NC0025453_Authorization to Construct_20030415

NPDES DOCYNENT SC,ANNINL COVER SKIEET
NPDES Permit:
NC0025453
Clayton WWTP
Document Type:
Permit Issuance
Wasteload Allocation
/
Authorization to Construct
(AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Plan of Action
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
I Aril 15, 2003
This document is printed on reuse paper - ip,Pnore any
Content On the weYer6e s1cle

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
Mr. R. Steven Biggs, Town Manager
Town of Clayton
P.O. Box 879
Clayton, North Carolina 27520
Dear Mr. Biggs:
L
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
April 15, 2003
Subject: Authorization to Construct Permit Issuance
ATC (ATO) Number 025453AO2
NPDES Permit NCO025453
Johnston County
A request for an Authorization to Operate (ATO) was received by the Division and calculations
for this project have been reviewed and found to be satisfactory. Authorization is hereby granted for
Clayton - Little Creek Water Reclamation Facility (WRF) to operate at 2.5 MGD, effective May 1, 2003.
Final effluent limits for a design flow of 2.5 MGD must be met beginning May 1, 2003.
Treatment components related to this Authorization to Operate have been approved through
Authorization to Construct permits dated: July 10, 2000 (with speculative effluent limits letter), May
24, 2001, and February 24, 2003. This Authorization to Operate also approves the inclusion of
additional standby power at the WRF, via Generator Set No. 2.
The Division of Water guality encourages the Town of Clayton to move forward with nutrient
reduction (and understands that this is in process). Also, although not part of this Authorization to
Operate, the Division encourages the Town to apply for an Authorization to Construct permit in the
future and add an additional sludge thickener to assist.with residuals handling at the plant.
This Authorization to Construct is issued in accordance with NPDES Permit No. NCO025453
issued March 11, 2003, and shall be subject to revocation unless the wastewater treatment facilities
are constructed in accordance with the conditions and limitations specified in the permit.
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 guality.
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.
1617 MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1617 -TELEPHONE [phone]/FAX [phone]
AN EQUAL OPPORTUNITY AFFIRMATIVE ACTION EMPLOYER - 50%i RECYCLED/ 10% POST -CONSUMER PAPER
VISIT US ON THE wER AT http://h2o.enr.state.nc.us/NPDE5

Mr. Biggs
NC0025243
2
Upon classification of the facility by the Certification Commission, the Permittee shall employ a
certified water pollution control treatment system operator to be in responsible charge (ORC) of the
water pollution control treatment system. The operator must hold a certificate of the type and grade at
least equivalent to or greater than the classification assigned to the water pollution control treatment
system 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, .0202. The
ORC of the facility must visit each Class I facility at least weekly and each Class 11, 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 must comply with all other conditions outlined in Title
15A, Chapter 8G, .0204. Once the facility is classified, the Permittee must submit a letter to the
Certification Commission which designates the operator in responsible charge within: (A) Sixty
calendar days prior to wastewater being introduced into a new system or (B) within 120 calendar days
of the following, (i) after receiving notification of a change in the classification of the system requiring
the designation of a new ORC and back-up ORC or (ii) a vacancy in the position of ORC or back-up
ORC.
A copy of the approved calculations for a design flow of 2.5 MGD shall be maintained on file by
the Permittee for the life of the facility.
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 Operate 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 Operate 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 calculations for the design flow of 2.5 MGD is being forwarded to you.
If you have any questions or need additional information, please contact Ms. Susan A. Wilson, P.E.,
telephone number [phone], extension 510.
Sincerely, n
an W. liKlimek, P.E.
cc: Central Files
NPDES Unit, Permit File
Raleigh Regional Office, Water Quality
Construction Grants & Loans, Rob Brown

Clayton LCWRF: Authorization to Operate for permitted 2.5 mgd flow
8
Subject: Clayton LCWRF: Authorization to Operate for permitted 2.5 mgd flow
Date: Wed, 9 Apr 2003 10:20:30 -0400
From: Shankar Mistry <[e-mail]>
To: Susan A Wilson <[e-mail]>
Susan:
Effective May 1, 2003 for Authorization to Operate for 2.5 mgd
permitted flow is O.K. with
the Town. Thanks for your help in this matter.
Shankar
1 of 1 4/9/03 1:29 PM

3�ZZ'D3 ,
THE
March 27, 2003
WOOTEN
COMPANY
Ms. Susan Wilson
E N G I N E E R I N G
Point Source Branch
NC Division of Water Quality/NPDES Unit
P L A N N I N G
1617 Mail Service Center
A R C H I T E C T U R E
Raleigh, NC 27699-1617
Re: Authorization To Operate
Clayton Little Creek WRF
NPDES Permit No NC 0025453
Wake County
TWC No. 2461
Dear Ms. Wilson:
Reference is made to your March 26, 2003 e-mail concerning clarification of some
questions you have on the subject Authorization To Operate 2.5 mgd Clayton LCWRF.
The items of concern are addressed as follows:
1) The peak flow of 5.9 mgd was determined using the peak daily flow to average
daily flow factor of 2.36, based upon the influent flow data at the plant. It is
recognized that the State design guidelines require peak flow of 2.5 times the
design average daily flow. The lower peak factor of 2.36 may have been
attributed to the discharge of the wastewaters from industries having pretreatment
facilities and the Town's ongoing sewer system evaluation and rehabilitation
program to reduce infiltration/inflow in the sewer system. However, we have
revised the "Supporting Calculations For Authorization To Operate The
Expanded 2.5 MGD LCWRF" for 20 mgd peak flow and a copy of the revised
document is attached herewith. 1 �
2) The treatment plant currently has two (2) existing standby generators in
operation. Generator Set No. 1 supplies back-up power to the plant headworks,
influent pump station, administration building, aerobic digester and the old
trickling filter plant. Generator Set No. 2 supplies back-up power to the existing
aeration basins, secondary clarifiers, return sludge pump station, tertiary filters,
U.V. disinfection equipment, effluent pump station, chemical feed equipment,
and sludge handling facilities. Clark, Richardson & Biskup Consulting
Engineers, hic (CRB) conducted a study of the plant's existing standby power
capacity and found the Generator Set No. 2 was marginal in capacity to carry the
120 North Boylan Avenue current connected load. As a result of the CRB study and in anticipation of
Raleigh NC 27603-1423 additional standby power capacity needed for our upcoming reclaimed water and
nutrient removal projects, the Town is planning to replace Generator Set No. 2
919.828.0531 with a new 1000 kw generator set with automatic transfer switch. Attached
fax [phone] please find the design loads for the new generator Set No. 2.
w'�� s

3) The UV disinfection system is designed with audio/visual alarms to notify the
UV system failure. The UV system includes two banks, designed to operate in
series. Each bank includes 13 UV modules and each module contains 8 UV
lamps. Each module is designed with independent electric control circuit. In
case of a failure of a UV module, a major alarm will be activated to notify a
module failure on the UV system control as well as on the main control panels at
the plant, equipped with an auto dialer system. In this situation the operator(s)
are required to pay immediate attention to correct the module problem or to use
standby chlorination/dechlorination system until the module problem is
corrected. In case of a failure of a UV lamp in a module, a minor alarm will be
activated to notify a lamp failure. In this situation the operator(s) are also
required to replace the lamp as quickly as possible. The UV banks are designed
to alternate for duty by timer controls built in the UV system. The UV system
operation control also allows the system to operate one bank up to a set effluent
flow rate and will automatically activate another bank for duty when the flow
exceeds the set effluent flow rule for one bank operation. Both banks together
will handle peak flow of 6.25 mgd. At present the banks operation control is set-
up to operate one bank up to 2.5 mgd and when the flow exceeds 2.5 mgd
another bank will activate for duty to handle the increased flow at the plant. It
should be noted that the failure of a complete UV bank is very remote and it may
most likely happen during the power failure at the plant. For this situation the
existing standby power generator is adequate to meet automatic power supply
need for the UV system.
We sincerely appreciate your assistance provided in this matter. If you have any
questions concerning this matter, please call me at [phone].
Sincerely,
THE WOOTEN COMPANY
mil. �►� �,. 1Z
Shankar R. Mistry, Ph.D., P.E.
SRM:sml
Enclosures
cc: Mr. Steve Biggs, Town Manager
Mr. Tom Simpson, Director of Public Works
Mr. James Warren, Clayton LCWRF Superintendent

'
GENERATOR LOADS
Load
Kva/Hp
Amps
Comments
Fluorescent Lighting
15.90
19.13
Incl 1 kva for Bldg. Add.
HID Lighting
3.66
4.40
Incl .5 kva for Bldg. Add.
Incandescent Lighting
1.20
1.44
Receptacles
5.16
6.21
Incl 2 kva for Bldg. Add.
Resistance Loads
25.10
30.19
Incl 6 kva for Bldg. Add.
Clarifier
1.00
1.80
Clarifier
1.00
1.80
Alum Feed Pump
1.00
1.80
Polymer Feed Pump
1.00
1.80
Sod. Hydrox. Pump
1.00
1.80
Methanol Feed Pump
1.00
1.80
Polymer Feed Pump
2.00
3.40
Polymer Feed Pump
2.00
3.40
Thickened Sludge System Compressor
3.00
4.80
Thickened Sludge System Compressor
3.00
4.80
Thickener Drum Motor
2.00
3.40
Flocc Gear Motor
0.50
1.00
Denite Filter Backwash Blower
100.00
124.00
Autotransformer Start
Effluent Pump
100.00
124.00
VFD
Effluent Pump
100.00
124.00
VFD
Reuse Pump
100.00
124.00
Autotransformer Start
Aerator
75.00
96.00
VFD
Aerator
75.00
96.00
VFD
•
Aerator
Aerator
50.00
50.00
65.00
65.00
VFD
VFD
Sludge Holding Tank Blower
60.00
77.00
Autotransformer Start
Sludge Holding Tank Blower
60.00
77.00
Autotransformer Start
Sludge Recirc. Pump
40.00
52.00
Autotransformer Start
Denite Filter Backwash Pump
40.00
52.00
Autotransformer Start
Sludge Holding Tank Mixer
30.00
40.00
Aerated Sludge Digester Blower
15.00
21.00
Sludge Loading Pump
15.00
21.00
Sludge Holding Tank Mixer
10.00
14.00
Sludge Holding Tank Mixer
10.00
14.00
Clarifier
10.00
14.00
Clarifier
10.00
14.00
Make Up Water Pump
10.00
14.00
Rotary Drum Thickener Booster Pump
7.50
11.00
Anoxic Mixer
6.30
9.20
Anoxic Mixer
6.30
9.20
Waste Sludge Pump
5.00
7.60
Mudwell Pump
5.00
7.60
Rotary Drum Thickener Booster Pump
5.00
7.60
Thickened Sludge Pump
5.00
7.60
Thickened Sludge Pump
5.00
7.60
Aerated Sludge Digester Mixer
5.00
7.60
Hoist
5.00
7.60
Anoxic Mixer
3.80
5.80
Mixer
3.80
5.80
iAnoxic
Anaerobic Mixer
3.80
5.80

' Anaerobic Mixer 3.80 5.80
Anaerobic Mixer 3.80 5.80
Total Amperes 1432.57
•
•

ItA+uD Lam"-�J`��
Town of Clayton
C�'IailYc
t
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9T�� CARn�
March 27, 2003
Mr. Dave Goodrich, P.E., Supervisor
NPDES Unit
NCDENR-DWQ
1617 Mail Service Center
Raleigh, North Carolina
Re: Request for Authorization to Construct
Emergency Standby Generator
NPDES No. NC0025453
Town of Clayton, Johnston County
Dear Mr. Goodrich:
We hereby request that an Authorization to Construct be issued for the construction of a new emergency standby
generator at the Little Creek Water Reclamation Facility located in Clayton, N.C. The treatment plant currently has two
(2) existing standby generators in operation. Generator Set No. 1 supplies back-up power to the plant headworks, influent
pump station, administration building, aerobic digester and the old trickling filter plant. Generator Set No. 2 supplies
back-up power to the existing aeration basins, secondary clarifiers, return sludge pump station, tertiary filters, U.V.
disinfection equipment, effluent pump station, chemical feed equipment, and sludge handling facilities. Clark,
Richardson & Biskup Consulting Engineers, Inc (CRB) conducted a study of the plant's existing standby power capacity
and found that Generator Set No. 2 was marginal in capacity to carry the current connected load. As a result of the CRB
study and in anticipation of additional standby power capacity needed for our upcoming reclaimed water and nutrient
removal projects, we propose to replace Generator Set No. 2 with a new 1000 kw generator set with automatic transfer
switch.
Enclosed, please find the following for your review:
1. Three (3) sets of Design Plans and Specifications
2. Two (2) sets of Design Calculations.
If you should have any questions please contact me at [phone].
Sincerely,
R. Steven Biggs
Town Manager
Enclosures
c: The Wooten Company
IAiS wiu- 13= 9Pu� IMTO
-C Z.�hp4r�,
.X/ " (gip
P.O. Box 879 • Clayton, North Carolina 27520 • [phone] • Fax [phone]

0
THE
WOOTEN
COMPANY
ENGINEERING
PLANNING
ARCHITECTURE
120 North Boylan Avenue
Raleigh NC 27603-1423
919.828.0531
fax [phone]
I Jg2Ee> 9AIUD
3111103
/01
March 19. 2003
Ms. Susan Wilson
Point Source Branch
N.C. Division of Water Quality/NPDES Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Dear Ms. Wilson:
Re: Authorization to Operate
Clayton — Little Creek WRF
NPDES Permit No. NC 0025453
Wake County
TWC No. 2756
Reference is made to Supplement to Permit Cover Sheet, Item No. 3 —
requiring to receive Authorization to Operate from the Division of Water
Quality to a maximum design flow of 2.5 mgd and discharge to the
location included in the NPDES Permit.
Attached please find three (3) copies of the Supporting Calculations for
Authorization to Operate the Expanded 2.5 MGD LCWRF.
We appreciate your assistance in issuing the NPDES Permit. Should you
have any questions concerning the information submitted to receive
Authorization to Operate the Clayton LCWRF at 2.5 MGD, please call me
at 919-828-0531.
Sincerely,
THE WOOTEN COMPANY
R. M111�3
Shankar R. Mistry, Ph.D., P.E.
SRM:hmm
Attachment
cc: Mr. Steve Biggs, Town Manager
Mr. Tim Simpson, Director of Utilities
Mr. James Warren, LCWRF Superintendent

41
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SUPPORTING CALCULATIONS
om FOR
AUTHORIZATION TO OPERATE THE EXPANDED 2.5 MGD LCWRF
CLAYTON, NORTH CAROLINA
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Shankar R. Mistry, P.E., Ph.D.
Prepared by:
THE WOOTEN COMPANY
Engineers • Architects • Planners
120 North Boylan Avenue
Raleigh, North Carolina 27609

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TABLE OF CONTENTS
Oft
PAGE
1.0 Design Influent Wastewater Characteristics
1
2.0 Effluent Limitations (given in draft NPDES Permit No. N0025453)
1
3.0 Compliance with Annual Limits for Total Nitrogen
1
4.0 Evaluation of the LCWRF Unit Operations/Processes
7
4.1 Mechanical Screen/By-Pass Manual Screen
7
4.2 Grit Removal System
10
4.3 9-Inch Parshall Flume
12
4.4 Influent Pumps
12
4.5 Activated Sludge (Oxidation Ditch Type) System
12
4.6 Evaluation of Alkalinity Requirement and Chemical Feed Facilities
20
4.7 Alum Feed System (For Chemical Phosphorus Removal, Polishing)
22
4.8 Polymer Feed System (For Flocculation and Improved Clarification)
26
4.9 Tertiary Filtration
26
+�►
4.10 Effluent Disinfection
27
4.11 Evaluatiohn of Sludge Handling Facilities
29
1. Estimate of Sludge -Quantity
29
2. Rotary Drum* Sludge Thickenng
30
3. Sludge Stabilization/Storage Tanks
31
4. Sludge Drying Beds
32
5. Sludge Disposal
32
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SUPPORTING CALCULATIONS
FOR
AUTHORIZATION TO OPERATE THE EXPANDED 2.5 MGD LCWRF
1.0 Design Influent Wastewater Characteristics
Average daily flow, mgd =
2.5
Maximum daily flow, mgd =
5.0
Peak daily flow, mgd =
6.25 2 �
,••►
BOD5, mg/L =
.230
TSS, mg/L =
215
TKN, mg/L =
35
NH3-N, mg/L =
25
Total Phosphorus as P, mg/L =
7
Total Alkalinity as CaCO3, mg/L =
135
pH, Standard Units =
6.8 - 7.0
Temperature, °C Winter = 12; Summer
= 27
NOTE: The reported year 2000 average BODs and NH3-N concentration
were 210
mg/L and 22 mg/L, respectively.
2.0 Effluent Limitations (given in draft NPDES Permit No. N0025453)
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Effluent Characteristics
Limits
Monitoring Requirements
Monthly Average
Weekly
Average
Daily
Maximum
Measurement
Frequency.
Sample
Type
Sample Location!
Flow
2.5 MGD
Continuous
Recording
Influent or Effluent
BOD, 5 day (20Z)2
(April 1 - October 31)
5.0 mg/l
7.5 mg/1
Daily
Composite
Influent or Effluent
BOD, 5 day (20-C)2
(November 1 - March 31)
10.0 mg/l
15.0 mg/1
Daily
Composite
Influent or Effluent
Total Suspended Residue2
30.0 mg/1
45.0 mg/I
Daily
Composite
Influent or Effluent
NH3 as N (April - October
31)
1.0 mg/1
3.0 mg/l
Daily
Composite
Effluent
NH3 as N (November
1-March 31)
2.0 mg/l
6.0 mg/1
Daily
Composite
Effluent
Dissolved Oxygen3
Daily
Grab
Effluent
Dissolved Oxygen
3/Week
Grab
Upstream &
Downstream
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Effluent Characteristics
Limits
Monitoring Requirements ,
Monthly '.Average..
--Weekly
Average
Daily, =
Maximum
Measurement
Frequency
Sample
Type
Sample Locations
Fecal Coliform
(geometric mean)
2001100 ml
40D/100 ml
Daily
Grab
Effluent
Fecal Coliform
(geometric mean)
3/Week
Grab
Upstream &
Downstream
Total Residue Morine4
28 µg /l
Daily
Grab
Effluent
TKN (mg/1)
Monitor & Report
Weekly
Composite
Effluent
NO2-N _ NO3-N (mg/0
Monitor & Report
Weekly
Composite
Effluent
TN (mg/1)5
Monitor & Report
Weekly
Composite
Effluent
Total Monthly Flow
(MG)
Monitor & Report
Weekly
Calculated
Effluent
TN Load6
Monitor & Report (lb/month)
21,400 lb/year (Annual Mass Loading)?
Monthly
Weekly
Calculated
Calculated
Effluent Effluent
Total Phosphorus li
2.0 mg/L (Quarterly Average)
Weekly
Composite
Effluent
Temperature (-C)
Daily
Grab
Effluent
Temperature (-C)
3/Week
Grab
Upstream &
Downstream
Conductivity
Daily
Grab
Effluent
Conductivity
3/week
Grab
Upstream &
Downstream
Chronic Toxicity9
Quarterly
Composite
Effluent
Copper
Monthly
Composite
Effluent
Zinc
Monthly
Composite
Effluent
Silver
Monthly
Composite
Effluent
pHlO
6-9
Daily
Grab
Effluent
Footnotes:
a4
1. Sample locations: E - Effluent, I - Influent, U - Upstream at NCSR 1700, D - Downstream at
(1) NC Highway 42 and (2) NCSR 1908. Stream samples shall be grab samples and shall
be collected 3/Week during June - September and 1/Week during the remaining months of
the year. Instream monitoring is provisionally waived in light of the permittee's
participation in the Lower Neuse Basin Association. Instream monitoring shall be
conducted as stated in this permit should the permittee end its participation in the
*■+ Association.
Per 15A NCAC 2B .0505(c)(4), stream sampling (as well as influent/effluent sampling) may
be discontinued when flow conditions could result in injury or death of the person(s)
00 collecting the samples. In such cases, on each day that sampling is discontinued, written
justification shall be specified in the monitoring report for the month in which the event
-2-
0"

0"
occurred.
a'+ 2. The monthly average effluent BOD5 and Total Suspended Residue concentrations shall not
exceed 15% of the respective influent value (85% removal).
3. The daily average dissolved oxygen effluent concentration shall not be less than 6.0 mg/l.
4. Total residual chlorine is required only if chlorine is used as a disinfectant (or elsewhere in
the process).
**► 5. TN means Total Nitrogen. For a given wastewater sample, TN is the sum of Total Kjeldahl
Nitrogen and Nitrate -Nitrite Nitrogen: TN = TKN + NO2-N + NO3-N.
6. TN load is the mass load of TN discharged by the Permittee in a period of time. See Special
Condition A.(3.), Calculation of TN loads.
7. The annual TN load limit shall become effective with the calendar year beginning on January
1, 2003. Compliance with this limit shall be determined in accordance with Special A.(4).
Compliance with Annual Limits for Total Nitrogen.
8. The quarterly average for total phosphorus shall be the average of composite samples
collected weekly during the calendar quarter (January -March, April -June, July -September,
October -December).
9. Chronic Toxicity (Ceriodaphnia dubia) P/F at 1.6%: March, June, September, and December
[see Special Condition A.(6)]. Toxicity monitoring shall coincide with metals monitoring.
10. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall
be monitored daily at the effluent by grab sample.
3.0 Compliance with Annual Limits for Total Nitrogen
The compliance requirements with the annual limits for Total Nitrogen, as given in the draft
NPDES Permit are listed as follows:
For any given calendar year, the Permittee shall be in compliance with the annual TN
load limit in this permit if:
(a) The Permittee's annual TN Load is less than or equal to said limit, or
(b) the Permittee is a Member of a group compliance association and a Co-Permittee
to that association's group NPDES permit, in which case the Permittee's TN
discharge is governed primarily by the association's permit.
2. If the Permittee elects to become a Co-Permittee Member of a group compliance
association or if it withdraws or otherwise loses its Co-Permittee Member standing in an
association, it must notify the Division in writing of the proposed change.
(a) Notification shall be sent to:
NCDWQ / NPDES Unit
Attn: Neuse River Basin Coordinator
~' 1617 Mail Service Center
Raleigh, NC 27699-1617
(b) The Division must receive notification no later than August 31 for changes
proposed for the following calendar year.
a*
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3. For the purpose of Condition (1)(b) above, an association's Co-Permittee Members in
any calendar year shall be as defined in its group NPDES permit.
(a) Changes in an association's membership become effective only through
modification of its NPDES permit.
(b) Such changes become effective on January 1 st following permit modification.
�► (c) Beginning on January 1st of each year, the association's membership is fixed for
the remainder of the calendar year.
The Town of Clayton will comply with the annual limit for Total Nitrogen by becoming a
member of the Neuse River Compliance Association (the "Association") and a co-permittee to the
Association's group NPDES Permit. Articles of Incorporation forming the Neuse River
Compliance Association (the "Association") have been filed, establishing the Association as a
non-profit corporation. The Town has submitted the required resolution of intent to join the
Association in form acceptable to the Association. See the attached copy of the letter from the
Association confuming the formation of Association. A copy of the Town's resolution of intent to
w join the Association is also attached hereto.
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Lower Neuse Basin Association, Inc.
Raleigh, North Carolina
September 27, 2002
J. William Reid, Supervisor
.. Point Source Branch
Division of Water Quality
NC Dept. of Environment and Natural Resources
1617 Mail Service Center
Raleigh, NC 27699-1617
Re: Town of Clayton — Membership in the Neuse River Compliance Association
Dear Mr. Reid:
This letter is being sent at the request at the Town of Clayton in response to your
letter of June 10, 2002 concerning their application for a modification of NPDES Permit
No. NC0025453. Articles of Incorporation forming the Neuse River Compliance
Association (the "Association's have been filed, establishing the Association as a
nonprofit corporation. Furthermore, the Town of Clayton has submitted the required
resolution of intent to join the Association in a form acceptable to the Association. The
final Association membership roster and operational parameters will be completed upon
approval of the operational agreement by the Division of Water Quality and
.� Environmental Management Commission.
If you have any questions regarding this matter, don't hesitate to contact me at
.. [phone].
Sincerely,
Timothy L. Donnelly, PE
Chairman
Lower Neuse Basin Association
And Neuse River Compliance Association
Cc: Town of Clayton
.. The Wooten Co.
P. O. Box 590 Raleigh, North Carolina 27602
[phone]

0"
08/13/2002 14:27 9195531918
It V
TOWNOFCLAYTO:N
PAGE 02
a*
out
0"
04
0"
r
0"
IM
0%
Town of Clayton
Resolution to Join the Neuse River
Compliance Association
WHEREAS, the Lower Neuse Basin Association (LNBA), formerly the Neuse Basin
Association was created in 1994 to establish a formal, voluntary'agreementbetweer itself and
the North Carolina Division of Water Quality (DWQ), by which the LNBA is responsible for
surface water monitoring, reporting, and other cooperative efforts by NPDES dischargers within
the Lower Neuse River Basin to obtain water quality information in the basin.
AND WHEREAS, in addition to such ongoing coopbrative surface water monitoring
activity and other joint efforts, the LNBA and DWQ jointly support other additional strategies to
ensure overall Total Nitrogen reduction at the mouth of the Neuse River in the Pamlico Sound as
required by the wastewater discharge requirements of the Neuse River Basin Nutrient Sensitive
Waters Management Strategy.
AND WHEREAS, the formation of another body, the Neuse River Compliance
Association (Association) is necessary to. obtain a group NPDES permit for Total Nitrogen, as an
alternative framework in which interested point source dischargers in the lower Neuse River
Basin can work cooperatively to reduce their individual and collective discharge of that nutrient
pollutant and comply with applicable limits. s
THEREFORE, the Town of Clayton agrees with the overall intent of the cooperative
arrangements set out in the By -Laws of the Neuse River Compliance Association and, at this
time, intends to join the ,Association and to p ' ipate according to said By -Laws.
—IAAte
Douglas cCorniac
Attest: Mayor
K ' Reed
Town Clerk
OR RALE10WO15017-WI/337231 v.)

04
4.0 Evaluation of the LCWRF Unit Operations/Processes
The Unit Operations/Processes, incorporated in LCWRF are evaluated as follows for
adequacy of hydraulic capacity and overall LCWRF compliance with the effluent limits for 2.5 mgd
flow.
4" 4.1 Mechanical Screen/By-Pass Manual Screen
The plant includes one (1) mechanical screen and one (1) by-pass manual screen for
screening of the influent wastewater at the plant.
The mechanical screen unit (HYCOR HELISIEVE UNIT, MODEL HLS500XL) consists of
a spiral assembly, screen basket, transfer tube, press zone assembly, discharge section, drive system,
pivot stand, and controls. The design description of the screen is summarized as follows:
Number of unit, Hycor Helisieve Model HLS500XL 1
Peak hydraulic capacity, mgd 5.9
Screen opening, inch 0.25
Channel width, inch 24
Channel width, inch 99
Screen installation angle, degree 35
�+ Drive horsepower, hp 3
Electrical service 230/460 Volts, 3 Phase, 60 Hz
Accessories: Level controls and timer for operation of the screen and screenings container
Based upon the attached manufacturer's Hydraulic Performance Chart of the Helisieve HLS
500 XL Screen Unit with 1/4-inch diameter screen openings, it can be seen that the screen is
'.., capable of handling up to 6.5 MGD peak flow. The design peak flow is 6.25 MGD which indicates
that the mechanical screen is more than adequate to handle the design peak flow at the plant.
Considering 23.28 inches downstream water level in the screen channel, controlled by a 9-
inch Parshall Flume, and using the attached screen hydraulic performance chart, the headloss
through the screen at 6.25 MGD peak flow is estimated to be 8.5 inches. Accordingly, the upstream
-7-

OW
water depth in the screen channel will be equal to 23.28" + 8.5" = 31.78 inches. The screen basket
., height from the screen channel bottom is 32.01 inches which indicates the screen is adequate to
handle the 6.25 MGD peak flow.
The design description of the by-pass manual screen is summarized as follows:
«.� Number of units 1
Unit capacity, mgd 5.9
Screen opening, inch 1
Bar spacing, inch 1 I/4
Channel width, inches 24
r� Channel height, inches 99
Screen installation angle, degree 45
Method of cleaning Manual
The screen is designed for stand-by service and considering the screen openings and
associated head loss, when compared with the 1/4 inch mechanical screen opening, the manual by-
pass screen should be adequate to handle 6.25 MGD peak flow.
H.
0"

25
20
U
CD
15
En
En
0
L
u
10
Cn
O
v
W
5
e
HLS500XL Hydraulic Performance W
Sieve with 1/4" -Diameter Perforations �
I I I I r I
1 I 1 I I t
I I I I I I
'6.5 MGD '
I I 1 I I r
— — 5.� MGD — ; ------ � ------ ;------�------ �----__
I I I I
I I 1 I I
I 1 1 1 I I
4.5 MAD
1 I I 1 I
3.5MGD� —1 0
I I ( 1 I
I 1 1 I I I
2.5MGD
------ —A— ---- 1------ -I------
I 1 t 1 I 1
1.5 MGD
I I 1 1 1
1 I I 1 1
1 I I
I I I I G
1 I 1
I I I
5 10 15 20 25 30
Downstream Water Level (Inch)
W
CD
V
�
Mb
o
w
�
�p
Z
en
W
CDwILA
35
is
0
0

4"
4.2 Grit Removal System
The plant includes a Vortex type grit removal system, manufactured by Jones and Atwood.
The system consists of a rotating impeller mechanism housed within a specifically designed tank to
give sufficient retention to allow efficient grit collection, grit pump, grit concentrator, grit dewatering
0" screen and grit storage container. The design description of the grit removal system is summarized
am
piq
P"
M
P"
am
an
MR
F�
E-1
as follows:
Number of units, Jeta Vortex Type (By Jones and Atwood)
1
Unit capacity, mgd
4
Percent grit removal of grit size greater than 100 mesh (0.15 mm) %
60
Grit chamber diameter, ft.
8
Grit chamber depth, ft.
6
Grit chamber volume, gal.
2,255
grit storage zone diameter, ft.
3.25
Grit hopper depth, ft.
3
Grit storage volume, cu. Ft.
25
Propeller drive horsepower, hp.
1
Grit pump capacity, gpm
200
Grit pump drive, horsepower, hp
3
Electrical service 460 Volt, 3 Phase, 60 Hertz
Accessories: Grit concentrator, grit dewatering screen, grit container and controls for grit
paddle and manual and time based operation of the grit pump.
Evaluation of the Grit Removal System for 6.25 MGD Peak Flow:
1. Check Inlet Velocity to Grit Chamber
Peak Flow, mgd (cfs) = 6.25 (9.670)
Inlet channel invert level, ft. = 228.92
Maximum water level in inlet channel = 230.86
-10-
I"

IL
PM
Width of inlet channel, ft. = 1.5
ON
Velocity in inlet channel at 6.25 MGD Peak Flow, ft. /sec.
9.67 cfs
Am (230.86 — 228.92) x 1.5
am
3.32 ft./sec.
Velocity in inlet channel at 80% of Peak Flow, ft./sec.
9.67cfsx0.8
(230.86 — 228.92) x 1.5
0" = 2.65 ft./sec.
As per the WEF Manual of Practice No. 8 - Design of Municipal Wastewater Treatment
MR
Plant , the ideal velocity (at flows 40 to 80 percent of peak flow) in the influent channel
should be in the range of 2 to 3 ft./sec. The manufacturer of Vortex grit removal system
recommends that the influent channel velocity should not exceed 3.5 ft./sec. This indicates
that the existing grit removal system is within the acceptable velocity range of the inlet
channel at the design peak flow of 6.25 MGD.
2. Check for Hydraulic Retention Time
Peak Flow = 6.25
Grit Chamber Volume, gal. = 2,255
�. Hydraulic Retention Time, Seconds
= 2255 gal x 1,440 mn. x 60 sec.
+ 6250,000 gal / day day min.
�► = 31.17 seconds
As per the WEF Map 8, typical hydraulic retention times for the Vortex grit removal
system at peak flow are in the range of 20 to 30 seconds. This also indicates that the
existing grit removal system will provide more than adequate hydraulic retention time at a
peak flow of 6.25 mgd.
0"
-11-
P"

4.3 9-Inch Parshall Flume
The influent flow to the LCWRF is continuously monitored by a 9-inch Parshall Flume. The
design description of the Parshall Flume is summarized as follows:
Parshall Flume size (throat width), inch = 9
Flume capacity, mgd = 0.058 - 5.73
Accessories: Ultrasonic level sensor, flow transmitter, indicator and totalizer
Evaluation of the Parshall Flume at 6.25 MGD peak flow indicated that maximum water depth
in the Flume will be 2 feet, 1.3 inches. The total Flume height is 4 feet, 2 inches which indicates the
existing Flume should be adequate to handle the peak flow.
4.4 Influent Pumps
The influent pump station includes three (3) 2,170 gpm capacity dry pit submersible pumps
�+ and one 1,200 gpm capacity dry pit submersible pump. The drive horsepower for the 2,170 gpm
is 75 h , each and the drive horsepower for the 1,200 m um is 40 h . Two of the 2,170
pumps P P gpm pump P
cove---
gpm pumps are designed to operate with the float level control Variable Frequency Drives. The
gpm
controlled remaining 2,170 gpm and 1,200 gpm pumps are operated at constant speed by float level
controls. Operation of the two 2,170 gpm pumps will pump 6.25 mgd which is more than adequate
for handling peak flow at the plant. The other two pumps will be used for stand-by mode operation.
4.5 Activated Sludge (Oxidation Ditch Type) System
The plant includes the extended aeration (Carrousel Oxidation Ditch) 'type activated sludge
system. The design description of the system is summarized as follows:
Aeration Tanks (Carrousel Oxidation Ditches)
Number of units: 0.75 MG capacity 1
1.15 MG capacity 1
Total aeration tank volume, mil gal. 1.90
Hydraulic retention time, hr., at 2.5 mgd avg. Daily flow 18.24-
+� Number of aerators in 0.75 MG tank, 25 hp 1
50 hp 1
a%
-12-
W

P"
Number of aerators in 1.15 MG tank, 50 hp
1
0 °
p.,
75 hp
1,�°
Total aeration horsepower, hp
200
oov8
' o, b
Aeration horsepower capacity, hp/mil. Gal 7_ o .? 5 0 PILO' f k _
105.26
3�
N-P
Aeration capacity of the aerator, lb 02/h /hr at stand. Condition ° `$—i�
p ty p �03�3
3.5
k/t co � PI
i
Total aeration capacity, lb 02/hr
700
Operating MLSS concentration, mg/L
4,000
O!--
Sludge retention time, days
16
MLVSS/MLSS ratio
0.8
BOD5 loading, lb BOD5/day
4,795.5
lb BOD5/1000 cu. Ft./day
18.87
F/M ratio, lb BOD5/lb MLVSS/day
0.094
Net sludge yield, lb solids/lb BOD5 removal
, 0.75
b
Sludge recycle ratio, percent
100
Clarifiers:
Number of clarifiers, 55 ft diam x 12 ft. SWD
1
65 ft diam x 14 ft. S WD
2
Clarifier volume, gal. 55 ft diam clarifier
2131,146
�+
65 ft diam clarifiers
694,634
Total
907,780
Surface area, sq ft 55 ft diam clarifier
2,375
65 ft diam clarifiers
6,633
Total
9,008
Surface overflow rate, gpd/sq ft at 2.5 mgd flow
277.53
Weir length, ft 55 ft diam clarifier
172.7
65 ft diam clarifiers
408.2
Total
580.9
Weir overflow rate, gpd/lin ft
49304
Solids loading rate, lb solids/sq ft/day,
including sludge recirculation flow, 2.5 mgd
18.52
-13-
P"

',
PR1
00
Sludge Recirculation/Waste Pumps
Number of recirculation pumps, 800 gpm capacity 1
1,100 gpm capacity 1
1,700 gpm capacity 1
Number of waste sludge pumps, 250 gpm capacity 1
Drive horsepower, hp, 800 gpm pump 15
1,100 gpm pump 25
1,700 gpm pump 40
250 gpm pump 5
NOTE: The sludge piping design also allows sludge wasting from the sludge recirculation
line.
Evaluation Of The Oxidation Ditch System For BODs Removal And Nitrification
1. Design Considerations
Average daily flow = 2.5 mgd (Influent flow to 0.75 MG ditch = 0.987 mgd and
Influent flow to 1.15 MG ditch = 1.513 mgd)
BODs: Influent = 230 mg/L; Effluent = 5.0 mg/L ✓
TSS: Influent = 230 mg/L; Effluent = 10.0 mg/L
TKN: Influent = 35 mg/L; Effluent = 3.0 mg/L
NH3-N: Influent = 25 mg/L; Effluent = 1.0 mg/L
NO3-N: Influent = 0 mg/L; Effluent = 2.0 mg/L
Temperature: Winter =12° C; Summer = 280 C
Operating MLSS Concentration = 4,000 mg/L
Sludge retention time = 16 days
Net Sludge Yield, Yn, lb solids/lb BODs removed = 0.75
Oxygen Requirements, lb 02/lb BOD removed = 1.5
lb 02/lb NH3-N removed = 4.6 t/
NOTE: The reported year 2000 average BOD5 and NH3-N concentrations were
210 mg/L and 22 mg/L, respectively.
-14-
am

a"
2. Required Oxidation Ditch Volume
The required oxidation ditch volume is determined using the following equation:
,.., B ODR x Yn x SRT
Volume, mil. gal. = MLSS x 8.34
Where B ODR = (230 - 5) mg/L B ODs x 8.34 x 2.5 mgd
= 46911 BOD/day
Yn = Net sludge yield = 0.75 lb solids/lb BODR
SRT = Sludge retention time required for complete nitrification = 16
days
MLSS = Operating mixed liquor suspended solids concentration
= 4,000 mg/L
Volume, mil. gal. _
4691x0.75x16
4000 x 8.34
= 1.687 mil. gallon
The available volume in the existing carrousel oxidation ditches = 0.75 MG + 1.15 MG
= 1.90 MG which is more than adequate for the required ditch volume of 1.687 MG.
3. Aeration Requirement for 0.75 MG Carrousel Ditch
a. Oxygen Requirements for BODs Removal
Considering influent flow to 0.75 MG ditch = 0.987 mgd, influent BODs = 230 mg/L,
effluent BODs = 5.0 mg/L and oxygen requirement for BODs = 1.5 lb 02/lb BODs
removed, the total oxygen requirement for BODs removal is:
_ (230-5) mg/L BOD5 x 8.34 x 0.987 mgd x 1.5 = 2778 lb 02/day �
b. Oxygen Requirement for Nitrification (NH3-N Removal)
Considering influent flow to 0.75 MG ditch = 0.987 mgd, 5 mg/L nitrogen
requirement for each 100 mg/L BODs for cell synthesis, influent TKN = 35 mg/L,
effluent NH3-N = 1.0 mg/L and oxygen requirement for nitrification = 4.6 lb
0z/NH3-N nitrified, the total oxygen requirement for nitrification is:
35 — 230x 5 100 —1 mg/LNH— N x 8.34 x 0.987 mgd x 4.6
� 3
= 852 lb 02/da
y
-15-

f�1
c. Total Oxygen Requirement
Owl = 2778 + 852
= 3630 lb 02/day
= 151.25 lb 02/hr.
d. Aeration Horsepower Requirement
The total required horsepower for the platform mounted mechanical aeration is
estimated as follows:
5
IM S OR = AOR S
lR C sw — C o)eAT-20 xa
Where: AOR = Actual oxygen requirement = 231.8 lb 02/hr
Cs = Oxygen saturation value of clean water at standard conditions = 9.092
,..ti mg/L
= Ratio of oxygen saturation value of waste to that of clean water = 0.95
r•� Csw = Oxygen Saturation value of clean water for the site conditions of
Temperature = 28' C and actual barometric pressure (Pa = 14.575 psia) _
7.76 mg/L.
p•, Co = Residual concentration of dissolved oxygen desired during normal
operation = 2.0 mg/L.
a = Ratio of oxygen transfer in waste to that of clean water at the same
temperature = 0.8
T = Design temperature = 28 ° C
P" 9 = Temperature correction constant = 1.024
p•, SOR = i151.25 9.092
(0.95 x 7.76. — 2.0) (1.024)28-20 x 0.8
�► _ 1375
5.195
264.7 lb 02/hr
Considering 3.5 lb 02/hp/hr standard oxygen transfer rate of the EIMCO platform
mounted aerator, the required horsepower is: a �� 1kr
^--� 405.68 L$ 0 2 / hr
3.5 lb 02/hp/hr
= 75.63 hp
OR
IR
0=4

Mn
f�l
The existing 0.75 MG ditch is equipped with one (1) - 25 hp aerator and one (1) -50 hp
aerator. This will provide the total aeration horsepower of 75 hp. The required aeration
horsepower without th denitrification-QMen credit is 75.63 hp. In the oxidation ditch
some denitrification will occur that should supplement the oxygen need for BODs removal.
Accordingly, the current aeration capacity should be adequate to handle the expanded 2.5
mgd flow.
4. Aeration Requirement for 1.15 MG Carrousel Ditch
a. Oxygen Requirements for BODs Removal
Considering influent flow to 1.15 MG ditch = 1.513 mgd, influent BODs = 230 mg/L,
effluent BODs = 5.0 mg/L and oxygen requirement for BOD5 = 1.5 lb 02/lb BODs
removed, the total oxygen requirement for BODs removal is:
_ (230-5) mg/L BOD5 x 8.34 x 1.513 mgd x 1.5 = 4258 lb 07Jday
�+ b. Oxygen Requirement for Nitrification (NH3-N Removal)
Considering influent flow to 1.15 MG ditch = 1.513 mgd, 5 mg/L nitrogen
requirement for each 100 mg/L BODs for cell synthesis, influent TKN = 35 mg/L,
effluent NH3-N = 1.0 mg/L and oxygen requirement for nitrification = 4.6 lb
02/NH3-N nitrified, the total oxygen requirement for nitrification is:
M9
rM
M
M"
M
= 35 — 230 x 5 —1 mg / L NH — N x 8.34 x 1.513 mgd x 4.6
100 3
= 1306 lb 02/day
c. Total Oxygen Requirement
= 4258 + 1306
= 5564 lb 02/day
= 231.8 lb 02/hr.
d. Aeration Horsepower Requirement
The total required horsepower for the platform mounted mechanical aeration is
estimated as follows:
SOR = AOR
((3 C
W
s
- C o) eT-20 x a I
Where: AOR = Actual oxygen requirement = 231.8 lb 02/hr
SOR = Oxygen transfer rate, lb 02/hr at standard conditions = 3.5 lb 02/hp/hr
Cs = Oxygen saturation value of clean water at standard conditions = 9.092 mg/L
R = Ratio of oxygen saturation value of waste to that of clean water = 0.95
Csw = Oxygen Saturation value of clean water for the site conditions of Temperature
= 28° C and actual barometric pressure (Pa=14.575 psia) = 7.76 mg/L.
-17-
P"

M
Co = Residual concentration of dissolved oxygen desired during normal operation
= 2.0 mg/L.
a = Ratio of oxygen transfer in waste to that of clean water at the same
temperature = 0.8
T = Design temperature = 28° C
0 = Temperature correction constant =1.024
Mel
SOR = �. 231.8/
9.092
(0.95x7.76 — 2.0) (1.024)28-20 x 0.8
= 2107.5
5.195
405.68 lb 02/hr
Considering 3.5 lb 02/hr/hp standard oxygen transfer rate of the EIMCO platform
mounted aerator, the required horsepower is:
405.681b 02 / hr
3.5 lb 02/hp/hr
= 115.9 hp
116 hp
The existing 1.15 MG ditch is equipped with one (1) - 50 hp aerators and one 75 hp
aerator. This will provide the total aeration horsepower of 125 hp. The required i
aeration horsepower without the denitrification oxygen credit is 116 hp. Accordingly,
the current aeration capacity should be adequate to handle the expanded 2.5 mgd flow.
Evaluation of Clarifiers:
1. Check for Surface Overflow Rates
Design average flow, mgd = 2.5
Total surface area of the clarifiers, sq ft = 9008
Surface Overflow Rate, gpd/sq ft
2,500,000 gpd
f"
IM
/VVV 0%1 AL
277.53 gpd/sq ft
The surface overflow rate at 5.8 mgd peak flow is 644 gpd/sq ft
-18-

M
As per the WEF MOP 8, the average and peak allowable clarifier surface overflow rates
for secondary clarifiers are 560 gpd/sq ft and 644 gpd/sq ft, respectively.This indicates
that the existing clarifiers are more than adequate to handle the hydraulic loadings at the
plant.
2. Check for Solids Loading Rate
Design average daily flow, mgd = 2.5
Sludge recirculation flow, mgd = 2.5
?" Operating MLSS concentration, mg/L = 4,000
Total surface area of the clarifiers, sq ft = 9,008
M Solids Loading Rate, gpd/sq ft
PM
4,000 mg / L x 8.34 x (2.5 + 2.5) mgd
9,008 sq ft
= 18.52 lb solids/sq ft/day
As per the WEF MOP 8, the allowable maximum solids loading rate for efficient
secondary clarifier operation is in the range of 20 - 30 lb solids/sq ft/day. This indicates
that the existing clarifiers are more than adequate to handle the anticipated solids loading
at 2.5 mgd influent flow with 100 percent recirculation flow.
Evaluation of Sludge Recirculation Pumps
1. Check for Required Sludge Recirculation (hydraulic) Capacity
Sludge recirculation pumps: One - 800 gpm capacity
One -1,000 gpm capacity
One -1,700 gpm capacity
The sludge recirculation pumps are designed to operate one - 1,700 gpm pump to provide
2.5 mgd, i.e. 100 percent sludge recirculation pump capacity. The one - 800 gpm and one
- 1,000 gpm pump are used together to provide standby capacity and alternate pumps
operation flexibility to maintain even wear of the pumps. As per the WEF MOP 8, the
design sludge recirculation capacities are in the range of 75 to 150 percent of the average
daily influent flow. This indicates that the pump's capacities are adequate for the sludge
recirculation needs, including standby capability.
fin
M
-19-
F"

Evaluation of Waste Sludge Pumps
1. Check for Required Sludge Wasting Need
Waste sludge quantity lb/day, at design 2.5 mgd flow = 3,882
Waste sludge quantity, gal/day, at design 2.5 mgd flow = 57,000*
Waste Sludge pump capacity, gpm = 250
* Sludge quantity at 1.02 specific gravity of sludge and 0.8 % waste sludge solids
concentration.
Considering 57,000 gal/day waste sludge production and 250 gpm waste sludge pumping
capacity, the required sludge pumping can be accomplished in 3.80 hours/day. This
?"" indicates that the waste sludge pumping capacity is adequate for sludge wasting needs.
The design of sludge recirculation and waste piping also allows for sludge wasting from
the recirculation line.
4.6 Evaluation of Alkalinity Requirement and Chemical Feed Facilities
a. Design Considerations
Average daily flow = 2.5 mgd
Pat TKN: Influent = 35 mg/L; Effluent = 2.0 mg/L
NH3-N: Influent = 25 mg/L; Effluent =1.0 mg/L
NO3-N: Influent = 0.0 mg/L; Effluent = 0.5 mg/L
B ODs: Influent = 230 mg/L; Effluent = 5 mg/L
MR
Total Alkalinity = 130 mg/L; Effluent = 50 mg/L
Total Nitrogen requirement for cell synthesis = 5 mg/L N/100 mg/L BOD5
Alkalinity requirement for nitrification = 7.14 mg/L alkalinity/mg/L of NH3-N
Alkalinity recovery in denitrification = 3 mg/L alk/mg/L NO3 denitrified
b. Amount of Nitrogen Nitrified
Considering most of the organic nitrogen portion of TKN will be mineralized to NH3-N,
5 mg/L N/100 mg/L BOD5 nitrogen requirement for cell synthesis and effluent TKN =
2.0 mg/L, the total amount of nitrogen nitrified is:
= 35 _ 5 x 230 _ 2.0
100
= 21.5 mg/L NH3-N
0"
-20-
0"

It
c. Alkalinity Addition Requirement
`lw' Considering the alkalinity requirement of 7.4 mg/L alkalinity/mg/L NH3-N nitrified, the
alkalinity loss during the nitrification process is:
0"
FOR
= 21.5 mg / L NH3 — N x 7.14 mg / L alkalinity
mg/LNH3 N
=153.51 mg/L alkalinity
Considering all the NH3-N got converted to nitrate, 4.0 mg/L effluent NO3-N
concentration and the alkalinity recovery of 3.0 mg alk/mg NO3-N denitrified, the recovery
of alkalinity during the denitrification process is:
_ (21.5 — 4.0) mg / L NO 3 — N x 3.0 mg / L alkalinity
mg/L NO3 N
= 52.5 mg/L alkalinity
Considering the influent alkalinity of 130 mg/L, alkalinity loss of 178.5 mg/L in
nitrification and alkalinity gain of 75 mg/L in denitrification, the effluent alkalinity will be:
= 130 - 153.51 + 52.5
= 28.99 mg/L
Considering the effluent residual alkalinity requirement of 50 mg/L for nitrification
�+ process stability and improved sludge settling characteristics, the supplemental alkalinity
additional requirement is:
MR
= 50 - 28.99
= 21.01 mg/L
'"' . . d. Alkali (Magnesium Hydroxide) Feed System
f"
ow
1. Magnesium Hydroxide Dose:
Considering approximately 0.60 mg/L magnesium hydroxide is required to raise 1.0
mg/L alkalinity, the magnesium hydroxide dose requirement is:
21.01 mg/L alkalinity x 0.60 mg/L Mg (OH)2
= 12.6 mg/L Mg (OH)2
2. Magnesium Hydroxide Feed Rate
Considering the plant average daily flow of 2.5 mgd, liquid Mg (OH)2 slurry
concentration of 53% and Mg (OH)2 bulk density of 12.3 lb/gal., the amount of liquid
-21-

Ma(OH)z required is:
_ 12.6 mg / L x 8.34 x 2.5 mgd
12.3 lb / gal x 0.53
= 40.32 gal/day
3. Bulk Storage Requirement
Considering the Mg (OH)2 is delivered as 3,800 gallon/truck load and providing bulk
storage of 1.5 times the truck load volume, the total Ma(OH)2 bulk storage required is:
= 3,800 gal. X 1.5
= 5,700 gallon
The existing 6,000 gallon bulk storage tank at the plant is adequate for the bulk �G
storage need.
4. Magnesium Hydroxide Feed Pumps
Considering the Mg(OH)2 feed rate of 40.32 gal/day and applying peak to average
volumetric ratio of 2.0, the required size of the feed pump is:
= 40.32 gal / day x 2.0 x day
24 hr
= 3.36 gal/hr
poll
The existing two feed pumps are designed for 0 -10 gal/hr, each, which are more than
adequate for feeding the required magnesium hydroxide.
OR 4.7 Alum Feed System (For Chemical Phosphorus Removal, Polishing)
The alum feed system at the plant is designed for chemical phosphorus removal on an as
PON
needed basis for compliance with the Total Phosphorus limit of 2.0 mg/L, on quarterly average
basis. The design description of the alum feed system is summarized as follows:
Number of 7,500 gal. Bulk storage tanks 1
Number of 500 gal day tanks 1
Number of metering pumps 2
Metering pump capacity, gallhr 0-20
Feed points: Effluent weir boxes of the oxidation and/or distribution box to the clarifiers.
oft
-22-
0"

Evaluation of Alum Feed System for Phosphorus Removal:
1. Design Considerations
Average daily flow, mgd
= 2.5
Target phosphorus concentration to be removed chemically
during the biological process upset, mg/L
= 2.0
Chemical(s) considered for P removal:
Liquid Alum
Design mole ratio of A 1:P
— 2.0:1
Atomic weight of Al
= 27
Atomic weight of P
= 31
Atomic weight of Al PO4
= 122
Atomic weight of A1(OH)3
= 78
Liquid alum data: Bulk density =1.33 g/cc
= 11.1 lb/gal
Percent Al2 (SOa)3 14 H2O
= 49
Percent A 1203
= 8.3
Percent Al
= 4.37
Feed Points: Effluent weir boxes of the oxidation ditches and/or distribution box to
the clarifiers
�•►
2. Alum Requirement and Feed Rate
a. Chemically Removable Phosphorus as P
2.0mg/LPx8.34x2.5mgd
= 41.7 lb P/day
= 41.7 lb P/day
31
= 1.345 lb mole P/day
0"
P"
Oft
-23-
OR

WA
.I
b. Alum Requirement
Considering the design ALP mole ratio of 2.0:1, the total lb -mole of Al required
is:
= 1.345 lb mole P x 2.0 lb mole Al
day 1.0 lb mole Al
= 2.69 x lb mole Al
day
= 2.69 lb mole P x 27 lb Al
day 1.0 lb mole Al
lb mole Al
= 72.63 x
day
+�►
Considering liquid alum having 4.37 percent Al (8.3% as A1203 or 49% as A21
(SO4)3. 14 H20) and density of liquid alum of 11.1 lb/gal, the total quantity of
liquid alum required is:
72.63 lb A 1 / day
11.1 lb / gal x 0.0437
= 149.73 gallon liquid alum/day
C. Alum Dose
Considering the 149.73 gal/day liquid alum requirement, 11.1 lb/gal bulk density
Olt of liquid alum and design average daily flow of 2.5 mgd, the liquid alum dose for
chemical phosphorus removal is:
149.73 gal / day x 11.1 lb / gal
8.34 lb / gal x 2.5 mgd
= 79.71 mg/L liquid alum
d. Bulk Storage Requirement
Considering the liquid alum is delivered in 4,000 gallon/truck load and providing
bulk storage of 1.5 times the truck load volume, the total liquid alum bulk storage
requirement is:
4,000 gal x 1.5
truck load
= 6,000 gallon
go
-24-
ON

w►
The existing liquid alum bulk storage tank capacity is approximately 7,500 gallon
Oft which is more than adequate for the bulk storage need. Using the liquid alum feed
rate of 149.73 gal/day, the total number of days of alum supply available from the
existing bulk storage tank is:
�al
_ 7500 gal
149.73 gal / day
- 50 days
e. Alum Feed Pumps
Considering the liquid alum feed rate of 149.73 gal/day and applying peak to
average volumetric requirement ratio of 2.5, the required size of the alum feed
pump is:
= 149.73 gal x 2.5 day
day 24 hr
an
= 15.60 gal/hr
r•► The existing two alum feed pumps are designed for 0 - 20 gal/hr, each, which are
adequate for alum feed needs for chemical phosphorus removal.
f. Sludge Production Due to Chemical P Removal
Stoichiometry of Sludge Production:
Al + POa = A1PO4
Al + 3 OH = Al (OH)3
2.0 mg / L P = 0.0645 mmol added / L A1PO4 produced
31
(2.0 mg / L P x 2.0 x 27 / 31 = 0.129 mmole / L Al added
,.., 27
0.129 — 0.0645 = 0.0645 mmole in excess as A1(OH) 3
FOR A1PO4 Sludge = 0.0645 mmole/L x 122
= 7.869 mg/L A1PO4
Al (OH)3 sludge = 0.0645 mmole/L x 78
= 5.031 mg/L A 1 (OH)3
Total Chemical Sludge Produced
= 7.869 + 5.031
= 12.9 mg/L
IN%
-25-

Considering the reported sludge production to be higher than the calculated sludge
Oft production by use of stoichiometry it has been recommended that the calculated
sludge production value be increased by 35 percent. Accordingly, the chemical
sludge production is estimated to be:
M" = 12.9 mg/L x 1.35
= 17.415 mg/L sludge
= 17.415 mg/L x 8.34 x 2.5 mgd
= 363 lb sludge/day
4.8 Polymer Feed System (for flocculation and improved clarification)
The polymer feed system at the plant is provided for flocculation and improved clarification to
enhance quality of the effluent discharge. The design description of the polymer feed system is
summarized as follows:
Number of 1,250 gal mix tank with mixer 1
Number of polymer solution transfer pumps 2
+� Transfer pump capacity, gpm 25
Number of 500 gal polymer solution storage tanks 3
Number of polymer feed pumps 1
Polymer feed pump capacity, gal/hr 25
Polymer blending system 0-24 gallon of neat polymer per day 1
Based upon the polymer dose of 0.25 to 0.5 mg/L at 0.5 % solution strength, used at the plant,
the polymer feed rate for improved clarification is estimated to be 10.4 to 20.8 gal/hour. This
indicates that the polymer feed system is more than adequate to handle the clarification need, if
required, at the plant. It should be noted that the polymer feed system is used only during the time
of process upset or bulking situations experienced at the plant.
4.9 Tertiary Filtration
The tertiary filtration system at the plant consists of two shallow bed traveling bridge filters
with integral backwash pumps, indexing, backwash hood and piping. The design description of the
0"
-26-
M

filters is summarized as follows:
o, Number of filters (48'-8" x 12'-6", each) DAVCO traveling bridge type 2
Filter area, sq ft, each
608.33
Total filter area, sq ft
11,216.66
Filtration rate, gpm/sq ft, at avg. Daily flow - both filters online
1.42
one filter online
2.85
at peak daily flow - both filters online
3.56
one filter online
7.13
Filter Media: Material Depth Effective Size
Course Sand 9 inches 0.80 to 1.20 mm
�► Silica Sand 5 inches 0.55 to 0.65 mm
Anthracite 6 inches 1.00 to 1.10 mm
Accessories: Filter backwash pumps, traveling bridges, controls, and filter backwash waste
recycle pumps.
per
As the WEF MOP 8, the filtration rate normally used in design of the gravity filters are in
� P J
the range of 2 to 6 gpm/sq ft. As per the Ten State Standards for Wastewater Treatment Facilities,
,.., the design filtration rate at peak flow should not exceed 5.0 gpm/sq ft. Considering the design
filtration rate of the existing filter system and the acceptable design hydraulic loading rates for
tertiary filtration system it is evident that the existing filter system is more than adequate to handle
the design average and peak daily flows at the plant.
4.10 Effluent Disinfection
The effluent disinfection at the plant. consists of UV disinfection and back-up chlorine
disinfection with dechlorination. The design description of the effluent disinfection system is
summarized as follows:
UV Disinfection (Trojan UV 3000 System)
Peak daily flow, mgd 4.75
UV Transmission, percent 65
Filter effluent TSS, mg/L 30
Number of UV Channels 1
-27-
on

Number of UV banks 2
Number of UV modules per bank 13
Total number of UV modules 26
Number of UV lamps per module 8
Total number of lamps 208
I
Accessories: Control and instrumentation panel, automatic level controller and portable �e
cleaning tank.
Chlorine Disinfection System (Back-up Only)
�► Chlorine Contact Tanks
Number of tanks 2
Tank volume, gal, each 39,000
Total tank volume, gal 78,000
Hydraulic retention time, min, at 2.5 mgd flow 44.92
�., Chlorine (Sodium Hypochlorite) Feed System
Number of hypochlorite feed pumps 2
Feed pump capacity, gal/hr 7.5
Number of 55 gallon hypochlorite storage container 4
Dechlorination System (Back-up Only)
Number of sodium bisulfite feed pumps 2
Feed pump capacity, gal/day 50
�+ Number of 55 gallon sodium bisulfite container 1
Note: The plant is also equipped with gas chlorine and sulfur dioxide feed equipment for
chlorination and dechlorination, respectively.
Evaluation of the existing UV 3000 system by Trojan Technologies, Inc. indicated that the
existing UV 3000 system was designed using the UV lamps that decayed from 100% to 65%
output after one year. The system was installed in year 1995 and all the UV lamps have been
replaced with the new UV lamps that decay from 100% to 80% output after one (1) year. As per
-28-
M

y
�r►
the Trojan Technologies, Inc. evaluation, the UV system with new lamps will disinfect the peak
.M flow of 6.25 mgd. It should be noted that the system was designed using the 65% UV
transmission and 30 mg/L TSS concentration in the filter effluent. The filter effluent at the plant
has a UV transmission in the range of 70 to 75 percent and an average TSS concentration of <5.0
mg/L which indicates that the UV disinfection system will be more than adequate to disinfect the
peak flow at the plant.
The chlorine disinfection and dechlorination facilities are provided at the plant for standby and
emergency use only and are more than adequate to provide disinfection and dechlorination needs
of the effluent discharge.
�., 4.11 Evaluation of Sludge Handling Facilities
1. Estimate of Sludge Quantity
a. Design Considerations
Average daily flow = 2.5 mgd
B OD5 : Influent = 230 mg/L; Effluent = 5.0 mg/L
Sludge produced in activated sludge system = 0.75 lb solids/lb BODR
Sludge produced in Chemical P removal = 17.415 mg/L
�+ Percent solids in waste sludge = 0.8 percent
Specific gravity of the waste activated sludge = 1.02
b. Waste Sludge Production
1. Waste Activated Sludge
Sludge quantity, lb/day:
_ (230 -5) mg/L BODS x 8.34 x 2.5 mgd x 0.75 lb solids
lb B OD R
M"
= 3518 lb solids/day vl
2. Chemical Phosphorus Removal (Polishing) Sludge
fm Chemical sludge quantity, lb/day
= 17.415 mg/L x 8.34 x 2.5 mgd
-29-

Oft
-e
= 363 lb solids/day
3. Total Sludge Production, lb/day
= 3518 + 363
= 3881 lb solids/day
4. Total Sludge Volume, gal/day
3881 lb /day
8.34 x 1.02 x 0.008
= 57,000 gal/day
c. Percent Volatile Solids Content in Waste Sludge
out Considering that waste activated sludge contain 80% volatile solids and the chemical
phosphorus removal sludge contain 80% volatile solids and the chemical
phosphorus removal sludge contain 5% volatile solids, the percent volatile solids, the
percent volatile solids in the combined sludge is:
% volatile solids = (80 x 3512) + (5 x 363 )
3518 + 363
In
MM
73%
2. Rotary Drum Sludge Thickening
The waste activated sludge at the plant is thickened by a rotary sludge thickener
manufactured by Parkson Corporation. The design description of the sludge thickener is
summarized as follows:
Number of thickeners 1
Thickener capacity, gpm, at 0.7 to 1.0 percent feed solids 75 to 95
Thickened solids concentration, percent 3.5 to 5.0
Accessories: polymer feed system, flocculation tank, washwater supply and controls.
Evaluation of the Rotary Drum Sludge Thickening
a. Design Considerations
Sludge Quantity = 3,881 lb/day
57,000 gal/day at 0.8% solids
Operation Schedule = 8 hrs/day, 5 days/wk
Polymer Dose = 6 to 8 lb polymer/dry ton of solids
-30-
no

a�q
Thickened solids concentration = 4.0 Percent
b. Sludge Loading to Rotary Drum Thickener
Considering 57,000 gal/day sludge production and thickener operating schedule of
8 hrs/day, 5 days/wk, the sludge loading to the rotary drum thickener is:
Sludge Loading, gpm — 57,000 gal / day x 7 day / wk
8 hr / day x 5 day I wk x 60 min / hr
= 166 gpm
c. Required Rotary Drum Thickener Size
The existing rotary drum sludge thickener has a design capacity of 75 gpm at 1.0
percent feed solids concentration. The solids loading capacity is 375 lb dry
solids/hr. The equivalent thickener capacity at 0.8 percent solids is approximately 93
gpm. This indicates that for 8 hrs/day, 5 days/wk operation schedule, additional
rotary drum thickener capacity of 166 - 93 = 73 gpm will be required to handle the
design sludge thickening need.
If no addition to the thickener capacity is considered, then the existing 93 capacity
thickener will be required to operate at the following hours/day on 5 days/wk basis:
Thickener operation, hr/day = 57000 gal / day x 7 day / wk
93 gpm x 5 day / wk x 60 min / hr g
�► = 14.3 hours/day �1VD
From the above, it can be seen that by extending the operating hours of the sludge��
thickening operation, no additional thickener capacity is required to handle the
sludge production at a design average flow of 2.5 mgd. It should be noted that the
waste activated sludge can also be discharged directly to the existing sludge
stabilization/holding tanks. The Town is also planning to provide one additional 250
gpm thickener for which the plans and specifications for submittal to the State are
being prepared at the present time.
3. Sludge Stabilization/Storage Tanks
The plant includes one 90,000 gallon capacity and another 360,000 gallon capacity
sludge stabilization/storage tank. The 90,000 gallon tank is equipped with a 5 hp floating
mixer and a 220 SCFM diffused aeration system. The 360,000 gallon tank is equipped
with a 30 hp floating mixer and 1,100 diffused aeration capacity. Considering a
discharge of 11,295 gal/day thickened (4%) sludge from the thickener to the sludge
stabilization/storage tanks the total hydraulic sludge retention time provided by the tanks
is 39.84 days which is more than adequate to meet the 30-day storage requirement by the
State regulations for land application of residuals. Please note that the Town is also in the
process of providing one additional 360,000 gallon capacity sludge stabilization/storage
r•► tank for which plans and specifications are being prepared for submittal to the State.
Oft
-31-
M

+4 c
am
4. Sludge Drying Beds
The plant includes nine (9) - 97' x 20', each , sludge drying beds providing total bed
area of 17,460 sq. ft. The beds are used only in emergencies when sludge disposal needs
warrant the use of the sludge drying beds for dewatering. The dewaeered sludge from the
beds is normally disposed of at Johnston County's landfill and Waste Industries
Sampson County landfill.
0" 5. Sludge Disposal
The current practices of sludge disposal by the Town include: (1) land application of
stabilized sludge using private contractors (East Coast Resources - Permit No.
WQ0000506 and Granville Farms - Permit No. WQ0004801) in accordance with
requirements set forth in the State and EPA 503 sludge regulations and the Non -
Discharge Permits, (2) sludge dewatering, composting and disposal using McGill
Environmental Services, (Permit No. WQ0006816) and (3) dewatering and disposal at
Johnston County's and Waste Industries Sampson County landfills, using private
contractors(s).
For disposal of sludge by application, the Town will comply with the Pollutant Limits,
Pathogen Reduction, Vector Attraction Reduction, General Requirements and
Management Practices, and frequency of monitoring, record keeping, and reporting
requirements contained in the EPA 503 sludge regulations and the Non -Discharge
Permits for land application of sludge.
Class B Pathogen Reduction: Compliance with the Class B pathogen reduction is
achieved by using one of the following alternatives: Alternative 1 - Monitoring of Fecal
Coliform [503.32 9b) (2)] or Alternative 2 - Use of Lime Stabilization PSRPS [503.32
(b) (3)]•
Class A Pathogen Reduction: Compliance with Class A pathogen reduction is
achieved by using Alternative 5 - Use of composting PFRP [503.22 (a) (7)]. It should be
noted that McGill Environmental Service, one of the Town's sludge disposal contractors
use Alternative 5 for complying with Class A Pathogen reduction requirements.
Vector Attraction Reduction: Compliance with the Vector Attraction Reduction for
land application of sludge is achieved by using one of the following options: Option 1 -
Reduction of Volatile Solids Content [503.33 (b) (1)], Option 3 - additional Digestion of
Aerobically Digested Sludge [503.33 (b) (1)], Option 5 - Aerobic Processes
""► (composting) at greater than 40 °C 503.33 (b) (5)], Option 6 - Additional of Alkali
[503.33 (b) (6)] , Option 9 - Injection [503.33 (b) (9)], or Option 10 -Incorporation of
Sludge into Soil [503.33 (b) (10)]. The Town has primarily used Option 5, Option 6,
Option 9 and Option 10 for compliance with the vector attraction reduction requirements.
ran
am
om
-32-
va

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Pump Station
M-
a gnesium
Hydroxide
Grit Removal
Feed or
Sodium
Hydroxide
-b -f-
Mechanical
Screen
Influent
Legend
Wastewater / Effluent
- - - -
Sludge
-- -- -
Scum
—m—
Magnesium Hydroxide Feed
A—
Alum Feed
Polymer Feed
P.S.
Pump Station
D.B.
Distribution Box
Ox. Basin No. 2 (1.15 MG)
-
O
O
D.B. P.S. /
Alum Feed -
Polymer Feed -P-/
D.B.
--� P.S/.Pj-/,
scum-A,ji
Clarifier a ,"Clarifier
No.1 No. 2--
1
1 O
I
I I
I O I
I _
I 1
I
I Ox. Basin No.1 (0.75 .75 MG) �- Sludge Recirc. P.S.
�------ - - -- t- I
Scum Waste to � - -1- _
Aerobic Digester �- - - - - - -
Waste Sludge to Sludge Recirc./Waste
Thickener /
Aerobic Digester UV Disinf /
Chlorination -
Dechlorination
Exhibit 1
Schematic Flow Diagram of Alternative 1
Clayton LCWRF Upgrading and Expansion to 2.5 mgd
II
�-
P.S.�Drain
.— I
Clarifier
No. 3
Tertiary
Filters
2.5 mgd to Neuse River
Eff. Pump Sta.

[Fwd: Clayton]/fyi
Subject: [Fwd: Clayton]/fyi
Date: Tue, 04 Mar 2003 16:53:57 -0500
From: Susan A Wilson <[e-mail]>
Organization: NC DENR DWQ
To: Dave Goodrich <[e-mail]>,
Ken Schuster <[e-mail]>, Paul Clark <[e-mail]>
In case you get calls - they neglected to submit all calculations for
all components for this re -rating. They only submitted calculations for
the BOD5/NH3-N removal (which appear to be OK). I think this has
happened because they switched consultants and Wooten didn't work on
some of the previous modifications to the plant. But, I think this is
very bad because I stated in 2 correspondences that they would have to
provide complete calculations for this re -rating.
Subject: Clayton
Date: Tue, 04 Mar 2003 16:50:14 -0500
From: Susan A Wilson <[e-mail]>
Organization: NC DENR DWQ
To: Shankar Mstry <smistry @TheWootenCompany.com>
Shankar-
Well, I've got good news and bad news. Here's the good news: we should be able to issue the permit soon
and get it out to them (Mike T says he has resolved the issues with EPA). I'm hoping to get it finalized by
the end of the week.
The bad news is I have problems with the re -rating and Authorization to Operate. This is not directed at
you Shankar, as I am well aware that you guys inherited this project and another consulting firm worked on
pieces/parts of it before. I'm fine with the calculations you submitted with regard to the BOD5/NH3-N
removal (although I do have a couple of questions) - but for the most part I'm confident we'll work through
that piece just fine.
The Town of Clayton was informed in correspondence dated 7/10/00 (speculative limits), as well as in
correspondence dated 5/24/01 (Authorization to Construct) that DWQ needed to have all calculations
associated with the re -rating to 2.5 MGD submitted when the time came. Although we did permit
construction of many components in the ATC issued 5/24/01, we notified the Town that calculations must
still be submitted to ensure that limits and hydraulic requirements could be met at the 2.5 MGD flow (all
of this correspondence was copied to their consultant as well). We also notified the Town that they built
all components at risk - that the components approved, were only approved for the flow of 1.9 MGD (since
there was not even a draft out for 2.5 MGD).
Bottom line - I need to see calculations to ensure that all components can meet the requirements (both
hydraulically and for limits compliance) for 2.5 MGD in order to issue the Authorization to Operate. This
means pump capacities, clarifier overflow rates, etc. (although some of that appears to be given in the
document), tertiary filter loading, disinfection detention times/UV requirements, etc., assurances that
current residuals capacity is sufficient (and if not - what the schedule will be for increasing residuals
management), etc., etc.
Re -ratings are not easy to deal with - but I had hoped through all the correspondence that we had with the
1 of 2 3/4/03 4:54 PM

[Fwd: Clayton]/fyi
Town and their former(?) consultants that we could have run through it fairly quickly. In addition to the
correspondence, this was also discussed in the meeting between the Town, DWQ, and their consultants on
4/25/01.
Give me a call if you'd like to discuss this (733-5083, ext. 510). I'll need to send out a formalized
additional information letter. Just wanted to give you a heads -up. Thanks.
Susan
2 of 2 3/4/03 4:54 PM

S t.?:'. 2000 4:20PM PETE DUTY & ASSOCIATES No.4110 P- 112
Pete Duty and Associates
311 Howard Street Durham NC 27704 [phone] fax[phone]
Date: Monday, September 25, 2000
Fax To: Shankar Mistry
The Wooten Co
Phone: [phone]
Fax: [phone]
From: David Duty
Phone: [phone]
Fax: [phone]
Pages:
Subject: Clayton
Attached is the information on the present Clayton UV system as requested.
The present system was designed for 4.75NIGD but with lamp improvements
is now capable of treating to 6.25MGD.
EDI is working on a couple layouts for the digester. Should have that
tomorrow. I will send a catalogue and brochure information out right away.
Thanx, DD
.1�

. t
Trojan T8chnalogies inc.
World Leader In UV Disinfection Systems
25. 2000'* 4:20PM'PETE DUTY & ASSOCIATES ;,7y q
No•4115
P • 2/2' " '
FAX
To; David Duty of PETE DUTY Si ASSOCIATES, INC. Number of pages including coversheet 1
Fmc 030
From: Todd Bard9 t
E4nai1: tbaMett(orojanuvz rn
Date: 9/25/00
Res Clayton, NC
❑ Urgent For Your Infonnaffim ❑ Please Comn=ent
David,
As requested, I have looked into what was sold to Clayton, NC. It was a W3000M designed as follows:
• Peak Flow: 4.75 MGD
• Avg. Flow. 1.9 MGD
• tom: 65°%
• TSS: 30 mg/L
• No. of Channels: 1
• No. of Banks: 2
• No. of Modules: 26 (13 per bank)
• No. of Lamps/Module:8
• Total No. of Lamps: 208
The O&M costs that were given back on December 20,1996 were:
• Annual Power Costs: $3,981
• Annual Lamp Replacement Costs: $7,131
The UV3000TMm system designed for Clayton, NC was based on a previous version of the UV30007m lamp.
This old lamp decayed from 100% to 650% output after one (1) year. The newest version of the UV3000TM
lamp will only decay from 100% to 80°% output after one 1
peak flow, thesystemt )Year. if the plant is looking to increase the
system will be able t dis fe�i�� and purchase �e new lamps. With the new lamp, the existing
a peak flow of 6.25 MGD.
If you have any questions, please do not hesitate to call.
Cheers,
Todd Bartl
Please visit us at WEFTEC 2000 In Anaheim, C81000310 - October 15 -18, 2000 - Booth # 2245.
3020 Gore Road. London, Ontario Canada N5V 4T7 • Tel. [phone] *Far (5191467-3030 • www.bvjanuVXM

Re: Clayton standby power
1 ,
Subject: Re: Clayton standby power
Date: Fri, 28 Mar 2003 14:41:51 -0500
From: Shankar Mistry <smistry @TheWootenCompany.com>
To: Susan A Wilson <susan.a.wilson @ncmail.net>
CC: Charlie Davis <[e-mail]>
Susan:
We sincerely appreciate your assistance provided in this matter.
Shankar
On Friday, March 28, 2003, at 12:15 PM, Susan A Wilson wrote:
> No problem with moving forward with the standby power for Clayton; you
> may let the contractor proceed - as far as WQ is concerned. .(Got the
> OK
> from Ken Schuster, WQ Supervisor, and Ted Cashion, Environmental
> Chemist, at the RRO, as well).
> We'll just wrap it in to the ATO.
> Thanks for keeping us informed.
1 of 1 3/31/03 11:04 AM

A;"r-08-2003 09:05 From -THE WOOTEN COMPANY 919-834-3589
April 8, 2002
I
THE
WOOTEN Ms. Susan Wilson
Point Source Branch
COMOANY NC Division of WaterQualtiy/NPDES UNIT
1 1617 Mail Service Center
E N G I N E F, R I N G Raleigh, North Carolina 27699-1617
P L A N NISI N G Re: Authorization to Operate
Clayton Little Creek WRF
A R C H I T E T u n E NPDES Permit No. NC 0025453
Wake County
TWC No. 2756
Dear Ms. Wilson:
I
120 North Boylan Avenue
Raleigh NC 27P03-1423
919.82B, 1531
fax [phone]
1
T-035 0.001/002 F-105
Attached please find the corrected page 16 of the Supporting Calculations
for Authorization to operate the Expanded 2.5 MGD LCWRF, Clayton,
North Carolina.
Thanks for yourthorough review and assistance provided in this matter.
Sincerely,
THE WOOTEN COMPANY
Shankar R. Mistry, Ph.D., P.E.
PLF43r, 1'0CR RD TNF
FAA[1ICIL 4tim
FAx uaVi 'MIL
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A,00r-08-2003 09 :0 6
I
From -THE WOOTEN COMPANY
919-834-3589 T-035 P.002/002 F-105
r, Toial (hrygcu RrgpirCmcat
2774 1453
- 300 1L 6ji-,
- 151.25 lb 02/hr.
d. Acaailua'lux aclnrwca Rcgaltcutvtti
rur un nr rrrjjnu rn nnr�rin purr un nrr luvrrrp... rnrn.nrwn u......pl..'a l'.:gl'ullUll lu
GM111n ticU = IU11U W 5.
C
SOR=AIR s
(� C SIN- Cp) (8) T-20 x ot
Vr'Iwl�. hbR-h�r.ual vnyg�u al.yuLl,un;ul - 291.n lU O:/In
Cx = ^xytW n xaulr'ndun vuluc UI Clean waver m stmdara cotlairiti p.. —
R = Ratio of oxygen saturation value of waste to that of clean water = 0.95
1''41N � Ilvpgrn 1nmrftlnn valet` At rloTn vrTtrr rnr rho We rnnriirinnr if
't'nn glen a l It'll W V. .9 P. and nrfnnt }nrlrvlmr frir prr wilirp (rrn —I A S7r. l.ii rr)
7.76 mg/L.
Co = Residual concentration of dissolved oxygen desired during normal
operation = 2.0 mg/L.
a - Ratio of onygon teasafor iu v.+onto Oa lkut of algal+ a AUX at d1., ss ....
tamparatura - 0.2
T = Design temperature = 28° C
0 = Temperature correction constant =1.024
I
SOR = 151.25
9.092
(0.95 x 7.76 — 2.0) (1.024)28-20 x 0.8
1375
5.195
= 264.7 lb 0whr
Considering 3.5 lb 02/hpft standard oxygen transfer rate of the E MCO platform
mounted aerator. the required horsepower is:
21CAU A 02/hr
3.5lb02/hp/9
= 75.63 hp
-16-

Re: [Fwd: typo]
Subject: Re: [Fwd: typo]
Date: Tue, 8 Apr 2003 10:16:37 -0400
From: Shankar Mistry <[e-mail]>
To: Susan A Wilson <[e-mail]>
Susan:
I have talked with the Town and effective May 1, 2003 is O.K. with the
Town for Authorization to operate 2.5 mgd Plant.
I have put three copies of the corrected page 16 in mail. Also I have
faxed you the same.
Please use my second fax I send you to day which also includes the
correction to the equation for SOR. Again I sincerely appreciate your
help.
Shankar
On Monday, April 7, 2003, at 04:41 PM, Susan A Wilson wrote:
> That would be great - just the corrected sheet is fine.
> Shankar Mistry wrote:
>> Susan:
>> Thanks for bringing to my attention the typo error. I have corrected
>> the error and if it is o.k. with you then I will fax You the corrected
>> page 16 . if you need revised repot for the calculations , please let
>> me know.
>> I appreciate your reviewing the calculations.
>> Shankar
>> On Monday, April 7, 2003, at 03:51 PM, Susan A Wilson wrote:
>>> I mispoke - since this is an Authorization to Operate - they'll not
>>> be
>>> getting plans/specs - only stamped approval of the calcs.
>>> From: Susan A Wilson <[e-mail]>
>>> Date: Mon Apr 7, 2003 3:27:37 PM US/Eastern
>>> To: Shankar Mistry <[e-mail]>
>>> Subject: typo
>>> Shankar -
>>> Found a typo in the calcs (you may want to correct) . On p . 16 at the
>>> bottom - the required horsepower is correct - but the SOR is
>>> incorrect
>>> (should be 264.7 lb 021hr) . I'll just mark and initial in the copy
>>> s en t
>>> back with the plans/specs.
>>> Of course, I was racking my brain trying to figure out how you got
>>> that
>>> no. for awhile, then I turned a few pages further and figured it out.
>>> (amazing - we really do look at these calcs).
I of 2 4/8/03 10:15 AM

Clayton ATO calculations
t
q 6.0 MdU i
s
Subject: Clayton ATO calculations
Date: Tue, 15 Apr 2003 14:05:57 -0400
From: Paul Clark <[e-mail]>
To: Susan A Wilson <[e-mail]>
Susan,
Hey, I had a chance to quickly review Clayton package. It is a thorough
document. Go ahead and issue. Do you need a staff report from me?
thanks.
paul
Kc' l )AFL �F1 c c
Co/UM&J 75
1 of 1 4/15/03 3:00 PM

ATC PROCESSING
PUBLIC INFO. ASSIST.
CHECK LIST
SCOPE of Project: Le
1-14
Facility:
NPDES No.:
ATC No.:
J 6� - (f
❑ Pull existing permit, (is this action allowed?):
• Will this activity require a change notice to compliance?
❑ Point Assignment: Z0
SUBMITTAL:
Letter of Request from the Permittee
(3) Plans, Specifications and Design Calculations
* signed & sealed by NC PE ?
* three sets of each?
ACTION:
rejection (reason):
hold for:
✓ accept (date):
ee,k tutu-w
YES NO
LOG IN A DISPERSAL (Once package is complete):
L/Log on BIMS / determine the ATC number/ create and print out tracking slip
✓Log on the Units' ATC data base
✓Create and send acknowledge letter (date sent):
* to permittee/consultant/NPDES file U
`Request Staff Report from Regional Office sent on: j U
(assemble the following and mail by courier to the appropriate RO):
* copy of the acknowledgment letter (highlight RO),
* copy of the request letter,
* copy of submittal package (plans, specs and calculations),
ASSIGNED:
L/ V �� reviewer: T date: 1 �%
ATC process 8127198

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�1�3�03

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
January 31, 2003
Mr. Steven Biggs
Town of Clayton
P.O. Box 879
Clayton, North Carolina 27520
1, •�'
�r
�vvrr• r
NCDENR
Subject: ATC Request Acknowledgment
NPDES Permit NCO025453
ATC Number 025453A02
Little Creek WWTP
Johnston County
Dear Mr. Biggs:
The Division of Water Quality's NPDES Unit hereby acknowledges receipt of your request for
Authorization to Operate in accordance with NPDES Permit Number NC0025453. This
application has been assigned the number highlighted above.
Please be aware that the Division's regional office, copied below, must provide recommendations
from the Regional Supervisor prior to final action by the Division.
The ATC review process generally takes 90 days from the date your complete submittal is
received, however, due to current staff shortages that review period may take longer. Should any
additional information be required, the review engineer will contact you. If you have any
questions, please contact Ms. Susan Wilson at [phone], extension 510.
PLEASE REFER TO THE ABOVE APPLICATION NUMBER WHEN MAKING ANY
INQUIRIES ABOUT THIS APPLICATION.
Sincerely,
David A. Goodrich
Supervisor, NPDES Unit
cc: Raleigh Regional Office
NPDES Unit Permit File
Mr. Shankar R. Mistry, Ph.D., P.E. —The Wooten Company
120 N. Boylan Avenue
Raleigh, NC 27603
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper