NC0088781_NPDES Permit Renewal_20110815

North Carolina Department of Environment and Natural Resources
Division of Water Quality V .a
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
August 15, 2011
DON BETZ
EXECUTIVE DIRECTOR
LOWER CAPE FEAR WATER AND SEWER AUTHORITY
1107 NEW POINT.BLVD, SUT.CE 17
LELAND NC 28451
Subject: Receipt of permit renewal application
NPDES Permit NC0088781
Bladen Bluffs Regional Surface WTP
Bladen County
Dear Mr. Betz:
The NPDES Unit received your permit renewal application on August 15, 2011. A member of the NPDES
Unit will review your application. They will contact you if additional information is required to complete your ,
permit renewal. You should expect to receive a draft permit approximately 30-45 days before your existing permit
expires.
If you have any additional questions concerning renewal of the subject permit, please contact Bob Sledge at
[phone].
Sincerely,
zatizu,40,LIA,
Dina Sprinkle
Point Source Branch
cc:. CENTRAL FILES
FayettevilleRegional^Office.Surface Water Protection
NPDES Unit
Kelly R. Boone, P.E., Camp Dresser & McKee, 5400 Glenwood Avenue, Suite 300, Raleigh, NC 27612
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] t Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity \ Affirmative Action Employer
NorthCarolina
Nat rally

5400 Glenwood Avenue, Suite 300
Raleigh, North Carolina 27612
tel: [phone]
fax: [phone]
August 11, 2011
Mrs. Dina Sprinkle
North. Carolina Department of Environment and Natural Resources
Division of Water Quality, Point Source Branch
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Subject: Lower Cape Fear Water and Sewer Authority (LCFWASA)
Bladen Bluffs Regional Surface Water Treatment Plant
• NPDES Permit No. NC0088781 (Bladen County) - Application for Permit Renewal
Dear Mrs. Sprinkle:
The Lower Cape Fear. Water_andSewer Authority requests renewal of NPDES Permit
NC0088781-allowing discharge of decant from the reclamation basins at the Bladen Bluffs
Regional Surface Water Treatment Plant (WTP). Enclosed please find an original and two copies
- of an application (Short Form C - WTP) to renew the permit. A narrative description of the
sludge management plan is included on the application form (Item 8, paragraph 4, pages 5-6).
The currently. authorized NDPES Perrnit (NC0088781) allows discharge of decant from the
reclamation basins to a, ditch on the WTP site. The reclamation basins will receive sedimentation
basin sludge and filter backwash water. The basins will allow for clarification of backwash
waterand handling of filtered and settled solids. Construction of the Bladen Bluffs Regional
Surface:WTP is -currently ongoing and is expected to be completed in spring 2012. Discharges
authorized _under the permit have not begun but are expected to begin in early 2012.
Please call me at (919) .325-3508 if you have any questions. Thank you for your assistance.
Very truly yours,
Kelly R. Boone, P.E.
Camp Dresser & McKee
E R@EIME
AUG 15 2011
DENR-WATEP QUALITY
POINT SOURCE BRANCH
Enclosures: - Short Form C - WTP including sludge management plan (pg. 5-6 of application)
USGS Topographic Map
= Drawing M-1: Hydraulic Profile and Flow Schematic for WTP
cc: Don Betz, LCFWASA
File 360 (46227-57217)
consulting • engineering • construction • operations

.NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
Mail the complete application to:
• N. C. Department of Environment and Natural Resources
• Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number
NC0088781
. .1f you are completing -.this form in.computer use the TAB key or the up - down arrows to move from one
field to the next: To check the:boxes, click your mouse on top of the box. Otherwise, please print or type.
1. Contact Information:
-Owner Name
_ • .
Facility Name
_ .
. Mailing Address
City
. _
State / Zip Code
Lower Cape Fear Water and Sewer Authority
Bladen Bluffs Regional Surface Water Treatment Plant
1107 New Pointe Boulevard, Suite 17
Leland
NC / 28451
Telephone Number [phone]
Fax Number [phone]
e-mail Address [e-mail]
2. Location of facility producing discharge:
Check here if same as above
Street Address or State Road
City Tar Heel
State / Zip Code
County
17014 NC 87 Hightway W
NC / 28392
Bladen
3; Operator Information:
Nameof the firm, consultant -onother.entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name
Mailing Address
City
Lower Cape Fear Water and Sewer Authority
1107 New Pointe Boulevard, Suite 17
Leland
1= 7
State / Zip Code NC / 28451
Telephone Number [phone]
Fax Number
4. Ownership Status:
[phone]
AU 15 1011
DENR-I/VAIEe,. QUAL TY
POINT SOURCE BRANCH
Page 1 of 7 C-WTP 03/05

.NPOES: PERMIT APPLICATION - SHORT FORM C -. WTP
For discharges associated with water treatment plants
Federal ❑ _ State ❑ Private ❑ Public El
5. Type of treatment plant:
. Conventional (Includes coagulation, flocculation, and sedimentation, usually followed by
filtration and disinfection)
❑" Ion Exchange (Sodium Cycle Cationic ion exchange)
❑ Green Sand Filter (No sodium recharge)
❑ . Membrane Technology (RO, nanofiltration)
Check here if the treatment process also uses a water softener
:6. - Description of source water(s) (i.e. groundwater, surface water)
Cape Fear River
Describe the treatment process(es) for the raw water:
Tie recommended treatment process for the Bladen Bluffs Regional Surface WTP is based
.on -conventional treatment. Principal plant features include:
- Rapid Mix
Two rapid:mix basins will be -provided. Provisions will be made for feeding ferric or alum
coagulant,•polymer, and --caustic to the rapid mix chambers. The rapid mix chambers will
each be -5 feet x "5 -feet x 8.2 feet water depth, with a detention time of 30 to 20 seconds
:;each at_a plant "flow rate -of 4.4 to 6 mgd. Two chambers are provided in series to allow
the flexibility: of adding coagulant chemicals at separate locations. Design power input as
defined;by. G-value will be about 1000/second at 68°F in the mixing. zone.
- Flocculation
-'l''o:trains of four -stage flocculators will be provided. Each flocculation_ basin will be
:about_10.5;feet.long and 10;5 feet wide per compartment with four equal compartments,
-==and will have an .approximate.-13 foot side water depth at design flow. A baffle .wail will
Separate -each flocculation stage. Each compartment will be equipped with a vertical
floccolator of the -turbine type driven by a variable frequency drive (VFD). Maximum
:water .power. -input; as defined by G-value will be approximately 80/second. The four
- :'compartmentswill allow for tapered flocculation, which will allow for optimization of the
flocculation :process. It is estimated that average energy input will be approximately
equal to a G-value of 20/second to 40/second. The VFDs for the flocculators will be of the
variable frequency type for. optimum efficiency. Flocculation detention time is about 30
to 20 minutes in the basins at 4.4 to 6 mgd. -
- Sedimentation .
Twit) :sedimentation basins will be provided. The basins will have approximately 15 foot
-average" side-water-depth_at design flow. The total tank volume -will provide for a
detention time of"4.0 hours at 4.4 mgd to 6.0 mgd.
- Sludge•wili be --manually or automatically withdrawn through the use of telescopic valves
to a_viewbox; ""which will allow -the operators to visually monitor the sludge consistency "
in order to determine the- length of time for sludge removal and minimize discharge of
clean water. -
Water will flow "from • each sedimentation basin into a filter influent flume. Provisions
,will be-aaadetofeed chlorine, caustic, and polymer into the filter' influent.
- Filtration
z-.Four .filters 'will be, provided, each having a design capacity of 1.5 mgd. Each filter cell
Page 2 of 7 C-WTP 03/05

,NPDES PERMIT APPLIICATION - SHORT- FORM C :- WTP
For discharges associated with water treatment plants
will_be_21.75.feet-x.12 fee;,having an area of 261 sf and a filtering rate of 4.0 gpm/sf.
The filters._will :be equipped With air water backwash, wastewatertroughs, sand, and GAC.
or anthracite media.
Settledwater: enters the filter from the filter influent channel through an influent valve,
flows into the inlet and backwash trough ports, and from the troughsis distributed over
the: filter bed. The filters will initially be rated at 4 gpm/sf, but will be hydraulically
capable of up to 6.0 gpm/sf.
The filters_are- designed with one effluent flow controller per falter, consisting of a venturi
type flow meter.and an electrically operated butterfly control valve. The rate of flow
through -each -filter will be manually set with option for level control to match raw .water
flow: using a single rate -set load station. Controls will be electronic with electric valve
operators:. All filter operations will be from a local control panel at each filter with flows,
head -losses, turbidity, and particle counts transmittedto the main
control panel for supervisory control.
- Backwash System.
Finished._water.from the Smithfield Packing Company (SPC)°s elearwell will be piped back
to thefilters for backwashing.- This water will flow through the wastewater header in the
:pipe -gallery to the filter gullet, -through the underdrain, and up through the filter media.
A:blower_ and:air piping will be provided to allow air/water bed expansion and
backwashing: This system is designed to wash one filter-at.a time. The backwash water
.will flow into the backwash troughs located above the expanded filter bed and into the
wasteloackwash water collection channel. From there the backwash water flows to the
residuals basins: If clearwell:level is low, the transfer pumps can be valved to pump the
backwash water from the SPC clearwells.
. Describe the wastewater andthe treatment process(es) for wastewater generated by the
facility:
1. Residual Sources
Provision- of -adequate residuals handling facilities and proper residuals management is
critical- to •the `successful. operation of a water treatment plant (WTP). The major sources
of residuals at _the'Bladen Bluffs Regional Surface WTP `include the sedimentation sludge
and spent filter backwash water. Suspended matter, color, and other, impurities in the .
-Train water are removed mostly during the coagulation,/clarification process, A small
.. amount of these=residuals not removed in the sedimentation basins is removed in the
"fiiters,::and the, solids are -subsequently removed in the spent filter backwash water.
2. Residuals Quantity .
The quantity of residuals produced by the plant depends on the raw water quality and the
chemicals used to treat theeraw water. Knowledge of water chemistry and extensive
experience at operating other -treatment plants has shown that a relationship exists
between these factors that can be used to predict the amount of residual solids produced.
By far; the: majority" .of residuals produced in the plant come from the coagulation process..
Other additives,such aspolymer; and powdered activated carbon (PAC) can be assumed to
produce amounts of residuals equivalent to the dosages added to the water. Suspended
solids also produce an equivalent weight of residuals, as they are non -reactive. Iron and
manganese: (including manganese from permanganate) are oxidized in the treatment
plant and are removed" in the oxidized precipitate form. Therefore, then equation used to
calculate the amount of solids produced is: - -
S = 8.34 * Q (0.53C + SS + A +1.9Fe +1.58 Mn)
Where the parameter values used for calculations include,
S . • - = solids produced (lb/day)
(1)
Page 3 of 7 . C-WTP 03/05

:. NPDES PERMIT APPLICATTION - SHORT FORM C. = WTP
For discharges associated with water treatment plants :
= average plant flow (mgd), 3.3 mgd -
= average coagulant dose, 60 mg/L-Fe2(SO4)3
= average raw water suspended solids (nig/L)
b*Tu,•where b :constant, assume 1;5 and Tu = average raw water turbidity
- in nephelometric turbidity units (NTU)
42 mg/L
=.A - additional: chemicals added (mg/L), 2 yang/L for estimated annual average
-Fe, average .raw water iron concentration (mg/L), 0.90 mg/L
Mn- _ . 'average raw water manganese concentration (mg/L), 0.1 mg/L
--The raw-water:suspended solids can be estimated from the -raw water turbidity:
SS (mg/L) = b* Tu as shown above. -
;The correlation--factor.betWeeu turbidity and suspended-solids'may'vary from 0.7 to 2.2
and. may seasonally vary -for the same raw water supply; Since no suspended solids data •
were available;' the ,value: of b was assumed to be 1.5 for the purpose of estimating the
residuals quantity.
-_ Using equation (1) and the above parameter values, 8 =. 2,138 dry lb/day.
:Based.on'our. experience -from -other treatment plants, roughly 90 percent of the solids
produced :will end up in the sedimentation sludge. The rest will be collected in the spent
filter, backwash- water: Table-1 provides a summary of estimated sedimentation residuals
quantities under current and future flow conditions. Anaverage flow of 6.6 aigd allows
, _fordoubling of the plant flow to 8.8 mgd daily maximum capacity. -
Table 1
Summary of Sedimentation Sludge. Quantities (based on 90 percent of the solids being in
the sedimentation sludge at a concentration of 0.5 percent solids)
Average Daily Plant Flow (mgd) 3.3 6.6
Solids (1b/day) 1,924 3,848
Volume (gpd) 46,000 92,000
The_quantityof filter.: backwash water produced is a function of filter to waste run time -
and the amount- of water used in backwashing. Based on our experience with other
_treat .ent plants, °approximately. 86,000 gallons of water will be produced in each niter of
;the size _proposed .while backwashing typically, though this number can vary. The
calculated backWash}volume.is based on a maximum backwash rate of 22 gpai/sf for 15
minutes .duration. in -addition, approximately 31,000 gallons of filter -to -waste will be
discharged per filter backwash at an average plant flow of 3.3 mgd before putting the
filters -back -into service,. assuming 30 minutes of filter -to -waste per backwash at 4 gpm/sf
falter -rate. -:Table 2 summarizes the estimated average quantity of backwash water
produced for-;.current:and.future flow conditions; It is'assumed=that• twofilters at 4.4
mgd and four filters at 6.6 mgd will be backwashed each day.
Table 2
= Summary of Estimated Average Spent Filter Backwash Water Quantity
Average Daily Plant Flow (mgd) 3.3 6.6 --
Total. Number of Filters - 3 Up to 6
No. of Filters Backwashed 2 4
Backwash Volume (gpd) 172,000 344,000
Filter -to -Waste (gpd) 62,000 124,000
Average Daily Total (gpd) 234,000 468,000
3. Waste. Characteristics
Page4of7
C-WTP 03/05

: NPDES PERMIT APPLICATION - SHORT FORM C - WTP
_ , For discharges associated with water treatment plants _
- The sedimentation solids and spent filter backwash water have significantly different
,characteristicsa Sedimentation sludge is a small flow with high solids concentrations
- • • • typically between 0.5 percent to 2 percent, depending on the raw water quality and
. coagulant conditions a-s _well as the frequency and duration of sludge removal.' We
_ . estimate that roughly 90 percent of the solids generated are removed in the
. - • _ sedimentation basins. Sedimentation basin sludge is removed each day and its removal
- . can be' timed to be proportional to the volume of water treated by each sedimentation
basin.
The approximately 10 percent of the solids not removed in the sedimentation basins will
baremoved by the filters add subsequently removed from the filter media during filter
backwashing. Spent filter backwash water is discharged after each filter backwash.
4. Residuals Handling Approach
The proposed gravity thickener/clarifier and the two -residuals basins will serve to receive
the' sedimentation sludge, washwater from the sedimentation basins, and filter backwash
waste at the Maden Bluffs Reennal Surface WTP. The residuals basins will be used for
storage and as an equalization/clarification basin. In normal operation, backwash water
• _ $and -other high flows would be directed to one basin while the other basin functions as
more of a polishing -basin: When one basin is down for cleaning, the other basin would be
decanted down prior to backwashing so as to capture the backwash and then allow it to
settle before decanting. •
a Putting all thasolids in theresiduals basins appears most cost effective. Once a basin
_ -
reaches 5 percent solids concentration, bidding for contract removal is needed. Decant
from the residuals basins will be pumped using the recycle pump station to the raw water
_ • piping upstreamehe impoundment or flow to a ditch towards the river for discharge in
accordance with the NPDES permit.
- Each of the two residuals basins will ha.ve a capacity of approximately 2.0 MG and a depth
of approximately 7- ft. Each of the basins has been sized to provide approximately 365
days of storage.capacity for an average daily flow rate of up to 3.3 mgd, assuming that no
' - land -application of thickened sludge were to take place on -site.
Various sludge disposal options were considered including disposing 2 to 5 percent
thickened sludge from the residuals basins or gravity thickener by either land application
..orosite, contract hauling and disposal off -site, or contract dewatering and disposal.
The least cost option is currently to put all solids in the residuals basins and to take
-- backwash high flows to one basin first, then to the other basin at lower decanted flow
• rates for polishing. Once a basin is full of sludge, contract sludge removal will occur. In
the long-term, once the plant is expanded or if contract cleaning bids are much higher
_ than currentlsr quoted; the other disposal options can be revisited. Based on the residuals •
_ productioteprojected above, and assuming that the solids concentration of 2 to 5
percent, the estimated residuals basins cleaning frequencies are presented in Table 3.
as:
Table 3
Estimated Residuals Basins Cleaning Frequency -
Average Daily Plant Flow (mgd)
Residuals Volume
Depth of Residuals per year
Estimated Dredging Frequency
3.3
At 5 percent Solids
1.9 MG/year
6 ft
Once every year
At 2 percent Solids
•.;
Page 5 of 7
GAWP 03/05'

:NPDES. PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associatedwith water.treatment plants
Estimated Dredging Frequency Once every 4 months
Note::. Dredging requirements estimated based on reserving the top 2ft of lagoon depth for
proper plant operation.
• Number of separate discharge points: 1
Outfall Identification number(s) 001
10.- Frequency--of-discharge:
Continuous El Intermittent [I
If intermittent:
Days per week discharge occurs: Duration:
11. - Plant design potable flowrate 4.4 (up to 6.0) MGD
Backwash or reject flow 0.9 MGD
,12:...Name,of.receivinag Stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Unnamed tributary to Cape Fear River;
Latitude: N 34° 45' 53 (34.7647)
Longitude: W 78 48' 16" (-78.8044)
See attached figure
:13: :Please list all water: treatment: additives, including cleazzing chemicals or disinfection
treatments, that have the potential to be discharged.
Alum, chorine -(sodium :hypochlorite), caustic soda, polymer, corrosion. inhibitor
(orthophosphate) aqueous ammonia (future), sodium permanganate, powdered
activated carbon, and thiosulfate.
14.. - Is this facility located on Indian country? (check one)
Yes ❑ No El
15. Additional Information:
Page 6 of 7 C-WTP 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
• Provide a schematic_of:flow through the facility, include How volumes at all points in
the treatment:process, and point of addition of chemicals.- .. .
Solids Handling Plan See Item 8, Paragraph 4 "Residuals
Handling Approach" (above)
3.6: - NEW -Applicants
Information needed in addition to items 1-15:
:. * New • applicants must contact a permit coordinator with the NCDENR Customer
Service Center.
.Wasthe Customer Service Center contacted? ❑ Yes ❑ No
See attached drawing M-1
Analyses of source water collected
» Engineering Alternative Analysis
y Discharges from Ion Exchange and Reverse Osmosis plants -shall be evaluated using a
water quality model.
17. Applicant Certification
E. certify that i am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Don Be
ignature of Applicant
Executive Director
Title
North -Caroliina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement -.representation, or cea'dfication in any application, record, report, plan, or other document files or
required to - be _maintained under .Article 21 or regulations of the Environmental Management Commission
implementing that Article, orwho falsifies, - tampers with, or knowingly renders inaccurate any recording or
monitoring device or method: required to be operated or maintained under Article 21 or regulations of the
Environmental Management Coinrnission implementing that Article, shall be guilty of a misdemeanor punishable
by a.fine .not to exceed S25,000, or by imprisonment not to exceed six months, or by both, (18 U.S.C. Section
.1001 provides a.punishment by.a fine of not more than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Page 7 of 7 C-WTP 03/05

Outfall 001
(34.7647, -78.8044)
Bladen Bluffs Regional Surface WTP - NC0088781
USGS Quad Name: Duart
Receiving Stream: UT Cape Fear River
(34.7647, -78.8044)

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LONER CANE FEAR WATER ANSI SEWER AUTHORITY
NORTH CAROLINA
BLADEN BLUFFS REGIONAL
SURFACE WATER TREATMENT PLANT
•
HYDRAULIC PROFILE
&PROCESS SCHEMATIC,
FINN= Ma 014/0 .4320
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SUER N0.
M-1
•
CONFORMED DRAINING - DECEMBER 2009