NC0024538_Permit Issuance_20100611

NPDES DOCIMENT SCANNING COVER SHEET
NC0024538
Shelby / First Broad River WWTP
NPDES Permit:
Document Type-
Permit Issuanc
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Inspection
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
June 11, 2010
This document its printed on reuse paper - ignore arty
content on the reirerse side

Beverly Eaves Perdue
Govemor
Mr. Brad Cornwell, Utilities Director
City of Shelby
P. O. Box 207
Shelby, 28151-0207
ern
MENR
• North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins Dee Freeman
Director Secretary
June 11, 2010
Subject: Issuance of NPDES Permit NC0024538
City of Shelby — First Broad River WWTP
Cleveland County
Dear Mr. Cornwell:
Division personnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued pursuant
to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement
between North Carolina and the U.S. Environmental Protection Agency dated October 15, 2007 (or as
subsequently amended).
This final permit includes the following changes from the draft permit sent to you on March 17, 2010:
• Corrections have been made to the facility description to state there is only one standby power
generator and to remove reference to the sludge incinerator.
The Division is unable to satisfy your request to maintain permit effluent limits for ammonia nitrogen at
the same levels found in the currently active permit. The more stringent ammonia nitrogen limits
established in the attached permit are set at levels necessary to protect the receiving stream from
ammonia toxicity. This in accordance with EPA's 1990 requirement for each delegated state to develop
controls on ammonia as a toxicant. The Division has been setting ammonia limits based on toxicity
since that time. EPA's recent proposals (attached) have the potential to lower the ammonia criteria
further; it would behoove permittees to plan now in order to effectively deal with this eventuality.
In imposing the new ammonia nitrogen limits, the Division is aware of the economic circumstances that
face the City of Shelby and the fact that meeting the new limits will almost certainly require capital
investment in wastewater infrastructure. For this reason, the Division is including a six year compliance
schedule in the peCrmit that should allow the City the time it will need to plan and construct the facilities
necessary to ensure compliance with the new ammonia nitrogen limits.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity \ Affirmative Action Employer
One
NorthCarQlina
7VatmaIIb'

Mr. Brad Cornwell
NC0024538 Permit Renewal
p. 2
Please be aware that this segment of the First Broad River is listed as an impaired stream on North
Carolina's 2008 303(d) list. This means the stream does not meet all water quality standards. Although
non -point sources are believed to be the main contributors to this degradation, should the discharge be
found to cause or contribute to the impairment, the Division may require the facility to take steps to
alleviate the situation.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty
(30) days following receipt of this letter. This request must be in the form of a written petition,
conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of
Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless
such demand is made, this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division may
require modification or revocation and reissuance of the permit. This permit does not affect the legal
requirements to obtain other permits which may be required by the Division of Water Quality or permits
required by the Division of Land Resources, the Coastal Area Management Act or any other Federal or
Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Bob Sledge at telephone number (919)
807-6398 or via e-mail at [e-mail].
Sincerely,
i)
i -,1, t I t..\?4,1(
olcen H. Sullins
cc: Central Files
Mooresville Regional Office/Surface Water Protection Section
NPDES Unit
ec: Aquatic Toxicology Unit
EPA Region 4

.r
•
Permit NC0024538
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
. DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and
the Federal Water Pollution Control Act, as amended, the
City of Shelby
is hereby authorized to discharge wastewater from a facility located at the
First Broad River WWTP
Off NC Highway 18
Southwest of Shelby
Cleveland County
to receiving waters designated as the First Broad River in the Broad River Basin in accordance with effluent
limitations, monitoring requirements, and other conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective August 1, 2010.
This permit and authorization to discharge shall expire at midnight on August 31, 2013.
Signed this day June 11, 2010.
•
44
6been H. Sullins, Director
9'(/ Division of Water Quality
By Authority of the Environmental Management Commission

• Permit NC0024538
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked.
As of this permit issuance, any previously issued permit bearing this number is no longer effective.
Therefore, the exclusive authority to operate and discharge from this facility arises under the permit
conditions, requirements, terms, and provisions included herein.
The City of Shelby
is hereby authorized to:
1. Continue to operate a 6.0 MGD wastewater treatment plant that includes the following:
• bar screen;
• grit removal;
• cylindrical fines screen;
• aeration basin;
• two (2) primary clarifiers;
• two (2) trickling filters;
• four (4) final clarifiers;
• pump stations;
• two chlorinators;
• two sulfonators;
• sludge pump station;
• aerated sludge holding tank;
• two filter belt presses;
• ten bay sludge compost building; and
• standby power generator
These facilities are located at the First Broad River WWTP, off NC Highway 18, southwest of
Shelby in Cleveland County.
2. Discharge from said treatment works at the location specified on the attached map into the First
Broad River, currently classified C waters in the Broad River Basin.

•
Shelby — First Broad River WWTP — NC0024538
USGS Quad Name: Blacksburg North
Receiving Stream: First Broad River
Stream Class: C
Subbasin: Broad - 030804
Lat.: 35°14'32"
Long.: 81°34'31"
North
Permit NC0024538
Not to Scale

•
Permit NC0024538
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - FINAL
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 001. Such discharges shall be limited and monitored by the Pennittee
as specified below:
EFFLUENT
CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
Monthly
_Average
Weekly
Average
Daily
Maximum'
Measurement
Frequency "
S ample Type
Sample Lccation�
Flow
6.0 MGD
Daily
Instantaneous
Influent or Effluent
BOD5, 202C 2
25.0 mg/L
37.5 mg/L
Daily
Composite
Effluent, Influent
Total Suspended Solids2
30.0 mg/L
45.0 mg/L
Daily
Composite
Effluent, Influent
NH3 as N
18.5 mg/L
35.0 mg/L
Daily
Composite
Effluent
NH3 as N (summer)3. 4
4.7 mg/L
14.1 mg/L
Daily
Composite
Effluent
NH3 as N (winter)3' 4
18.5 mg/L
35.0 mg/L
Daily
Composite
Effluent
Dissolved 0xygen5
Daily
Grab
Effluent _
Fecal Coliform
(geometric mean)
200 / 100 mi
400 / 100 ml
Daily
Grab
Effluent
Total Residual Chlorines
28 µg/L
Daily
Grab
Effluent
pH
>6.0 and <9.0 standard
units
Daily
Grab
Effluent
Temperature (QC)
Daily
Grab
Effluent
Total Nitrogen (NO2 + NO3 +
TKN)
Quarterly
Composite
_
Effluent
Total Phosphorus
Quarterly
Composite
Effluent
Chronic Toxicity?
Quarterly
Composite
Effluent
Total Copper
2/Month
Composite
Effluent _
Total Zinc
2/Month
Composite
Effluent
Total Nickel
261 µg/L
261 41.
2/Month
Composite
Effluent
Dissolved 0xygen8
See footnote 8
Grab
Upstream, Downstream
Temperature (°C)8
See footnote 8
Grab
Upstream, Downstream
,Conductivity$ i
- .
-
See footnote 8
. Grab
Upstream, Downstream
Priority Pollutant Scan
See Condition A. (3) of this permit .
NOTES:
1. Upstream: upstream 100 feet above outfall. Downstream: downstream at 1) Stice Shoals Dam and 2) above
Beaverdam Creek.
2. The monthly average effluent BOD5 and TSS concentrations shall not exceed 15% of the respective influent
value (85% removal).
3. Summer = April 1— October 31. Winter = November 1— March 31.
4. Summer & winter ammonia limits will become effective August 1, 2016 (six years following the effective
date of the permit).
5. The daily average dissolved oxygen concentration shall not be less than 5.0 mg/L.
6. The Division shall consider all effluent TRC,values reported below 50 µg/L to be in compliance with the
•
permit. However, the Permittee shall continue to record and submit all values reported by a North Carolina
certified laboratory (including field certified), even if these values fall below 50 µg/L.
7. Whole Effluent Toxicity shall be measured by the Chronic Toxicity (P/F) test using Ceriodaphnia dubia at
17%. Testing shall be conducted in February, May, August and November (see Part A. (2.). Monitoring for
Copper, Zinc, and Nickel shall coincide with toxicity sampling
8. Instream samples shall be collected three times per week during the months of June -September and once per
week during the remaining months of the year.
There shall be no discharge of floating solids or visible foam in other than trace. amounts.
• s,

Permit NC0024538
A. (2.) CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia
dubia at an effluent concentration of 17 %.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina
Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase II
Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be performed
during the months of February, May, August and November. Effluent sampling for this testing shall be performed at the
NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit,
then multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in
"North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent
versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration
having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable impairment
of reproduction or survival. The definition of "detectable impairment," collection methods, exposure regimes, and further
statistical methods are specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form
(MR-1) for the months in which tests were performed. If reporting pass/fail results using the parameter code TGP3B, DWQ
Form AT-1 (original) is sent to the below address. If reporting Chronic Value results using the parameter code THP3B, DWQ
Form AT-3 (original) is to be sent to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30 days after the
end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response data,
and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the effluent
toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the permittee will
complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit number,
pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the form. The
report shall be submitted to the Environmental Sciences Section at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required during
the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water Quality
indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring
requirements or limits.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall be
included in the calculation and reporting of the data submitted on the DMR and all AT Forms submitted.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival,
minimum control organism reproduction, and appropriate environmental controls, shall constitute an invalid test and will require
immediate follow-up testing to be completed no later than the last day of the month following the month of the initial monitoring.
• •

Permit NC0024538 •
A. (3.) EFFLUENT POLLUTANT SCAN
The Permittee shall perform an annual Effluent Pollutant Scan for all parameters listed in the attached table (in
accordance with 40 CFR Part 136). Samples shall represent seasonal variations. Unless otherwise indicated,
metals shall be analyzed as "total recoverable."
Ammonia (as N) Trans-1,2-dichloroethylene Bis (2-chloroethyl) ether
Chlorine (total residual, TRC) 1,1-dichloroethylene Bis (2-chlaroisopropyl) ether
Dissolved oxygen 1,2-dichloropropane Bis (2-ethylhexyl) phthalate
Nitrate/Nitrite 1,3-dichloropropylene 4-bromophenyl phenyl ether
Kjeldahl nitrogen Ethylbenzene Butyl benzyl phthalate
Oil and grease Methyl bromide 2-chloronaphthalene
Phosphorus Methyl chloride 4-chlorophenyl phenyl ether
Total dissolved solids Methylene chloride Chrysene
Hardness 1,1,2,2-tetrachloroethane Di-n-butyl phthalate
Antimony Tetrachloroethylene Di-n-octyl phthalate
Arsenic Toluene Dibenzo(a,h)anthracene
Beryllium 1,1,1-tichloroethane 1,2-dichlorobenzene
Cadmium 1,1,2-tichloroethane 1,3-dichtorobenzene
Chromium Trichloroethylene 1,4-dichlorobenzene
Copper Vinyl chloride 3,3-dichtorobenzidine
Lead Acid -extractable compounds: Diethyl phthalate
Mercury (method 1631) P-chloro-m-creso Dimethyl phthalate
Nickel 2-chlorophenol 2,4-dinitrotoluene
Selenium 2,4-dichtorophenol 2,6-dinitrotoluene
Silver 2,4-dimethylphenol 1,2-diphenylhydrazine
Thallium 4,6-dinitro-o-cresol Fluoranthene
Zinc 2,4-dinitrophenol Fluorene
Cyanide 2-nitrophenol Hexachlorobenzene
Total phenolic compounds 4-nitrophenol Hexachlorobutadiene
Volatile organic compounds: Pentachlorophenol Hexachtorocyclo-pentadiene
Acrotein Phenol Hexachtoroethane
. Aaylonitrile 2,4,6-trichlorophenol Indeno(1,2,3-cd)pyrene
Benzene, Base -neutral compounds: Isophorone
Bromoform Acenaphthene Naphthalene
Carbon tetrachloride Acenaphthylene Nitrobenzene
Chtorobenzene Anthracene N-nitrosodi-n-propylamine
Chtorodibromomethane Benzidine N•nitrosodimethytamine
Chloroethane Benzo(a)anthracene N-nitrosodiphenytamine
2-chloroethyNinyl ether Benzo(a)pyrene Phenanthrene
Chloroform 3,4 benzofluoranthene Pyrene
Dichlorobromomethane Benzo(ghi)perylene 1,2,4-trichlorobenzene
1,1-dichloroethane Benzo(k)fluoranthene
1,2-dichloroethane Bis (2-chloroethoxy) methane
Test results shall be reported to the Division in DWQ Form- A MR-PPA1 or in a form approved by the
Director within 90 days of sampling. The report shall be submitted to the following address: Division of
Water Quality, Water Quality Section, Central Files, 1617 Mail Service Center, Raleigh, North Carolina
27699-1617.

Shelb
NORTH CAROLINA
Post Office Box 207 Shelby, NC 28151-0207
April 15, 2010
Mr. Bob Sledge
NCDENR/Point Source Branch
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
RE: DRAFT NPDES PERMIT NC0024538
City of Shelby, NC
Dear Mr. Sledge:
APR i 9 Z010
The City has received and reviewed the draft copy of the NPDES Permit dated March 17, 2010
and would like to provide the following comments regarding this permit:
As noted in our previous telephone discussions, the City of Shelby is highly concerned with the
lowering of the ammonia nitrogen limits within this draft permit. The limit which currently
stands at 18.5 mg/L is proposed to be significantly reduced to 4.7 mg/L as a monthly average
and 14.1 mg/L as a weekly average with both of these limitations taking place during summer
months. Based upon our review of supporting documentation used in the permitting process
by NCDENR, the City believes that these limits have no technical merit and should not be
imposed on the City.
Review of the Broad River Basin Plan and other basin summaries do not indicate that the First
Broad River is impaired nor is it an at risk stream. The First Broad is actually listed as good or
good -fair in quality between Casar, NC and south of Shelby to Earl and the only water quality
stressor indicators include turbidity, fecal coliform and low pH. In the Triennial Review which
has recently been completed, EPA has indicated that ammonia nitrogen re-evaluation was
needed and "To date, EPA has not made any final decisions on what to do with ammonia
criteria, and will not do so until all issues, questions and new scientific information is explored".
Therefore we believe that it is premature to require limit changes in this category.
During the last permit renewal the Permitting Unit discussed establishing lower limits for the
First Broad WWTP. In the City's response to the draft permit of 2004, the City provided
documentation to the State indicating that the plant design which was approved by the State of
North Carolina was not designed to meet a high level of ammonia nitrogen removal. After plant
upgrades were completed in the early 1990's, a memo from the Water Quality Section was
www.cityofshelby.com

submitted to the design engineer thus notifying the City that the State would not lower
ammonia nitrogen limits in response to a decrease in the 7Q10 flow (due to water withdrawals)
until the treatment plant was expanded. This document indicates that decreased limits would
not be imposed as long as effluent toxicity was met consistently. A copy of this letter is
attached for your review.
In a conference call with you a few weeks ago we asked you to clarify the reasoning for adding
the lower limits; and we were told originally that "EPA may require lower limits" during the
review of the permit. In addition, we requested information from EPA supporting these
statements and to date have not received any documentation. Later on we were told that
ammonia toxicity is of concern with our toxicity test failures. In either case the City has not
been provided with sound technical data and supporting documentation from the State
justifying the desire of the State to lower effluent limitations for ammonia nitrogen.
The City has reviewed our test data and the First Broad WWTP has failed only two out of forty
eight (48) toxicity tests within the last ten years. Toxicity testing failures occurred in May of
2007 and again in November of 2008 (please see attached data). In review of the toxicity data,
ammonia nitrogen levels were near or below the limits when failure occurred and other tests
which showed passes had corresponding higher ammonia nitrogen discharge results. Based
upon this data we feel that it is difficult to say that ammonia toxicity was the reason for the
failures and the ammonia toxicity issue does not warrant change in effluent limits.
Over the past ten years the City of Shelby has played a key role in the Future Initiatives
identified in Chapter 7 of the Broad River Basin Plan and in doing so the City has worked to
provide wastewater services for the previous stream dischargers:
• Crest Middle School
• Crest High School
• Lawndale/E-flex
• Burns Middle School
• Burns High School
• Specialty Lighting
• Smurfit Stone
• Fallston Elementary School
In this time frame the City has also began treating wastewater flows from the Town of Fallston,
Town of Kingstown, Town of Polkville and the Town of Lawndale. All of these actions should
reflect that the City of Shelby is serious about improving water quality and has stepped up to
improve water quality in Cleveland County; however now, we feel as if we are being punished
for doing so by having lower limits imposed on our treatment plant.
The First Broad WWTP has recently made several operational improvements and our data
indicates higher removal rates for ammonia nitrogen over the past year. The existing treatment
facilities cannot meet proposed lower limits which will likely result in permit violations and
potential enforcement action by NCDENR. The City of Shelby will therefore need to undergo an
estimated $7 million upgrade to the treatment plant in order to remain compliant. This is a
huge financial burden for any town in the current economy and for a project that would
provide very little environmental gain.
www.cityofshelby.com

Based upon the information we have provided above regarding ammonia nitrogen the City of
Shelby respectfully requests that these proposed ammonia nitrogen limits be removed from the
Draft NPDES Permit.
Other Notes:
On Supplement to Permit Cover Sheet Item (1):
• Only one Standby power generator exists at the WWTP (The draft permit
references two).
• Remove Sludge Incinerator (The Sludge Incinerator was removed many years ago
and Shelby now utilizes a biological composting facility for sludge handling
purposes).
If you have any questions, please don't hesitate to contact myself or David Hux at 704-484-
6840.
Brad R. Cornwell, PLS,EI
Public Utilities Director
Cc: Mr. Rick Howell, City Manager
Mr. David Hux, Assistant Utilities Director -Operations
Certified Mail 7002 2410 0005 5805 6645
www.cityofshelby.com

City of Shelby Utilities
Electric, Gas, Water, Wastewater
P.O. Box 207
Shelby, North Carolina 28151-0207
Phone: [phone] Fax: [phone]
February 24, 2004
Mr. Mark McIntire, P.E.
NCDENR-Division of Water Quality-NPDES Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Subject: Draft NPDES Permit Number NC0024538
City of Shelby
Broad River WWTP
Dear Mr. McIntire:
We have received your letter of February 4, 2004 and the Draft NPDES Permit for the
Broad River WWTP. The City of Shelby concurs with most of the changes proposed by
the new Permit but strongly objects to several of the items as addressed herein.
• A monthly average ammonia limit of 4.7 mg/L (summer) and 18.5 mg/L (winter) has
been added to the Permit. The corresponding weekly average limit at a ratio of 3:1
has also been included. The City's wastewater treatment facilities were not
designed for, nor have they been previously permitted for such stringent ammonia
limits.
When the facilities were constructed in the 1990s the City received assurance from
the Water Quality Section that the ammonia limit would not be Tess than 18.5 mg/L
until the waste treatment facilities are expanded. These assurances were provided
to the City in a letter from J. Trevor Clements of the Water Quality Section to
Piedmont Olsen Hensley, the City's consulting engineer for the project. A copy of
that letter is attached for your reference. Since then, the facilities have remained
unchanged and the City has continued to consistently meet its discharge
requirements. We therefore expect the State to continue to honor this prior
agreement.
• The proposed Permit includes monitoring and a daily maximum limit of 261 ug/L for
nickel on the basis that the Tong -term monitoring plan demonstrates a potential to
exceed water quality criteria in the receiving stream. Although the City has detected
some nickel in previous tests, the level has never approached the 261 ug/1 level.
The City does not have any significant industrial users that utilize nickel. The City
therefore does not understand the rationale for including this additional monitoring.
We respectfully request the State please explain the methodology used to derive
the requirement.
Quality Always
It's about the people.

Page 2
NPDES Draft
February 24, 2004
The City does not object to the other changes proposed in the Draft NPDES Permit.
We are proceeding with the steps necessary to comply with these requirements when
the Permit becomes effective.
We appreciate your consideration in these items and look forward to your response. If
you have any questions or need any additional information, please let me know.
Yours very truly,
Coleman M. Keete
Assistant Utilities Director
Attachment
cc: Mr. ,lay Stowe, P.E., Utilities Director
Mr. Grant Goings, City Manager
Mr. Michael Kennedy, City Attorney
Mr. Rex Gleason, Mooresville Regional Office / Water Quality Section
Mr. Chuck Willis, P.E.,Willis Engineers
Mr. William Ross, Secretary DENR
Mr. Patrick Grogan, P.E., Mooresville Regional Office, DENR

State of North Carolina _
Department of Environment, Health and Natural Resources
Division of Environmental Management
" 512 North Salisbury Street • Raleigh, North Carolina 27604
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Regional Offices
Asheville .
704/251-6208
Fayetteville
919/486-1541
Mooresville
704/663-1699
Raleigh
919/571-4700
Washington
919/946-6481
• Wilmington
• 919/395-3900
Winston-Salem
919/S96-7007
November 20, 1992
Mr. Dallas Brickhouse, Jr., P.E.
Piedmont Olsen Hensley
P.O Box 31388
Raleigh, N.C. 27622-1388
441)
NOV 23 1992
EIM MAP
TILE 3?o?3
A. Preston Howard, Jr., P.E.
Acting Director
Subject: Speculative Effluent Limits for City of Shelby WWTP due to
Reduced 7Q10 in the First Broad River
NPDES Permit No. NC0024538
Cleveland County
Dear Mr. Brickhouse:
Your request for speculative effluent limits for the subject facility has
beenlcompleted by the staff of the Technical Support Branch. The previous
letter to Mr. Brookhart did not incorporate information concerning increased
water withdrawals upstream. Our Branch did not receive any correspondence on
the water plant until after the evaluation for the wastewater treatment plant
had been completed and sent to your firm.
Revised stream flow information has been obtained from the Department's
Divislion of Water Resources (DWR) concerning estimates of the 7Q10 flow in
the First Broad River due to water plant expansions for the City of Shelby
and the Cleveland County Sanitary District (CCSD). Previous wasteload allo-
cations for effluent limits for the Shelby WWTP have been evaluated using a
summer 7Q10 of 70 cfs. The DWR has determined the upstream water supply
withdrawals by Shelby and the CCSD will result in a reduced 7Q10 of 44.3 cfs
at the WWTP's discharge point.
Using the revised 7Q10 flow, tentative effluent limits were determined
-using a Level B modelling analysisfor the Shelby WWTP at 6.0 MGD. Prelimi-
nary limits for the conventional constituents are:.
25
18.5*
5
30
200
Polluttion(SPrevention Pays 6-9
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer
BODS (mg/1)
NH3-N (mg/1)
Dissolved Oxygen (mg/1)
TSS (mg/1)
Fecal Coliform (,#/100m1)

Letter to Mr. Brickhouse
- page 2-
The NH3-N limit of 18.5 mg/1 given is based on protection of the dis-
solved oxygen standard of 5 mg/1 in the First Broad River. An analysis for
NH3 toxicity was also completed and summer/winter limits of 4.7 and 9.3 mg/1,
respectively, would be needed to protect the instream NH3 criteria. As
previously stated'in the July 22nd letter to Mr. Brookhart, ammonia toxicity
limits based on toxicity will not be applied until the plant expands because
Shelby has, consistently passed its whole effluent toxicity test.
The new instream waste concentration (IWC) is 17% and quarterly chronic
toxicity testing will be a permit requirement. Effluent limits for metals
were also affected by the reduced 7Q10 flow. The revised daily maximum
limits are:
Cadmium 11 ug/1
Chromium 288 ug/1
Nickel 507 ug/1
Lead 144 ug/1
Cyanide 29 ug/1
Selenium 29 ug/1
Based on recently updated pretreatment information, a new constituent,
selenium, is now limited, while the previously recommended limit (per July
22nd letter) for mercury of 0.103 ug/1 has been. rescinded. Monthly effluent
monitoring for copper, zinc, and silver is still required.
While this letter primarily addresses the parameters directly affected by
the reduction in 7Q10 flow, items previously mentioned in the July 22nd
letter regarding instream and color monitoring, chlorination/dechlorination
processes, and the basinwide water quality management plan for the Broad
River Basin are still applicable.
Please consider the above information carefully when evaluating the
impact of the proposed flow withdrawal increase. If there are any remaining
questions concerning the Shelby WWTP, please contact Ruth Swanek or Jackie
Nowell of my staff at [phone].
JTC/JMN
cc: Don Safrit
Rex Gleason
Boyd Devane
W.S. Hoffman
Cecil Madden
Central Files
Sincerely,
Trevor Clements, Asst. Chief
er Quality Section

City of Shelby
First Broad WWTP
Effluent Toxicity Results
Week
Toxicity Results
Average Effluent
NH3-N (mg/L)
2/21/2000
PASS
3.8
5/1/2000
PASS
0.6
8/7/2000
PASS
0.7
11/6/2000
PASS
0.9
2/27/2001
PASS
4.8
5/1/2001
PASS
0.5
8/9/2001
PASS
0.5
11/5/2001
PASS
0.5
2/14/2002
PASS
0.5
5/13/2002
PASS
10
8/5/2002
PASS
0.7
12/4/2002
PASS
1
4/1/2003
PASS
13.5
5/12/2003
PASS
3.8
8/4/2003
PASS
0.9
10/7/2003
PASS
0.5
11/4/2003
PASS
0.5
12/7/2003
PASS
0.9
2/26/2004
PASS
3.4
5/13/2004
PASS
5.2
8/2/2004
PASS
0.5
11/1/2004
PASS
0.9
2/7/2005
PASS
1.4
5/2/2005
PASS
15.5
8/4/2005
PASS
11.2
11/7/2005
PASS
13.4
2/6/2006
PASS
11
5/4/2006
PASS
12.7
8/10/2006
PASS
12.6
11/6/2006
PASS
1.7
2/5/2007
PASS
13.6
5/7/2007
FAIL
11.9
6/18/2007
PASS
2.4
7/16/2007
PASS
8.5
8/13/2007
PASS
15.5
10/9/2007
PASS
12.7
11/4/2007
PASS
12.1
12/9/2007
PASS
11.9
1/6/2008
PASS
8.7
2/18/2008
PASS
15.6
5/5/2008
PASS
20.6
8/4/2008
PASS
12.6
11/3/2008
FAIL
7.6
12/8/2008
PASS
5.9
1/12/2009
PASS
2.4
2/2/2009
PASS
3,4
5/4/2009
PASS
6.7
8/10/2009
PASS
5.7
11/16/2009
PASS
1.3
Number of Tests
Number of Failures
48
2

ledge, Bob
From: [e-mail]
Sent: Thursday, March 25, 2010 9:03 AM
To: Sledge, Bob
Subject: NC0024538 - Shelby First Broad River WWTP
EPA has no comments on this draft permit.
1

CC bob 51a'je/Shelb)WWTr
r 0 Smurfit -Stone
Smurfit -Stone Container Corporation
662 Washburn Switch Road
P. O. Box 369
Shelby, N. C. 28151-0369
March 30, 2010
Mr. Tom Belnick
NPDES Permitting Western
1617 Mail Service Center
Raleigh, N. C. 27699-1617
Subject: NPDES Permit
Cleveland Coun
Dear Mr. Belnick:
51-51/t°1'' led-ef( 11
woof Ao fedi& jerve
qco.poet /114,1 , 1 /14
teei W,t4 &Y.44
v1/11)eresiiiic_
resc,mk
murfit-Stone WWTP
This is in response for discontinuing our Outfall 001 and diverting this flow into City
of Shelby wastewater treatment plant. On March 24, 2010 our facility starting
discharging our flow to city sewer system.
Thanks for your help and attention to this matter.
If you 482-4471,have any questions, you can contact me at (704) or by email at
[e-mail].
Sincerely,
g ae,01:6,4
Richard D. Hendrick
ORC
Cc: Central Files
Mooresville Regional Office
(t"1 7E1 .EN
MAR 312010
DENR WATER QUALM
POINT SOURCE BRANCH

North Carolina
Mecklenburg County)
) ss
The Charlotte Observer Publishing Co.
Charlotte, NC
Affidavit of Publication
THE CHARLOTTE OBSERVER
DINA SPRINKLE
NCDENR/DWO/POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH NC 27699
REFERENCE: 30063432
6448001 nc env mgmt come
Before the undersigned, a Notary Public of said
County and State, duly authorized to administer
oaths affirmations, etc., personally appeared,
being duly sworn or affirmed according to law,
doth depose and say that he/she is a
representative of The Charlotte Observer
Publishing Company, a corporation organized and
doing business under the laws of the State of
Delaware, and publishing a newspaper known as The
Charlotte Observer in the city of Charlotte,
County of Mecklenburg, and State of North Carolina
and that as such he/she is familiar with the
books, records, files, and business of said
Corporation and by reference to the files of said
publication, the attached advertisement was
inserted. The following is correctly copied from
the books and files of the aforesaid Corporation
and Publication.
PUBLISHED ON: 03/20
AD SPACE:
FILED ON:
NAME:
72 LINE
03/25/10
In Testimony Whereof I have
day and y:ar aforesaid. /
Motar
I I
lJ
My Commission Expires May 27, 2011
hereunto
l
set my hand
Public Notice
North Carolina Environmental Management Commission/
NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Notice of Intent to Issue a NPDES Wastewater Permit
The North Carolina Environmental Management Commission pro-
poses to issue a NPDES wastewater discharge permit to the per-
son(s) listed below.
Written comments regarding the proposed permit will be accept-
ed until 30 days after the publish date of this notice. The Director
of the NC Division of Water Quality (DWQ) may hold a public hear-
ing should there be a significant degree of public interest. Please
mail comments and/or information requests to DWQ at the above
address. Interested persons may visit the DWQ at 512 N.
Salisbury Street, Raleigh, NC to review information on file.
Additional information on NPDES permits and this notice may be
found on our website; www.ncwaterquality.org, or by calling (919)
807-6304.
The City of Lowell requested renewal of permit NC0025861 for its
Lowell WWTP in Gaston County; this permitted discharge is treat-
ed domestic wastewater to South Fork Catawba River, in the
Catawba River Basin.
The City of Rockingham requested renewal of permit NC0020427
for Rockingham WWTP in Richmond County. This permitted dis-
charge is treated municipal wastewater to the Pee Dee River,
Yadkin Pee -Dee River Basin.
The City of Shelby requested renewal of permit NC0024538 for
the First Broad River WWTP in Cleveland County; this permitted
discharge is treated wastewater to the First Broad River in the
Broad River Basin.
LP6448001
and affixed my seal,
Commission Expires: _/_/_
the

IWC Calculations
Shelby WTP
NC0024538
Prepared By: Bob Sledge, NPDES Unii
Enter Design Flow (MGD):
Enter s7Q10(cfs):
Enter w7Q10 (cfs):
6
44.3
112
Residual Chlorine
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (I
IWC (%)
Allowable Conc. (ug/I)
Fecal Limit
(If DF >331; Monitor)
(If DF <331; Limit)
Dilution Factor (DF)
NPDES Servor/Current Versions/IWC
Ammonia (NH3 as N)
(summer)
44.3 7Q10 (CFS)
6 DESIGN FLOW (MGD)
9.3 DESIGN FLOW (CFS)
17.0 STREAM STD (MG/L)
0 UPS BACKGROUND LEVEL
17.35 IWC (%)
98 Allowable Conc. (mg/I)
200/100m1
5.76
Ammonia (NH3 as N)
(winter)
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL
IWC (%)
Allowable Conc. (mg/I)
44.3
6
9.3
1.0
0.22
17.35
4.7
112
6
9.3
1.8
0.22
7.67
20.8

REASONABLE POTENTIAL ANALYSIS
City of jShelby WWTP
NC0024538
Time Period January 2007 - August 2009
Ow (MGD) 6
7010S (cis) 44.3
7010W (cis) 112
3002 (cis) 154
Avg. Stream Flow, QA (cis) 333.8
Rec'ving Stream First Broad River
WWTP Class IV
!WC (%) 7010S 17.351
@ 7010W 7.6669
3002 5.695
QA 2.7106
Stream Class C
Outfall 001
Qw=6MGD
PARAMETER
TYPE
(1)
STANDARDS &
CRITERIA (2)
PQL
Units
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
NC WOs/ *FAY /
Chronic Acute
n I Dri Nix Pred Cw Atiowabls Cw
Cyanide
NC
5 N 22
10
ug/L
139 1
15.1
Acute: 22
_ •
Chron-_ -- -29 —
Remove limits & monitoring from permit; add parameter - to 1
— — - ----- —. .— — --
Nickel
NC
88.0 261
uglL
66 53
333.0
Acute: 261
Chronic: -- ��--
Add limits to permit
--------- - ---.—_—_—.—.—_—_—.—.—
Copper
NC
7 AL 7.3
ug/L
66 55
41.6
Acute: 7
__ -
_ _--TO—
Chronic: 40 —
monitoring—_—_—
Action Level parameter -retain• .—_—
-- ---—_---
Zinc
NC
50 AL 67
ug/L
66 59
81.1
Acute: 67
_ _-_ _ _-
Chronic: 288
Action Level parameter- retain- monitoring -__ —
'— - — — -- - -
Mercury
NC
12
2
rtgfL
11 11
Note: n<12
Limited data
8.5
sot
Acute: WA
_ _ _-- _ -
Chronic: -69 —
Only 11 low level sampling events reported
Retain monitoring In LIMP_-- _— —
------
—� --- — — — - — —
0 0
N/A
Acute: WA
Chronic:.rrorTill- Type---
----- — —----------- --- —
0 0
WA
Acute: N/A
Chrortic: Jror O Type
_—_—_—•—_—-----•-------.—_—•— —
0 0
WA
Acute: WA
___ Type-
Chrort_i: rror O
-----
0 0
WA
Acute: WA
Chronic: ?mor O Type
-------------- ------------ ---
0 0
N/A
Acute: N/A
_ _ _ _ _
Chronic: Error 0 Type
— ——•—•—.— —
-------- - — — --
0 0
WA
Acute: WA
__
Chron-Z- nor O Type
---- --- — ---
0 0
WA
Acute: N/A
_
Chroni_c::ma_ O Type
------------— — — — - — ---------
0 0
WA
Acute: N/A
-----•-------------
0 0
WA
Acute: N/A
Chronic: ?mor O Type
•—_—.—.—.—._
0 0
N/A
N/A
Acute: N/A
_hronic: ___Error O
TypeC
_-----.—.—.—_—.—_—_—.—_—_—.—_—.—
• Legend:
C = Carcinogenic
NC = Non -carcinogenic
A = Aesthetic
Freshwater Discharge
Shelby RPA Feb 2010 v2, rpa
3/17/2010

NC0024538 City of Shelby WWTP
Monthly Average Ammonia 2004 - 2009
Month Year Parameter UoM Value
1 2004 00610 - Nitrogen, Ammonia Total (as N) mgA 3.735
2 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 3.055
3 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 1.691304
4 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 1.242857
5 2004 00610 - Nitrogen, Ammonia Total (as N) mgA 2.655
6 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 1.181818
7 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 0.5
8 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 1.681818
9 2004 00610 - Nitrogen, Ammonia Total (as N) mgA 1.409524
10 2004 00610 - Nitrogen, Ammonia Total (as N) mgA 0.480952
11 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 0.675
12 2004 00610 - Nitrogen, Ammonia Total (as N) mgA 0.675
Annual Average 1.581939
1 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 1.025
2 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 1.715
3 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 5.863636
4 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 11.419048
5 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 13.766667
6 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 2.3
7 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 2.835
8 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 11.291304
9 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 15.185714
10 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 11.685714
11 2005 00610 - Nitrogen, Ammonia Total (as N) mgA 12.4
12 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 14.05
Annual Average 8.62809
1 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 12.295
2 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 12.905
3 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 11.234783
4 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 13.
5 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 13.672727
6 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 14.981818
7 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 14.26
8 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 13.291304
9 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 14.24
10 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 14.027273
11 2006 00610 - Nitrogen, Ammonia Total (as N) mgA 10.055
12 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 14.384211
Annual Average 13.195593
1 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 12.385714
2 2007 00610 - Nitrogen, Ammonia Total (as N) mg/1 12.03
3 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 11.004545
4 2007 00610 - Nitrogen, Ammonia Total (as N) mg/1 13.81
5 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 13.272727
6 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 7.084762
7 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 9.280952
8 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 12.317391
9 2007 00610 - Nitrogen, Ammonia Total (as N) mg/1 8.642105
10 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 14.304348
11 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 13.595
12 2007 00610 - Nitrogen, Ammonia Total (as N) mgA 11.021053
Annual Average 11.562383

NC0024538 City of Shelby WWTP
Monthly Average Ammonia 2004 - 2009
1 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 10.233333
2 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 15.842857
3 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 17.635
4 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 18.709091
5 2008 00610 - Nitrogen, Ammonia Total (as N) mg/l 16.87619
6 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 12.647619
7 2008 00610 • Nitrogen, Ammonia Total (as N) mg/1 7.070455
8 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 10.561905
9 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 5.1
10 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 10.482609
11 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 7.483333
12 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 5.971429
Annual Average 11.551152
1 2009 00610 - Nitrogen, Ammonia Total (as N) mg/I 3.52
2 2009 00610 - Nitrogen, Ammonia Total (as N) mg/I 4.435
3 2009 00610 - Nitrogen, Ammonia Total (as N) mg/1 4.922727
4 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/I 4.357143
5 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 6.73
6 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 6.05
7 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 6.213636
8 2009 C0610 - Nitrogen, Ammonia Totai (as N) - Concentration mg/I 5.3
9 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 2.090476
10 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 7.481818
11 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 1.372222
12 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/I 0.680952
Annual Average 4.429498

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0024538
Facility Information
Applicant/Facility Name:
City of Shelby/Broad River WWTP
Applicant Address:
P.O. Box 207; Shelby, North Carolina 28151
Facility Address:
Off NC Highway 18; southwest of Shelby, North Carolina 28151
Permitted Flow
6.0 MGD
Type of Waste:
Domestic (68%) and industrial (32%) with pretreatment program
Facility/Permit Status:
Class IV /Active; Renewal
County:
Cleveland County
Miscellaneous
Receiving Stream:
First Broad River
Regional Office:
Mooresville (MRO)
Stream Classification:
C
State Grid / USGS Quad:
G 12NE
303(d) Listed?
No
Permit Writer:
Bob Sledge
Subbasin:
03-08-04
Date:
March 17, 2010
Drainage Area (mi2): 112
Summer 7Q10(cfs) 44.3
Winter 7Q10 (cfs) 112.0
30Q2 (cfs) N/A
Average Flow (cfs): 333.8
IWC (%):
17%
Lat. 35° 14' 28" N Long. 81° 34' 20" W
BACKGROUND
The Shelby WWTP is a Class IV facility with a permitted flow of 6.0 MGD. The plant treats
wastewater from residential, commercial and industrial sources. The existing permit was issued
on July 1, 2004 and expired on August 31, 2008. The Permittee submitted Standard Form A on
March 3, 2008 in order to request renewal of the permit. The facility has a full pretreatment
program, which it will continue to implement in the coming permit term.
Instream Monitoring, Verification of Existing Conditions and DMR Data Review
This facility discharges to the First Broad River in subbasin 03-08-04 of the Broad River Basin.
The First Broad River is classified C waters at the point of discharge and is not on the 2006-
303(d) list. However, this particular stream segment is deemed to be impaired based on aquatic
life on the draft 2008 303(d) list, both upstream and downstream of the WWTP discharge. The
problem parameter is turbidity. There are also concerns with regard to fecal coliform bacteria
levels observed in the river, but no impaired determination is proposed based upon this
parameter. According to the latest basin plan, elevated turbidity in the river is thought to be due
to development and urbanization. The plan also points to livestock and pets as being more likely
causes of elevated fecal coliform numbers, as opposed to the result of the WWTP discharge.
Shelby is required to sample upstream and downstream (at two points) of the discharge for
dissolved oxygen and temperature. Little difference between upstream and downstream
temperature values was noted and temperatures appear seasonally appropriate. Dissolved oxygen
values were slightly lower at the first downstream location (a dam about a mile downstream of
the discharge) Values almost always recover toward upstream values at the second downstream
sampling point, and were always above the standard of 5.0 mg/L.
F ac l Sheet
\Nt'002z38 Ren,n,-al

Effluent DMR data from July 2004 through August 2009 were reviewed. Data for conventional
parameters are summarized in Table 1. For the most part, the Permittee maintained compliance
with the permit limits for those parameters.
Maximum
Minimum
Flow Temperature Dissolved
(MGD) (°C) Oxygen
(mg/L)
2.74
10.7
1.7
19.6
26
9
7.4
11.6
5.3
BOD TSS Fecal
(mg/L) (mg/L) Coliform
(#/100 mL)
12.8
113.6
2
5.7
133
0
5.3
12000
1
Table 1. NC0024538 Conventional Data (July 2004-August 2009)
BOD and TSS % Removal during this time period were 95% and 98.2%, respectively.
This facility also collects data for total nitrogen, total phosphorus, ammonia nitrogen (NH3-N),
and total residual chlorine. These are summarized in Table 2.
Avera • e
Maximum
Minimum
NH3-N Total Nitrogen Total
(mg/L) (mg/L) Phosphorus
(mg/L)
9.6
25
0.08
13.6
29.5
0.72
2.8
5.5
0.47
Total Residual
Chlorine;:
(µg/L)
16.1
27
0
Table 2. NC0024538 Nutrient and Toxicant Data (July 2004 — August 2009) * TRC Review period = 01/2006 — 08/2009
It should be noted that the facility experienced a change in operations management at the
beginning of 2008. Overall performance at the WWTP has shown measureable improvement.
Effluent data submitted per the Priority Pollutant Scan requirement of the permit and as
summarized in Part D of the renewal application were reviewed. Most results of the analyses
from 2005 — 2009 monitoring came back as "non -detect" and none of the results of the
monitoring showed such significance that new parameters should be added as specific terms of
the permit.
A review of the metals (from both the DMRs and Pretreatment data) data was also performed.
These are discussed in the Reasonable Potential Analysis section.
Correspondence
A review of correspondence files for the 2005-2009 period revealed no recurring problems or
major deficiencies in Shelby's compliance history. WWTP performance resulted in 5 NOVs
being issued to the facility during the last permit cycle, all for minor, isolated excursions of non
monthly average permit limits. All of the noncompliant values were within 20% of the permit
limit, and therefore none triggered the Division's criteria for civil penalty assessment. Nine
inspections of various types have been conducted at the WWTP since the last permit was issued.
Most found the facility to be operating in compliance with the terms of the permit. An October
16, 2006 inspection noted some deficiencies in collection of influent composite samples
(constant time/volume v. flow proportional), and the sampling point of the effluent (prior to
dechlorination). Both of these deficiencies were adequately addressed.
Fact Sheet
NPDES NC0024538 Renewal
Page 2

Perhaps the most significant issue from a regulatory perspective during the past 5 years was the
matter of an overflow pipe at the headworks/influent pump station of the WWTP. This structure
is located away from the main part of the WWTP and includes the bar screen, grit chamber and
pumps to carry wastewater to the remainder of the WWTP. When heavy rains occurred, I/I
caused the pumps to be overwhelmed and wastewater backed up at this point, rising to the level
of a 45 inch overflow line that discharged directly to the First Broad River. Its purpose was to
protect electronics within the apparatus. Several bypasses were reported from this location. In
addition to performing collection system work to reduce I/I, the City installed higher capacity
pumps at the location and permanently sealed the overflow pipe, thus resolving the problem.
PERMITTING STRATEGY
Waste Load Allocation (WLA)
The Division prepared the last WLA for the 1999 permit renewal. The previous and current
effluent limits were based on guidelines and water quality standards. The Division has judged
previous parameters and limits to be appropriate for renewal.
Documentation within the permit file suggests more stringent limits for ammonia could be
established within the permit. The 18.5 mg/L limit is based upon modeling to protect the water
quality standard for dissolved oxygen in the receiving stream, but does not reflect ammonia
limits based on aquatic toxicity. The existing WWTP is an older, trickling filter plant with
limited aeration capacity, and was not designed to consistently treat ammonia to such low levels.
Historical datal'show the plant has in the past been efficient in ammonia removal. Problems with
mercury seals on the trickling filters necessitated their being taken off line. While existing
permit limits were met, effluent ammonia values from 2005 through 2008 were higher than what
is typically expected of a major municipal discharge. Increased operational oversight has led to
much improved ammonia performance during 2009.
During the past five years, the facility reported two "fail" results of its chronic toxicity tests (May
2007 and November 2008). Required follow up testing performed during months following
these test failures demonstrated compliance with the permit limit. Furthermore, trends in the
establishment of stream standards for ammonia point toward lower numerical standards may be
on the horizon.
With this rene''al the Division proposes to impose stricter ammonia limits in the new permit. In
order to consistently meet the new limits it is expected that upgrades to existing facilities will
have to be made. However, it is recognized the City is already burdened with wastewater
infrastructure debt, and current economic conditions have negatively impacted the City's ability
to take on additional debt in order to finance upgrades. Accordingly, the renewed permit will
include with the imposition of those limits a compliance schedule extending six years from its
effective date. This schedule will provide the City adequate time to evaluate and plan for
necessary upgrades while existing debt is being serviced, and to secure financing and construct
new treatment units.
Reasonable Potential Analysis (RPA)
The Division conducted EPA -recommended analyses to determine the reasonable potential for
toxicants to be discharged by this facility, based on DMR data from September 2006-August
2009. Calculations were performed for four parameters monitored per terms of the current permit
(Cyanide, Nickel, Copper and Zinc). The overall result of the analysis for nickel suggested there
was reasonable potential to cause violation of the water quality standard and therefore monthly
average and weekly average limits will be added to the permit for this parameter.
Fact Shee
NPI)1 - N(1)0.'_4538 R,newai
Pa c

1
The RPA for cyanide did not indicate reasonable potential for exceeding the water quality
standard. As a result, limits and monitoring for this parameter will be removed from the permit
and added to the facility's Long Term Monitoring Plan.
Copper and zinc, which are action level parameters, did exceed the acute allowable
concentrations, however, the facility has demonstrated consistent compliance with toxicity
testing, and copper and zinc have not been determined to be as causative of toxicity. Therefore,
no limit is added to the permit and monitoring will remain at 2/month.
Mercury was also analyzed using results from the LTMP. Its analysis did not indicate any
reasonable potential for violation of water quality standards for this parameter due to the
discharge. Maximum predicted concentrations were less than the chronic allowable
concentration. Therefore this parameter shall remain monitored as part of the Long Term
Monitoring Plan.
RELIABILITY ISSUES
The City of Shelby WWTP, having a design capacity of greater than 5 MGD, is required to be
staffed by certified operators around the clock pursuant to 15A NCAC 2H .0124. The WWTP
has been granted a waiver from this requirement in the past based upon its use of telemetry to
monitor plant operations during the overnight hours and on weekends. The propriety of the
waiver was called into question in early 2009 during a DWQ inspection that included testing of
the telemetry system. It did not perform well during the test. Following this incident, the
WWTP staff has stated all problems associated with telemetry and remote operation issues have
been resolved. They provided the following information regarding the system presently in use:
• The First Broad WWTP is equipped with Allen Bradley Programmable Logic Controllers
throughout the treatment plant for automated control of the treatment plant. These PLCs control
the function of the equipment and also alert on -call staff of any alarms. As a back-up the main lift
is also equipped with an autodailer that also alerts staff if a problem occurs.
• Even though we have been given the 24/7 exemption, on -call staff still visit the treatment plant
every day of the week including holidays. During the hours that staff is not on site, on -call staff
carry pagers and cell phones in order to be contacted in case of an emergency. Multiple staff
members are notified in the event of a problem until the alarm has been acknowledged; the Water
Plant is also notified in the event of an alarm.
• From any computer with Internet access, staff can access the treatment plant and also make
control changes from any remote location. On -call staff and the ORC will periodically check the
treatment plant via the Internet access while not on site.
• Both the maintenance supervisor and ORC have less than a 10 minute response time to the
plant. All on -call personnel can be at the plant within 30 minutes and with the Internet capabilities
can check and dispatch closer personnel if the need arises.
• During periods of heavier flows (rain events) staff will come into the plant and operate until
conditions are normal. SCADA will notify on -call staff when flows indicate the plant is reaching rain
event status.
DWQ staff from the Mooresville Regional Office inspected the facility on November 5, 2009 and
verified each of the above items. The Division is satisfied with the WWTP's staffing and its
telemetry capabilities. The 24 hour staffing waiver will be continued.
Fact sheet
NPDES NC'()O245 38 Renewal
Pane 4

SUMMARY OF PROPOSED CHANGES
r
• New summer and winter limits for ammonia have been added to the permit. A compliance
schedule has also been added, making the new limits effective six years following the
effective date of the permit.
• A footnote is being added discussing reporting and compliance determination for Total
Residual Chlorine values.
• Monthly average and daily maximum limits have been added for Nickel.
• Monitoring and limits for cyanide have been removed. Monitoring for this parameter shall
continue as part of the facility's long term monitoring plan.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice:
Permit Scheduled to Issue:
NPDES DIVISION CONTACT
March 17, 2010
June 1, 2010
If you have questions regarding any of the above information or on the attached permit, please contact
Bob Sledge at [phone] or via e-mail at [e-mail].
NAME:
REGIONAL OFFICE COMMENTS
NAME:
DATE: 3/
SUPERVISOR:
DATE:
DATE:
Fact Shed
I'UI'. NC0024) s R:ncti+wa1
Nags 5

To: Permits and Engineering Unit
Water Quality Section
Attention: Dina Sprinkle
SOC PRIORITY PROJECT: No
Date: April 14, 2008
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Cleveland
NPDES Permit No.: NC0024538
PART I - GENERAL INFORMATION
1. Facility and Address: City of Shelby WWTP
Post Office Box 207
Shelby, N.C. 28151
2. Date of Investigation: March 26, 2008
3. Report Prepared By: Samar Bou-Ghazale, Env. Eng. II
4. Person Contacted and Telephone Number: Mr. David Hux, [phone].
5. Directions to Site: Travel south from the City of Shelby on Hwy. 18 to the jct of Hwy. 18
and the second intersection with Old Gaffney Road. Turn right at this intersection and
immediately bear left onto a paved access road. The WWTP will be at the end of this
paved access road.
6. Discharge Point(s), List for all discharge Points: -
Latitude: 35° 14' 24"
Longitude: 81° 34' 29"
Attach a USGS Map Extract and indicate treatment plant site and discharge point on map.
USGS Quad No.: G 12 NE
7. Site size and expansion area consistent with application: Yes.
8. Topography (relationship to flood plain included): Gently rolling topography, 3-8%
slopes. The WWTP site is not located in a flood plain.
9. Location of Nearest Dwelling: Approx. 500± feet from the WWTP site.

Page Two
10. Receiving Stream or Affected Surface Waters: First Broad River
a. Classification: C
b. River Basin and Subbasin No.: Broad 03-08-04
c. Describe receiving stream features and pertinent downstream uses: Good flow
observed in the River. Downstream uses are primarily agriculture.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater: 6.0 MGD (Design Capacity)
b. What is the current permitted capacity: 6.0 MGD
c. Actual treatment capacity of current facility (current design capacity): 6.0 MGD
d. Date(s) and construction activities allowed by previous ATCs issued in the
previous two years: N/A
e. Description of existing or substantially constructed WWT facilities: The existing
WWT facilities consist of mechanical screening and grit removal followed by two
primary clarifiers, two trickling filters (not in operation at this time), six diffused
aeration tanks, four final clarifiers, a chlorine contact chamber, dechlorination, an
aerated sludge mixing/holding tank, a sludge thickener, two filter belt presses,
dual stand-by power generators, and a composting facility consisting of ten bay
sludge compost building. Please note that there is no sludge incinerator at the
facility.
f. Description of proposed WWT facilities: N/A
g-
Possible toxic impacts to surface waters: This facility failed its toxicity test in
May 2007.
h. Pretreatment Program (POTWs only): approved.
2. Residual handling and utilization/disposal scheme: Residuals are being composted using
an invessel type operation and are distributed as a Class A soil conditioner.
3. Treatment Plant Classification: Class IV (no change from previous rating).
4. SIC Code(s): 4952 Wastewater Code(s): 01
5. MTU Code(s): 40005

•
Page Three
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? No
2. Special monitoring or limitations (including toxicity) requests: N/A.
3. Important SOC/JOC or Compliance Schedule dates: N/A
PART IV - EVALUATION AND RECOMMENDATIONS
The City of Shelby requests renewal of the subject Permit for the continued operation of
the City's WWTP.
The City sealed the 42 inches by-pass pipe located at the influent pumps and installed two
additional pumps in order to capture all the wastewater/stormwater during a rain event and direct
it through the plant. The City is experiencing severe I & I problems and is providing an annual
funding of $100,000.00 to make necessary repairs for the sewer system. The City has completed
two projects at Marion Street and US 74 By-pass and will start repair of Chestnut Street in the
very near future.
During the investigation at the WWT plant, it was noted that the two trickling filters were
not in operation, the final clarifiers experiencing settling problems as pin flocks were noted on
the surface. According to Mr. Hux, a lot of solids were removed from the clarifiers recently as
the previous ORC let the solids accumulate in these clarifiers. Excessive foam was noted at the
discharge location in the river. A follow up inspection has been scheduled in order to provide
assistance for the operators if needed.
Pending review and approval by The P & E, it is recommended that the permit be
renewed.
/5
Signature of Report ' .arer Date
Water Quality Regional Supervisor
Date

North Carolina 2006 303(d) List
Broad River Basin
Subbasin 03-08-02
Assessment Impaired Year
Waterbody and Description Unit (AU) Class Subbasin Use Listed Category and Reason for Listing
Potential Source(s)
Miles or Acres
Broad River Basin Subbasin 03-08-02
Catheys Creek 9-41-13-(6)a C 03-08-02 6 1.9 FW Miles
From 0.4 miles downstream of Rutherford County SR 1538 to confluence with
Hollands Creek
Catheys Creek
0 1998 6 Impaired biological integrity Municipal Pretreatment (indirect
dischargers)
Agriculture
9-41-13-(6)b C 03-08-02 6 1.9 FW Miles
From confluence with Hollands Creek to S. Broad R.
Hollands Creek
9-41-13-7-(3) C 03-08-02
AL 1998 6 Impaired biological integrity Urban Runoff/Storm Sewers
Minor Municipal Point Source
6
2.8 FW Miles
From Duke Power Co. old Auxiliary Raw Water Supply Intake to Catheys Creek
Second Broad River
AL 1998 6 Impaired biological integrity Urban Runoff/Storm Sewers
Minor Municipal Point Source
9-41-(24.7) C 03-08-02 5
2.2 FW Miles
From Cone Mills Water Supply Intake to Broad River
AL 2004 5 Standard violation: Turbidity
impaired Uses
AL- Aquatic Life
Shellfish Harvesting
0- Overall
REC- Recreation
Fish Consumption
Broad Summary Information
Category Miles and Acres Category Count of AUs
2 813.0 FW Acres 2 55
2 491.2 FW Miles 3 358
3 959.9 FW Miles 5 1
5 2.2 FW Miles 6 3
6 6.6 FW Miles
FW- Freshwater
S- Salt water
North Carolina 303(d) List- 2006 Tuesday, June 19, 2007
Broad Basin 03-08-02 Page 1 of 125

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Planning Section
Basinwide Planning Unit
April, 2008

City of Shelby Utilities
Electric, Gas, Water, Wastewater
P.O. Box 207
Shelby, North Carolina 28151-0207
Phone: [phone] Fax: [phone]
February 24, 2004
Mr. Mark McIntire, P.E.
NCDENR-Division of Water Quality-NPDES Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Subject: Draft NPDES Permit Number NC0024538
City of Shelby
Broad River WWTP
Dear Mr. McIntire:
We have received your letter of February 4, 2004 and the Draft NPDES Permit for the
Broad River WWTP. The City of Shelby concurs with most of the changes proposed by
the new Permit but strongly objects to several of the items .as addressed herein.
• A monthly average ammonia limit of 4.7 mg/L (summer) and 18.5 mg/L (winter) has
been added to the Permit. The corresponding weekly average limit at a ratio of 3:1
has also been included. The City's wastewater treatment facilities were not
designed for, nor have they been previously permitted for such stringent ammonia
limits.
)OJhen the facilities were constructed in the 1990s the City received assurance from
the Water Quality Section that the ammonia limit would not be less than 18.5 mg/L
until the waste treatment facilities are expanded. These assurances were provided
to the City in a letter from J. Trevor Clements of the Water Quality Section to
Piedmont Olsen Hensley, the City's consulting engineer for the project. A copy of
that letter is attached for your reference. Since then, the facilities have remained
unchanged and the City has continued to consistently meet its discharge
requirements. We therefore expect the State to continue to honor this prior
agreement.
e proposed Permit includes monitoring and a daily maximum limit of 261 ug/L for
nickel on the basis that the long-term monitoring plan demonstrates a potential to
exceed water quality criteria in the receiving stream. Although the City has detected
some nickel in previous tests, the level has never approached the 261 ug/l level.
The City does not have any significant industrial users that utilize nickel. The City
therefore does not understand the rationale for including this additional monitoring.
We respectfully request the State please explain the methodology used to derive
the requirement.
Quality Always
It's about the people.

�r
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Regional Offices
Asheville
704/251-6208
Fayetteville
919/486-1541
Mooresville
704/663-1699
Raleigh
919/571-4700
Washington
919/946-6481
Wilmington
919/395-3900
Winston-Salem
919/896-7007
,,zA /' f.r12i
State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27604
A. Preston Howard, Jr., P.E.
Acting Director
November 20, 1992
Mr. Dallas Brickhouse, Jr., P.E.
Piedmont Olsen Hensley
P.O. Box 31388
Raleigh, N.C. 27622-1388
Subject: Speculative Effluent Limits for City of Shelby WWTP due to
Reduced 7Q10 in the First Broad River
NPDES Permit No. NC0024538
Cleveland County
Dear Mr. Brickhouse:
Your request for speculative effluent limits for the subject facility has
been completed by the staff of the Technical Support Branch. The previous
letter to Mr. Brookhart did not incorporate information concerning increased
water withdrawals upstream. Our Branch did not receive any correspondence on
the water plant until after the evaluation for the wastewater treatment plant
had been completed and sent to your firm.
Revised stream flow information has been obtained from the Department's
Division of Water Resources (DWR) concerning estimates of the 7Q10 flow in
the First Broad River due to water plant expansions for the City of Shelby
and the Cleveland County Sanitary District (CCSD). Previous wasteload allo-
cations for effluent limits for the Shelby WWTP have been evaluated using a
summer 7Q10 of 70 cfs. The DWR has determined the upstream water supply
withdrawals by Shelby and the CCSD will result in a reduced 7Q10 of 44.3 cfs
at the WWTP's discharge point.
Using the revised 7Q10 flow, tentative effluent limits were determined
using.a Level B modelling analysis for the Shelby WWTP at 6.0 MGD. Prelimi-
nary limits for the conventional constituents are:
BOD5 (mg/1) 25
NH3-N (mg/1) 18.5*
Dissolved Oxygen (mg/1) 5
TSS (mg/1) 30
Fecal Coliform (#/100m1) 200
p 1 (SD) 6-9
Pollution Yrevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

Letter to Mr. Brickhouse
- page 2-
The NH3-N limit of 18.5 mg/1 given is based on protection of the dis-
solvgd oxygen standard of 5 mg/1 in the First Broad River. An analysis for
NH3 toxicity was also completed and summer/winter limits of 4.7 and 9.3 mg/1,
respectively, would be needed to protect the instream NH3 criteria. As
previously stated in the July 22nd letter to Mr. Brookhart, ammonia toxicity
limits based on toxicity will not be applied until the plant expands because
Shelby has consistently passed its whole effluent toxicity test.
The new instream waste concentration (IWC) is 17% and quarterly chronic
toxicity testing will be a permit requirement. Effluent limits for metals
were also affected by the reduced 7Q10 flow. The revised daily maximum
limits are:
Cadmium 11 ug/1
Chromium 288 ug/1
Nickel 507 ug/1
Lead 144 ug/1
Cyanide 29 ug/1
Selenium 29 ug/1
Based on recently updated pretreatment information, a new constituent,
selenium, is now limited, while the previously recommended limit (per July
22nd letter) for mercury of 0.103 ug/1 has been rescinded. Monthly effluent
monitoring for copper, zinc, and silver is still required.
While this letter primarily addresses the parameters directly affected by
the reduction in 7Q10 flow, items previously mentioned in the July 22nd
letter regarding instream and color monitoring, chlorination/dechlorination
processes, and the basinwide water quaaity management plan for the Broad
River Basin are still applicable.
Please consider the above information carefully when evaluating the
impact of the proposed flow withdrawal increase. If there are any remaining
questions concerning the Shelby WWTP, please contact Ruth Swanek or Jackie
Nowell of my staff at [phone].
Sincerely,
Trevor Clements, Asst. Chief
er Quality Section
JTC/JMN
cc: Don Safrit
Rex Gleason
Boyd Devane
W.S. Hoffman
Cecil Madden
Central Files
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Flow Temperature Dissolved SOD TSS
(MGD) ("C) Oxygen (mg/L) (mg/L)
(mg/L)
A
Ma;
Mir
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Table 1
(NH,
Fecal
Coliform
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4.13
9.35
9.09
24.09
10.42
6.84
2.28
11.05
1.11
y 2001-May 2003)
data for total nitrogen, total phosphorus, ammonia nitrogen
d chlorides. These are summarized in Table 2.
NH,-N Total Nitrogen Total Chlorides Total Residual
(mg/L) (mg/L) Phosphorus (mg/L) Chlorine (pg/L)
(m:/L)
Average
0.08
12.4
3.29
602
15.1
Maximum
1.33
25.3
4.6
784
21.7
Minimum
0
6
2.2
350
7.95
Table 2. NC0024538 Nutrient and Toxicant Data (January 2001— May 2003)
A review of the metals (from both the DMRs and Pretreatment data) data was also performed.
These are discussed in the Reasonable Potential Analysis section.
Correspondence
A review of correspondence files for the 2001-2003 period revealed no recurring problems or
major deficiencies in Shelby's compliance history. In a Compliance Inspection Report dated
August 6, 2001, the inspector notes that the permit description may be inaccurate. The
description did not include an influent pump station or an additional aeration basin (two basins
total). Also, there is no sludge incinerator. The inspector also notes that TRC values ranged from
300%tg/1 to 500,ug/1 and advises that an action level has been set at 17-28ftg/1, however there is no
further mention of TRC values being a concern throughout the following two years.
Few NOVs were issued to Shelby. There was one for a cyanide limit violation (reported value
120.0,ug/l) in Dec 2001 and another for a BOD limit violation (reported value 37.83 mg/1),
however neither appeared to indicate a recurring problem. In June 2003 a $2000 civil penalty
was issued for TSS and TSR effluent limit violations while one of the primary clarifiers was out
of service. A $500,000 renovation project to upgrade both clarifiers was underway. The project
was completed in June 2003.
PERMITTING STRATEGY
Waste Load Allocation (WLA)
The Division prepared the last WLA for the previous permit renewal. The previous and current
effluent limits were based on guidelines and water quality standards. The Division has judged
previous parameters and limits to be appropriate for renewal with some exceptions. Changes to
toxicant monitoring are discussed in the Reasonable Potential Analysis section, with the
exception of ammonia.
The previous permit contains a summer limit for ammonia that appears to be based on the results
of Level B modeling. When assessing ammonia with respect to instream toxicity, however, it is
evident that both summer and winter limits are necessary. Based on the Instream Waste
Concentration (IWC), a summer monthly average limit of 4.7 mg/L and a winter monthly
average limit of 20.8 mg/L should be implemented. Since the current limit of 18.5 mg/L is more
stringent, it will be retained for the winter months. Moreover, weekly average ammonia limits
Fact Sheet
NPl:)ES NC002453K Ren;.Wa
Page
17-4' jl6 dQ �c.RKt cJ

• based on a 3:1 ratio with the monthly average (but no higher than 35.0 mg/L) will be
implemented in this permit. This is a new statewide policy that resulted from EPA requirements.
The resulting summer weekly average limit will be 14.1 mg/L and the winter limit will be 35.0
mg/L. A review of the effluent ammonia data suggests that meeting these new limits should not
be a problem for Shelby. '?
In addition, an annual pollutant scan will be added such that the Permittee can collect the
necessary data required by EPA Form 2A throughout the permit term. This condition is now
standard on all major municipal permits in North Carolina.
•
Finally, a total residual chlorine (TRC) limit of 28 µg/L will be added to the permit, reflecting
the recently passed standard for TRC and new Division policy. Shelby will be granted 18
months to build dechlorination facilities in order to attain compliance with this limit.
Reasonable Potential Analysis (RPA)
The Division conducted EPA -recommended analyses to determine the reasonable potential for
toxicants to be discharged by this facility, based on DMR data from January 2000-June 2003.
Calculations included parameters listed in the previous permit and pre-treatment documents to
include: arsenic, cadmium, chromium, cyanide, lead, mercury, nickel, selenium, silver, copper,
and zinc.
Results suggest no reasonable potential for the facility ' to discharge arsenic, cadmium,
chromium, lead, mercury, silver and selenium. Monitoring for selenium and silver may be
eliminated from the permit, as they are required parameters to be monitored through the
Pretreatment Long Term Monitoring Plan (LTMP). The remaining parameters are monitored
through the LTMP and not the permit; this will be continued in the next permit term.
Effluent from the facility did demonstrate reasonable potential to exceed water quality criteria for
copper, cyanide, nickel and zinc. All but nickel are already monitored in the current permit. The
limit for cyanide will be changed from 29 to 22 µg/L to reflect the current final acute value.
Weekly nickel monitoring will be added to the permit with a daily maximum limit of 261 µg/L.
Copper and zinc, which are action level parameters, will continue to be monitored twice per
month unless they are identified as causative of toxicity.
SUMMARY OF PROPOSED CHANGES
In keeping with Division policies, the following will be incorporated into the permit:
• New monthly and weekly average ammonia limits (both summer and winter)
• Annual pollutant scan
• Addition of TRC limit with 18 month compliance schedule
• Elimination of the selenium and silver monitoring requirement (Permittee will continue to
monitor these parameters through the LTMP).
• Addition of nickel monitoring and daily maximum limit
• Change cyanide limit
New Weekly Average and Daily Maximum limits are derived from the latest NC/EPA policies
considering 1 FAVs and allowable concentrations based on reasonable potential.
Fart Sheet
NPDES NCOO245 +K Renewal

• NC0024538 City of Shelby WWTP
Monthly Average Ammonia 2004 - 2009
Month Year Parameter UoM Value
1 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 3.735
2 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 3.055
3 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 1.691304
4 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 1.242857
5 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 2.655
6 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 1.181818
7 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 0.5
8 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 1.681818
9 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 1.409524
10 2004 00610 - Nitrogen, Ammonia Total (as N) mg/1 0.480952
11 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 0.675
12 2004 00610 - Nitrogen, Ammonia Total (as N) mg/I 0.675
Annual Average 1.581939
1 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 1.025
2 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 1.715
3 2005 00610 - Nitrogen, Ammonia Total (as N) mg/I 5.863636
4 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 11.419048
5 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 13.766667
6 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 2.3
7 2005 00610 - Nitrogen, Ammonia Total (as N) mg/I 2.835
8 2005 00610 - Nitrogen, Ammonia Total (as N) mg/I 11.291304
9 2005 00610 - Nitrogen, Ammonia Total (as N) mg/I 15.185714
10 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 11.685714
11 2005 00610 - Nitrogen, Ammonia Total (as N) mg/1 12.4
12 2005 00610 - Nitrogen, Ammonia Total (as N) mg/I 14.05
Annual Average 8.62809
1 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 12.295
2 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 12.905
3 2006 00610 - Nitrogen, Ammonia Total (as N) mg/I 11.234783
4 2006 00610 - Nitrogen, Ammonia Total (as N) mg/I 13.
5 2006 00610 - Nitrogen, Ammonia Total (as N) mg/I 13.672727
6 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 14.981818
7 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 14.26
8 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 13.291304
9 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 14.24
10 2006 00610 - Nitrogen, Ammonia Total (as N) mg/I 14.027273
11 2006 00610 - Nitrogen, Ammonia Total (as N) mg/I 10.055
JI
12 2006 00610 - Nitrogen, Ammonia Total (as N) mg/1 14.384211
Annual Average 13.195593
1 2007 00610 - Nitrogen, Ammonia Total (as N) mg/1 12.385714
2 2007 00610 - Nirogen, Ammonia Total (as N) mg/1 12.03
3 2007 00610 - Nitrogen, Ammonia Total (as N) mg/1 11.004545
4 2007 00610 - Nitrogen, Ammonia Total (as N) mg/I 13.81
5 2007 00610 - Nitrogen, Ammonia Total (as N) mg/I 13.272727
6 2007 00610 - Nitrogen, Ammonia Total (as N) mg/I 7.084762
II
7 2007 00610 - Nitrogen, Ammonia Total (as N) mg/I 9.280952
8 2007 00610 - Nitrogen, Ammonia Total (as N) mg/I 12.317391
9 2007 00610 - Nitrogen, Ammonia Total (as N) mg/I 8.642105
10 2007 00610 - Nitrogen, Ammonia Total (as N) mg/1 14.304348
11 2007 00610 - Nitrogen, Ammonia Total (as N) mg/1 13.595
12 2007 00610 - Ntrogen, Ammonia Total (as N) mg/I 11.021053
Annual Average 11.562383

NC0024538 City of Shelby WWTP
Monthly Average Ammonia 2004 - 2009
1 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 10.233333
2 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 15.842857
3 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 17.635
4 2008 00610 - Nitrogen, Ammonia Total (as N) mgA 18.709091
5 2008 00610 - Nitrogen, Ammonia Total (as N) mgA 16.87619
6 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 12.647619
7 2008 00610 - Nitrogen, Ammonia Total (as N) mgA 7.070455
8 2008 00610 - Nitrogen, Ammonia Total (as N) mgA 10.561905
9 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 5.1
10 2008 00610 - Nitrogen, Ammonia Total (as N) mg/1 10.482609
11 2008 00610 - Nitrogen, Ammonia Total (as N) mgA 7.483333
12 2008 00610 - Nitrogen, Ammonia Total (as N) mgA 5.971429
Annual Average 11.551152
1 2009 00610 - Nitrogen, Ammonia Total (as N) mgA 3.52
2 2009 00610 - Nitrogen, Ammonia Total (as N) mgA 4.435
3 2009 00610 - Nitrogen, Ammonia Total (as N) mgA 4.922727
4 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 4.357143
5 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 6.73
6 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 6.05
7 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 6.213636
8 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 5.3
9 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 2.090476
10 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 7.481818
11 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mgA 1.372222
12 2009 C0610 - Nitrogen, Ammonia Total (as N) - Concentration mg/1 0.680952
Annual Average 4.429498

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27604
James G. Martin, Governor
William W. Cobcy, Jr., Secretary
Regional Offices
Asheville
704/251-6208
Fayetteville
919/486-1541
Mooresville
704/663-1699
Raleigh
919/571-4700
Washington
919/946-6481
Wilmington
919/395-3900
Mr. Morris V. Brookhart
Piedmont Olsen Hensley
P.O. Box 31388
Raleigh, N.C. 27622-1388
July 22, 1992
Subject: City of Shelby, Cleveland County
NPDES Permit No. NC0024538
Dear Mr. Brookhart:
A. Preston Howard, Jr., P.E.
Acting Director
Thank you for the opportunity to provide comments on the facility upgrade
for the City of Shelby. This information should be helpful in the planning
endeavors and should result in long range modifications for the protection of
the First Broad River.
Winston-Salem Based on the information available, the Technical Support Branch developed
919/896-7007 effluent limits at the wasteflow of 6.0 MGD. The tentative limits for conven-
tional constituents are as follows:
Summer Winter
BOD5 (mg/1) 30 30
NH3-N (mg/1) 6.9* 20.8*
TSS (mg/1) 30 30
Fecal Coliform (#/100m1) 200 200
pH (SU) 6-9 6-9
It should be noted that tentative summer and winter NH3 limits of 6.9 and
20.8 mg/1, respectively, were evaluated for the Shelby WWTP, however these
limits would probably not be applied during renewal because Shelby has con-
sistently passed its chronic toxicity testa These ammonia limits are based on
the protection of the First Broad River against instream toxicity. North Caro-
lina is currently evaluating all NPDES dischargers for ammonia toxicity and
following the Environmental Protection Agency's (EPA) guidance to protect the
waters for an instream criteria of 1 mg/1 in the summer and 1.8 mg/1 in the win-
ter,. under 7Q10 conditions. The State may eventually develop a standard or
criteria for ammonia and a limit for NH3-N rather than a whole effluent toxicity
test would be applicFo1liation Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportuiity Affirmative Action Employer
'MO
.f `'o cis

Letter to Mr. Brookhart
- page. 2 -
Due to the large industrial constituency of Shelby's discharge, effluent
limits were developed for metals. The recommended daily maximum limits are:
Cadmium 17 ug/1
Chromium 429 ug/1
Nickel 755 ug/1
Lead 214 ug/1
Cyanide 43 ug/1
Mercury 0.103 ug/1
Although the effluent limits for chromium, nickel, and lead are high, the
Division may set caps for chemical specific toxicants in the future and Shelby
should make the effort to keep the concentrations as low as possible. Monthly
effluent monitoring requirements should also be included for copper, zinc, and
silver. The instream waste concentration (IWC) at 6 MGD is 12% and a chronic
toxicity testing requirement, with sampling in the months of February, May,
August and November, will remain a condition of the NPDES permit. The facility
should continue instream monitoring above and below the effluent pipe for the
parameters of temperature, dissolved oxygen, fecal coliform, conductivity, BOD5,
and NH3-N. It should be noted that instream monitoring for BOD5 may be replaced
by periodic long-term BOD monitoring after the State adopts a standard method of
analysis.
Under a relatively new Division of Environmental Management (DEM) procedure,
dechlorination and chlorine limits are now recommended for all new or expanding
dischargers proposing the use of chlorine for disinfection. An acceptable
level of chlorine in your effluent is 28 ug/1 for protection against acute tox-
icity. The process of chlorination/dechlorination could be required treatment
that should allow the facility to comply with the total residual chlorine limit.
The DEM is currently planning a basinwide water quality management initia-
tive. Our schedule for implementation in the Broad River Basin is tentatively
set for 1998. The plan will address all sources of point and nonpoint pollu-
tants. In addressing interaction of sources, wasteload allocations may be
affected. Those facilities that already have high levels of treatment technol-
ogy are least likely to be affected. The City of Shelby may want to consider
the implementation of this basinwide strategy in planning its upgrade, as
opposed to limits proposed here which only address localized receiving waters of
the First Broad River.
Basin management plans are likely to develop strategies to address docu-
mented water quality problems. Our records indicate that color problems exist
at the Shelby WWTP at this time. The City should note that DEM is evaluating
the state color standard and is considering potential management actions.
Therefore, you may wish to begin building a data -base of influent and effluent
color (we recommend monitoring in units of ADMI).
•

NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NC0024538
PERMITTEE NAME:
FACILITY NAME:
City of Shelby
Broad River Wastewater Treatment Plant
Facility Status: Existing
Permit Status: Renewal
Major Minor
Pipe No.: 001
Design Capacity: 6.0 MGD
Domestic (% of Flow): 68 %
Industrial (% of Flow): 32 %
Comments: /Liao !� nu.„ ` uv1 1 0/(15i e
P 1 l ypa415i it ;1rto.5 pl cu -2 Ocui6"i
°Li k)L,/ .
RECEIVING STREAM: the First Broad River
Class: C
Sub -Basin: 03-08-04
Reference USGS Quad: G 12 NE (please attach)
County: Cleveland
Regional Office: Mooresville Regional Office
Previous Exp. Date: 12/31/93 Treatment Plant Class: IV
Classification changes within three miles:
Requested by: Charles Alvarez Date: 4/16/93
Prepared by:. / Date:
Reviewed , c all Y) CIJA.c7 -tJ'Y) Date:
)54
/w 1 r7 / 7 co 1 I 7 / -'
Modeler
Date Rec.
#
0-AAA)/r(,/93
7Lz4L
Drainage Area (mil) o2( 7
Avg. Streamflow (cfs): 333.
7Q10 (cfs) .j1:1:3 Winter 7Q10 (cfs)
30Q2 (cfs)
Toxicity Limits: IWC /% % Acute/
Instream Monitoring: w"
Parameters )°
Upstream Locati
Downstream Location
Effluent
Characteristics
Summer
Winter
BOD5 (mg/1)
2S (c i9)
NH3-N (mg/1)
/i. S (,,u/
D.O. (mg/1)
TSS (mg/1)
20
F. Col. (/100 ml)
02-cr0
pH (SU)
G —,
CA64.,„z)„I (vr/9
(�i �tn+aiL..,` Uv
!/
zi i
�l� k Cv /e
Li.,.� 6v Y7
go7
/ y 5/
ih'd /v
E/%V, vM (1719
.2 9
-)(ita-4,,,
-
4�
TP '
2
Comments � � �2 -�— �^ u"~' 1 p
1141
1

City of Shelby - NC0024538
DMR Data Summary
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Mar-01
3.561 14.74 7.78 18.67 18 3.7 243.2 3.42
Apr-01
3.130 18.4 7.78 10.88 11 7.1 375.3 3.41 3.8 2.1
May-01
2.965 21.54 7.29 7.11 12 12 400.97 0.46
Jun-01
3.037 24.1 7.39 4.1 9.5 7.2 434.7 0.17
Ju1-01
2.929 25.22 7.4 3.23 7.8 14.6 305.8 0.03 5.2 2.7
Aug-01
2.852 26.25 7.34 3.06 8.7 27.8 234.5 0
Sep-01
2.827 23.8 7.39 2.68 7.4 12.9 313 0.22 5 3
Oct-01
2.506 19.09 7.76 2.29 6.4 20.4 283.5 0.03 1.3 3.4
Nov-01
2.357 16.93 8.37 2.78 7.15 25.76 0.08
Dec-01
2.442 15.03 8.15 3.77 6.58 23.12 328.7 0.31
Jan-02
2.919 11.55 8.41 4.48 12 8.39 430.3 0.22 4.6 3.6
Feb-02
2.804 12.61 7.83 5.25 12.85 7.46 385.4 0.91
Mar-02
3.245 13.87 7.73 6.68 12.2 2.18 454.8 0.98
Apr-02
2.870 18.33 7.26 13.11 16.59 6.86 251.3 1.96 2.7 2.8
May-02
2.823 20.55 6.54 23.31 16.18 10.59 450.6 10.76
Jun-02
2.730 23.87 6.62 11.29 7.7 11.61 388 3.23
Ju1-02
2.539 25.77 7.06 3.54 4.95 34.14 419.7 1.21 10 5.7
Aug-02
1.610 25.94 6.69 3.55 3.77 11.46 428.7 1.07
Sep-02
1.723 24.23 6.98 5.22 7.25 7.33 577.3 4.8
Oct-02
1.784 21.58 7.02 5.83 5.52 4.74 623.2 3.67 6.8 2.7
Nov-02
2.007 16.57 7.38 6.93 7.63 8.22 558.3 4.79
Dec-02
2.484 12.74 7.99 13.63 11.05 6.58 630.3 13.41
Jan-03
1.670 11.71 7.85 17.3 16.14 1.94 737.7 15.8 2.3 0.7
Feb-03
2.510 11.5 8.09 22.73 36.95 12.07 624.3 17.23
Mar-03
3.770 13.71 7.36 43.62 82.29 24.79 471.3 10.44
Apr-03
4.540 15.67 7.42 10.19 10.71 6.14 445 10.14 0.3 0.6
May-03
4.140 19.06 7.04 12.99 7.67 2.47 353.9 5.02
Jun-03
3.350 21.77 6.64 6.61 7.14 13.12 499 0.74
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t4%/iDt4ax +lc4n{l
Belnick, Tom
From: Belnick, Tom
Sent: Monday, September 14, 2009 12:07 PM
To: [e-mail]; denr.dwq.eastnpdes©Iists.ncmail.net
Cc: Poupart, Jeff; Templeton, Mike
Subject: MonthlyAvg/DailyMax Permit Limits- Toxicants
Monthly Average/Daily Max for Toxicants (POTW and Non-POTW)
Per discussion from Combined NPDES staff meeting today, permit writers should begin to use both Monthly Average and
Daily Maximum effluent limits for toxicants (cyanide, metals) for both municipal/non-muni, as required by EPA.
Reminder, Monthly Average limits will be developed based on longer -term CHRONIC aquatic life standards and human
health standards, while ACUTE limits will be developed based on short-term ACUTE aquatic life criteria. I know- there
are still a lot of questions- what about mercury, what if acute limit< chronic limit, what if no acute criteria for human
health, etc. Please put your questions on the staff meeting board so the entire group learns how to get through this
transition. Ultimately we'll write up our updated policy and have a training session.
Monthly Average/Weekly Average (POTWs only)
PS- Monthly Average/Weekly Average limits are still appropriate for POTWs for BOD, TSS, Fecal, NH3.
Let me know if you have any questions.
Tom Belnick
Supervisor, NPDES West Program
NC DENR/Division of Water Quality
1617 Mail Service Center, Raleigh, NC 27699-1617
[phone]; fax [phone]
E-mail correspondence to and from this address may be subject to the North Carolina Public Records Law and may be
disclosed to third parties.
i

Shelby
NORTH CAROLINA
Mr. Bob Sledge
NC DENR - DWQ
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699
February 28, 2008
Re: Renewal Application of Permit NC0024538 First Broad WWTP
Dear Mr. Sledge:
On behalf of the City of Shelby, I am requesting renewal of the National Pollutant Discharge Elimination
System Permit #NC0024538 for the First Broad Wastewater Treatment Plant. A permit application and
associated information including a sludge management plan are being submitted along with this letter. This
permit renewal application is being submitted by the March 2, 2008 deadline to comply with requirement to
apply 180 days prior to the date of permit expiration (August 31, 2008). As requested, please find the original
signed version of this information along with two copies.
The First Broad Wastewater Treatment Plant continues to operate a 6.0 MGD activated sludge plant for
treating municipal wastewater for the City of Shelby. Several minor upgrades have taken place at the plant
since the previous permit renewal request, which have all been made to enhance the treatment process and
efficiency.
All analyses have been tested by North Carolina certified laboratories in accordance with 40 CFR Part 136
requirements. This application includes all data gathered for the last three years up to December 31, 2007.
Efforts have been made to obtain seasonal variation in the sampling as much as was possible.
If you have any questions regarding the permit renewal application, please feel free to contact David Hux at
704-484-6840 or email him at david.hux(a�cityofshelbv.com.
Sincerely,
414Weill
Brad R. Cornwell, PLS, El
Utilities Director
RECEIVED
MAR - 3 2008
DENR - WATER QUALITY
cc: David Hux—Assistant Utilities Director —Operations, Shelby,
Duane Sando — Plant Operations Superintendent, Shelby OINT SOURCE BRANCH
John Rhom — WWTP Supervisor/ORC, Shelby
Certified Mail: 7002 1000 0005 5805 6768
Post Office Box 207 - Shelby, NC 28151-0207
Phone [phone] - Fax [phone]
Visit us at www.citvofshelbv.com

FACILITY NAME AND PERMIT NUMBER:
PERMIT ACTION REQUESTED:
RIVER BASIN:
First Broad WWTP, NC0024538
Renewal
Broad
Additional Information for NPDES Permit Application
Section B.1. Inflow and Infiltration.
Briefly explain any steps underway or planned to minimize inflow and infiltration.
The City of Shelby seeks to correct all sources of inflow or infiltration. The First Broad Wastewater
Treatment Plant and most of the collection system are in good condition. The City of Shelby continues to
perform manhole evaluations, vidcoing and smoke testing of the system to determine problematic areas.
The City provides an annual funding of $100,000 for Field Operations to make point repairs within the
system.
PIM
Other Projects:
• Carolina and Suttle Street Repairs — Completed I & I repairs
• Marion Street Replacement and Extension Project — 840 feet of sewer line replacement.
• US 74 By-pass — 300 feet of sewer line replacement.
• Chestnut Street Project- Completed evaluation process and recommendations for point repairs and
sewer lining. Estimated Cost - $400,000

First Broad WWTP - Compost Facility
Latitude 35 degrees 14' 34" N
Longitude 81 degrees 34' 19" W
3006
300830 3011 102
First Broad WWTP - Outfall 001
Latitude 35 degrees 14' 24" N
Longitude 81 degrees 34' 29" W
Legend
® Plant
O Facility Boundary
O WWTP Buffer
—0- Gravity Main
t Force Main
ri Pump Station
— Streets
Parcels
Compost Facility
2107
2109 2104
2111
2130 2134
1764
1141766
1772
1853
1857
1863103
107
186910
1873
1749 17N
1753
1761
1765
1769
157
-
Shelb
NORTH CAROLINA
Map Produced By:
Map Information:
FIRST BROAD WWT P
..a„ Y mop data `pr`a'ned
in this reap Is en approxlmere
representation of the zoning
This map Is not a substitute
for ern aaud survey. This
map Ia not to be used }or
conveyances. Utility
f�
•..
Gty of Shelby
t35 Officeirxerprered
Daum HAD nave
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Scale: 1" = 1000' Date: 1/28/08
botadary."
definitive means to locate
utility features.

FACILITY NAME AND PERMIT NUMBER:
PERMIT ACTION REQUESTED:
RIVER BASIN:
First Broad WWTP. NC0024538
Renewal
Broad
Additional Information for NPDES Permit Application
Section B.3. Process Flow Diagram or Schematic
Process Flow Description
The First Broad WWTP is a 6-mgd facility operated by the City of Shelby which
e
discharges treated effluent to the First Broad River. Influent wastewater enters the plant
through a gravity feed sewer line and passes through coarse manual and fine mechanical
screens and a grit classifier. Grit slurry is dewatered by an auger type classifier and is
deposited into a dumpster for disposal at landfill. Following preliminary treatment, the
flow enters the main lift station. Four influent pumps lift the influent flow to a splitter
box and the flow is split to two primary clarifiers. Settled solids are removed by pumps
located in the primary sludge pump station, where they are pumped to the Aerated Sludge
holding tank. Wastewater carries on to either the trickling filters or the aeration basin.
Currently operation of the plant does not include the use of the trickling filters.
The primary clarifier effluent is combined with the return activated sludge (RAS) in
where the flow is split to two biological treatment sides. The activated sludge system
consists of aeration basin and blowers. The aeration basin consists of six cells with
arrangement to either be operated in series or parallel. Mixing and aeration are provided
through a jet pod aerator each cell. Three cells use mixed flow propeller pumps and three
cells use submersible pumps. Four positive displacement blowers have a combined
capacity of 2,400 cfm are used for aeration.
Four final clarifiers provide separation of the mixed liquor suspended solids (MLSS)
.� generated in the activated sludge basins. The return activated sludge (RAS) is pumped by
two RAS pump stations for return to the activated sludge basin. Waste Activated Sludge
— (WAS) is metered and pumped to two gravity thickeners for thickening. Water is sent
back to the primary clarifiers and thickened sludge is pumped to the aerated sludge
holding tank.

— The plant uses chlorine and sulfur dioxide for disinfection/chlorine removal at the
effluent. Two compartment contact tank provides detention time for reactions to occur.
The sludge management system includes the aerated sludge holding tank, dewatering by
— belt presses and a composting facility. More details are in the sludge management plan.
'—' The plant is equipped with back-up generation of 750KW generator.

DEPOSAL
MR TO SLUDGE HOLDING TAM(
AERATED
SLUDGE
HOLDING TAW
INFLUENT
PUMP STATION
3 PUPS
INFLUENT
Box
PRIMARY CLARFET3 AND TRICKLNG FLIER BYPASS
BLOWERS
1
COMPOST BULONG
PULP STATION
ist
PRIMARY
CIJUDFERS
1.4
VAULT
TRK21)IG
ALTERS
'""— FLIER RE
PUISP STATION +
PRIMARY SLUDGE
PUMP STATION
2 PULPS
5*
RA8 RAS PULP
STATION
FLIER EFFLUENT 1
PULP STATION
3 PUMPS
AERATION
TANKS
CLARFER
SPUTTER BOX
7
4
I RAS IETER
VAULT
FINAL
CL.AF FERS
CCT DRAIN
PUP STATION
JN
U
WAS
4 PROCESS DRAIN4L PUMP STATION
WAS PUMP
STATION
CHLORINE
CONTACT TAM(
THCKBE RS
THICKENED SLUDGE
PUMPS
CO
CCUBMTERS
BELT PRESS
FEED PULPS
-T-
i
ri
POLYMHi
FEED PUMPS
BELT
FLIER
PRESS
DEWATERED
SLUDGE UVE
BOTTOM INN
MATED
BIOFLTER
LEGEND
NORMAL OPERATION
----INTER ITTENT OPERATION
AERATION
BLOWERS
COMPOST
BAYS
ZOtE 'D'
DISCHARGE HARGE TO
FAST BROAD RIVER
FIGURE 1-1
PLANT FLOW SCHEMATIC
FIRST BROAD RIVER
WASTEWATER TREATMENT PLANT

INFLUENT METER
4.
UNCOVERED
AMENDMENT STORAGE
.-DUKE POWER TRANSFORMER
FUEL TANK I
750 KVA GENERATOR
COMPOST BLDG. DRAIN
PUMP STATION
OOWRED AMENDMENT STORAGE
10. DIP PROCESS;
DRAM
CONIROE. OFFICE
LAB/FLEC,
FIRST BROAD =RIVER
WASTEWATER TREATMENT PLIANT
SHELBY, NORTH CAROLINA
14-1
SLUDGE
PROCESSING
A
0A
1L
�=JL_JJ
COVERED CDFAPOST
STORAGE
UNCOVERED COMPOSE
STC!(ACE
LOADING RAMP
6' DM
DRAIN
CLARIFIER
SPUTTER
WAS PUMP
SSTARU4
MH-25
OPERATIONS
at LAB
LIED
—1AH-24 4
MAINTENANCE
BUILDING
AERATED
sluo x
NOLDNG TANK
2C13.001 G14�
s[0x14'3
9LUKA
9VKf6NG
F(11LRE AERAIICN
C16
AERATION TANKS
HRT- 6 HRS.
W/1= 723
6075 SF x
16.5' SYA
750,000 CAL
EACH SIDE
WO 412;5 SRO
FINAL
CLARIFIER 14
W/L=713
s LW #
-�L
FINAL
CLARA1OR 13
�PROc S A"/L=713.
—DRAIN PUMP STA
RAS PUMP STAT. 12 11111 /3
MH ..2-
24'
"- INFLUENT
DISTRIBUTION BOK
WAS
NC
f
c> '.1
PRIMARY CLARIFIER /2
80'0x12. SID
W/L = 732
TRICKUNG FILTER 112
150'0
FIL1EP.
PUMP STAR
7
MH
MTC-D
46
/4
W/1 = 725
N7
24'
WAS _ter
/ FILTER RECIRC
PUMP STATION
RECYCLE RECYCV
SLUDGE
THICKENERS
WL 743.0
VOL = 40000 GAL
EACH TANK
la
PR1K. 5(UDGE
PUMP STAT.
424
-+_16' r7'ati
MH
MAG METER
F10-311
47
MN I49
FINAL
CLARIFIER /2
70'6 x ID' SWD
�DIS CONTRa:
—` —�
�0#5 13
RUM PUMP
AM CONTROL BLDG.
69•4816.5 511G
44,g00 DAL
PRIMARY CLARIFIER 11
N0'0 x 12 SYp
732.
- SLUICE
GATE
TRICKLING FLIER e1
150b
W/L = 725
BO425,6.5 R142
07010 CAL
0 04,
MR #12
CHLORINE CONTACT TANK
DRAIN PUMP STATION(
CHLOF)NE CONTACT
TANK
PROCESS PIPING LEGEND
0 .
PIPE DE506P11W
I4NCR04
1
24" UP
MANE FORCE NAB(
2
Bib
24' OP
CW1F1ER INFLUENT
3
a/b
3r OP -
OMR INFLUENT
4
0/5
JO' OP
FILTER EFFLUENT
5
NOT USED (SEE 42)
5
a/b
24' RCF
CIARNIFR EFFLLERT
7
a/b
16' OP
FLIER REOROILA1IDq
B
a/b
10' OP
RA5
9
a/b .
10' CV
PRAMY SLU090
ID
qt.
6' CIP
'MART SEM
11
16' OP
FLIERRECMN.x11A1N1N
12
a/b
16' OP
Fl1ER 6EORC LA11014
13
10' OP
PRIMARY/SECONDARY NUDGE
14
24' RCF
PANT INFLUENT
15
24' IKF
PC EFFLUENT R,TER BY-PASS
16
24' OP REPLAOS 24' RO
PC EmWENI nine 6Y-PA55
17
24' RCF
DOMING Fir ESRUENT 10 F
'17,
REPLACE 24' RCP W/ 30' BP
MN-B 10 FLIFP. EFFLUENT P.
rro➢ei
• 4.`2 -551 =127 W
16
24' RCP'
19
30' RCP.
CURRIER EFFLUENT
20
a/b
a=. 30' RCP 1r- 24' DIP
PUNT EFFLUENT
a
30' HCF
PLAT EFFLUENT
22
3r RCP.
PLANT EFFLUENT
23
NOT USED
t4
6' OP .
ELM REAR:. P.S. CRAIN
25
6' OP (6011NG
O665 RAS P.S. FI .
25a
6' Op NEW
DRAM TO 02 P.S.
26
10' OP
OLARFLOW-SLULNE RoL'N.
9
6' OP
ORAN MANIENANCE BUILDING
20
6' OP
CONAP.ND TO REUSE WATER
29
AFANDOYED SLUDGE LBIE
30a
4' OP - REPLACES; 6 >
SANITARY WASTE
31-32
A0ANANIONEO MONNE SOLU701L LINES
33
6' 0P
SANITARY/4AO BASTE
33A
6' OP
TEMPORARY LNE 10 ELECIER
34
OS
A. 6' PVC ➢. 4' j5C (DQ
1FUPOIARY UNE TO E.ECTOF
35 04LI
30
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39
6• PIC
SANITARY WASTE
40
,/b
a. 24' DP. b• 30' OP
0E61.110N BASIN INFLUENT
A
4/11
36' OP '
AERATION BASIN EFFLUENT
42
4/0/C/6
24' CAP
FINAL 61ARIFER FEED
43
4/1
10/16 OP
RAS
4/
N/b/c/O
4=16` DP. p•16' CP. c/6.24• DP
.1545 .
45
,/b '
16' DP
.FINAL CLARIFIER EFFLUENT
46
24' DIP
FINAL CLABBER EFFLUENT
47
4/1//c/M
6' OP
FAIL CLARIFIER SAIL(
re
6' DP -
MAIN P.S. O15CAARGF
49
d OP
WAS PS DPLUETIT
50
,/6
6' OP
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51
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52
12' OF
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53
12' DP
- AERA1104 CRAM
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d OP _
FINAL CLARIFIER DRAIN
35
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PROCESS GRAN P.S. O604AR
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52
d OP FORCE MAN
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16' DP..
NR'APPLY - AERA1101 BAD
59
6' OP
CHLORINE CONTACT OR/RI
60
6' DIP\SS -
WIRE TANK OFT -CAS
•61
6' OP\SS
SLUDGE TANK AERATION
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iz

FACILITY NAME AND PERMIT NUMBER:
PERMIT ACTION REQUESTED:
RIVER BASIN:
First Broad WWTP, NC0024538
Renewal
Broad
Additional Information for NPDES Permit Application
Section B.4. Operation/Maintenance Performed by Contractor(s).
If yes, list the name, address, telephone number, and status of each contractor and describe the
contractor's responsibilities (attach additional pages if necessary).
Name: Carolina Engine
Mailing Address: P.O. Box 1095
Charlotte. N.C. 28201 1095
,m, Telephone Number: [phone]
foul
I1
COM
r#t
Responsibilities of Contractor: Preventative and corrective maintenance on emergency generators.
Name: C. Wright Instruments
Mailing Address: 3820 Foxridge Road
Charlotte. N.C. 28226-7256
Telephone Number: [phone]
Responsibilities of Contractor: Instrumentation Calibration Services
Name: Expert Services CITI
Mailing Address: P.O. Box 37047
Charlotte. NC 28237
Telephone Number: [phone]
Responsibilities of Contractor: Repairs. adjustments and upgrades to SCADA system.
Name: Piedmont Chlorinator Service
Mailing Address: 7424 Orr Road
Charlotte. N.C. 28213
Telephone Number: [phone]
Responsibilities of Contractor: Preventative and corrective maintenance on all vacuum regulators and flow proportional
min smart valves.

rya
fgml
folFI
raR
FACIUTY NAME AND PERMIT NUMBER:
PERMIT ACTION REQUESTED:
RIVER BASIN:
First Broad WWTP, NC0024538
Renewal
Broad River
Additional Information for NPDES Permit Application
Section B.4. Operation/Maintenance Performed by Contractor(s) (Continued)
Name:
Mailing Address:
Telephone Number:
GDS Cleveland
1160 Airport Road
Shelby, NC 28152
( 704) 482-9791
Responsibilities of Contractor: Disposal of waste from grit and bar screenings.

FACILITY NAME AND PERMIT NUMBER:
First Broad VVWTP, NC0024538
PERMIT ACTION REQUESTED:
Renewal
RIVER BASIN:
Broad
SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Copeland Corporation
Mailing Address: 4404 East Dixon Blvd.
Shelby, North Carolina 28150
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Discharge from process, washdown, air quality units, boiler blowdown and domestic.
F.5. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal Reciprocating Scroll Refrigeration Compressors
product(s):
Raw material(s): Cast Iron Castings, Aluminum Castings, Cold Rolled Steel Plate, Iron and Zinc Phosphorus Coatings
F.6. Flow Rate.
a. Process wastewater flow rate. Indicate thc average daily volume of process wastewater discharge into the collection system in gallons per day (gpd) and
whether the discharge is continuous or intermittent.
34,000 gpd (X continuous or intermittent)
b. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
gpd (_ continuous or intermittent) "Flow based on 25 gallons per person.
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits ® Ycs ❑ No
b. Categorical pretreatment standards 0 Yes ® No
If subject to categorical pretreatment standards, which category and subcategory?
40 CFR 433
F.8. Problems at the Treatment Works Attributed to Waste Discharge by the SIU. Has the SIU caused or contributed to any problems (c.g., upsets,
interference) at the treatment works in the past three years?
0 Yes ® No If yes, describe each episode.

FACILITY NAME AND PERMIT NUMBER:
First Broad VVVVTP, NC0024538
PERMIT ACTION REQUESTED:
Renewal
RIVER BASIN:
Broad
SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Curtiss Wright Flight Systems
Mailing Address: 201 Old Boiling Springs Road
Shelby. North Carolina 28152
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Machining. heat treating electroplating and painting
F.5. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Mechanical Actuators for aircraft industry
Raw material(s): Steel, aluminum, Cadmium. chromium. nickel. copper, acids and bases from electroplating process.
F.6. Flow Rate.
a. Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per day (gpd) and
whether the discharge is continuous or intermittent.
1,000 gpd ( continuous or X intermittent)
b. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
1,800 gpd ( continuous or X intermittent) *Flow based on 25 gallons per person.
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits ® Yes 0 No
b. Categorical pretreatment standards ® Yes 0 No
If subject to categorical pretreatment standards, which catcgory and subcategory?
Metal Finisher 40 CFR Part 433
F.8. Problems at the Treatment Works Attributed to Waste Discharge by the SIU. Has the SIU caused or contributed to any problems (e.g., upsets,
interference) at the treatment works in the past three years?
0 Yes ® No If yes, describe each episode.

FACILITY NAME AND PERMIT NUMBER:
First Broad VVVVTP, NC0024538
PERMIT ACTION REQUESTED:
Renewal
RIVER BASIN:
Broad
SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Dicey Fabrics
Mailing Address: 430 Ncisler Street
Shelby, North Carolina 28150
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Yarn Manufacturing, weaving, finishing, printing and dyeing, nylon flock
F.6. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Upholstery. Fabric
Raw matcrial(s): Polypropylene chip, cotton yarn. latex finishes and dyes
F.6. Flow Rate.
a. Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per day (gpd) and
whether the discharge is continuous or intermittent.
32,000 gpd ( continuous or X intermittent)
b. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
gpd ( continuous or intermittent) *Flow based on 25 gallons per person.
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits ® Yes ❑ No
b. Categorical pretreatment standards ❑ Yes (0 No
If subject to categorical pretreatment standards, which category and subcategory?
F.8. Problems at the Treatment Works Attributed to Waste Discharge by the SIU. Ilas the SIU caused or contributed to any problems (c.g., upsets,
interference) at the treatment works in the past three years?
❑ Yes ® No If yes, describe each episode.

FACILITY NAME AND PERMIT NUMBER:
First Broad VWVfP, NC0024538
PERMIT ACTION REQUESTED:
Renewal
RIVER BASIN:
Broad
SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information
provide the information
for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
requested for each SIU.
F.3. Significant Industrial
as necessary.
Name:
Mailing Address:
F.4. Industrial Processes.
Manufacture electronic
User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
FAS Controls (Honeywell)
1100 Airport Road
Shelby, North Carolina 28150
Describe all the industrial processes that affect or contribute to the SIU's discharge.
and mechanical switches
F.S. Principal Product(s)
discharge.
Principal product(s):
Raw material(s):
F.6. Flow Rate.
a. Process wastewater
whether
27,000
and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the Sills
Pressure switches, circuit breakers
metals and plastics
flow rate. indicate the average daily volume of process wastewater discharge into the collection system in gallons per day (gpd) and
the discharge is continuous or intermittent.
gpd ( continuous or X intermittent)
b. Non -process
day
wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system in gallons per
(gpd) and whether the discharge is continuous or intermittent.
gpd ( continuous or X intermittent) *Flow based on 25 gallons per person.
F.7. Pretreatment Standards.
a. Local limits
b. Categorical pretreatment
If subject to categorical
Metal Finisher 40 CFR
Indicate whether the SIU is subject to the following:
® Yes ❑ No
standards ® Yes ❑ No
pretreatment standards, which category and subcategory?
Part 433
F.8. Problems at the
interference) at
0 Yes
Treatment Works Attributed to Waste Discharge by the SIU. Has the SIU caused or contributed to any problems (e.g., upsets,
the treatment works in the past three years?
® No If yes, describe each episode.

FACILITY NAME AND PERMIT NUMBER:
First Broad WVVfP, NC0024538
PERMIT ACTION REQUESTED:
Renewal
RIVER BASIN:
Broad
SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Metals America
Mailing Address: 135 Old Boiling Springs Road
Shelby. North Carolina 28152
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Copper anodes and metallic salt solutions
F.5. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Copper and tin anodes
Raw material(s): cobalt, nickel copper, acids and bases
F.6. Flow Rate.
a. Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into thc collection system in gallons per day (gpd) and
whether the discharge is continuous or intermittent.
19.000 gpd ( continuous or X intermittent)
b. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
2,200 gpd ( continuous or X intermittent) *Flow based on 25 gallons per person.
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits ® Yes 0 No
b. Categorical pretreatment standards ® Yes 0 No
If subject to categorical pretreatment standards, which category and subcategory?
Metal Finisher 40 CFR Part 464
F.8. Problems at the Treatment
interference) at the
0 Yes
Works Attributed to Waste Discharge by the SIU. Has the SIU caused or contributed to any problems (c.g., upsets,
treatment works in the past Three years?
® No If yes, describe each episode.

SIR
II
rall
fug
FACILITY NAME AND PERMIT NUMBER:
PERMIT ACTION REQUESTED:
RIVER BASIN:
First Broad WWTP, NC0024538
Renewal
Broad
Additional Information for NPDES Permit Application
Sludge Management Plan
for
First Broad Wastewater Treatment Plant
NPDES Permit # NC0024538
The First Broad Wastewater Treatment Plant (WWTP)designfor sludge handlingconsists of
g
sludge dewatering and composting. This plan describes the processes in place for treating and
disposing of this material.
WASTEWATER PROCESS
The First Broad WWTP is a 6.0 MGD Biological Activated Sludge Wastewater Treatment Facility. The
process consists of a Barscreen, cylindrical fine screen, grit removal, two primary clarifiers, two trickling
filters (currently out of service), aeration basin, four secondary clarifiers, chlorination/dechlorination,
sludge holding tank with aeration, compost building (dewatering included). The Facility discharges into
the First Broad River, which is a Class C stream in the Broad River Basin.
RESIDUALS CHARACTERISTICS
The First Broad River WWTP operates a Compost Facility equipped with IPS /Wheelabrator (US Filter)
equipment and technology. Source of the residuals processed through the facility is from primary and
secondary residuals produced by the WWTP with a very small percentage of digested WAS sludge
processed for the Town of Boiling Springs. The primary sludge is pumped to the sludge holding tank at a
solids concentration of about 4%. WAS sludge is thickened by gravity to about 4% solids prior to being
blended in the sludge holding tank with the primary sludge.
Quantity Diameter/Size
PrimaryllClarifiers Two (2) 80ft / 451,000 gals each
Secondary Clarifiers Four (4) (2) @ 70ft / 288,000 gals each
(2) @ 80ft / 451,000 gals each
m, Gravity Thickeners Two (2) 26ft / 80,000 gals each
Sludge Holding Tank One (1) 50ft/210,000 gals
RESIDUALS DE -WATERING
Sludge is stored in the Sludge Holding tank and aerated using a combination of three (3) blowers housed
in the blower building adjacent to the sludge holding tank.
When operating the blended sludge is conveyed to one of two (2) meter Roediger Tower Presses by one
'�' of three Moyno positive displacement pumps, prior to being deposited on the press the sludge is mix with

polymer through the use of an in line velocity mixer. The sludge reaches the press at about 3% to 5%
solids content. After dewatering through the press, the fmished cake is about 18% to 23% solid content.
AMENDMENT PROCESSING
The City of Shelby's Public Works Department gathers "Yard Waste" throughout the city; this material is
delivered to the composting Facility. After delivery the yard waste (brush) is feed through a "Diamond Z
pot tub grinder equipped with a set of 3 X 5 screens which produce a ground material from saw dust to pieces
roughly as large as 2 to 5 inches in length. This material is transported into a covered area of the compost
building where there is approximate room for 2 weeks storage.
COMPOST MIXING
After discharge from the press the dewatered sludge travels a conveyor and is deposited into the top of a
"Reel Auggie" (agricultural feed mixer). The amendment travels on another conveyor and is deposited into
the top of the mixer. The Compost mix is dependent on the moisture content of the amendment. A
"Normal" mix is based on a 1:1 ratio by weight (approx. 30% sludge and 70% amendment by volume).
After the weights set points are reached (approx. 8000 lbs. Per load) and the mixing is complete the
`o' product is discharged from the mixer onto the floor. From the floor the mix is transported to the "bays" by
the use of a "Skid Steer Loader". It takes about 2 mixer loads to load a bay. The "Load Zone" for each bay
is an area 6' X 6' X 12', or about 16 cu. yds. The mix enters the bay at about 60% moisture and 40% solids
content.
COMPOST PROCESS
The Compost Process is a 21-Day In -Vessel Aerated Static Pile Process that consists of ten (10) vessels
(bay) 6' wide and 180' long. There are two (2) Agitators, one each for five (5) bays. The agitator travels
down the length of the bay in an "UP" position, after reaching the far end it "LOWERS" the drum and
starts its travel back up the bay. As the agitator travels through the material, the drum pitches the mix back
onto a conveyor that discharges about 12' behind the drum. This action basically moves all the material
12' down the bay. Throwing the first material (fmished compost) it comes in contact with out of the bay,
moving the rest down and after completing it's travel back up the bay, creating an empty "Load Zone" for
min
the next material to go into.
After the material is discharge from the bay and prior to distribution as fmished compost, it is sampled for
Fecal Coliform and is stored inside (covered) for 30 days while awaiting test results.
LEACHATE COLLECTION
Decant from the belt presses and leachate for the collection/piping system on the vessels is collected from
the system and drains to a manhole located outside the Compost facility. The manhole is equipped with
two pumps that are used to pump the leachate back to the primary clarifier splitter box.
AERATION AND TEMPERATURE CONTROL
In each bay there are 4 zones (A, B, C, D) each zone has a series of perforated pipes underneath a stone
plenum that is connected to an air blower. The zones are monitored by thermocouples mounted in the
common walls between bays. The blower system monitors on a "TIME — TEMPERATURE" bases. If the
temperature in the bay reaches a set point the blow comes on and runs until it reduces the temperature in
that zone. If the temperature does not reach the set point within one hour, the blower comes on for one
minute to help discharge the moisture from the mix in each zone.

DISTRIBUTION
Compost generated at the First Broad WWTP is currently distributed to the public (landscapers and
homeowners) during the week and on weekends. The City provides the free compost as an unbagged bulk
product that is loaded for customers at no charge. The City of Shelby uses about 10% of the finished
compost in parks and green spaces throughout the City.
ODOR CONTROL
The compost building is equipped with five (5) 50 HP exhaust blowers that discharge the air and moisture
from inside the building through a series of large perforated pipes to the atmosphere, after passing through
a `BIO-FILTER". The bio filter is basically a static compost pile approx. 4 feet deep. The air from the
building passes through this organic material prior to escaping to the atmosphere. This material strips the
odor from the air as it passes through. The moisture helps with the biological process taking place in the
static compost.
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