NC0051969_Application (ATC)_20220701

STROUD ENGINEERING, P. A.
CON9.LIP G ENGNEERS
102D CINEMA DRIVE
VALAW4Cs'TON,NORTH CAROLINA 28403 RECEIVED
MNAWSIROLCEN61NEER.COM
"ENE NO.C-0647 J U L_ 01 2022
June 20,2022 NCDEQIDWRINPDES
North Carolina Department of Environmental Quality
Attn. Morella Sanchez King
Division of Water Resources
127 Cardinal Drive Ext.
Wilmington, NC 28405-3845
Re: Castle Haynes Memory Care WWTP, NC0051969
Dear Morella,
Please find the attached Authorization to Construct,ATC application for proposed improvements
to address Chloride and Total Copper concentrations in the subject facility's waste water treatment plant
effluent. The elevated Chlorides were the result of discharging concentrated water softening filter
backwash into the waste flow. This has been addressed by removing the filter backwash from the waste
stream as summarized prior. We have concluded that the elevated total copper levels are the result of
degradation of copper plumbing within the facility. Subsequently, we have proposed and continue to
permit through the Public Water Supply Section,chemical inhibitor injection and more recently additional
soda ash injection to elevate the PH and better enable the chemical inhibition of the copper degradation
in the buildings plumbing. The copper concentrations observed as a result of these activities are
improved however not to such extent that these improvements alone can be considered enough for
reliable compliancy. As a result of this realization, the operator has conducted the prior disclosed pilot
study to reduce the residual copper concentration in the waste water effluent as a final filtration process
to the treatment plant's discharge. The study included capturing a portion of the effluent, routing it
through an ion exchange filter media and testing the downstream effluent. The pilot study proved
satisfactory to proceed to permitting. The attached application, substantiating plans and product data
sheets are aimed at permitting the permanent installation of this filtration process for the effluent leaving
this facility.
ctfull
.4.A\ s,
Ja . Fentress,Jr. PE, c LS
Attachments
JHF/jf
file:W:\master\pw1445\wpd\CASTLE CREEK COPPER REDUCTION ATC COVER.doc
1078 COMMERCE STREET 102D CINEMA DRIVE 3302C BRIDGES STREET
GREENVLLE,PCRIH CAROLINA 27858 WILMINGTON,NORTH CF ROLNA 28403 MOR EHEAD C11%NORTH GIROLNA 28687
252.756.9352 910.815.0775 252.247.7479

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
kNVINONMCNIAL OVAlI' APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
SECTION 1:INSTRUCTIONS AND INFORMATION
A. The Division of Water Resources will accept this application package for review only if all of the items are provided and the
application is complete.Failure to submit all of the required items will result in the application package being returned as incomplete
per 15A NCAC 02T.0105(bl.
B. Plans and specifications must be prepared in accordance with 15 NCAC 02H.0100 15A NCAC 02T North Carolina General Statute
13�-3-3 North Carolina General Statute 143-215.1 and Division of Water Resources Minimum Design Criteria for NPDES
Wastewater Treatment Facilities.
C. The plans and specifications submitted must represent a completed final design that is ready to advertise for bid.
D. Any content changes made to this Form ATC-12-14 shall result in the application package being returned.
E. The Applicant shall submit ONE ORIGINAL and ONE DIGITAL COPY(CD)of the application,all supporting documentation and
attachments.All information must be submitted bound or in a 3-ring binder,with a Section tab for each Section,except the
Engineering Plans.
F. Check the boxes below to indicate that the information is provided and the requirements are met.
G. If attachments are necessary for clarity or due to space limitations,such attachments are considered part of the application
package and must be numbered to correspond to the item referenced.
H. For any project that requires review under the State Environmental Policy Act(SEPA),an Authorization to Construct cannot be
issued prior to the completion of a State Clearinghouse advertisement period for a FONSI,EIS,etc.unless the project qualifies for
a Determination of Minor Construction Activity.
I. For more Information,visit the Division of Water Resources web site at:https://deq.nc.gov/about/divisions/water-resources/water-
resources-perm its/wastewater-branch/npdes-wastewater/a utho ri zation-to-construct.
J. In addition to this Authorization to Construct,the Applicant should be aware that other permits may be required from other Sections
of the Division of Water Resources(for example:reclaimed water facilities permits;Class A or B biosolids residuals permit).
SECTION 2:APPLICANT INFORMATION AND PROJECT DESCRIPTION
A. APPLICANT
Applicant's name Castle Hayne Health Health Holdings,LLC
Signature authority's name per 15A NCAC 02T.0106(b) Rodney Propst
Signature authority's title Maintenance Engineer
Complete mailing address PO BOX 2568 Hickory,NC 28603
Telephone number 828-448-1555
Email address [e-mail]
B. PROFESSIONAL ENGINEER
Professional Engineer's name James H Fentress Jr.
Professional Engineer's title Branch Manager
North Carolina Professional Engineer's License No. PE 20643
Firm name Stroud Engineering P.A.
Firm License number C-0647
Complete mailing address 102 D Cinema Drive Wilmington,NC 28403
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 1

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
LNVINONMENiAL OVAui, APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
Telephone number [phone]
Email address [e-mail]
C. NPDES PERMIT
NPDES Permit number NC0051969
Current Permitted flow(MGD)—include permit 0.012
flow phases if applicable
D. PROJECT DESCRIPTION
Provide a brief description of the project:Existing wwtp consists of lift station,aeration basin,dual gravity clarifiers,
backwashing drum filter w/20um media,and 48"UV disinfection. The purpose of the proposed modification is to remove
copper containing solids from effluent using 1 micron cartridge filters. A pilot study was conducted testing various filter
medias to gain confidence. New components and modification to include: Installation of(1)550 gal poly tank,(2)effluent
pumps,(2)filter vessels containing(4)24"cartridge filters each,float controlled pump controls,associated pipe.
SECTION 3:APPLICATION ITEMS REQUIRED FOR SUBMITTAL FOR ALL PROJECTS
A. Cover Letter
X The letter must include a request for the Authorization to Construct;the facility NPDES Number;a brief project description
that indicates whether the project is a new facility,facility modification,treatment process modification,or facility expansion;
the construction timeline;and a list of all items and attachments included in the application package.
❑ If any of the requirements of 15 NCAC 02H.0100,15A NCAC 02T North Carolina General Statute 133-3 North Carolina
General Statute 143-215.1 and Division of Water Resources Minimum Design Criteria for NPDES Wastewater Treatment
Facilities are not met by the proposed design,the letter must include an itemized list of the requirements that are not met.
B. NPDES Permit
X Submit Part I of the Final NPDES permit for this facility that includes Part A(Effluent Limitations and Monitoring Requirements)
for the monthly average flow limit that corresponds to the work that is requested for this project.
C. Special Order by Consent
O If the facility is subject to any Special Orders by Consent(SOC),submit the applicable SOC.
X Not Applicable.
D. Finding of No Significant Impact or Record of Decision
❑ Submit a copy of the Finding of No Significant Impact or Record of Decision for this project.
❑ Provide a brief description of any of the mitigating factors or activities included in the approved Environmental Document
that impact any aspect of design of this project,if not specified in the Finding of No Significant Impact or Record of Decision.
X Not Applicable.
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 2

IIC State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
E. Engineering Plans
X Per 15A NCAC 02T.0504(c)(1) submit one set of detailed plans that have been signed,sealed and dated by a North Carolina
Licensed Professional Engineer.
X Per 21 NCAC 56.1103(a)(6) the name,address and License number of the Licensee's firm shall be included on each sheet of
the engineering drawings.
X Plans must be labeled as follows:FINAL DRAWING—FOR REVIEW PURPOSES ONLY—NOT RELEASED FOR CONSTRUCTION.
X 15A NCAC 02H.0124 requires multiple(dual at a minimum)components such as pumps,chemical feed systems,aeration
equipment and disinfection equipment. Is this requirement met by the design?XX Yes or❑❑ No. If no,provide an
explanation:
Plans shall include:
ot Plans for all applicable disciplines needed for bidding and construction of theproposedproject(check as appropriate): _ --{Commented pF1]:
X Civil D Not Applicable
❑ Process Mechanical I$Not Applicable
❑ Structural Not Applicable
❑ Electrical RI Not Applicable
❑ Instrumentation/Controls X Not Applicable
❑ Architectural M Not Applicable
❑ Building Mechanical Ea Not Applicable
❑ Building Plumbing $1 Not Applicable
X Plan and profile views and associated details of all modified treatment units Including piping,valves,and equipment(pumps,
blowers,mixers,diffusers,etc.)
X Are any modifications proposed that impact the hydraulic profile of the treatment facility?XX Yes or❑❑No. If yes,provide
a hydraulic profile drawing on one sheet that includes all impacted upstream and downstream units.The profile shall include
the top of wall elevations of each impacted treatment unit and the water surface elevations within each impacted treatment
unit for two flow conditions:(1)the NPDES permitted flow with all trains in service and(2)the peak hourly flow with one
treatment train removed from service.
® Are any modifications proposed that impact the process flow diagram or process flow schematic of the treatment facility?XX
Yes or❑❑No. If yes,provide the process flow diagram or process flow schematic showing all modified flow paths including
aeration,recycle/return,wasting,and chemical feed,with the location of all monitoring and control instruments noted.
F. CIt Engineering Specifications
X Per 15A NCAC 02T.0504(c)(2) submit one set of specifications that have been signed,sealed and dated by a North Carolina
Licensed Professional Engineer.
X Specifications must be labeled as follows:FINAL SPECIFICATIONS—FOR REVIEW PURPOSES ONLY—NOT RELEASED FOR
CONSTRUCTION.
Specifications shall include:
IX Specifications for all applicable disciplines needed for bidding and construction of the proposed project (check as
appropriate):
X Civil 0 Not Applicable
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 3

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
eNvneahneNru auA,n. APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
X Process Mechanical ❑Not Applicable
❑ Structural X Not Applicable
X Electrical ❑Not Applicable
X Instrumentation/Controls 0 Not Applicable
O Architectural X Not Applicable
❑ Building Mechanical X Not Applicable
X Building Plumbing ❑Not Applicable
X Detailed specifications for all treatment units and processes including piping,valves,equipment(pumps,blowers,mixers,
diffusers,etc.),and instrumentation.
X Means of ensuring quality and integrity of the finished product including leakage testing requirements for structures and
pipelines,and performance testing requirements for equipment.
❑ Bid Form for publicly bid projects.
G. Construction Sequence Plan
X Construction Sequence Plan such that construction activities will not result in overflows or bypasses to waters of the State.
The Plan must not imply that the Contractor is responsible for operation of treatment facilities. List the location of the
Construction Sequence Plan as in the Engineering Plans or in the Engineering Specifications or in both:
see plan sheet 2
H. Engineering Calculations
X Per 15A NCAC 02T.0504(c)(3),submit one set of engineering calculations that have been signed,sealed and dated by a North
Carolina Licensed Professional Engineer;the seal,signature and date shall be placed on the cover sheet of the calculations.
For new or expanding facilities and for treatment process modifications that are included in Section 4.C,the calculations shall
include at a minimum:
X Demonstration of how peak hour design flow was determined with a justification of the selected peaking factor.
O Influent pollutant loading demonstrating how the design influent characteristics in Section 4.B.2 of this form were
determined.
❑ Pollutant loading for each treatment unit demonstrating how the design effluent concentrations in Section 4.B.2 of this form
were determined.
O Hydraulic loading for each treatment unit.
X Sizing criteria for each treatment unit and associated equipment(blowers,mixers,pumps,etc.)
X Total dynamic head(TDH)calculations and system curve analysis for each pump specified that is included in Section 4.C.6.
❑ Buoyancy calculations for all below grade structures.
X Supporting documentation that the specified auxiliary power source is capable of powering all essential treatment units.
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 4

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
,G„10,,,.,,00 ,11* APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
I. Permits
l Provide the following information for each permit and/or certification required for this project:
Permit/ If Not Issued Provide
Not Date Date Certification Status and Expected
Permit/Certification Applicable Submitted Approved Number Issuance Date
Dam Safety X
Soil Erosion and Sediment Control X
USCOE/Section 404 Permit X
Water Quality Certification(4011 X
USCOE/Section 10 X
Stormwater Management Plan X
CAMA X
NCDOT Encroachment Agreement X
Railroad Encroachment Agreement X
Other:
J. Residuals Management Plan
X For all new facilities,expanding facilities, or modifications that result in a change to sludge production and/or sludge
processes,provide a Residuals Management Plan meeting the requirements of 15A NCAC 02T.0504(11 and 15A NCAC 02T
.0508.the Plan must include:
X A detailed explanation as to how the generated residuals(including trash,sediment and grit)will be collected,handled,
processed,stored,treated,and disposed.
❑ An evaluation of the treatment facility's residuals storage requirements based upon the maximum anticipated residuals
production rate and ability to remove residuals.
❑ A permit for residuals utilization or a written commitment to the Applicant from a Permittee of a Department approved
residuals disposal/utilization program that has adequate permitted capacity to accept the residuals or has submitted a
residuals/utilization program application.
❑ If oil,grease,grit or screenings removal and collection is a designated unit process,a detailed explanation as to how the
oil/grease will be collected,handled,processed,stored and disposed.
❑ Not Applicable.
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 5

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resaurc,
1.1,„11o,1FIEN,,:a APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
SECTION 4:PROJECT INFORMATION
A. WASTEWATER TREATMENT PLANT FLOW INFORMATION—COMPLETE FOR NEW OR EXPANDING FACILITIES
1. Provide the following flow information:
Plant Flows
Existing Plant Design 0.012 MGD
Current NPDES Permit Limit 0.012 MGD
Current Annual Average 0.0065 MGD
(past 12 months)
For Past 12 Months: For Past 24 Months:
Start Date:05/21 Start Date:05/20
End Date:05/22 End Date:05/22
Maximum Month 0.0089 MGD 0.0089 MGD
Maximum Day 0.0089 MGD 0.0089 MGD
Peak Hour 0.0089 MGD 0.0089 MGD
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 6

NC
State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
kNVIPONMU AL OVA,/r APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
B. WASTEWATER TREATMENT FACILITY DESIGN INFORMATION—COMPLETE FOR NEW OR EXPANDING FACILITIES AND
FOR TREATMENT PROCESS MODIFICATIONS
1. Have all of the requirements of 15 NCAC 02H.0100 15A NCAC 02T North Carolina General Statute 133-3,North Carolina
General Statute 143-215.1 and Division of Water Resources Minimum Design Criteria for NPDES Wastewater Treatment
Facilities been met by the proposed design and specifications?XX Yes or DO No. If no,provide justification as to why the
requirements are not met,consistent with 15A NCAC 02T.0105(n):
2. Provide the design influent and effluent characteristics that are used as the basis for the project design,and the NPDES
permit limits for the following parameters: Design is intended to address Copper
Project Basis of Design
Design Influent Design Influent
Influent Concentration Load
Concentration- (Must be (Must be
Current Annual supported by supported by
Average(past Engineering Engineering Design Effluent
12 months)if Calculations Calculations Concentration and/or NPDES Permit Limits
Parameter Available [Section 3.H]) [Section 3.H]) Load (monthly average)
Ammonia Nitrogen mg/L Summer mg/L Summer
(NH3-N) mg/L mg/L lb/day
mg/L Winter mg/L Winter
Biochemical mg/L Summer mg/L Summer
Oxygen Demand mg/L mg/L lb/day
(BODs) mg/L Winter mg/L Winter
Fecal Coliform per 100 mL per 100 mL
Nitrate+Nitrite
Nitrogen(NO3-N+ mg/L mg/L
NO2-N)
Total Kjeldahl mg/L
Nitrogen
mg/L mg/L
Total Nitrogen
Ib/year lb/year
mg/L mg/L
Total Phosphorus mg/L mg/L lb/day
lb/year lb/year
Total Suspended mg/L mg/L lb/day mg/L mg/L
Solids(TSS)
3. Based on the"Project Basis of Design"parameters listed above,will the proposed design allow the treatment facility to
meet the NPDES Permit Limits listed above?DO Yes or DO No. If no,describe how and why the Permit Limits will not be
met:
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 7

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
lNVI1to wr..rAL oua,i V APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
4. Per 15A NCAC 02T.0505(i) by-pass and overflow lines are prohibited. Is this condition met by the design?XX Yes or DO
No If no,describe the treatment units bypassed,why this is necessary,and where the bypass discharges:
5. Per 15A NCAC 02T.0505(k) multiple pumps shall be provided wherever pumps are used.Is this condition met by the
design?XX Yes or DO No. If no,provide an explanation:
6. Per 15A NCAC 02T.0505(I),power reliability shall be provided consisting of automatically activated standby power supply
onsite capable of powering all essential treatment units under design conditions,or dual power supply shall be provided
per 15A NCAC 02H.0124(2)(a).Is this condition met by the design? XX Yes or❑❑No. If no,provide(as an attachment
to this Application)written approval from the Director that the facility:
➢ Has a private water supply that automatically shuts off during power failures and does not contain elevated water
storage tanks,and
S. Has sufficient storage capacity that no potential for overflow exists,and
➢ Can tolerate septic wastewater due to prolonged detention.
7. Per 15A NCAC 027.0505(o) a minimum of 30 days of residual storage shall be provided. Is this condition met by the
design? XX Yes or❑❑No. If no,explain the alternative design criteria proposed for this project in accordance 15A NCAC
02T.105(n):
8. Per 15A NCAC 02T.0505(q) the public shall be prohibited from access to the wastewater treatment facilities.Explain how
the design complies with this requirement: Posted and continual onsite presence by staff
9. Is the treatment facility located within the 100-year flood plain? ❑❑Yes or xx No. If yes,describe how the facility is
protected from the 100-year flood:
C. WASTEWATER TREATMENT UNIT AND MECHANICAL EQUIPMENT INFORMATION—COMPLETE FOR NEW OR
EXPANDING FACILITIES AND FOR MODIFIED TREATMENT UNITS
1. PRELIMINARY AND PRIMARY TREATMENT(i.e.,physical removal operations and flow equalization):
No.of Plan Sheet Specification Calculations
Treatment Unit Provided?
Units Type Size per Unit Reference Reference
w (Yes or No)
—
a Manual Bar Screen MGD at peak hourly flow
O Mechanical Bar
cc
cc Screen MGD at peak hourly flow
tD Grit Removal MGD at peak hourly flow
Q Flow Equalization -- gallons
ft diameter; ft side
O Primary Clarifier Circular water depth
Primary Clarifier Rectangular square feet; ft side
water depth
Other
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 8
PP g

I IC State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
ciVI/tO+r-LNrA a, t APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
2. SECONDARY TREATMENT(BIOLOGICAL REACTORS AND CLARIFIERS)(i.e.,biological and chemical processes to remove
organics and nutrients) NO CHANGE PROPOSED
No.of Plan Sheet Specification Calculations
Treatment Unit Type Size per Unit Provided?
Units Reference Reference
(Yes or No)
Aerobic Zones/ gallons
Tanks
Anoxic Zones/ gallons
Tanks
Anaerobic
Zones/Tanks gallons
Sequencing Batch
gallons
Reactor(SBR)
Membrane
Bioreactor(MBR) -- gallons
Secondary Circular ft diameter; ft
Clarifier side water depth
Secondary Rectangular square feet; ft
Clarifier side water depth
Other
3. TERTIARY TREATMENT NO CHANGE PROPOSED
No.of Plan Sheet Specification Calculations
Treatment Unit Type Size per Unit Provided?
Units Reference Reference
(Yes or No)
Tertiary Clarifier Circular ft diameter; ft
side water depth
Tertiary Clarifier Rectangular square feet; ft
side water depth
Tertiary Filter square feet
Tertiary Membrane
Filtration square feet
Post-Treatment POLY TANK 500 gallons
Flow Equalization
Post-Aeration gallons
Other
4. DISINFECTION NO CHANGE PROPOSED
No.of Plan Sheet Specification Calculations
Treatment Unit Provided?
Units Type Size per Unit Reference Reference
(Yes or No)
gal/day per bank at
Ultraviolet Light (Parallel;in peak hourly flow;
number of banks;
series) number of lamps/bank
Chlorination (Gas; gallons of contact
tablet;liquid) tank/unit
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 9

State of North Carolina
lit13 Department of Environmental Quality
Division of Water Resources
Water Resources
ENVINONNENiAC OYAlt1 V APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
Dechlorination (Gas; gallons of contact
tablet;liquid) tank/unit
5. RESIDUALS TREATMENT FILTER CARTRIDGES ADDRESSED BY NOTE ON PLAN SHEET 2
No.of Plan Sheet Specification Calculations
Treatment Unit Provided?
Units Type Size per Unit Reference Reference
(Yes or No)
Gravity Thickening square feet; ft side
Tank water depth
Mechanical
Thickening/ dry lb/hour
Dewatering
Aerobic Digestion gallons
Anaerobic
Digestion gallons
Composting dry lb/hour
Drying dry lb/hour
Other
6. PUMP SYSTEMS(include influent,intermediate,effluent,major recycles,waste sludge,thickened waste sludge and plant
drain pumps)
Capacity of
Location No.of Purpose Type each pump Plan Sheet Specification
Pumps Reference Reference
GPM TDH
EFFLUENT PRESSURIZING
END 2 FILTER CENTRIFUGAL 35 24 2 TS 66
7. MIXERS NO CHANGE PROPOSED
No.of Power of Plan Sheet Specification
Location Mixers Purpose Type eac(Hh PM;xer Reference Reference
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 10

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
LNVIRONMEM1AL OVALIIV APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
8. BLOWERS NO CHANGE PROPOSED
Capacity of
Location No.of Purpose Type each Blower Plan Sheet Specification
Blowers (CFM) Reference Reference
9. ODOR CONTROL N/A NO CHANGE PROPOSED
Location No.of Purpose Type Plan Sheet Specification
Units Reference Reference
D. SETBACKS—COMPLETE FOR NEW WASTEWATER TREATMENT STRUCTURES
1. The minimum distance for each setback parameter to the wastewater treatment/storage units per 15A NCAC 02T.0506(b)
are as follows:
Minimum Distance Is Minimum Distance
Required from Nearest Requirement met by the
Setback Parameter Design?If"No",identify
Treatment/Storage
Unit Setback Waivers in Item D.2
Below
Any habitable residence or place of assembly under separate 100 ft Ng Yes ❑❑No
ownership or not to be maintained as part of the project site
Any private or public water supply source 100 ft RR Yes ❑❑No
Surface waters(streams—intermittent and perennial, 50 ft ]Yes ❑❑No
perennial waterbodies,and wetlands)
Any well with exception of monitoring wells 100 ft ♦; ]Yes ❑❑No
Any property line SO ft KI Yes ❑❑No
2. Have any setback waivers been obtained per 15A NCAC 02T.0506(d)?❑❑Yes or❑❑No. If yes,have these waivers been
written,notarized and signed by all parties involved and recorded with the County Register of Deeds?(&K]Yes or❑❑No. If
no,provide an explanation:
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 11

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
ENVIRONMENT ALOUALITY APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
SECTION 5:APPLICATION CERTIFICATION BY PROFESSIONAL ENGINEER
Professional Engineer's Certification per15A NCAC 02T.0105:
I,Ma� \&• =3.]�J;attest that this application package for an Authorization to Construct
(Typed Name of Professional Engineer) 1
for the l AST�E 0-�c(NE Mtrit.4.1Z161-"f
(Facility and Project Name)
was prepared under my direct supervisory control and to the best of my knowledge is accurate,complete and consistent
with the information supplied in the engineering plans,specifications,calculations,and all other supporting
documentation for this project. I further attest that to the best of my knowledge the proposed design has been
prepared in accordance with all applicable regulations and statutes,15 NCAC 02H.0100,15A NCAC 02T North Carolina
General Statute 133-3,North Carolina General Statute 143-215.1 and Division of Water Resources Minimum Design
Criteria for NPDES Wastewater Treatment Facilities,and this Authorization to Construct Permit Application,except as
provided for and explained in Section 4.B.1 of this Application.I understand that the Division of Water Resources'
issuance of the Authorization to Construct Permit may be based solely upon this Certification and that the Division may
waive the technical review of the plans,specifications,calculations and other supporting documentation provided in this
application package.I further understand that the application package may be subject to a future audit by the Division.
Although certain portions of this submittal package may have been prepared,signed and sealed by other professionals
licensed in North Carolina,inclusion of these materials under my signature and seal signifies that I have reviewed the
materials and have determined that the materials are consistent with the project design.
I understand that in accordance with General Statutes 143-215.6A and 143-215.6B any person who knowingly makes
any false statement,representation,or certification in any application package shall be guilty of a Class 2 misdemeanor,
which may include a fine not to exceed$10,000,as well as civil penalties up to$25,000 per violation.
North Carolina Professional Engineer's seal with written signature placed over or adjacent to the seal and dated:
:ok SIC)^6,7
;oQ l''
(� N 2 �•
cN
"o•��5.H. Fed,
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 12

State of North Carolina
Department of Environmental Quality
Division of Water Resources
Water Resources
ENV1R!}NMENTAi.9UAL#TY APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT(FORM ATC-12-14)
SECTION 6:APPLICATION CERTIFICATION BY APPLICANT
Applicant's Certification per 15A NCAC 02T.0106(b):
I, drj(le q( S , attest that this application package for an Authorization to Construct
(Typed Nam of Signature Authority and Title)
for the CCA64t ItoIle ["lnJCh 1i6.A9 UC ) A60_ Cw '1C (talcill,MTD (ct�
(Facility and Project Name)
has been reviewed by me and is accurate and complete to the best of my knowledge. I also understand that if all
required parts of this application package are not completed and that if all required supporting information and
attachments are not included,this application package will be returned to me as incomplete. I further certify that in
accordance with 15A NCAC 02T.0120(b),the Applicant or any affiliate has not been convicted of environmental crimes,
has not abandoned a wastewater facility without proper closure,does not have an outstanding civil penalty where all
appeals have been abandoned or exhausted, are compliant with any active compliance schedule, and does not have any
overdue annual fees.
I understand that the Division of Water Resources' issuance of the Authorization to Construct Permit may be based
solely upon acceptance of the Licensed Professional Engineer's Certification contained in Section 5, and that the Division
may waive the technical review of the plans,specifications,calculations and other supporting documentation provided
in this application package. I further understand that the application package may be subject to a future audit.
I understand that in accordance with General Statutes 143-215.6A and 143-215.6E any person who knowingly makes
any false statement, repr ntation,or certification in any application package shall be guilty of a Class 2 misdemeanor,
which may include a f. o exceed $1 , as well as civil penalties up to$25,000 per viol tion.
Signature: tom:
0��
THE COMPLETED APPLICATION AND SUPPORTING INFORMATION SHALL BE SUBMITTED TO:
NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER RESOURCES/NPDES
By U.S. Postal Service By Courier/Special Delivery:
1617 MAIL SERVICE CENTER 512 N. SALISBURY STREET,9TH FLOOR
RALEIGH, NORTH CAROLINA 27699-1617 RALEIGH, NORTH CAROLINA 27604
TELEPHONE NUMBER: [phone]
Application for Authorization to Construct Permit(FORM ATC-12-14) Page 13

ROY COOPER
Governor
MICHAEL S. REGAN
Serretan,
S. JAY ZIMMERMAN
Water Resources
Dorn tor'
ENVIRONMENTAL OUAL tTY
January 25,2017
Charles E.Trefzger,Jr.Owner
Castle Haynes Health Holdings LLC
P.O.Box 2568
Hickory,North Carolina 28603
Subject: Review of DRAFT Permit NC0051969
Castle Haynes Memory Care WWTP,Class II
4724 Castle Haynes Road,Hickory
New Hanover County
Dear Mr.Trefzger:
In response to your request to renew the subject NPDES permit,received August 5,2016,the Division of
Water Resources(DWR or the Division)hereby transmits this draft for your review and comment.Please
review this document carefully to assure your understanding of the permit limits and monitoring
conditions,and to correct errors,if any.
Concurrent with this notification,the Division will solicit public comment on this draft by publishing a
notice in newspapers having circulation in the general New Hanover County area,as required by the
NPDES Program.Please provide your written comments,if any,to me via email
[[e-mail]],or write to my attention care of NCDEQ/DWR/NPDES Program no later
than March 1,2017,approximately 30 days after receiving this letter. Your written comments are
welcome,but are not mandatory.
The Division understands that you have made no significant changes to your treatment processes since
last renewal.However,please note the following permit changes required for renewal:
Changes for Renewal
1. Updated facility description and site map
2. Discontinued Total Iron and Total Manganese(no longer required for WTP discharge)
3. Revised Dissolved Oxygen limits from 6.0 mg/L to 5.0 mg/L,appropriate for stream Class C; SW
4. Revised WET-Test"monitoring only"to WET-Test"Limited,"based on poor compliance history
5. Added permit limits for Total Copper and Chloride [see A. (1.)] based on reasonable potential
analysis(RPA);monitoring increased from Quarterly to Weekly, as appropriate for limited
parameters.Please note that compliance to these permit limits will commence on March 1,2019,
two(2)years from the permit Effective Date.
Implementing Electronic Discharge Monitoring Reports(eDMRs).Please be advised that the Division
has implemented an electronic Discharge Monitoring Report(eDMR)program,in accord with
requirements promulgated by the US EPA.We include the details to implement the eDMR program in
this permit [see Section A.(3.)].
Nothing Compares
State of NorthCarolna I Environmental Quality I Water Resources
512 N.Salisbury Street 11611 Mail Service Center I Raleigh,NC 2 76 9 9-1 611
919.707.9000

Federal regulations require electronic submittal of all DMRs and specify that,if North Carolina does not
establish a program to receive such submittals, Permittees must then submit eDMRs directly to EPA. For
more information on eDMRs,registering for eDMR submittal, and obtaining an eDMR user account,
please visit DWR's webpage:
httil:/portal_ncde111",t?r�� web/wkj/admin/botlipu/edmr
�1 ...
For information on EPA's proposed NPDES Electronic Reporting Rule,please visit EPA's website:
ht tt,://w w w 2.ep a.,y ov/e omp li anee/proposed-npdes-electronic-reporting-rule
Following the mandatory 45-day public-comment period,the Division will review all pertinent
comments,if any,and take appropriate action prior to issuing an NPDES permit final.If you have
questions concerning this draft,please e-mail me[[e-mail]],or call my direct line
[phone].
Respectfully,
J R.Corpor ,L.G.
CDEQ/NPDES
Enclosure:NPDES Permit NC0051969(renewal RAFT) ,
hc: NPDES Program Files[draft permit and Fact heet]
ec: WiRO/SWPS,Jim Gregson,Supervisor,Dean Hunkele[draft permit,Fact Sheet]
OCU,Maureen Kinney[draft permit and Fact Sheet]
ATU,Cindy Moore;Susan Meadows[draft permit and Fact Sheet]
Charles E.Trefiger[[e-mail]]
-<>"Nothing Compares_
State of North Carolina I Environmental Quality I Water Resources
512 N.Salisbury Street 11611 Mail Service Center I Raleigh.NC27699-1611
919.707.9000

Permit NC0051969
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENTAL QUALITY
DIVISION OF WATER RESOURCES
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
(NPDES)
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Management
Commission, and the Federal Water Pollution Control Act, as amended,
Castle Hayne AL Holdings, LLC
(
r `
` . ) _
is hereby authorized to discharge wastewater from`a facility located at the
Castle Creek,Memory.Care(.WWTP
4724 Castle,Rayne Road, Castle Hayne
NewEanover County
to receiving waters designated as an untrained tributary to Prince George Creek in the Cape Fear River
Basin in accordance with effluent limitations,monitoring requirements,and other conditions set forth in
Parts I, II, and III hereof.
This permit shall become effective , 2017.
This permit and authorization to discharge shall expire at midnight on January 31, 2022.
Signed this day , 2017.
S. Jay Zimmerman, P.G.
Director, Division of Water Resources
By Authority of the Environmental Management Commission
Page l of 7

Permit NC0051969
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.
Castle Hayne AL Holdings, LLC
is hereby authorized to:
1. continue to operate a potable-water treatment system(WTP) for filter,backwash, and a wastewater
treatment system (WWTP) for 100%-domestic wastewater utilizifig'the following components:
/,.
WWTP: r'•. \.
• influent lift station
• dual (2)pumps
• 12,000 GPD aeration basin
• dual (2)hopper clarifiers
• micro-screen drum filter
• UV disinfection
WTP: c ,
• two (2) each media filters (iron removal)
• an Ion Exchange unit •
• storage tank(filter,backwash)
• storage tank(potable,water) ` 2
• appurtenant piping and discharge sample port
these facilities located at the Castle Creek Memory Care WWTP,4724 Castle Hayne Road, Castle
Hayne, New Hanover County, and
2. discharge the combined effluent(0.012 MGD) from said treatment works via Outfall 001, at the
location specified on the attached map, into an unnamed tributary to Prince George Creek [stream
index 18-74-53], a waterbody currently classified C-Sw within subbasin 03-06-23 [HUC: 03030007]
of the Cape Fear River Basin.
Page 2 of 7

Permit NC0051969
Part I
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
[15 NCAC 02B .0400 et seq., 02B .0500 et seq.]
Beginning on the effective date of this permit and lasting until expiration,the permittee is authorized to
discharge a combined treated ion-exchange filter backwash, and treated 100% domestic wastewater
from Outfall 001. Such discharges shall be limited,monitored and reported 1 by the permittee as
specified below:
EFFLUENT LIMITS MONITORING REQUIREMENTS
CHARATERISTICS
(PARAMETER CODE) Monthly Daily Measurement Sample Sample
Average Maximum Frequency Type Location 2
Flow 50050 0.012 MGD Weekly Instant E
TRC 3 50060 17.0 µg/L 2, eek Grab E
pH 00400 Not<6.0 or>9.0 s.u. ., .\,;Weekly Grab E
BOD,5-day(20°C)
(0lApr-310ct) C0310 5.0 mg/L 7.5 mg/L, Weekly Grab E
BOD,5-day(20°C) \ % ,1 \
(01Nov-31Mar) C0310 10.0 mg/L 15.0 mg/L•., ` Weekly Grab E
Total Suspended Solids 00530 30.0 mg/L \45:0ing/L 'N "Weekly Grab E
NH3 as N
C0610 2.0.mg/L 10.0irig/L' . Weekly Grab E
(OlApr-310ct) \\1 ,,, _o'
NH3 as N C0610 4.0 mg/L 20A mg/L Weekly Grab E
(01Nov—31Mar)
4 E
Total Copper _01040 7.88 µg/L 10,47,µg/L Weekly Grab E
Chloride 4 . 00940 \`230 mg/1_, Weekly Grab E
Fecal Coliform •31616 200/100 ml 400/100 ml Weekly Grab E
(geometric mean)
Fecal Coliform 31616 Monitor&Report Weekly Grab U,D
(geometric mean)
Temperature(°C) 00010 Monitor&Report Weekly Grab E,U,D
Dissolved Oxygen 00300 Effluent:not<5.0 mg/L Weekly Grab E,U,D
Conductivity 00094 Monitor&Report Monthly Grab E,U,D
Salinity 00480 Monitor&Report Monthly Grab E,U,D
Total Hardness
[as CaCO3 or Ca+Mg] 00900 Monitor&Report Monthly Grab E,U
Salinity 00480 Monitor&Report Monthly Grab E
Turbidity 00076 Monitor&Report Monthly Grab E
Total Dissolved Solids C0530 Monitor&Report Quarterly Grab E
Total Zinc 01090 Monitor&Report Quarterly Grab E
Total Fluoride 00950 Monitor&Report Quarterly Grab E
Chronic Whole Effluent
5
TH3PB Quarterly Grab E
Toxicity(WET)
See Footnotes next pai e.
Page 3 of 7

Permit NC0051969
Table A.(1.)Footnotes:
1. Electronic reporting(eDMR)is required using DWR's eDMR reporting system[see A.(3.)].
2. E=Effluent;U=Upstream—50 feet above outfall;D=Downstream—0.5 miles downstream of outfall.
3. Total Residual Chlorine(TRC)limit and monitoring apply only if the Permittee uses chlorine or a
chlorine derivative to disinfect.The Division shall consider compliant all TRC values reported below
50 µg/L.However,the Permittee shall continue to record and submit all values reported by a North
Carolina-certified test method,even if these values fall below 50 µg/L.
4. Compliance to permit limits begin on March 1,2019,two(2)years from the permit Effective Date.
5. Chronic WET-Testing[THP3B] Pass/Fail using Ceriodaphnia dubia;effluent concentration at 90%,during
the months of January,April,July and October[see A. (2.)].
Condition:
The Permittee shall discharge no floating solids or foam visible in other than trace amounts.
A. (2.) CHRONIC TOXICITY- Limited (QUARTERLY)
[15A NCAC 02B .0500 et seq.]
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to
Ceriodaphnia dubia at an effluent concentration of 90 °io.
The permit holder shall perform at a minimum,quarterly monitoring using test procedures outlined in the"North
Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure,"Revised December 2010,or subsequent versions
or"North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"(Revised-December 2010)or
subsequent versions.The tests will be performed during the months of January,April,July and October.
These months signify the first month of each three-month toxicity testing quarter assigned to the facility.Effluent
sampling for this testing must be obtained during representative effluent discharge and shall be performed at the
NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the
permit limit,then multiple-concentration testing shall be performed at a minimum,in each of the two
following months as described in"North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure"(Revised-December 2010)or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form(MR-1) for the months in which tests were performed,using the parameter code TGP3B for the
pass/fail results and THP3B for the Chronic Value. Additionally,DWR Form AT-3 (original)is to be sent to the
following address:
Attention: North Carolina Division of Water Resources
Water Sciences Section/Aquatic Toxicology Branch
1621 Mail Service Center
Raleigh,NC 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Water Sciences Section no later than 30 days after
the end of the reporting period for which the report is made.
Page 4 of 7

Permit NC0051969
Test data shall be complete,accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature.
Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required,
the permittee will complete the information located at the top of the aquatic toxicity(AT)test form indicating the
facility name,permit number,pipe number, county,and the month/year of the report with the notation of"No
Flow"in the comment area of the form. The report shall be submitted to the Water Sciences Section at the
address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required,monitoring will be
required during the following month.Assessment of toxicity compliance is based on the toxicity testing quarter,
which is the three-month time interval that begins on the first day of the month in which toxicity testing is
required by this permit and continues until the final day of the third month. ,
Should any test data from this monitoring requirement or tests performed'by the North Carolina Division of Water
Resources indicate potential impacts to the receiving stream,this permit maybere-opened and modified to
include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism
survival,minimum control organism reproduction,and appropriate environmental controls,shall constitute an
invalid test and will require immediate follow-up testing to be completed no later than the last day of the month
following the month of the initial monitoring. •
A. (3.) ELECTRONIC REPORTING',OF DISCHARGE MONITORING REPORTS
[NCGS 143-215.1 (b)]
•
Federal regulations require electronic submittal..of all discharge monitoring reports(DMRs)and program reports
and specify that,if a state does`not establish a system to receive such submittals,then permittees must submit
monitoring data and reports electronically to the Environmental Protection Agency(EPA). The final NPDES
Electronic Reporting Rule was adopted and became effective on December 21,2015.
NOTE: This special condition supplements or supersedes the following sections within Part II of this permit
(Standard Conditions for NPDES Permits):
• Section B. (11.) Signatory Requirements
• Section D. (2.) Reporting
• Section D. (6.) Records Retention
• Section E. (5.) Monitoring Reports
1. Reporting Requirements [Supersedes Section D. (2.)and Section E. (5.) (a)]
Effective December 21,2016,the permittee shall report discharge monitoring data electronically using the
NC DWR's Electronic Discharge Monitoring Report(eDMR)internet application.
Monitoring results obtained during the previous month(s)shall be summarized for each month and submitted
electronically using eDMR. The eDMR system allows permitted facilities to enter monitoring data and
submit DMRs electronically using the internet. Until such time that the state's eDMR application is
Page 5 of 7

Permit NC0051969
compliant with EPA's Cross-Media Electronic Reporting Regulation(CROMERR),permittees will be
required to submit all discharge monitoring data to the state electronically using eDMR and will be required
to complete the eDMR submission by printing, signing, and submitting one signed original and a copy of the
computer printed eDMR to the following address:
NC DENR/Division of Water Resources/Water Quality Permitting Section
ATTENTION: Central Files
1617 Mail Service Center
Raleigh,North Carolina 27699-1617
If a permittee is unable to use the eDMR system due to a demonstrated hardship or due to the facility being
physically located in an area where less than 10 percent of the households have broadband access,then a
temporary waiver from the NPDES electronic reporting requirements maybe granted and discharge monitoring
data may be submitted on paper DMR forms(MR 1, 1.1,2, 3)or alternative forms approved by the Director.
Duplicate signed copies shall be submitted to the mailing address above. See"How to Request a Waiver from
Electronic Reporting"section below.
•
Regardless of the submission method,the first DMR is due on the last-day of the month following the
issuance of the permit or in the case of a new facility,on the last day of the month following the
commencement of discharge.
Starting on December 21,2020,the permittee must electronically report the following compliance monitoring
data and reports,when applicable: J
• Sewer Overflow/Bypass Event Reports;
• Pretreatment Program Annual Reports; and
• Clean Water Act(CWA)Section 316(b)Annual Reports.
The permittee may seek an electronic reporting waiver from the Division(see"How to Request a Waiver
from Electronic Reporting"section below).
2. Electronic Submissions
In accordance with 40 CFR 122.41(1)(9),the permittee must identify the initial recipient at the time of each
electronic submission. The permittee should use the EPA's website resources to identify the initial recipient
for the electronic submission. '-
2
Initial recipient of electronic NPDES information from NPDES-regulated facilities means the entity(EPA or
the state authorized by EPA to implement the NPDES program)that is the designated entity for receiving
electronic NPDES data[see 40 CFR 127.2(b)].
EPA plans to establish a website that will also link to the appropriate electronic reporting tool for each type of
electronic submission and for each state. Instructions on how to access and use the appropriate electronic
reporting tool will be available as well. Information on EPA's NPDES Electronic Reporting Rule is found at:
http://www2.epa.gov/compliance/final-national-pollutant-discharge-elimination-system-npdes-electronic-
reporting-rule.
Electronic submissions must start by the dates listed in the"Reporting Requirements"section above.
Page 6 of 7

Permit NC0051969
3. How to Request a Waiver from Electronic Reporting
The permittee may seek a temporary electronic reporting waiver from the Division. To obtain an electronic
reporting waiver,a permittee must first submit an electronic reporting waiver request to the Division.
Requests for temporary electronic reporting waivers must be submitted in writing to the Division for written
approval at least sixty(60)days prior to the date the facility would be required under this permit to begin
submitting monitoring data and reports. The duration of a temporary waiver shall not exceed 5 years and
shall thereupon expire. At such time,monitoring data and reports shall be submitted electronically to the
Division unless the permittee re-applies for and is granted a new temporary electronic reporting waiver by the
Division. Approved electronic reporting waivers are not transferrable. Only permittees with an approved
reporting waiver request may submit monitoring data and reports on paper to the Division for the period that
the approved reporting waiver request is effective.
Information on eDMR and the application for a temporary electronic reporting waiver are found on the
following web page:
http://deq.nc.gov/about/divisions/water-resources/edmr
4. Signatory Requirements [Supplements Section B. (11.)(b)and•Supersedes Section B. (11.)(d)].
All eDMRs submitted to the permit issuing authority shall'be signed by a person described in Part II, Section
B.(11.)(a)or by a duly authorized representative of that person as described iri`Part II, Section B. (11.)(b).
A person,and not a position,must be delegated signatory authority for'eDMR reporting purposes.
For eDMR submissions,the person signing and submitting the DMR must obtain an eDMR user account and
login credentials to access the eDMR system. For more information on North Carolina's eDMR system,
registering for eDMR and obtaining an eDMR user account,please visit the following web page:
http://deq.nc.gov/about/divisions/water-resources/edmr
Certification. Any person submitting an electronic DMR using the state's eDMR system shall make the
following certification [40 CFR 122.22].
NO OTHER STATEMENTS OF CERTIFICATION WILL BE ACCEPTED:
"I certij5), under penalty of law, that this document and all attachments were prepared under my direction or
supervision in accordance with a system designed to assure that quaked personnel properly gather and
evaluate the information submitted.Based on my inquiry of the person or persons who manage the system, or
those persons directly responsible for gathering the information, the information submitted is, to the best of
my knowledge and belief true, accurate, and complete. I am aware that there are significant penalties for
submitting false information, including the possibility of fines and imprisonment for knowing violations."
5. Records Retention[Supplements Section D. (6.)]
The permittee shall retain records of all Discharge Monitoring Reports, including eDMR submissions. These
records or copies shall be maintained for a period of at least 3 years from the date of the report.This period
may be extended by request of the Director at any time [40 CFR 122.41].
Page 7 of 7

DENR/DWQ/NPDES Unit
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES Permit NC0051969
Facility Information
Applicant/Facility Name: Castle Hayne Health Holdings LLC/Castle Creek Memory Care WWTP
Applicant Address: P.O.Box 2568,Hickory,NC 28603-2568
Facility Address: 4724 Castle Hayne Road;Castle Hayne,NC 28429
Permitted Flow 0.012 MGD
Type of Waste: 82%domestic; 18%WTP backwash
Facility/Permit Status: Class II/Renewal
County: New Hanover County
Miscellaneous
Receiving Stream: UT Prince George Creek Regional Office: Wilmington
Stream Classification: C-Swamp USGS Quad: New Hanover
303(d)Listed? No Permit Writer: Joe R.Corporon,L.G.
HUC: 03030007 Date: 24Jan2017
Drainage Area(mi2): 0
Summer 7Q10 (cfs) 0
Winter 7Q10(cfs) 0
Average Flow(cfs): 0
IWC(%): 100
Lat. 34°20'20"N Long. 77°54'47"W
Facility Summary
Castle Hayne Health Holdings LLC operates a healthcare facility serviced by a combined RO-treatment system to
provide potable water(groundwater)and a wastewater treatment plant(WWTP)serving rest-home residents and
staff.Effluents combine to discharge at the same outfall,001.Two converted sand filters remove iron.An ion
exchange unit is maintained for water softening.Filter backwash discharges to a storage tank draining as influent to
the WWTP.The WWTP is treated utilizing an aeration basin,dual clarifiers,drum filter and UV disinfection.
Effluent and Compliance-Data Review
Flow averaged—0.0267 MGD over three years(Jan2014-Jan2017).Considering compliance,the Division generated
NOVs in 2013,2014,and 2015 for BOD,fecal coliform,dissolved oxygen,flow,and total suspended solids(TSS).
Year 2013 was particularly noncompliant demanding 27 case proceeding to enforcement(see attached history);
however,there were no violations in 2016.The permittee's generally poor Whole Effluent Toxicity(WET)-test
record indicates six(6)failures in the last 18 Quarterly tests,including failure of the last two(2)in 2016.WET
testing has previously been permitted as"monitoring only,"herein revised to"limited"[THPB3]for this renewal.
Note:failure of WET-testing may in part be attributed to relative high concentrations of Chloride in the effluent
averaging 4X aquatic-life standards(see RPA).
Instream Data Analysis
Upstream and downstream data from January 2010 to the present were analyzed by examining monthly DMRs.
Instream fecal coliform sample results are extremely high both upstream and downstream of the outfall,consistently
well above water quality standards. Dissolved oxygen sample results downstream generally show an improvement
over upstream sample results. However,the majority of downstream samples are still under 5.0 mg/L,as may be
considered typical of Class C-Sw conditions.The Division recommends continuing the presently-required weekly
instream monitoring.

Changes for Renewal
• Updated facility description and site map
• Discontinued monitoring for Total Iron and Total Manganese(no longer required for WTP discharge)
• Revised Dissolved Oxygen limits from 6.0 mg/L to 5.0 mg/L,as appropriate for stream Class C; SW
• Revised WET-Test"monitoring only"to WET-Test"Limited,"based on poor compliance history
• Added permit limits for Total Copper and Chloride[see A.(1.)]based on reasonable potential analysis(RPA);
monitoring increased from Quarterly to Weekly,as appropriate for a limited parameter.
• Added Special Condition[see A.(3.)]providing a Compliance Period for Total Copper and`Limited"WET-Test.
Proposed Schedule of Issuance
Draft Permit to Public Notice: January 25, 2017
Final Permit Action: March 3, 2017
NPDES Contact
If you have questions regarding any of the above information,or the attached permit,please contact Joe R.
Corporon,L.G.Uoe.corporon&cdenr.gov]or call 919 807-6394.
/
SIGNATURE: C—- L"� `A a' DATE: t9 A J U C 11

CASTLE CREEK MEMORY WWTP ATC DESIGN CALCULATIONS
ENGINEER: STROUD ENGINEERING,P.A.
DATE:NNE 24,2022
DESIGN FLOW
12000 GALLONS PER DAY MENTAL CARE FAC.WITH 80 BEDS NCAC 2T I50GPDBED
PUMP DESIGN FLOW PF=(18+Po s)/(4+Po.$)
8.3 HOURLY FLOW(GPM) P=SERVICE POPULATION(IN THOUSANDS)
4.22 PEAKING FACTOR NOTE:STATE REQ'D.MINIMUM PF IS 2.5
35.2 GPM REQUIRED PUMP CAPACITY BASED ON PEAK FLOW
7.6 GPM REQUIRED PUMP CAPACITY BASED ON 2 FPS FORCEMAIN FLI'SI i VPi 0(I I
(LARGER CONTROLS)
FORCE MAIN DIMENSIONS Performance of Straight Centrifugal Pumps
ria0 '1
FORCEMAIN DIAMETER(IN.) 1.25 - - A.16$&moo.r.vr1IJMPMIMI
aierrewswi
HAZEN-WILLIAMSCOEFFICIENT I20 aC Maa.ds.1, Mr 1.•Icy0.iMar1M1•1/4.NaF WOM70
a•anawMl•M•an•1019*�w1
FORCEMAINLENGTH(FT.) 20 E.aMYamts..1MWI%awl
ADD.LENGTH FOR BENDS ALONG ROUTE(FT.) 1(ASSI . ___ . el•WOaa'im Hew=116•.1.3II ipla/wilADD.LENGTH FOR BENDS AT LIFT STATION SITE:DESCRIPTION QUANTITY L/D RATIO EQUIV.LENGTH(FT) H
22.5 BEND 0 9 0 -
45 BEND 0 16 0 c
90 BEND 3 30 9.375 E F
BRANCH TEE 2 60 12.5 \0l1►81uItL I ImlCHECK VALVE 1 135 14.0625 • ' M 10 1GATE VALVE 2 17 4 <°` ,a�aa 250]11a 'R.l1a--• • S 2TOTAL BEND EQUIVALENT LENGTH(FT) 390 10 10 30 40 50 60 70 SO 90 100 PIA ypml
TOTAL EFFECTIVE FORCEMAIN LENGTH(FT.) 60 10 a 14 10 10 20 22 PAN
Capacity 0 3450 RPM(60 Hz)
('(Convert to psi,divide by 2.31 Liquid-Water specific gravity 1.0
FORCE MAIN SYSTEM CURVE
FORCEMAIN MAX.GUAGE MAX.GUAGE
FLOW FRICTION HEAD STATIC HEAD SYSTEM HEAD TOTAL HEAD
(GPM) (FEET1 (FEET) (FEET)39osi (FEET)
0 0.000 2 0.00 2.00
5 0.596 2 0.00 2.60
10 2.147 2 0.00 4.15
15 4.546 2 0.00 6.55 `,`3111111111 ,,,I
20 7.741 2 0.00 9.74 ,��%0 G PFtO L Iryq ism
`Z` 1O/1
25 11.697 2 0.00 13.70
5j
30 16.389 2 0.00 18.39 v '<, q<'••• '.
35 21.797 2 0.00 23.80 = 0 O �•'W
40 27.905 2 0.00 29.90 = Z :CC CjCGPb3 =
45 34.699 2 0.00 36.70 - •'C- r•pu 0;i co-
PUMP CURVE SYSTEM OPERATION POINT v'•. ENGtr;•'• Q2'e:
'''+s1147. H.. •`�a
FLOW HEAD 35 GPM .t11�1 ` `
o
(GPM) (FEET) 24 TDH
0 45.0
5 44.0 Pump Data
10 41.0 Model AMT
15 38.0 Model 370E E5 .\\J)\\n
20 35.0 Impeller CENTRIFUGAL
25 31.0 RPM 1750
30 27.0 Outlet 3/4"
I 35 23.0 Volts 115
40 15.0 Cycle 60
Phase 1

SYSTEM CURVE
50
40 -
30
— •SYSTEM CURVE
a (MAX GUAGE)
/— 20 - —PUMP CURVE
O
i
10
•
0 10 20 30 40 50 60 70 80
FLOW(GPM)
CYCLE AND RUN TIMES
V=TQddf(I-Qddf/Q)
WHERE Active Storage Volume V(gal)= I91
Cycle time T(minutes) 30.0
Cycles per hour 2.0 b/w 2 and 8
Daily design flow Qddf(gal./min.)= 8.33
Pump rate Q(gal./min.)= 35
Pump run time per cycle(minutes)= 7.1
Pump run time per day(minutes)= 341
V(gal.)= 190.8
WETWELL INSIDE DIAMETER(fl)= 5
REQUIRED DEPTH IN WELL(ft.)= 1.30 PUMP ON/PUMP OFF CYCLE
FORCE MAIN VELOCITY
VELOCITY"V"(fps)=0.409Q/D^2
WHERE D IS FORCE MAIN DIAMETER(in.) 1.25
Q IS FORCE MAIN FLOW(gpm) 35 AVG.
V(fps)= 9.21 OK

SPECIFICATIONS
Castle Hayne Memory Care
Waste Water Treatment Plant
Effluent Copper Reduction Filtration
Castle Hayne Health Holdings, LLC
101 S Stratford Rd Ste 210
Winston Salem, NC 27104
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[phone] k •,'ssio%vq•
v --....,:%,-.... .,,G .,,q,4zi,;:
Ja, - . Fen ess PE
col24 )202-z
Date
STROUD ENGINEERING, P.A.
CONSULTING ENGINEERS
102-D CINEMA DRIVE
WILMINGTON, NORTH CAROLINA 28403
[phone]

Contents
Part I DEFINITIONS, ABBREVIATIONS AND GENERAL REQUIREMENTS 4
I. STANDARD DEFINITIONS 4
2. STANDARD ABBREVIATIONS 7
3. GENERAL REQUIREMENTS 9
4. SUBMITTALS AND GUIDELINES 10
5. CONCEPTUAL PHASE 11
Part II GENERAL SPECIFICATIONS 13
1. CLEARING 13
2. EXCAVATING, GRADING,TRENCHING, & BACKFILLING 13
3. EXECUTION 15
Part III SUBMITTALS 21
1. GENERAL 21
2. SUBMITTALS 21
3. SUBMITTAL PROCEDURES 21
4. CATALOG SHEETS 21
5. SHOP DRAWINGS 21
Part IV Record Drawings 24
1. RECORD DRAWINGS 24
2. DIGITAL INFORMATION 24
Part V Gravity Sewer 25
1. Material 25
2. Design 30
3. Construction 40
4. Testing 44
5. Repairs 49
Part VI Sewer Force Main 51
1. Material 51
2. Design 55
3. Construction 59
4. Testing 61
5. Valves and Appurtenances 65
Part VII Sewer Pump Stations 66
2

1. Material 66
2. Design 67
3. Testing 96
4. Electrical 99
Part VIII Simplex Stations 103
1. Policy on Allowing Simplex Stations 103
2. Simplex Pump Station Design 104
3.Testing 107
3

Part I DEFINITIONS, ABBREVIATIONS AND GENERAL
REQUIREMENTS
When standards are referred to in this "design criteria document", the most recent
revision shall be applicable. This document addresses the collection and transmission of
wastewater, not the treatment of wastewater.
Pump stations, force mains, and all related appurtenances shall be manufactured, designed,
constructed, and tested in accordance with accepted standards, good engineering
practice, and in complete compliance with the most current state regulations as well as
the NCDEQ Minimum Design Criteria.
These standards apply to gravity collection sewers, pump stations, force mains, and
appurtenances.
STANDARD DEFINITIONS
a. DEFINITIONS
Wherever used in this Manual, the following terms shall have the meanings
indicated which shall be applicable to both the singular and plural thereof. There
are other terms used in this document, which are defined in the sections to which
they apply.
Applicant - Entity which is financially responsible for the proposed sewer collection
system construction or modification, and who shall maintain operational
responsibility of said system unless fee simple title is granted to ENGINEER.
Application - Form or forms provided by NCDEQ and completed by the Design
Engineer and Applicant providing pertinent information regarding the design
and the proposed construction or modification of sewer collection facilities.
It includes all required associated documents.
Approving Authority — Authorized agent of ENGINEER, who shall be responsible for
approving plans and granting service.
Approved Plans - Sewer system improvement plans, which have been reviewed by and
received the approval of CFPUA and/or the appropriate state and local
agencies.
CFPUA — Cape Fear Public Utiliity Authority
Contract Documents- The term "Contract Documents" shall refer to the project plans
and specifications for sewer system improvements.
Contractor- The person, business, or corporation responsible for the performance of
4

Sewer system construction work.
Design Engineer - Professional Engineer, licensed to practice in the state of North
Carolina, responsible for performing the design and preparing the drawings
and specifications for the proposed sewer collection system construction or
modification(s), construction administration and certifying the completion of
such construction or modification(s) in accordance with the approved plans,
specifications, and permits. The design engineer has demonstrated special
experience and knowledge regarding the design and operation of sewer
improvements.
Design Population - The population figure obtained by multiplying the effective
h design flow.
o population figure bythe proper factors for determiningthe
P P P P
Developer - The person(s) or corporation(s) financially responsible for the design and
construction of a development for which wastewater service by CFPUA will
be requested.
Documents - Anyand all drawings, graphs, charts, calculations, compilations of data,
g g P P
writings, photographs, audio or video tape recordings, or other such records
from which project pertinent information can be obtained, extracted, or
translated in a usable form.
Manual - The term "Manual" shall refer to all applicable standards, specifications,
standard details, and policies contained in or referenced by this document.
NCDEQ - North Carolina Department of Environmental Quality
Permit (NCDEQ Permit) - Written document which is issued by NCDEQ authorizing
the construction or modification of sewer infrastructure.
Permit Period - Duration during which a NCDEQ Permit is valid, commencing on the
date of permit issuance by the Approving Authority, and unless suspended,
modified or revoked for cause, shall be valid for the succeeding 12 months,
or until work is complete, accepted and certified by the Design Engineer,
whichever occurs first.
Person - Individuals, soleproprietorships, artnershi s limited liabilitycorporations,
P P �
corporations, professional associations, firms, joint ventures, businesses,
institutions, municipal or other local government subdivisions, governmental
agencies, or any other body corporate or political, for profit or non-profit.
Pipe Trench - The following terms are used in reference to excavation and backfill for
pipes:
5

Bedding - That portion of the pipe support structure bounded by the
Foundation or undisturbed trench bottom, the trench walls and the
bottom of the pipe.
Final Backfill-That portion of the backfill lying above the Initial Backfill.
Foundation - That portion of the pipe support structure bounded by the
undisturbed trench bottom, the trench walls, and the pipe Bedding.
Haunching - That portion of the pipe support structure bounded by the
Bedding, the trench walls, the outside of the pipe and a horizontal
plane having an elevation equal to that of the spring line of the pipe.
Initial Backfill - That portion of the backfill lying above the spring line (mid-
line) of the pipe and below a horizontal plane having an elevation
which is one (I) foot above the top of the pipe.
Professional Engineer (PE) - A person who has been duly licensed as a professional
engineer by the North Carolina State Board of Examiners for Professional
Engineers and Land Surveyors, with experience and special knowledge
concerning sewer improvements.
Record Drawing—A complete set of drawings, consisting of one (I) hard copy, on bond
paper and one (I) electronic copy, in PDF format, which can be printed out,
but not modified and which shows actual installed or constructed conditions.
Controlled location shall be based upon North American Datum of 1983
(NAD 83). Vertical control shall be based upon North American Vertical
datum of 1988 unless no such control is available within 2,000' of the
property, in which case the datum used in setting the control monument will
be used
Required Fee - Fees levied by CFPUA, as established in adoption of their User Rates
and Application Fee for construction observation, permit application,
modification, or renewal, as well as administrative review.
Service Lines - Small pipelines (sewer lines six (6) inches or less) connecting homes
and buildings to the collection system.
Sewer Collection System - The meaning as stated in North Carolina General Statute
143-213 (I 5) in its most current amended form.
Standards - Where this Manual makes a reference to published standards such as
ASTM, ANSI, AWWA, etc., the latest revisions of such standard shall apply.
6

Sewer Service Area - Area designated as the franchise area by the North Carolina
Public Utilities Commission (The land area within which sewer service is
or will soon be available).
CFPUA Sewer Collection System - Part or portion of the facilities owned by CFPUA,
which are used to collect and carry wastewater to the treatment works and
ending at the sewer service lateral cleanout or other designated connection.
2. STANDARD ABBREVIATIONS
Several specific standards and practices are referenced in these minimum design
criteria. The following acronyms and abbreviations shall be used when referring to
these standards and practices for purpose of enhancing the clarity of this document:
A
AASHTO - American Association of State Highway Transportation Officials
ABC -Aggregate Base Course ACI -
American Concrete Institute
ANSI - American National Standards Institute API-
American Petroleum Institute
ASTM - American Society for Testing and Materials AWWA -
American Water Works Association
D
DI - Ductile Iron
E
EA - Environmental Assessment
EEP - Environment Enhancement Program
EIS - Environmental Impact Statement
F
FEMA - Federal Emergency Management Agency
FIRM - Flood Insurance Rate Map
7

FONSI - Finding of No Significant Impact
G
Gal/Person - Gallons per Person
Gal/Unit - Gallons per Unit
Gal/Acre - Gallons per Acre
GPD - Gallons per Day
GPM - Gallons per Minute
H
HDPE - High Density Polyethylene
HI — Hydraulic Institute
I/I - Inflow and Infiltration
M
MGD - Million Gallons per Day
N
NC - North Carolina
NCAC - North Carolina Administrative Code
NCDA - North Carolina Department of Administration
NCDEH - North Carolina Division of Environmental Health
NCDEQ - North Carolina Department of Environment and Natural
Resources
NCDOT - North Carolina Department of Transportation
NCDWQ - North Carolina Division of Water Quality
NEC - National Electric Code
NEMA - National Electric Manufacturer's Association
NFPA - National Fire Protection Association
NPDES - National Pollutant Discharge Elimination System
NPSHA- Net Positive Suction Head Available
NPSHR- Net Positive Suction Head Required
0
OSHA - Occupational Safety and Health Administration
P
8

PPI - Plastic Pipe Institute psi - Pounds
per square inch
psig - Pounds per square inch gauge PVC -
Polyvinylchloride
S
SF - Safety Factor
T
TDH - Total Dynamic Head
U
UL - Underwriters Laboratories
USCE - United States Corps of Engineers
3. GENERAL REQUIREMENTS
a. Sewer Permits —Prior to submitting the application to NCDEQ, CFPUA will need
to issue a flow acceptance letter for the additional flow to systems owned,
operated, and maintained by an entity other than CFPUA. CFPUA will review and
approve all plans for the proposed sewer improvements, prior to submission to
NCDEQ for permitting. In the case of extensions that will be dedicated to CFPUA,
the Applicant will provide a completed application in the name of CFPUA for the
proposed work.
The following situations require approval and are permitted by the State
(NCDEQ-DWQ), regardless of ownership (in addition to CFPUA approval):
i. Outfalls into a basin where sewer service has not yet been provided;
ii. Low pressure sewer systems or STEP systems;
iii. Projects involving Environmental Assessments; and
iv. Any collection system where a variance from State regulations is required.
b. All CFPUA Design Standards shall be incorporated and become an integral part of
the Plans, Specifications, and Contract Documents submitted for review and
approval. Deviations must be noted in writing and receive written approval from
CFPUA prior to final Contract Document approval.
c. The Contract Documents shall insure that all structures, pavements, utilities, and
other facilities, which may possibly be damaged as a result of project work, are
replaced or repaired in a manner, which meets the approval of ENGINEER or any
governing bodies having jurisdiction.
9

d. No connection to, or alteration of any existing facilities owned or maintained by
CFPUA shall be permitted without the express permission of CFPUA and, where
required, the presence of CFPUA's representative, except as directed by
ENGINEER.Where a connection or alteration of any existing facilities is approved,
the connection or alteration shall conform to the standards of this Design Manual
for new installations.
e. All sewer extensions to be operated and maintained by CFPUA, in addition to any
extensions not owned by CFPUA, shall be designed and built in accordance with
this Design Manual, and all applicable State and local regulations.
4. SUBMITTALS AND GUIDELINES
a. REQUIRED COPIES OF CONTRACT DOCUMENTS FOR ENGINEER
APPROVAL
The Design Engineer should submit for a preliminary review to CFPUA one
(I) set of application, pertinent calculations, plans sheets, specifications, and all
required supporting documentation in preparation of filing for applicable permits
to NCDEQ, prior to submission to NCDEQ as is necessary. These documents
shall be presented in duplicate to NCDEQ as an entire submission package
complete with associated fees for permitting once the flow acceptance is issued
from CFPUA.
CFPUA shall review such plans and make the appropriate notes and return the
"redlined drawings" to the Engineer marked so that the necessary revisions can
be made and the Contract Documents revised. Upon review by ENGINEER of the
"red lines", ENGINEER may request to meet to discuss comments. All comments
shall be addressed so as to comply or an explanation of reasons for not complying
must be provided and approved by CFPUA.
The submitted plans are to meet CFPUA design requirements. If plans or
specifications do not meet CFPUA design requirements (unless a variance has been
given and a copy of such variance included with submission), CFPUA may elect to
return the submittal package until such time, the plans and specifications meet
CFPUA design requirements. Any applicable review fees paid to CFPUA are non-
refundable and any applicable fees are required for each review submittal.
The revised plans, applicable permit applications, and fees, and other supporting
documentation shall be submitted for the approval by ENGINEER and the
appropriate state agencies, as appropriate.
b. ENGINEERING DESIGN CALCULATIONS & REPORTS
11

All Contract Documents submitted to CFPUA for approval shall be accompanied
with the necessary design calculations as specified herein or requested by CFPUA.
The calculations and any reports prepared by the Design Engineer must be
reviewed and approved by a Professional Engineer in responsible charge over the
project and so indicated by sealing and signing the said documents.
All design calculations based on data not contained therein shall be referenced to
the source. The calculations shall be submitted in duplicate, clearly referencing the
project and presented in a neat, orderly, and logical procedure. All reports
prepared by sub-consultants shall list the assumptions made in the report
preparation.
c. SEWER DESIGN CALCULATIONS
Sanitary sewer, force main, and pump station improvement calculations shall
demonstrate adequate capacity to serve the entire contributing area. The
calculations for the gravity mains shall be based on Manning's Formula, using a
roughness ("n" factor) appropriate for the material in question. This "n factor"
must be supported by published data from the manufacturer or other industry
publication.
5. CONCEPTUAL PHASE
a. GENERAL
The Engineer and Developer shall become familiar with the sewer improvement
policies of CFPUA prior to making conceptual plans for developments, which will
require sewer service.
b. INITIAL CONFERENCE
Prior to finalizing any plans for sewer collection system improvements, the
Developer or his Engineer shall consult with CFPUA's Authorized Agent to
determine if an initial conference will be necessary prior to the submission of plans
for approval. If the scope of the proposed development is such that an initial
conference will be beneficial prior to the development of final plans and
specifications ("Final - Not Released for Construction"), the Developer will
request schedulingof an initial conference. The Developer shall present the
q P
following:
i. Conceptual Plans: Submit two (2) copies of conceptual subdivision plans or site
plans at a scale of I inch equals 200 feet (or larger scale) showing the proposed
layout of the sewer extensions. The conceptual plans should show
12

all proposed pipelines and sizes, manholes, valves, and pump stations and the
nearest existing sewer facilities to which the proposed new improvements will
be located near or connect. All proposed easements shall be shown. Provide
sketch of improvements and projected inverts within service area for sanitary
sewer.
ii. Design: Provide copies of preliminary engineering design calculations used to
determine estimated wastewater demands used to size line and pump station
requirements including expected initial and future populations to be served.
The probable character of the wastewater generated should be provided.
iii. Estimated Time Schedules: Submit an estimated time schedule identifying the
expected dates of completion of the final plans and specifications and expected
beginning and completion dates of construction.
13

Part II GENERAL SPECIFICATIONS
1. CLEARING
a. All clearing will follow the guidelines for erosion control per a NCDEQ approved and
permitted erosion control plan if one is required. Projects that do not require an approved
plan will follow all industry standards for erosion control. All disturbed areas will be
stabilized within 21 days of the end of work in that area. Stabilization of disturbed areas
should follow the seeding guidelines set forth in Specification 3.
2. EXCAVATING, GRADING, TRENCHING, &BACKFILLING
b. General
i. The contractor shall furnish all labor, equipment, supplies and materials, and
perform all operation in connection with the excavations, grading and backfilling,
including borrow for drainage structures, curb and gutter, sidewalks, driveways,
pavements, slopes, storm drains, water and sanitary sewer lines, including all
hauling, wetting, rolling and other operations pertaining thereto within the
clearing limits, complete, in strict accordance with this section of thespecifications
and all applicable NCDEQ approved drawings, plans and permits.
c. Existing Conditions
i. Every reasonable effort should be made to provide accurate information on
existing site conditions. The Contractor should become familiar with the site and
satisfy himself as to the scope of the work involved and the materials to be
encountered.
d. References
i. ASTM C33 - Standard specification for concrete aggregates
ii. ANSI/ASTM C 136 - Sieve analysis of fine and coarse aggregates.
iii. ANSI/ASTM D698 - Tests for moisture-density relations of soils and soil-aggregate
mixture using 5.5 lb (2.49 kg) rammer and 12 inch (305 mm)drop.
iv. ANSI/ASTM D 1556 - Density of soil in place by sand-cone method.
v. ASTM D2487 - Classification of soils for engineering purposes.
e. Products - Soils
i. General: Use soils free of organic matter, refuse, rocks and lumps greater than 4
inches in diameter and other deleterious matter.
I. Backfilling Materials: Suitable material, when used as backfill in paved areas,
shall be capable of being compacted as specified in paragraph "Compaction
and Testing" of this section of these specifications.
14

a. Type I Material: Excavated material from the trench or materials
from other sources which are free from large clods, roots or stones
larger than I inch may be used as initial backfill in trenches.
b. Type 2 Material: Excavated material from the trench or materials
from other sources which are free from large clods, roots or stones
larger than 8 inches may be used as final backfill in trenches (see
Trench Details)
ii. Classification: For the purpose of this specification, soils to be used as fill material
are grouped into five classes according to soil properties and characteristics.
I. Class I - Angular, 6 to 40-mm (1/4 to I-1/2 in.), graded stone, including a
number of fill materials that have regional significance such as coral, slag,
cinders, crushed stone, crushed gravel, and crushed shells.
2. Class II - Coarse sands and gravels with maximum practical size of 44 mm
(I-1/2 in.), including variously graded sands and gravels containing small
percentages of fines, generally granular and non-cohesive, either wet or dry.
Soil Types GW, GP, SW, and SP are included in this class.
3. Class III - Fine sand and clayey gravels, including fine sands, sand-clay
mixtures, and gravel-clay mixtures. Soil Types GM, GC, SM, and SC are
included in this class.
4. Class IV- Silt, silty clays, and clays, including inorganic clays and silts of low
to high plasticity and liquid limits. Soil Types MH, ML, CH, and CL are
included in this class. These materials are not recommended for bedding,
pipe haunching, or initial backfill.
5. Class V - This class includes the organic soil, OL, OH, PT as well as soils
containing frozen earth, debris, rocks, larger than 40 mm (I-1/2 in.) in
diameter, and other foreign materials. These materials are not
recommended for bedding, pipe haunching or initial backfill.
iii. Topsoil: Natural, friable soil free of subsoil, stumps, rocks larger than 2 inches in
diameter, weeds and other material detrimental to plant growth.
iv. Granular Fill: Granular fill under floor slabs shall be Class I material.
v. Structural Fill: Fill material placed inside the line of the building foundation or slab
shall be Class I or II.
vi. Fill Beneath Pavement: Fill material used beneath pavement and for road shoulders
shall be Class II or III.
vii. General Fill: General fill material not otherwise specified shall be Class II or Ill.
15

viii. Trench Backfill: Material used for bedding, pipe haunching and initial backfill shall
be as specified hereinafter.
I. Crushed Stone: Crushed stone shall be size no. 57, washed stone. If fines
are insufficient, stone screenings shall be added to extent required to
stabilize it in the trench.
2. Concrete: Concrete placed for cradles, thrust blocks, or encasement shall
be 3000 psi 28 day concrete.
3. EXECUTION
f. General
i. Familiarization: Prior to commencement of the earthwork, become thoroughly
familiar with the site, the site conditions, and all portions of the work specified in
this Section.
g. Surface Preparation
i. Clearing: Areas designated for clearing and required for construction operations
shall be cleared of trees, brush, structures and other materials. Trees which are to
remain shall be protected during clearing operations and subsequent work.
ii. Grubbing: Roots, stumps and other materials shall be grubbed from the cleared
areas to a depth of at least 18 inches. Tree stumps shall be grubbed in their
entirety, including tap roots where applicable.
iii. Topsoil: Strip existing topsoil to a depth of 4 inches from areas to be excavated or
graded. Stockpile the topsoil in a suitable area for use during final grading
operations. Protect the topsoil from excessive erosion.
iv. Unsuitable Material: Remove sod, muck or other unsuitable material to firm
subsoil in areas designated for filling or grading operations.
v. Disposal: Trees, stumps, roots, rubbish, unsuitable soil or other material resulting
from surface preparation shall be removed from the site by the Contractor and
disposed of.
h. Excess Water Control
i. General: Grade and maintain all areas of the site to preclude surface runoff into
excavations and prevent ponding of water.
ii. Dewatering: Excavations should be kept free of surface water and/or
groundwater. Provide and maintain at all times the necessary means and devices
16

to prevent water from entering the excavations and for removing all water
entering the excavations, at no additional cost to the owner.
iii. Softened Subgrade: Remove all soil softened or eroded by the presence of water
and replace with suitable backfill material.
i. Excavation
i. Excavation shall be accomplished in accordance with the grades and lines as
established by the applicable plans and as required by the work to be performed.
Excavation shall include the removal and replacement of all asphalt, concrete,
curb, rock, earth, fences, trees (as directed by the Engineer of Record), shrubs,
and other materials as applicable. The contractor will exercise care to prevent
undercutting lower than the required subgrades. All materials from excavation,
considered as suitable by the Engineer of Record, shall be used as fill wherever
required, and the Contractor shall arrange his work so that this usage of
excavated materials will be possible. Unsuitable and surplus materials from
excavation, if any, shall be disposed of by the Contractor at this expense. All areas
of the site shall be graded and maintained at all times to prevent surface runoff
from draining into the excavations, and to prevent ponding of water therein.
ii. Excavated materials not required for topsoil, fill or backfill shall be removed from
the site of the work by the Contractor, but none shall be deposited on private
property without written consent of the property owner.
iii. Unsuitable Materials: Unsuitable materials encountered in an excavation shall be
removed as directed by the Owner's representative, backfilled with suitable
material and compacted. Unsuitable materials include organic soils, muck, soft and
compressible silts and clays and running sands.
iv. Undercutting: Undercutting, unless authorized by the Engineer of Record, shall be
replaced and compacted, as specified in f. (Fill and Compaction), at the
Contractor's expense. If the material, after excavation to subgrade, is found to be
soft, spongy or pumping and thus unfit for use as subgrade, such unsuitable
material shall be removed to a depth as directed by the Engineer of Record and
the subgrade shall be brought to proper elevation by filling with suitable material
from excavation or from an approved borrow site.
v. Borrow: The Contractor will supply all borrow necessary and will provide all
labor and equipment necessary to dig and haul such borrow. The placing of
borrow shall be as provided for section f(Fill and Compaction).
j. Preparation of Subgrade
i. General: Upon completion of site preparation and excavation, scarify to a depth of
12 inches and compact as specified. For areas to receive fill, the compacted
subgrade shall be scarified to a depth of four inches prior to placing thefill.
17

k. Fill and Compaction
i. General: When and where existing plans and grades require the use of fill to reach
the required elevation, the Contractor shall deposit suitable material from
previously excavated areas. Such material shall be free from debris, roots, trash,
stones, or other harmful substances, and shall be spread in successive layers of
loose material not more than 8 inches in depth. Each layer shall be spread
uniformly by motor grader or other approved device and rolled with an approved
tamping or three-wheeled power roller until thoroughly compacted to 90 percent
of maximum density obtained at optimum moisture content, as determined by the
A.A.S.H.T.O. Standard Method T-180. When any portion of the fill is constructed
on an old road bed, the existing surfaces shall be scarified and manipulated as
directed by the Engineer of Record in order that, when compacted, it shall have a
uniform density, as specified above. Fills shall be shaped and maintained at all times
during their construction to prevent an accumulation of standing water in the
event of rain.
ii. Moisture Conditioning: Moisten or aerate the subgrade and fill material as
required to obtain proper compaction.
iii. Structural Fill: Compact the subgrade and fill to a minimum of 98 percent ASTM
D698 (Standard Proctor) maximum density at optimum moisture content.
iv. Granular Fill: Place granular fill on compacted, unscarified fill or subgrade and
compact to a minimum of 100 percent, ASTM D698, maximum density at
optimum moisture content.
v. Pavement Areas: Compact the subgrade and fill material beneath paved areas and
shoulders to a minimum 100 percent ASTM D698 maximum density at optimum
moisture content.
vi. Landscaped Areas: Compact the subgrade and fill to a minimum 98 percent ASTM
D698 maximum density at optimum moisture content. Compact topsoil to 85
percent ASTM D698 maximum density at optimum moisture content.
I. Finish Grading
i. General: Perform finish grading to the lines and grades shown on the drawings.
Finished grades should be smooth and uniform and provide positive drainage..
ii. Tolerances:
I. Rough Grade Plus or minus 0.I foot
2. Finish Grade Plus or minus 0.I foot
iii. Topsoil: The top 4 inches of soil in landscaped areas shall be topsoil.
iv. Protection: Protect areas which have been graded from equipment traffic.
18

m. Trenching, Backfilling and Compaction for Utility Systems
i. General: Refer to specific utility sections in these specifications for installation
requirements. Trench, backfill and compact as specified except as modified herein.
ii. Trenching: Trench widths at and below the top of the pipe shall be the minimum
necessary for proper installation. Trench banks above the top of the pipe shall be
as vertical as practicable. Overdepth excavation shall be backfilled with Class I
material and compacted. The Contractor shall provide, at his expense and as
directed by the Owner's representative, special bedding material or concrete
encasement as may be necessary due to over-width excavation.
iii. Depth: Trench to the lines and grades shown on the drawings. Where elevations
are not shown, trench to a depth sufficient to provide at least 36 inches of cover
above the top of pipe, unless otherwise specified. Grade trenches to provide a
constant slope free of sags and high spots.
iv. Dewatering: Keep trenches free of water. Include cost of dewatering in unit price
bid for pipe. No additional payment for this item is permitted.
v. Trench Bracing: Properly brace, sheet and support trench walls as soil conditions
indicate and in strict conformance with all pertinent laws and OSHA regulations.
Provide adequate bracing and shoring to protect adjacent improvements.
Contractor shall provide certification for all premanufactured trench bracing
devices prior to any excavation activities.
vi. Bedding, Pipe Haunching and Initial Backfill: Tamp to provide firm, even bedding.
Excavate bedding material to match the shape of the bottom of the pipe and bell,
as detailed in the drawings. Place haunching material so as to provide full bearing
around the bottom of the pipe. Place bedding haunching and initial backfill as
specified below.
vii. Pipe Bedding:
I. P.V.C. Gravity Main - Provide six (6) inches of Class I bedding material
compacted to 98 percent ASTM D698 density. Haunching material shall be
Class I material compacted to 98 percent ASTM D698 density. Haunching of
pipe from invert to springline shall be by hand placement to ensure material
is worked under Haunch. Initial backfill shall be Class I to top of pipe
(washed #57 stone preferred).
2. D.I..P. and C900/905 PVC Gravity Main - Provide six (6) inches of Class
bedding material compacted to 98 percent ASTM D698 density. Haunching
material shall be Class I material compacted to 98 percent ASTM D698
density. Haunching of pipe from invert to springline shall be by hand
placement to ensure material is worked under Haunch. Initial backfill shall
be Class Ito springline of pipe Class I, II or III material to top of pipe.
19

3. Pressure Main P.V.C. or D.I.P. - Provide six (6) inches of Class I or II
bedding material compacted to 98 percent ASTM D698 density. Haunching
material shall be Class I or II material compacted to 98 percent ASTM D698
density. Haunching of pipe from invert to springline shall be by hand
placement to ensure material is worked under Haunch. Initial backfill shall
be Class I or Class II to top of pipe Class I, II or III material from top of pipe
to 6-inches above pipe.
4. Service Pipe (Schedule 40) - Provide six (6) inches of Class I or II bedding
material compacted to 98 percent ASTM D698 density. Haunching material
shall be Class I or II material compacted to 98 percent ASTM D698 density.
Haunching of pipe from invert to springline shall be by hand placement to
ensure material is worked under Haunch. Initial backfill shall be Class I or II
to top of pipe.
viii. Backfill: Backfill the remainder of the trench in accordance with paragraphs 2d
(Products-Soils) and f. (Fill and Compaction) of this section. Backfill from
embedment zone to surface grade may be by hand of mechanical placement.
Trench backfill shall be compacted in 8-inch lifts.
ix. Foundation: Foundation materials shall be required in wet, yielding and mucky
locations. Foundation shall be constructed by removal of wet, yielding or mucky
material and its replacement with sufficient Class I material to correct the
instability. In areas where foundation is required bedding shall be class I only.
x. Backfilling in Traffic Areas (Highways, paved streets, paved parking lots,alleys,
driveways, highway and street shoulders)
I. Initial Backfilling of Pipe (Ordinary Bedding for DIP Pipe)
a. After preparing the trench for ordinary bedding as described under
h. Trenching, Backfilling and Compaction for Utility Systems) of this
section, this portion of the pipe trench shall be backfilled with
suitable materials (Type I) under and around the pipe, carefully
deposited in uniform layers on both sides of pipe and compacted by
hand or pneumatic tampers until backfill reaches one (I) foot above
top of pipe. The depth of backfill layers shall be six (6) inches
maximum. Each layer of material shall be compacted to a dry
density 95 percent of the maximum determined by the Standard
Proctor Compaction Test.
b. When crushed stone or concrete encasement is used, the initial
backfill of suitable materials will not be required.
c. The tampers shall be of proper sized to operate between trench
wall and pipe without damaging the pipe.
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2. Initial Backfilling of Pipe (Crusted Stone Encasement for PVC pipe, DIP in
unstable or wet conditions, or crushed stone encasement)
a. This portion of the pipe trench shall be backfilled with crushed
stone to provide crusted stone encasement.
b. When concrete cradle is used, the initial backfill will start at the top
of the concrete and then continue as specified above.
c. When concrete encasement is used, the initial backfill of crushed
stone will not be required.
3. Backfilling Trench to Subgrade After Initial Backfilling (Suitable Materials)
a. After initial backfilling has been compacted as specified above,
backfill the remainder of the trench in compacted layers not to
exceed twelve (I 2) inches using a mechanical tamper up to the
bottom elevation of the pavement structure with suitable materials
(Type 2) to be a dry density 95 percent of the maximum
determined by the Modified Proctor Compaction Test.
n. Field Quality Control
i. Field inspection, sampling and testing will be performed per owner's instructions.
ii. An independent soils Engineer of Recording and testing laboratory shall perform
sufficient tests and inspection procedures, to the satisfaction of the Engineer of
Record, both in the field and lab to ensure that the provisions of this specification
are met. The testing shall be paid by the Contractor. The testing lab shall be
approved by the Engineer of Record. After testing is completed and reports are
provided, all subgrades below the paving will be examined by the Engineer of
Record before any paving is authorized. The responsibility of the soils Engineer of
Recording and testing laboratory is to the Engineer of Record, to whom that firm
must promptly, faithfully and accurately report the results of its tests and
inspections. The firm must, in addition, work in coordination with the Contractor,
making all tests required. The reports must state whether or not the reported
results comply with contract requirements. The testing and control firm shall
promptly type and deliver all its reports to the Engineer of Record with a copy to
the Contractor.
2. SEEDING AND STABILIZATION OF DISTURBED AREAS
a. The seeding and stabilization of all disturbed areas shall conform to the NCDEQ approved
soil erosion plan and permit. If an approved plan is not requires than all disturbed areas will
be seeded and stabilized per the latest edition of the "Erosion and Sediment Control
Planning and design Manual"
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Part III SUBMITTALS
1. GENERAL: Before any work is started at the job site, the Contractor shall make submittals
to the Engineer of Record in accordance with the requirements of this section. The
Contractor shall be responsible for preparing a progress or work schedule for the project.
The Contractor shall process the shop drawings for all materials required by his work to the
Engineer of Record and he shall be responsible for their timely submission in accordance with
the shop drawing schedule which is included in the overall progress or work schedule as
described in this section.
2. SUBMITTALS
a. Submittals are defined as shop drawings, diagrams, illustrations, schedules,
performance charts, brochures and other data prepared by each contractor which
illustrate how specific portions of the work shall be fabricated and/or installed.
b. Shop drawings are not part of the Contract Documents, but are a supplementary
means of communications to assist in understanding what each Contractor proposes
to provide and to establish whether or not what he intends to install conforms to the
drawing and specifications.
c. In the instance of a substituted item, the Contractor shall verify that it will fit into the
space allocated to the originally required item giving due regard to all other trades'
requirements. Where modifications to the Plans and Specifications are proposed, the
Contractor must indicate such deviation in writing in his submittal.
3. SUBMITTAL PROCEDURES: All shop drawings shall be delivered to the Engineer of
Record. The Engineer of Record will screen shop drawing submittals to insure that the shop
drawings have been properly certified and identified. If they are submitted properly, he will
review the items.
4. CATALOG SHEETS: For standard manufactured items considered by the Engineer of
Record as not requiring special shop drawings, each Contractor shall submit seven (7) copies
of manufacturer's catalog sheets showing illustrated cuts of the items to be furnished, scale
details, sizes, dimensions, performance characteristics, capacities,wiring and control diagrams,
and all other pertinent information. Engineer of Record will retain five (5) copies and return
remainder to the Contractor submitting the catalog sheets.
5. SHOP DRAWINGS
a. Each contractor will submit for review seven (7) white prints of shop and working
drawings of materials fabricated especially for his contract, and of equipment and
materials for which such drawings are specifically requested.
b. Prior to submitting drawings to the Engineer of Record, the
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Contractor shall check thoroughly all such drawings to satisfy himself that the
subject matter conforms to the Plans and Specifications in all respects. Drawings
which are correct shall be marked with the date, checker's name and certification
of the Contractor's approval, and then shall be submitted to the Engineer of
Record. Any shop drawings submitted without the Contractor's certification will
be returned without review.
c. Engineer of Record will retain five (5) copies and return remainder to the
respective Contractor.
d. Shop drawings shall show the principal dimensions, weight and structural and
operating features, performance characteristics and wiring diagrams, space
required, clearances, type and/or brand of finish or shop coat, grease fittings, etc.,
depending on the subject of the drawing. When it is customary to do so, when
the dimensions are of particular importance or when so specified, the drawings
shall be certified by the manufacturer or fabricator as correct.
e. When so specified or if considered by the Engineer of Record to be acceptable,
manufacturer's specifications, catalog data, descriptive matter, illustrations, etc.,
may be submitted for review in place of shop and working drawings. In such case,
the requirements shall be as specified for shop and working drawings, insofar as
possible.
f. The Contractor shall be responsible for the prompt submission of all shop and
working drawings in accordance with the shop drawing schedule so that there
shall be no delay to the work due to the absence of such drawings.
g. No material shall be purchased or fabricated until the required shop and
working drawings have been submitted and reviewed. All materials and work
involved in the construction shall then be as represented by said drawings.
h. Only drawings which have been checked or corrected by the fabricator should be
submitted to the Contractor by his subcontractors and vendors. Prior to
submitting drawings to the Engineer of Record, the Contractor shall check
thoroughly all such drawings to satisfy himself that the subject matter thereof
conforms to the drawings and specifications in all respects. Drawings which are
correct shall be marked with the date, checker's name and indication of the
Contractor's approval, and then shall be submitted to the Engineer of Record;
other drawings shall be returned for correction.
The Engineer of Record's review of shop and working drawings will follow a
general check made to ascertain conformance with the design concept and
functional result of the project and compliance with the information given in the
Plans and Specifications. The Contractor is responsible for details and accuracy,
for conforming and correlating all quantities and dimensions at the job site; for
information that pertains to the fabrication processes or to techniques of
construction; for coordination of the work of all trades; and for timely
delivery of all materials so that the project will not be delayed.
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Part IV Record Drawings
1. RECORD DRAWINGS
Certified, surveyed record drawings ("as-built" plans), sealed by a North Carolina
licensed Professional Land Surveyor or Professional Engineer (engineer seal required
for profiles), shall be furnished by the Engineer of Record (or Developer where
applicable) upon completion and acceptance of the infrastructure.
Record drawings should, at a minimum reflect all information found on the approved
plans with all pertinent revisions and field changes.
For gravity sewer and force main projects, the "as-built" plans shall include accurate
information regarding pipe size, pipe material, pipe length, manhole construction
(size of manhole, invert, rim, alignment, location), services, and pump stations along
with any relevant rights-of-way, property boundaries and easements. Plans shall
also include sewer profiles showing any utility crossings along with the
aforementioned information.
the "as-built" plans shall include accurate
For pump station projects,
information regarding interior and exterior pipe sizes, material, length, as
well as all structural dimensions of the pump station, all electrical
equipment (make and model), pump information (make, model, and impeller
size), and site layout information. Both plan view and section view drawings are
required on the "as-built" plans.
F Z. DIGITALIN ORMATION
Digital "as-built" information shall be provided by the Engineer of Record in AutoCAD
and PDF format and shall include all information required on the "as-built" drawings.
Digital pictures of all items of interest such as utility crossings and separations should
be included.
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Part V Gravity Sewer
1. Material
Suitable couplings complying with ASTM specifications shall be used for joining dissimilar
materials which take into account the leakage limitations on these joints.
a. Ductile Iron Pipe
Pipe shall be manufactured as per AWVVA C 141 in 18 foot lengths. Pipe
shall be Class 50, as manufactured by Griffin, U. S. Pipe, American, Tyler,
or Clow.
i Pipe joints shall be of the push-on type as per AWWA C I I I. Pipe lining
shall be cement mortar with a seal coat of bituminous material, all in
accordance with AWWA C 104.
i Ductile Iron Pipe shall be designed and manufactured in accordance with
AVVWA C 150 and C 15 I for a laying condition Type 2 and pressure class
rating as follows:
Minimum Pressure Class for DIP Sewer Mains
Pipe Depth of Pressure
Diameter Cover Class
8-Inch 3 to 20 Feet 350 psi
10 to 12-Inch 3 to 14 Feet 350 psi
14 to 20-Inch 3 to 10 Feet 250 psi
24 to 64-Inch 3 to 8 Feet 200 psi
Note: For cases not specified, consult vith ENGINEER for uidance.
iv All buried DIP and fittings shall have bituminous coating on the exterior
surface in accordance with AVVWA C151.
b. Polyethylene Sewer Pipe
Polyethylene sewer pipe shall be Spirolite as manufactured by Spiral
Engineered Systems, or approved equal.
c. Polyvinyl Chloride (PVC) Pipe
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PVC pipe shall be made of PVC plastic having a cell classification of I 2454-
B, 12454-C, or 13364-B (with minimum tensile modulus of 500,000 psi) as
defined in ASTM Specification D 1784.
PVC pipe shall have integral wall bell and spigot joints for the conveyance
of domestic sewage and shall be supplied in minimum 12.5 foot lengths.
Fittings (private sewer service fittings) shall be made of PVC plastic having a
cell classification of 12454-B 12454-C or 13343-C as defined in ASTM
Specification D 1784.
All PVC gravity sewer pipe and PVC fittings shall be manufactured in
accordance with the latest version of ASTM D3034. Fittings shall be
manufactured by pipe supplier or approved equal, and have bell and/or
spigot configurations compatible with that of the pipe. Fittings shall be
ductile iron fittings for 6" and larger pipes.
iv. All PVC pipe up to and including 15 inches in diameter shall have a
minimum Standard Dimension Ratio (SDR) of 26.Where laying conditions
so warrant, and in accordance with the manufacturer's recommendations,
lower SDR values (stronger pipe) may be required. ENGINEER reserves
the right to require the installation of SDR 21 or SDR 19 pipe at the
discretion of ENGINEER.
v. PVC pipe of any make, brand, or type shall not be used for installations
larger than 15 inches in diameter, without first receiving written approval
of ENGINEER.
vi PVC pipe shall not be used for installations deeper than 20 feet.
d. Material Identification
i Each length of pipe shall have plainly and permanently marked thereon the
following information, as well as any additional information specifically noted
in the sections below:
• Pipe class or strength designation
• Manufacturer's name or trademark
• Nominal pipe size
e. Bedding Materials
For PVC and PVC Composite sewer mains see Section L in the
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Construction Requirements "Additional Requirements for Flexible and
Semi-Rigid Pipe" and the Standard Details for bedding requirements.
f. Manholes
Concrete Manholes
a. Manholes shall be precast concrete
b. All manholes shall have eccentric cone sections
c. Precast manholes shall meet ASTM C478 as to design and manufacturing
requirements
d. The standard joint shall be sealed with a plastic cement putty meeting
Federal Specification SS-S-00210, such as Ram-Nek or a butyl rubber
sealant
e. All lift holes must be plugged with non-shrinking grout after installation
f. All grade adjustment rings shall be sealed with non-shrink grout.
g. All grade adjustment rings will be of precast concrete. No block or brick
risers will be accepted.
h. All manholes shall have 6 inch, 3,000 psi concrete bottoms resting on a
minimum of 12 inches of#57 stone
i. Sewer mains shall enter and exit radially through the manhole
j. Inverts shall be constructed with a width and height equal to '/z that of the
effluent pipe and shall be so finished that a minimum energy loss occurs in
the manhole.
k. At each inlet and outlet of 8 inches or greater, compression connectors
(flexible sleeves) shall be cast into the manhole section.
I. Flexible connectors are to be manufactured of high quality rubber or
synthetic rubber and all strap clamps or draw bolts shall be stainless steel
m. Boots are to meet standards of ASTM C923.
n. Rings and clamps are to meet standards of ASTM A 167 and/or ASTM C923
o. Watertight manhole covers are to be used wherever the manhole tops
may be flooded by street runoff or high water. Locked manhole covers
may be desirable in isolated easement locations or where vandalism may
be a problem.
Manhole Frame and Cover Materials
a Manhole Frames and Covers shall be Class 35 gray iron with "Sanitary
Sewer" forged into the cover as indicated in the details.
la Rings and cover shall be stamped with the make and model
c All manhole frames and covers shall be domestically made and
manufactured in the USA from domestic iron.
d For installation in roadways, use Type 1 ring and cover and place
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sufficient depth concrete below the pavement around the ring to ensure
contact with manhole.
e For installation in unpaved areas, use Type 2 ring and cover
f Use Type 3 ring and cover for installations necessitating watertight
requirements.
g Locking covers shall be required in all outfall locations
h Castings shall be machined to give even and continuous bearing on the
full length of the frame
i. Castings shall be free of porosity and blow holes
} Manhole frames shall be bolted to the manhole, except in paved streets
k All manhole rings in roadways shall be encased in a concrete collar of 3,000
psi concrete beneath the asphalt, with the cover flush with the top of
pavement
1. Watertight manhole frames and covers shall have neoprene gasket and
machined bearing surfaces
m Bolts shall be standard hexagonal-head, countersunk such that when fully
tightened the bolt head is flush with the top of cover
n Only stainless steel tightening bolts shall be used.
Manhole Steps
a. Manhole steps shall be furnished with the precast manhole sections
b. Steps shall be of polypropylene material reinforced with a '/z inch
diameter reinforcing rod
c. Manhole steps shall be designed for a vertical load of 400 pounds
and a horizontal pull out load of 1,000 pounds
d. Steps shall be set 12 inches on center
e. Holes for the installation of manhole steps shall not project through
the manhole wall, but shall stop a minimum of one inch from the outside
wall
f. Steps shall be at least 12 inches clear width and shall project at least
5 inches from the wall into which they are embedded
g. Steps shall be located along the effluent side of the manhole
h. The eccentric cone shall be oriented so that the steps are vertical
over the downstream invert of the primary flow path to allow ease of
access for maintenance, camera, or cleaning operations
The minimum diameter of manholes shall be 4 feet (48 inches).
Larger diameters are preferable for large diameter sewers. A
minimum access diameter of 22 inches shall be provided.
i Manholes for sewers less than 16 inches in diameter shall be a
minimum of 4 feet in diameter. Manholes for sewers 16 inches in
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diameter or greater shall be 5 feet in diameter. No inside drops
shall be allowed.
i Any manholes without rubber boots will not be accepted. Boots
shall be accompanied by stainless steel banded #3 16 connection
iv. Manholes located within 100 year flood plain or in areas of high
ground water shall be waterproofed by wrapping all joints with a
minimum 8" width band of inorganic asbestos felt saturated in
waterproofing asphalt.
v. Waterproofing shall be installed by mopping asphalt over the joint
area, then wrapping the felt around the joints, and finally mapping
the felt with another coat of asphalt.
g. For Service Connections
Pipe Materials
a. Cast Iron Soil Pipe — Cast Iron Soil Pipe shall be heavy weight hub and
spigot meeting Federal Specifications WW-401. The joints shall be rubber
type elastomeric as per ASTM C425
b. PVC Pipe— PVC pipe shall be schedule 40 or greater supplied in minimum
of 18 foot lengths. The pipe may be joined by solvent weld.
c. PVC Pipe shall meet the requirements of ASTM D3033 (SDR 35) as
furnished by Johns-Manville, Gifford Hill, David, Olin, or approved equal.
The pipe may be joined by elastomeric gaskets. Schedule 40 PVC pipe may
also be used.
d. Ductile Iron Pipe— Ductile Iron Pipe shall be used for sanitary sewer with
services with less than 3 feet of cover or in excess of 20 feet of cover.
Pressure class and thickness class of all ductile iron lines with less than 3
feet of cover will be indicated on all plan and profile sheets. Ductile iron
services shall also be used in all cases where a water supply well is located
within 100 feet of the sewer service line.
ii. Service Saddle Materials
a. PVC service saddles shall be of the same material as the main and shall be
solvent welded and fastened with double stainless steel bands. Service
saddles are not allowed for use with newly constructed mains.
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b. Ductile iron service saddles shall be "ROMAC CB" type consisting of a
virgin SBR gasket compounded for sewer service, a ductile iron saddle
casting, a 304 stainless steel adjustable strap for fastening the gasket and
the saddle casting to the sewer main and a 304 stainless steel adjustable
circle clamp for securing the service line into the SBR gasket
c. Service Saddles for PVC services shall be PVC with a cast iron plug at the
right-of-way; a glued-on full circle wye with double stainless steel bands as
shown on ENGINEER Standard Details. Cast iron saddles shall be sealed
with a layer of mortar around the outside edge of the saddle as shown on
ENGINEER Standard Details.
2. Design
a. Location
i All public sanitary sewer mains shall be installed in dedicated street right-of-
way or in dedicated utility easements. Mains located within NCDOT right-of-
way shall be placed in accordance with NCDOT standards and the applicable
encroachment permit.
i Minimum widths of public sanitary sewer easements shall
be as follows:
50 feet Construction Easement
30 feet Permanent Easement
i The size of easements for sanitary sewer mains greater than 24" shall be
determined by ENGINEER.
iv. Sewer mains shall be centered within their easements unless otherwise
determined by ENGINEER.
v. Proposed sewers paralleling a creek shall be designed to a proper depth to
allow lateral connections such that all creek crossing will be below stream bed
elevation. The top of the sewer main shall have at least one foot of cover
between it and the stream bed. Concrete encasement shall be required when
the cover between the top of the pipe and the stream bed is less than three
(3) feet. Sewers entering or crossing streams shall be constructed of ferrous
material pipe with mechanical joints; otherwise they shall be constructed so
they will remain watertight and free from changes in alignment or grade and
tested to 150 psi. PVC pipe may be used where a minimum of three feet of
cover can be maintained. Material used to backfill the trench shall be stone,
30

coarse aggregate, washed gravel, or other materials which will not readily
erode, cause siltation, damage pipe during placement, or corrode the pipe.
vi Sanitary sewer mains shall not be installed under any part of water
impoundments.
vi All private sewer collection mains inside CFPUA service area that will connect
or are planning to discharge into CFPUA sewer system shall comply with all
CFPUA design, siting, and installation criteria outlined herein. The Owner of
the private sewer collection system shall meet all State design requirements
and obtain a State permit to construct and operate the private system.
vi No developer, contractor, or property owner shall place any part of
a structure, any permanent equipment, permanent retaining wall or
impoundment within sanitary sewer easements or utility easements dedicated
to CFPUA.
a Fences are not allowed across easements.
x Fill or cut slopes are not allowed to extend into easements except by specific
approval of CFPUA.
xi Sewer line easements shall be graded smooth,free from rocks, boulders, roots,
stumps, and other debris, and seeded and mulched upon the completion of
construction. Easements across sloped areas shall be graded uniformly across
the slope to no steeper than a 5 to I ratio.
xi Mains shall be deep enough to serve the adjoining property and allow for
sufficient slope in lateral lines, and shall have the following minimum covers.
These requirements may be waived at the direction of CFPUA, in which case
ductile iron pipe shall be installed.
a. 4 feet from the top of the pipe to finished subgrade in roadways
b. 3 feet from the top of pipe to finished grade outside roadways
xi Mains over 20 feet deep require ductile iron for the entire run between
manholes and shall be specifically approved by ENGINEER.
xiv Mains shall have a minimum vertical separation of 24 inches between storm
pipe when the horizontal separation is 3 feet or less unless structural bridging
is provided.
xv. There shall be a minimum of 5 feet horizontal separation between parallel
31

gravity and/or force mains.
xvi. Sewer mains shall have a minimum horizontal separation of 10 feet from water
lines, unless the top of the sewer main is at least 18 inches below the bottom
of the water main and there is a horizontal separation of at least 3 feet from
the closest edge of pipes.
xvi Where sewer mains cross beneath water mains with a vertical separation of
18 inches or less, or where water mains cross under sewer mains, the entire
leg of sewer main shall be ductile iron pipe and the void space between the
pipe crossing shall be backfilled with suitable fill that meets or exceeds
NCDOT specifications. The water main shall be centered at the point of
crossing, which shall be at an approximate 90 degree angle.
xvi. Structures - The sewer outfalls, headwalls, manholes, gate valve boxes, or
other structures shall be located so they do not interfere with the free
discharge of flood flows of the stream.
ixx.Alignment - Sewers crossing streams shall be designed to cross the stream as
nearly perpendicular to the stream flow as possible and shall be free from
change in grade. Sewer systems shall be designed to minimize the number of
stream crossings.
xx Aerial Crossings - Aerial crossings shall be prohibited unless
specifically allowed by ENGINEER and only under extreme
circumstances.
a. Proper joint technology, such as flanged or restrained, adequate supports
to prevent excessive flexion, or a combination of both shall be provided
for all aerial pipe crossings. Supports shall be designed to prevent frost
heave, overturning, and settlement.
b. Precautions against freezing, such as insulation and increased slope, shall
be provided. Expansion jointing shall be provided between above ground
and below ground sewers. Where buried sewers change to aerial sewers,
special construction techniques shall be used to minimize heaving.
c. For aerial stream crossings, the impact of flood waters and debris shall be
considered. The bottom of the pipe should be placed no lower than the
elevation of the 25 year flood. Ductile iron pipe with mechanical joints shall
be required.
d. In the event that the 25 year flood elevation can not be determined or the
proposed gravity sewer must be placed below the 25 year flood
32

elevation, a letter shall be provided by the applicant upon certification
stating: "Regular and proper inspection and maintenance of the aerial
crossing shall be provided to insure that the creek/stream flow is not
impeded and that no damage will be caused to upstream or adjacent
properties.
>oa Anti-Seepage Collars - In areas where the sewer trench has the potential to
drain wetlands, anti-seepage collars shall be installed. Please be advised, in
these areas, a 401/404 permit may be required. All areas directional bored
under wetlands require anti-seep collars.
b. Protection of Potable Water Supplies and Storm Sewers
Cross Connections Prohibited - There shall be no physical connections between
a public or private potable water supply system and a sewer, or appurtenance
thereto which would permit the passage of any wastewater or polluted water into
the potable supply. No water pipe shall pass through or come into contact with
any part of a sewer manhole.
c. Size
i The minimum diameter size for gravity sewer mains conveying wastewater shall be
eight (8) inches for public sewers and six (6) for private sewers.
i New sewer systems shall be designed based on NC Regulation Design Criteria and
NCDEQ requirements for flow as found in I 5A NCAC 02T .01 14.
The ratio of peak to average daily flow shall be as follows:
avg
Q �Q max avg. Flow (GPD)
4.0 3,000 or less
3.5 3,000 — 6,000
3.0 6,000— 10,000
2.5 Greater than 10,000
iv. Sewers shall be designed flowing half full at the average daily flow.
v. Sanitary sewers shall be designed to carry the projected peak flow at no more than
3/4 full.
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vi All sewers shall be designed and constructed to give mean velocities, when flowing
full, of not less than 2.0 feet per second, based on Manning's formula using an "n"value
of 0.013. The following are the minimum slopes which shall be provided; however,
slopes greater than these are recommended.
The minimum grades for public sanitary sewers shall be as follows:
Main Size (in.) Minimum Slope (ft/100 ft)
6 0.60
8 0.40
10 0.28
12 0.22
14 0.17
15 0.15
16 0.14
18 0.12
21 0.10
24 0.08
27 0.07
30 0.06
The minimum slope for the uppermost reach of a sanitary sewer line shall be 1.00%
regardless of sewer line size.
A. The maximum grade for sanitary sewers is 10%. The maximum velocity in sanitary
sewers is 15 ft./sec.
a Sewer extensions should be designed for projected flows even when the diameter of
the receiving sewer is less than the diameter of the proposed extension at a manhole,
with special consideration of an appropriate flow channel to minimize turbulence
when there is a change in sewer size.
x A downstream analysis of the receiving sewer is required prior to submitting for
applicable permits associated with the proposed project.
xi Pipe diameter changes shall occur in a manhole with the invert of the larger pipe
lowered sufficiently to maintain the same energy gradient. An approximate method of
securing these results is to place the 0.8 depth point of both sewers at the same
elevation.
xi Manning's Equation for Gravity Flow
V = [1.486/n] x R.66 x S5
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Where:
V = Velocity in feet per second
n = Coefficient of Roughness (0.013)
S = Slope in foot per foot
R = Hydraulic Radius in feet(cross sectional area divided by the wetted perimeter)
i The pipe diameter and slope shall be selected to obtain the greatest practical velocities
to minimize settling problems. Designs must include a minimum scouring velocity of 2
feet per second. Sewers shall not be oversized to justify using flatter slopes. If the
minimum scouring velocity cannot be maintained during initial operation prior to the
design flow capacities being reached, the ability to periodically flush the system shall
be required.
d. Manholes
i Manholes shall be spaced at a maximum distance of 400 feet apart for all sewer lines.
i Manholes for sewers less than 16 inches in diameter shall be a minimum of 4 feet in
diameter. Manholes for sewers 16 inches in diameter or greater shall be 5 feet in
diameter. A minimum access diameter of 22 inches shall be provided.
i Manholes shall be installed at each deflection of line and/or grade. The flow channel
through manholes should be made to conform in shape and slope to that of the
entering sewer line. Therefore, no elevation drop shall occur at the manhole and
centerline inverts shall be used.
iv. Inside drop manholes shall not be used. Moor base shall not be used. Outside drops
shall be used when free drops exceed 24 inches above the manhole invert.
v. Where the difference in elevation between the incoming sewer and the manhole
invert is less than 2 feet (24 inches), the invert shall be filleted to prevent solids
deposition.
vi Due to the unequal earth pressures that would result from the backfilling operation
in the vicinity of the manhole, the entire outside drop connection shall be encased in
concrete or ferrous pipe specified with necessary blocking for drop connection.
A bench shall be provided on each side of any manhole channel when the pipe
diameter(s) are less than the manhole diameter. The bench shall be sloped no less
than 1/2 inch per foot (4 percent). The invert elevation of any lateral sewer, service
connection, or drop manhole pipe shall be above the bench surface elevation. No
invert shall be located directly on the surface of the bench.
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vi Inlet and outlet pipes shall be joined to the manhole with a gasketed flexible watertight
connection or any watertight connection arrangement that allows minor differential
settlement of the pipe and manhole wall to take place.
Dc Flow Channel
a The flow channel straight through a manhole shall be made to conform as
closely as possible in shape, and slope to that of the connecting sewers. The
channel walls shall be formed or shaped to three quarters (3/4) of the height
of the crown of the outlet sewer in such a manner to not obstruct
maintenance, inspection or flow in the sewers.
B When curved flow channels are specified in manholes, including branch inlets,
minimum slopes should be increased to maintain acceptable velocities.
x Sewers shall be laid with uniform slope between manholes.
xi All sewers shall have straight alignment between manholes. Straight alignment shall be
checked by either using a laser or lamping.
xi Location
a Manholes shall be installed: at the end of each line, at all changes in grade, size,
or alignment, at all intersections, and at distances not greater than 400 feet for
all sewers.
B Cleanouts may be used in lieu of manholes for 6 inch private sewer lines with
distances between cleanouts not to exceed 100 feet.
xi Watertightness
a Manholes shall be designed for protection from the 100-year
flood by either:
i. Manhole rims shall be 24 inches (2 feet) above the 100-year flood elevation
or,
ii. Manholes shall be watertight and vented 24 inches (2 feet) above the 100-
year flood elevation. Manholes shall be vented every 1,000 feet or every
other manhole, whichever is greater.
xbv. Buoyancy - Buoyancy shall be considered and flotation of the manholes shall be
prevented with appropriate construction in every design where high groundwater
conditions are anticipated. All manholes shall have a minimum 6" extended base.
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xv. Inspection and Testing - The specifications shall include a requirement for inspection
and testing for watertightness or damage prior to placing into service.
xvi Corrosion Protection For Manholes
a Where corrosive conditions due to septicity or other causes are anticipated,
consideration shall be given to providing corrosion protection on the interior
of the manholes.
b Where high flow velocities are anticipated, the manholes shall be protected
against displacement by erosion and impact.
e. Pipes
i The pipe material selected shall be adapted to local conditions, such as: character of
industrial wastes, possibility of septicity, soil characteristics, exceptionally heavy
external loadings, abrasion, corrosion, and similar problems. Consideration shall also
be given to pipes and compression joint materials subjected to corrosive or solvent
wastes.
i The specifications shall stipulate: the pipe interior, sealing surfaces, fittings and other
accessories shall be kept clean; pipe bundles be stored on flat surfaces with uniform
support; stored pipe shall be protected from prolonged exposure (six months or
more) to sunlight with a suitable covering (canvas or other opaque material); air
circulation shall be provided under any covering; gaskets shall not be exposed to oil,
grease, ozone (produced by electric motors), excessive heat and direct sunlight;
consultation with the manufacturers shall be undertaken for specific storage and
handling recommendations.
I. All sewers shall be designed to prevent damage from superimposed live, dead, and
frost induced loads. Proper allowance for loads on the sewer shall be made because
of soil and potential groundwater conditions, as well as the width and depth of trench.
Where necessary, special bedding, haunching and initial backfill, concrete cradle, or
other special construction shall be used to withstand anticipated potential
superimposed loading or loss of trench wall stability. See ASTM D 2321 OR ASTM C
12 when appropriate.
iv. For new pipe materials for which ASTM standards have not been established, the
design engineer shall provide complete pipe specifications and installation
specifications developed on the basis of criteria adequately documented and certified
in writing by the pipe manufacturer to be satisfactory for the specific detailed plans.
f. Joints
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i The installation of joints and the materials used shall be included in the specifications.
Sewer joints shall be designed to minimize infiltration and to inhibit the entrance of
roots throughout the life of the system.
i Relation to Water Supply Sources
a A distance of 100 feet shall be maintained between any private or public water
supply source, including any WS-1 waters or Class I or Class II impounded
reservoirs used as a source of drinking water. If this minimum separation can
not be maintained, ferrous sewer pipe with joints equivalent to public water
supply design standards and pressure tested to 150 psi to assure
watertightness, shall be used. The minimum separation shall, however, not be
less than 25 feet from a private well or 50 feet from a public water supply well.
b. All existing waterworks units, such as basins, wells, or other treatment units,
within 200 feet of the proposed sewer shall be shown on the engineering plans.
i Relation to Water Mains and Storm Sewers
a Horizontal and Vertical Separation
i. Sewers shall be laid at least 10 feet horizontally from any existing or
proposed water main. The distance shall be measured edge to edge. In
cases where it is not practical to maintain a 10 foot separation, the
appropriate reviewing agency (NCDEQ) may allow deviation on a case- by-
case basis, if supported by data from the design engineer. Such deviation
may allow installation of the sewer closer to a water main, provided that
the water main is in a separate trench or on an undisturbed earth shelf
located on one side of the sewer and at an elevation so the bottom of the
water
main is at least 18 inches above the top of the sewer.
ii. If it is impossible to obtain proper horizontal and vertical separation as
described above or anytime the sewer is over the water main, both the
water main and sewer must be constructed of ferrous pipe complying with
public water supply design standards and be pressure tested to 150 psi to
assure watertightness before backfilling.
iii. A 24 inch vertical separation shall be provided between storm sewer and
sanitary sewer lines or ferrous pipe specified.
b. Crossings
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i. Sewers crossing water mains shall be laid to provide a minimum vertical
distance of 18 inches between the outside of the water main and the
outside of the sewer. The crossing shall be arranged so that the sewer
joints will be equidistant and as far as possible from the water main joints.
ii. When it is impossible to obtain proper horizontal and vertical separation
as stipulated above, one of the following methods must be specified:
(I) The sewer shall be designed and constructed of ferrous pipe and shall
be pressure tested at 150 psi to assure water tightness prior to
backfilling, or
(2) Either the water main or the sewer line may be encased in a watertight
carrier pipe which extends 10 feet on both sides of the crossing,
measured perpendicular to the water main. The carrier pipe shall be of
materials approved by the regulatory agency for use in water main
construction.
g. Buoyancy - Buoyancy of sewers shall be considered and flotation of the pipe shall be
prevented with appropriate construction where high groundwater conditions are
anticipated.
h. Depth - Three (3) feet minimum cover shall be provided for all sewers unless ferrous
material pipe is specified. Ferrous material pipe, or other pipe with proper bedding to
develop design supporting strength, shall be provided where sewers are subject to traffic
bearing loads. Additional protection shall be provided for sewers that cannot be placed at
a depth sufficient to prevent damage.
i. Design Capacity and Design Flow - Sewer capabilities shall be designed for the estimated
ultimate tributary population including consideration given to the maximum anticipated
capacity of institutions, industrial parks, etc. The capability of downstream sewers to
accept future flow made tributary to the collection system shall be evaluated by the
engineer. Where future relief sewers are planned, analysis of alternatives should
accompany initial permit applications.
j. Standards - Installation specifications shall contain appropriate requirements based on the
criteria, standards, and requirements established by the construction industry in its
technical publications. Requirements shall be set forth in the construction specifications
for the pipe and methods of bedding and backfilling thereof so as not to damage the pipe
or its joints, impede cleaning operations and future tapping, nor create excessive side fill
pressures and ovalation of the pipe, nor seriously impair flow capacity.
k Service Connections
i General Requirements
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a All residential subdivision lots shall be served by gravity unless otherwise
approved by CFPUA otherwise. If a pump is approved, it shall be privately
maintained, must pump into a service connection placed on the lot, and must
have a note on the recorded plat indicating that a private pump is required to
serve the lot.
b. Service connections to the main lines shall be perpendicular to the main line
and shall extend to the edge of the right of way or easement line.
c Cleanouts are required on all services with a maximum spacing of 75 feet on
4 inch services and 100 feet on 6 inch services, and at the right of way line or
edge of easement. All cleanouts shall extend a minimum of 6 inches above
finished grade with brass caps or meet the optional cleanout method
requirements in accordance with the Standard Details.
d Sewer cleanouts located in paved areas, which bear vehicle loading, must have
ductile iron risers, ductile iron fittings and brass caps or meet optional cleanout
method requirements in accordance with Standard Details.
3. Construction
a. Siltation and Erosion
Construction methods that will minimize siltation and erosion shall be employed. The
design engineer shall include in the project specifications the method(s) to be employed
in the construction of sewers. Such methods shall provide adequate control of siltation
and erosion by limiting unnecessary excavation, disturbing or uprooting trees and
vegetation, dumping of soil or debris, or pumping silt-laden water into streams.
Specifications shall require that cleanup, grading, seeding, and planting or restoration of
all work areas shall begin immediately. Exposed areas shall not remain unprotected for
more than seven days unless a sedimentation and erosion control plan is submitted to,
and approved by, the NCDEQ Division of Land Resources.
b. Bedding, Haunching, and Initial Backfill
i Bedding Classes A, B, C or crushed stone as described in ASTM C 12 shall be used
and carefully compacted for all rigid pipe provided the proper strength pipe is used
with the specified bedding to support the anticipated load, based on the type soil
encountered and potential ground water conditions.
i Embedment materials, Classes I, II, or Ill, as described in ASTM D 2321, for bedding,
haunching and initial backfill, shall be used and carefully compacted for all flexible pipe
provided the proper strength pipe is used with the specified bedding to support the
anticipated load, based on the type soil encountered and potential groundwater
conditions. (See Class definitions in section L.2.f.)
ii. All water entering the excavations or other parts of the work shall be removed until
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all the work has been completed. No sanitary sewer shall be used for the disposal of
trench water.
c. Sanitary sewer mains shall be deep enough to serve the adjoining property and allow for
sufficient slope in lateral lines. All sanitary sewer mains shall have the following minimum
covers:
I. 4 feet from the top of pipe to finished subgrade when under a roadway or
parking lot.
2. 3 feet from the top of pipe to finished grade when outside a roadway.
The above requirements may be waived at the direction of ENGINEER, in which case
ductile iron pipe shall be installed of appropriate thickness and pressure class.
d. Sewer mains from 14 to 20 feet deep shall require special bedding in accordance with the
Standard Details.
e. Sewers over 20 feet deep shall require ductile iron or reinforced concrete pipe for the
entire run between manholes.
f. Pipe trench excavation and backfilling shall be performed in accordance with Part II of
these specifications.
I The width of the trench shall be ample to allow the pipe to be laid and jointed properly
and to allow the bedding and haunching to be placed and compacted to adequately
support the pipe. The trench sides shall be kept as nearly vertical as possible. When
wider trenches are specified, appropriate bedding class and pipe strength shall be used.
i In unsupported, unstable soil the size and stiffness of the pipe, stiffness of the
embedment and in-situ soil and depth of cover shall be considered in determining the
minimum trench width necessary to adequately support the pipe.
i Ledge rock, boulders, and large stones shall be removed to provide a minimum
g g
clearance of 4 inches below and on each side of all pipe(s).
g. Transitions of pipe material shall occur only at manholes.
h. Where sanitary sewers cross beneath water mains with a vertical separation of 18 inches
or less or where water mains cross under sewer mains, both lines shall be ductile iron
pipe for a distance of 10 feet on either side of the point of crossing. The waterline pipe
shall be centered at the point of crossing.
i. Sanitary sewers shall have the top of pipe at least 24 inches below the bottom of storm
41

sewer pipe when the horizontal separation between the closest edges of the two pipes is
3 feet or less. Where sanitary and storm sewers cross with a vertical separation of less
than 24 inches the sanitary sewer shall be of water main standard ductile iron pipe for a
distance of 10 feet on either side of the point of crossing with the sanitary sewer pipe
section centered at the crossing.
j. There shall be a 5 foot horizontal separation between parallel gravity and/or force
mains.
k. Additional Requirements for Flexible, and Semi-Rigid Pipe (Polyethylene and PVC)
i For Polyethylene and PVC pipe, the pipe shall be produced with bell and spigot end
construction. Joining will be accomplished by rubber gasket in accordance with
manufacturer's recommendation, unless otherwise directed or approved by
ENGINEER. Each pipe length shall be clearly marked with information including pipe
size, profile number and class number.
i The installation shall satisfy the requirements of the manufacturer,
and/or the following, whichever is more stringent:
a Installation of polyethylene and PVC pipe shall follow the recommendations of
ASTM D-232I "Underground Installation of Flexible Thermoplastic Sewer Pipe".
For flexible pipe bedding and embedment material shall be either Class I or Class II.
For semi-rigid pipe, Class III materials may also be used. In any area where the pipe
will be installed below existing or future ground water levels or where the trench
could be subject to inundation, only Class I material shall be used for bedding and
embedment.
b. The manufacturer's specifications or otherwise approved method shall be used in
determining the stiffness class of the pipe to be installed so as to attain the required
deflection control. The class of the pipe must be approved by ENGINEER prior to
installation.
c The bedding (4" minimum) and embedment materials shall be per ASTM D2321.
The embedment materials shall be installed from trench wall to trench wall and
from the invert to a minimum of 6" above the crown of the pipe.
d. The bedding and embedment material shall be compacted to a minimum of 90%
Standard Proctor density for Class I and II materials, and a minimum of 95
Standard Proctor density for Class III materials.
e. If hydraulic jack shoring is utilized for trench walls, where shoring is used, it shall
be kept to the area just above the top of the pipe. This will ensure the embedment
materials and pipe will not be disturbed when removal is made.
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f Bedding and embedment material classifications shall be defined as follows:
CLASS I - Angular, (1/4 to I-1/2 inch) graded stone, including a number of fill materials that have
regional significance such as coral, slag, cinders, crushed stone, crushed gravel, and crushed shells.
CLASS II - Coarse sands and gravels with maximum particle size of I- I/2 inch, including variously
graded sands and gravels containing small percentages of fines, generally granular and non-
cohesive, either wet or dry. Soil types GW, GP, SW and SP are included in this class.
CLASS III - Fine sand and clayey gravels, including fine sands,_sand- clay mixtures, and gravel-clay
mixtures, Soil Types GM, GC, SM and SC are included in this class.
CLASS IV - Silt, silty clays, and clays, including inorganic clays and silts of medium to high plasticity
and liquid limits. Soil Types MH, ML, CH and CL are included in this class. These materials are
not recommended for embedment.
i Pipe shall be laid going uphill.
I. For Service Connections
i General Requirements
a. See design criteria contained herein for additional installation requirements.
b. Sewer laterals shall not be located in easements when gravity service can be
provided to the property frontage at the street.
c. Direct sewer service taps shall not be allowed on sewer interceptor or outfall
mains 18-inches in diameter or larger, except by manhole connection.
d. Each separately owned structure requires a separate tap to a public sewer.
e. All service connections to existing sanitary sewer mains shall be made by
ENGINEER. Service connections to new mains may be made by the
Contractor, but must include the use of wye (not tee) connections. Taps onto
new lines may only be approved by CFPUA.
f. All service lines with less than 3-ft of cover or deeper than 20-ft shall be made
of ductile iron pipe.
g. Service lines between 3 and 8 feet in depth do not require special bedding.
PVC service lines between 8 and 20 feet in depth shall require Class I bedding
from 4 inches below the service line to 4 inches above the service line.
h. Service connections made using a "ROMAC CB" sewer saddle shall be made
only when the service line is iron pipe and only when the sewer main is 8",
I 0", or 12" diameter concrete, ductile iron, or PVC sewer pipe. This service
connection shall not be used when the sewer main material is truss sewer
43

pipe. The opening in the sewer main for the "ROMAC CB" sewer saddle shall
be cut with a hydraulically or pneumatically driven circular tapping saw of the
same nominal diameter as the sewer service line.
i Individually owned structures shall require at least one sewer tap.
i Service taps into mains shall be made on the top quarter of the main at a 45° angle
to vertical with the wye saddle angled with the direction of flow in the main.
iv. Services are to be done by auger unless otherwise approved by ENGINEER.
v. Service connections to the main lines shall be perpendicular to the main line and
shall extend to the edge of the right-of-way or easement line. 4 inch lines shall
have a minimum slope of 0.60 ft./100 feet. Cleanouts shall be required on all sewer
services with a maximum spacing of 50 feet on 4 inch services and 100 feet on 6
inch services. A cleanout shall be placed on all service lines at the right- of-way
line or at the edge of the easement. All cleanouts shall extend a minimum of 6
inches above finished grade as in accordance with the Standard Details.
vi Service lines shall not be installed into manholes.
m. Final Backfill
i Final backfill shall be of a suitable material removed from excavation except where
other material is specified. Debris, frozen material, large clods or stones, organic
matter, or other unstable materials shall not be used for final backfill within 2 feet of
the top of the pipe. Stones used in backfills shall not be greater than 6 inches along
any axis.
i Final backfill shall be placed in such a manner as not to disturb the alignment of the
pipe.
4. Testing
The Contractor/Applicant shall furnish all materials, labor, and equipment to
perform all testing.
a. The maximum allowable deflection after installation shall BE LESS THAN 5% of the pipe
diameter. The mandrel (go/no-go) deflection test must be performed on each line prior
to acceptance, and no less than 30 days after installation. The Contractor shall supply the
mandrel used for this performance test. The mandrel device shall be cylindrical in shape
having 9 possible contact points with the pipe. The mandrel's diameter (ID of
44

proving right) shall equal the dimensions in the following table, and shall be subject to
the Engineer's approval.
For Polyethylene and PVC Pipe the following shall apply:
Nominal (Proving Ring)
Diameter Dia. Mandrel
(inches) (inches)
6" 5.65"
8" 7.76"
10" 9.08"
12" 10.79"
15" 14.09"
18" 16.53"
21" 19.30"
24" 22.08"
27" 24.84"
30" 27.62"
33" 30.38"
36" 33.15"
42" 38.68"
48" 44.21"
54" 49.74"
60" I 55.27"
For flexible pipes such as PVC, the following shall apply: Mandrel Test criteria for
PVC Pipe
Nominal Proving Ring Mandrel
Diameter Minimum Length (diameter)
(inches) (inches) (inches)
6 6 5.65
8 8 7.40
10 10 9.3I
12 10 11.22
15 12 14.09
i For semi-rigid pipes, such as PVC Composite (Truss) Pipe, the following shall apply:
Nominal Diameter I Proving Ring I Mandrel
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(inches) Minimum Length (inches) (diameter)
(inches)
8 8 7.52
10 10 9.46
12 10 11.40
15 I2 14.31
b. Deflection Test
i Deflection tests shall be performed on all pipe installations. The test shall be
conducted after the final backfill has been in place at least 30 days to permit
stabilization of the soil-pipe system. As an alternative to waiting 30 days to permit
stabilization of the soil-pipe system, ENGINEER will accept certification from a soil
testing firm verifying that the backfill of the trench has been compacted to at least 95%
maximum density.
i No pipe shall exceed a deflection of 5 percent. If deflection exceeds 5 percent,
replacement or correction shall be accomplished in accordance with requirements in
the approved specifications.
i The rigid ball or mandrel used for the deflection test shall have a diameter not less
than 95 percent of the base inside diameter or average inside diameter of the pipe
depending on which is specified in the ASTM Specification, to which the pipe is
manufactured. The pipe shall be measured in compliance with ASTM D2I 22 Standard
Test Method of Determining Dimensions of Thermoplastic Pipe and Fittings. The test
shall be performed without mechanical pulling devices.
c. Leakage Tests
i Leakage tests shall be specified. This may include appropriate water or low pressure
air testing. The testing methods selected should take into consideration the range in
groundwater elevations during the test and anticipated during the design life of the
sewer.
i Water (Hydrostatic) Test-The leakage exfiltration or infiltration shall not exceed 100
gallons per inch of pipe diameter per mile per day for any section of the system. An
exfiltration or infiltration test shall be performed with a minimum positive head of 2
feet.
i Air Test
a. The air test shall, as a minimum, conform to the test procedure described in
ASTM C-828-86 for clay pipe, ASTM C 924 for concrete pipe, and for other
materials, test procedures approved by NCDEQ and ENGINEER.
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b. Low-pressure air testing shall be performed on all sewer mains before the
laterals or stubs are installed on the line, and after the trench has been
backfilled to finished grade. Plugs shall be installed at each manhole to seal
off the test section. The line will be pressurized with a single hose and
monitored by a separate hose connection from the plug. Air then shall be
slowly introduced into the sealed line until the internal air pressure reaches
4.0 psig. The air pressure shall then be allowed to stabilize for a minimum of
2 minutes at no less than 3.5 psig (plus groundwater pressure, if any). When
the pressure reaches 3.5, the time required for the pressure to drop
I.0 psi will be observed and recorded. The line shall be "acceptable" if the
pressure does not drop more than 1.0 psi in the time prescribed for the test
in the Sanitary Sewer Air Test table found in the Standard Details.
c. If the section fails to meet these requirements, the source of leakage shall be
repaired and the pipe section re-inspected.
d. ENGINEER may require that an infiltration test be performed that shall not
exceed 100 GPD/inch/mile.
d. Visual Testing and Observation
i. All materials used must be approved by ENGINEER prior to installation. Rejected
materials shall be immediately removed from the job.
ii. Gravity sanitary sewer lines shall be clean and free from obstructions, and shall be
visually inspected from every manhole. Lines which do not exhibit a true line and grade
or which have structural defects shall be corrected. Sanitary sewer service
connections shall be visually inspected prior to backfilling.
e. Video Assessment and Cleaning
i. As a final measure required for acceptance, the Contractor shall clean and televise all
newly installed sewer mains prior to acceptance by ENGINEER. The Contractor shall
televise the sewer main and all lateral connections installed from the upstream to
downstream manhole with no reverse setups or cutaways. Throughout shooting, the
camera shall be panned and tilted for a complete view of the main. Lighting shall be
adequate to view the entire sewer main and service connections from beginning to
end. The video inspection shall be submitted to ENGINEER on DVD and formatted
with software compatible and readable by ENGINEER. ENGINEER shall not be
responsible for purchasing additional software necessary to view the videos.
ii. The camera shall be advanced at a uniform rate that allows a full and thorough
inspection of the new sewer main. The camera shall be a color, pan, and tilt camera.
The picture quality and resolution shall be acceptable and sufficient to allow a
47

complete inspection with no lapses in coverage. The length of the sewer main shall be
measured and recorded on the video screen. The distance counter shall be calibrated
before shooting the inspection video.
iii. The Contractor shall clean the sewer mains ahead of video inspection with a high-
velocity water jet. The video inspection shall take place within 2-hours of cleaning
operations as witnessed by ENGINEER. All construction debris shall be collected and
removed in the downstream manhole and shall not be released into the sewer system.
iv. A ENGINEER representative shall be present throughout the cleaning and televising
of the sewer mains to verify that the video work complies with the specifications.
v. Prior to submitting the DVD to ENGINEER, the Contractor shall label the DVD with
the following information:
• Name of the Project/Development.
• Name and contact information of responsible party.
• Date of televising.
• Manhole identification as shown on the design plans.
f. Manholes
i. Vacuum Testing
a. All newly installed manholes shall pass a vacuum test in accordance with ASTM
C 1244-93. The Contractor shall supply all equipment and materials necessary
to vacuum test the manholes.
b. Vacuum Testing shall not be initiated until the manholes and all specified
coatings and lining materials have been cured in accordance with manufacturer
recommendations.
c. A ENGINEER representative shall be present and witness all vacuum testing.
d. The following vacuum testing criteria shall apply for compliance with the
testing procedure.
• A vacuum of I0-inches of mercury shall be drawn with an approved
vacuum testing unit.
• The testing time shall not be measured until after the vacuum
pump has been shut off.
• The time required for the vacuum to drop from I 0-inches to 9-inches of
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mercury shall meet or exceed the values listed in the following table:
Manhole Vacuum Testing Time
Depth (feet) Manhole Diameter (inches)
48 I 60 I 72
Time (seconds)
8 20 26 33
10 25 33 41
12 30 39 49
14 35 48 57
I6 40 52 67
18 45 59 73
20 50 65 81
22 55 72 89
24 59 78 97
26 64 85 105
28 69 91 113
30 74 98 121
Note: If depth falls below 8 feet or between two depths,the
next deepest increment of depth shall be used.
5. Repairs
a. Sewer Main Repairs
i PVC Pipe— replace damaged section with PVC Pipe and install a Fernco coupling at
each end encased in concrete.
i ABS/PVC Truss Pipe— replace damaged section with D.I.P. and install a Fernco
coupling at each end encased in concrete.
A.C. Pipe — use a full circle repair clamp for the damaged section or replace
damaged section with DIP and couplings encased in concrete.
iv. HDPE Pipe — replace damaged section with new HDPE pipeline section and install
electrofusion couplings at both ends; minor breaches may be repaired with an
electrofusion repair coupling as deemed appropriate by manufacturer's
representative.
b. Installation
i All repairs to damaged sanitary sewer lines in paved areas shall be backfilled with
ABC stone (crusher run) to a density of 95 percent Standard Proctor.
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i All repairs to damaged sanitary sewer lines shall be bedded with 6-inches of washed
stone and compacted to a minimum of 95% Standard Proctor density before
installing the new joint of ductile iron.
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Part VI Sewer Force Main
1. Material
a. General
i. Force mains smaller than 4 inches in diameter shall be PVC or HDPE, while force
mains 4 inches or larger shall be DIP, PVC, or HDPE.
ii. Force mains shall be of a size greater than the diameter of solid capable of being passed
by the sewage pumps.
a PVC and HDPE pipe requires the installation of 3 inch wide detector tape a
maximum of 2 feet below the finished grade
iii. All fittings shall be as manufactured by Russco, Clow, Tyler, American, Union, or
Griffin.
iv. Force main shall be installed with a minimum cover of three feet measured from the
top of the pipe to the finished subgrade.
b. Ductile Iron Pipe
i. Pipe shall be manufactured as per AWWA C 141 in minimum 18 foot lengths. Pipe
shall be Class 51, as manufactured by Griffin, U. S. Pipe, American, or Clow.
ii. Ductile Iron Pipe shall be designed and manufactured in accordance with AWWA
C 150 and C 15 I for a laying condition Type 2. Pipe joints shall be of the push-on type
per AWWA C I I I. Pipe lining shall be cement mortar with a seal coat of bituminous
material, all in accordance with AWWA C 104. Ductile Iron Pipe Joints shall be
mechanical or gasketed joint as per AWWA C 15 I.
Working pressure shall be as follows:
2" — 12" 350 psi
14" — 20" 250 psi
24" 200 psi
30" — 54" 150 psi
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iii. DI pipe shall conform to ANSI/AWWA C 15 I/A21.5 I "Ductile Iron Pipe, Centrifugally
Cast in Metal Molds for Water or Other Liquids."
iv. The thickness and pressure class of DI pipe required for the installation and operating
conditions during the expected service life of the force main shall be determined in
accordance with ANSI/AWWA C 150/A2I.50"Thickness Design of Ductile Iron Pipe."
v. Fittings for DI pipe shall conform to ANSI/AWWA C 110/A21.10 "Ductile-Iron and
Gray-Iron Fittings, 3 In.through 48 In.for Water and Other Liquids" or ANSI/AWWA
C 153/A2I.53 "Ductile Iron Compact Fittings, 3 In. through 24 In. and 54 In. through
66 In., for Water Service."
vi. Force mains of DI pipe shall have mechanical or gasketed push-on type joints. If
exposed, force mains of DI pipe shall have flanged joints. Restrained joint DI pipe may
be used for anchoring purposes as described in Section 4.03C.
a Gaskets shall be manufactured of vulcanized natural or synthetic rubber in
accordance with ANSI/AWWA CIII/A21.1 I "Rubber Gasket Joints for
Ductile Iron and Gray-Iron Pressure Pipe and Fittings."
b. Flanged DI pipe shall conform to ANSI/AWWA C 115/A21.15 "Flanged Ductile
Iron Pipe with Ductile Iron or Gray Iron Threaded Flanges.
vii. Consideration shall be given to the existence of or the potential for development of
corrosive environments within and outside the force main shall be performed. Sources
of corrosion may include: acidic soils, septic wastewater, and air entrainment within
the force main. Where corrosion is deemed to be a serious problem, DI pipe shall be
provided with cathodic protection or an internal/external encasement, lining, or
coating appropriate for the pipe material and situation. Such encasements, linings, and
coatings shall be manufactured or applied in accordance with the appropriate ANSI
and AWWA standards.
c. PVC Pipe
i. PVC Pipe shall meet the requirements of AWWA C900.
ii. Pipe shall be pressure rated 160 psi, SDR-26, integral bell with strength equal to the
pipe wall, cast iron O.C., 18 foot lengths, with a solid elastomeric ring as furnished by
Johns-Manville, Clow, North Star, or Robin-Tech.
iii. PVC pipe will require the installation of a detector tape and wire placed a maximum
of 2 feet below the covering surface. The detector tape shall be a wide wire as
manufactured by Allen or approved by ENGINEER.
52

iv. All fittings shall be as manufactured by Russco, Clow, Tyler, American, Union, or
Griffin or approved by ENGINEER.
v. PVC Pipe shall be SDR 21 or schedule 40 PVC pipe with push joints. Pipe and joints
shall meet all applicable requirements of ASTM D-2241 and D-1785. PVC pipe
requires the installation of detector tape and wire a maximum of 2 feet below the
finished grade.
vi. PVC material used in the manufacture of PVC pipe shall conform to ASTM D 1784
"Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride)
(CPVC) Compounds."
vii. PVC pipe shall conform to ASTM DI 785 "Poly(Vinyl Chloride) (PVC) Plastic Pipe,
Schedules 40, 80, I20" or to ASTM D224I "Poly(Vinyl Chloride) (PVC) (SDR-PR)."
viii. The thickness and pressure class of PVC pipe required for the installation and
operating conditions during the expected service life of the force main shall be
determined in accordance with AWWA C900 "Poly(Vinyl Chloride) (PVC) Pressure
Pipe, 4 In. through 12 In., for Water" or AWWA C905 "Poly(Vinyl Chloride) (PVC)
Water Transmission Pipe, Nominal Diameters 14 In. through 36 In."
ix. Force mains of PVC pipe shall have gasketed push-on type joints. Gaskets shall be
manufactured of elastomeric material in accordance with ASTM F477 "Standard
Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe."
x. Mechanical joint DI pipe fittings conforming to ANSI/AWWA C 1 10/A21.10 or
gasketed PVC fittings shall be used for force mains four inches in diameter and larger.
Solvent-welded or gasketed fittings may be used for smaller diameter force mains.
d. High-Density Polyethylene Pipe (HDPE)
i. HDPE pipe shall be produced from a high molecular weight, high density, polyethylene
resin, meeting the requirements of ASTM D3350 "Standard Specification for
Polyethylene (PE) Plastic Pipe and Fitting Materials." Resin material shall be listed by
PPI in the name of the manufacturer and shall be based on testing in accordance with
ASTM D2837 "Standard Test Method for Obtaining Hydrostatic Design Basis for
Thermoplastic Pipe."
ii. HDPE pipe shall conform to ASTM D3035 "Standard Specification for Polyethylene
(PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter" or ASTM F714
"D3035 "Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on
53

Outside Diameter."
iii. The thickness and pressure class of HDPE pipe required for the installation and
operating conditions during the expected service life of the force main shall be
determined in accordance with AWWA C906 "Polyethylene (PE) Pressure Pipe and
Fittings, 4 In. through 63 In., for Water Distribution."
iv. Fittings for HDPE pipe shall conform to ASTM D326 I "Standard Specification for Butt
Fusion of Polyethylene (PE) Plastic Fittings for PE Plastic Pipe and Tubing" and shall be
manufactured by injection molding, a combination of extrusion and machining, or
fabrication from HDPE pipe material.
v. Force mains of HDPE pipe shall be joined by the thermal butt fusion process and shall
be performed in accordance with ASTM A2657 "Standard Practice for Heat Fusion
Joining of Polyolefin Pipe and Fittings" and the manufacturer's recommendations
during installation.
e. Pipe Fitting Materials
i. Pipe fittings shall be cast or ductile iron designed and manufactured per AWWA C 110.
Fittings up to and including 12 inches shall be designed for an internal pressure of 250
psi. Fittings larger than 12 inches shall be designed for an internal pressure of I 50 psi.
Joints for fittings shall be mechanical joint and shall be cement mortar lined with a seal
coat of bituminous material, in accordance with AWWA C 104.
ii. All buried DIP and fittings shall have bituminous coating on the exterior surface in
accordance with AWWA C 15 I.
iii. Except for HDPE, pipe shall be supplied in minimum of I 8-foot lengths unless approved
otherwise by ENGINEER.
f. Material Identification
i. Force mains shall be appropriately identified upon installation so they will not be
confused with potable water lines. Green detector tape and wire 3 inches in width
and clearly labeled sanitary sewer shall be laid a maximum of 2 feet below the finished
grade.
ii. Force main valves shall have valve box covers marked"Sewer".
g. Manhole Materials - All manholes installed along a force main and the discharge manhole
shall be installed according to Section 7.2.I(F) of ENGINEER Standard Specifications and
coated with an approved epoxy coating.
III
54

2. Design
a. General
i. Sizes of fittings up to and including 16 inch shall be designed for an internal pressure
of 250 psi.
ii. Reaction blocking for all fittings or components subject to hydrostatic thrust shall be
securely anchored by the use of concrete thrust blocks poured in place. The reaction
areas are shown in Standard Detail 6.I 1. No concrete shall interfere with the removal
of fittings. Materials for reaction blocking shall be 3,000 psi concrete.
iii. Air release valves shall be designed at the high points of all force mains and in the valve
vault of all lift stations. The air release valves shall be constructed from stainless steel
and utilize a ball valve.
iv. Force sewer mains shall be installed in dedicated public right-of-way or in dedicated
utility easements having the following dimensions:
50 feet Construction Easement
30 feet Permanent Easement
b. Material
i. Pipe material and specifications shall be selected based on the installation and
operating conditions of the force main following installation. Such factors shall include,
but shall not be limited to:
a Installation depth and overburden pressure.
b. Soil conditions and groundwater presence
c Corrosion resistance from both external and internal sources.
d Strength required to withstand internal pressures expected during normal
operation as well as those resulting from hydraulic surges and water hammer.
ii. Force mains shall be constructed of one of the following types of pipe:
a Ductile iron (DI)
b. Polyvinyl chloride (PVC)
c High-Density Polyethylene Pipe (HDPE)
d All pipe used for force main construction shall be labeled or otherwise identified
as conveying wastewater.
55

c. Diameter
i. The pipe diameter of the force main shall be larger than the diameter of the
maximum solid size that is passed by pumps present in the pump station.
a A minimum four-inch force main shall be used unless the force main is served by
pumps capable of grinding, chopping, or cutting solids or a mechanical means of
reducing the size of a three-inch solid and any trash or stringy material that can
pass through a four-inch hose is installed in the pump station. Acceptable
mechanical means of solids reduction shall be as defined in I 5A NCAC 02T
regulations.
d. Velocity
i. Wastewater velocity occurring in a force main shall be calculated using the
continuity equation:
V = 0.409Q/D2
V = velocity(feet per second)
Q = pumping rate of a single pump(gpm)
D = diameter of the pipe segment(inches)
ii. A self-cleansing velocity of at least two feet per second shall be provided throughout
the length of the force main in accordance with I 5A NCAC 2H.021 9(i)(2)(B).
a Consideration shall be given to preventing or alleviating the accumulation of solids
in the force main by providing one or more of the following:
i The ability to provide velocities of between two and five feet per second during
a cleaning event that are suitable to resuspend any solids that may have settled
out.
i Drain or blow-off valves provided at all low points in the force main. Such
valves shall either be connected to an available entry point into the wastewater
collection system, provided with a connection for a vacuum pumper truck, and
designed with some other method to prevent an intentional discharge of
wastewater during their operation.
i Flushing ports along the length of the force main as well as a water supply of
sufficient quantity and pressure. Such ports shall either be connected to an
available entry point into the wastewater collection system, provided with a
connection for a vacuum pumper truck, and designed with some other method
toprevent an intentional discharge of wastewater duringtheir operation.
g P
56

iv. Pigging device launching and retrieval stations of a size sufficient to clean the
inside diameter of the force main.
b. Compliance with NC DENR's Minimum Design Criteria for the Fast-Track
Permitting of Pump Stations and Force Mains Section4.03 B.I shall also be required
when engineering calculations determine that depressed sections of the force main
will not be completely flushed in a single pumping cycle.
iii. Anchorage
a Force mains shall be adequately anchored to resist thrusts that may develop at
bends, tees, valves, fittings, plugs, and at any other location where a change in flow
direction occurs.
i Such anchoring shall be provided through the use of concrete thrust blocking
and/or restrained joint pipe.
(I) Concrete thrust blocks shall be located between the fitting to be
anchored and undisturbed soil material. Appropriate thrust reaction
block bearing areas shall be calculated based not only on the maximum
expected force, but also on the soil material. Concrete thrust blocks
shall have a minimum compressive strength of 3,000 pounds per square
inch.
(2) Self-restrained joints or joints restrained with tie rods and clamps shall
both be acceptable. In both cases, component parts shall either be
manufactured of corrosion-resistant materials or coated liberally with
a corrosion-retarding product.
i Anchoring devices shall be designed to withstand force main pressures of at
least 25 percent greater than the maximum pump shut-off head plus an
allowance for water hammer and an appropriate factor of safety.
e. Surge and Water Hammer
i. Consideration shall be given to analyzing force mains in conjunction with their
associated pump stations with respect to the development of hydraulic transients.
ii. Force main design shall be such that active devices for control of transient hydraulic
conditions are minimized to the greatest extent possible; however, if this is not
feasible, the following shall be acceptable control strategies:
a Variable-speed pumps or constant-speed pumps in combination with control
57

valves that open and close slowly.
b. Providing air scouring velocities in the force main.
c Construction of the force main using a higher-strength pipe.
d Vacuum relief valves in accordance with NC DENR's Minimum Design Criteria for
the Fast-Track Permitting of Pump Stations and Force Mains Section 4.05.
e. Specialized control and/or release valves and other devices designed to prevent
transient pressures from reaching levels that could damage the pump station and
force main systems.
f. Appurtenances
i Air Release and Vacuum Relief Valves
a The route of the force main shall be such that the number of air release and
vacuum relief valves are minimized to the greatest extent possible.
h In accordance with I5A NCAC 02T .0305(h)(5), an air release valve shall be
provided at all high points to prevent air locking of the force main. NC DENR has
interpreted this regulation as requiring an air release valve at locations where the
distance between the low point and high point in the force main exceeds 10
vertical feet.
i. Automatic or manual air release valves shall be acceptable.
ii. Consideration shall be given to using manual air release valves in lieu of
automatic air release valves or providing automatic air release valves with flood
protection in areas within the 100-year floodplain or any where flooding is
anticipated to occur.
iii. Automatic air valves shall be of the quick-opening, slow-closing type to prevent
the development of hydraulic surge conditions.
c Consideration shall be given to locating vacuum relief valves at locations along the
force main where sub-atmospheric pressures or column separation may occur.
g. Force mains shall be installed with a minimum cover of three (3) feet measured from the
top of the pipe to the finished subgrade.
h Dedicated easements for force mains and appurtenances shall be recorded as "Utility and
Pipeline Easement" or"Sanitary Sewer Easement". sewer easements shall not contain any
other utilities.
Force mains shall discharge at the invert of the receiving manhole and shall be as close as
possible to 180 degrees from the outlet pipe.
58

j. Sewage Combination Air Valves shall be installed at all the high points or runs exceeding
3,000-ft on all force mains in accordance with the Standard Details.
k A plug valve shall be installed every 3,000 feet of force main length, unless otherwise
directed by ENGINEER.
I. All air release valves, plug valves, or other fittings or appurtenances that have moving or
operating parts and require maintenance and routine access shall have a manhole placed
over them or over the operating portion of the device. Manholes shall be designed and
installed as described in Section 7.0 of ENGINEER Standard Specifications.
m Refer to Part I and Part II of Specifications for more details on easements, separation
distances, bedding requirements, installation requirements, etc.
3. Construction
a. Ductile Iron Pipe force main may be cored if necessary.
b. PVC pipe will require the installation of a detector tape placed a maximum of 2 feet below
the surface. #I2 gage copper tracer wire with green plastic coating will be laid with all
force mains and made accessible at all valve boxes.
Force mains shall be appropriately identified upon installation so they will not be confused
with potable waterlines or other utilities.
c. Reaction blocking for all fittings or components subject to hydrostatic thrust shall be
securely anchored by the use of concrete thrust blocks poured in place.
d. Force mains shall be installed with a minimum cover of three feet measured from the top
of the pipe to the finished subgrade.
e. Force main valves shall be spaced at appropriate intervals as determined by ENGINEER,
and shall have valve box caps marked "Sewer".
f. The receiving manhole for a force main shall receive an interior coating of Koppers "Super
Service Black" with a total dry film thickness of 10 mils. All nicks and scratches shall be
touched up prior to acceptance of the manhole. The force main shall discharge at the
invert of the receiving manhole and shall be as close as possible to 180° from the outlet
pipe.
g. Installation
i. Joints and Bedding
a Force mains shall be installed such that pipe and joint deflection is minimized.
59

i Force mains of DI pipe shall be installed in accordance with AWWA C600
"Installation of Ductile Iron Water Mains and Their Appurtenances."
i Force mains of PVC pipe shall be installed in accordance with AWWA C605
"Installation of Underground Installation of Polyvinyl Chloride (PVC) Pipe and
Fittings for Water."
I Force mains of HDPE pipe shall be installed as described in NC DENR's
Minimum Design Criteria for the Fast-Track Permitting of Pump Stations and
Force Mains Section 4.01 B.3.e. Contractors shall be fully-trained and qualified
by the manufacturer to install HDPE pipe.
b. Continuous and uniform bedding, haunching, and backfill that is appropriate for
the soil type and pipe material shall be provided in the force main trench.
ii. Burial
a A minimum burial depth of three feet as measured from the crown of the pipe to
the ground surface shall be provided throughout the length of the force main in
accordance with I5A NCAC 02T .0305(g)(4). Consideration shall be given to
utilizing a greater burial depth in locations where the frost depth exceeds three
feet.
b. In the event that the appropriate installation depth cannot be met by the design,
the force main shall be constructed of ferrous pipe or provided with a ferrous pipe
encasement in accordance with State requirements.
iii. Separations
a Minimum separations between pump stations/force mains and natural features,
other utilities, etc. shall be maintained in accordance with I5A NCAC 02T
.0305(f).
b. Stream Crossings
i Force mains shall be routed such that the number of stream crossings is
minimized. When a stream crossing is required by the design, the crossings
shall be as nearly perpendicular to the stream flow as possible.
i DI pipe with joints equivalent to water main standards or a watertight ferrous
encasement pipe shall be used to construct force mains that cross streams.
The DI or encasement pipe shall be extended horizontally for a length equal
to that required by I 5A NCAC 02T .0305 on either side of the stream.
i. Force main bedding, haunching, and backfill shall be appropriate for the
installation location and pipe material. However, the ability of the bedding
60

and backfill material to readily erode, cause siltation, damage the force main
during installation, and corrode the force main after installation shall also be
considered.
iv. No aerial stream crossing of force mains will be permitted. All stream
crossings will be by directional bore.
c In the event that the appropriate separation cannot be met by the design,the force
main shall be constructed of ferrous pipe material with joints equivalent to water
main standards or provided with a watertight, ferrous pipe encasement. However,
force mains shall not be closer than 25 feet from a private water supply well or 50
feet from a public water supply well, even if ferrous pipe material with joints
equivalent to water main standards is used.
4. Testing
a. Hydrostatic Testing of Force Main
The force main shall be completely filled with water, all air shall be expelled from the pipe
and the discharge end of the pipeline shall be plugged and adequately blocked before the
hydrostatic test begins.
The force main shall be tested to a pressure of I50 psi or three times the rated TDH of
the pumps in psi, whichever is larger, as measured at the lowest elevation of the pipeline,
for a duration of 2 hours. The pressure gauge used in the hydrostatic test shall be
calibrated in increments of I 0 psi or less. At the end of the test period, the leakage shall
be measured with an accurate water meter.
Once full of water, the force main segment shall be pressurized and allowed to
stabilize at a minimum test pressure of 1.5 times the maximum design pressure of
the force main pipe material.
Pipe Size Allowable Leakage
Pipe Size (Gal. per 1000 ft. of pipe)
4 0.85
6 1.28
8 1.70
12 2.56
All leaks shall be located and repaired regardless of the amount of leakage. If the force
main does not pass the leakage test requirements, the cause of the failure shall be
identified and repaired. Testing shall be repeated until the force main passes.
61

b. Force Main Testing
i. General
a Prior to testing any segment of force main, care shall be taken to prevent the pipe
from moving while under pressure.
b. Temporary taps and air releases shall be permissible to facilitate testing.
c Water used for testing force main installations shall either be disposed in a nearby
sanitary sewer, as authorized by the local sewer authority, or in another location
in accordance with state and federal laws and regulations.
d All testing shall be performed in the presence of the applicant and the Engineer of
Record or his representative.
e The results of all testing shall be maintained by the applicant as part of the
construction record documentation as n stipulated in NC DENR's Minimum Design
g
Criteria for the Fast-Track Permitting of Pump Stations and Force Mains Section
I.03B.
ii. Force mains shall be installed in a manner such that pipe deflection is minimized.
iii. Pressure Testing
a A hydrostatic pressure test shall be performed on each segment of installed force
main.
b. The test shall be performed after the force main has been backfilled and at least
seven days following the pouring of the last thrust block.
c The following procedures shall be followed in performing hydrostatic pressure
tests on force mains:
i The force main segment shall be carefully filled with water at a velocity of
approximately one foot per second.Water may be introduced from either the
pump station or a temporary connection made in the force main. Appropriate
measures necessary to eliminate all air from the force main shall be
taken during this process.
i Once full of water, the force main segment shall be pressurized and allowed to
stabilize at a minimum test pressure of 1.5 times the maximum design pressure
of the force main pipe material.
i This pressure shall be maintained for at least two consecutive hours.
iv. If the stated pressure cannot be maintained, the applicant is responsible for
assuring that the cause of test failure is determined, all necessary repairs are
made, and repeating the hydrostatic pressure test until the force main segment
passes.
d The pressure test may be performed concurrently or separately with the leakage
62

test as required in NC DENR's Minimum Design Criteria for the Fast-Track
q g
Permitting of Pump Stations and Force Mains Section 6.04D.
iv. Leakage Testing
a A leakage test shall be performed on each segment of installed force main at the
hydrostatic pressure test stipulated in NC DENR's Minimum Design Criteria for
the Fast-Track Permitting of Pump Stations and Force Mains Section 6.04C.
b. Leakage shall be defined as the quantity of water required to maintain a pressure
within five pounds per square inch of the specified test pressure after the pipe has
been filled with water and all air has been expelled.
c Leakage shall be measured with a calibrated test meter and shall not exceed the
amount given by the following formula:
L = (N x D x sqrt(P))/ 7400
L = Allowable leakage (gallons per hour)
N = Number of joints in length of pipe segment tested
D = Nominal diameter of pipe segment tested (inches)
P = Test pressure (pounds per square inch)
All visible leaks shall be repaired regardless of the amount of leakage. If leakage
exceeds this rate, the applicant is responsible for assuring that the cause of test
failure is determined, all necessary repairs are made, and repeating the test until
the force main segment passes.
d The leakage test may be performed concurrently or separately with the leakage
test stipulated in NC DENR's Minimum Design Criteria for the Fast-Track
Permitting of Pump Stations and Force Mains Section 6.04D.
v. Each layer of fill or backfill over the force main shall be compacted to a density needed
to accommodate the use of the force main installation area or otherwise may be
required (e.g., encroachment agreement with the North Carolina Department of
Transportation, etc.)
c. Inspections
i. All materials and equipment used in the construction of the wastewater pumping
system must be verified for compliance with the specifications by the Engineer prior
to installation. Non-conforming materials or equipment shall be immediately removed
from the job site.
ii. Compliance with plans and specifications shall be verified on a regular basis by the
Engineer of Record.
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d. General
i. The Contractor shall furnish all materials, labor, and equipment to perform all testing.
ii. All water or wastewater used during testing of the pump station, force main, or any
of the systems described in this section, must be disposed of with regard to all
NCDEQ regulations.
iii. Before the operational tests are conducted, the required copies of the Operation
and Maintenance Manuals shall be delivered to ENGINEER.
iv. ENGINEER reserves the right to require further testing, as necessary, to assure that
all components and infrastructure are performing in accordance with the
manufacturer recommendations and ENGINEER specifications. All testing, repairs
and/or readjustments, and necessary re-testing, shall be at no additional cost to the
owner.
v. All on-site testing and/or installation verification shall be performed in the presence
of the Inspector or other representative authorized by ENGINEER.
vi. All testing, installation verification, and training, shall be performed in the presence of,
or by, an experienced, competent, and authorized manufacturers' representative.
vii. Factory testing shall consist of testing all operating functions of the equipment under
varying operating conditions to assure that it will perform as specified. Any specific
testing that may be required is discussed under the individual equipment items below.
Results of factory testing shall be presented to ENGINEER prior to delivery of the
equipment.
viii. Installation Verification shall consist of a visit to the site by a manufacturer's
representative to inspect, check, adjust if necessary, and approve the equipment
installation. The manufacturer's representative shall certify that the equipment has
been properly installed and lubricated, is in accurate alignment, and is free from any
undue stress imposed by connecting piping or anchor bolts. Any specific verification
requirements are discussed under the individual equipment items below. Results of
the installation verification shall be presented to ENGINEER prior to start-up of the
equipment.
ix On-Site Testing shall consist of all manual and automatic operating functions under
various operating conditions, including full load conditions. The equipment shall also
be tested under adverse or emergency conditions. All alarms and remote signals shall
also be tested. Any specific testing that may be required is discussed under the
individual equipment items below. Results of the on-site testing shall be presented to
ENGINEER prior to final acceptance of the project.
64

x All functions and systems of the pump station, even those not specifically listed below,
shall be tested to ensure proper operation under normal and emergency situations.
xi. All defective equipment or malfunctioning systems shall be replaced or corrected, and
the full system placed in a fully operational condition to the satisfaction of ENGINEER,
at no cost to the owner.
xii. Results of all factory testing, installation certifications, and on-site operational testing
shall be provided to ENGINEER in the final construction documents as described in
the Submittals portion of this specification section.
5. Valves and Appurtenances
a. Check Valve: Check valves shall be iron bodied,fully bronze mounted with bronze clapper
disc and bronze seat ring, and shall have a spring loaded lever arm capable of being
mounted on either side of the valve.
b. Plug Valve: Plug valves shall be eccentric action and resilient plug facing with heavy duty
stainless steel bearings and welded-in corrosion resistant nickel seal. Force main plug
valves shall provide clean passage for a solid sphere of at least 67% of the adjoining pipe
diameter to facilitate pigging of the force main. Force main plug valves shall be "full-port"
cross-sectional area perpendicular to the flow of at least 100% of the adjoining pipe.
c. Air Release Valve:
i. The valve shall be sized bya North Carolina licensed Engineer, and approved
g � PP by
ENGINEER. Information on the manufacturer's recommended sizing, along with the
Project Engineer's recommendation, shall be submitted to ENGINEER for review
when applying for approval of the sizing.
ii. Combination air valves shall be of the single housing style that combines the operation
of both an air/vacuum and air release valve. The valve shall have a minimum two (2)
inch NPT inlet and I 50-psig working pressure. The valve must meet the requirements
of AVVWA C512.
65

Part VII Sewer Pump Stations
1. Material
a. Site Work - There shall be provided a high pressure sodium vapor luminary light of 600
watt (min) capacity to illuminate the pump station area. The light shall be mounted on a
Class V utility pole at a height of 30 feet and controlled by means of a photo cell and
manual switch to bypass photo cell.
b. Piping and Valves - Suction and discharge piping shall be Class 50 ductile iron flanged pipe
as manufactured under AWWA Specification C 141. A check valve and a gate valve shall
be provided in a valve vault outside the station for the discharge pipe of each pump. A
tee shall be installed in the valve vault to join each discharge pipe into the common
force main line. An air release valve shall be located in the valve vault downstream of
the gate and check valves. In addition a 3" stub with valve and quick connect coupling
shall be installed after the tee to provide an emergency bypass in case of both pumps
failing.
c. Electrical - The electrical power entrance shall be through a meter base, followed by a
NEMA 4X heavy duty, single throw, fusible safety switch with a solid neutral; followed
by a NEMA 4X heavy duty, double throw, three pole safety switch which feeds the
control panel from one side and heavy duty, circuit breaking 4 wire, 4 pole receptacle
assembly as manufactured by Crouse-Hinds or other approved equal from the other
side.
d. Control Equipment Enclosure - Liquid Level Controls — The cord connection for the
control shall be numbered 16-2, rated for 13 amps, and shall be type SJTO. To ensure
optimum longevity contacts shall be rated for 20 amps at 1 15 V AC and shall be sealed
in a heavy duty glass enclosure.
e. Pump Station — Submersible Pump Type
i. Sewage Pumps and Motors
a. Pumps shall be Myers or other approved manufacturer submersible, large
grinder or non-clog sewage pumps.
b. The common pump shaft shall be of 416 stainless steel.
c. Power cables to pumps shall be AWG (min) hypalon jacketed type SPC cable of
thirty (30) feet in length as a minimum.
ii. Discharge Piping and Valves
66

a. Discharge piping shall be flanged ductile iron pipe pipe (Class 50
min) sized to produce a minimum head loss while maintaining a minimum velocity of
2.5 feet per second, as here in before specified.
b. All hardware used shall be 3 16 stainless steel.
iii. Lift Out Rail System - Guide Rails shall be stainless steel pipe.
iv. Telemetry — Mission Control Model M-110 Series wireless monitoring and alarm
system.
2. Design
a. General Requirements
i. Sewage pumping stations shall meet the requirements as stated below and as
described in each section for the type of station selected. Pump stations may be
submersible grinder pumps only.
ii. All stations shall have a minimum of 2 pumps of equal capacity. The pumps shall be
solids handling, grinder or non-clog pumps capable of handling flows in excess of the
expected peak flow. Where three or more pumps are required, they should be of
such capacity that with any one unit out of service, the remaining units will have
capacity to handle peak sewage flows. Pumps and the sewage force main shall be sized
to provide a minimum velocity in the force main of 2.5 fps.
iii. Sewage pumping stations, all related structures and controls, shall be protected from
physical damage by the 100 year flood. Stations shall be designed to remain fully
operational and accessible during the 25 year flood. The 100 year flood elevation shall
be shown on all site plans. All sewage pump stations which are adjacent to stream
classified as WS-I, WS-II, or B waters shall be equipped with an alternate power
source. All lift station with a tributary flow of 15,000 gallons per day must be equipped
with an emergency self-priming by-pass pump with diesel engine and controlled by
independent floats. All pump stations with less than 15,000 gallons per day tributary
flow must be plumbed with ports for a mobile by-pass pump. Plumbing connections
shall be specified by ENGINEER.
b. Site Work
i. The site shall be graded generally to drain away from the pump station and to remove
stormwater runoff from site in a non-erosive manner.
ii. The site shall be stabilized by crushed stone, low maintenance vegetative ground
67

cover or other suitable materials. A shrubbery screen shall be provided on three
sides of all pump stations, outside the security fence.
iii. The site area shall be secured by a six (6) foot high chain link fence. Fence products
shall be only new materials using hot dipped galvanized iron or steel components and
aluminum coated fabric. Line posts, top and bottom rails, gate and fabric shall be as
specified on the Standard Detail Drawings. Gates shall permit 180 degree opening and
shall be located so as to provide vehicle accessibility for lifting the pumping units.
There shall be a minimum gate opening of twelve (14) feet to facilitate truck access.
iv. The site shall feature adequate turn around areas for a WB-20 service vehicle and
provide a 12 foot (minimum) wide access road to the site with grades not to exceed
10 feet in one hundred feet(10%).
v. There shall be provided a high pressure sodium vapor luminary light of 600 watt (min)
capacity to illuminate the pump station area. The light shall be mounted on a Class V
utility pole at a height of 30 feet and controlled by means of a photo cell and manual
switch.
c. Piping Valves - Check valves shall be iron bodied, fully bronze mounted with bronze
clapper disc and replaceable bronze seat ring, and shall have a spring loaded lever arm
capable of being mounted on either side of the valve and rated for 175 psi working
pressure.
d. Wetwell
i. The wet well shall be precast concrete manhole sections conforming to ASTM C-478,
latest revision, with a six (6) foot minimum diameter. The base of the wet well shall
be pre-cast, steel reinforced concrete and have a minimum extended base of 6 inches
greater than the outside diameter of the wet well. The concrete shall have a minimum
28 day compressive strength of 3,000 psi.
ii. The manhole sections shall have joints of a durable mastic sealing material and the
joints shall be further waterproofed on the outside of the wet well by the application
of asphalt, overlapped by a 12 inch wide band of inorganic asbestos felt, and a finish
mopping of asphalt. The interior side of the joints shall be plastered smooth with 3
coats of portland cement grout. The interior and the exterior of the wet well shall
then receive two successive coats of Koppers `Super Service Black, or a suitable coal
tar epoxy, With a total dry film thickness of ten (I 0) mils, All nicks and scratches shall
be touched up in the field before backfilling occurs. The access hatch to the wet well
shall be a square hatch of 1/4" aluminum, 6063 alloy, diamond pattern plate with steel
hinges on an aluminum frame cast in place in the cover slab.
ii. The wet well shall have a vent made from ductile iron, flanged joint, pipe fittings, as
shown on the plans. An insect screen shall be included at the exposed end of the
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vent pipe. The insect screen shall be bronze insect screening or aluminum insect
screening.
d. Electrical
i. Electrical service to all pumpstations shall be three phase, 240 or 480 V AC with a
wye connection. The electrical power entrance shall be through a meter base,
followed by a NEMA 4X heavy duty, single throw, fusible safety switch which feeds
the control panel from one side and heavy duty, circuit breaking 4 wire, 4 pole
receptacle assembly as manufactured by the Crouse-Hinds or other approved equal
from the other side. All of these electrical components shall be suitably sized to be
capable of service with all sewage pumps running.
ii All electrical components, including panel shall be sealed off with Ductiseal type sealant
in accordance with the N. C. Electrical Code requirements for electrical service to
gas pumps.
e. Pump Motor Controls - Pump motor controls equipment shall be located within a
NEMA 4X stainless steel above ground housing.
f. Control Equipment Enclosure
i NEMA4X_Enclosure - Enclosure shall be a NEMA type 4X and be of suitable size to
house all components. A locking hasp shall be provided in addition to screw clamp
type latches. Enclosure shall be fabricated from 14 gauge stainless steel. The top of
the enclosure shall serve as a drip shield and the seam free sides shall prevent rain
and sleet from entering. Inner panel shall be made of 12 gauge steel and shall be
painted white. The enclosure and interior panel shall be painted with heat fused
modified polyester powder, electrostatically applied over a phosphatized base.
Enclosure shall be ANSI/ASI 6I grey.
ii Hinged Inner Door—An inner door shall be furnished. Overload reset push buttons,
circuit breakers, switches and pilot lights shall be the only components accessible with
door closed. Door shall be hinged and may be opened when service is required.
iii. Line Terminal Block—A terminal block shall be furnished with properly sized line lugs
to accept the main power source entering the control panel. Load lugs shall be
adequate to accept all required load side wiring requirements. All live parts shall be
fully shielded.
iv. Motor Circuit Breakers (240 or 460 V AC) - A properly sized, molded case, thermal
magnetic circuit breaker shall be provided for each pump motor. Line and load sides
shall be equipped with lugs properly sized for the horsepower and current rating of
the motor(s). They shall be attached to mounting brackets which are specifically
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manufactured for use with the particular circuit breaker. The interrupting rating shall
be I0,000 RMS symmetrical amps.
v. Transformer Primary Circuit Breaker (When Transformer Is Required) —A properly
sized, two pole, molded case circuit breaker shall be furnished ahead of the control
power I20 V AC power transformer for short circuit protection and disconnecting
power to the transformer. The circuit breaker shall conform to the specifications for
the motor circuit breaker(s).
vi. Control Power Transformer (When Neutral Is Not Available at Jobsite—Std. on 460
V AC) -An industrial quality control transformer shall be furnished to provide control
voltage. The transformer shall be sized with an adequate KVA rating to provide 120
V AC power for all items required in the control and alarm circuits. - Transformer
shall be protected in its secondary by properly sized fuses and/or circuit breaker(s).
vii. Magnetic Contactors and Overload Relays- A magnetic contactor shall be furnished
for each motor. A separate, panel mounted, 3 leg (three phase) or I leg (single phase)
overload relay shall be supplied for each motor. Each leg of the overload relay shall
be equipped with a properly sized overload heater. Contactor and overload relay shall
be properly sized for the required horsepower, voltage and phase.
viii Elapsed Time Meters —Six digit, non-resetable elapsed time meters shall be mounted
in the control panel enclosure t o record the running time of each pump.
ix Phase and Voltage Monitor- A phase failure, reversal and under voltage monitor shall
be supplied to prevent the motors from running under low voltage, phase loss, or
phase reversal conditions. The monitor will lock out the control circuit until the
problem is corrected and automatically reset.
x Lightning Arrestor- Suitable lightning arrestors shall be provided to protect motors
and control equipment from lightning induced line surges.
xi. Thru-Door Overload Reset Push Buttons - Overload reset push buttons shall be
provided for each overload relay. Push buttons shall be mounted so that with inner
door closed, overload relays may be reset without entering high voltage compartment.
jai Switches - Heavy duty industrial grade oiltight switches shall be provided for each
pump for "Hands-Off-Automatic' operation selection. All switch components shall be
made of corrosion resistant metals and polyesters. Contact blocks shall be made of
see-through polycarbonate for simplified inspection of contacts, Cams and strokes
shall be Teflon impregnated for abrasion free service without lubrication.The switches
required shall be as follows:
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Switch Function Voltage
(Name Plate)
Manual-off-Automatic 120 V AC
xii Pilot Lights — Full voltage heavy duty industrial grade oiltight pilot lights shall be
provided. All pilot light components shall be made of corrosion resistant metals and
polyesters. An insulated socket shall be furnished to eliminate the possibility of shock
during bulb change. Lens shall be made of lexan. The pilot lights required shall be as
follows:
Pilot Light Voltage Lens Color
Function
(Name Plate)
PUMP I 120 V AC GREEN
PUMP 2 120 V AC GREEN
xiv. Seal Failure Circuit Test Push Button (illuminated) - Heavy duty industrial grade oiltight
push buttons shall be provided for each submersible pump motor. All push button
components shall be made of corrosion resistant metals and polyesters. Contact
blocks shall be made of see-through polycarbonate for simplified inspection of
contacts. An insulated socket shall be furnished to eliminate the possibility of shock
during bulb change. Lens shall be made of lexan. The push buttons required shall be
as follows:
Pilot Light Function Voltage Lens Color
(Name Plate)
PI SEAL FAIL 120 V AC AMBER
P2 SEAL FAIL 120 V AC AMBER
xv. Pump Alternator Circuit (For Duplex Pump Operation) - The electromechanical
alternator relay shall be of industrial design specifically for use in pump applications. It
shall have single pole double throw heavy duty 10 amp silver cadmium oxide contacts
enclosed in a transparent cover. The contacts shall transfer when the unit is
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deenergized. The circuit shall never be closed or opened while current is being
conducted. The alternator circuit shall alternate the lead pump position between the
and shall allow the lagpumpto start in response to a risingwater level in the
pumps P
wet well. Needs to be switchable I.E. PI or P2 lead. (P I alt. P2).
xvi. Power Failure - Once power is restored after a failure and the pump has pumped the
water from alarm level down to pump off, the alarm should automatically reset itself.
xvii Control Relay(s) - Plug-in control relays with 120 V AC coils shall be provided as
Y( ) g Y
required. Contact rating shall be 5 amps (minimum). Sockets shall be of the same
manufacture as the relays and hold-down clips shall be furnished to prevent relay from
sliding out of the socket.
xvii. High Wet Well Level Alarm -The control panel shall be provided with a suitable alarm
circuit, activated by a separate level control. This alarm shall signal a high water
condition in the sump. Terminals shall be furnished in the control panel for connection
of an externally mounted alarm device. A red flashing light shall be provided as a visual
alarm and a horn provided as an audible alarm of the high water condition in the wet
well. The pump station shall also be equipped with buttons to both test and silence
the horn and light.
xix Liquid Level Controls - Mercury level control switches shall be provided for pumps
on, lead pump on, lag pump on; and high level alarm functions. The mercury switch
shall be encapsulated in polyurethane foam for corrosion and shock resistance. Level
switches shall be weighted to hold desired position in the sump. The cord connection
for the control shall be numbered 16-2, rated for 13 amps, and shall be type SJTO. To
ensure optimum longevity contacts shall be rated for 20 amps at 115 V AC and shall
be sealed in a heavy duty glass enclosure. No junction boxes or cable splices of any
kind will be allowed in the wet well. Float leads shall not be in the same conduit as
the motor leads.
xx. High Temperature Shutdown Circuit(s) - The high pump motor temperature circuit
shall provide terminals for connection of the leads from the temperature sensor
provided in the pump motor windings. Upon a high temperature condition in the pump
windings, the control power to the pump motor contactor shall be disconnected, thus
stopping the pump motor and an-overheating light shall come on. The pump shall
automatically restart when the pump motor temperature returns to an acceptable
level.
xxi. Ground Lug(s) - Equipment ground lug(s) shall be provided for grounding the
enclosure.The ground lug(s) shall be suitable for the service provided to the enclosure
and shall be sized per table 250-95 of the N.E.C. In all cases the enclosure must be
adequately grounded per article 250 of the N.E.C.
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xxi. Terminals - Terminals shall be provided for connecting mercury float switch leads,
temperature sensor and seal fail sensor leads. Terminal blocks shall be rated for 600
volt use and accept a wire range of#22-8. All live parts shall be fully shielded. Block
shall be constructed of nylon and have insulating walls on all sides of the lug. Blocks
must be U. L. recognized.
xxii Construction Standards - Subpanel shall be drilled and tapped to accept machine
thread bolts (self tapping screws are not acceptable). All control wiring shall be 16
AWG machine tool wire, Carol type 76512 or equal. All control wire shall be color
coded or numbered in accordance with)IC standards. Power (motor) wiring shall be
in accordance with the 1984 National Electrical Code. Major groups of wires shall be
contained in a plastic wiring trough such as Panduit Type E or other approved equal.
xxdv.Guarantee- The manufacturer of the control panel shall furnish a warranty for one
year from the date of start-up stipulating that all equipment shall be free from defects
in design, materials and workmanship. The control panel manufacturer shall furnish
replacement parts for any component proven defective, whether of his or other
manufacturer during the guarantee period, excepting only those items which are
normally consumed in service, such as light bulbs.
g. Pump Station — Submersible Pump Type
i. General - The submersible um station structure shall consist of the wet well, duplex
pump
pumps and rails, pump controls and related appurtenances, discharge piping, valves,
and valve vault, cover slabs and access hatches.
The wet well shall have as a minimum a diameter of five (6) feet, and shall be large
enough to easily accommodate the location and removal of each pump so that no
pump will have more than 5 stalls per hour when the other pump is out.
ii Sewage Pumps and Motors - Pumps shall be Myers or other approved manufacturer,
submersible, large grinder or non-clog sewage pumps, or a pump approved by
engineer. Submersible pumps shall be provided each capable of handling raw,
unscreened sewage at peak design flow. Major pump components shall be of gray cast
iron devoid of burr, pits or other irregularities: The pump motors shall be sealed
submersible type, and shall be three phase, 60 Hertz, 240 or 460 volt motors with a
wye connection. The motors shall meet the U. S. requirements of Class I, Division I,
Group D for hazardous locations, and shall be sized to non- overloading throughout
the entire operating range of the pump.
Stator winding shall be of the open type with insulation good for 1,800 Centigrade
maximum temperature. Winding housing shall be filled with a clean high dielectric oil
that lubricates bearings and seals and transfer heat from windings and rotor to outer
shell.
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Motor shall have two heavy duty ball bearings to support pump shaft and take radial
and thrust loads and a sleeve guide bushing directly above the lower seal to take radial
load and act as flame path for seal chamber. Ball bearings shall be designed for 30,000
hours B-I 0 life. Stator shall be heat shrunk into motor housing.
A heating sensor thermostat shall be attached to and embedded in the winding and be
connected in series with the motor starter contactor coil to stop motor if
temperature of winding is more than 220° F. Thermostat shall reset automatically
when motor cools to safe operating temperature. The common pump shaft shall be
of 416 stainless steel.
The pump motor shall be protected by two mechanical seals mounted in tandem with
a seal chamber between the seals. Seal chamber shall be oil filled to lubricate seal face
and to transmit heat from shaft to outer shell. Seal face shall be carbon and ceramic
and lapped to a flatness of one light band. Lower seal faces shall be tungsten carbide.
A double electrode shall be mounted in the seal chamber to detect any water entering
the chamber through the lower seal. Water in the chamber shall cause a red light to
turn on at the control panel. This signal shall not stop the motor but shall act as a
warning only.
Power cables to pumps shall be AWS (mm) hypalon jacketed type SPC cable of thirty
(30) feet in length as a minimum.
ii Discharge Piping and Valves - Discharge piping shall be flanged ductile iron pipe (Class
50 mm) sized to produce a minimum head loss while maintaining a minimum velocity
of 2.5 feet per second, as herein before specified. All exposed piping shall have
adequately sized and located thrust rods.
The discharge connection elbow shall be a straight through fitting with no flap valve
and shall be permanently installed in the wet well along with the discharge piping. The
pumps shall be automatically connected to the discharge connection elbow when
lowered into place. A sliding guide bracket shall be guided no less than two guide bars.
The entire weight of the pump shall bear upon the guides and base support with no
part of the pump bearing directly on the floor of the sump. A stainless steel chain shall
be provided for lifting each pump from the wet well and shall be in a single length and
extend a minimum of 15 feet past the hatch. All hardware used shall be 316 stainless
steel.
Gate valves and check valves on the discharge side of each pump shall be located in a
valve vault separate from and adjacent to the wet well. A Dresser coupling shall be
installed one each discharge main between the wet well and the valve vault. The
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valve vault shall consist of a precast rectangular structure at least 6 feet square, all
complete with a drain that goes to the wet well and that has a back water valve on
the drain line, access ladder or rungs, and access cover cast in the top slab.
The access cover for the valve vault shall be a square hatch of 1/4 inch aluminum
diamond pattern plate with steel hinges on an aluminum frame cast in place in the
cover slab.
iv. Lift Out Rail System - The lift out systems shall consist of a straight elbow that bolts
to bottom of basin, a combination disconnect assembly with a seal flange that mounts
to pump, rail support guides that fasten to wall of basin and guide and support brackets
that mount to pump.
Guide rails shall be Stainless steel pipe.
The discharge quick disconnect shall be tapered and have a holding groove machined
into the face to hold a-sealing--O-ring. The tapered seat shall allow the pump to be
nearly sealed to the discharge elbow before the sealing faces make contact. A guide
plate and adjustable guide bar shall be fastened to top of the pump to insure good
alignment and for support of the pump.
The rail support and mounting bushing shall be securely mounted to the basin wall
and shall not be attached to the basin cover or cover frame.
The guide rail support shall be adjustable so that a perfect vertical alignment of the
rails can be obtained.
h. Warranties and Documentation
Warranties - The pump manufacturer shall warrant to the Developer and
subsequently ENGINEER, that the pumps, motors, and controls supplied to be free of
defects in workmanship and material for a period of one (I) year. The warranty shall
be in printed form and made applicable to Developer (as Warrantee) at the time of
acceptance for maintenance by Developer. Digital and hardcopy drawings of the as-
builts shall be provided to ENGINEER. The drawings shall contain all adjacent utility
information including, but not limited to, forcemains, valves, and gravity sewer
manholes.
ii Documentation — Documentation to be supplied to ENGINEER shall be three copies
of the complete Operation and Maintenance manuals which include the following:
a. Cover Sheet Listing: Pump manufacturer; source of repair parts, complete with
address and phone number; operating conditions — rated capacity and TDH of
each pump; model number, serial number, impeller diameter of each pump; all data
plate information from each pump motor; data on other equipment
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included as components in the pump station.
b. Pump Performance Curve with operating conditions indicated on it.
c. Detailed dimensional drawings of the pump and pump base elbow.
d. Detailed dimensional drawings of the pump motor.
e. A control panel wiring diagram.
f. Pump and motor installation and service manual.
g. Detailed information related to other components of the pump station.
i. Pump Design
i. General Requirements
a. Only pumps designed and manufactured for use in conveying raw, unscreened
wastewater shall be acceptable
b. Pump selection shall consider the duty requirements as well as the physical and
chemical characteristics of the wastewater being conveyed. Materials used in pump
construction shall also be suitable for the physical and chemical characteristics of
the wastewater being conveyed.
c. Pump stations conveying residential, commercial, institutional, or industrial
domestic wastewater shall be provided with pumps that are suitable for
continuous duty in conveying raw, unscreened wastewater.
i. Pumps shall be capable of handling a three-inch solid and any trash or stringy
material that can pass through a four-inch hose unless a mechanical means of
solids reduction is installed at the pump station.
(I) Pumps shall be made non-clog either by passing solids, trash, stringy material
through a non-clog- or vortex-type impeller or by grinding, chopping, or
cutting them prior to passing them through the impeller. Impellers shall have
blades that are generally forward rounded or otherwise configured to avoid
catching solids, trash, and stringy material.
(2) Mechanical bar screens, communicators, diminutors, or other similar devices
may be required at regional pump stations.
ii. Pump suction and discharge openings shall be no less than four inches in
76

diameter unless the pump is capable of grinding, chopping, or cutting solids or
a mechanical means of reducing the size of a three-inch solid and any trash or
stringy material that can pass through a four-inch hose is installed at the pump
station.
iii. Pumps shall be designed for continuous duty pumping of raw, unscreened
wastewater. Pumps shall be adequately protected from damage due to failure
conditions specific to the selected pump type and pump station configuration.
ii. Number and Capacity
a. Pump stations shall be provided with the number and capacity of pumps that is
stipulated in I 5A NCAC 02T .0305(h)(I).
i. Multiple pumps shall be used such that the pump station is capable of conveying
the peak hourly wastewater flow to its desired outfall location with the largest
single pump out of service.
(I) In duplex pump stations, the pumps shall be of the same capacity.
(2) If pumps in series are required to meet capacity or total dynamic head
requirement, each set of pumps in series shall be viewed as a single pumping unit.
(3) Priming pumps as well as any other auxiliary system that is required for pump
functionality shall also be provided in multiple numbers.
ii. Determination of pump capacity shall be based on wastewater flows expected to
become tributary to the pump station for the entire project/development at build
out. For regional pump stations, pump capacity shall be based on wastewater flows
expected to become tributary from the entire service area over the life of the
pump station.
(I) Interim sizing of pumps and associated pump stations shall be allowable; however,
it shall only be used to meet requirements as set forth in 15A NCAC 02T .0305
or the minimum design criteria contained in this document and not for economic
purposes.
(2) A conspicuous statement that specifies the initial service capacity shall be
provided on the drawings for projects that are approved for an interim condition.
Additional wastewater flows (i.e., those in excess of that approved for the interim
condition) shall not be made tributary to the pump station until a request for
permit modification is submitted to and approved by NCDEQ, the pumps and
associated pump station are upgraded, and the required certificate of completion
and other supporting documentation are received by NCDEQ.
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iii. The minimum allowable design daily wastewater flow to the pump station shall be
determined in accordance with I 5A NCAC 02T.0305.
(I) Where a pump station is designed to serve a developed service area, historical
potable water use or wastewater flow generation data may be used to determine
design daily wastewater flows.
(2) Where a pump station is designed to serve a broad service area for which specific
development is not known, design daily wastewater flows may be established
based on historical data for the broad service area or established long-range
wastewater planning criteria.
iv. The selected peak hourly wastewater flow to the pump station shall be
appropriate for the service area as well as the associated wastewater generation
patterns and population being served by the pump station. The minimum peak
hourly wastewater flow to the pump station shall be calculated using the design
daily wastewater flow in conjunction with a peaking factor determined from the
following equation:
PF = Qphf/ Qddf [(I8 + sgrt(P)/(4 + sqrt(P)]
Where:
PF = Peaking Factor
Qphf= Peak hourly flow (gpd)
Qddf = Design daily flow(gpd)
P = service population(thousands)
(I) The above equation yields a peaking factor that is intended to cover normal
infiltration and inflow for well-maintained sewer systems and/or those built
with modern materials and construction methods. Consideration shall be given
to applying higher peaking factors for special conditions such as pump stations
serving older collection systems, those serving collection systems located in
areas with high actual groundwater tables, those serving areas that have
combined sewer systems, etc. Infiltration and inflow allowances shall be
incorporated usingactual flow data whenever possible.
p
(2) Peaking factors for pump stations conveying industrial or other process
wastewater shall be determined based on actual operating conditions of the
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facility; however, in no case shall the peaking factor be less than the minimum
set forth in NC DENR's Minimum Design Criteria for the Fast-Track
Permitting of Pump Stations and Force Mains Section 2.02A.4.c.
(3) In no case shall a peaking factor less than 2.5 be used to calculate peak hourly
wastewater flows for any pump station.
b. Pump capacity shall also be based upon the need to maintain a minimum velocity
of two feet per second in the force main in accordance with State requirements.
is Selection Methodology
a. Pump selection shall be based on a hydraulic analysis of the system through which
the wastewater is to be conveyed.
i. The design operating point(s) of the pump(s) shall be determined using a pump
curve-system curve analysis. Pumps shall be selected such that the pumps shall be
capable of pumping the required capacity, as described in NC DENR's Minimum
Design Criteria for the Fast-Track Permitting of Pump Stations and Force Mains
Section 2.02, for all total dynamic head requirements developed by the system for
the lifetime of the pump station.
ii. A system curve, plotting total dynamic head versus capacity, shall be developed
for all operating conditions that may be imposed on the system. Total dynamic
head requirements for the system shall be calculated as the total of the following
individual components:
of the system, including head requirementsy g that associated with both
the suction and discharge sides of the pumps, shall be evaluated. In addition to
g P P �
calculating static head with the discharge evaluation of the force main, any
intermediate high points in the force main that would have an effect on the total
dynamic head requirements of the pump shall be analyzed.
2 Friction head requirements of the system, including that associated with
both the suction and discharge sides of the pumps, shall be evaluated. The friction
head shall be calculated using the Hazen-Williams formula:
hf = L[ 4.73Q1.85/ C'.85D4.87]
Where:
hf= Friction head in feet
L = Length of the pipe segment in feet
Q = Flow rate in gpm
C = Hazen Williams coefficient
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D = Inside pipe diameter in inches
All operating conditions shall be evaluated including, but shall not be limited to,
multiple pump operation within the subject force main, simultaneous pump station
operation for common force main situations, as well as the possibility for gravity
flow conditions in force main segments with extreme negative slopes that may not
flow full.
3. Head derived from any minor losses of the system, including that
associated with the both the suction side and discharge side of the pump, shall be
evaluated. Such minor losses shall include head derived from valves and other
fittings such as tees, bends, angles, etc.
iii. If applicable, the pressure head at the junction of the existing force main shall also
be evaluated for its effect on the total dynamic head requirements of the system.
The evaluation shall take into account the effects of simultaneous pump station
operation as well as multiple pump operation in other pump stations.
iv. System curves shall be generated and evaluated not only for present day
conditions, but also for those conditions that may exist over the expected lifetime
of the pump station.
v. The Hazen-Williams friction coefficient, C, appropriate for the force main pipe
material and age of the force main shall be used. The following maximum values
shall be allowable for C:
Pipe Type Initial Service C End-of-Service C
DI 125 100
PVC 140 120
H D PE 140 120
vi. Friction head and minor losses associated with the system shall be evaluated at
both the initial service condition and the end-of-service condition.
vii. The design operating point(s) shall be defined as the intersection of the pump
curve and the calculated system curve(s).
viii. Pumps shall be selected such that all design operating points are on the pump
curve as supplied by the pump manufacturer. In addition, pumps shall be selected
such that the net positive suction head available (NPSHA) shall be greater than the
net positive suction head required (NPSHR) at each of the design operating
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points.
ix. Pumps shall be selected such that the pumps will not cavitate at any of the design
operating points. Pumps that operate within the unstable portion of the pump
curve under any of the expected design conditions shall not be allowed.
Freewheeling (i.e., operating at pump run-out) or deadheading (i.e., operating at
pump shut-off) of pumps shall not be allowed.
x. To the greatest extent possible, pumps shall be selected such that their operating
efficiency is maximized during all hydraulic conditions that may exist over the
expected lifetime of the pump station.
b. Consideration shall be given to minimizing motor speeds during the pump selection
process.
c. The horsepower rating of each pump motor shall be at least 1.15 times that required
by the pump when operating at all design operating conditions.
iv. Cycle and Pump Run Times
a. Constant speed pumps shall be cycled such that the number of starts are minimized
and resting times are maximized to avoid overheating and overstressing of the pump
motor.
i. Automatic pump alternation shall be provided.
ii. Pumps shall be designed to operate between two and eight times per hour at
design daily flow in accordance with 15A NCAC 02T .0350(h)(I) whenever
practicable (see NC DENR's Minimum Design Criteria for the Fast-Track
Permitting of Pump Stations and Force Mains Section 2.04A.2.b.).
The following equation shall be used to determine the active storage
volume in the pump station (i.e.,the volume between the pump-on and all pump-
off elevations) required to elicit the required pump cycle time:
V = T Qddf[I-(Qddf/Q)]
V = active volume within the pump station (gallons)
T = allowable cycle time between starts (minutes)
Qddf = design daily flow to pump station (gallons per minute)
Q = pumping rate of a single pump (gallons per minute)
2 If the wastewater generation patterns are such that less than two
pumping cycles per hour will occur at design daily flow or if the pump station
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is intended to provide equalization of hydraulic surges, measures to control
odor and corrosion shall be employed when resultant detention times cause
septic conditions. These measures shall take into consideration protection of
the pump station, the force main, the outfall sewer, any related appurtenances,
as well as the surrounding area.
b. Consideration shall be given to using variable speed pumps for main pump
stations or those pump stations that discharge directly into the wastewater
treatment facility.
c. Pump run times shall be such that excessive wear of the pumps does not
occur.
d. At design daily flow, adequate time shall be provided to allow a constant speed
pump to "ramp up" to full speed before the pumping cycle ends.
e. Pump run times at design daily flow shall not be less than or greater than those
recommended by the pump manufacturer.
v. Pump Station Design
i. General Requirements
a Pump stations shall be designed to achieve total containment of the influent
wastewater prior to being conveyed through the force main
b. Pump stations shall be designed such that infiltration and inflow is minimized.
ii. Site Selection
a Location and Access
i. Pump stations shall be designed to achieve total containment of the influent
wastewater prior to being conveyed through the force main.
ii. Pump station sites shall be accessible by an all-weather roadway in
accordance with I 5A NCAC 02T.0350(h)(4)
I. The roadway shall be provided from a hard surface road. The minimum
acceptable surface shall be a 6" compact gravel base able to support large
vehicular traffic loads.
2 Wherever practicable, no portion of the roadway shall be located below
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the 100-year flood elevation as identified on the most recent FEMA Flood
Insurance Rate map when available or as established through appropriate
modeling techniques.
a The roadway shall be designed to accommodate the largest vehicle
expected to service the pump station. In no case shall the roadway be less
than 12 feet in width. Roadway widths may me reduced to mitigate wetland
impacts.
4. At a minimum, the roadway shall be constructed from a six-inch layer of
compacted aggregate base course (ABC) stone. In no case shall uncompacted
gravel or stone material be allowed for roadway construction.
b. Security
i. Access to the pump station structures as well as all associated equipment and
appurtenances shall be restricted in accordance with I 5A NCAC
02T.0350(h)(4)
I. All ports of entry into pump station shall be locked.
2 Fencing provided around pump station structures shall be of sufficient
height and material to deter entry. Locked gates, a minimum of 14-feet wide,
shall be provided in the fence to allow vehicular access byoperation and
P
maintenance staff. Consideration shall be given to complying with the
requirements in Section 3.02B.I.c. as well.
a There shall be no overhead obstruction above the pump station to allow
the use of a boom truck at the pump station for lifting pumps. Additionally,
stainless steel chain shall be used for lifting out the pumps and the cable shall
be in a single length with the cable being able to extend 15 feet above the
wetwell hatch.
ii. The pump station shall be provided with adequate outdoor and indoor lighting
to facilitate normal and emergency operation and maintenance activities during
daylight and non-daylight hours.
iii. Safety placards for all pump station structures and equipment, as required by
OSHA, shall be provided and be readily visible.
iii. Structural Design
a Materials of Construction
i. Pump station structures shall be designed and built in complete compliance
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with all applicable state, local, and federal codes as well as any applicable OSHA
standards.
ii. Material selection for pump station structures shall be based on installation
and operating factors including, but not limited to, the following:
I. Physical, chemical, and biological wastewater characteristics.
2 Corrosive gas production.
3. Soil characteristics.
4 Groundwater presence.
iii. Pump station structures shall be completely separated unless made completely
watertight and gas-tight.
iv. Pump station structures shall be adequately protected to minimize damage
from vehicular traffic.
b. Buoyancy Protection
i. Below-ground pump station structures shall be protected from buoyant forces
of groundwater.
ii. Buoyancy protection shall be demonstrated through the use of flotation
calculations.
I. Flotation calculations shall be performed on below-ground pump station
structures using the assumption that the elevation of the groundwater table is
equivalent to the ground elevation.
2 Flotation calculations shall not add the weight of the pumps, internal piping
and appurtenances, or wastewater present in the pump station, including the
wastewater below the all pumps-off activation level, into the downward forces
used to counteract buoyancy.
3. The use of the saturated weight of any soil above the extended footing of
the pump station structure shall be allowed in the flotation calculations.
iii. Flotation calculations shall show that the design of the below-ground pump
station structures will be protected from buoyancy with a factor of safety that
is equal to or greater than one.
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c. Flood Resistance
i. Pump station structures as well as all associated equipment and appurtenances
shall be protected from the 100-year flood, in accordance with 15A NCAC
02T .0350(e).
ii. Such protection measures shall ensure that the pump station shall remain fully
functional, operational, and free from physical damage during a 100-year flood.
iii. The pump station shall be protected from inundation of floodwaters by
elevating structures at least two-feet above the 100-year flood elevation. An
alternate design shall include providing all pump station structures with
watertightports of entryas well as electrical, instrumentation/control, and
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ventilation systems that are elevated at least two-feet above the 100-year flood
elevations.
iv. The 100-year flood elevation shall be that as identified on the most recent
FEMA Flood Insurance Rate map when available or as established through
appropriate modeling techniques.
d. Solids Collection
i. Wet wells shall be designed to minimize pump or pump suction piping
operational problems resulting from the accumulation of solids and grit
material within the wet well.
I. Acceptable designs include the use of fillets and sloped wet well floors
alone or in conjunction with a hopper bottom.
2 The design of fillets and slopes shall be such that solids are effectively
moved toward the pump or pump suction piping.
ii. No projections within the wet well which would allow deposition of solids
under normal operating conditions shall be allowed.
e. Depth
i. Pump Submergence Depth
I. Sufficient submergence of the pump or pump suction piping shall be
provided to prevent the occurrence of vortexing within the wet well.
2 In no case shall the all pumps-off activation level be less than the minimum
level required for successful pump operation, as recommended by the pump
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manufacturer.
ii. The wet well shall be provided with a depth as required to maintain the active
storage volume as required in Section 2.04A.2.a of the NCDEQ Minimum Design
Criteria.
iii. The wet well shall be provided with a depth as required to maintain the emergency
storage volume as required in Section 5.04B.3 and Section 5.04B.4. of the NCDEQ
Minimum Design Criteria.
iv. Piping and Valves
a. Suction and Discharge Piping Configurations
i. Each pump shall be provided with separate suction and discharge piping
systems
Pump suction and discharge piping shall be no less than four inches
in diameter unless the pump is capable of grinding, chopping, or cutting
solids or a mechanical means of reducing the size of a three-inch solid and
any trash or stringy material that can pass through a four-inch hose is
installed in the pump station. Acceptable mechanical means of solids
reduction shall be as defined in Section 2.01 C.I.b of the NCDEQ Minimum
Design Criteria.
2. The ultimate pump suction and discharge piping sized shall be
selected such that a velocityof between two and eight feet per second is
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achieved.
ii. The discharge piping systems shall be provided with sufficient valves to
effect proper operation and maintenance of the pump station during both
normal and emergency conditions.
Selected valves shall be suitable for use with raw, unscreened
wastewater and shall be of a design suitable for its function, its installation
location, as well as the normal and maximum operating pressures expected
at the pump station.
(i) A full-closing shut-off valve shall be provided on the discharge piping
of each pump and on the suction piping of each dry well pump.
(ii) A check valve shall be provided on the discharge piping of each
pump, between the pump and the shut-off valve. Check valves shall be
places in the horizontal position unless the valve is of a ball check-type.
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2. All valves shall be located such that they are readily accessible.
Valves shall be placed either in the dry well or in a separate valve vault.
b. Pipe Connections
i. Flexible pipe joints shall be used on pipes between the pump station
structures to allow for differential settlement without compromising the
integrity of the overall pump station.
ii. Pipe inlets and outlets of pump station structures shall be made watertight.
iii. Existing pump station structures shall be core drilled or saw-cut when
connections are made through the structure wall. In no case shall
penetrations into pump station structures be made by hammering.
c. Water Service
i. Wherever practicable or required by the design, potable or reclaimed
water service shall be provided to the pump station.
ii. Cross-connection control for potable water services shall be provided in
accordance with I 5A NCAC I 8C .0406(b). Cross-connection control for
reclaimed water services shall be provided in accordance with I 5A NCAC
02T .0909(f).
d. Pig Launching/Retrieval Stations
i. When pig launching and retrieval stations are made part of the pump
station, their design shall be such that they may be isolated from the force
main.
ii. The design of the pig retrieval station shall be such that accumulated
material dislodged from the force main may be properly removed and
disposed.
v. Appurtenances
a. Consideration shall be given to protecting pump station structures and equipment
from physical damage or clogging from solid material normally present in wastewater
through the use of screening and other solids reducing equipment.
b. Pump Removal Methods/Equipment
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i. Provisions shall be so that the largest piece of equipment installed at the pump
station may be removed. Such provision may include supplying of hoisting
equipment and/or designing sufficient clearance around the pump station for
mobile hoisting equipment access.
ii. Pump station structures shall be provided with access hatches, doors, sky lights,
etc. of sufficient size such that the largest piece of equipment may be removed
without damaging the integrity of the structural design.
iii. Pump stations utilizing submersible pumps installed in wet wells shall be provided
with a system that allows for the removal and installation of the pumps without
requiring entry into the wet well.
I. Each pump shall be provided with a guide rail system and a lift-out chain.
2. Both the guide rail system and the lift-out chain shall be capable of
withstanding the forces required to disengage the pump from the wet well.
3. Both the guide rail system and the lift-out chain shall be manufactured of
stainless steel. Under no circumstances shall steel or galvanized steel be used.
c. Access Equipment
i. Each pump station structure shall be designed such that access to perform routine
and emergency operation and maintenance is easy, unobstructed, and safe.
ii. Each pump station structure shall be provided with a separate means of access.
Under no circumstance shall access to the wet well be provided through a dry
well.
iii. Steps, ladders, stairs, landings, hatches, and other means of access shall conform
to OSHA standards as well as all applicable local and state building codes regarding
design characteristics.
d. Ventilation Equipment
i. Pump stations shall be adequately vented in accordance with I 5A NCAC 02T
.0350(h)(3) as well as in complete compliance with all applicable local and state
building codes as well as OSHA and NFPA standards.
ii. At a minimum, pump station wet wells shall be provided with a gooseneck-type
vent. Active ventilation units shall also be acceptable.
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I. Vents shall be constructed of sturdy material that is resistant to ultraviolet
light and adequately supported to withstand damage during normal and emergency
operation and maintenance.
2. Vent elevations shall be a minimum of two feet above the 100-year flood
elevation as identified on the most recent FEMA map when available or as
established through appropriate modeling techniques.
3. Vents shall be provided with an insect/bird screen of stainless steel,
aluminum, corrosion-resistant material. Under no circumstances shall steel or
galvanized steel be used.
iii. Dry wells or other enclosed pump station structures into which routine operator
entry is required shall either have a positive-pressure ventilation system that
meets, at a minimum, the requirements of NFPA 820"Standard for Fire Protection
in Wastewater Treatment and Collection Facilities.". Consideration shall be given
to installing sensor and alarm systems to detect the accumulation of dangerous
levels of hazardous gases.
e. Other Equipment
i. Consideration shall be given to controlling the pump station temperature and
humidity to a level appropriate for reliable operation of the electrical and
instrumentation/control systems.
ii. Pump station structures other than the wetwell shall be provided with a means to
remove accumulated water and wastewater from the structure. All floor and
walkway surfaces shall be sloped such that water and wastewater drains to the
removal area under the influence of gravity. Acceptable removal means include the
following:
1. An appropriately-sized drainage pipe.
n The drainage pipe shall convey accumulated water and wastewater to the
wet well or other available entry point into the wastewater collection
system. Under no circumstances shall the drainage pipe convey
accumulated water and wastewater to daylight, into a surface water, or
into the ground.
() The discharge of the drainage pipe shall be higher than the high-water alarm
activation level in the wet well or the maximum water level expected at
the other available entry point into the wastewater collection system.
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(i) The drainage pipe shall be provided with device to prevent backflow of
wastewater and gases from the wet well into the structure.
k. Electrical and Instrumentation/Control Systems Design
i. General Requirements
a. Electrical systems for pump stations shall be designed and installed in strict
conformance with NFPA 70 "National Electric Code," ANSI, as well as all
applicable federal, state, and local codes.
i In general, electrical and instrumentation/control systems and components
shall be protected against corrosive conditions.
a If located in a wet well or other location where explosive or flammable gases
may concentrate, electrical and instrumentation/control systems and
components shall meet the requirements for a Class I, Group D, Division I
location.
b. Each pump and motor unit shall be provided with a separate electrical supply,
motor starter, alarm sensors, as well as electrical and instrumentation/control
systems and components.
i Electrical and instrumentation/control systems and components shall be
located such that they may be disconnected from outside a wet well.
i. Cables and conduits shall be provided with seals that are both water-tight and
gas-tight, shall be protected from corrosion, and shall allow separate strain
relief.
c. The main power feed to all pump stations shall be equipped with an above-grade,
fused disconnect switch.
ii. Enclosures
a. Enclosures for electrical and control components for the pump station shall be
located outside of the wet well and in a location such that they are readily
accessible, ensure maximum electrical and personnel safety, and are protected
from damage due to vehicular traffic and flooding.
b. Enclosures shall have a NEMA-rating that is appropriate for the installation
location at the pump station.
i If not housed, enclosures shall have a minimum NEMA 3R rating. NEMA 4X
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enclosures shall be used in locations where the potential for flooding and the
development and accumulation of corrosive gases exist. NEMA 4X stainless
steel enclosures shall be used for all outdoor installations.
ii. Enclosures shall be protected by a conduit seal or other appropriate sealing
method that meets the requirements of NFPA 70 to protect the wet well
atmosphere from gaining access to the enclosure. This seal shall be located
such that it will not be disturbed during routine operation and maintenance
functions at the wet well for a Class I, Division 2 location.
c. All enclosures as well as all switches and indicator lights, whether mounted on an
inner door or face of the enclosure, shall be provided with a label that conforms
to UL descriptions and procedures.
d. The applicant's lock-out/tag-out procedures shall be considered in the design of
all enclosures to be installed at the pump station.
iii. Instrumentation and Controls
a. Wastewater Level Sensing Equipment
i Pump station cycles, as described in Section 2.04A.2., shall be controlled
through the use of wastewater level sensing equipment in the wet well.
ii At a minimum, wastewater levels within the wet well shall be detected through
the use of sealed mercury-type float switches. In the event that an alternate
method of level detection (i.e., bubble tube, ultrasonic meter, etc.) is used, a
float switch at the high-water alarm level shall be installed as a back-up.
ii Wastewater level sensing equipment shall be used to indicate the following
levels and operate the pump station correspondingly: all pumps off, lead pump
on, lag pump on, and high-water alarm.
iv. Wastewater level sensing equipment shall be located so as not to be affected
by flows entering the wet well or the turbulence created by the suction of the
pump.
b. Components
i The pump station shall be equipped with sufficient instrumentation/control
systems and components to monitor and control key operating conditions.
ii At a minimum, the following systems and components shall be provided for
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the pump station:
I. Pump Station Function
(i) Each pump installed at the pump station shall be provided with a"Hand-
Off-Auto" selector switch so that the operational mode of the pump
may be selected.
(ii) Each pump installed at the pump station shall have a pump run timer
that is capable of keeping a cumulative log of the operational time of
each pump.
2. Sufficient indicator lights shall be used to demonstrate the operational
status of the pump station. The indication lights shall be specific to the
condition detected. At a minimum, indicator lights shall be provided for each
pump to indicate a pump on condition and a pump alarm/failure condition.
3. Weather-proof audible and visual alarms that are external to any structure
or enclosure shall be provided at the pump station in accordance with I 5A
NCAC 2H .02I9(h)(5). In the event of a power loss at the pump station or a
failure of the automatically-activated stand-by power generation source, the
alarm system shall be operated from a battery back-up power source. This
battery back-up power source shall be provided with continuous charge. At a
minimum, the following conditions shall be monitored by the system, and each
shall cause activation of the audible and visual alarms:
(i) Pump failure.
(ii) Wastewater level sensing failure (if applicable).
(iii) High-water in the wet well.
(iv) High-water level in the dry well sump (if applicable).
(v) Loss of telemetry transmission line (if applicable).
(vi) Loss of power supply.
(vii) Automatically-activated stand-by power generation source failure(if
applicable).
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4. A telemetry system shall be installed at all pump stations
regardless of the reliability method employed in the pump station
design.
(i) The telemetry system shall contact personnel capable of initiating a
response to a pump station alarm condition 24 hours per day, 365 days
per year.
(ii) In the event of a power supply loss at the pump station or a failure of
the automatically-activated stand-by power generation source, the
telemetry system shall be operated from a battery back-up power
source. This battery back-up power source shall be provided with
continuous charge.
(iii) The telemetry system shall be activated for any of the following alarm
conditions: high-water in the wet well, pump failure, loss of power
supply, and automatically-activated stand-by power generation source
failure (if applicable).
5. Appurtenances
(i) Sufficient 110-volt electrical receptacles shall be provided to facilitate
maintenance at the pump station. If located in an outdoor area, the
receptacles shall be of the ground fault interruptible type and shall be
protected from the weather elements.
(ii) If reliability for the pump station is based on a contingency plan that
involves portable power generation units (see Section 5.04B.3.), the
pump station shall be provided with a quick connection plumbing port
for a mobile by-pass pump.
iv. Reliability
a. Pump station reliability shall be in accordance with I 5A NCAC 02T .0350(h)(I)
and shall be considered a key, integral part of the overall pump station design.
b. One of the following reliability options shall be incorporated into the pump
station design:
i. The pump station shall be connected to multiple power sources.
I. A multiple power source shall be defined as a completely separate power
feeder line(s) connected to the pump station from a substation or transformer
that is independent from the primary feeder.
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2. Each separate substation or transformer and associated transmission lines
shall be capable of starting and operating the pump station at its rated capacity.
4 The pump station shall be connected to an automatically-activated stand-by
bypass pumping system. The pumping system will operate independently from
the pump station submersible pumps and be activated by an independent level
sensor/float system.
I. The permanently installed emergency back-up pumpset specified in this
section will be used to pump wastewater and raw sewage in
applications requiring a suction lift or as an inline booster pump.
2. The pump and accessories shall be supplied by the pump manufacturer.
3. The pump shall be fitted with a fully automatic priming system
incorporating an air compressor, air ejector assembly, and an air/water
separation tank. The priming system shall be capable of priming the
pump from a completely dry pump casing. The air ejector shall operate
on the discharge side of the compressor, eliminating the possibility of
water being drawn into the air source. The pump must be capable of
running totally dry for periods up to twenty-four hours, then
automatically re-priming and returning to normal pumping volumes
without need for any adjustment.
4. The priming system shall not use a vacuum or diaphragm pump, nor
require the use of a "Foot"-type valve. It shall contain no moving parts
or protective float gear. Priming systems that require manual water
additions to facilitate pump priming are not acceptable. A
demonstration of the pump's ability to repeatedly cycle from dry
suction / pump/ snore/ repriming/ pump shall be required. This will
necessitate the draining of all residual water from the pump case to
initiate a dry suction starting condition.
5. Pump and priming system shall be fully automatic, needing no form of
adjustment or manual addition of water for the priming system. The
pump shall be capable of static suction lifts to twenty-eight vertical feet,
at sea level. It shall also be capable of operation using extended suction
lines.
6. Equipment acceptance shall be contingent upon the pumps ability to run
continuously at full speed in a completely dry condition for periods up
to twenty-four hours. This may require the draining of all residual
water in the pump casing to simulate a dry suction/case condition. The
engineer may require a demonstration.
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7. The engine and pump shall be completely enclosed with fourteen-gauge
sheet metal panels backed with one-inch and two-inch layers of
polydamp acoustical sound-deadening material. The acoustical
enclosure shall reduce pump and engine noise to sixty-eight dBA or less
at a distance of thirtyfeet. The enclosure shall be removable for easy
Y
access to the engine/pump for maintenance and repair. The enclosure
doors shall all be equipped with latches that are keyed alike. For
maintenance and service needs, the enclosure sides shall have hinged
doors for quick access to the engine oil fill, fuel fill port, oil dipstick, and
filters.
8. A complete submittal of the bypass pumping system shall be submitted
to ENGINEER for review. This submittal shall include all engineering
calculations for the system. ENGINEER may be contacted prior to
bypass system design for additional specifications and acceptable
system manufacturers.
I. Operations and Maintenance (O&M) Manuals
i. An O&M Manual shall be prepared for each pump station and shall be made available
to the applicant upon start-up of the pump station/force main system.
ii. A copy of the O&M Manual shall be kept at the applicant's main office. The O&M
Manual shall be kept on file for the life of the pump station and updated as required.
ii. At a minimum, O&M Manuals shall contain the following minimum information:
a Approved shop drawings, including design data for all installed equipment and each
major component and a pump curve/system curve analysis showing the design
operating point(s).
b. Control panel wiring diagrams.
c Warranty information for all installed equipment and each major component.
d Inventory, functional descriptions, and complete operating instructions for all
installed equipment and each major component.
e Instructions for start-up/shut-down as well as for calibration and adjustment of all
installed equipment and each major component.
f Recommended maintenance management system, including preventative and
predictive maintenance, for all installed equipment and each major component.
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g Contingency plan and analysis of critical safety issues.
h. Contact information for local service companies as well as instructions for
replacement of all installed equipment and each major component.
i Contact information for local contractors capable of performing emergency
repairs.
j. Contact information for regulatory and other agencies.
1. Testing
a Operational Test - Before the operational test is conducted, the required copies of the
P P q P
Operation and Maintenance Manuals shall be delivered to ENGINEER and the wet well
shall be thoroughly cleaned to remove dirt, mud, gravel and other foreign debris. The
operational test shall check the proper functioning of the pumps and pump controls. The
pump and motor serial numbers shall be verified. All components and motor serial
numbers shall be verified. All components of the pump station shall be checked to ensure
that they are capable of performing the service intended. The operational test shall be
performed by the contractor. The Contractor or Developer shall ensure that a
representative from the pump station equipment manufacturer is present at the
operational test to review proper operation of the equipment with ENGINEER personnel.
b. Contractor's Responsibility - The Contractor shall furnish all materials, labor, and
equipment to perform all testing. Water for testing purposes will be provided by CFPUA.
The Contractor shall coordinate with CFPUA for the use of water for testing.
c Watertightness Testing (Pump Station Testing)
i. Wetwells and other wastewater-containing structures at the pump station shall be
inspected and tested for watertightness.
ii. The watertightness test for the wet well and other wastewater-containing structures
at the pump station shall be completed separately and independently of the leakage
test performed on the force main as required in Section 6.04D of the NCDEQ
Minimum Design Criteria.
iii. The watertightness test shall be performed in the presence of the applicant, the PE,
or other authorized representative.
iv. The watertightness test shall be performed in accordance with ACI 350.I R "Testing
Reinforced Concrete Structures for Watertightness," AWWA D 100 "Welded Steel
Tanks for Water Storage," or the manufacturer's recommendations. A vacuum test
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method in accordance with ASTM C 1244"Standard Test Method for Concrete Sewer
Manholes by Negative Test Pressure (Vacuum) Test" may be used for small diameter
wetwells in lieu of a hydraulic test
a. Unless the pump station wetwell is constructed of cast-in-place concrete, testing
shall not commence until the structure being tested has been fully assembled and
backfilling is complete.
b. All inlets and outlets in the structure shall be temporarily plugged and braced or
otherwise sealed prior to initiating the test.
c. Pump station wetwells th
at fail to meet the watertightness test requirements shall
be inspected, made watertight, and retested until the test passage is assured.
d. Pump Testing
i. Factory Testing
a All pumps shall be tested by the manufacturer in accordance with the appropriate
UL standard prior to shipment for installation.
b. The results of all factory testing shall be maintained by the applicant as part of the
construction record documentation as stipulated in NC DENR's Minimum Design
Criteria for the Fast-Track Permitting of Pump Stations and Force Mains Section
I.03 B.
ii. Drawdown Testing
a Following installation, each pump in the pump station shall be subjected to a
drawdown test or other similar testing procedure to confirm that the pump is
operating at or near the required design operating point(s).
b. The drawdown test shall be performed in the presence of the applicant, the PE,
or other authorized representative.
c The results of all drawdown testing shall be maintained by the applicant as part of
the construction record documentation as stipulated in NC DENR's Minimum
Design Criteria for the Fast-Track Permitting of Pump Stations and Force Mains
Section I.03B.
iii. Witnessed Testing
a Consideration shall be given by the applicant to require a witnessed test for large
97

pumps, pumps in critical installations, or pump replacement/repair situations.
b. All witnessed testing shall be performed in accordance with the appropriate HI
standard.
c Witnessed testing shall be performed in the presence of the applicant, the PE, or
other authorized representative.
d The results of all witnessed testing shall be maintained by the applicant as part of
the construction record documentation as stipulated in NC DENR's Minimum
Design Criteria for the Fast-Track Permitting of Pump Stations and Force Mains
Section I.03B.
e Electrical and Instrumentation/Control System Testing
i The applicant shall ensure that a formal testing program of all electrical as well
as instrumentation and control systems installed at the pump station is
developed and performed.
i The program may consist of a combination of unwitnessed/witnessed factory
tests, field readiness tests, and witnessed field tests. At a minimum, however,
the applicant shall witness a field test of the pump station's electrical and
instrumentation/control systems. The basic functions which shall be tested for
operation as intended by the pump station design shall include, but shall not
be limited to, the following:
a. Pump operational functions.
b. Level-sensing equipment.
c. Alarm system.
d. Telemetry system.
e. Stand-by or emergency power system.
i. All testing of the electrical and instrumentation/control systems shall be
performed in the presence of the applicant, the PE, or other authorized
representative.
iv. The results of all testing shall be maintained by the applicant as part of the
construction record documentation as stipulated in NC DENR's Minimum
Design Criteria for the Fast-Track Permitting of Pump Stations and Force
Mains Section I.03B.
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2. Electrical
a General - Electrical service to all pump stations shall be three phase, 240or 460 V AC
with a wye connection. The electrical power entrance shall be through a meter base,
followed by a NEMA 4X heavy duty, single throw, fusible safety switch with a solid neutral;
followed by a NEMA 4X heavy duty, double throw, three pole safety switch which feeds
the control panel from one side and heavy duty, circuit breaking 4 wire, 4 pole receptacle
assembly as manufactured by Crouse-Hinds or other approved equal from the other side.
All of these electrical components shall be suitably sized to be capable of service with
both sewage pumps running.
All electrical components, including panel shall be sealed off with Ductiseal type sealant in
accordance with the N. C. Electrical Code requirements for electrical service to gas
pumps.
h Control Equipment Enclosure
i. NEMA4X Enclosure - Enclosure shall be a NEMA type 4X and be of suitable size to
house all components. A locking hasp shall be provided in addition to screw clamp
type latches. Enclosure shall be fabricated from 14 gauge steel. The top of the
enclosure shall serve as a drip shield and the seam free sides shall prevent rain and
sleet from entering. Inner panel shall be made of 12 gauge steel and shall be painted
white. The enclosure and interior panel shall be painted with heat fused modified
polyester powder, electrostatically applied over a phosphatized base. Enclosure shall
be ANSI/ASI 61 grey.
ii. Hinged Inner Door—An inner door shall be furnished. Overload reset push buttons,
circuit breakers, switches and pilot lights shall be the only components accessible with
door closed. Door shall be hinged and may be opened when service is required.
iii. Line Terminal Block—A terminal block shall be furnished with properly sized line lugs
to accept the main power source entering the control panel. Load lugs shall be
adequate to accept all required load side wiring requirements. All live parts shall be
fully shielded.
iv. Motor Circuit Breakers (240 V AC) -A properly sized, molded case, thermal magnetic
circuit breaker shall be provided for each pump motor. Line and load sides shall be
equipped with lugs properly sized for the horsepower and current rating of the
motor(s). They shall be attached to mounting brackets which are specifically
manufactured for use with the particular circuit breaker. The interrupting rating shall
be I 0,000 RMS symmetrical amps.
v. Transformer Primary Circuit Breaker (When Transformer Is Required) —A properly
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sized, two pole, molded case circuit breaker shall be furnished ahead of the control
power I20 V AC power transformer for short circuit protection and disconnecting
power to the transformer. The circuit breaker shall conform to the specifications for
the motor circuit breaker(s).
vi. Control Power Transformer (When Neutral Is Not Available at Jobsite—Std. on 460
V AC) -An industrial quality control transformer shall be furnished to provide control
voltage. The transformer shall be sized with an adequate KVA rating to provide I20
V AC power for all items required in the control and alarm circuits. - Transformer
shall be protected in its secondary by properly sized fuses and/or circuit breaker(s).
vii. Magnetic Contactors and Overload Relays- A magnetic contactor shall be furnished
for each motor. A separate, panel mounted, 3 leg (three phase) or I leg (single phase)
overload relay shall be supplied for each motor. Each leg of the overload relay shall
be equipped with a properly sized overload heater. Contractor and overload relay
shall be properly sized for the required horsepower, voltage and phase.
viii. Elapsed Time Meters — Six digit, non-resetable elapsed time meters shall be mounted
in the control panel enclosure t o record the running time of each pump.
ix Condensation Strip Heater with Thermostat A strip heater shall be furnished to
prevent condensation within the control panel enclosure. The heater shall be
controlled by a panel mounted, adjustable thermostat.
x Phase and Voltage Monitor- A phase failure, reversal and under voltage monitor shall
be supplied to prevent the motors from running under low voltage, phase loss, or
phase reversal conditions. The monitor will lock out the control circuit until the
problem is corrected and automatically reset.
xi. Lightning Arrestor- Suitable lightning arrestors shall be provided to protect motors
and control equipment from lightning induced line surges.
xii. Thru-Door Overload Reset Push Buttons - Overload reset push buttons shall be
provided for each overload relay. Push buttons shall be mounted so that with inner
door closed, overload relays may be reset without entering high voltage compartment.
xiii. Switches - Heavy duty industrial grade oiltight switches shall be provided for each
pump for "Hands-Off-Automatic' operation selection. All switch components shall be
made of corrosion resistant metals and polyesters. Contact blocks shall be made of
see-through polycarbonate for simplified inspection of contacts, Cams and strokes
shall be Teflon impregnated for abrasion free service without lubrication. The
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switches required shall be as follows:
Switch Function Voltage
(Name Plate)
Manual-off-Automatic 120 V AC
xiv. Pilot Lights — Full voltage heavy duty industrial grade oiltight pilot lights shall be
provided. All pilot light components shall be made of corrosion resistant metals and
polyesters. An insulated socket shall be furnished to eliminate the possibility of shock
during bulb change. Lens shall be made of lexan. The pilot lights required shall be as
follows:
Pilot Light Function Voltage Lens Color
(Name Plate)
PUMP I I20 VAC GREEN
PUMP2 120VAC GREEN
xv. Seal Failure Circuit Test Push Button (illuminated) - Heavy duty industrial grade oiltight
push buttons shall be provided for each submersible pump motor. All push button
components shall be made of corrosion resistant metals and polyesters. Contact
blocks shall be made of see-through polycarbonate for simplified inspection of
contacts. An insulated socket shall be furnished to eliminate the possibility of shock
during bulb change. Lens shall be made of lexan. The push buttons required shall be
as follows:
Pilot Light Function Voltage Lens Color
(Name Plate)
PI SEAL FAIL 120 V AC AMBER
P2 SEAL FAIL 120 V AC AMBER
xvi. Pump Alternator Circuit (For Duplex Pump Operation) - The electromechanical
alternator relay shall be of industrial design specifically for use in pump applications. It
shall have single pole double throw heavy duty 10 amp silver cadmium oxide contacts
enclosed in a transparent cover. The snal action contacts shall transfer when the unit
is deenergized. The circuit shall never be closed or opened while current is being
conducted. The alternator circuit shall alternate the lead pump position between the
pumps and shall allow the lag pump to start in response to a rising water level in the
wetwell. (P I —ALT— P2 selector switch)
xvii. Power Failure - Once power is restored after a failure and the pump has pumped
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the water from alarm level down to pump off, the alarm should automatically reset
itself.
xviii.Control Relay(s) - Plug-in control relays with 120 V AC coils shall be provided as
required. Contact rating shall be 5 amps (minimum). Sockets shall be of the same
manufacture as the relays and hold-down clips shall be furnished to prevent relay form
sliding out of the socket.
xix. High Wetwell Level Alarm - The control panel shall be provided with a suitable alarm
circuit, activated by a separate level control. This alarm shall signal a high water
condition in the sump. Terminals shall be furnished in the control panel for connection
of an externally mounted alarm device. A red flashing light shall be provided as a visual
alarm and a horn provided as an audible alarm of the high water condition in the
wetwell. The pump station shall also be equipped with buttons to both test and silence
the horn.
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Part VIII Simplex Stations
1. ENGINEER Policy on Allowing Simplex Stations
i. It is the intention of CFPUA to limit the addition of new simplex pump stations to the
current collection system. New simplex pump stations will only be allowed under the
following conditions:
a. Service areas with gravity collection systems will require a gravity service for
residences. In the case where a gravity service is not practical due to low lot
elevations, a simplex station may be allowed on a case by case basis. These
situations will allow for a simplex station to pump to a gravity line only. In this
situation the pump station is the sole jurisdiction of the NC Plumbing Code and will
not be incorporated into the collection system.
Large numbers of simplex stations pumping to gravity collection lines will not be
allowed in new developments and will in no way account for more than 5% of the
total services for any development.
b. In areas where force mains are installed and no gravity line is within reasonable
distance, simplex pump stations may be allowed by CFPUA approval on a case by
case basis. CFPUA reserves the right to require any developer or applicant to
install gravity collection lines and standard duplex pump stations as outlined in Part
VII of these specifications. Multiple homes, multifamily structures, and areas of new
development will not be permitted to install simplex pump stations in lieu of
conventional gravity collection systems.
c. Simplex pump stations will be permitted for single family home sites only. The use
of simplex pump stations for commercial use shall not be permitted unless the
following conditions apply:
i. The projected average daily flow for the facility is less than the current single
family equivalent for a three bedroom residence in the same area. This includes
areas that have been granted flow reductions. In no way shall a commercial
service be allowed to use a simplex pump station exceeds the average daily flow
of 360 gallons per day. The applicant must provide flow calculations signed and
sealed by a NC Professional Engineer outlining the average daily flow for the
facilities. These calculations shall reflect the standard rates of discharge allowed
for such facilities by NCDEQ regulation., specifically I 5A NCAC 02T .0305 and
all applicable design criteria and future revisions of this rule.
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ii. The applicant may need obtain a variance for the use of a simplex pump
station from the NCDEQ.
iii. The applicant will provide all required permits and design documents for the
pump station. All required permitting, design fees, permit fees, material costs,
installation costs and any other applicable costs will be the responsibility of the
applicant.
d. All costs associated with the installation of a simplex pump station will be the
responsibility of the Applicant. This includes but is not limited to the cost of any
required permits or variances, design fees, material costs, installation costs,testing
and inspection costs or any other applicable fees.
e. If required by NCDEQ the Applicant will furnish, at his or her expense, a hydraulic
model of the proposed simplex station and its effect on the collection system. This
model will be used to determine required head pressures, pump size and other
design criteria. This model data will be provided to ENGINEER for review and will
become the intellectual property of ENGINEER.
f. If required by NCDEQ the Applicant will apply for a variance for a simplex pump
station based on the rules and requirements of NCDEQ specifically the August
2008 Draft Alternative Design Criteria for Minimum Separation for Sewer Systems
to Wetlands I 5A NCAC 2T .0305(f) and the Policy for Meeting the Reliability
Requirements of 15a NCAC 2T .305(h)(I)(D) for Pressure Sewers Utilizing Simplex
Pump Stations.
g. The electrical service and power consumption for all simplex stations will be the
responsibility of the Applicant. This responsibility will transfer to any person or
entity that purchases any real estate served by a simplex pump station.
2. Simplex Pump Station Design
i. Siting—All simplex pump stations will be sited on the Applicant's private property and
not located in a public right of way. The location of all simplex pump stations will be
approved by CFPUA. The simplex pump station will be located in a recorded utility
easement in an area that provides the shortest distance from the pump station to the
connection point in the collection system. All applicable separations as stated in NCAC
2T .0305 will be met. For installations that are unable to meet the required separations,
the applicant may apply for a variance from NCDEQ.
Care will be taken not to locate the pump station in excessive vegetation or landscape
position that hinders maintenance of the station.
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ii. Approved manufacturers —All simplex stations will be manufactured for use as a
package system complete with all required valves, piping, level control devices, wet
wells, control panels and all other appurtenances required. Simplex pump stations will
be manufactured by Meyers or other approved manufacturer. The applicant will furnish
all specifications, shop drawings, cut sheets and other applicable information to
ENGINEER prior to approval for installation and connection to the collection system.
iii. Materials —All materials used in the simplex pump station will correspond to industry
standards for use with sanitary sewage. All materials shall be non-corrosive such as
stainless steel, aluminum, plastic, fiberglass or composite whenever practical.
ENGINEER reserves the right to deny the installation of any package system that uses
substandard corrosive materials.
iv. Wetwell Storage
a. The wet well of a simplex pump station will meet the required to meet the Policy
for Meeting the Reliability Requirements of I 5a NCAC 2T .305(h)(I)(D) for
Pressure Sewers Utilizing Simplex Pump Stations. The requirements for storage are
as follows:
I. The first option for meeting reliability requirements is to provide 24 hours
storage in the wet well above the pump-on elevation as requested in the permit
application. However, since this may add to the cost and make installation
difficult in certain areas, another option may be pursued.
Alternatively, the applicant may provide documentation regarding both power
reliability and response times for pump replacement.
a. In the case of power reliability, 3 years of power history data in the area
from the power company must be provided. The amount of storage required
shall be equal to the duration of the longest power outage (minus
catastrophic events such hurricanes). Storage shall be provided above the
pump-on elevation.
b. For response times, the applicant shall provide an estimate of the response
time to replace a failed pump. The estimate shall include time for answering
after hours calls, travel time to maintenance shop, preparing equipment to
respond, travel time to site, and time to replace the pump. For existing
systems, the Permittee should indicate if they currently maintains a supply of
pumps on hand at this time (a permit condition). Also, personnel must be on-
call 24 hours a day, 7 days a week as well as a phone number with 24-hour
answering service clearly posted on the pump station. Storage shall be
provided above the high water alarm.
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2. A minimum of 120 gallons of storage above alarm shall be included in the
evaluation.
3. These storage requirement are not cumulative, rather, the storage which
provides the largest wet well shall be specified.
4. Storage in the service line to the pump station will not be included in these
calculations.
b. All wet wells shall be installed a minimum of 2 feet above the 100 year flood
elevation unless a variance is granted by NCDEQ.
v. Pump Sizing—Simplex pumps will be sized based upon a hydraulic model of the
collection system and the anticipated head pressure at the force main connection point.
At no time will the pump size be less than 2 HP. Where a hydraulic model of the
system is not required by NCDEQ the default pump size will be a 2 HP grinder pump.
The pumps shall be a Meyers WGL20-2 I 2 HP capable of pumping 20 gallons per minute
at 56 feet of total dynamic head or equal.
vi. Control Panel —The control panel shall be a single phase 230 volt simplex panel with
visual and audible alarms. The enclosure shall be a NEMA-4X rated enclosure with a
gasketed door. The control circuit shall be single phase 120 volts. The control panel
shall meet or exceed the specifications of the pump manufacturer and have the
following:
a. A Hand — Off—Automatic control Switch
b. Cycle counters and elapsed time meters
c. Audible alarm and Visual alarm
d. The control panel shall meet all NC Building codes and NEC codes and the power
to the panel shall be installed by a licensed electrician.
e. All control panels shall be installed a minimum of 12 inches above the 100 year flood
elevation unless a variance is granted by NCDEQ.
vii. Venting—The wet well shall be vented above the 100 year flood elevation and the vent
shall have a no corrosive insect screen installed.
viii. Antiflotation —The applicant will demonstrate through signed and sealed engineering
calculations, a method of restraining the wetwell from flotation during flood events or
high ground water. Typical restraints shall include a concrete lug poured around an
extended lip manufactured into the wetwell.
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3. Testing
i. All simplex pump stations and associated force mains will be tested for operation and
leakage. All control mechanisms, alarms and control panel functions will be verified.
ii. In cases where the system was designed by a NC Professional Engineer and permitted
through NCDEQ, the Engineer's and Owner's certifications will be provided to
CFPUA prior to the system being activated.
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