NC0025542_Authorization to Construct_20150825

NPDES DOCUHENT SCANNING COVER SHEET
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NPDES Permit:
NC0025542
Catawba WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct
(AtC) - --`"
Permit Modification
Complete File - Historical
Report
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
August 25, 2015
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City of Hickory
A To C No. 025542A02
August 25, 2011
Engineer's Certification
1, Danny M. Ware , as a duly registered Professional Engineer in
the State of North Carolina, having been authorized to observe (periodically/weekly/full time)
the construction of the modifications and improvements to the Catawba WWTP, located in
Catawba County for the City of Hickory, hereby state that, to the best of my abilities, due care
and diligence was used in the observation of the following construction:
Installation of an automatic bar screen rated for a peak flow of 7.5 MGD; a
manual bar screen; a 100 fts/hr automatic washing press; a vortex grit removal
system rated for 12 MGD with grit classifier and grit washer; oxidation ditches
splitter box; two (2) 0.75 MGD oxidation ditches each consisting of two (2)
0.0235 MG anaerobic basins each with two (2) 2.3 Hp submersible mechanical
mixers, a 0.107 MG anoxic basin with a 7.4 HP submersible mechanical mixer,
and a 0.462 MG aerobic basin with a 100 HP surface aerator/mixer with VFD;
clarifier splitter box; two (2) 50-foot diameter clarifiers with 14-foot sidewater
depth, a scum pump station with two (2) 100 GPM grinder pumps; four (4) 735
GPM RAS/WAS/sludge transfer pumps with VFDs; a continuous backwash sand
filter system rated for a peak flow of 2,604 GPM and a 31.2 SCFM air scour
compressor; a disinfection system consisting of two (2) 6,600 gallon sodium
hypochlorite storage tanks with two (2) 317 GPH chemical feed pumps, two (2)
2,800 gallon sodium bisulfite storage tanks with two (2) 317 GPH chemical feed
pumps, two, (2) 5,262 cubic -foot chlorine contact basins; two (2) 40-foot diameter,
24.5 ft sidewater depth aerobic digester tanks with coarse bubble aerator/mixer
and three (3) 925 scfm blowers; an effluent pump station with two (2) 2,604 GPM
pumps with VFDs and an effluent metering and sampling station; a cascade
aerator; a plant drain pump station with two (2) 325 GPM submersible pumps; a
600 KW standby power generator with automatic transfer switch; a control and
pumps building; and associated electrical work, site work, yard piping, and
appurtenances, in conformity with the project plans, specifications, and other
supporting data subsequently filed and approved by the Department of
Environment and Natural Resources.
I certify that the construction of the above referenced project was observed to be built within
substantial compliance and intent of the approved plans and specifications.
We understand that the new limits associated with the modifications to expand to 1.5 MGD now
apply.
Signature °`�`-0-
Date 8/25/2015
Send to: Stcve.Tsadwa, EIT
Ron Berry
Complex Permitting Unit
DENR/DWR/Water Quality Programs
1617 Mail Service Center
Raleigh, NC 27699-1617
1633 Mail Scrvicc Center
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. Registration No. 041015
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City of Hickory
A To C No, 025542A02
August 25, 2011
Partial
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Engineer's Certification
I, W1LU4.4 # .C. c to41t Toni , as a duly registered Professional Engineer in
the State of North Carolina, having been authorized to observe (periodically/weekly/full time)
the construction of the modifications and improvements to the Catawba WWTP, located in
Catawba County for the City of Hickory, hereby state that, to the best of my abilities, due care
and diligence was used in the observation of the following construction:
Installation of an automatic bar screen rated for a peak flow of 7.5 MGD; a
manual bar screen; a 100 ft3/hr automatic washing press; a vortex grit removal
system rated for 12 MGD with grit classifier and grit washer; oxidation ditches
splitter box; two (2) 0.75 MGD oxidation ditches each consisting of two (2)
0.0235 MG anaerobic basins each with two (2) 2.3 Hp submersible mechanical
mixers, a 0.107 MG anoxic basin with a 7.4 HP submersible mechanical mixer,
and a 0.462 MG aerobic basin with a 100 HP surface aerator/mixer with VFD;
clarifier splitter box; two (2) 50-foot diameter clarifiers with 14-foot sidewater
depth, a scum pump station with two (2) 100 GPM grinder pumps; four (4) 735
GPM RAS/WAS/sludge transfer pumps with VFDs; a continuous backwash sand
filter system rated for a peak flow of 2,604 GPM and a 31,2 SCFM air scour
compressor; a disinfection system consisting of two (2) 6,600 gallon sodium
hypochlorite storage tanks with two (2) 317 GPH chemical feed pumps, two (2)
2,800 gallon sodium bisulfite storage tanks with two (2) 317 GPH chemical feed
pump's, two. (2) 5,262 cubic -foot chlorine contact basins; two (2) 40-foot diameter,
24.5 ft sidewater depth aerobic digester tanks with coarse bubble aerator/mixer
and three (3) 925 scfin blowers; an effluent pump station with two (2) 2,604 GPM
pumps with VFDs and an effluent metering and sampling station; a cascade
aerator; a plant drain pump station with two (2) 325 GPM submersible pumps; a
600 KW standby power generator with automatic transfer switch; a control and
pumps building; and associated electrical work, site work, yard piping, and
appurtenances, in conformity with the project plans, specifications, and other
supporting data subsequently filed and approved by the Department of
Environment and Natural Resources.
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I certify that the construction of the above referenced project was observed to be built within
substantial compliance and intent of the approved plans and specifications.
This is an intermediate phase completion. This is not a request to operate at the expanded flow.
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Signature
Date to ^,ZU IC(
Send to: Stevc.Tsadwa, LIT
Construction Grants & Loans
1633 Mail Service Ccntcr
Ron Berry
Complex Permitting Unit
DENR/DWR/Water Quality Programs
1617 Mail Service Center
Raleigh, NC 27699-1617
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North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
August 25, 2011
Mr. Mick W. Berry, City Manager
City of Hickory
P.O. Box 398
Hickory, North Carolina 28603
SUBJECT: Authorization to Construct
A to C No. 025542A02
City of Hickory
Catawba WWTP
Catawba County
Dear Mr. Berry:
A letter of request for an Authorization to Construct was received January 25, 2010, by
the Division of Water Quality (Division), and final plans and specifications for the subject
project have been reviewed and found to be satisfactory. Authorization is hereby granted for the
construction of the modifications to the existing 0.225 MGD Wastewater Treatment Plant, with
discharge of treated wastewater into Lyle Creek in the Catawba River Basin.
This authorization results in an increase in design and permitted capacity to 1.5 MGD,
and is awarded for the following construction:
Installation of an automatic bar screen rated for a peak flow of 7.5 MGD; a manual bar
screen; a 100 ft3/hr automatic washing press; a vortex grit removal system rated for 12
MGD with grit classifier and grit washer; oxidation ditches splitter box; two (2) 0.75
MGD oxidation ditches each consisting of two (2) 0.0235 MG anaerobic basins each with
two (2) 2.3 Hp submersible mechanical mixers, a 0.107 MG anoxic basin with a 7.4 HP
submersible mechanical mixer, and a 0.462 MG aerobic basin with a 100 HP surface
aerator/mixer with VFD; clarifier splitter box; two (2) 50-foot diameter clarifiers with 14-
foot sidewater depth, a scum pump station with two (2) 100 GPM grinder pumps; four
(4) 735 GPM RAS/WAS/sludge transfer pumps with VFDs; a continuous backwash sand
filter system rated for a peak flow of 2,604 GPM and a 31.2 SCFM air scour compressor;
a disinfection system consisting of two (2) 6,600 gallon sodium hypochlorite storage
tanks with two (2) 317 GPH chemical feed pumps, two (2) 2,800 gallon sodium bisulfite
storage tanks with two (2) 317 GPH chemical feed pumps, two (2) 5,262 cubic -foot
chlorine contact basins; two (2) 40-foot diameter, 24.5 ft sidewater depth aerobic digester
tanks with coarse bubble aerator/mixer and three (3) 925 scfm blowers; an effluent pump
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer
NorthCarolinan
Naturally

Mr. Mick W. Berry, City Manager
August 25, 2011
Page 2
station with two (2) 2,604 GPM pumps with VFDs and an effluent metering and
sampling station; a cascade aerator; a plant drain pump station with two (2) 325 GPM
submersible pumps; a 600 KW standby power generator with automatic transfer switch; a
control and pumps building; and associated electrical work, site work, yard piping, and
appurtenances, in conformity with the project plans, specifications, and other supporting
data subsequently filed and approved by the Department of Environment and Natural
Resources.
This Authorization to Construct is issued in accordance with Part III, Paragraph A of
NPDES Permit No. N00025542 issued January 28, 2010, and shall be subject to revocation
unless the wastewater treatment facilities are constructed in accordance with the conditions and
limitations specified in Permit No. NC0025542.
The sludge generated from these treatment facilities must be disposed of in accordance
with G.S. 143-215.1 and in a manner approved by the Division.
In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as may
be required by the Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
The Mooresville Regional Office, telephone number [phone], shall be notified at
least forty-eight (48) hours in advance of operation of the installed facilities so that an on site
inspection can be made. Such notification to the regional supervisor shall be made during the
normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State
Holidays.
Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted facility
has been installed in accordance with the NPDES Permit, this Authorization to Construct and the
approved plans and specifications. Mail the Certification to: Construction Grants & Loans,
DWQ/DENR, 1633 Mail Service Center, Raleigh, NC 27699-1633.
Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at
least equivalent to or greater than the classification assigned to the wastewater treatment
facilities by the Certification Commission.
The Permittee must also employ a certified back-up operator of the appropriate type and
grade to comply with the conditions of T15A:8G.0202. The ORC of the facility must visit each
Class I facility at least weekly and each Class II, III and IV facility at least daily, excluding

Mr. Mick W. Berry, City Manager
August 25, 2011
Page 3
weekends and holidays, must properly manage the facility, must document daily operation and
maintenance of the facility, and must comply with all other conditions of T15A:8G.0202.
A copy of the approved plans and specifications shall be maintained on file by the
Permittee for the life of the facility.
During the construction of the proposed additions/modifications, the permittee shall
continue to properly maintain and operate the existing wastewater treatment facilities at all times,
and in such a manner, as necessary to comply with the effluent limits specified in the NPDES
Permit.
You are reminded that it is mandatory for the project to be constructed in accordance
with the North Carolina Sedimentation Pollution Control Act, and when applicable, the North
Carolina Dam Safety Act. In addition, the specifications must clearly state what the contractor's
responsibilities shall be in complying with these Acts.
Prior to entering into any contract(s) for construction, the recipient must have obtained all
applicable permits from the State.
Failure to abide by the requirements contained in this Authorization to Construct may
subject the Permittee to an enforcement action by the Division in accordance with North
Carolina General Statute 143-215.6A to 143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from
complying with any and all statutes, rules, regulations, or ordinances which may be imposed by
other government agencies (local, state, and federal) which have jurisdiction.

Mr. Mick W. Berry, City Manager
August 25, 2011
Page 4
One (1) set of approved plans and specifications is being forwarded to you. If you have
any questions or need additional information, please contact Seth Robertson, P.E. at telephone
number [phone].
st:sr
Sincerely,
deA Coleen H. Sullins
cc: Scott Snyder, P.E., AECOM, 1460 John B. White, Sr. Blvd, 1C, Spartanburg, SC
Catawba County Health Department
DWQ Mooresville Regional Office, Surface Water Protection
Technical Assistance and Certification Unit
Point Source Branch, NPDES Program
Steve Tsadwa, EIT
ATC File