NC0023876_Authorization to Construct_20020214

PROFESSIONAL ENGINEER'S STATEMENT
FOR
CONSTRUCTION OF WASTEWATER TREATMENT FACILITIES
I, Michael C. Wicker, P.E. , as a duly registered Professional
Engineer in the State of North Carolina, having been authorized to observe
full time the construction of the project.
for the
SOUTH BURLINGTON WASTEWATER TREATMENT PLANT
INFLUENT PUMP STATION MODIFICATIONS
(PROJECT NAME)
BURLINGTON, N.C.
(PROJECT LOCATION)
ATC 02387ACC, NPDES NCO023876
(PERMIT NO.)
CITY OF BURLINGTON
(OWNER)
hereby states that with the best of my abilites, due care and diligence was used in
the observation of the project construction such that the construction was observed
to be built within substantial compliance and intent of the approved plans and
specifications and the Authorization to Construct.
SIGNATURE
REGISTRATION NO. 11325 DATE 2/14/02
Dtv}ddnAL of
SE $ 11325 $cadan
A*
GIN

.i
State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley Jr., Governor
William G. Ross, Secretary
Kerr T. Stevens, Director
Mr. Stephen Shoaf
Director of Utilities
City of Burlington
P.O. Box 1358
Burlington, North Carolina 27216-1358
Dear Mr. Shoaf:
NCDENR
February 9, 2001
Subject: Authorization to Construct
ATC No. 023876ACC
NPDES Permit No. NCO023876
City of Burlington
South Burlington Wastewater Treatment Facility
Alamance County
The Division of Water Quality's NPDES Unit has reviewed your request for an Authorization to Construct at
the City of Burlington Southside WWTP. The Division finds the proposed improvements to be -satisfactory
and hereby grants authorization for the following:
• Replacement of the four existing influent station pumps with two 225 HP centrifugal pumps with
variable frequency drives rated at 5,000 gpm at 1,000 rpm and 7,000 gpm at 1,140 rpm and two
225 HP centrifugal constant speed pumps rated at 7,000 gpm.
• Replacement of valves, fittings, motors and electrical components on the influent pump station.
• Installation of a new monorail and hoist system for the pump motors.
This Authorization to Construct is issued in accordance with NPDES Permit No. NC0023876, issued
February 16, 1996, and shall be subject to revocation unless the wastewater treatment facilities are
constructed in accordance with the terms and conditions of the permit.
The Permittee shall notify the Water Quality Supervisor of the Winston-Salem Regional Office, telephone
number [phone], at least forty-eight (48) hours prior to operation of the installed facilities, so that an
in -place inspection can be made. Notification shall be made during the normal office hours of 8:00 a.m. until
5:00 p.m., Monday through Friday.
Engineer's Certification
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide
the Division with a certification (copy enclosed) from a professional engineer registered in North Carolina
certifying that the permitted facility has been installed in accordance with the NPDES Permit, this
Authorization to Construct, and the approved plans and specifications. The Certification should be submitted
to: NCDENR / DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617.
Requirements for Certified Operator
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
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer Internet: http://h2o.enr.state.nc.us/

South Burlington WWTP
NPDES Permit No. NCO023876
ATC No. 02 3876ACC
Page 2
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 Title 15A, Chapter 8G, .0200. 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; and must properly manage and document daily operation and maintenance of the
facility and comply with all other conditions of Title 15A, Chapter 8G, .0200.
Additional Requirements
The Operational Agreement between the Permittee and the Environmental Management Commission is
incorporated herein by reference and is a condition of this Permit. Noncompliance with the terms of the
Operational Agreement shall subject the Permittee to all sanctions provided by G. S. 143-215.6 for violation
of or failure to act in accordance with the terms and conditions of this Permit.
Failure to abide by the requirements contained in this Authorization to Construct may subject the Permittee
to an enforcement action by the Division of Water Quality 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.
The Permittee shall maintain a copy of the approved plans and specifications on file for the life of the
facility. One (1) copy of the approved plans and specifications is enclosed for your records.
If you have any questions about this Authorization to Construct, please contact Teresa Rodriguez, at (919)
733-5083, extension 595.
Sincerely,
/ / 1 A161 1 � �__ -
Kerr T. Stevens
Director
Enclosures: Project Plans and Specifications (approved)
Engineer's Certification Form
cc: Winston-Salem Regional Office, Water Quality
Technical Assistance and Certification Unit
Central Files
NPDES' Unit Files
Mr. Michael Wicker, P.E. — Hubbs, Upchurch and Associates
290 S.W. Broad Street
Southern Pines, NC 28388

LFwd: Renovation of the South Burlington WWTP Raw Sewage Pump Station]
Subject: [Fwd: Renovation of the South Burlington WWTP Raw Sewage Pump Station]
Date: Tue, 06 Feb 2001 17:22:00 -0500
From: Mike Mickey <[e-mail]>
Organization: NC DENR Water Quality
To: Teresa Rodriguez <Teres a.Rodriguez @ ncmail. net>
Teresa,
Here is a response from Steve Shoaf, Utility Director, concerning the
pump replacement and I/I status at the South Burlington WWTP. Hope this
answers your question.
Also, did you get my map to Monarch Hosiery yet? Mike.
Subject: Renovation of the South Burlington WWTP Raw Sewage Pump Station
Date: Tue, 6 Feb 2001 17:03:53 -0500
From: Shoaf Steve <[e-mail]>
To: "'[e-mail]"' <[e-mail]>
CC: Sykes Jesse <[e-mail]>, Davis Eric <[e-mail]>
Mike,
Jay has been out for about 4 weeks recovering from surgery. He will
probably be out for another 2 weeks. Leon Teague fowarded me your email.
We are replacing the pumps at the South plant due to age and
condition of the pumps, problems with the suction and discharge valves, and
the condition of the header pipe. We cannot remove some of the pumps for
maintenance because the suction and discharge valves won't seal. The pipe
header is in need of new gaskets at the flanges, and new paint. The pumps
have been in service for over 20 years and have not been rebuilt with the
exception of parts here and there as needed.
In order to fix any of the problems we will have to bypass the pump
station and pump to the equalization basin with rental pumps and pipe. It
made sense to replace everything at once if we were going to go to the
expense of paying for bypass pumping ($24,000 per week!). Once we started
talking about this the state wanted us to bring our pump capacity up to the
rule of thumb guidelines of 2.5X permitted flow. Thus the increase is an
outgrowth of the state's guidelines.
To answer the question about I&I, we do have I&I entering our
system. I don't think our problem is unusual or excessive. We have a
program to address I&I. We have purchased TV equipment to inspect new and
existing lines and have found many problems and corrected them. We have
divided the City into zones and have a smoke testing plan to systematically
test and repair problems. We are using trenchless technologies (liners) to
improve sewer lines (mains and outfalls) when that is most appropriate.
This year we have identified and replaced two mains that collapsed due to
age and material failure. We rehabilitated over 50 manholes on one ,
sub -basin last year and have been over about that many this year as well.
We inspect our outfalls, and have applied for the collection system permit
as required.
So the answer is that we needed to renovate the pump station for
reliability. I&I was not a consideration in deciding to fix the problems at
the pump station. We are actively trying to reduce I&I as its own issue.
If you have any further questions, please call me at 336 222-5130.
Thanks, Stephen Shoaf, Director of Utilities
1 of 2
2/7/01 8:07 AM

01/22/2001 16:29 3367714630 DIV OF WATER QUALITY PAGE 02/04
a
NO* iRTH CAROLINA DEPARTMrVN`t° OF
ENVIRONMENT AND NATURAL RESOWRcEs
DIVISION OF WATER QUALITY
WINSTON-SALEM REGIONAL 01rFICF
'Tr p Irk;;•,+,}o.,
July 27, 2000
Mr- Dave Goodrich, P.E.
�. _,•41
NPDES Permit Group
Division of Water Quality
512 N. Salisbury Street
Archdale Building
�... iol:r�n>b
Raleigh, NC 27626
�4 RETARy
-'
Subject: Authorization to Construct Permit Review Process
City of Burlington, S. Burlington WWTP
NPDES Permit No. NCQ023876, Alamance Co. NC
Dear Mr. Goodrich.
The above referenced review was conducted by this office. This is a much needed
upgrade for this facility which will more than double their peak pumping capacity. It
appears that everything is in order with the plans and design calculations. At this time there
are no comments- If you need additional information concerning this matter, please contact
=
Ms. Sue White at (336) 7714600
Sincerely,
Larry D. Coble
Regional Supervisor
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ATC No. 023876ACC
FACILITY: South Burlington Wastewater Treatment Facility
NCO023876
Alamance County
APPLICATION/PLANS PREPARED BY:
Hubbs Upchurch and Associates
290 S.W. Broad St.
Southern Pines, N. C. 28388
SCOPE:
Replace the four influent station pumps with four centrifugal pumps rated at 225 HP and 7,000 gpm.
Replace the valves, fittings, motors and electrical components on the influent pump station. Install a new
monorail and hoist system in the motor room. Demolition and removal of existing valves, piping, fittings
and pumps in the existing pump station. Temporary by-pass pumping from the influent station to the
equalization basin will be provided during construction.
SUMMARY:
The four existing pumps in the influent pump station are rated at 125 HP and 3,125 gpm and were
installed when the plant was built in 1968. They provide a capacity of 18 MGD when pumping in parallel.
During periods of high flows the'influent pump station is sometimes surcharged to the upper level of the
wet well. The proposed upgrade will provide a capacity for the influent pump station of 30 MGD with
three pumps running and one as standby. The new pumps will be rated at 225 HP; two of the pumps will
have variable frequency drives rated at 5,000 gpm at 1,000 rpm and at 7,000 gpm at 1,140 rpm and the.
other two pumps will be constant speed pumps rated at 7,000 gpm. This modification will not increase the
permitted flow of 12 MGD.
The wastewater treatment facility consists'of.
• Grit chamber
• Influent pump station
• Equalization basin
• Primary clarifiers
• Phosphorous removal tanks
• Aeration basins
• Secondary clarifier
• Tertiary filters
• Chlorination
• Dechlorination
RECOMMENDATIONS:
It is recommended that the ATC be approved. Design calculations, drawings and project specifications
for the proposed modification were reviewed and they are adequate. See attached spreadsheet results of
the evaluation of the proposed pumps. The Winston Salem Regional Office staff recommends approval
of the modifications.

Project Name:
CI . , Of BU iingtOtl
Engineer (A/E):HOI3E)S,
LJ" Cj1UlC}1 alld ASSOCIafeS'' '$ " °�
Date:
Permit #
Review Engineer:
[TRH
Pump Conditions
Qcalculated
7742.574
gpm
Qapplication
7000
gpm
% Difference
9.590791
%
TDlicalculated
83.81519
ft
TDHapplication
84
ft
% Difference
0.220498
%
No. of Pumps
1
Qcombined
7742.574
gpm
Qapplication
7000
gpm
% Difference
9.590791
%
Forcemain Conditions
Velocity (fps) Pipe size (in)
Pump Pipe 1
Pump Pipe 2
Pump Pipe 3
12.35 16
Forcemain 1
Forcemain 2
Forcemain 3
3.51+ 30
1 pump running
average flow condition (5900 gpm)

System Graph
Number of Pumps Operating = t
Flowrate TDH
Individual Pump Operating Point for m feet Combined Flow in Force Main = 7742.57 (g m
Average Wet -Well Water Level —» 1 7742.57 83.82

Project Name:
iCit ,Of ` yIjib t0►1
Engineer (A/E):
Hobbs,. Upchurch and" Associates ,
Date:;
Permit #`
023876ACCy'
Review Engineer:
�,T-,F3
Pump Conditions
Qcalculated
15275.36
gpm
Qapplication
7000
gpm
% Difference
54.17458
%
TDlicalculated
85.36596
ft
TDI-lapplication
84
ft
% Difference
1.600122
%
No. of Pumps
2
Qcombined
7637.682
gpm
Qapplication
7000
gpm
% Difference
8.349159
%
Forcemain Conditions
Velocity (fps) Pipe size (in)
Pump Pipe 1
Pump Pipe 2
Pump Pipe 3
12.19 16
Forcemain 1
Forcemain 2
Forcemain 3
6.93 30
2 pump running
average flow condition (5900 gpm)

System Graph
2
Flowrate TDH
Individual Pump Operating Point for m feet Combined Flow in Force Main = 15275.36 9 m)
Average Wet -Well Water Level ===>> 7637.68 85.37

Project Name:
`Clty,Of,BUrlingt0.1I
Engineer (A/E):
M,6615 Q, 06b'UCCft and A 664teS.
Date:,„
Permit#
Review Engineer:
[TR'
Pump Conditions
Qcalculated
21919.79
gpm
Qapplication
7000
gpm
% Difference
68.06539
%
TDHcalculated
90.19551
ft
TDHapplication
84
ft
% Difference
6.868983
%
No. of Pumps
3
®combined
7306.598
gpm
Qapplication
7000
gpm
Difference
4.196182
%
Cycle Conditions
Avg. Flow In
14760 gpm
Wet Well Dia.
ii
Pump On Time
i.nCycles/Hour
JOK-
c hour
Emergency Storage
Forcemain Conditions
Velocity (fps) Pipe size (in)
Pump Pipe 1
Pump Pipe 2
Pump Pipe 3
11.66 16
Forcemain 1
Forcemain 2
Forcemain 3
9.95 30
3 pumps running
peak flow condition (14,760 gpm)

System Graph
Number of Pumps Operating = 3
Individual Pump Operating Point for
Average Wet -Well Water Level ===>>
Flowrate
(gpm)
TDH
feet
7306.60
90.20
Combined Flow in Force Main = 21919.79 (gpm)

CITY of Burlington
TELEPHONE [phone] • FAx [phone]
P.O. Box 1358
BURLINGTON, N.C. 27216-1358
STEPHEN R.SHOAF
DIRECTOR OF UTILITIES
July 3, 2000
JUL 0 5 2000
Mr. Dave Goodrich
NPDES Permit Group
Division of Water Quality
512 North Salisbury Street
Archdale Building
Raleigh, NC 27626
Re: Authorization to Construct Permit
City of Burlington
South Burlington WWTP
NPDES Permit No. NCO023876
Alamance County, NC
Dear Mr. Goodrich:
J U L 1 2 2000
r" '.R - V .TER AUAL!IY
,'T '^E RRA.A'CH
We are requesting an Authorization to Construct Permit from the Division of Water
Quality for an upgrade to the influent pump station at the South Burlington Wastewater
Treatment Facility. The influent pump station upgrade includes the following:
Replacement of four (4) existing 125 HP vertical shaft driven centrifugal influent
pumps rated at 3125 gpm each, associated gate valves, check valves and discharge
piping in the dry pit of the existing pump station;
Installation of four (4) new 225 HP dry pit submersible centrifugal influent pumps
rated at 7000 gpm each at 1140 rpm, new gate valves, check valves and discharge
header piping in the dry pit of the existing pump station; and
Replacement of the existing electrical power and control system, as needed, with new
electrical power and controls consisting of two (2) VFDs and two (2) constant speed
motor control centers for the four (4) new pumps.
The upgrade is needed because of the condition of the existing 30-year-old equipment
(original installation 1968) and because the existing permitted flow is 12 mgd and our
current peak pumping capacity is 18 mgd with all four (4) existing pumps running. The
proposed upgrade will provide the permitted flow x 2.5 for a peak pumping capacity of 30
mgd with three (3) pumps running and one (1) pump as standby. This upgrade complies
with current State guidelines for pump station design.

Mr. Dave Goodrich
July 3, 2000
Page —2-
No increase in the NPDES permitted flow is needed for this modification.
Please find attached three (3) sets of plans, specifications, design calculations and
construction sequence. A separate copy has been forwarded to the Winston Salem
Regional Office. Hobbs, Upchurch & Associates, P.A. is our consulting engineer on the
project and should be copied on all correspondence.
If you have any further questions about this matter, please contact myself at (336) 222-
5130 or Michael Wicker, P.E., of Hobbs, Upchurch & Associates, P.A. at (910) 692-
5616.
Sincerely,
City of Burlington, Utilities Department
Stephen R. Shoaf
Director of Utilities
SRS:Im
Enclosures
cc: Larry Coble, Winston Salem Regional Office
Michael Wicker, Hobbs Upchurch & Associates, P.A.