NC0037834_Authorization to Construct_20080512

NPDES DOCIMENT SCANNING COVER SHEET
NC0037834
Archie Elledge WWTP
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
May 12, 2008
Thiss document is printed on reuae paper - ignore any
content on the resterae aide

Winston-Salem/Forsyth County Utilities Commission
A to C No. 037834A02
Issued March 31, 2006
Engineer's Certification 06N (,
L� C? r$
1, PAAJDALL D. A Vilvi -A) , as a duly registered Professional Engineer in
the State of North Carolina, having been authorized to observe (periodically/weekly/full time)
the construction of the modifications and improvements to the Archie Elledge WWTP, located
on NCSR 2972 Road, and Muddy Creek Wastewater Treatment Plants located off Cooper Road
in Forsyth County for the City of Winston-Salem, hereby state that, to the best of my abilities,
due care and diligence was used in the observation of the following construction:
A 26,076 square -foot (existing 8,320 and new 17,756) biosolids management
facility, capable of producing up to 51.4 dry tons per day of Class A pelletized
biosolids (equating to 55.87 tons per day of pelletized biosolids at an average
pellet solids content of 92%), which includes:
(a) Two sludge blending tanks which are recommissioned secondary
digesters, four 30-HP blending tank mixers, one new centrifuge (capable
of dewatered cake production at 2,600 dry pounds/hour at 21 % solids)
with a 395 gpm feed pump, digester gas control equipment,
(b) one 600 gpm sludge macerator with a maximum particle size of 0.5 inch
passing the grinder, two dewatered sludge screw conveyors with capacities
of 350 cu. ft./hr. and 500 cu. ft./hr., a dewatered sludge screw conveyor
and a dewatered sludge belt conveyor (existing modified to be reversible)
with a capacity of 900 cu ft./hr., and two 60 GPM dewatered sludge cake
pumps driven by adjustable frequency drives,
(c) a polymer feed system consisting of dual 6,500 gallon polymer storage
tanks, two polymer blending units with a 15 gph transfer pump, a 100
gpm dilution water pump, and a 5 HP mechanical blender, two 3,600
gallon stainless steel polymer aging tanks, polymer metering pumps, a
dispersant feed system,
(d) a front end loader cake receiving hopper with a material conveyance
capacity of 500 cu. ft./hr., one dewatered sludge screw conveyor with a
capacity of 500 cu. ft. per hour, and pipeline lubrication system,
(e) two 275 gpm dewatered sludge centrate transfer pumps,
(f) a direct hot air contact triple pass rotary drum residuals dryer (51.4 dry
tons per day) consisting of hot air furnace, drum dryer, air/solids separator,
product screening, product cooler, off -gas scrubbing, and a regenerative
thermal oxidizer (RTO) to thermally oxidize off -gasses, building traveling
bridge crane (TB-1) with a 5 ton capacity, two dried product storage silos
with minimum storage capacity of 360 dry tons total with baghouse
controls, a trucks scale having a 50 ton capacity, miscellaneous piping,
electrical work, controls, and all site work necessary to make a complete
and functional residuals thermal dryer facility,

Winston-Salem/Forsyth County Utilities Commission
A to C No. 037834A02
Issued March 31, 2006
(g)
Engineer's Certification Continued
and replacement of three new non -potable water putnps of 1,670 gpm
capacity each in the existing NPW pump station,.
in conformity with the project plans, specifications, and other supporting data
subsequently tiled and approved by the Department of Environment and Natural
Resources.
I certify that the construction of the above referenced project was observed to be built within
substantial compliance and intent of the approved plans and specifications.
Signature Registration No. I (21 13
Date .E I (ZQOS
Send to:
Construction Grants & Loans
DENRIDWQ
1633 Mail Service Center
Raleigh, NC 27699-1633
REGt L ,
P

March 31, 2006
Mr. Ron Hargrove, Deputy Utilities Director
Winston-Salem/Forsyth County Utilities Commission
P.O. Box 2511
Winston-Salem, North Carolina 27102
SUBJECT:
Dear Mr. Hargrove:
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Quality
- E C f 11 U E
ill APR 7 2006
DENR - WATER QUALITY
POINT SOURCE BRANCH
Authorization to Construct
A to C No. 037834A02
Winston-Salem/Forsyth County
Utilities Commission
Archie Elledge WWTP
Forsyth County
A letter of request for Authorization to Construct was received November 2, 2005, by the
Division, and final plans and specifications for the subject project have been reviewed and found
to be satisfactory. Authorization is hereby granted for the construction of modifications to the
existing 30 MGD Archie Elledge Wastewater Treatment Plant, located on NCSR 2972, in
Winston-Salem with the discharge of treated wastewater into the Salem River in the Yadkin -Pee
Dee River Basin.
This authorization results in no increase in design or permitted capacity and is awarded
for the construction of the following specific modifications:
A 26,076 square -foot (existing 8,320 and new 17,756) biosolids management
facility, capable of producing up to 51.4 dry tons per day of Class A pelletized
biosolids (equating to 55.87 tons per day of pelletized biosolids at an average
pellet solids content of 92%), which includes:
(a) Two sludge blending tanks which are recommissioned secondary
digesters, four 30-HP blending tank mixers, one new centrifuge (capable
of dewatered cake production at 2,600 dry pounds/hour at 21% solids)
with a 395 gpm feed pump, digester gas control equipment,
(b) one 600 gpm sludge macerator with a maximum particle size of 0.5 inch
passing the grinder, two dewatered sludge screw conveyors with capacities
of 350 cu. ft./hr. and 500 cu. ft./hr., a dewatered sludge screw conveyor
and a dewatered sludge belt conveyor (existing modified to be reversible)
with a capacity of 900 cu ft./hr., and two 60 GPM dewatered sludge cake
pumps driven by adjustable frequency drives,
(c) a polymer feed system consisting of dual 6,500 gallon polymer storage
tanks, two polymer blending units with a 15 gph transfer pump, a 100
gpm dilution water pump, and a 5 HP mechanical blender, two 3,600
tl0t hCarolina
aurally
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Custorner Service
Internet: ____ 512 N. Salisbury St. Raleigh. NC 27604 FAX [phone]
An Equal Opportunity/Affirmative Action Employer —50% Recycled/10% Post Consumer Paper

Mr. Ron Hargrove, Deputy Utilities Director
Winston-Salem/Forsyth County Utilities Commission
March 31, 2006
Page 2
gallon stainless steel polymer aging tanks, polymer metering pumps, a
dispersant feed system,
(d) a front end loader cake receiving hopper with a material conveyance
capacity of 500 cu. ft./hr., one dewatered sludge screw conveyor with a
capacity of 500 cu. ft. per hour, and pipeline lubrication system,
(e) two 275 gpm dewatered sludge centrate transfer pumps,
(0 a direct hot air contact triple pass rotary drum residuals dryer (51.4 dry
tons per day) consisting of hot air furnace, drum dryer, air/solids separator,
product screening, product cooler, off -gas scrubbing, and a regenerative
thermal oxidizer (RTO) to thermally oxidize off -gasses, building traveling
bridge crane (TB-1) with a 5 ton capacity, two dried product storage silos
with minimum storage capacity of 360 dry tons total with baghouse
controls, a trucks scale having a 50 ton capacity, miscellaneous piping,
electrical work, controls, and all site work necessary to make a complete
and functional residuals thermal dryer facility,
(g) and replacement of three new non -potable water pumps of 1,670 gpm
capacity each in the existing NPW pump station,
in conformity with the project plans, specifications, and other supporting data
subsequently filed and approved by the Department of Environment and Natural
Resources.
This Authorization to Construct is issued in accordance with Part III, Paragraph A of
NPDES Permit No. NC0037834 issued June 28, 2004, and shall be subject to revocation unless
the wastewater treatment facilities are constructed in accordance with the conditions and
limitations specified in Permit No. NC0037834.
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 Winston-Salem Regional Office, telephone number [phone], shall be notified
at least forty-eight (48) hours in advance of operation of the installed facilities so that an on site
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 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

Mr. Ron Hargrove, Deputy Utilities Director
Winston-Salem/Forsyth County Utilities Commission
March 31, 2006
Page 3
approved plans and specifications. Mail the Certification to Cecil G. Madden, Jr., P.E.,
Construction Grants & Loans, DWQ / DENR, 1633 Mail Service Center, Raleigh, NC 27699-
1633.
Upon classification of the facility by the Certification Commission, 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 and
grade to comply with the conditions of T15A:8G.0202. 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, must properly manage the facility, must document daily operation and
maintenance of the facility, and must comply with all other conditions of T 15A:8G.0202.
A copy of the approved plans and specifications shall be maintained on file by the
Permittee for the life of the facility.
During the construction of the proposed additions/modifications, the permittee shall
continue to properly maintain and operate the existing wastewater treatment facilities at all times,
and in such a manner, as necessary to comply with the effluent limits specified in the NPDES
Permit.
You are reminded that it is mandatory for the project to be constructed in accordance
with the North Carolina Sedimentation Pollution Control Act, and, when applicable, the North
Carolina Dam Safety Act. In addition, the specifications must clearly state what the contractor's
responsibilities shall be in complying with these Acts.
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.

A
Mr. Ron Hargrove, Deputy Utilities Director
Winston-Salem/Forsyth County Utilities Commission
March 31, 2006
Page 4
One (1) set of approved plans and specifications is being forwarded to you. If you have
any questions or need additional information, please contact Cecil G. Madden, Jr., P.E. at
telephone number [phone].
Sincerely,
an W. Klime P.E.
ID:cgm
cc: Randall D. Ashburn, P.E., Black and Veatch, Charlotte
Forsyth County Health Department
DWQ Winston-Salem Regional Office, Surface Water Protection
Technical Assistance and Certification Unit
Daniel Blaisdell, P.E.
Point Source Branch, NPDES Program
Cecil G. Madden, Jr., P.E.
Ishwar Devkota, P.E.
A to C File