NC0088781_Permit (Issuance)_20111118

NPDES DOCIMENT SCANNING COVER SHEET
NPDES Permit:
NC0088781
Bladen Bluffs Regional WTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Staff Report
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
November 18, 2011
This document its printed on reuose paper - ignore any
content on the re w erse side

ern
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Govemor Director Secretary
November 18, 2011
Mr. Don Betz, Executive Director
Lower Cape Fear Water and Sewer Authority
1107 New Point Boulevard; Suite 17
Leland, NC 28451
Subject: Issuance of NPDES Permit NC0088781
Lower Cape Fear Water and Sewer Authority — Bladen Bluffs Regional WTP
Bladen County
Dear Mr. Betz:
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 no significant changes from the draft permit sent to you on September 14,
2011; however, its terms are significantly different from those found in the current permit. A summary
of changes to the existing permit is shown below. You should read the entire permit carefully in order to
help you maintain compliance with its terms and conditions.
• The Flow limit has been removed from the permit.
• Effluent monitoring for Turbidity has added to the permit with a weekly monitoring frequency..
• Monitoring requirements for Calcium and Magnesium have been removed from the permit.
• The monitoring frequencies for Total Copper, Total Iron, Fluoride and Total Zinc have been reduced
to quarterly. Quarterly monitoring should be performed to coincide with whole effluent toxicity
testing.
• A condition has been added that will allow the permit to be reopened for the purpose of requiring
additional nutrient monitoring of the discharge to support water quality modeling efforts within the
Cape Fear River Basin.
• The effluent limit for Total Residual Chlorine (TRC) has been lowered from 28 µg/L to 17 p,g/L.
Please note that the permit still retains the same footnote language stating reported TRC values of
less than 50 µg/L will be deemed compliant with the terms of the permit.
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.ncwaterquailty.org
An Equal Opportunity 1 Affirmative Aeon Employer
Nye Carolina
7V'atura/Iij

Mr. Don Betz
Bladen Bluffs Regional WTP Permit Renewal 2011
p. 2
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,
771.4,
Coleen H. Sullins
cc: Central Files
Fayetteville Regional Office/Surface Water Protection Section
.NPDES File
ec: Aquatic Toxicology Unit

Permit NC0088781
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 provisions 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
Lower Cape Fear Water and Sewer Authority
is hereby authorized to discharge wastewater from a facility located at the
Bladen Bluffs Regional Surface Water Treatment Plant
NC Highway 87
Tar Heel
Bladen County
to receiving waters designated as Unnamed Tributary to the Cape Fear River in the Cape Fear 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 January 1, 2012.
This permit and authorization to discharge shall expire at midnight on October 31, 2016.
Signed this day November 18, 2011.
Yku.
Colee . Sullins, Director
Divipn of Water Quality
By Authority of the Environmental Management Commission

Permit N00088781
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 Lower Cape Fear Water and Sewer Authority
is hereby authorized to
1. After completion of construction, and after submitting an Engineer's Certificate, to discharge
treated filter backwash wastewater from a conventional water treatment plant that includes the
following wastewater treatment components:
• Two Residuals Basins for settling/ decanting
• One Recycle Pump
• Dechlorination
This facility is located at the Bladen Bluffs Regional Surface Water Treatment Plant, off NC
Highway 87, north of Tar Heel, in Bladen County.
2. Discharge from said treatment works at the location specified on the attached map into an unnamed
tributary to the Cape Fear River, class C waters of the State in the Cape Fear River Basin.

Permit NC0088781
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USGS Quad Name: Duart, K22NE
Receiving Stream: UT Cape Fear River
Lat.: 34° 45' 53"
Long.: 78° 48' 16"
Locations t..
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Stream Class: C
Subbasin: Cape Fear-03-06-16
North
Bladen County

Permit NC0088781 ,
0
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 wastewater associated with the water treatment plant and overflow
from the raw water spillway from Outfall 001. Such discharges shall be limited and monitored by the
Permittee as specified below:
-, Effluent Characteristics
- 1 . `�L1mlts
,; �: ; • £ Mon orinci Require�'1'tents ` -
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fig: '- : _,
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Sample Type
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7..,xsampte
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Lcc�trort:
Flow 50050
Continuous
Recording
Effluent
Total Suspended Solids C0530
30.0 mg/L
45.0 mg/L
Weekly
Grab
Effluent
Total Residual Chlorine1 50060
17 pg/L
Weekly
Grab
Effluent
pH 00400
z 6.0 s.u. and s 9.0 s.u.
Weekly
Grab
Effluent
Turbidity 00076
Weekly
Grab
Effluent
Aluminum 01105
Quarterly2
Grab
Effluent
—Manganese— 01055
Quarterly2
Grab
Effluent
Fluoride 00951
Quarterly2
Grab
Effluent
Total Zinc 01092
Quarterly2
Grab
Effluent
1otal#en-- 01045
Quarterly2
Grab
Effluent
Total Copper 01042
Quarterly2
Grab
Effluent
Ammonia Nitrogen C0610
Quarterly2
Grab
Effluent
Total Phosphorus (TP) C0665
Quarterly2
Grab '
Effluent
Total Nitrogen (TN)3 C0600
Quarterly2
Grab •
Effluent
Whole Effluent Toxicity Monitoring4 TGE6C
Quarterly
Grab
Effluent
NOTES:
1. The. Division shall consider all effluent TRC values reported below 50 ug/1 to be in compliance with the
permit. However, the Permittee shall record and submit all values reported by a North Carolina certified
laboratory (including field certified), even if these values fall below 50 ug/l.
2. Monitoring should be performed in conjunction with toxicity testing.
3. TN means Total Nitrogen. For a given wastewater sample, TN is the sum of Total Kjeldahl Nitrogen and
Nitrate -Nitrite Nitrogen: TN = TKN + NO3-N + NO2-N.
4. Acute Toxicity (Fathead Minnow) Monitoring at 90%: February, May, August, and November [see
Condition A.(2)] and sampling should coincide with sampling for parameters covered by footnote 2.
All samples collected should be representative of the discharge.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
There shall be no discharge of waste or chemicals that do not directly result from the responsible treatment of raw water.
The discharge ditch shall be lined to prevent erosion and washing of soil and silt to the river.

Permit NC0088781
A.(2.) ACUTE TOXICITY MONITORING (QUARTERLY)
The permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined in the
North Carolina Procedure Document entitled "Pass/Fail Methodology. For Determining Acute Toxicity
In A Single Effluent Concentration" (Revised -July, 1992 or subsequent versions). The monitoring shall
be performed as a Fathead Minnow (Pimephales promelas) 24 hour static test. The effluent
concentration at which there may be at no time significant acute mortality is 90 % (defined as treatment
two in the procedure document). Effluent samples for self -monitoring purposes must be obtained
during representative effluent discharge below all waste treatment. The tests will be performed during
the months of February, May, August and November.
The parameter code for Pimephales promelas is TGE6C. All toxicity testing results required as part of
this permit condition will be entered on the Effluent Discharge Form (MR-1) for the month in which it
was performed, using the appropriate parameter code. Additionally, DWQ Form AT-2 (original) is to
be sent to the following address:
Attention: North Carolina Division of Water Quality
Environmental Sciences Section
1621 Mail Service Center
Raleigh, N.C. 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 and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity tests, as well as all dose/response data. 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 any month, 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 any test data from either these monitoring requirements 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 than required by this permit, the results of such
monitoring shall be included in the calculation & reporting of the data submitted on the DMR & all AT
Form submitted.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival 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 NC0088781
A. (3.) PERMIT RE -OPENER: NUTRIENT MONITORING
Pursuant to N.C. General Statutes Section 143-215.1 and the implementing rules found in the North
Carolina Administrative Code at 15A NCAC 2H.0112 (b) (1) and 2H.0114 (a) and Part II sections B-
12 and B-13 of this permit, the Director may reopen this permit to require supplemental nutrient
monitoring of the discharge. The purpose of the additional monitoring will be to support water quality
modeling efforts within the Cape Fear River Basin and shall be consistent with a monitoring plan
developed jointly by the Division and affected stakeholders. In addition, the results of water quality
modeling may require that limits for Total Nitrogen and Total Phosphorus be imposed in this permit
upon renewal.

A752A
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
September 21, 2011
MEMORANDUM
To: Bob Sledge
Point Source Branch, Expedited Unit
Through: Belinda Henson, Water Quality Regional Supervisor 444)91444°471
Fayetteville Regional Office
From: Mark Brantley, Environmental Chemist 7,10
4i
Fayetteville Regional Office
SUBJECT: Minor NPDES Permit Renewal
Lower Cape Fear Water and Sewer Authority
Bladen Bluffs Regional Surface WTP
NPDES Permit No. NC 0088781
Bladen County
Please find below, regional comments for the subject minor permit renewal.
• Facility is currently under construction with startup scheduled for sometime in spring of 2012. No wastewater has
been discharged yet. According to their permit application they expect to start discharging sometime in the early
part of 2012.
• Applicant is not requesting modification of the facility or increasing flow at this time.
• A rating sheet is not attached as no modifications were made to this facility during the previous permit cycle.
The Fayetteville Regional Office agrees in re -issuing this permit in keeping with the Cape Fear River Basin Wide
Planning Strategy.
Cc: Central Files
FRO Files (mb)
Location: 225 Green Street, Suite 714, Fayetteville, North Carolina 28301
Phone: [phone] FAX: [phone] \ Customer Service: 1-877-623-6748
Internet: www.ncwaterauality.orq
An Equal Opportunity Employer
p(i?.,ww[g
SEP 23 2011
DENR-WATER QUALITY
POINT SOURCE BRANCH
No NthCarolina
atura!ly

AFFIDAVIT OF PUBLICATION
NORTH CAROLINA
Cumberland County
Public Notice
North Carolina Environmcn -
tal Management
Commission/NPDES Unit
1617 Mall Service Center
Raleigh. NC 27699-1617
Notice of Intent to Issue a
NPDES Wastewater Permit
The North Carolina Envimn -
mental Management Com -
mission proposes to issue a
NPDES wastewater dis-
charge
person(s) listed below. to the
Written comments regarding
the proposed permit will be
accepted until 30 days after
the publish date of this no-
tice. The Director of the NC
Division of Water Quality
(DWQ) may hold a public
hearing should thcrc be a
significant degree of public
interest. Please mail com -
tmcnts and/or information re-
quests ro 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 no-
tice may be found on our
w e h s I t e
http://portal.ncdenr.org/web/
wq/swp/ps/ri sdeslcalendar,
or by calling [phone].
The Lower Cape Fear Water
and Sewer Authority re-
quested renewal of permit
NC0088781 for the Bladen
Bluffs Regional Surface Wa-
ter Treatment Plant in Bladen
County; this perultted dis-
chtuge is treated Biter back -
wa wastewater to an un-
named tributary to the Cape
Fear River in the Cape Fear
River Basin.
The Public Works Commis -
sion of Fayetteville request -
ed renewal of permit
NC0076783 for the Hoffer
WTP in Cumberland County;
this permitted discharge is
treated filter -backwash
wastewater to the Cape Fear
River in the Cape Fear River
Basin.
Columbus County Schools
requested renewal of NPDES
permit NC0043796/Acme
Delco Elementary School.
Facility discharges to an un-
nntoed tributary to Pretty
Creek/Cape Fear River Basin.
Currently BOD, ammonia ni-
trogen. dissolved oxygen. fe-
cal coliform and total residu -
al chlorine are water quality
limited.
Columbus Count Schools
requested renewal y of NPDES
permit NC0043788/Acme
Delco Middle School. Facili-
ty discharges to an unnamed
tributary to Lindscomb
Branch/Cape Fear River Ba-
sin. Cogently BOD, ammo -
nia nitrogen. dissolved oxy-
gen, fecal colifoms and total
residual chlorine are water
quality limited.
Notice o[ Intent to Issue a
NPDES Wastewater Permit
9/20 3388548
Before the undersigned, a Notary Public of said County and state, duly
commissioned and authorized to administer oaths, affirmations, etc.,
personally appeared. CINDY L. OROZCO
Who, being duly sworn or affirmed, according to law, doth depose and say
that he/she is LEGAL SECRETARY
of THE FAYETTEVILLE PUBLISHING COMPANY, a corporation organized
and doing business under the Laws of the State of North Carolina, and
publishing a newspaper known as the FAYETTEVILLE OBSERVER, in the
City of Fayetteville, County and State aforesaid, and that as such he/she
makes this affidavit; that he/she is familiar with the books, files and
business of said Corporation and by reference to the files of said publication
the attached advertisement of CL Legal Line
NPDES WASTEWATER PERMIT
of NC DIVISION OF WATER QUALITY
was inserted in the aforesaid newspaper in space, and on dates as follows:
9/20/2011
and at the time of such publication The Fayetteville Observer was a
newspaper meeting all the requirements and qualifications prescribed by
Sec. No. 1-597 G.S. of N.C.
The above is correctly copied from the books and files of the aforesaid
corporation and publication.
LEGAL SECRETARY
Title
Cumberland County, North Carolina
Sworn or affirmed to, and subscribed before me, this 20 day
of September, A.D., 2011.
In Testimony Whereof, I have hereunto set my hand and affixed my
official seal, the day and year aforesaid.
Pamela H. Walters, Notary Public
My commission expires 5th day of December, 2015.
MAIL TO: NC DIVISION OF WATER QUALITY
1617 MAIL SERVICE CENTER
RALEIGH, NC 27699-00001617
0003388548

5400 Glenwood Avenue. Suite 300
Raleigh, North Carolina 27612
tel• 919 787-5620
fax: [phone]
August 11, 2011
Mrs. Dina Sprinkle
North Carolina Department of Environment and Natural Resources
Division of Water Quality, Point Source Branch
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Subject: Lower Cape Fear Water and Sewer Authority (LCFWASA)
Bladen Bluffs Regional Surface Water Treatment Plant
NPDES Permit No. NC0088781 (Bladen County) - Application for Permit Renewal
Dear Mrs. Sprinkle:
The Lower Cape Fear Water and Sewer Authority requests renewal of NPDES Permit
NCO038781 allowing discharge of decant from the reclamation basins at the Bladen Bluffs
Regional Surface Water Treatment Plant (WTP). Enclosed please find an original and two copies
of an application (Short Form C - WTP) to renew the permit. A narrative description of the
sludge management plan is included on the application form (Item 8, paragraph 4, pages 5-6).
The currently authorized NDPES Permit (NC0088781) allows discharge of decant from the
reclamation basins to a ditch on the WTP site. The reclamation basins will receive sedimentation
basin sludge and filter backwash water. The basins will allow for clarification of backwash
water and handling of filtered and settled solids. Construction of the Bladen Bluffs Regional
Surface WTP is currently ongoing and is expected to be completed in spring 2012. Discharges
authorized under the permit have not begun but are expected to begin in early 2012.
Please call me at [phone] if you have any questions. Thank you for your assistance.
Very truly yours,
Kelly R. Boone, P.E.
Camp Dresser & McKee
10@lEINE
AUG 1 5 2011
DEt•1R=Wt r ER QUALITY
POINT SOURCE BRANCH
Enclosures: Short Form C - WTP including sludge management plan (pg. 5-6 of application)
USGS Topographic Map
Drawing M-1: Hydraulic Profile and Flow Schematic for WTP
cc: Don Betz, LCFWASA
File 360 (46227-57217)
consulting • engineering • construction • operations

Name Lower Cape Fear Water and Sewer Authority
Mailing Address 1107 New Pointe Boulevard, Suite 17
City Leland
State / Zip Code NC / 28451
Telephone Number [phone]
NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mall Service Center, Raleigh, NC 27699-1617
NPDES Permit Number NC0088781
If you are completing this form in computer use the TAB key or the up - down arrows to move from one
field to the next. To check the boxes, click your mouse on top of the box. Otherwise, please print or type.
1. Contact Information:
Owner Name Lower Cape Fear Water and Sewer Authority
Facility Name Bladen Bluffs Regional Surface Water Treatment Plant
Mailing Address 1107 New Pointe Boulevard, Suite 17
City Leland
State / Zip Code NC / 28451
Telephone Number [phone]
Fax Number [phone]
e-mail Address [e-mail]
2. Location of facility producing discharge:
Check here if same as above 0
Street Address or State Road 17014 NC 87 Hightway W
City
State / Zip Code
County
Tar Heel
NC / 28392
Bladen
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
D
11
(g_ilVig
AUG 15 20111
DENR-WATER QUALITY
CH
Fax Number [phone]
4. Ownership Status:
Page 1 of 7
C-WTP 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
Federal 0 State 0 Private 0 Public
5. Type of treatment plant:
® Conventional (Includes coagulation, flocculation, and sedimentation, usually followed by
filtration and disinfection)
❑ Ion Exchange (Sodium Cycle Cationic ion exchange)
❑ Green Sand Filter (No sodium recharge)
❑ Membrane Technology (RO, nanofiltration)
Check here if the treatment process also uses a water softener
6. Description of source water(s) (i.e. groundwater, surface water)
Cape Fear River
7. Describe the treatment process(es) for the raw water:
The recommended treatment process for the Bladen Bluffs Regional Surface WTP is based
on conventional treatment. Principal plant features include:
- Rapid Mix
Two rapid mix basins will be provided. Provisions will be made for feeding ferric or alum
coagulant, polymer, and caustic to the rapid mix chambers. The rapid mix chambers will
each be 5 feet x 5 feet x 8.2 feet water depth, with a detention time of 30 to 20 seconds
each at a plant flow rate of 4.4 to 6 mgd. Two chambers are provided in series to allow
the flexibility of adding coagulant chemicals at separate locations. Design power input as
defined by G-value will be about 1000/second at 68°F in the mixing zone.
- Flocculation
Two trains of four -stage flocculators will be provided. Each flocculation basin will be
about 10.5 feet long and 10.5 feet wide per compartment with four equal compartments,
and will have an approximate 13 foot side water depth at design flow. A baffle wall will
separate each flocculation stage. Each compartment will be equipped with a vertical
flocculator of the turbine type driven by a variable frequency drive (VFD). Maximum
water power input, as defined by G-value will be approximately 80/second. The four
compartments will allow for tapered flocculation, which will allow for optimization of the
flocculation process. It is estimated that average energy input will be approximately
equal to a G value of 20/second to 40/second. The VFDs for the flocculators will be of the
variable frequency type for optimum efficiency. Flocculation detention time is about 30
to 20 minutes in the basins at 4.4 to 6 mgd.
- Sedimentation
Two sedimentation basins will be provided. The basins will have approximately 15 foot
average side water depth at design flow. The total tank volume will provide for a
detention time of 4.0 hours at 4.4 mgd to 6.0 mgd.
Sludge will be manually or automatically withdrawn through the use of telescopic valves
to a view box, which will allow the operators to visually monitor the sludge consistency
in order to determine the length of time for sludge removal and minimize discharge of
clean water.
Water will flow from each sedimentation basin into a filter influent flume. Provisions
will be made to feed chlorine, caustic, and polymer into the filter influent.
- Filtration
Four filters will be provided, each having a design capacity of 1.5 mgd. Each filter cell
Page 2 of 7 C-WTP 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
will be 21.75 feet x 12 feet, having an area of 261 sf and a filtering rate of 4.0 gpm/sf.
The filters will be equipped with air water backwash, washwater troughs, sand, and GAC
or anthracite media.
Settled water enters the filter from the filter influent channel through an influent valve,
flows into the inlet and backwash trough ports, and from the troughs is distributed over
the filter bed. The filters will initially be rated at 4 gpm/sf, but will be hydraulically
capable of up to 6.0 gpm/sf.
The filters are designed with one effluent flow controller per filter consisting of a venturi
type flow meter and an electrically operated butterfly control valve. The rate of flow
through each filter will be manually set with option for level control to match raw water
flow using a single rate set load station. Controls will be electronic with electric valve
operators. All filter operations will be from a local control panel at each filter with flows,
head losses, turbidity, and particle counts transmitted to the main
control panel for supervisory control.
- Backwash System
Finished water from the Smithfield Packing Company (SPC)'s clearwell will be piped back
to the filters for backwashing. This water will flow through the washwater header in the
pipe gallery to the filter gullet, through the underdrain, and up through the filter media.
A blower and air piping will be provided to allow air/water bed expansion and
backwashing. This system is designed to wash one filter at a time. The backwash water
will flow into the backwash troughs located above the expanded filter bed and into the'
waste backwash water collection channel. From there the backwash water flows to the
residuals basins. If clearwell level is low, the transfer pumps can be valved to pump the
backwash water from the SPC clearwells.
S. Describe the wastewater and the treatment process(es) for wastewater generated by the
facility:
1. Residual Sources
Provision of adequate residuals handling facilities and proper residuals management is
critical to the successful operation of a water treatment plant (WTP). The major sources
of residuals at the Braden Bluffs Regional Surface WTP include the sedimentation sludge
and spent filter backwash water. Suspended matter, color, and other impurities in the
raw water are removed mostly during the coagulation/clarification process. A small
amount of these residuals not removed in the sedimentation basins is removed in the
filters, and the solids are subsequently removed in the spent filter backwash water.
2. Residuals Quantity
The quantity of residuals produced by the plant depends on the raw water quality and the
chemicals used to treat the raw water. Knowledge of water chemistry and extensive
experience at operating other treatment plants has shown that a relationship exists
between these factors that can be used to predict the amount of residual solids produced.
By far, the majority of residuals produced in the plant come from the coagulation process.
Other additives such as polymer and powdered activated carbon (PAC) can be assumed to
produce amounts of residuals equivalent to the dosages added to the water. Suspended
solids also produce an equivalent weight of residuals, as they are non -reactive. Iron and
manganese (including manganese from permanganate) are oxidized in the treatment
plant and are removed in the oxidized precipitate form. Therefore, the equation used to
calculate the amount of solids produced is:
S = 8.34 * Q (0.53C + SS + A +1.9Fe +1.58 Ma)
Where the parameter values used for calculations include,
S = solids produced (lb/day)
(1)
Page 3 of 7 C-WTP 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
Q = average plant flow (mgd), 3.3 mgd
C = average coagulant dose, 60 mg/L Fe2(804)3
SS = average raw water suspended solids (mg/L)
= b*Tu, where b = constant, assume 1.5 and Tu = average raw water turbidity
in nephelometric turbidity units (NTU)
42 mg/L
A = additional chemicals added (mg/L), 2 mg/L for estimated annual average
Fe = average raw water iron concentration (mg/L), 0.90 =ag/L
Mn = average raw water manganese concentration (mg/L), 0.1 mg/L
The raw water suspended solids can be estimated from the raw water turbidity:
SS (mg/L) = b* Tu as shown above.
The correlation factor between turbidity and suspended solids may vary from 0.7 to 2.2
and may seasonally vary for the same raw water supply. Since no suspended solids data
were available, the value of b was assumed to be 1.5 for the purpose of estimating the
residuals quantity.
Using equation (1) and the above parameter values, 8 = 2,13€ dry lb/day.
Based on our experience from other treatment plants, roughly 90 percent of the solids
produced will end up in the sedimentation sludge. The rest will be collected in the spent
filter backwash water. Table 1 provides a summary of estimated sedimentation residuals
quantities under current and future flow conditions. An average flow of 6.6 mgd allows
for doubling of the plant flow to 8.8 mgd daily maximum capacity.
Table 1
Summary of Sedimentation Sludge Quantities (based on 90 percent of the solids being in
the sedimentation sludge at a concentration of 0.5 percent solids)
Average Daily Plant Flow (mgd) 3.3 6.6
Solids (lb/day) 1,924 3,848
Volume (gpd) 46,000 92,000
The quantity of filter backwash water produced is a function of filter to waste run time
and the amount of water used in backwashing. Based on our experience with other
treatment plants, approximately 86,000 gallons of water will be produced in each filter of
the size proposed while backwashing typically, though this number can vary. The
calculated backwash volume is based on a maximum backwash rate of 22 gpm/sf for 15
minutes duration. In addition, approximately 31,000 gallons of filter -to -waste will be
discharged per filter backwash at an average plant flow of 3.3 mgd before putting the
filters back into service, assuming 30 minutes of filter -to -waste per backwash at 4 gpm/sf
filter rate. Table 2 summarizes the estimated average quantity of backwash water
produced for current and future flow conditions. It is assumed that two filters at 4.4
mgd and four filters at 6.6 mgd will be backwashed each day.
Table 2
Summary of Estimated Average Spent Filter Backwash Water Quantity
Average Daily Plant Flow (mgd) 3.3 6.6
Total Number of Filters 3 Up to 6
No. of Filters Backwashed 2 4
Backwash Volume (gpd) 172,000 344,000
Filter -to -Waste (gpd) 62,000 124,000
Average Daily Total (gpd) 234,000 468,000
3. Waste Characteristics
Page 4 of 7
C-WTP 03/05

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

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

NPDES PERMIT APPLICATI N RT FORM C - WTP
fr
For discharges associated with water treatment plants
Provide a schematic; of flow through the facility, include flow volumes at all points in
the treatment process, and point of addition of chemicals.
Solids Handling Plan
16. NEW Applicants
information needed in addition to items 1-15:
New applicants must contact a permit coordinator with the NCDE1' R Customer
Service Center.
Was the Customer Service Center contacted? 0 Yes 0 No
Fee attached drawing M-1
See Item 8, Paragraph 4 "Residuals
Handling Approach" (above)
Analyses of source water collected.
Engineering Alternative Analysis
Discharges from Ion Exchange and Reverse Osmosis plants shall be evaluated using a
water quality model.
17. Applicant Certification
I certify that I am familiar with. the information contained in the application and that to the
best of my knowledge and belief such information is true, complete., and accurate.
ignature of Applicant Date
North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Page 7 of 7 C-WTP 03/05

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