NC0020401_AUTHORIZATION TO CONSTRUCT_20090205

WDES DOCUWEMT SCAMMIM& COVER SHEET
NPDES Permit: NC0020401
Hickory - Northeast WWTP
Document Type: Permit Issuance
Wasteload Allocation
Authorization to Construct
(AtC)
Permit Modification
Speculative Limits
201 Facilities Plan
Instream Assessment (67B)
Environmental Assessment (EA)
Permit
History
Document Date: February 5, 2009
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North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
February 5, 2009
The Honorable Rudy Wright, Mayor
City of Hickory
P.O. Box 398
Hickory, North Carolina 28603-0398
SUBJECT: Authorization to Construct
A to C No. 020401 AO
,.City of-Hickory
Northeast WWTP Improvements
Dear Mayor Wright:
A letter of request for an Authorization to Construct (ATC) was received June 19, 2008,
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
construction of the 6.0 MGD Wastewater Treatment Plant, with discharge of treated wastewater
into Lake Hickory in the Catawba River Basin.
This authorization results in the design and permitted capacity of 6.0 MGD, and is
awarded for the following construction:
The 6.0 MGD Northeast Wastewater Treatment Plant consisting of: an influent pump
station with dual mechanical bar screens rated at 15 MGD (each) peak flow, influent
magnetic flow meter, two (2) 6,920 GPM, 200 Hp pumps, two (2) 3,513 GPM, 125 Hp
pumps; influent pump station 750 kW on-site generator; vortex grit removal system rated
at 20 MGD with grit classifier; flow splitter; two (2) oxidation ditches each rated at 3
MGD, with each ditch consisting of 0.25 MG anaerobic basin with two (2) 4.8 Hp
submersible mixers, 0.29 MG anoxic basin with one (1) 7.7-Hp submersible mixer, 2.22
MG oxidation ditch with two (2) 200 Hp mechanical surface aerators and one (1) 18.2 Hp
submersible mixer; clarifier flow splitter box; two (2) 100-ft diameter clarifiers with 16 ft
side water depth; a dual channel 0.132 MG (each) chlorine contact basin, with on-site
sodium hypochlorite generation system; a bisulfate feed dechlorination system; a cascade
post-aerator; four (4) RAS 2,100 gpm, 40 Hp sludge pumps; four (4) aerobic digesters
(AD), AD1 and AD2 sized at 0.469 MG (each), and AD3 and AD4 sized at 0.228 MG
(each), and four(4) 100 Hp digester blowers and one (1) 60 Hp digester blower; two (2)
1633 Mail Service Center,Raleigh,North Carolina 27699-1633. One
location:2728 Capital Blvd.Raleigh,North Carolina 27604 North Caro 1 i n a
Phone:[phone] FAX:[phone] Customer Service:1-877.623.6748
Internet:www.ncwaterquality.org �atKt'��I�/
An Equal Opportunity 1 Affirmative Mean Employer ff// �J

The Honorable Rudy Wright, Mayor
February 5, 2009
Page 2
in-line sludge grinders, two (2)400 gpm progressive cavity feed sludge pumps, two (2)
400 gpm feed rate rotary drum thickeners, two (2) progressive cavity discharge sludge
pumps; odor control system; two (2) WWTP 1,500 kW on-site generators; plant SCADA
system; demolition of the existing plant; and associated site work.
This ATC is issued in accordance with Part II1, Paragraph A of NPDES Permit No.
NCO02040 I-issued April 19, 2006, and shall be subject to revocation unless the wastewater
treatment facilities are constructed in accordance with the conditions and limitations specified in
Permit No. NC0020401.
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 North Carolina Division of Water Quality.
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 this Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
The Mooresville 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. Mail the Certification to: Construction Grants & Loans,
DWQ/DENR, 1633 Mail Service Center, Raleigh, NC 27699-1633.
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 11, 111 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 Tl 5A:8G.0202.
A copy of the approved plans and specifications shall be maintained on file by the
Permittee for the life of the facility.

The Honorable Rudy Wright, Mayor
-e February 5, 2009
Page 3
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 of Water Quality in accordance
with North Carolina General Statute 143-215.6A to 143-215.6C.
The issuance of this ATC 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.
One (1) set of approved plans and specifications is being forwarded to you in a separate .
transmittal. If you have any questions or need additional information, please contact Seth
Robertson, P.E. at telephone number [phone].
Sincerely,
Coleen H. Sullins
st:sr
cc: Scott Snyder, P.E., AECOM, 1460 John B. White, Sr. Blvd, IC, Spartanburg, SC
Catawba County Health Department
DWQ Mooresville Regional Office, Surface Water Protection
DWQ, Technical Assistance and Certification Unit
DWQ, Point Source Branch, NPDES Program
Daniel Blaisdell, P.E.
Seth Robertson, P.E.
Steve Tsadwa, E.I.
SRF File

To: Construction Grants & Loans Section
ATTN: Ken Pohlig
Date: July 28, 2008
AUTHORIZATION TO CONSTRUCT
NPDES PERMIT
STAFF REPORT AND RECOMMENDATIONS
County: Catawba
Permit No. NCO020401
WWTP Improvements
Authorization to Construct No: 0204OIA01
PART I - GENERAL INFORMATION
1. Facility and address: City of Hickory Northeast WWTP
Post Office Box 398
Hickory, N.C. 28603-0398
2. Date of investigation. NIA
3. Report prepared by: Samar Bou-Ghazale, Env. Engineer II
4. Persons contacted and telephone number: NIA
5. Directions to Site: The WWTP site is located on the right (west) side of SR 1400
(Cloninger Mill Rd., N.E.) approximately 0.15 mile southeast of the jct. of SR 1400 and
Hwy 127 in northern Catawba County.
6. Discharge point(s). List for all discharge points:
Latitude: 35' 48' 00" Longitude: 81' 18' 05"
Attach a U.S.G.S. map extract and indicate treatment facility site and discharge point on
map.
U.S.G.S. Quad No.: D 13 SE
7. Site size and expansion are consistent with application?
Yes_X_No If No, Explain: N/A

8. Topography(relationship to flood plain included): Hilly, 5-12% slopes. The WWTP site
does not appear to be located in a flood plain area.
9. Location of nearest dwelling: There is one dwelling within 100 feet from the WWTP.
Several dwellings are located within 500 feet of the site.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. Existing Treatment Facilities: The existing WWT facilities consist of a parshall flume
with an ultrasonic flow transmitter followed by dual influent bar screens (one mechanical
and one manual), an aerated grit, four(4) rectangular and one circular primary clarifiers,
eight (8) aeration basins, two circular secondary clarifiers, a sludge pumping station,
gaseous chlorine disinfection, de-chlorination (sulfur dioxide), diffused post aeration, two
gravity belt thickeners and stand-by power generator.
2. Proposed Treatment Facilities: The proposed treatment facilities will consist of the
following:
a. Replacement of the existing aeration basins with an extended biological
aeration process.
b. Renovation of the sludge handling process to include more storage and the
use of a rotary drum filter.
c. Replacement of the existing chlorination/de-chlorination equipment with on-
site generation of Sodium hypochlorite and sodium bi-sulfite.
d. Enlargement of plant processes to provide improved hydraulic capacity
during peak flows.
These above upgrades are considered essential due to the inadequacy of the
processes to handle the peak flows seen during large rain events.
3. Sludge Handling and Disposal Scheme: Residuals are transported to the City's Regional
Composting Facility for treatment and disposal (WQ0004563). The permittee has
available (if necessary) the County landfill as a back-up disposal location.
4. Treatment Plant Classification (attached completed rating sheet): Class IV
5, SIC Code(s): 4952 Wastewater Code(s): 01,55,09 MTU Code(s): 04003
PART III - EVALUATION AND RECOMMENDATIONS
The City of Hickory is applying for an authorization to construct in order to expand the

plant and to replace many of the existing facilities. The planned improvements include new
clarifiers, oxidation ditches, digesters, chlorine contact chamber, post aeration chamber, grit
collector, return sludge building, electrical building, an influent pump station building, wet well
and other auxiliary structures.
To facilitate construction of the new plant while maintaining 6.0 MGD treatment
capacity, the construction will be divided into four phases.
The first phase will consist of the construction of 3 MGD oxidation ditch, a new influent
pump station, a vortex grit chambers, a grit washer, disinfection building, a new chlorine contact
chamber, a new cascade post aerator, a new electrical gear and a new laboratory and
administration building. The second phase will consist of the demolishing of the original
headworks, primary clarifiers and aeration basin and the construction of a new 3 MGD oxidation
ditch, WAS storage, thickened sludge storage, and the sludge building (includes sludge
thickeners, RAS/WAS pumps, and sludge transfer pumps) can be completed. During phase 3,
the remaining aeration basin of the existing plant will be demolished and two new 100 ' diameter
clarifiers will be constructed. Phase 4 will consist of demolishing the existing clarifiers, finish
grading, and paving all gravel areas.
The proposed additions will enhance solids production as the new treatment process is
designed to meet more stringent discharge limits that may be required in the future. Also, the
proposed additions will enable the WWTP to handle the peak flow and provide more efficient
removal of biosolids
Pending review and concurrence by Construction Grants & Loans Section, it is
recommended that the authorizations to construct be issued.
Signature of Report Preparer
Water Quality Regional Supervisor
Date