin Gonyea
BEECH
MOUNTAIN
NORTH CAROLINA
Eastern America's Highest Fawn
October 8, 2020
North Carolina Department of Environmental Quality
Division of Water Resource
Non Discharge Permit Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Attention: Ms. Poonam Giri
Dear Ms. Giri,
Interim Town
Manager
Bob Pudney
Town Attorney
Stacy C. Eggers IV
On behalf of the Town of Beech Mountain, I respectfully submit to you a response to your
request for additional information dated August 13, 2020 for the renewal of Permit No.
WQ0002523, Beech Mountain Distribution of Residual Solids for your inspection and approval.
Although we have not composted in recent years, we are looking forward to keeping this permit
current to allow us to utilize composting in the future.
Please call me at 828-387-9368 is you have any questions. Thank you.
Sir •erely,
onald S. Moree, E.I.T.
Eastern Ame-I ca's Highest Town
www.townofbeechmountain.com

Council Members
Barry Kaufman, Mayor
Jimmie Accardi, Vice
'Mayor
Weidner Abernethy
Kelly Melang
Erin Gonyea
Ms. Poonam A Giri
/V�
N D R T H
BEECH
MOUNTAIN
C A R D L i N A
Eastern America's Highest Town
October 9, 2020
Hydrogeologist
North Carolina Department of Environmental Quality
Division of Water Resources
Non Discharge Permit Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1636
Response To:
Renewal: Application No. WQ0002523
Permit Application Return
Town of Beech Mountain DCAR
Distribution of Residual Solids
Watauga County
Dear Ms. Giri
Interim Town
Manage
Bob Pudney
Town
Stacy C. Eggers IV
In response to your comments dated August 13, 2020 regarding Permit Renewal Application
No. WQ0002523, we submit the following itemized responses:
A. Cover Letter
L Please see above clearly stating that this application is
for the renewal of permit No. WQ0002523.
B. Application
1. Please see completed DCAR 06-16. Pages B1-B3
2. Presently, sludge from Grassy Gap WWTP is removed by a local tanker truck and
transported to an adjacent municipality for disposal into their wastewater treatment
plant. Because of this, we have no data to include on form FORM: RSC 06-16 for
this facility. If in the future, composting for this facility became an option, the sludge
www. townofbeechmountain.com

would be transported to Pond Creek WWTP and be mixed with sludge generated by
that facility.
Please find attached combined dry tons per year requested for both facilities in this
renewal.
4. Please find attached FORM RSC 06-16 for Pond Creek WWTP. We presently have
no RSC data for Grassy Gap WWTP due to the fact that all sludge is hauled away and
disposed of at another WWTP
5. Please find attached the RSC Summary Table which indicates 60 dry tons. Page B9
C. Residuals Source Certification
1-3. We currently have no data to provide regarding residuals since neither facility has
produced any compost and all sludge has been transported offsite to a landfill or WWTP.
D. Program Information
a.-f. Please find attached Compost Use information Sheet which
includes all information requested in this section. Page D1
E. Operation & Maintenance Plan
1 and 2 a-i. See attached Operation and Maintenance Plan that includes all
information requested in this section. Pages E 1-E48
Please call me at 828-387-9368 if you have any questions. Thank you,
Donald S. Moree, E.I.T.
Town of Beech Mountain

DWR
State of North Carolina
Department of Environmental Quality
Division of Water Resources
Division of Water Resources 15A NCAC 02T .1100 — DISTRIBUTION OF CLASS A RESIDUALS
FORM: DCAR 06-16
I. APPLICANT INFORMATION:
1. Applicant's name: Town of Beech Mountain
Applicant type: ❑ Individual ❑ Corporation ❑ General Partnership El Privately -Owned Public Utility
❑ Federal ❑ State Z Municipal ❑ County
Signature authority's name per 15A NCAC 02I' .0106: Bob Pudney Title: Town Manager
Applicant's mailing address: 403 Beech Mountain Parkway
City: Beech Mountain State: NC Zip: 28604-
Telephone number: 828)387-9282 Email Address:
2. Consultant's name: Donald S. Moree E.I.T. License Number (for P.E.):
Affiliation: ED On Staff ❑ Retained (Firm: )
Consultant's mailing address: 403 Beech Mountain Pkwy
City: Beech Mountain State:NC Zip: 28604
Telephone number: [phone] Email Address: bucke ewt ci-townotbeechmountain.com
3. Fee submitted: 0.00 (See Instruction B)
H. PERMIT INFORMATION:
1. Application is for (check all that apply): ❑ new, ❑ modified, ED renewed permit
2. If this application is being submitted to renew or modify an existing permit, provide the following:
Permit number:.0002523
Date of most -recently issued permit: March 13, 2015
Date of most -recently certified Attachment A (if different than the permit):
III. FACILITY INFORMATION:
I. Name of residuals processing facility: Town of Beech Mountain Residuals'Composting Facilijy and Distribution Pro am
City: Beech Mountain State: NC Zip: 28604-
Coordinates: Latitude: 360 12' 49" Longitude: 81' 52' 30"
Datum:
Method of measurement:
Level of accuracy:
County where facility is located: Watauga
2. Facility contact (person familiar with residuals preparation):
Name: Daniel Davis Title: Utilities Sul3erintendent
Mailing address: 403 Beech Mountain Parkway
City: Beech Mountain State: NC
Telephone number: [phone]
Zip: 28604-
E-mail address: bmuskc'townofbeechmountain.com
FORM: DCAR 06-16
�� 1 Pagel of 3

3. Is the residual process facility also the generator? 1Z yes; ❑ No
If No, please specify delivery frequency and quantity of residual to be processed:
4. Length ofresiduals storage at facility: 600 days (Note: the Division requires minimum 30 days storage in units that are separate
from treatment system, i.e. not in clarifiers, aeration basins, etc.)
IV. RESIDUALS QUALITY INFORMATION:
1. Specify how these residuals will be distributed:
❑ sold or given away in bags or other containers; Z lawn (bulk); ❑ home garden (bulk);
❑ other (explain);
Note: Bulk residuals shall mean residuals that are transported and not sold or giving away in a bag or other receptacles with a
load capacity of one metric ton or less.
2. Complete the following if residuals are to be mixed with other materials:
3
Approximate amounts of the residuals received and processed at the facility: N/A dry tons per year.
4. Approximate amounts of the final product (processed residuals) to be distributed: N/A dry tons per year.
5. Provide a description of the onsite storage management plan for the treated residuals (including estimated average and
maximum storage times prior to distribution): N/A
6. Does the facility have a stormwater management plan? E Yes, • ❑ No
Explain whether the treatment and storage areas are under roof or how stormwater runoff will be handled: Drains into
Wastewater Treatment Facility.
V. RESIDUALS SOURCE INFORMATION: (Required for all new, renewed, or modified residuals source)
Complete and submit the attached Residuals Source Certification and all associated documentation.
11
RSC 06-16.doc
FORM: DCAR 06-16 Page 2 of 3

Professional Engineer's Certification: (Application Involving New or Changes to Treatment or Storage Units)
I,
, attest that this application for
has been reviewed by me and is accurate and complete to the best of my knowledge. I further attest that to the best of my knowledge
the proposed design has been prepared in accordance with the applicable regulations. Although certain portions of this submittal package
may have been developed by other professionals, inclusion of these materials under my signature and seal signifies that I have reviewed
this material and have judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Seal, Signature, and Date:
Applicant's Certification:
The applicant or any affiliate has not been convicted of an environmental crime, has not abandoned a wastewater facility without proper
closure, does not have an outstanding civil penalty where all appeals have been exhausted or abandoned, are compliant with any active
compliance schedule, and do not have any overdue annual fees under Rule 15A NCAC 02T .0.1 G'S.
® Yes ❑ No, Explain;
I, Bob Pudne
(Signature Authority's Name — PLEASE PRINT)
(Title)
attest that this application for Town of Beech Mountain Residuals Composting Facility and Distribution Center
(Facility Name)
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand that the Division of Water Resources
may not conduct a technical review of this program and approval does not constitute a variance to any rules or statutes unless specifically
granted in the permit. Further, any discharge of residuals to surface waters or the land will result in an immediate enforcement action,
which may include civil penalties, injunctive relief, and/or criminal prosecution. I will make no claim against the Division of Water
Resources should a condition of this permit be violated. I also understand that if all required parts of this application are not completed
and that if all required supporting information and attachments are not included, this application package will be returned to me as
incomplete.
Note: In accordance with North Carolina General Statutes § 143-215.6A and § 143-215.613, any person who knowingly makes any false
statement, representation, or certification in any application shall be guilty of a Class 2 misdemeanor, which may include a fine not to
exceed $10,000 as well as civil penalties up to $25,000 per violation.
Si Date:
FORM: DCAR 06-16 Page 3 of 3

D-1
,.__ ...
'<DFvtsion of Water Resources
State of North Carolina
Department of Environmental Quality
Division of Water Resources
RESIDUALS SOURCE CERTIFICATION
FORM: RSC 06-16
I. RESIDUALS SOURCE -GENERATING FACILITY INFORMATION (See Instruction B.):
1. Facility Name: Town of Beech Mountain Residuals Composting Facility and Distribution Program.
2. Facility permit holder is: ❑ Federal, ❑ State, 0 Local Government, or ❑ Private.
Facility permit issued by: ❑ Div. of Water Resources, ❑ Div. of Environmental Health,
or ❑ Other (explain: ).
3. Facility contact person and title: Daniel Davis Utilities Superintendent
Complete mailing address: 403 Beech Mountain Parkwav
City: Beech Mountain State: NC Zip: 28604-
Telephone number: [phone] E-mail address: bmusCaa)ownofbeechmountain.com
4. Facility physical address: 364 Locust Ridge Rd
City: Beech Mountain State: NC Zip: 28604-
Coordinates: Latitude: 360 12' 49" Longitude: 81 ° 52' 30"
Datum: Level of accuracy:
Method of measurement:
5. Purpose of the facility:
Z treatment of municipal wastewater, ❑ treatment of 100% domestic wastewater,
treatment of potable water, ❑ treatment of 100% industrial wastewater,
El treatment of industrial wastewater mined with domestic wastewater,
(approximate percentages: % industrial and % domestic)
❑ other (explain: ).
6. Does the facility have an approved pretreatment program: ❑ Yes 0 No
7. Facility permitted/design flow: 0.40 MGD and facility average daily flow: 0.125 MGD
8. Average amount of residuals being generated at this facility 14 dry tons per year.
9. Specify the following regarding treatment and storage volumes available at the facility:
Type and volume of residuals treatment: N/A
Type and volume of residuals storage (i.e., outside of residuals treatment units): 16 Cu Yd
II. RESIDUALS QUALITY INFORMATION (See Instruction C.):
1. Specify if residuals are regulated under:
40 CFR Part 503 or ❑ 40 CFR Part 257.
Note: Only residuals that are generated during domestic/municipal wastewater treatment processes are regulated under 40
CFR Part 503, otherwise, the residuals are regulated under 40 CFR Part 257.
2. Specify if residuals are defined under 15A NCAC 02T.1102(6) as:
Biological ❑ Non -Biological
Note: Biological residuals are residuals that have been generated during the treatment of domestic wastewater, animal
processing wastewater, or the biological treatment of industrial wastewater (biological treatment is a system that utilizes
biological processes including lagoons, activated sludge systems, extended aeration systems, and fixed film systems).
FORM: RSC 06-16 Page 1 of 5
it u

3. Hazardous Waste Determination: Complete the following to demonstrate that the residuals are non -hazardous under
RCRA: (Note - this item does not have to be completed for facilities that are less than 0.5 MGD in design flow that treat
100% non -municipal, domestic wastewater only)
a. Are the residuals listed in 40 CFR §261.31-§261.33: 0 yes no.
If yes, list the number(s):
b. Specify whether or not the residuals exhibit any of the characteristics defined by 40 CFR §261.21-
261.24: 0 yes 0 no.
Fill in the following tables with the results of the latest toxicity characteristic leaching procedure (TCLP) analysis as
well as those for corrosivity, ignitability, and reactivity:
Laboratory: Research and Analytical Laboratories. Inc. and Date of analysis: 9/17/2019
Passed corrosivity test: yes ❑ no. pH: s.u. (2 < pH < 12.5)
Passed ignitability test: yes ❑ no. Flashpoint: °F (> 140°F)
Passed reactivity test: 0 yes Qno. HCN: mg/kg (<250) & H2S: mg/kg (<500)
TCLP Parameter
Limit
Result
TCLP Parameter
Limit
Result
(Mg/1)
(Mg/1)
<mg�l�
(9/7)
Arsenic
5.0
BQL
Hexachlorobenzene
0.13
BQL
Barium
100.0
0.524
Hexachloro-1,3-Butadiene
0.5
N/A
Benzene
0.5
BQL
Hexachloroethane
3.0
BQL
Cadmium
1.0
BQL
Lead
5.0
BQL
Carbon Tetrachloride
0.5
BQL
Lindane
0.4
N/A
Chlordane
0.03
N/A
Mercury
0.2
BQL
Chlorobenzene
100.0
BQL
Methoxychlor
10.0
N/A
Chloroform
6.0
BQL
Methyl Ethyl Ketone
200.0
N/A
Chromium
5.0
0.041
Nitrobenzene
2.0
BQL
m-Cresol
200.0
N/A
Pentachlorophenol
100.0
BQL
o-Cresol
200.0
N/A
Pyridine
5.0
N/A
p-Cresol
200.0
N/A
Selenium
1.0
BQL
Cresol
200.0
N/A
Silver
5.0
BQL
2,4-D
10.0
BQL
Tetrachloroethylene
0.7
BQL
1,4-Dichlorobenzene
7.5
BQL
Toxaphene
0.5
N/A
1,2-Dichloroethane
0.5
BQL
Trichloroethylene
0.5
BQL
1,1-Dichloroethylene
0.7
BQL
2,4,5-Trichlorophenol
400.0
BQL
2,4-Dinitrotoluene
0.13
BQL
2,4,6-Trichlorophenol
2.0
BQL
Endrin
0.02
N/A
2,4,5-TP (Silvex)
1.0
N/A
Heptachlor and its Hydroxide
0.008
N/A
Vinyl Chloride
0.2
BQL
FORM: RSC 06-16
Page 2 of 5
01t

4. Metals Determination: Complete one of the following tables (i.e., as applicable) to demonstrate that the residuals do not
violate the ceiling concentrations for metals regulated under 15A NCAC 02T .1105.
a. For Distribution/Land A licalion: Fill in the following table with the results of the latest analyses (i.e., on a dry weight
basis) for the following metal parameters:
Laboratory: Research and Anal ical Laboratories. Inc and Date of analysis: 9/17/2019
Parameter
Ceiling
Monthly Average
Result
Concentration Limits
Concentration Limits
(ClassA & ClassB)
(Class A Only)
(mglkkg)
(mglkg)
(mglk-g)
Arsenic
75
41
< 4.14
Cadmium
85
39
0.801
Copper
4,300
1,500
130
Lead
840
300
17.4
Mercury
57
17
0.532
Molybdenum
75
n/a
5.71
Nickel
420
420
6.95
Selenium
100
100
< 4.14
Zinc
7,500
2,800
265
b. For Surface Disposal Unit (landfill): Fill in the following table with the results of the latest analyses (i.e., on a dry weight
basis) for the following metal parameters:
Laboratory: and Date of analysis:
Distance from Disposal
Arsenic
Chromium
Nickel
Unit to Boundary to
Closest Property Line
(meters, check one)
(mg/kg)
(mg/kg)
(mg/kg)
El > 0 but < 25
30
200
210
> 25 but < 50
34
220
240
>_ 50 but < 75
39
260
270
El >_ 75 but < 100
46
300
320
❑ > 100 but < 125
53
360
390
> 125
62
450
420
Result (mg/kg)
FORM: RSC 06-16
Page 3 of 5
42i

5• Nutrient�icro
nutrientDetern,i,,afi�n. Co
a Total solids:
2� / mplete the following:
b Fill in the follow'
ing table with the results of the latest
in
parameters: analyses
Laboratory'.
aborato (i.e.,
on a d
rY. Research and Anal ry weight basis) for
ical Laboratories. Inc the following nutrient a,
Parameter
and Date of analysis:
9/17
/201
Aluminum Result
?Mng/kg)
` nimonia-Nitrogen
5720
Calcium
2740
Magnesium 4360
Nitrate -Nitrite Nitrogen
1700
PI-1 (Standard Unit)
730
Phosphorrus
6.65
Potassium
1640
Sodium
Total i145p
C. eldahl Nitrogen
266
UsKing the results
[Note: If residuals co listed in Ite 5400
Extension ntain SAP, of 10 IT. 5b'
Office, the De or higher, the ave, calculate the
North Carolina Licensed pent of sodium
address Soil Scientist or pplicant shall obtain
adsorption
the sodium a and Consumer m recommendations1fro radon and conditions co application rate, an agronomist Services, m the (l C , 0
nducive to crop soil amendments prior to land a the Natural Resource Co local Coo
.424
d Specify the p growth] application of residuals. The nsery perative
mineralization rate (e g•' gypsum, etc. ation Service a
rate is a (check to be )' °r a mechanism for recommendations
one): used in calculating the maintainin shall
If the residuals are plant availableg site integrity
default value, or nitrogen
Justification as to why
generated fro (PAN) of the residuals: o
Y the selected m the treatment of actually
e. Calculate the p default value is a murllci established. 10 This
AN for the residuals ( appropriate to be or domestic
wastewater, explain or
Application r'e'> on a d applied to these residuals:
Method n` v'e1ght basis provide technical
First ("' ) and fill the results
h Year p rn the followin
g table:
Omglkgi Five-year
Surface Maximu
2103 mg/kg Adjusted
d usted PAN
Injection/Incorporation N/A g g)
6. OtherAuta 2103 mg/kg
the re,
natio �olof thets Deterrt>in; S
latest a pecify whether or, not there are any Other Pollutants
of concern in the residuals and provide
ZM: RSC 06-16
pn--

7 Pathoben Reduction: Per 1.5A NCAC 02T.1106, specify how residuals will meet the pathogen reduction requirements:
a. For Distribution/Land Application of Class A or E uivalent.
A fecal coliform density that is demonstrated to be less than 1,000 MPN per gram of total dry solids,
or
❑ A salmonella sp. density that is demonstration to be less than 3 MPN per 4 grams of total dry solids.
AND one of the followings (except for non -biological residuals):
Alternative 1 [15A NCAC 02T.I 106(b)(3)(A)] - Time/Temperature Compliance.
El Alternative 2 [15A NCAC 02T.I 106(b)(3)(B)] - Alkaline Treatment.
El Alternative 3 [15A NCAC 02T.1106(b)(3)(C)] - Prior Testing for Enteric Virus/Viable Helminth Ova.
El Alternative 4 [15A NCAC 02T.I 106(b)(3)(D)] - No Prior Testing for Enteric Virus/Viable Helminth Ova.
❑ Alternative 5 [15A NCAC 02T.1106(b)(3)(E)-(K)] - Process to Further Reduce Pathogens (PFRP).
Specify one: composting, ❑ heat drying, ❑ heat treatment,
thermophilic aerobic digestion, ❑ beta ray irradiation,
El gamma ray eradiation, or ❑ pasteurization.
b. For Land A wlication of Class B:
El Alternative 1 [15A NCAC 02T. I 106(c)(1)] - Fecal Coliform Density Demonstration.
Alternative 2 [15A NCAC 02T. 1106(c)(2)] - Process to Significantly Reduce Pathogens (PSRP).
Specify one: ❑ aerobic digestion, [] air drying, ❑ anaerobic digestion,
❑ composting, or ❑ lime stabilization.
c. For Surface Disposal:
❑ Select One of the Class A or Equivalent Pathogen Reduction Alternatives in Item II. 7a. above.
El Select One of the Class B or Equivalent Pathogen Reduction Alternatives in Item II. 7b. above.
El Exempt -If Daily Cover Alternative is chosen in Item 11.8. below [15A NCAC 02T. 1106(a)(2)].
Not Applicable - Non -Biological Residuals with NO Domestic Wastewater Contribution.
8. Vector Attraction Reduction VAR : Per 15A NCAC 02T.1107. specify how residuals will meet the VAR requirements:
El Alternative 1 [15A NCAC 02T.1107(a)(1)] - 38% Volatile Solids Reduction (Aerobic/Anaerobic Digestion).
Alternative 2 [15A NCAC 02T.I 107(a)(2)] - 40-Day Bench Scale Test (Anaerobic Digestion).
Alternative 3 [15A NCAC 02T.1107(a)(3)] - 30-Day Bench Scale Test (Aerobic Digestion).
❑ Alternative 4 [15A NCAC 02T.I 107(a)(4)] - Specific Oxygen Uptake Rate Test (Aerobic Digestion).
0 Alternative 5 [15A NCAC 02T.1107(a)(5)] - 14-Day Aerobic Processes.
❑ Alternative 6 [15A NCAC 02T. 1 107(a)(6)] - Alkaline Stabilization.
❑ Alternative 7 [15A NCAC 02T.1107(a)(7)] - Drying of Stabilized Residuals.
Alternative 8 [15A NCAC 02T.I 107(a)(8)] - Drying of Unstabilized Residuals.
❑ Alternative 9 [15A NCAC 02T.1107(a)(9)] - Injection.
El Alternative 10 [15A NCAC 02T.I107(a)(10)] - Incorporation.
El Alternative for Surface Disposal Units Only - Soil/Other Material Cover [15A NCAC 02T.I 107(b)(2)].
Not Applicable - Non -Biological Residuals with NO Domestic Wastewater Contribution.
Note: For animal processing residuals, only alternatives 9 or 10 may be chosen due to the nuisance conditions that typically
occur when these residuals are applied and left on the land surface.
FORM: RSC 06-16
Page 5 of 5
a

RESIDUALS SOURCE FACILITY SUMMARY
Applicant's name: Town of Beech Mountain
- 3iaius t;oae for source facility are: ♦ N (New) ♦ R (Renewed) ♦ M (Modified) ♦ D (Deleted) *Total for both facilities included in permit
SUMMARY FOR FORM: RSC 06-16
Page 1
Aq

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Process Flow Narrative For Residuals If Not Composted
I. Residuals generated by the operation of Beech Mountain Wastewater Plant.
2. Residuals then stored in digester to thicken and prepare for pressing.
3. After pressing with belt press, residuals are stored temporarily in covered metal
Container.
4. Fully intact covered metal container then hauled off to municipal landfill where
residuals are deposited.
.11

Process Flow Narrative For Residuals If Composted
Residuals Sampling/Monitoring Plan for Pond Creek compost
The compost is mixed at a 3:1 ratio. The mix is tested for pH, % moisture at the time of mix.
Temperature is measured twice per day at two different points of the pile.
After 28 days, the mix is turned and goes through 28 more days, twice per day temp reading.
At the end of this phase, the mix is moved to the storage pad for 30 days.
At this point, the mix is sampled for 503's and pathogens. In the event that the solids did not
compost or there is not enough to compost, they will be hauled off to the municipal landfill.
The mix is not allowed to leave the facility until the mix passes all required testing.
The Town of Beech Mountain will retain ownership of the mix and keep in their sole possession
for specific use on town projects.
iu

For: Water Tech Labs, Inc.
P.O. Box 1056
Granite Falls, NC 28630
Attie Joe Gragg
Report of AnalysN
10/10/2010
�I�fVJT� a
MC934 �o
NC #37701 m
M
Client Sample ID:
Pond Greek Sludge Town of Beech Mtn
Lab Sample ID: 72307-01
Site:
Water Tech Labs
Collection Date: 9117/2019 8:20
i Parameter
Method -
liegult
Units
And
Anal"ia 132tetiirrse
PAN
Calculation
2900
% Solids
SM 2540B
24.1
%
AW
9/24/2019
Total Kjeldahl Nitrogen SM 4600 N Org B-1997 (NH3
5400
mg/kg
FK
10/2/2019
D-1997)
Ammonia Nitrogen
SM 4500 NH3 D-1997
2740
mg/kg
FK
10/212019
Total Phosphorus
SM 4500 P E
1640
mg/kg
BJ
1019/2019
Nitrate + Nitrite
SM4500 NO3E
730
mglkg
DW
10/3/2019 1640
Aluminum, Total
SW 846 601 OD
5720
mg/kg
JF
9/25/2019
Arsenic, Total
SW 846 601 OD
<4.14
mg/kg
JF
9/25112019
Cadmium, Total
SW 846 6010D
0.801
mglkg
JF
9/25/2019
Calcium, Total
SW 846 6010D
4360
mglkg
JF
9/25/2.019
Chromium, Total
SW 846 601 OD
27.4
rnglkg
JF
9/25/2019
Copper, Total
SW 846 6010D
130
mg/kg
JF
9/25/2019
Lead, Total
SW 846 601 OD
17.4
mg/kg
JF
9/25/2019
Magnesium, Total
SW 846 601 OD
1700
mg/kg
JF
9125/2019
Molybdenum, Total
SW 846 601 OD
5.71
mg/kg
JF
9/25/2019
Potassium, Total
SW 846 601 OD
1450
mg/kg
JF
9125/2019
Selenium, total
SW 846 601 OD
<4.14
mg/kg
JF
9125/2019
P.O. Box 473 106 Short Street Kernersville, North Carolina 27284 Tel: [phone] Fax: [phone] www.randalabs.com
Page 1
C S

RESEARCh&ANAIYTICAI
Report of n l �
�4.
LAbORATORI"ESP Nc.
10/10/201
Client Sample ID:. Pond Creek Sludge Town of Beech Mtn
Lab Sample ID:
72307-01
Site:
Water Tech Labs
Collection Date:
9/17/2019 8:20
Pararraeter
3Jlethod
f3nlis
Anal: st Ansl is Date/Time
Zinc, Total
SW 846 6010D
266
mg/kg
JF
9/2512019
Mercury, Total
SW846 74716
0.632
mg/kg
MM
9/25/2019
Cyanide, Total
SW846 9014
2,91
mglkg
EE
9/2412019
Nickel, Total
SW846 Method 6010 C
6.95
mglkg
JF
9/25/2019
Sodium, Total
SW846 Method 6010 C
266
mg/kg
JF
9125/2019
pH
SW846 Method 9045
6-65
Std- Units MIA
9123/2019 1645
NA = not onolyzed
P.C. l3ox 473 100 Short Street Kerners011e, North Carolina 27284 Tel: [phone] Fax. 336-M-032e www. randa labs. cam Page 2

Laboratories, Inc,
Analytical / $'1'4) ess Ci)alsalltaalir3ats
J°home [phone]
Company
eVaater •1'ecla t,;11)s
Address
p.as. box I056
C'it r, SI:ata , Zip
-�-- GrAllite Falls, NC 28630
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REsEARcb ANA[YIriCA[
LAORAr®Ri(ES, LVC..
AtnWeaVRoc m Coruuitoffons
Chemical Artalysis forSeleeted Parameters and Sampling Locations Idem fled aas Pond Creek Sludge Town of Beech Min
(R Water Teed: Labs project, collected 17aSeptember 2019)
L Semi-Volallk Organics
Quanlifatiou
Pond Creek -Mudge
E?A Msihod $270 BNA
Limit
irarameteAm=r
to leg}
�mg/kel
A hd ylecnc
Anihraeett0
OMO 0330ROL
QL
Ba=k Acid
0
6.670
BQL
BQL
Beazal0)xettlgeoeM
0.330
BQL
Benzo(lciffdw ftw
0.330
BQL
2-100WIP tylaea
0.330
0.334
Bcazo(r)pyrene
BQL
ROL
Beaty) Akvh01
M12.c1 ame0mxyjmetha0c
3330
3330
0330
BQL
awl-aAamethActhee
0.330
BQL
Wa2.ehbwba=pytkther
0330.
SOL
S30
BSOL
aW2.ehyl4wxyllphthac
tel
U03330
m0
4-Btn0hany1 pbmi cthw
30
OL
Benny) hrtepl
0330
ROL
1.metitylpheta0l 330
0
SO
4
zMD
-cldI`
e0s3o
ROM
4 Chb0v0heftyl phenyl ether
0330
BQL
0330
emu
BQL
M��_
Ph W to
0330
SOL
i 2-ISlehl0tpl>eaaxec
0930
0330
BOL
t 3•Diehlat0he0zats
1.4 DfOhltgghe0ts
0330
RO
3.3•DlehlambefmdW
00 .
066D
BQL
SOL
2,4-D!ebhn0phetm!
Diethyl Phlhabw
y&&tcSOL
1
0330
0.330
BQL
BQL
Dmtethy phl
4.frDGfitro-2 aeethy01
OMO
1.B0
BQ
214-Diaiuopbmol
2,4-Daritrotuhcys
1.650
L
BQL
2,6•Vh*mfahxae
0330
SOL
Az Azabenrcm
03311
BOL
330 0
0330
SQL
BOL
Pltmmm
tlexechtmobmzctx
0.330
933U
BQL
ttexrehl0tohutadune
MM
SOL
BQL
0330
BQL
tndeim{t 2 3 cd) 9fatoe
0.330
0330
BQL
2-Mghylntaphd+rlene
0330
BQL
2-McAylphaml
0.330 0
I
1.650
BQL
Nitmeae
2dtftivpfe00!
0330
0330
BQL
BQL
4 Nlttophea0l
P1 NitrO:adiylxayfrmuta
t.650
SOL
BQL
0330
OQL
BQL
�BYfatause
LMROL
Ph=]
0330
0330
130E
Pyfene
1.2.4-Tel matwome
033 0
ROL
BOL
2;4A-7&J* mp1=I
0330
o3
BQL
2-Ma1h M.&dhzhraphenol
a
BQL
t.2 DipbbcMYv**wLm
1.fi30
BBQL
0
0.330 1.
MOW
0330
SOL
BOL
rMaWn P6tfor
1
Sample Plumber
Sample Date .
72307-01
Sample Time! (hen)
Q9A7119
Extracted
OM
D210 Addyzed
09/23119
Time Analyzed
09M,19
Surrogate Recovery
�e
1837
(2-Floorapbettol)
(21-110%)
(Pheonl-d6)
()
l%
71%
(Plitrobenaeu6"
$414%
(244,6-Tribr= piaw0R
(10-I23%)
91%
{2-Plane o6(phetBylj
(43-116%)
74%
(4-Terphe3yl-d14)
{33 14F45)
97%
malk6 �fnt�llpemsPerkilogtua=Fartsperassllian{ppm]
BNABase-N..t.1ActttEwclebhs
BQL - &I..Quta Lsg n U3 d s
„""Bob
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ES Rc NAly-FiCAI
Ab o RAC' i S, INC.
Anafytical/process Consultations
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Toxicity Characteristic Leachate Procedure (TCLP) Analysis of Sample Identified as Pond Creek Sludge Town of Beech Mtn
(A Water Tech Labs, Inc. Project, collected 17 September 2019)
Pond Creek Sludge
Town of Beech Mtn
EPA PAW
Quantitation
Results
Characteristic
hlumber
Contaminant
Limit(mg/L)
fi /�
Levef(ttte/i]l
EPA Method
I• TCLF METALS
D-004
Arsenic -
0.010
BQL
5.00
6010
D-005
Barium
0.010
0.524
100
6010
D-006
Cadmium
0.005
BQL
1.00
6010
D-077
Chromium
0.010
0.041
5.00
6010
D-008
Lead
0.005
BQL
5.00
6010
D-009
Mercury
0.0020
BQL
0.200
7470
D-010
Selenium
0.100
SQL
1.00
6010
D-01 I
Silver
0.010
BQL
5.00
6010
M REACTIVITY
D-003
Cyanide
1.00
BQL
9010
D-003
Sulfide
5.00
BQL
9030
III. COId12OSIVITY
D-002
Of
Sid. units
6.65
9045
1 V. IGNITABILITY
D-001
lgnitabiliry
WNI
1010
Sample !Number
72307-01
Sample Date
09/17/19
Sample Time (firs)
0920
Sample Matrix
Solid
mg/L—milligrams per Lifer - puts per million (pptn)
mgJka _ millignum per kilogram = parts per million (ppm)
WNI — Will Not Ignite
BQL BelowQuontitution Limits
( 4

RESEARCh & ANAtyTiCAt
„ Anplylleai/Process Consultatfons
m�,eA00,0nG.Pod
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°d°s�assseaso`�'
Chemical Anarlysts, for Sekcledpar4melers and Sampling Locations Idenkpped as Pond Creek Sludge Town Of Beecb ti In
(A Water Tech Labs Project, collected 17Se remiaer 2019)
1. 'sofa we Organics Quantitadon Pond Creek -Sludge
ETA Method 8260 B Liatit
rameter
f 1l
Acetone
Bums
0.00
BQL
Bromobenzeac
MODS
BQL
Banmochlaromedme
SOL
Brotum
mudichloeihane
0.005
Btnmororm
0,005
BQL
Bramemelhnne
0.005
BQL
2-Butanpne
0.010
8QL
N-Bmlbenmc
0.010
BQL
Sec-Bueylbeprene
0.100
BQL
Ter- Butylbeozme
0.005
BQL
Carbon Tetrachtorw
0.005
BQL
Chlombimm
do10
BQL
Dibronwhicromethme
0.0U5
BQL
chforoethnno
0.005
BQL
Chloroform
0.005
BQL
Chlorommhmre
BQL
2-Chlommluene
0.003
1
BQL
4,Chlorotoluene
0m
.00
1,2,Dibrommthaoa (FISH)
O
BQL
t,2-Dichlorobco e,
0.005
5 .00 0
BQL
13.171eiderobarae�e
BQL
1,4-Dichfem6mtme
0.005
BQL
Dlehlorodi0uoromeah�rc
0.005
BQL
1,l-DiahloroMhane
0.005
BQL
1,2-Dlchlemmhdtre
0.005
BQL
I,i-Dichlotoethme
0.005
BQL
acs-fl.8f]ichloroelhene
0,005
L
leans-1,2-DiehlaroeUrene
0.005
BQL
l,2 k7ichlotGpropane
0 .005
BQL
1,3-i77ehfarapropane
0.005
BQL
2,2 0ichloropropeoe
0.003
SQL
I.l-Dfchloropropme
0.605
BQL
Cis-13-Dichlaropropene
0.005
BQL
Trans-1,3-DichloMraporre
0.010
BQL
EOryl Acetate
0.010
0.010
BQL
Ethyl Benzcoa
BQL
2-Hormone
O.OOS
BQL
I-Propylbenzene
0.005
Isopropyl amer OFF-)0.005
)
SQ L
P lsopropyltolurne
0.005
BQL
UdeOrylene Chloride
0.010
0.005
BQL
0-Methyt-2-Pcq=ono
.
BQL
Wwwl•Ten-Butyl ether (MTBE)
0.100
BQL
Yaphthalene
0.00
SOL
V-Paopylhemxne
0.010
BQL
; fie
0.005
BQL
l.12,2-TetraehlcmeHTrane
0.010
BQL
retraehloruca me
0.005
BQL
atuena
0.005
BQL
.1,1 Triehlowedosne
0.005
BQL
.1.2-Tiiehfcrodilaft
BQL
'riohlomethene
0.005
BQL
Inedorolluotomahm
0.005
BQL
,23 Trfchlombea=e
0.005
BQL
2.4-Triehlowbea re
00E
0005
BQL
.23-TriehloropwWe,
B
.2,4-Tsimethylbenzzna
moos
8�
3,5-Trim dhyl6enrxne
O.016
MODS
BQL
'my, Acetate
5rryt Chloride
0.050
B0L
etal xylmm
0.0 10
SQL
rba 'snDieuffid►e
0.010
BQL
mylanitrife
4100
BQL
rarts-1.4-131chloto-2•buteme
0100
BQL
rerbyl Iodide
0. 00
BQL
lhromometheae
0.010
BQL
1.1.2 TehaeMoroeahaee
BQL
2-Dr omo-3 Chforpprapece(DBCP)
0.00.01010
05
BQL
ifution rector
0.0
BQL
I
ample Number
mmple mate
72307-01
rmpla 97me (hm)
09/i 9/19
ate Aaetyzed
0117.0
late Analyzed
09/26/19
erragats Recovery (DBFM)
Range (78-130%)
2104
rrroBa to F&OVe ry (Toluene-d8)
119%
Irarogste Raxovery (4-HFB)
Range (70-130%)
91a/e
Range (70-130c/a)
98 /o o
!kg �n•JIIitGx++nspaS�itogam=pera+lxrmittionappm)
BQL Bd-QuenGrmtaammils

Town of Beech Mountain
Pond Creek Wastewater Residuals Compost
Grassy Gap Creek Residuals Compost
Compost Use Information
Composted Wastewater Residuals and Waste Products
This product may be broadcast or incorporated in intended usage areas at a rate of 1 ton per 1000 cubic
feet. Do not use in gardens where root and leaf crops are grown, in playgrounds or on frozen snow
covered or flooded land. Limit usage within 100 feet of any public or private water supply, wells or
surface waters. The application of residual to the land is prohibited except in accordance with the
instructions on the label sheet.
Compost offers a consistent quality for:
Landscaping for parks or buildings
Plant enrichment
Top soil substitute or land renewal
Nursery production of trees
Potting mixes
Mulches and establishment of turf grass
Prepared by:
Randy Horney, WWTP ORC
364 Locust Ridge
Beech Mountain, NC 28604
828-387-4724

Town of Beech Mountain
Class A Compost Program
Operational and Maintenance Plan

DRAWING NAME: P:\PRO.ECT\BafthMtn\E3160\dwg\E3160—SITE.dwg — OM Fig 2-1 Dec 19, 2007 — 11:35"
EFFLUENT x
IUV BUILDWG
X ti'r`
J x
:t
% 5 RAS VAULT
x
I I AERATION 1
AZ SPLITTER `
11 1" F& I SCREENING X
1 AT-2
1 XI
x BLOWER. -
ELECTRIC.
DEWATERING
BUILDINGx
PRESS' -
IGEN x
ED
/ DIG-2 l
k DIG-1 x
x
x
x �OMPaST �?AD ' - , BLOW R
ENGINEERING
dmp LAND PLANNING
SURVEYING
I" = 50 FT
LEGEND
FC
FINAL CLARIFIER
AZ
AERATION ZONE
DIG
DIGESTER
GEN
GENERATOR
FIGURE 2-1
OVERALL SITE PLAN
t(

DRAWING NAME: P:\PROJECT\BeechMtn\E3160\dwg\PondOM Schematic.dwg — FIG-2-2 Dec 19, 2007 — 11:37am
INFLUENT
�----
MECHANICAL
SCREEN
MANUAL
SCREEN
m
- DECANT &
FILTRATE
AERATION
BASIN
AB-1
AB--2
CLARIFIER it
I
#1
M
L - - - - -1 -Q->- TO DIGESTERS
SLUDGE M
PUMP
UV
I UV I
L*EFFUENT
--/L/L/L
POND CREEK
ENGINEERING
dmp LAND PLANNING
SURVEYING
LEGEND
AB AERATION BLOWER
DB DIGESTER BLOWER
FC FINAL CLARIFIER
M FLOW METER
RPZ BACKFLOW PREVENTER
N VALVE
PROCESS FLOW
- -F - SLUDGE FLOW
Qj PUMP
FIGURE 2-2
OVERALL TREATMENT
SCHEMATIC
t��

DRAWING NAME: P:\PROJECT\8eechMtn\E3160\dwg\PondOM Schematic.dwg — FIG-2-3 Dec 19. 2007 — 11:37am
-< TO SAN---------------- <------ -I
SEWER I
i
I
FROM
SLUDGE --O->J
PUMP M
i
�----�--- --go-
I
vi
I
GRINDER
I FEED
I PUMP
I POLYMER
SYSTEM
I TOWN RPZ
I WATER
ENGINEERING
dmp LAND PLANNING
SURVEYING
(DECANT,
ITYP
T
FILTRATE
LANDFILL
DISPOSAL
BELT PRESS
BOOSTER
PUMP
I COMPOST
BLOWER
I
COMPOST PAD
DISPOSAL
FIGURE 2-3
SLUDGE PROCESSING
SCHEMATIC

Pond Creek WWTP
Operation & Maintenance Manual
2.1 Process Description
Following is a brief narrative of the wastewater treatment process used at the Pond Creek
WWTP. Please refer to the overall Plant Layout shown in Figure 2-1 and the Treatment
Process Schematic shown in Figure 2-2. A schematic of the sludge processing system is
included as Figure 2-3.
Influent wastewater enters the site by gravity and enters the screening structure. Debris is
removed via the mechanical screen, and screenings are compacted and conveyed to a
dumpster for disposal in a solid waste facility.
The influent wastewater then is piped to diversion box, where it is mixed with return activated
sludge (RAS).
Water then flows into the aeration basin. There fine bubble diffused aeration agitates the
water, allowing the wastewater to be consumed by the bacteria present in the activated
sludge mixed liquor.
Effluent from the aeration basin enters into either clarifier basin via overflow weirs designed to
evenly split flow between the two clarifiers.
The clarifier basins are conventional circular center feed, peripheral overflow devices. Each
unit is provided with a center feedwell, and effluent v-notch weir plates. Each unit has a drive
motor, and mechanical scraper for solids removal. Clarifier #1 is an existing package
treatment unit, which uses an. air lift pump and v-notch weir for RAS rate control and
measurement. Clarifier #2 is a typical unit installed in a concrete basin, and uses a
telescoping valve for rate control.
Clarified wastewater exits each clarifier basin over an effluent v-notch weir and is piped to a
junction box. From there, the treated water enters the UV disinfection facility.
The UV Disinfection equipment is enclosed in a 1,000 square foot building. There is one
channel with two independent banks of UV lamps. The UV system is commonly referred to as
a "low pressure -high intensity" system. Each bank is sized to treat the full peak flow. The
UV system can be flow and dose paced to maximize lamp life and minimize electrical
consumption.
Disinfected effluent from the UV system flows through a 6" parshall flume before being
discharged to Pond Creek. The effluent flow is monitored via an ultrasonic flow meter.
2.2 Sludge Handling Description
The Sludge Pump Station wetwell is incorporated into Clarifier #2 and receives RAS flow from
both units. Sludge is then pumped via a submersible pump to a sludge control vault. There
electrically actuated valves are provided to RAS control flow rate and to divert waste sludge
(WAS) into the aerobic digesters. Each sludge line is provided with a magnetic flow meter to
provide indication of rate and volume of sludge conveyed.
Two aerobic digester basins are provided. Each unit includes a sludge feed line, telescoping
valve for decant, sludge withdrawal line, and coarse bubble diffusers. Levels are monitored.
Town of Beech Mountain r(q
DMP Project E3160.30

Pond Creek WWTP
Operation & Maintenance Manual
Dual positive displacement blowers are provided, each sized to operate both basins. Air piping
can be directed to either or both basins as needed.
A 1,350 square foot Dewatering Building is provided which houses a sludge grinder, sludge
feed pump, and belt filter press. The building also houses the main motor control center and
main aeration basin blowers in a separate room.
Digested sludge is pumped from the digesters to the belt filter press for dewatering, and then
is composted onsite using an aerated static pile composting system. The compost is
considered a Class A biosolids and is used beneficially throughout the Town.
A standby diesel generator is provided to maintain operations in the event of electrical supply
failure. An automatic transfer switch is included in the main switch gear in the Dewatering
Building.
A 740 square foot Laboratory building houses the Superintendents office, restroom facilities
and a testing laboratory.
2.3 NPDES Effluent Parameters
The Pond Creek WWTP is a conventional activated sludge facility designed to meet secondary
treatment limits. The facility is operated under NPDES Permit NCO069761 and is classified as
a Class II facility by the North Carolina Certification Commission. The most recent permit was
reissued in 2007.
As a secondary treatment facility, the WWTP must achieve not less than 85% removal of
biological oxygen demand (BODS) and total suspended Solids (TSS). The following table
summarizes major NPDES effluent parameters, and a complete copy of the NPDES permit is
included in Appendix B.
Table 2-1
NPDES Limits
Parameter
Monthly
Weekly
_
Average
Average
BOD5
30.0 mg/L
45.0 mg/L
Total Suspended Solids
30.0 mg/L
45.0 mg/L
Fecal Coliform
200 / 100 mL
400 / 100 mL
Flow
0.40 MGD
N/A
NH3 as N (ammonia) I
N/A
N/A
Town of Beech Mountain
DMP Project E3160.30 ��

Pond Creek WWTP
Operation & Maintenance Manual
2.4
2.5
Individual Processes
The WWTP includes the following individual processes. Additional information is provided in
Section 3, Operation & Control of Unit Processes.
Process
Influent Screening
Activated Sludge Basin
Clarifiers
RAS / WAS Pump Station
Ultraviolet Disinfection
Effluent Flow Measurement
Aerated Sludge Digestion
Sludge Dewatering
Sludge Composting
Utility Services
Table 2-2
Summa of Processes
Description
One (1) mechanically clean bar screen with Ile bar
s acin and screenings compactor
One (1) manually cleaned bypass bar screen with 1"
bars acin
One 257,650 gallon aeration basin with fine bubble
diffused aeration. 15.5 hour detention time
Two 950 SCFM centrifugal -blowers-
Two 30 foot circular bottom scraper clarifiers
Design overflow rate = 305 GPD/sf
One air-lift pump
350 GPM Submersible Pump
Automatic RAS/WAS Control Valves & Flow Meters
Dual bank ultraviolet disinfection system with two
banks with 12 lamps each
6" Parshall Flume with ultrasonic transducer
Two 52,000 gallon basins with coarse bubble diffused
aeration
Two 350 SCFM positive displacement blowers
One 0.75 Meter belt filter press
One 45 GPM Sludge Feed Pump
One Sludge Grinder
One magnetic flow meter
One aerated static pile pad
One 250 SCFM positive displacement blower
The WWTP requires several support utilities to function and operate efficiently. Contact
information for these are provided in Section 5.
Obviously, the most critical of these is electrical power. Electric service is provided by
Mountain Electric Company, a public utility. Additional information is provided in Section 3,
Operation & Control of Unit Processes.
Telephone service to the facility is provided by Skyline Telephone Company. The location of
the site and surrounding topography make cellular service unreliable, so this is the primary
method of communication with other Town Departments and during emergencies. Internet
service is also provided through a DSL connection using the telephone system. Phones are
provided in the Lab Building. Conduit spares are available to extend circuits to the UV and
Dewatering Building if desired.
Town of Beech Mountain
DMP Project E3160.30

Pond Creek WwTP
Operation & Maintenance Manual
3.7 SLUDGE PUMPING
A. DESCRIPTION
The Sludge Pump Station is located adjacent to Clarifier #1. Return Sludge from both
clarifiers enters the wetwell. A single submersible pump is provided and control valves
located in the valve vault adjacent to the station. A spare pump is provided and s es are
stored onsite for quick replacement. should be
The pump station is designed to return activated sludge
RAS) to the
Valves are provided to divert flow (WAS) to the aerobic dige ter bas nseration basin influent.
B. EQUIPMENT
removal system located in the sludge wetwellThe Sludge Pump is a vertical submersible centrifugal pump. It is installed with a
. Each pump has the following charac
_ Sludge Pump terstics:
Capacity 450 GPM at 40 feet TDH
Manufacturer KSB INC
Model KRTE 80-251/66XG-S
Motor 7.5 HP 1200 RPM
Voltage 480 V, 3-phase, 60 hz.
The pump discharges through a 4" plug valve and check valve located in the valve v
The discharge header splits to function either as a 4" RAS line to the aeration s li abo
a 4" WAS line to the aerobic digester. p tter box or
Each line is provided with a 4" plug valves for flow control. An EIM electric o erat
the valve position as directed by the pump control panel. p or moves
A 4" pump around connection is provided in the valve vault for connection of a orta
Pump. This is in the event of failure of the main pump, p ble
C. NORMAL OPERATION
The Sludge Pump is controlled from the Pump Control Panel located at the e P
Station. e Sludge Pump
A three position (HAND)—
(OFF) —(AUTO) selector switch is provided in the PCP, In HAND
mode the pump is energized. In OFF mode the pump will not run. In AUTO mode th
operates based on inputs from the float switches in the wetwell in a P e pump
control sequence. typical Pump -down
In normal operation, the RAS valve will be partially open to throttle the Pump and decrease
flow. RAS flow is metered via the mag meter, and displayed at the PCP. The Operator
should experiment with valve settings to determine the optimal flow rates and valve
Position
settings.
To waste sludge the Operator must manually open one of the Digester Influent valve
(located to the east of the digester), then begin to open the WAS valve at the PCP. s
after the WAS valve is at least 50% open, the RAS valve can be closed to divert addiThen
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flow to the digester. Reverse the sequence to end the wasting process. Monitor the WAS
Flow Meter and Digester Level to waste the correct volume and avoid overflows.
Digital indicators for RAS and WAS flow are located in the PCP. Both record and display
Maximum Rate, Minimum Rate, and totalized flow.
Digital indicators for RAS and WAS valve position are also located in the PCP.
D. EMERGENCY OPERATION
The sludge pump is critical to proper operation of the activated sludge process. In the
event of pump failure, a spare pump is to be stored at the plant site. The pump can readily
be removed using the davit crane provided.
Lockout power to the Pump Control Panel, then disconnect the pump cable from the
terminals in the junction box. Not the correct cable connections and connect the spare pump
in the same fashion. See the manufacturer's 0&M manual for details on calibrating the
protective devices and checks required.
The new pump should then be lowered into the wetwell, seating on the discharge elbow and
power restored to the control panel.
Follow specific directions provided in the KSB O&M Manual.
Alternately a portable pump can be used. Lower the suction line into the sludge wetwell and
connect a quick connect fitting to the blind flange in the valve vault to provide full sludge
pumping ability, or simply route the discharge hose into the head of the aeration basin to
temporarily return sludge. Pump capacity should be approximately equal to the average
plant flow.
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Operation & Maintenance Manual
3.8 . AEROBIC DIGESTION
A. DESCRIPTION
The aerobic digester is critical to the operation of the activated sludge process. Waste
sludge (WAS) generated in the aeration basin is periodically wasted to the digester for
further treatment.
Digested sludge is then pumped to the Dewatering Facilities for dewatering prior to c
or ultimate disposal. compost
B. EQUIPMENT
Two rectangular concrete basins, approximately 52,000 gallons each, are provided for u
aerated digester basins. Each basin is 15' long, 32' wide, and 14.5' deep. se as
WAS enters the western end of each basin though a 4" pipe. Isolation of the each basi
control by a 4" plug valve located adjacent to the tank. n is
Each tank is equipped with a telescoping valve for decanting clarified liquid to thicken th
sludge during digestion. The telescoping valves also act as overflow devices and have e
effective range of 48". Decanted liquid returns to the gravity influent line. an
Coarse bubble diffused air is provided for mixing and aeration. The system includes two
dedicated positive displacement blowers, air Piping.
i in Diffusers are Environmental Dynamics
FlexAir Magnum 84P diffusers. Each diffuser includes an PVC body with an EPDM cs
membrane. The 8 diffusers are arranged on a 4" center header and provide full floo �orated
coverage.
Digester Blower
Manufacturer
Model
Capacity (Max / Min)
Max Pressure
Operating Speed (Max / Min)
Drive Motor
Electrical Supply
C. NORMAL OPERATION
DB-1, DB-2
United Blower, Inc. - -
UBI 41
�50 SCFM
7.0 PSIG
3590 (Max)
25 HP, 1800 RPM, TEFC
480 VAC, 3P, 60 Hz
The Operator will periodically waste sludge to one of the two basins. Generally the basi
should be operated in batch mode to maximize detention and provide the maximum amos
of sludge stabilization. unt
The Digester blowers are operated from MCC1 located in the Digester Building. Each blower
is provided with a HAND -OFF -AUTO SELECTOR switch. In HAND the Blower will operate
continuously. In OFF the Blower will not operate. In AUTO the blower will operate in
accordance with a cycle timer located in the MCC. Operator shall select a repeatable on off
cycle (ie 30 minutes on then 15 minutes off). /
Positive Displacement Blower capacity (SCFM) can be not reduced by throttling inlet or
discharge valves. The only way adjust the capacity is by bleeding off of part of the dischar
ge
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or varying the speed. VFD's and changing sheave diameters & drive belts are acceptable
methods. DO levels in the digesters can be controlled by adjusting the Blower Cycle timers.
Each blower is sized to operate both basins at full capacity and provide 30 CFM / 1000 ft3 of
volume for adequate mixing. This was a State review comment, in lieu of providing a third
backup blower. When operating one blower with both basins, air may be unequally divided
if water levels differ. It may be desired to operate each basin with a separate blower and
varying the cycle times to avoid over aeration.
Periodically shut down air to one basin for at least 30 minutes. Once solids have begun to
settle, the operator can decant clarifier upper level using the telescoping valve. Monitor the
decant quality and stop decanting when solids are being removed. The ideal sludge
thickness should be between 2 and 3% for optimum digestion and dewatering performance.
Foaming may be a common problem in aerobic digesters. This can be due to seasonal
variations, high organic loading (and low DO), or growth of filamentous bacteria. Foam
should be broken up using water spray, or when excessive, antifoaming chemicals may be
used. If foam is a problem, operate the digester with a 36" or greater freeboard.
Generally odors from aerated digesters are not offensive, and usually are a. result in
Inadequate aeration resulting in septic conditions.
When sludge will be disposed of by composting, achieving 38% VSS reduction in the digester
is not the objective, as the volatiles in the dewatered sludge are beneficial to the compost
process.
However, when the dewatered sludge will be trucked to a landfill for disposal, the digester
should be operated to achieve greater than 38% VSS reduction. This project was designed
meet this reduction with the following parameters:
Sludge Age (SRT) = 60 days
Winter temperature = 10 DegC
Temp days = (Average temp, DegC)(SRT, days) = 600 DegC-days or more
Hydraulic detention time of 13.3 days (based on average wasting rate)
D. PROCESS CONTROL
Typically process control will be to monitor sludge quality and adjust the cycle timer to
operate each blower. Generally, the aeration system should be operated to maintain 2 mg/L
DO level in the digester.
Monitor DO levels during decant cycles to prevent extended anaerobic conditions, typically
limit decant periods to less than 2 hours.
The Operator should regularly monitor and record DO, pH, temperature, VSS and liquid
levels of each digester tank. This is in addition to tracking the volume of sludge wasted to,
decanted from, and dewatered from each basin. TSS of all flows in and out are necessary to
development mass balances and verify solids retention times. A process control sheet for
each digester may be a useful tool.
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Operation & Maintenance Manual
E. NORMAL MAINTENANCE
The blowers are basically air pumps and require routine maintenance as summarized herein
and detail in the manufacturer's 0&M manual.
Weekly
❑ Check oil level in sight glass (2 per blower)
❑ Add oil as needed
❑ Visually inspect for oil leaks
❑ Check drive belt tension
❑ Check enclosure ventilation fan operation
❑ Check inlet filter restriction gauge
Monthly
❑ Check motor for vibration and hot spots
❑ Inspect drive belts for abnormal wear
❑ Spray WD40 into pressure relief valve internals
Quarterly
❑ Clean inlet filters with vacuum cleaner
❑ Check pressure relief valve operation
❑ Check sealing of isolation valves and check valves
Semi-annually (or every 1000 operating hours)
❑ Change oil on gear end and drive end
❑ Rotate by hand and check backlash
❑ Grease motor bearings
Bi-annually - Check blower lobe clearance
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Pond Creek WWTP
Operation & Maintenance Manual
3.9 SLUDGE DEWATERING
A. DESCRIPTION
Sludge Dewatering is a process which greatly reduces the volume of waste sludge which is
composted or hauled from the site by removing excess water. Typically sludge in the
digester basin will be at 2 to 4% solids. The Dewatering Equipment provided should produce
a sludge cake of 15% or more.
The dewatering facilities were installed in 2007 and replaced the use of sand drying beds at
the facility. In the past, Operators pumped waste sludge to the drying beds and relied upon
gravity, evaporation, and favorable weather conditions to produce a sludge cake. Once all
the beds had been loaded, no further sludge could be added until cake could be removed
from a bed.
The Dewatering Facilities are housed in the Dewatering Building. The major component is a
belt filter press, which utilizes gravity separation and pressure to remove excess water. The
dewatered cake can be stockpiled on the remaining sand bed or compost pad. Options for
ultimate disposal include composting or hauling to a municipal solid waste facility (landfill) for
disposal.
B. TERMINOLOGY
Some common terms used in sludge processing that operators should become familiar with:
❑ Sludge Cake — the dewatered product. This is similar to sludge removed from the
drying beds, and can have a solids concentration of 12% and higher.
❑ Dry Solids — the actual solids material in all sludge after all water has been removed.
This is the basis of most calculations. Dry solids are not reduced by thickening,
dewatering, or composting.
❑ Wet Weight — the weight of dry solids plus remaining water content. This is the
measurement that must be used for hauling or tipping fees, etc.
❑ Capture — the amount of dry solids retained in the dewatered cake, compared to the
dry solids in the feed, typically expressed as percent.
Some common formulas and relationships:
1% Concentration = 10,000 mg/L = 10,000 ppm
Water weighs 8.34 lb per gallon
1 MGD = 694.4 gpm
Lb/day = 8.34 * ppm * MGD
Lb dry solids per hours = 5 * %Conc * gpm
Dry weight = wet weight * %Conc
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Operation & Maintenance Manual
C. EQUIPMENT
The Dewatering Building houses the waste sludge flowmeter, grinder, belt press feed pump,
belt press, and polymer system. The belt press used at this plant is a packaged system
designed for smaller WWTP's as described herein.
The belt press system includes a central control panel, and operation of all ancillary
equipment is controlled from this panel. This ensures that all components are working prior
to introducing sludge into the system.
The sludge feed pump is a positive displacement progressive cavity pump, operated on a
variable speed drive. This style of pump is commonly used in sludge pumping applications
because of its linear flow vs. speed characteristics. Positive displacement pumps work well
with the varying head conditions, and the progressive cavity design produces a pulse free
flow pattern, which is ideal for dewatering equipment.
The sludge pump and belt press are protected from rags or debris by grinding the sludge
prior to pumping. The sludge grinder is controlled by a reversing controller and interlocked
with the sludge pump. If the grinder trips out the sludge pump will also cease operation.
The Grinder will operate until stopped (local or remote). If the unit encounters debris that
"jams" the cutters the PLC controller will initiate a reversal cycle. If the obstruction is
cleared, normal operation continues, however if the jam still exists, the unit will Stop and
Indicate a "GRINDER JAM" alarm. This will shut down operation of the Sludge Feed Pump.
The sludge pump cannot run dry or damage to the rotor and stator will occur!
The belt press includes two dewatering belts, driven by a single variable speed drive. The air
compressor operates the belt tracking and tensioning cylinders, which are monitored and
continually adjusted during operation.
Polymer is one of the keys to successful dewatering. The polymer system includes several
components. The polymer system utilizes liquid (neat) polymer which is pumped from a
drum at a controlled rate, then mixed (activated) with dilution water. The activated solution
is then injected into the sludge feed piping via an injection ring. A vortex mixer is provided
to gently mix the polymer solution and sludge as it is pumped to the belt press.
The Booster pump provides high pressure wash water to clean belts as the unit operates to
optimize dewatering performance. If the belts are dirty, less water will pass through.
Sludge Grinder
Manufacturer Yeomans Chicago Corporation
Model Sewer Chewer SC-04
Motor Data 3 HP, 460V, 3P, TEFC
Feed Pump
Manufacturer
Moyno
Model
B1G-CDQ-3APA
Capacity
45 GPM at 30 psig
Motor Data
3 HP, 460V 3P, TEFC
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Operation & Maintenance Manual
Filter Press
Manufacturer
PHOENIX Process Equipment
Model
LC-80OLS
Belt Width
0.75 meter
Liquid Capacity
45 GPM (maximum)
Solids Capacity
350 lb/hour dry solids
Feed Solids
1.5 to 3 %
Cake Solids
16% minimum
Solids Capture
95%
Polymer Dose
6-10 lb Active / ton
Motor Data
1 HP 230/460V 3P
Polymer Sstem
Manufacturer
Velodyne -
Model
VH-1 D-300-BX-PHX
Polymer Pump
LMI Series AA9
Capacity
Neat Polymer: 0.05 to 1.0 GPH
Dilution Water: 0.5 to 5 GPM
Electrical Data
120V 1P
Booster Pump _
Manufacturer
Grundfos -
Model
CR10-4
Capacity
55 GPM @ 55 psig boost
Motor Data
3 HP, 460V 3P TEFC
_Air Com ressor
Manufacturer Emglo - - - -
Model KIA-30
Capacity 4 CFM @ 95-125 psig
Motor Data 1.5 HP, 230/460V 3P TEFC
Manufacturers Operation and Maintenance manuals for all equipment are on file.
D. NORMAL OPERATION
The Dewatering Process requires constant operator attention. Most plants will operate the
dewatering facilities only a few days per week as needed to maintain a suitable solids
inventory. Operating a full shift optimizes the labor required for setup, startup, and cleanup.
This is generally the most efficient use of resources.
Prior to dewatering the Operator should perform the following tasks:
1. Verify that there is an adequate supply of polymer on hand.
2. Perform routine maintenance needed on the press components.
3. Verify space is available to store the sludge cake.
4. Test the digested sludge (percent solids, volatile solids, pH, etc).
5. Verify that all plug valves from the digester tank to the press are open.
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6. Connect the polymer pump to an adequate supply of polymer.
7. Open NPW valves supplying the booster pump & polymer system.
8. Position the cake hopper or loader under the discharge chute.
The Master Control Panel has been designed for automatic operation of all dewatering
components. Normal operation is for all equipment to be powered up, and any local
controls set in AUTO or REMOTE.
The Operator will then got the Main Control Panel and verify the following selector switches
are in AUTO: Belt Wash Water, Belt Filter Press, Sludge Feed Pump, Polymer Feed Pump.
The Air Compressor should be set to ENABLE, and the Belt Press Maint. Control set to RUN.
The Operator starts the process by depressing the AUTO START button. The system will
sequence through the preprogrammed startup sequence unless a fault is detected.
Once the system is running, the Operator should optimize treatment as described herein.
Monitor the Gravity Zone:
❑ Insure free water drainage is occurring.
❑ Sludge should have a "cottage cheese" appearance
❑ Sludge should be evenly distributed across the belt.
❑ Increase the belt speed to prevent liquid level from rising.
❑ Adjust polymer feed rate to provide good flocculation.
Increasing solids loading:
❑ After stable operation is achieved, the Operator can begin increasing throughput by
increasing the feed rate in 5 gpm intervals. Wait 10 minutes between adjustments.
❑ Adjust the polymer feed and belt speed based on conditions in the Gravity Zone.
❑ Monitor the liquid level in the Feed Containment Box to prevent overflow.
❑ Maintain a cake thickness of 1/2" at the discharge chute.
❑ Keep in mind, that the solids loading rate may govern, not the flow rate!
Increasing Cake Dryness:
❑ Increase belt tension in 5 psi steps. Wait 15 minutes between adjustments. Do not
exceed 56 psig.
❑ Watch for extrusion form the belt edges and fine solids penetration into the belt
fabric. Increase doctor blade pressure as needed.
❑ Decrease belt speed in small increments, monitoring liquid level in the Feed
Containment Box.
Optimize Polymer consumption:
❑ Reduce polymer dosage by 5% steps. Wait 15 minutes between adjustments.
❑ Monitor Gravity Zone conditions.
❑ If Gravity Zone level increases, belt extrusion starts, or solids recovery drops, increase
polymer in 5% steps until the conditions improve.
The Operator may occasionally need to hose down areas of the press when sludge leaks or
drips out. Do not aim the hose directly at electrical components, motors, or panels.
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When the Operator is finished dewatering for the day, depress the AUTO STOP button, and
the unit will automatically step through the shut down sequence.
The Operator should hose down the rollers and entire press unit. Flush out collection pans
and any solids which may accumulate on the structural components.
E. MANUAL OPERATION
All components can be operated in HAND mode from the control panel. Place the sector
switch in Hand and then depress the START button.
The Operator can commence the manual Startup Sequence:
1. Open Air supply to control panel and other air valves.
2. ENABLE Air Compressor
3. Start wash water booster pump
4. Set belt tension to 40 PSIG
5. Set belt drive speed to 50% speed
6. Operate press for at least 2 minutes to wet belts
7. Start Polymer system
8. Start Feed Pump at 50% capacity
Follow the operating / optimization instructions above.
Short term shutdowns (1/2 hour or less) can be accomplished simply by stopping the sludge
and polymer feed. Follow optimization instructions to restart.
When the Operator is finished dewatering for the day, follow this shutdown sequence:
1. Begin reducing the feed to the press and dilute feed box with NPW.
2. Shut off polymer feed approximately 10 seconds before shutting off sludge feed
pump.
3. Continue dilution water to flush lines.
4. Continue belt press operation with spray water on for 15 minutes or until belts are
clean.
5. Reduce belt speed and hose down the rollers and entire press unit. Flush out
collection pans and any solids which may accumulate on the structural
components.
6. Shut off spray water
7. Shut off belt drive
8. Disable the air compressor and close air valve.
F. NORMAL MAINTENANCE
Belt presses are typically heavy duty pieces of equipment. With proper care and
maintenance the press should operate for many years. The ancillary equipment will require
more intensive maintenance.
As -needed
❑ Grinder Jams. Lock out the Grinder and clear obstructions, return to normal
operation.
Daily Tasks
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❑ Lubricate Clevis & Pivot Eyes
❑ Check belts for damage
❑ Check doctor blades for damage
❑ Check wiper bars for damage
❑ Check belt tracking components, observe tracking, adjust as needed
❑ Check inline air lubrication — add as needed
❑ Check air & water pressure
❑ Listen for unusual noise or vibration from equipment
❑ Wash entire unit
Weekly or every 40 hours of operation
❑ Grease all press roller bearings
❑ Examine compressor air filter, clean/replace as needed
❑ Check oil level, top off as needed
Monthly
❑ Clean compressor unit
❑ Check compressor bolts and air connections for tightness/leaks
❑ Check & clean polymer check valve
❑ Clean polymer pump check valves and pump head
❑ Check sludge pump packing, adjust/replace as needed
Quarterly
❑ Drain compressor and refill with new oil
❑ Inspect booster pump motor, check electrical connections
❑ Grease booster pump motor bearings
Semi annually
❑ Flush polymer pump with mineral oil.
Bi-Annually (10,000 operating hours)
❑ Change belt drive gear reducer oil
❑ Clean & regrease belt drive gear reducer
• Lubricate/Replace sludge pump bearings
❑ Lubricate grinder motor bearings
❑ Service grinder speed reducer
G. SAFETY
The dewatering building is a damp environment. Use care when hosing down equipment
and working with electrical components.
Polymer can be a hazardous chemical. Keep MSDS sheets in the room and refer to these for
information on treatments if exposed to the chemical.
Cleanup any leaks and spilled materials immediately to minimize fall hazards. Polymer is
extremely slick, clean with adsorbents and use washwater as a last resort.
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Operation & Maintenance Manual
Familiarize Operators with locations of emergency stops.
Do not allow loose clothing, jewelry, or long hair to become entangled in moving belts.
Do not climb on the belt press at anytime.
Always follow lock/tag out procedures, as equipment may be controlled from several
locations, and can start automatically.
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Operation & Maintenance Manual
3.10 COMPOSTING
A. DESCRIPTION
Aerated Static Pile Composting is a process in which dewatered sludge is mixed with
common organic material (brush, limbs, yard waste, etc) which has been chipped or ground
WWTP site. .
The composting material is gathered by the Public Works Department and stockpiled at the
Composting creates a high temperature environment which serves to further breakdown
biological materials. The high temperatures and long detention times reduce pathogens to
acceptable levels.
Composting is an USEPA approved method for complying with the vector and pathogen
reduction requirements set forth in 40 CFR Part 503 regulations. Properly composted
materials are considered a Class A Biosolids product, which can be used and fertilizer, mulch
in landscaping. It is considered an inert material.
B. EQUIPMENT
The composting equipment is a blower for pile aeration, a skid steer loader for moving
materials, and an asphalt composting pad.
Compost Blower
Manufacturer
Model
Capacity
Max Pressure
Operating Speed
Drive Motor
Electrical Supply
United Blower, Inc.
UBI 41
250 SCFM
3 PSIG
2505 RPM
10 HP, 1800 RPM, TEFC
480 VAC, 3P, 60 Hz
The blower is powered from the Blower Room MCC. Air is discharged into a perforated
header underneath the asphalt composting pad.
Operation and Maintenance manuals for the blowers are on file.
C. NORMAL OPERATION
The Compost Blower is operated from the Blower Room MCC. In HAND the blower will run
continuously. In OFF the blower will not run. In AUTO the blower will operate in accordance
with a cycle timer located in the MCC. Operator shall select a repeatable on/off cycle (ie 30
minutes on then 15 minutes off).
The following procedure is followed for composting:
❑ Manually mix compost and dewatered sludge at a 3:1 ratio
❑ The pile is aerated 24 hours per day using the compost blower
❑ Mix is sampled for pH and % moisture at time of mixing
❑ Temperature is measured two times per day and two different locations in the pile
❑ After 28 day, the piles are turned
❑ Temperature is measured two times per day and two different locations in the pile
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❑ Mix is moved to the storage area for 30 days
❑ Mix is sampled for Part 503 compliance and pathogens
After the compost mix has passed all testing it may be removed from the site. It is Class A
biosolids and can be used without restrictions.
Positive Displacement Blower capacity (SCFM) can be not reduced by throttling inlet or
discharge valves. The only way adjust the capacity is by blowoff of part of the discharge or
varying the speed. VFD`s and changing sheave diameters & drive belts are acceptable
methods.
D. PROCESS CONTROL
Operator must keep a log of the parameters noted above for each pile. All samples are grab
samples.
E. ROUTINE MAINTENANCE
The blowers are basically air pumps and require routine maintenance as summarized herein
and detail in the manufacturer's 0&M manual.
Weekly
❑ Check oil level in sight glass (Z per blower)
❑ Add oil as needed
❑ Visually inspect for oil leaks
❑ Check drive belt tension
❑ Check enclosure ventilation fan operation
❑ Check inlet filter restriction gauge
Monthly
❑ Check motor for vibration and hot spots
❑ Inspect drive belts for abnormal wear
❑ Spray WD40 into pressure relief valve internals
Quarterly
❑ Clean inlet filters with vacuum cleaner
❑ Check pressure relief valve operation
❑ Check sealing of isolation valves and check valves
Semi-annually (or every 1000 operating hours)
❑ Change oil on gear end and drive end
❑ Rotate by hand and check backlash
❑ Grease motor bearings
Bi-annually
❑ Check blower lobe clearance
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Operation & Maintenance Manual
The other maintenance items are primarily good housekeeping practices. The dewatered
sludge should be stockpiled to prevent runoff from leaving the compost pad.
The aeration piping may need occasional cleaning, and the compost pad will need periodic
repaving. Area drains should be kept clean and functional to prevent runoff from entering
the adjunct stream.
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Pond Creek WWTP
Operation & Maintenance Manual
3.11 INSTRUMENTATION
A. DESCRIPTION
The WWTP includes a variety of instrumentation that is used for equipment control, process
control and reporting.
Additional detail on the operation and maintenance of each instrument is available in the
respective manufacturer's manuals.
B. EQUIPMENT
A summary of major instruments installed at the plant is provided in Figure 3-10.
In addition to the listed instruments there are also devices used in equipment control, which
are detailed in the respective equipment 0&M manuals.
Each pump is provided with a suction and discharge gauge, as applicable.
C. NORMAL OPERATION
The Instrumentation system is normally operational, and requires periodic calibration,
cleaning of sensors, changing of charts and pens, etc.
Questionable instrument readings should be verified as quickly as possible, and charts noted
if inaccurate. Correction action should be scheduled as soon as possible to maintain accurate
records.
D. EMERGENCY OPERATION
The overall instrumentation system is an important component of the WWTP, and must be
kept in good operating condition. Failure of any individual component can be handled by
increased Operator efforts and bench testing.
Some components, such as effluent flow are mandated by the State. A staff gauge is
provided in the effluent flume for manual flow determination.
Instrumentation is susceptible to electrical surges such as those caused by electrical storms
or blowouts. Ensure any electrical protective devices are functioning properly. Check
equipment regular after severe weather or power failures. Occasionally check programming
setpoints to ensure they have not accidentally been changed.
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System / Purpose
Influent Screen
Aeration Blower
Aeration Blower
L Clarifier #1
Clarifier #2
UV System
UV System
UV�System
Ui vS _
ystem
Effluent Flow
Effluent Sampler
RAS Sludge Flow
RAS Valve Position
WAS Sludge Flow
�AS Valve Position
Sludge Pump
Sludge Pump
Table 3-1
Instrumentation Schedule
Instrument /Alarm [instrument Display Location
ocation 0 eratio
General Alarm
General Alarm
Surge Monitor
Clarifier Torque
Clarifier Torque
Common System
Alarm
Lamp Failure
Bank Status
UV Intensity
6" Parshall flume w/
Ultrasonic Flow Meter
General Alarm
4" magnetic flow
meter
Valve Actuator
4" magnetic flow
meter
Valve Actuator
General Alarm
Float switches
Sludge Pump
I Moisture sensor
Sludge Pump
Temperature sensor
— —
Sludge Pump
Low wetwell level
Influent Screen
ns
Screen Control Panel / SCADA
Indicate Alarm
Blower Room
Blower Control Panel /SCADA
_
Alarm
Blower Room
Blower Control Panel
_
In_dicate, Alarm _
Clarifier #1
f Clarifier #1 Control Panel
Indicate, Alarm
Clarifier #2
Clarifier #2 Control Panel
Indicate, Alarm_
UV Building
UV Control Panel / SCADA
_
Alarm
UV Building
_
UV Control Panel
_
Indicate
UV Building
UV Control Panel
Indicate
Alarm
UV Building
UV Control Panel
Indicate, Alarm, Control
UV Building
UV Building / SCADA
Indicate, Totalize, Record
UV Building UV Building / SCADA
Alarm _
Sludge Valve Vault ' Sludge PCP/ SCADA
Indicate, Totalize, Record
Sludge Valve Vault Sludge PCP / SCADA
Indicate, Control
Sludge Valve Vault Sludge PCP / SCADA
Indicate, Totalize, Record
Sludge Valve Vault
Sludge PCP
Indicate, Control
Sludge Pump
Sludge PCP / SCADA
Station
Alarm
Sludge Pump
Sludge PCP
Station
Indicate, control, alarm
Sludge Pump
Sludge PCP
Station
Alarm
Sludge Pump
Sludge PCP
Station
Alarm
_
Sludge Pump
Sludge PCP /SCADA
Station
Alarm
Town of Beech Mountain
DMP Project E3160.30 3

Pond Creek WwTp
Operation & Maintenance Manual
L
urpose
p
Digester Blower
f Di est g er Blower
Digester Blower
Digester Blower
' Dig
ester Blower
Sludge
Flow
Belt Filter Press
Belt Filter Press
Belt Filter Press
Belt Filter Press
Belt Filter Press
Belt Filter Press
Generator Status
ATS Status
Town of Beech Mountain
DMP Project E3160.30
Table 3-1
Instrumentation Schedule
Instrument / Alarm Instrument~ Display Location
- - _ Location 0 erations
Low wetwell level Sludge Pump Sludge PCP /SCADA
Station Alarm
General Alarm Digester Blower Blower Control Panel / ACS DA
Alarm
Discharge Pressure Digester BI Blower Control Pane~
Vacuum Pressure
Discharge Pressure
Discharge
ern era re
4" magnetic flow
meter
Belt Breakage
Belt Tracking
Low Air Pressure
Emergency Stop
Polymer low flow
Polymer Running
General Alarm
Status
ower
Indicate
Digester Blower
Blower Control Panel
Indicate
Digester Blower
_
Blower Control Panel
-
Indicate
Digester Blower
Blower Control Panel
Indicate, Control
Dewatering
Belt Press Control Panel
Buildin
Indicate, Totalize
Dewatering
Belt Press Control Panel
- Buildin
Alarm
Dewatering
Belt Press Control Panel
Buildin
Alarm
Dewatering
Belt Press Control Panel
Buildin
Alarm
Dewatering
Belt Press Control Panel
Buildin
Alarm
Dewatering
Belt Press Control Panel
Buildin
Alarm
Dewatering
_
Belt Press Control Panel
Buildin4_
Indicate
Blower Room
Main Switch Gear / SCADA
- - _
Indicate, Alarm
Blower Room
Main Switch Gear / SCADA
- - -
Indicate, Alarm
f4�

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
4.1 Normal Operations
This facility is required to be manned 8 hours per day Monday thru Friday by the State of North
Carolina. Typically two operators are on duty during the first shift, which typically runs from
7:00 am to 3:30 pm.
The hours of operation should be extended as necessary to keep pace with system demands,
which vary seasonally.
4.2 Staffing Requirements
The current staffing plan requires a superintendent who also is the Operator Responsible
Charge (ORC). One assistant operator is also required.
At smaller facilities most activities are shared by all operators regardless of title or experience.
When sufficient staffing exists, tasks can be delegated as appropriate.
The following section describes the various tasks which must be performed. This information is
adopted from EPA Publications.
Operational Tasks
❑ Operation of process equipment
❑ Cleaning of weirs, bar screens, flumes, etc.
❑ Cleanup and maintenance of UV system
❑ Compliance & process control sampling
❑ Operation/adjust of controls
❑ Monitoring gauges, meter, panels
❑ Assessment of activated sludge process using observations & lab tests
❑ Recognition of process upsets
❑ Sludge/Wasting/Digestion/Thickening
❑ Sludge Dewatering
❑ Sludge Composting
Maintenance Tasks
❑ Inspection of mechanical equipment
❑ Lubrication of equipment
❑ Replace packing in valves and pumps
❑ Service & replace bearings & seals
❑ Remove & install equipment
❑ Clean out piping clogs
❑ Minor plumbing
❑ Minor shop work
❑ Calibrate & repair meters & instruments
d Minor electrical repairs
❑ Replace belts & adjust belt pressure
Note: These tasks may be contracted or performed by other departments.

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
Supervisory Tasks
❑ Over sight of Plant Operation & Maintenance
❑ Scheduling of Employees
❑ Organization & Director of Employees
❑ Organization & Director of Training
❑ Development of Operating Budget
❑ Development of Capital Budget
❑ Reporting to State & Federal Agencies
❑ Reporting to Public Works Director
❑ Public Relations
Clerical Tasks
❑ Maintain shift logs
❑ Maintain lab data
❑ Update Maintenance Records
❑ Fill out Regulatory Reports
❑ Track budgeted expenditures
❑ Routine correspondence
❑ Filing & Organizational Reports & correspondence
Laborator Tasks
❑ Collection of samples
❑ Chain of custody forms
❑ Perform on -site testing
❑ Coordinate contracted lab services
❑ Assemble & report test results
❑ Evaluate data in terms of performance
o Microscopic examinations
❑ Prepare common chemical reagents & media
❑ Note: Some tasks may be contracted out
General Tasks
❑ Custodial work (cleaning buildings)
❑ Load/unload trucks, pickup supplies, deliver samples
❑ Cutting grass, removing leaves
❑ Removing snow & ice
❑ Wash down equipment & tools
❑ Touch up painting
All personnel must work as a team to insure the WWTP operates efficiently and as designed.
Operators are encouraged to put forth effort to insure the best quality effluent is produced.
Responsibilities of all Operators
❑ Conscientious operation of plant and maintenance of building, grounds, & equipment
❑ Make observations and conduct tests required for optimum WWTP performance and
satisfy DWQ reporting requirements
E�'c

Pond Creek Wastewater. Treatment Plant
Operation & Maintenance Manual
❑ Be able to interpret observations and laboratory test results an apply them to process
control
❑ Become fully acquainted with the WWTP
❑ Attend training & educational activities & use knowledge gained to good use
❑ Comply with NPDES Permit requirements
❑ Reporting and testing shall be truthful to best of operators knowledge and abilities
❑ Maintain the highest level of ethics and professionalism
❑ Submit reports on time
❑ Report promptly spills, overflows, and other violations to appropriate agencies
❑ Keep this O&M Manual current and up-to-date
4.3 General Record Keeping
The Operators shall maintain up to date data regarding overall Operations on a daily basis. A
sample Operations Report is included as Figure 4-1. This form should be updated as changes
are implemented involving the data recorded and/or the processes used at the plant.
The daily records should also include an Operator's diary or journal that notes samples
collected, flow rates, weather conditions, and other items not normally included on the Daily
Plant Record. The journal should be used for noting the following items:
❑ Visitors
❑ Progress of maintenance or construction work
❑ Equipment failure or observation of potential problems
❑ Accidents
❑ Bypassing of units
o Complaints received
❑ Chemical or other supply orders issued
Likewise, "bench sheets" should be developed and utilized to document the various laboratory
methods used to test for the various parameters required by the State and USEPA. These
would include records of instrument calibrations, worksheets documenting the test procedures
and calculations for each test, and chain -of -custody form for the various samples collected and
shipped offsite for analysis.
The State requires several monthly (DMR) and quarterly forms. As these are regularly updated,
an up-to-date master should be inserted following the Operations Report. An up to date copy
of the previous years annual report should also be kept in this section.
Op On

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
4.4 Housekeeping
Housekeeping of the facilities, structures, and grounds should be incorporated into routine
schedules. Maintaining a neat and orderly appearance will increase public support for future
capital projects, improve employee morale, and present a professional image to state and
federal regulators.
Storage areas should be kept clean and well organized, so that items can quickly be found in
emergencies. This applies to chemicals, tools, spare parts, and documents.
Periodic or seasonal items include grounds maintenance, replacing burnt out light bulbs,
cleaning gutters, painting, etc.
4.5 Maintenance
Maintenance is extremely important, but often overlook component in the operation of a waste
water treatment facility, as the public relies upon this facility to operate under all conditions, 365
days a year. While most equipment is designed for continuous duty or extended operation
with relatively low levels of maintenance, the required maintenance items must be performed.
This facility has undergone numerous upgrades over the years and some equipment is over 20
years old and requires more frequent maintenance. In general, the pumps and equipment
used at this plant are custom made and replacement requires long lead times. In fact, most
equipment would take 6 to 12 weeks after ordering to even be shipped to the site.
There are two basic types of maintenance: Preventative and Corrective.
Preventative maintenance is defined as regularly schedules tasks, including inspection,
cleaning, lubrication, and replacement of assemblies that minimize or prevent major equipment
failures. Regularly performed maintenance can extend the times between major overhauls and
equipment replacement.
Corrective maintenance is the repairs that are unscheduled, unplanned events, often resulting
from equipment failure. Equipment failures may likely result in a reduced capacity or level of
treatment provided, and thus corrective repairs are emergency repairs.
The Operators and Public Works Department employees are expected to regularly perform
basic preventative maintenance tasks involving equipment located at the plant. Certain
maintenance tasks may be more economically handled by outside contractors due the
complexity and/or special technical training or equipment required. This may include electrical
and instrumentation repairs; pump/equipment rebuilds, motor overhauls, and major tank
maintenance. The Plants Supervisor and the Public Works Director should determine when to
obtain assistance with more involved troubleshooting and repair tasks.
The Operators should become familiar with the specific brands of equipment installed, and
review the manufacturers Operating & Maintenance instructions for detailed preventative

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
maintenance and lubrications schedules. Figure 4-2, below, includes a general preventative
maintenance schedule.
Monthly
Quarterly
Figure 4-2
Preventative Maintenance Schedule
Uneck pumps for excessive noise/vibrations
Check equipment oil levels, add as required
Check chemical feed pumps for leakage
Inspect for new piping leaks
Check operation of pump check valves (automated valves)
Inspect weirs and remove debris
Rotate Blower Sequences
Check operation of automatic controls (i.e.: pump level controls)
Record flow rate, suction pressure, discharge pressure, etc. for each pump
and compare with previous data. If performance/conditions change
significantly, additional investigation may be warranted.
Check air relief valves
Check equipment drive belts, adjust/replace as required
Check chemical feed pump calibration
Lubricate grease lubricated bearings
Have Instruments calibrated
Exercise all manually operated valves
Check weirs, adjust if not level
7:7Semi-Annually Inspect concrete structures for damage/leaks
Exercise all manually operated valves
Check weirs, adjust if not level
Annually Pull each pump and inspect equipment bearings, impellers, etc.
Inspect sedimentation basins and clean - inspect for concrete damage
121

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
F Unit
!I Bar Screen gear motor
Belt Press gear motor
Screenings Compactor
Hydraulic Oil
Clarifier Drive
Clarifier Main Bearing
Clarifier Torque Plunger
Sludge Grinder
Centrifugal Blower
Positive Displacement Blower
Air Compressor
Sludge Feed Pump
Belt Press Roller Bearings
Submersible Pumps
Electric Motors
Unless permanently lubricated
UV Hydraulic System Center
(HSC)
UV Hydraulic Cyliinder
UV Cleaning Gel
Generator
Figure 4-3
Lubrication Schedule
Lubricant
Mobilgear 630
Shell Omala 220
Shell Tellus T46
Shell Alvania #2
Mobilux EP2
Gardner -Denver AEON CF-46
Mobil SHC 629 Synthetic
Shell Tellus C150
Englo Compressor Oil
Shell Alvania EP2
Mobilux EP2
Oil Filled
Shell Dolium R
Chevron SRI#2
(NLG12 Grease)
Shell Tellus T15 Fluid
Jet Lube biodegradable grease
Acticlean Gel
SAE 15W-40
SAE 1 OW-30 Winter
(API CG-4 or CH-4)
Frequency
Change Annually
Change Annually
Check level weekly
Change bi-annually
Monthly
Weekly
Weekly
1500 hrs
Check level weekly
Change annually
Check level weekly
Change 1500 hrs
Replace quarterly
Annually
Weekly / 40 hrs
N/A
Annually
Change Biannually
6 months
Top off
6 months
500 hours

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
5.1 Emergency Operations
The overall purpose of this section is not to set forth firm procedures, but to aid the operating
personnel in developing a program designed to:
• Eliminate or minimize adverse effects from emergencies affecting the utility system
regardless if the cause is natural disaster, mechanical failure, operational error, or
intentional sabotage.
❑ Develop procedures for properly responding to such emergencies.
❑ Provide instruction for system personnel to assure they understand their responsibilities
during emergency situations.
❑ Provide inventories of available emergency equipment and outline existing mutual aid
agreements and contracts with outside organizations for specialized assistance.
5.2 General Emergency Response Patterns
There is a logical sequence of steps in responding to emergencies that should be followed by
the personnel on duty. This sequence includes identifying the emergency, investigation the
extent of the emergency, deciding on a proper initial course of action, taking corrective action
to rectify the situation, and following up with a post -emergency investigation.
A. Identirl, Emergence: This step is obvious in most cases and is essentially that of becoming
aware that an emergency exists. Injuries and natural disasters are usually rather dramatic
and will capture the personnel's attention immediately upon occurrence.
Some emergency situations could exist long before personnel are aware that an emergency
exists. Tank leaks or activities in remote locations may not be determined for many
months. Once discovered, the problem should be corrected in an efficient and effective
manner.
B. Initial Investigation: Once the personnel are aware that an emergency situation exists or
that a disaster is impending, an immediate initial investigation should be made. This step is
undertaken to assess the severity of the situation and collect just enough information to
make an initial action plan.
Assessment of the emergency should include identifying obvious injured persons (if any),
damage to system equipment and pipe lines, noting possible impending damage which
could occur if corrective action is not taken immediately, and itemizing resources required
immediately to correct the situation.
C. Initial Action: Once the extent of the emergency is known, the personnel should decide on
the initial steps that need to be taken to correct the emergency situation. This first action,
in the case of large scale emergencies, usually consists of notifying responsible authorities
and calling for the necessary assistance in order of priority. The Emergency Contact List
(Figure 5-1) is a critical asset to the personnel during this phase of the emergency.
After the necessary calls have been made, the personnel should begin action on their own,
within limitations to remedy matters. The personnel should not unduly endanger
AMP E 3 f

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
themselves or others by attempting tasks for which they are not trained, e.g., injury cases.
If the personnel are not familiar with first aid techniques, they should do little more for the
injured person than keep him out of further danger. Moving a patient unnecessarily or
attempting first aid when not absolutely needed may cause further, lasting injury to the
patient.
In all cases, if in doubt, wait until qualified help arrives before taking action.
Sources of qualified help includes the following:
❑ Medical Help — Paramedics/ambulance attendants and doctors.
❑ System Contamination — Public Health Service, Consulting Engineer, Rural Water
Association, Local Emergency Management
❑ Equipment Failure — Equipment Supplier/Representatives, Service Contractor,
Consulting Engineer.
❑ Piping breaks — Contractor and local heavy equipment operators/contractors.
❑ Power Failure — Power Company and local electrical contractors.
❑ Vandalism or Sabotage — Local Law Enforcement
D. Corrective Action: When help arrives, the personnel should immediately inform them of the
pertinent details. If the type of emergency is beyond their own capabilities, the personnel
should immediately appoint the proper person to supervise corrective action. While work is
underway, the personnel should find time to notify persons not called initially, but who
have interests at stake in the emergency.
Corrective action should be continued until the situation is under control or completely
rectified. If correction will take considerable time, the personnel should consult with the
required parties to outline a long-term effort to complete the task.
E. Follow -Up: After the situation is corrected, the personnel should make every effort to
determine why the emergency occurred, review the corrective action taken, and then take
preventive action to minimize the change of recurrence.
Summary: This subsection has outlined a general pattern that personnel should follow in
responding to emergencies. In most small emergencies the personnel will go through these
steps automatically; however, they should be kept in mind (and perhaps near telephones) in
order to effectively deal with major disasters. In summary, these steps are:
I. Identify the emergency (be aware)
2. Investigate quickly (know what has happened)
3. Take initial action (notification)
4. Take corrective action (remedy, implement action plans)
S. Follow-up (analysis and prevention of future similar disasters)

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
5.3 Vulnerability Analysis
The steps to be taken in each of several emergency operating conditions are detailed in this
subsection. In developing contingency plans, it is necessary to attempt to foresee as many
different types of emergencies as possible. A list of the more probable emergencies include:
❑ Process Failure
❑ Power Failure
❑ Equipment Breakdowns and Process Failures
❑ Personnel Injury
❑ Vandalism and Sabotage
The most likely emergencies will be power failures and equipment breakdowns/failures. Due to
the inherent dangers in operations of mechanical systems, personnel injuries should be guarded
against. Lesser probable emergencies would include major chlorine leaks.
A. Process Failure: If a process failure occurs, a violation of the effluent standards may
occur, requiring public notification. Process failures may be easily determined by visual
observation. Other failures may be not noticed until a test is performed or equipment
shutdown is found.
Whatever the cause of the problem, the current situation must be quickly reviewed to
determine corrective action. In most cases, a judgment must be made in regard to how
much, if any, affected water was released.
If the problem is a recurrent trouble, or it is likely to recur, corrective preventative
maintenance steps should be taken to prevent or minimize the problem.
B. Power Failure: The operations of the treatment facilities are totally dependent upon
electric power. The results of a power failure are obvious; all or parts of the system
cease to function for a short period. The cause of the power failure will be relatively
easy to trace since the circuit breakers can be checked quickly.
Most historical outages in the area are of short duration. The standby generator has a
24 hour fuel supply at full load. Most foreseeable outages should cause minimal
problems as fuel delivery can be scheduled and equipment operation minimized.
If only the WTP is affected, or if other electrical customers in the vicinity of the site still
have service during site problems, the problem is probably in the switchgear or incoming
service line. In this case, a quick investigation of the main service breaker should be
made. If the incoming power cannot be applied to the electrical system, the power
company should be called.
If an area -wide outage occurs, the Operator should contact the power company to
determine the estimated length of time before normal power is to be restored. The
operator should request that the plant site be put on the top of the priority list for
restoration of power.

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
If the failure was the result of a malfunction inside the facilities, then most likely it was
due to an overload of the main circuit, a problem in the main electrical distribution
panel, or a problem in a control panel. If a circuit was overloaded, the breaker must be
reset to supply normal power. If the problem was caused by faulty wiring in the main
distribution panel or in a control panel, an electrician should be called in to inspect the
electrical equipment.
Once electrical power is restored, the Operators should check each operating unit for
proper function. The overall function of the treatment system should also be checked
for proper efficiency.
To reduce system vulnerability, an electrician should inspect the wiring of the main
distribution panel, control panels and all electrical connections on an annual basis. If
any potential hazard areas exist, they should be corrected immediately. Future power
failures caused inside the facilities can be prevented by making sure electrical
connections are sound and by operating the electrical equipment only as recommended
by the manufacturer.
C. E ui ment Breakdowns: Most equipment gives warning of impending trouble (i.e.,
unusual noise, heat, vibration, etc.) However, there are exceptions to the rule that
failing equipment gives forewarning. For example, pumps may suddenly fail without
giving off any unusual noises, heat, or vibration prior to failure. Therefore, frequent
inspections of the equipment may not prevent breakdowns in certain cases. The
Operator must be prepared to act in the event of equipment failure by employing
alternate modes of operation and by repairing affected units as quickly as possible.
For failures that are not instantly identifiable by loss of flow or change in online
instrumentation parameters, the Operator's daily inspection of the equipment should
detect malfunctioning equipment.
If equipment suddenly ceases to function, then a quick check for electrical circuit failure
should be made first before thoroughly checking the affected unit. If the power is on,
then a check for the cause of the breakdown should be made. All Power feeds must be
locked out before disassembling electrical equipment.
The facilities must be returned to normal operation as soon as possible. The personnel
can achieve this by placing standby equipment into service and bypassing the affected
units if suitable quality water can be produced. Emergency operation of the equipment
is discussed in Section 3.
Once the facilities have been restored to some mode of efficient operation, the
personnel should repair or replace the broken equipment. If the malfunction involves a
serious breakdown, such as the failure of a large electric motor, it may be necessary to
call in an outside repairman specializing in that type of equipment. Equipment that
cannot be repaired should be replaced immediately. Note that delivery times of some
equipment is measured in weeks, not days.
dmp

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
Preventative Maintenance, including frequent inspections of all equipment and processes
is the best defensive measure against equipment breakdowns. If the personnel
regularly follow the equipment maintenance and lubrication schedules, changes of
equipment breakdown can be minimized.
Since any and all mechanical and electrical equipment is subject to breakdowns, it is
important that a good spare parts inventory be maintained so that equipment repairs
can be made as needed.
D. Personnel In'u The personnel should become familiar with basic first aid procedures.
Hazardous areas of the facilities should be identified, warning signs installed, and
preventive measures as suggested in the Safety Manual should be obeyed as methods
of preventing injures.
In the event of an injury, the need for additional assistance beyond the first aid
equipment in the system should be determined. Scratches or cuts should be
immediately treated with supplies from the first aid equipment. More serious injuries
may require that the person be taken to the hospital for treatment.
All personnel should be instructed in first aid procedures and inoculated against tetanus
every 5 years to protect against infection.
Signs should be put up in hazardous areas warning employees of the potential dangers
in the areas. These signs are generally required by OSHA and should be installed in
accordance with applicable regulations.
E. Windstorm Hurricane and Tornado: If a severe storm should strike the area, damage
will most likely be limited to fallen power lines, and the damage caused by blowing
debris.
There is little or no defense against a violent storm. Protective measures will be limited
to securing outside equipment so that it will not be blown away. Windows should be
closed on all buildings during windstorms.
If the power lines are blown down during a storm, electric power and communications
to the remote pump stations may be lost. As soon as the storm has passed, the Plants
Manager and Public Works Director should assess the damage and inform the Town
Manager on the nature and extent of any severe damage.
Fallen power lines create an extreme safe hazard — maximum caution must be
exercised following -a storm.
Steps should be taken to return the system to normal operating efficiency.
Storms are acts of nature that cannot be prevented. The only measure to be taken in
guarding against them will be to secure all light material and equipment that may be
blow away by the storm.
dm r-3S

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
F. Terrorism and Vandalism:
This information is provided from Rural Water Association, AWWA, and other available
sources As this is a relatively new concern in the industry, the Director and Operators
should closely monitor these organizations and update contingency plans as new threats
are identified and addressed.
While there has always been the potential for a terrorist act against public utilities, the
likelihood of such an event in a rural utility system is relatively low, but cannot be
ignored in today's world. Also not to be ignored is the potential for actions by
disgruntled employees, former employees, and other individuals can have the same
effects.
At this time it is believed that the major treat is from sabotage or vandalism of physical
structures.
While there is relatively little defense against a determined and coordinated terrorist
effort, basic security measures and employee vigilance can minimize risk to the facilities,
and collection system, as noted in Section 5.5.
The Town must be prepared to act immediately should an event occur. Initial reports of
damage to facilities would be very similar to the effects of fire fighting, power outages,
and mechanical failures; and could include the following alerts:
❑ Sudden changes in flows
❑ Loss of communications with remote sites or invalid data
The initial investigation must include a quick determination if the cause is normal
mechanical failure, an accident, or sabotage. The local authorities must be notified
immediately if there is suspicion of criminal activity.
5.4 Vulnerability Reduction Methods
The discussions of various emergency situations outline basic preventive and preparatory
measures that can reduce the adverse effects of an emergency on the system. In general, the
following methods can be employed to reduce the vulnerability of the system:
❑ Provide dual power sources and portable auxiliary power units.
❑ Maintain proper supply of on -site storage of fuel
❑ Train regular and auxiliary personnel in emergency operations and procedures. Training
should be a combination of classroom instruction and on-the-job training.
❑ Conducting emergency operations exercises periodically.
❑ Maintain good relations with utility company (power and telephone) management and
maintenance personnel.
❑ Insure the plant and pump stations are priority areas for utility service restoration during
disasters
❑ Increase system security measures
£34

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
Table 5-1
Emergency Contact List
Town Police, Fire & Rescue
911
Beech Mountain Buckeye WTP
828.387.9368
Beech Mountain Public Works Department
828.387.9282
Beech Mountain Town Hall
828.387.4236
Bill Ward (SCADA Integration)
704.795.4680
Building Crafts (General Contractor)
Cannon Hospital (Newland)
828.737.7000
Carotek, Inc
KSB Pump, Dezuirk, EIM Actuators Re
704.844.1100
Combs & Associates
M&N Re
704.374.0450
Cummins Atlantic
Generator Service
704.596.7690
Davis -Martin -Powell & Associates
336.886.4821
Consultin Engineer)
336-689-1208
EPA Region 4 Office (Atlanta)
800.241.1754
EW2
Tro'an UV Re
704.542.2444
Interstate Utility Sales
Wes -Tech, Phoenix EDI, UBI Reps)704.367.1970
Mountain Electric Company (utility)
828.733.0159
National Electric (Electrician)
423.283.3047
Piedmont Technical Service (UV System)
919.697.0128
Skyline Telephone Company (utility)
828.898.1350
Watauga County Emergency Services
828.264.4235
Watauga County Health Department
828.264.6635
Watauga Medical Center (Boone)
828.262.4100
Winston-Salem DENR Office
336.771.4600
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Pond Creek wastewater Treatment Plant
Operation & Maintenance Manual
6.1. General Safety
Historically water and wastewater treatment industry has one of the highest rates of accident
frequency and severity (National Safety Council), Thus, Operators and Maintenance staff are
cautioned to use extra care when working at the WWTP,
The Town of Beech Mountain has a safety program in place, and all staff are trained and aware
of this program. A copy of the Town's safety manual is to be kept onsite at all times, and all
new employees must be trained.
Occupational Hazards at this facility could include the following:
❑ Abnormal Atmospheres
❑ Airborne hazards (aerosols,
biological, chemical dusts/fumes,
toxic gases, explosive gasses)
o Burns (fire, hot surfaces, or
chemical)
❑ Chemicals
❑ Confined Spaces
❑ Drowning
❑ Electrical Shock
❑ Slips and Falls
❑ Explosive gases or liquids
❑ Fires
❑ Food contamination
❑ Housekeeping
❑ Infections and diseases
❑ Ingress/Egress
❑ Laboratory
❑ Ladders, stairs
❑ Materials handling
❑ Moving machinery
❑ Night operations
❑ Noise
❑ Noxious gases and vapors
❑ Open tanks and vaults
❑ Spillage
❑ Vehicle operation
❑ Ventilation
❑ Weather (heat, cold, ice, snow, lighting)
❑ Yard work
Operators should refer to the following WEF Publications for more information: "Safety &
Health in Wastewater Treatment Systems (MOP-1)". "Guidelines to Developing a Wastewater
Safety Program (MOP SM-2)'; and "Operation of Municipal Wastewater Treatment Plants (MOP
11)". NFPA has developed recommended fire prevention practices for wastewater facilities
addressing fire and explosion hazards.
A facility can also request an OSHA inspection to identify potential hazards. The representative
will visit the site and recommend improvements or practices to minimize hazards. While these
voluntary inspections normally do not result in citations or fines, the Town would be required to
correct any deficiencies within a specific time period.
The WWTP should have the following personal protective & safety equipment available in a
central location:
❑ Hard Hats, hearing protection, face shields, safety glasses, rain gear, goggles, rubber
boots, waders, safety shoes, gloves, chemical aprons.
❑ NIOSH certified respiratory devices
❑ Hard Hats, Safetly Glasses, and ear plugs for guests

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
6.2. Sampling Safety Tips
Sampling can pose several risks to the Operator from water borne contaminants to slipping and
falling hazards.
❑ Always wear protective gloves when handling wastewater and sludge
❑ Always thoroughly wash hands after handling wastewater
❑ Avoid getting wastewater on cuts, open sores, or abrasions
❑ Avoid leaning over or under railing or into tanks to collect a sample
❑ Use a long handled sampler or other device to safely grab your sample
❑ Use extra care around equipment
❑ Use extra care in adverse weather. conditions
❑ Never enter a confined space (tank or manhole) to collect a sample w/o using proper
confined space entry techniques
❑ Be familiar with locations of emerging showers and eye wash facility
6.3. Laboratory Safety Tips
In addition to wastewater and sludge samples there are many other hazards in the laboratory
area, so personnel must take precautions.
❑ Always wear personal protective clothing including apron, gloves, safety glasses (or
shields) when handling samples or chemicals
❑ Volatile solvents and acids should only be used in the fume hood or rear exhaust fans.
❑ Do not mix acids and bases because of potentially violent reactions
❑ Never pour water into an acid, always slowly mix the acid into water. Cool the solution
in an ice bath to prevent excessive heating
❑ Keep sodium bicarbonate (baking soda) on hand and accessible in the acid handling
area. This neutralizes acids spills by sprinkling the area with baking soda. Note this may
produce heat and make the solution very corrosive
❑ Use caution when mixing chemicals, as some incompatible chemicals can cause fumes,
explosions or violent reactions. Refer to Safety & Health in Wastewater Systems, (MOP1)
for examples
❑ Be familiar with location and proper use of the eyewash/shower unit
❑ Keep fire extinguisher accessible and serviced
❑ Label all chemical solutions, including expiration dates
❑ Always use suction bulbs on pipettes, never mouth pipette
❑ Always use insulated gloves or tongs when handling hot items
o Never smoke or eat in the lab
❑ Never prepare or store food in lab
❑ Always wash hands thoroughly
400 f 3q

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
6.4. Chemical Safety Tips
There are several chemicals and fuels located at the WWTP that can pose hazards to the
Operators. These could include the following:
❑ Laboratory Solvents & Chemicals
❑ Caustic
❑ Chlorine
❑ Citric Acid
❑ Diesel fuel
❑ Defoaming agents
❑ Degreasing agents
❑ Gasoline
❑ Grease
❑ Hydrochloric acid
❑ Lime
❑ LP gas
o Lubricants
❑ Methanol
❑ Odor control agents
❑ Oxygen
❑ Paint & Thinners
❑ Sulfuric acid
❑ UV Cleaning Solution
The Operator should keep an up to date copy of MSDS information on all compounds in use at,
or stored at, the WWTP. Tab 10 can be used for this, or another binder may be used,
depending on the number of sheets.
Operators should be familiar with the location and operation of the Emergency Eyewash/Shower
units in the Lab and Dewatering Room. In event of a spill, these devices should be used and
clothing immediately changed to prevent injury.
6.5. Confined Spaces
The Town should ensure that all confined spaces are properly labeled and that personnel are
trained in entry and recovery procedures.
The following areas at the WWTP could be considered a confined space per OSHA regulations;
❑ Manholes
❑ Channels
❑ Digester tank
❑ Aeration basin
❑ Clarifier basin
❑ Wet wells
❑ Vaults & Pits
❑ Trenches
i� O

Pond Creek Wastewater Treatment Plant
Operation & Maintenance Manual
6.6. Electrical Safety Tips
Electrical gear and equipment pose a special hazard due to the damp areas and outdoor
locations of much equipment. Basic Electrical Safety practices should always be followed:
❑ Always follow the Town's lockout/tagout procedures circuit breakers when working on
equipment or remote panels to prevent them from accidently being energized.
❑ Be aware that many components can be remotely or automatically started.
❑ If you are not trained to work on electrical equipment call in a specialist.
❑ Operate breakers and disconnects annually
❑ Test GFCI circuits annually
❑ Never remove or defeat receptacle or equipment grounding
❑ Ensure all medium or high voltage cables and switchgear is properly labeled
❑ Replace damage wiring or components as soon as possible
❑ Maintain required clearance around panels and MCC's
❑ Test emergency stops annually
❑ Maintain interior and site lighting in operating condition
❑ Use insulating mats at panels and MCC's
❑ Use insulated and non-conductive tools when working with electrical equipment
❑ Always use grounded extension cords
` £ '4i

Spill Response Plan
Onsite Plan: The compost shall be covered and stockpiled to prevent runoff from
leaving the compost pad. The aeration piping may need occasional cleaning and the
compost pad will need periodic repaving. Area drains will be kept clean and functional
to prevent runoff from entering surface waters. In the event of a spill, appropriate
measures shall be taken to prevent compost from entering surface waters. These
measures can include straw or hay applied around spill area or another absorbent
material to prevent runoff into surface waters. Daniel Davis, Land App. ORC, 828-387-
9282 or Randy Horney, ORC, WWTP, 828-387-4727 shall be contacted or their designee
as soon as the spill has been contained. If compost enters surface waters, the
appropriate state agency shall be notified within 24 hours.
• Offsite Plan: If the compost is moved offsite with town equipment or contracted
equipment, appropriate measures shall be taken to prevent compost spilling from the
equipment. In the event of an accident, once the accident scene has been secured,
appropriate measures shall be taken to prevent compost from entering surface waters.
These measures can include hay, straw or other absorbent material to prevent compost
from entering surface waters. A backhoe or tractor will be then utilized to load spill into
another piece of equipment and taken to the appropriate place. Daniel Davis, Land App.
ORC, 828-387-9282 or Randy Horney, ORC, WWTP, 828-387-4727 shall be contacted or
their designee as soon as the spill has been contained. If compost enters surface waters,
the appropriate state agency shall be notified within 24 hours.

Compost Inspection Plan
• The following inspections shall be conducted by Daniel Davis, Land Application ORC,
Randy Horney, WWTP ORC, or their designee.
The compost pile will be inspected 5 times per week, twice a day in 2 different locations
in the compost pile. Each inspection will include recording temperature, pH and
moisture on the Beech Mountain Compost Report Sheet. These inspections shall
continue a minimum of 58 days and the results shall be retained for a minimum of 5
years.
If non-compliance is observed, compost material must not be distributed and
operational changes will be taken to make compost material compliant.
S 43

Town of Beech Mountain
Residuals Sampling/Monitoring Plan for Pond Creek/Grassy Gap Compost
The compost is mixed at a 3:1 ratio. The mix is tested for pH, % moisture
at the time of mix. Temperature is measured twice per day at 2 different points
in the pile. After 28 days, the mix is turned and endured 28 more days monitoring
temperature, twice per day. At the end of this phase, the mix is moved to a storage
pad for 30 days. The mix is then sampled for 503's and pathogens. The mix is not
to leave the facility until the mix passes all tested.
Responsible Personnel for the sampling and monitoring:
Daniel Davis, Public Utilities Super., Land App. ORC
Randy Horney, ORC, Pond Creek WWTP, Grassy Gap WWTP
Monitoring Procedures Including Parameters to be Monitored
Parameters shall be tested annually per requirements of the governing permit.
49 U u

Beech Mountain Compost Report
Batch #
DATE Ambient Temp Mix Temp #1 Mix Temp #2 pH % Solids
Start Date: Date Turned: # Days Above 131F(SSC):
Sample Date: Date Moved to Aging: # Days Above 104F(40C):
Sludge Sample Date: Date Complete:
tGS

BEECH MOUNTAIN MONTH , 20_ OPERATIONS REPORT
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BEECH MOUNTAIN MONTH , 20 OPERATIONS REPORT
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BEECH MOUNTAIN MONTH 20_ OPERATIONS REPORT
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