NC0000752_Authorization to Construct_20020920

NPDES DOCUMENT !;CANNIN`: COVER SHEET
NPDES Permit:
NC0000752
Roanoke Rapids Mill WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
September 20, 2002
'rhis document is printed on reuse paper - ignzore any
content on the reszerse side

State of North Carolina
• Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
ATA
NCDENR
PROFESSIONAL ENGINEER'S CERTIFICATION
FOR
CONSTRUCTION OF WASTEWATER TREATMENT FACILITIES
ATC PROJECT NUMBER: 0000752A01
International Paper — Roanoke Rapids Mill
NPDES Permit No. NC0000752
I, Si Anl l-E9 S' CLk1To n1 , am a duly registered Professional Engineer
(please pn'nt)
in the State of North Carolina and have been authorized to observe (circle one: periodically, weekl
time) the construction of the subject project for the Permittee:
Project No.: 0000752A01
Project: Roanoke Rapids Mill
Halifax County
Installation of additional aerators and a nutrient addition system
Location: North Roanoke Avenue
Roxboro, North Carolina
The project consists of:
• Installation of six 75 hp aerators
• Installation of a nutrient addition system
Thef Water Quality bereby
dol oviledges � O° receipt a accePtance°Y
on
I hereby certify that I did regularly observe this project with due care and diligence and
that the construction was completed in substantial co 9rmance with the Authorization to
Construct and with the approved plans and sp$oJ atiR j, /e+
�'A1P.ESE
Slp44e.
• O a
• e
57251 Registration No. 17251
Signature
Date 91 2-0102-
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division with a certification from a professional engineer certifying that the permitted facility has been installed in
accordance with the NPDES Permit, this Authorization to Construct, and the approved plans and specifications.
The Certification should be submitted to:
NCDENR/DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617

INTERNATIONAL
September 25, 2002
NCDENR
DWQ, NPDES Unit
1617 Mail Service Center
Raleigh, N.C. 27699- 1617
PAPER
KE RAPIDS MILL
580
E RAPIDS. NC 27870
252 533 6000
Dear Sir or Madame: re: ATC Project Number: 0000752A01
Attached you will find a signed Professional Engineer's Certification for
Construction of Wastewater Treatment Facilities for the International Paper Co. Mill
located in Roanoke Rapids, NC If you have any questions, please feel free to contact me
at [phone].
Sicerely,
Chris Puryear
Environmental Supervisor
xc: Jim Cooper
Stan Clayton
Anitra Collins
Neal Davis
Mary Lee Ransmeier
Ken Schuster -NCDENR

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
Mr. Chris Puryear, Environmental Supervisor
International Paper
P.O. Box 580
Roanoke Rapids, North Carolina 27870
Dear Mr. Puryear:
1417A
NCDENR
September 10, 2002
Subject: Authorization to Construct
ATC No. 0000752A01
NPDES Permit No. NC0000752
Roanoke Rapids Mill
Halifax County
The Division of Water Quality's NPDES Unit has reviewed your request for an Authorization to Construct at
the Roanoke Rapids Mill. The Division finds the proposed improvements to be satisfactory and hereby grants
authorization for the following:
• Installation of six (6) 75 hp. aerators to the aeration basin.
• Installation of a nutrient addition system to assure optimum conditions for the
biological treatment system.
This Authorization to Construct is issued in accordance with NPDES Permit No. NC0000752, issued
August 25, 1997, and shall be subject to revocation unless the wastewater treatment facilities are constructed in
accordance with the terms and conditions of the permit. This Authorization to Construct in no way represents
any change to the permitted flow or capacity of the plant.
The Permittee shall notify the Water Quality Supervisor of the Raleigh Regional Office, telephone number
[phone], at least forty-eight (48) hours prior to operation of the installed facilities, so that an in -place
inspection can be made. Notification shall be made during the normal office hours of 8:00 a.m. until 5:00 p.m.,
Monday through Friday.
Engineer's Certification
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division with a certification (copy enclosed) from a professional engineer registered in North Carolina
certifying that the permitted facility has been installed in accordance with the NPDES Permit, this
Authorization to Construct, and the approved plans and specifications. The Certification should be submitted
to: NCDENR / DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617.
Requirements for Certified Operator
The Permittee shall employ a certified wastewater treatment plant operator to be in responsible charge (ORC)
of the wastewater treatment facilities. The operator must hold a certificate of the type and grade at least
equivalent to or greater than the classification assigned to the wastewater treatment facilities by the
Certification Commission. The Permittee must also employ a certified back-up operator of the appropriate type
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer Internet: http://h2o.enr.state.nc.us/

h
International Paper — Roanoke Rapids Mill
NPDES Permit No. NC0000752
ATC No. 0000752A01
Page 2
and grade to comply with the conditions of Title 15A, Chapter 8G, .0200. The ORC of the facility must visit
each Class I facility at least weekly and each Class II, III, and IV facility at least daily, excluding weekends
and holidays; and must properly manage and document daily operation and maintenance of the facility and
comply with all other conditions of Title 15A, Chapter 8G, .0200.
Additional Requirements
The Operational Agreement between the Permittee and the Environmental Management Commission is
incorporated herein by reference and is a condition of this Permit. Noncompliance with the terms of the
Operational Agreement shall subject the Permittee to all sanctions provided by G. S. 143-215.6 for violation of
or failure to act in accordance with the terms and conditions of this Permit.
Failure to abide by the requirements contained in this Authorization to Construct may subject the Permittee to
an enforcement action by the Division of Water Quality in accordance with North Carolina General Statute
143-215.6A to 143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from complying with any and
all statutes, rules, regulations, or ordinances which may be imposed by other government agencies (local, state,
and federal) which have jurisdiction.
The Permittee shall maintain a copy of the approved plans and specifications on file for the life of the facility.
One (1) copy of the approved plans and specifications is enclosed for your records.
If you have any questions about this Authorization to Construct, please contact Natalie Sierra, at (919) 733-
5083, extension 551.
Enclosures: Project Plans and Specifications (approved)
Engineer's Certification Form
cc: Raleigh Regional Office, Water Quality
Technical Assistance and Certification Unit
Central Files
NPDES Unit Files
Sincerely,
‘de,
an W. Klimek, P.E.

State of North Carolina
Department of Environment
and Natural Resources
Raleigh Regional Office
Michael F. Easley, Governor
William G. Ross, Secretary
August 14, 2002
TO: Natalie Sierra
NPDES Permitting
THROUGH: Kenneth Schuster, P.E.
Water Quality Supervisor
FROM: Myrl Nisely III,ae
Environmental Specialist II
SUBJECT: Staff Review Comments
Review of Condensate Hardpiping Specifications
International Paper NPDES Permit No. NC0000752
Roanoke Rapids, NC
Halifax County
A 6.'7; VA
NCDEJR
NORTH CAROLINA
ENVIRONMENT AND N
TI S&RC� 0
SEP - 9 2002
DENR - WATER QUALITY
POINT SOURCE BRANCH
At your request I have reviewed the information submitted for an A to C permit to construct a
hardpipe system for destruction of Condensate Hazardous Air Pollutants in the wastewater system.
This installation is necessary to meet MACT Clean Air regulations at the International Paper Mill.
The design is based upon considerable computer modeling using real operating data, and factored
to handle surge loads up to three standard deviations above mean conditions. During normal day
to day operations, the BOD5 load to the lagoon will not be any different from normal. The
condensates will simply be delivered by a special pipe instead of by way of the sewer system as in
the past.
Condensate capture, piping and pumping are designed using standard engineering practice and
appropriate materials, primarily stainless steel. The changes to the wastewater lagoon, adding a
nutrient addition system and 7- 75 HP Aero-2 aerators can be expected to improve the capacity of
the lagoon to handle shock/peak loads. The MACT regulation will also require I.P. to monitor the
pond more closely using TOC. Treatment system performance will be improved by these changes.
Regarding the additional aerators, I.P. transferred a total of 10 aerators to the Roanoke Rapids plant
from another of their mills. The Environmental Supervisor at the papermill reports that an outside
contractor refurbished them, replaced the motors, and guaranteed that in every way the aerators now
meet the specifications you supplied to me.
In conclusion, the technical merit of the submitted plans appears sound.

Re: All Wet MACT
m A cr-711
Subject: Re: All Wet MACT
Date: Thu, 20 Jun 2002 11:13:39 -0400
From: Tom Belnick <[e-mail]>
To: Charles McEachern <[e-mail]>
Charles- I had taken a brief look at the documents, but not enough to make
substantive comments. A better choice for review of these documents is Myrl
Nisely with DWQ/Raleigh Region. Myrl actually worked as the treatment plant
operator and environmental specialist at the Champion/IP facility for 20+
years before recently joining DWQ, so he is thoroughly familiar with the
issues there. He was still at the plant when they were starting the
hardpiping option. I talked with Myrl today, and he will get in touch with
you this week.
Charles McEachern wrote:
> Hi Betsy, Technical Services has punted the review of IP's (Champion's)
> Initial Performance Test Plan and CMS Protocol for Condensate Collection
> (and also for the Condensate Treatment) along with the resultant Test
> Reports since none of the testing has anything to do with air - makes
> sense to me but the issue still remains. The RRO received these reports
> in March and April, and a "formal response from DENR" is required
> acknowledging the rational behind the protocols. Today Shannon Vogel
> mentioned that you were doing your own review of these things, if that
> is true, do have any checklists or acquired knowledge that I might
> borrow? Any advice or suggestions? I'm considering waving the 'ol
> magic wand to create a new time -space continuum where I'll have the time
> and energy to learn the water testing stuff and be able to review these
> reports with some bit of competency, but I seem to have misplaced it...
> If nothing else I'll settle for sympathy.
>
> Thank you!
> Charles
>
> ps, Tom, has your staff looked these documents over and come to any
> conclusions?
Mailto:[e-mail]
N.0 DENR-DWQ/NPDES Unit
1617 Mail Service Center, Raleigh NC 27699-1617
Work: [phone] ext. 543
Fax: [phone]
1 of 1 6/20/02 11:17 AM

0 Washington
Revision
Originators Signature
Date
Project Engineer's
gnature
Date
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FINAL PLANS - NOT FOR CONSTRUCTION
SPECIFICATION NO. 23839.001/AERATOR S
REVISION 0, DATED MAY 13, 2002
INTERNATIONAL PAPER COMPANY
CLUSTER RULE PROJECT
ROANOKE RAPIDS MILL
ROANOKE RAPIDS, NC
Prepared By
Washington Group International, Inc.
Rust Engineering
Birmingham, Alabama
Contract No. 23839.001
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QUPUirY

International Paper
Cluster Rules Project
Roanoke Rapids, NC Mill
Mechanical High Speed Floating Aerator(s)
Rust Contract No. 79942.001
Inquiry No. 79942.001 RO-3
STAINLESS STEEL ENDURA SERIES
AERATOR SPECIFICATIONS
*Items included in the proposal as adders are in bold italic type.
1. GENERAL
Furnish al - 75 HP floating aerators. Each aerator shall consist of a motor, a
direct drive impeller driven at a constant speed and an integral flotation unit.
A. QUALIFICATION — Any supplier wishing to bid other than the specified
supplier shall provide the following:
A letter signed by an officer of the company certifying compliance with the
specifications without exception. In addition, the supplier must certify the
proposed motors will be warranted by the motor supplier as outlined in the
specified warranty.
A field test report documenting the proposed or similar units have been
field tested.
Proof of manufacturing and testing facilities.
Installation list with contact names and telephone numbers for a minimum
of ten installation of similar size in operation for ten years.
FAILURE FOR THE CONTRACTOR TO SUPPLY THIS INFORMATION WITH
THE BID MAY BE CAUSE FOR DISQUALIFICATION OF THE CONTRACTORS
BID.
2. AERATOR DRIVE MOTOR
2.1 The motor shall deliver 75 horsepower and shall be wired for 460 volt, 60
cycle, 3 phase service.

2
2.2 The motor shall be totally enclosed; fan cooled, and generally rated for
severe chemical duty, and shall have a 1.15 service factor.
2.3 The motor shall include vacuum pressure impregnated; non -
hygroscopic epoxy insulated form wound coils and inpro-rotating
shaft seals installed in the drive end. Motor shall be premium
efficient.
2.3 The motor windings shall be nonhygroscopic, and insulation shall equal or
exceed NEMA Class "F".
2.4 A condensate drain shall be located at the lowest point in the lower end- ,
bell housing.
2.5 All motor frame parting surfaces shall be deep registered and Permatex
sealed.
2.6 All through bolts, nuts, and screws shall be of type 18-8 stainless steel.
2.7 Each motor will have a rain cap constructed of cast iron or non -corrosive
304 stainless steel. Painted or plated carbon steel rain caps will not be
acceptable.
2.8 A stainless steel nameplate shall be provided with'each motor and shall
be securely fastened thereto. The voltage, speed, insulation class,
amperage, service factor, wiring diagram, motor serial number, and the
manufacturer's name and address shall be steel stamped or otherwise
permanently marked. In addition, a special 1" x 3" x 1/16" 316
stainless steel nameplate shall be affixed to the motor and float
w/equipment description and mill equipment number The motor shall
be an Aqua Aerobic Systems, Inc., "Centaur" model supplied by Reliance
Electric, or "Endura" model supplied by USEM or Teco-Westinghouse.
3. MOTOR SHAFT
Unit shall have a one-piece motor shaft continuous from the top motor bearing,
through the lower bearing and down to and through the propeller. This shaft will
have a minimum diameter of 2-1/2 " and be manufactured from 17-4 PH
stainless steel, or comparable stainless steel having a minimum yield strength of
100,000 psi on units 3 HP and larger.

3
4. RPM
Units shall operate at the lowest RPM offered in this size by the manufacturer. In
no case shall nominal RPM exceed 1800 for units meeting the one-piece shaft
specified above. Units featuring one-piece shaft shall operate nominally at 1800
RPM in the size range of 3 -15 HP, or at a nominal maximum speed of 1200
RPM for units in the 20 - 75 HP size range and 900 RPM for units in the 100 -
150 HP size range.
5. MOTOR BEARING
5.1 Motor bearings shall be regreasable. Sealed bearings are not acceptable.
Top bearing shall be shielded on the bottom side only. Bottom bearing
shall be open.
5.2 The top and bottom motor bearings shall be of the combined radial and
axial thrust type.
5.3 The lower motor bearing inner race shall be locked to the motor shaft via
a special washer and locking nut arrangement. The shaft shall be
threaded just below the lower bearing and shall have a keyway cut into
the motor shaft. This key shall accept a tab from the 1.D. of the locking
washer, and the locking nut shall have recesses to accept a tab from the
O.D. of the locking washer to prevent the nut from backing off. Snap ring
type bearing retainers will not be acceptable.
6. DIFFUSER HEAD
6.1 The diffusion head shall be a minimum of 34-1/4" in dia. with a minimum
overall opening dimension of 10". The top of the diffusion head shall be
11-1/2 " above the float.
6.2 The design of the diffuser head shall be such that the liquid spray will
discharge at angle of 90° to the motor shaft, and over a 360° pattern in
the horizontal plane, and shall be a stainless steel monolithic casting.
6.3 The diffuser head casting shall act as a base for the aerator motor, and
alignment of the motor to this base shall be controlled by machined index
fittings that engage the P-base of the motor. Diffuser head/motor
arrangements that are dependent upon boltholes only for alignment will
not be acceptable. All diffusion head hardware will be 304 stainless steel
and safety wired.

4
6.4 The diffuser head casting shall act as a thrust block to deflect the high
velocity, pumped volume of the aerator from the vertical to the horizontal
direction. In order to minimize vibration, and to provide adequate strength,
the diffuser head casting shall weigh no less than 325 lbs. The bottom
side of this casting shall have a 90° radiused transition to effect the
hydraulic change in direction with a minimum of head loss.
6.5 The diffuser head shall absorb all normal and shock loads encountered by
the propeller and transmitted to the diffuser head via the motor shaft and
lower motor end -bell. The diffuser head shall distribute these forces into
the float via webs that terminate in a flange or ring that is an integral part
of the diffuser head. This flange shall mate with a similar flange that is an
integral part of the float/volute to spread the stresses generated by the
propeller uniformly around the float so that no point loading of the float is
allowed. These flanges shall be machined flat to provide proper bearing
surfaces. The alignment of the diffuser head flange to the float/volute
shall be by use of a 360° index pilot; use of boltholes shall not be
acceptable.
6.6 Specifically, diffuser head designs that employ studs and spacers,
shoulder bolts or fiberglass are not allowed. Load bearing, machined flat,
flange -to -flange connections will be mandatory.
6.7 The diffuser head shall contain an anti -deflection journal insert to limit the
radial deflection of the motor shaft.
6.8 This anti -deflection journal insert shall be located in the lower extremity of
the diffusion head, approximately one-half the distance between the motor
base and the lower end of the shaft.
6.9 The journal insert shall be machined from Delrin and shall be a minimum
of 0.020" larger through the bore than the diameter of the motor shaft.
6.10 Units featuring a one-piece unsupported shaft will not be acceptable.
6.11 There shall be a fluid deflector located on the motor shaft immediately
below the anti -deflection journal, which shall cover completely the anti -
deflection journal insert and the lower portion of the diffusion head.
6.12 This fluid deflector shall be molded from black neoprene and shall be
press fit onto the motor shaft.

5
7. FLOTATION
7.1 Each aerator shall have 2555 lbs. reserve buoyancy to ensure stability
and to provide support flotation required during aerator servicing. Floats
shall be one-piece, i.e.; segmented floats are not acceptable.
7.2 Flotation stability will be mandatory. Under no circumstances will unstable
flotation designs requiring counterbalancing, ballast of liquid, solid mass
or submerged major fabricated assemblies to stabilize the operation of the
aerator be allowed. Only aerators demonstrating stable operational ,
characteristics, without rocking or oscillating will be acceptable.
7.3 The float shall be a minimum of 114-5/8 " in diameter and 14-7/8" thick
and shall be fabricated of a minimum of 14 gauge, 304 stainless steel.
7.4 The float shall be constructed so that all stress imposed from wave action
and mooring line tension shall be transmitted from `each mooring line to
another by pulling across the float in such a manner as not to "flex" the
structure.
7.5 All floats shall be constructed so that the internal void can be filled full of
closed cell polyurethane foam having a minimum 2.0 Ibs/ft3 density and
shall be completely sealed watertight.
7.6 All floats shall have six mooring points, spaced for 3 or 4-point mooring
around the outer circumference. No mooring connections will be allowed
as embedments in the upper or lower float covers. Only tension type
connections perpendicular to the outer sidewall will be approved. All
mooring connections shall be stainless steel.
7.7 The float construction shall be such that the volute will distribute the load
of the entire motor, drive, diffusion head and volute static load, plus the
entire dynamic load from the propeller thrust and radial forces by
spreading these forces uniformly around the full 360° circumference of the
floats central core. Point connected joints or point stressed connections
will not be accepted.
7.8 All floats shall include a permanently attached cable support bracket
of 304 stainless steel per International Paper Specification to prevent
the power cable from rubbing the edge of the float
7.9 All floats shall be coated with material to provide a non-skid surface.

6
8. PROPELLER
8.1 The propeller shall be a two -blade, left-handed, marine type precision
casting of 316 stainless steel, 19-1/2" diameter, and shall be specifically
designed for the application intended. It shall be a self-cleaning type that
will not accumulate fibers, rags, stringy materials, etc. The propeller will
have a diameter not allowing a greater clearance with the volute of .25".
8.2 Each propeller blade shall be pitched so that the pitch angle and rake
angle are within ± 2 percent of the other blade(s).
8.3 The propeller shall be pitched so that the drive motor is loaded between
88% and 95% of full load nameplate horsepower. Data confirming the
pitch, diameter and rake will be supplied with the submittals.
8.4 Units using inclined screw impellers will not be acceptable.
8.5 The propeller must be attached to the motor shaft with a hardened
stainless steel pin and set screw. No tapered, threaded shafts with nut
fasteners will be acceptable.
9. VOLUTE
9.1 The propeller shall operate in a volute made of 304 stainless steel and
shall be a minimum of 20 " in diameter. It shall be round and true so that
propeller blade tip clearance is uniform within the volute as it rotates. The
volute shall have a minimum of 3/16 inch wall thickness, and a minimum
of four full-length stainless steel gussets shall be welded on a 90° spacing .
around the circumference of the volute between the top and bottom
flanges.
9.2 The volute shall have a large machined flange at its top extremity that
completely encircles the volute, and this flange shall match a similar
flange on the bottom of the diffuser head to provide for a bolted, machined
flange -to -flange fit to provide uniform distribution of the dynamic loads
generated by the propeller and the static weight of the motor and drive. A
360° machined index in the upper flange shall provide concentric
alignment of the propeller in the volute by engaging the inside diameter of
the mating flange on the diffusion head. Bolt holes alone will not be
acceptable to locate the important alignment of the propeller.
9.3 Fiberglass volutes, or carbon steel volutes that are fiberglass, steel or
stainless steel Tined are not acceptable.

7
10. INTAKE CONE
10.1 The intake cone shall be fabricated from .135 " 304 stainless steel having
a gradually expanding opening outward to the intake end. The length and
inlet diameter shall be sufficient to provide uniform inlet hydraulics so that
no increase in vibration is caused due to its shape or size. The minimum
acceptable length is 20 " and minimum inlet diameter is 30-3/4 ".
10.2 The material used to fabricate the intake cone shall be structurally
sufficient to support the weight of the entire aerator assembly when the
aerator is freestanding on dry ground.
10.3 For maximum in-depth mixing efficiency, the intake cone shall be
designed so that the suction lift from the aerator propeller is vertical from
the liquid depth below the aerator. Unless specifically required for anti -
erosion requirements, side or angle entry suction inlets will not be
approved. Fiberglass intake cones are not allowed. All aerators 30 HP
and larger must provide anti -vortex crosses welded inside the cones.
Anti -erosion devices, if required, must be welded to the crosses.
11. BALANCING
11.1 The entire rotating assembly including the motor rotor, shaft, shaft
accessories, and impeller shall be dynamically balanced to within 0.12
inches/second velocity measured at the upper and lower motor bearing.
Measurements shall be taken at a frequency equivalent to the motor
RPM.
11.2 Measurements shall be taken with the motor in a vertical, shaft down
position with the entire power section mounted on resilient pads. Certified
copies of the balance inspection shall be supplied with each aerator.
11.3 Each unit shall be wet tested in liquid medium to include vibration or
power draw test.
11.4 Oxygen transfer testing on each unit will be performed at Aqua -
Aerobic Systems, Inc.

8
12. MOORING
Cable mooring can be used when water level variation is not great.
12.1 The anchor cable shall be installed as recommended by the manufacturer
so the aerator shall be permitted to rise and fall with some water level
variations, but will have a minimum of lateral movement.
12.2 The maximum amount of anticipated water level variation is . feet.
12.3 Anchor cable shall be 7 x 19 construction, 304 stainless steel and 1 /4 "
diameter.
12.4 Mooring hardware (thimbles and clips) shall be of 316 stainless steel.
Galvanized hardware is not acceptable.
13. ELECTRICAL SERVICE CABLE
13.1 Each unit shall require #0-4 AWG electrical service cable, continuous
length (non -spliced). The cable shall have three power conductors and a
ground conductor. Each unit shall include a 2-eye strain relief cord
grip assembly (kellems grip).
13.2 Conductorsshall be flexible type annealed copper stranded. Each
conductor, including the ground conductor, shall be insulated. Cables
containing an uninsulated ground conductor will not be acceptable.
13.3 The insulated conductors shall be assembled together with a non -
hygroscopic filler.material.
13.4 Outer jacket shall be high quality CPE, PVC, TPE or equal, and shall be
rated at a conductor operating temperature of not less than 90°C.
13.5 The cable shall be rated for hard usage outdoor service and shall be
resistant to oil, sunlight, ozone, grease, acids, water, abrasion and impact.
14. INSTALLATION, OPERATING, AND MAINTENANCE MANUALS
14.1 The aerator manufacturer shall provide required copies of a detailed
manual that shall include specific instructions for receiving and handling,
assembly, mooring, wiring, installation, repair and service, storage,
troubleshooting, detailed exploded drawings of the unit, and a full parts
list.

9
14.2 In addition, the manual shall contain complete detailed instructions on the
balancing procedure to be used for rebalancing to the propeller after it has
been in service for an extended period of time. These instructions shall
include, but not be limited to, a general procedural description, a detailed
explanation of preparing the unit for balancing, for setting up the dynamic
balancer, portable balancing technique, a detailed description of the
vector chart method of single plane balancing and sample balancing
record forms.
14.3 These manuals shall be submitted for review, along with other general ,
submittal information, including detailed drawings, brochures, cut -sheets, ,
motor data sheets, etc., as a part of the approval process.
15. MANUFACTURER
The aerator specified herein shall be the Aqua -Jet Endura series as
manufactured by Aqua -Aerobic Systems. The Endura series shall incorporate
design enhancements that provide operation for five years without routine
maintenance.
16. WARRANTY
The Endura series shall be warranted for three years fordefects in materials
and workmanship and five years as a no maintenance unit.
dfh
04/19/01
•
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Final Plans — Not for Construction
Rust Engineers, Birmingham, AL DDS RRO2X.xls Sheet 1 of 2
Job No. 79942.001
Made RRW 27-Nov-00
Checked
PRESSURE VESSEL
& STORAGE TANK
DESIGN DATA SHEET
RE&C Equip. No: 076-4-2000-5080
Client Equip. No. LATER
Revision: B 17-Apr-02
1
Client: INTERNATIONAL PAPER
Project: CLUSTER RULE PROJECT
Location: USA
Equip. Name: TANK, PHOSPHORIC ACID
Vendor:
P.O.Number:
2
3
4
Roanoke Rapids, NC
10'- 0" DIA X 13'- 0" HIGH
316L SS
Remarks:
FURNISH FOUNDATION LOADS DUE TO WIND, SEISMIC,
AND INTERNAL PRESSURE PER "SUPPORT LOADS AND
FOOTPRINT' SHEET.
FURNISH AND INSTALL 4 HOLD DOWN LUGS (CHAIRS)
FOR 1" DIA ANCHOR BOLTS (BOLTS BY OTHERS).
THICKNESSES SHOWN ARE MINIMUMS AND INCLUDE C.A.
INCLUDE A 360 DEGREE ROOF RAILING AND LADDER
FROM ROOF TO GRADE.
MECHANICAL DESIGN CRITERIA
Oper Press.
ATMOS
Oper.Temp.
AMBIENT
5
Design Press.
2.5 psig
Design Temp. max
100 °F
6
Design Vac.
NA
MDMT
#2
7
Sp.G.of Contents
1.85
Service
ACID
8
Standard or Code
API 650 S
Code Stamp
NA
9
Plate Condition
HRAP
Registration
NA
10
Postweld H.T.
NO
Radiography
SPOT
11
Joint Eff. Shell
0.85
Joint Eff. Roof
NA
12
Corr. Allow. Shell
0.0625 in
Corr. Allow. Top
0.0625 in
13
Corr. Allow. Other
NA
Corr. Allow. Bot
0.0625 in
14
Hydro.Test
YES, FULL
Air Test psig
REPADS ONLY
15
Wind Loading
#2
Seismic Loading
#2
16
Roof or Top Hd.
CONE
Bottom or BotHd
FLAT
17
Matls: Shell
A240-316 #3
Matls: Structurals
A276 316L
18
Roof or Head
A240-316 #3
LJ Flanges
NA
19
Bottom or Head
A240-316 #3
Stub Ends
NA
20
Noz.Necks
A312-316L
WN Flanges
A182 F316L
21
MW Necks
A240-316 #3
MW Flanges
A240-316 #3
22
MW Covers
A240-316 #3
Noz.Blinds
A240-316 #3
23
Internal Pipe
NA
Internal Figs.
NA
24
Couplings
NA
Handholes
NA
25
Bolts or Studs
A193-B7
Nuts
A 194 2H
26
Gaskets
Garlock
Blue -Guard Style 3700
or eq. •
27
MW Davits
YES, STD V-9A
MW Hinges
NO
28
Platforms
NO
Platform Clips
NO
29
Ladder. Cage
YES, NO
Ladder Clips
YES
30
Stair
NO
Stair Clips
NO
31
Insulation Thk.
1" BY OTHERS
Insulation Suppts.
YES, STD V-5
32
Fireproofing Thk.
NO
Fireproofing Suppts.
NO
33
Trays
NO
Tray Supports
NO
34
Stiffener Rings
NO
Lining
NO
35
Vessel Support
SLAB
Ground Lug
STD V-22
36
Surface Prep Ins.
#4
Surface Prep.Outs.
#1
37
Shop Paint Inside
NONE
Shop Paint Outside
#1
38
Field Paint Inside
NONE
Field Paint Outside
#1
39
Nominal Capacity
7,500 gal
Certificate
API Fig 8-2
40
Nameplate
API Fig 8-1
Wind Moment
#5
41
Mill Equipment No.
later
Wind Shear
#5
42
Service Location No
later
Seismic Moment
#5
43
Test Wt (HTW)
#5
_Seismic Shear
#5
44
45
SCHEDULE OF APPURTENANCES
NOTES:
46
Nozzles
No.
Size
Class
Type
Mark
Nozzles
No.
Size
Class
Type
Mark
#1 SEE PAINT DATA SHEETS FOR DETAILS
47
OVERFLOW
1
4
150#
RFWN
A
#2 SEE SITE DATA SHEET
48
INLET
1
4
150#
RFWN
, B
#3 DUAL CERTIFIED 3161316E
49
OUTLET
1
1
150#
RFWN
C
#4 CLEAN PER VS-2
50
DRAIN #6
1
4
150#
RFWN
0
#5 SEE REMARKS
51
LEVEL
1
1
150#
RFWN
L1
#6 FLUSH DRAIN STD V-2, -•, \, �,;, �. ' . ,,,
52
LEVEL
1
1
150#
RFWN
L2
#7 GOOSENECK STD V-19 " ,,• •,..r, ., , ' ''•
53
SHELL MW
1
30
API
STD
M1
._ 1�, %�
54
ROOF MW
1
24
API
STD
M2
_
S F bd.. ''
55
VENT #7
1
4
—
—
V
, 0, ,• s. r.
56
SPARE
1
4
150#
RFWN
X
,
. .,, -_ ' 4
<,. /
57
REV
DESCRIPTION
BY
DATE
CHECKED
•DA'TE' .'
"'0;,4-
`' ' �` j
58
B
(REV. NOZ. A)
JB
17-Apr-02
'���"
�"�. „"��,� Z
Printed 10:45 AM 4/17/02

Rust Engineers, Birmingham, AL
DDS RRO2X.xls Sheet 2 of 2
Job No. 79942.001
Made RRW 27-Nov-00
Checked
PRESSURE VESSEL
& STORAGE TANK
DESIGN DATA SHEET
RE&C Equip. No: 076-4-2000-5080
Client Equip. No. LATER
Revision: B 17-Apr-02
2
3
Ctient: INTERNATIONAL PAPER
Project: CLUSTER RULE PROJECT
Location: USA
Equip. Name: TANK. PHOSPHORIC ACID
Vendor
P.O. Number:
4
5
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
2X2X3/16TA
LEG TURNED IN
10'-01" ID
0.1875" MIN
0
c)
0.1875" MIN
to Z_
O �
4 BOLTS, I" DIA
r
IP 10
SCHEMATIC ELEVATION
57
58
Printed 10:45 AM 4/17/02
DDS

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Gregory J. Thorpe, Ph.D., Acting Director
May 6, 2002
Mr. Chris Puryear
International Paper
P.O. Box 580
Roanoke Rapids, North Carolina 27870
Dear Mr. Puryear:
46/77A
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: NPDES Permit No. NC0000752
Authorization to Construct Return
Return #2154
Roanoke Rapids Mill
Halifax County
In accordance with Division policy, we must hereby return the attached Authorization to Construct request
received on April 26, 2002. After a preliminary review. the Division has determined that the request
package lacks the following items:
• Although you have submitted specifications and calcualations, please ensure that they are signed
and sealed by a NC Professional Engineer.
If you have any questions about the NPDES Authorization to Construct process, please contact Christie
Jackson at telephone number [phone]. extension 538.
Sincerely,
rA
PrDavid A. Goodrich
NPDFS Supervisor
cc: Central Files
NPDES Unit, Permit File
Raleigh Regional Office, Water Quality
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 - Telephone [phone]/FAX [phone]
An Equal Opportunity Affirmative Action Employer - 50% recycled/ 10% post -consumer paper