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Home My WebLink AboutNC0046728_Authorization to Construct_20030520NPDES DOCUHENT SCANNING COVER SHEET NC0046728 Mooresville / Rocky River WWTP NPDES Permit: Document Type: Permit Issuance Wasteload Allocation n.Y ..••!f.: Y-MLIs"Yh11Yr u+- .,. .,ar. Authorization to Construct (AtC) Permit Modification Complete File - Historical Engineering Alternatives (EAA) Approval Instream Assessment (67b) Speculative Limits Environmental Assessment (EA) Permit History Document Date: May 20, 2003 This document is printed on reuse paper - ignore any content on the reverse side TOWN OF MOORESVILLE litillties Deparbnent May 20, 2003 NPDES Unit DENR/DWQ 1617 Mail Service Center Raleigh, NC 27699-1617 Attn: Mr. David Goodrich Wilce Martin Utilities Director Town of Mooresville P. O. Box 878 Mooresville, NC 28115 (704) 663-7282 Fax 663-7362 Mobile 980-722-6251 RE: Authorization to Construct Permit Issuance ATC Number 046728A03 Mooresville -Rocky River WWTP NPDES Permit NC0046728 Iredell County Mr. Goodrich: Upon receiving your authorization to construct in February 03 the Town asked the Town Engineering Consultant to update the costs of the project because it had been three years since the project was originally estimated. This was due to some delays on our part and a To co s L 4 l long review by the State because of personnel shortages and work Toad from what we J understand. The Town's engineers updated the estimated costs and they went up from $2.89 million to $6.1 million dollars. As a result the Town cannot afford to build this project at this time. We are planning to build it in several years. We are still meeting our NPDES permit requirements and land applying sludge on about 1,200 acres of farm land. I discussed this matter with Mr. Charles Weaver of your office who suggested that I contact you in writing to inform you that the Town of Mooresville will not be able to construct the sludge dewatering project at this time, so that it would be a matter of record. He stated that there isn't really any time limit, but you do want it constructed within a reasonable amount of time. However, as I stated above we will be planning to construct it within several years. Should you require additional information regarding this matter please contact me. Wilce Martin Utilities Director CC: Rick McLean Carson Fisher Joe DeBruhl • Page2 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 AC;rA NCDENR NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES January 21, 2003 Mr. H. Carson Fisher, P.E., Town Engineer Town of Mooresville P.O. Box 878 Moorseville, North Carolina 46728 Subject: Authorization to Construct Permit Issuance ATC Number 046728A03 Mooresville - Rocky River WWTP NPDES Permit NC0046728 Iredell County Dear Mr. Fisher: A request for an Authorization to Construct (ATC) was received by the Division and final plans and specifications for this project have been reviewed and found to be satisfactory. Authorization is hereby granted for the Mooresville - Rocky River Wastewater Treatment Plant improvements. Specifically, this ATC allows: • Addition of residuals thickening equipment and associated equipment (after clarification prior to aerobic digestion), • Thickener building sized for two, 3 m.gravity belt thickeners, • Polymer feed system for gravity belt thickeners, • Air compressors for gravity belt thickeners, • Belt washwater pumps, three, (using chlorinated effluent), • Thickened sludge return pumps (2, positive displacement -variable speed pumps) • Addition of a 1 MG concrete aerated sludge holding tank, • 180 inch submerged impeller and sparge ring for aeration (1800 scfm), • 2 blowers at 1000 scfm, • Addition of a tanker loading pump station, • 2 variable speed (up to 1200 gpm)drive tanker loading pumps, • Associated equipment for residuals transfer to tanker trucks, • Equivalent replacement parts for the following: • 2 digester aerators (100 inch submerged impeller and sparge ring , 1800 scfm) • 2 waste sludge pumps (25 Hp, variable speed drive up to 840 gpm), • 2 digester transfer pumps (15 Hp, 250 gpm), • 2 plant water pumps, (25 Hp, variable speed, up to 400 gpm - increased for thickening), • Drainage system for all filtrate and decant to divert back to the headworks, • and all additional piping, valves, control equipment and appurtenances. Once modifications approved under this ATC have been completed and an Engineer's Certificate has been submitted, the permittee is authorized to operate the units listed above. This Authorization to Construct does not alter the current design flow of 5.2 MGD for the Town of Mooresville. 1617 MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1617 - TELEPHONE 919-733-5083/FAX 919-733-0719 AN EQUAL OPPORTUNITY AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/ 1 0% POST -CONSUMER PAPER VISIT US ON THE WEB AT http://h2o.enr.state.nc.us/NPDES 4 d Mr. Fisher NC0046728 2 This Authorization to Construct is issued in accordance with NPDES Permit No. NC0046728 issued January 26, 2001, and shall be subject to revocation unless the wastewater treatment facilities are constructed in accordance with the conditions and limitations specified in the permit. The sludge generated from these treatment facilities must be disposed of in accordance with G.S. 143-215.1 and in a manner approved by the North Carolina Division of Water Quality. In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the Permittee shall take immediate corrective action, including those as may be required by this Division, such as the construction of additional or replacement wastewater treatment or disposal facilities. The Mooresville Regional Office, telephone number (704) 663-1699, shall be notified at least forty-eight (48) hours in advance of operation of the installed facilities so that an in -place inspection can be made. Such notification to the regional supervisor shall be made during the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State Holidays. Upon classification of the facility by the Certification Commission, the Permittee shall employ a certified water pollution control treatment system operator to be in responsible charge (ORC) of the water pollution control treatment system. The operator must hold a certificate of the type and grade at least equivalent to or greater than the classification assigned to the water pollution control treatment system by the Certification Commission. The Permittee must also employ a certified back-up operator of the appropriate type and grade to comply with the conditions of Title 15A, Chapter 8G, .0202. The ORC of the facility must visit each Class I facility at least weekly and each Class II, III, and N facility at least daily, excluding weekends and holidays, and must properly manage and document daily operation and maintenance of the facility and must comply with all other conditions outlined in Title 15A, Chapter 8G, .0204. Once the facility is classified, the Permittee must submit a letter to the Certification Commission which designates the operator in responsible charge within: (A) Sixty calendar days prior to wastewater being introduced into a new system or (B) within 120 calendar days of the following, (i) after receiving notification of a change in the classification of the system requiring the designation of a new ORC and back-up ORC or (ii) a vacancy in the position of ORC or back-up ORC. A copy of the approved plans and specifications shall be maintained on file by the Permittee for the life of the facility. The Operational Agreement between the Permittee and the Environmental Management Commission is incorporated herein by reference and is a condition of this Permit. Noncompliance with the terms of the Operational Agreement shall subject the Permittee to all sanctions provided by G. S. 143-215.6 for violation of or failure to act in accordance with the terms and conditions of this Permit. Failure to abide by the requirements contained in this Authorization to 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. Upon completion of construction and prior to operation of this permitted facility, a certification must be received from a professional engineer certifying that the permitted facility has been installed in accordance with the NPDES Permit, this Authorization to Construct and the approved plans and specifications. Mail the Certification to the NPDES Unit, Division of Water Quality, 1617 Mail Service Center, Raleigh, NC 27699-1617. Mr. Fisher NC0046728 3 One (1) set of approved plans and specifications is being forwarded to you. If you have any questions or need additional information, please contact Ms. Susan A. Wilson, P.E., telephone number (919) 733-5083, extension 510. cc: Central Files NPDES Unit, Permit File Mooresville Regional Office, Mr. Charles Willis, Jr., P.E. Since On W. Klimek, P.E. Water Quality WillisEngineers 1520 South Boulevard Charlotte, NC 28203 Town of Mooresville Rocky River WWTP Review Comments and Responses Solids Handling Facilities The following Comments were received from NCDENR — Division of Water Quality, 18 April 2002. Each comment from DWQ (underlined) is followed by a response from Willis Engineers List major components to be added (outside of those listed on PI-2-1 of the specs). For example, I know that the sludge holding tank is an addition, please state dimensions, etc. for that component and any other component to be added (it's difficult for me to tell from the plans — since those components are not in bold to differentiate new from existing). Major components of the project include the addition of a gravity thickening facility, one million gallon aerated storage tank, tanker vehicle loading pump station and various mechanical equipment replacements. Items listed in the Payment Items under PI-2.04 Schedule of Major Mechanical Equipment are limited to mechanical devices ancillary to those major facilities. The sizes of the facilities and their capacity are found on the attached Basis of Design. Provide a flow diagram for the area being modified, with an indication of the flow of all liquids and solids (for example, I'd like to see that the runoff of liquid from the belt press reverts back to the headworks or elsewhere in the treatment plant). A flow diagram for the proposed facilities is attached to the Basis of Design. Provide calculations for the new components (i.e., the loading rate for the belt press, the aeration requirement for the holding tank and subsequent aeration supplied, etc.). Reference the attached Basis of Design. For the replacement components — are these strict replacements of like components? If not, lust provide calculations to indicate that those replacement components are still adequate for what's to be accomplished. Yes. Replacement components as listed in the Contract are identical to those provided with the original facility with the exception of the plant water pumps. These pumps are being increased in size to provide additional washwater for the thickening facilities. Provide calculations to confirm that the residuals conform to the 503 rules. Is the landfill option to be abandoned and all of residuals to be land applied? The facilities as designed are capable of meeting the requirements of 40CFR Part 503. The dedicated landfill on the treatment plant site was closed at the end of 2000. Since that time the Town has developed a land application program. Provide calculations to ensure that the 30 day residuals holding time is being met. Reference the attached Basis of Design. Willis Engineers 1 912.102 (34) Town of Mooresville Rocky River Wastewater Treatment Plant Solids Disposal Facilities Basis of Design 1 Solids Loading Year 2000 Plant Flow 3.25 MGD Excess Solids 1,100 DT/Yr Year 2010 Plant Flow 5.20 MGD (Design Flow) Excess Solids 1,900 DT/Yr o ... 2 Disposal Method Liquid Land Application Solids Concentration 2% to 3% Unthickened 5% to 6% Thickened Treatment Type Class B Operator Private Contractor Permit Type Individual Site Permits Application Areas Private Farms 3 Thickening Facilities Feed Solids Concentration 0.3% to 0.7% O1A Output Solids Concentration 5% to 6% Number —Two — Type Gravity Belt Size 3 meter Capacity 750 gpm - each Throughput Capacity @ 0.3% Solids, 40 Hr/wk 1,170 DT/yr- each 40 Hrs/wk 4 Storage Facilities Number One Type Circular Tank Diameter 100 ft Depth 18 ft SWD Volume 1,000,000 gal Stoage Capacity @ 5.2 MGD, 5% Solids 40 days aiskf7'54s Willis Engineers 1 Appendix A •♦ • RECYCLE PUMPING STATION SECONDARY CLARIFIER 8" WASTE FORCE MAIN FILTRATE/DECANT DRAIN TO HEADWORKS TANKER PUMPING STATION -, SECONDARY CLARIFIER SLUDGE HOLDING TANK GRAVITY THICKENERS AEROBIC DIGESTOR DIGESTED SLUDGE FORCE MAIN AEROBIC DIGESTOR DIGESTOR PUMP STATION 0 0 0 DRAIN 0 uuilhis ENGINEERS TOWN OF MOORESVILLE ROCKY RIVER WWTP SOLIDS HANDLING FACILITIES JUNE 2002 NOT TO SCALE FLOW DIAGRAM /14005.elt �l l C ( 04.67Z S 1 :0_5c1) �i sa 4, r % / A-rf5 t4?,4 Peclie7%/_ (o/z/o2) C i)(! 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