NC0003450_Authorization to Construct_20111216

NPDES DOCUMENT :MCANNINO COVER SHEET
NC0003450
Wallace Plant WWTP
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
December 16, 2011
This document iea pririted on reuse paper - ignore arty
content on the resrermse side

-tiv,i4 Nap tic°
Town of Wallace
A To C No. 003450A01
SRF No. CS370445-04, STAG No. XP-96477407-0
Issued September 28, 2009
MARS
int4Istructufo i ;u:4
/ i Engineer's Certification
I, G--t /1 WOQCSA' c) d , as a duly registered Professional Engineer in the
State of North Carolina, having been authorized to observe (periodically/weekly/full time) the
construction of the modifications and improvements to the Town of Wallace WWTP #2, located
on NCSR 1939 in Duplin County for the Town of Wallace, hereby state that, to the best of my
abilities, due care and diligence was used in the observation of the following construction:
Demolition of existing chlorine contact tank and abandonment in place and/or removal of
various existing piping; a converted headworks structure consisting of a mechanical spiral
screen rated at 13.6 MGD with manual by-pass screen and a vortex grit removal rated at 13.6
MGD with grit washer unit; an influent pump station consisting of four (4) 3,137 gpm pumps
with flowmeter; conversion of the existing dual reactor basins to 1.894 MG each concrete -lined
sequencing batch reactor treatment system consisting of three (3) 1.894 MG reactors (SBR #1,
SBR #2 and SBR #3) with each SBR reactor having a 75 Hp floating mechanical mixer, fine -
bubble diffusers, decanter, dual 500 gpm sludge transfer pumps, five (5) 1,443 scfm blowers,
S' and a 0.606 MG post -equalization basin; dual disk filters units rated at 10.8 ,mgd peak flow; a
UV -disinfection system rated at 10.8 mgd peak flow, consisting of 2 channels with each channel
containing 3 banks in series; an effluent pump station consisting of four (4) 3,150 gpm pumps
and approximately 6,355 linear feet of 24-inch effluent force main, magnetic flowmeter and
composite effluent sampler, with discharge into Rockfish Creek, a 1.894 MG aerobic digester
with three (3) 100 Hp floating aerators, decanter, and dual 500 gpm sludge transfer pumps;
conversion of the existing dual settling basins to dual 0.33 MG sludge holding basins (Basin #1
and #2) with diffused air, decanter, one 500 gpm sludge transfer pump per basin, and three (3)
900 scfm blowers; a sludge loading station; modifications to the existing
Mechanical/Electrical/Blower Building, with an added Lab/Control/Office Building wing; a
2,250 kW emergency generator with automatic transfer switch; and associated electrical work,
sitework, and yard piping, in conformity with the project plans, specifications, and other
supporting data subsequently filed and approved by the Department of Environment and
( Natural Resources.
I certify that the construction of the above referenced project was observed to be built within
substantial compliance and intent of the approved plans and specifications.
J now apply.
Signature
Date
We understand that the new limits associated with the modifications to expand to 5.42 MGD
-i(
Registration No. 7 2 7
1
11444

ern
ThENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Govemor Director Secretary
September 28, 2009
Mr. Ken Cornatzer, Town Manager
Town of Wallace
Post Office Box 849
Wallace, North Carolina 28466
SUBJECT: Authorization to Construct
A to C No. 003450A01
Town of Wallace
Wastewater Treatment Plant #2
Stevcoknit Facility Conversion
Duplin County
SRF No. CS370445-04
STAG No. XP-96477407
Dear Mr. Cornatzer:
A letter of request for an Authorization to Construct was received March 5, 2009, by the
Division of Water Quality (Division), and final plans and specifications for the subject project
have been reviewed and found to be satisfactory. Authorization is hereby granted for the
existing 4.42 MGD Stevcoknit WWTP to be converted to the Town of Wallace Wastewater
Treatment Plant #2 with 5.42 MGD capacity, with discharge of treated wastewater into Rockfish
Creek in the Cape Fear River Basin.
This authorization results in an increase in design and permitted capacity to 5.42 MGD,
and is awarded for the construction of the following specific modifications:
Demolition of existing chlorine contact tank and abandonment in place and/or removal of
various existing piping; a converted headworks structure consisting of a mechanical
spiral screen rated at 13.6 MGD with manual by-pass screen and a vortex grit removal
rated at 13.6 MGD with grit washer unit; an influent pump station consisting of four (4)
3,137 gpm pumps with flowmeter; conversion of the existing dual reactor basins to 1.894
MG each concrete -lined sequencing batch reactor treatment system consisting of three (3)
1.894 MG reactors (SBR #1, SBR #2 and SBR #3) with each SBR reactor having a 75 Hp
floating mechanical mixer, fine -bubble diffusers, decanter, dual 500 gpm sludge transfer
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] \ Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer
NO115th Carolina
Naturally

Mr. Ken Cornatzer, Town Manager
September 28, 2009
Page 2
pumps, five (5) 1,443 scfm blowers, and a 2.303 MG post -equalization basin; dual disk
filters units rated at 10.8 mgd peak flow; a UV disinfection system rated at 10.8 mgd
peak flow, consisting of 2 channels with each channel containing 3 banks in series; an
effluent pump station consisting of four (4) 3,150 gpm pumps and approximately 6,355
linear feet of 24-inch effluent force main, magnetic flowmeter and composite effluent
sampler, with discharge into Rockfish Creek, a 1.894 MG aerobic digester with three (3)
100 Hp floating aerators, decanter, and dual 500 gpm sludge transfer pumps; conversion
of the existing dual settling basins to dual 0.33 MG sludge holding basins (Basin #1 and
#2) with diffused air, decanter, one 500 gpm sludge transfer pump per basin, and three (3)
900 scfm blowers; a sludge loading station; modifications to the existing
Mechanical/Electrical/Blower Building, with an added Lab/Control/Office Building
wing; a 2,250 kW emergency generator with automatic transfer switch; and associated
electrical work, sitework, and yard piping, in conformity with the project plans,
specifications, and other supporting data subsequently filed and approved by the
Department of Environment and Natural Resources.
This Authorization to Construct is issued in accordance with Part III, Paragraph A of
NPDES Permit No. NC0003450 issued April 14, 2009, and shall be subject to revocation unless
the wastewater treatment facilities are constructed in accordance with the conditions and
limitations specified in Permit No. NC0003450.
The sludge generated from these treatment facilities must be disposed of in accordance
with G.S. 143-215.1 and in a manner approved by the Division.
In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as may
be required by the Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
The Wilmington Regional Office, telephone number [phone], shall be notified at
least forty-eight (48) hours in advance of operation of the installed facilities so that an on site
inspection can be made. Such notification to the regional supervisor shall be made during the
normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State
Holidays.
Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted facility
has been installed in accordance with the NPDES Permit, this Authorization to Construct and the
approved plans and specifications. Mali the Certification to: Construction Grants & Loans,
DWQ/DENR, 1633 Mail Service Center, Raleigh, NC 27699-1633.

Mr. Ken Cornatzer, Town Manager
September 28, 2009
Page 3
Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at
least equivalent to or greater than the classification assigned to the wastewater treatment
facilities by the Certification Commission.
The Permittee must also employ a certified back-up operator of the appropriate type and
grade to comply with the conditions of T15A:8G.0202. The ORC of the facility must visit each
Class I facility at least weekly and each Class II, III and IV facility at least daily, excluding
weekends and holidays, must properly manage the facility, must document daily operation and
maintenance of the facility, and must comply with all other conditions of T15A:8G.0202.
A copy of the approved plans and specifications shall be maintained on file by the
Permittee for the life of the facility.
During the construction of the proposed additions/modifications, the permittee shall
continue to properly maintain and operate the existing wastewater treatment facilities at all times,
and in such a manner, as necessary to comply with the effluent limits specified in the NPDES
Permit.
You are reminded that it is mandatory for the project to be constructed in accordance
with the North Carolina Sedimentation Pollution Control Act, and when applicable, the North
Carolina Dam Safety Act. In addition, the specifications must clearly state what the contractor's
responsibilities shall be in complying with these Acts.
Prior to entering into any contract(s) for construction, the recipient must have obtained all
applicable permits from the State.
Failure to abide by the requirements contained in this Authorization to Construct may
subject the Permittee to an enforcement action by the Division in accordance with North
Carolina General Statute 143-215.6A to 143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from
complying with any and all statutes, rules, regulations, or ordinances which may be imposed by
other government agencies (local, state, and federal) which have jurisdiction.

Mr. Ken Cornatzer, Town Manager
September 28, 2009
Page 4
One (1) set of approved plans and specifications is being forwarded to you. If you have
any questions or need additional information, please contact Seth Robertson, P.E. at telephone
number [phone].
Sincerely,
Coleen H. Sullins
kp:sr
cc: Linwood E. Stroud, P.E., Stroud Engineering PA, 107B Commerce Street, Greenville,
NC 27858
Duplin County Health Department
DWQ Wilmington Regional Office, Surface Water Protection
DWQ, Technical Assistance and Certification Unit
DWQ, Point Source Branch, NPDES Program
Ken Pohlig, P.E.
SRF File
STAG File