NC0024970_Authorization to Construct_20010718

NPDES DOCIMENT SCANNING; COVER SHEET
NC0024970
McAlpine Creek WWTP
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Meeting Notes
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
July 18, 2001
This document in; printed on reuse paper - ignore any
content on the reYeree wide

'State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Kerr T. Stevens, Director
July 18, 2001
Mr. Barry Gullet
CMUD Administrative Division
5100 Brookshire Boulevard
Charlotte, North Carolina 28202
AirrA
NCDENR
Subject: Authorization to Construct
ATC No. 024970ACH
NPDES Permit No. NC0024970
McAlpine Creek VAICITP
Mecklenburg County
Dear Mr. Gullet:
The Division of Water Quality's NPDES Unit has reviewed your request for an Authorization to Construct at the
McAlpine Creek WWTP. The Division finds the proposed improvements to be satisfactory and hereby grants
authorization for the following:
• Addition of two new primary clarifiers of 130-ft. diameter with 13.5-ft. sidewall depth to the North Plant.
• Addition of a new primary clarifier pump station containing two primary sludge pumps (200 gpm at 125 ft.
total dynamic head) and two scum pumps (100 gpm at 104 ft. total dynamic head) to the North Plant.
• Addition of one new gravity thickener of 45 ft. diameter and 14 ft. sidewall depth.
• Modifications to the existing North Plant raw sewage pumping station including the addition of a new pump
and associated controls.
• Rehabilitation of the effluent filters including replacement of media, construction of new backwash
effluent troughs, and assorted maintenance work.
• Modifications to the screening and grit facility consisting of the addition of two mechanically cleaned
bar screens, one vortex grit removal unit and one grit pump.
• Construction of one new two -stage wet scrubber odor control facility for the treatment of air from
the North Plant primary clarifiers.
• Construction of one new three -stage vet scrubber odor control facility for the treatment of airflow
from the sludge silo and thickening/dewatering portion of the plant.
This Authorization to Construct is issued in accordance with NPDES Permit No` NC0024970, issued
January 1, 2001, and shall be subject to revocation unless the wastewater treatment facilities are
constructed in accordance with the terms and conditions of the permit. This Authorization to Construct
does not increase the permitted design flow of 64 MGD.
The Permittee shall notify the Water Quality Supervisor of the Mooresville Regional Office, telephone number
[phone], at least forty-eight (48) hours prior to operation of the installed facilities, so that an in -place
inspection can be made. Notification shall be made during the normal office hours of 8:00 a.m. until 5:00 p.m.,
Monday through Friday.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer Internet: http://h2o.enr.state.nc.us/

CMUD- McAlpine Creek WWTP
NPDES Permit No. NC0024970
ATC No. 024970ACH
Page 2
Engineer's Certification
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division with a certification (copy enclosed) from a professional engineer registered in North Carolina certifying
that the permitted facility has been installed in accordance with the NPDES Permit, this Authorization to
Construct, and the approved plans and specifications. The Certification should be submitted to: NCDENR /
DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617.
Requirements for Certified Operator
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 Title 15A, Chapter 8G, .0200. The ORC of the facility must visit each Class I
facility at least weekly and each Class II, III, and IV facility at least daily, excluding weekends and
holidays; and must properly manage and document daily operation and maintenance of the facility and
comply with all other conditions of Tide 15A, Chapter 8G, .0200.
Additional Requirements
The Operational Agreement between the Permittee and the Environmental Management Commission is
incorporated herein by reference and is a condition of this Permit. Noncompliance with the terms of the
Operational Agreement shall subject the Permittee to all sanctions provided be G. S. 143-215.6 for violation of or
failure to act in accordance with the terms and conditions of this Permit.
Failure to abide by the requirements contained in this Authorization to Construct may subject the Permittee to an
enforcement action by the Division of Water Quality in accordance with North Carolina General Statute 143-
215.6A to 143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from complying with any and all
statutes, rules, regulations, or ordinances which may be imposed by other government agencies (local, state, and
federal) which have jurisdiction.
The Permittee shall maintain a copy of the approved plans and specifications on file for the life of the facility.
One (1) copy of the approved plans and specifications is enclosed for your records.
If you have any questions about this Authorization to Construct, please contact Natalie Sierra, at [phone],
extension 551.
Sincerely,
fo, .Kerr T. Stevens
Enclosures: Project Plans and Specifications (approved)
Engineer's Certification Form
cc: Mooresville Regional Office, Water Quality
Technical Assistance and Certification Unit
Central Files
NPDES Unit Files
Mr. Scott Alpert, P.E. - FIDR Engineering, Inc.
128 South Tryon Street
Charlotte, North Carolina 28202-5001

ATC SUMMARY
SCOPE
CMUD — McAlpine Creek WWTP
Charlotte, NC
ATC No. ACH024970
McAlpine Creek, Class C
Catawba River Basin, 030834
Mecklenburg County
The scope of the project includes the addition of two new primary clarifiers, a new primary
clarifier pumping station, one new gravity thickener, modifications to the existing raw sewage
pumping station, effluent filter rehabilitation, and new odor control facilities.
RECOMMENDATIONS
1. Approve addition of two new primary clarifiers of 130-ft. diameter
with 13.5-ft. sidewall depth.
2. Approve new primary clarifier pumping station with two primary
sludge pumps (200 gpm @ 125 ft) and 2 scum pumps (100 gpm @
104 ft.).
3. Approve addition of one new gravity thickener (45 ft. diameter, 14 ft.
sidewall depth)
4. Approve modifications to existing raw sewage pumping station
including the addition of a new 17-MGD, 400-hp pump.
5. Approve effluent filter rehabilitation including replacement of media
and construction of new backwash effluent troughs
6. Approve modifications to screen and grit facility consisting of the
addition of two mechanically cleaned bar screens, one vortex grit
removal unit and one grit pump
7. Approve one new two -stage wet scrubber odor control facility
8. Approve new three -stage wet scrubber odor control facility.
REVIEW SUMMARY
Executive Summary
The subject facility operates a Class IV pollution control system for which the most recent
NPDES permit became effective on March 1, 2001. The treatment works currently consist of:
• Flow equalization
• Bar screens
• Grit removal
• Primary clarifiers
•Aeration basins
• Secondary clarifiers
• Chlorination
• Dechlorination
•Anaerobic sludge digestion
• Centrifuges and gravity sludge thickeners
Page 1

• Rapid sand filter
This proposal is a voluntary measure that should increase system reliability, particularly
during periods of high flow. The space exists within the existing process train for the
proposed additions and improvements. The plans are compatible with the existing process
train; and are, in most cases, operationally identical to existing equipment and facilities. It is
therefore recommended that the project be approved.
- end -
ATC REVIEW NOTES *
CMUD — McAlpine Creek WWTP
ATC No. ACH024970
Mecklenburg County
Project Name: Primary Treatment Improvements and Effluent Filter Rehabilitation
Project Number: HDR Project No. 0121-500-018 (File MCFR-6)
Applicant:
Mr. Barry M. Gullet
Charlotte -Mecklenburg Utilities Department
5100 Brookshire Boulevard
Charlotte, North Carolina 28216
Application/Plans Prepared by:
Mr. Scott M. Alpert, P.E.
HDR Engineering, Inc. of the Carolinas
128 South Tryon Street
Suite 4100
Charlotte, North Carolina 28202
Project Location:
CMUD - McAlpine Creek WWTP
US Highway 521
Charlotte, North Carolina
Mecklenburg County
Facility status: Existing.
Wastewater source: Domestic (91.8%) and industrial wastewater (8.2%) .
Project Description:
CMUD would like to increase treatment reliability at its McAlpine Creek WWTP, particularly
during times of high flow (the plant has a rated capacity of 64 MGD). The treatment train is
split into two parts - the North Plant and South Plant, rated at 32 MGD each. The treatment
plant additions and improvements consist of the construction of two North Plant clarifiers and
an associated sludge pumping station, construction of one gravity thickener, installation of a
fifth pump in the North Plant Raw Sewage Pumping Station, replacement of effluent filter media
and miscellaneous modifications and improvements to the backwash system, installations of
additional screens and grit removal equipment ant the Screen and Grit Facility and the
construction of odor control facilities - one to serve the North Plant primary clarifiers and one
for the biosolids processing and storage area. For the new equipment/treatment units, the
Page 2

space and piping exists already and the new units need only be installed and tied in to the
existing system.
Chronology:
APP RECD 05/ 1 /01 REVIEWED 06/08/01
ACKNOWLEDGED 05/09/01 DENIED
STAFF RPT REQS RETURNED
STAFF RPT RECD ISSUED
OTH AGY REQS EXPIRATION
OTH AGY RECD
ADD INFO REQS
ADD INFO RECD
SCH TO ISSUE
Does Land Disturbing Activities Exceed One Acre: Yes
Additional Permit Requirements:
Land Quality Erosion Control Permit granted (Project No. MECKL-2001-069)
Compliance Status:
Does facility currently have an NPDES Permit? Yes
If yes, Permit Number: NC0024970
Is the facility currently under a SOC, JOC or moratorium? No.
If yes, describe details of injunction:
Expiration date: June 30, 2005 (- game T')
Enforcement Actions Taken Over Last Two Years:
In 1999, the facility received a Notice of Violation (NOV) for sewer bypass and was
assessed in December 1999. In 2000, the facility received another NOV for bypass as well as
an NOV following a Compliance Evaluation Inspection for reporting errors and a violation of the
pH and cyanide limits.
SEPA Requirements:
Is an EA required? No.
If yes, has a FONSI been issued? N/A
If No, has an EIS been submitted? N/A
If yes, has a Record of Decision been issued? N/A
If yes, what were the findings? N/A
Funding Source: Private
EAA Requirement? None.
Estimated Project Schedule:
To start construct immediately upon receiving the ATC
Page 3

Submissions:
• Letter of Transmittal
• Engineering Plans
• Design Calculations
• Technical Specifications
North Plant Clarifiers
Number of clarifiers: two
Diameter: 130 ft.
Sidewall depth: 13 ft. - 6 in.
Total volume: 2.69 MG
Surface area per clarifier: 13200 ft2
Note: The addition of these clarifiers adds reliability to the system not just by providing extra
capacity but also by allowing for one clarifier to be out of service without interference to plant
operations. New sludge overflow boxes will be constructed to convey sludge from the clarifiers
by gravity. The construction schedule mandates tie-in within 8 hours.
Due to CMUD request, odor control covers will be constructed over the clarifier tanks. These
covers are low profile aluminum covers with exterior trusses. The headspace between the
covers and the water surface will be exhausted and conveyed to the odor control facility.
Primary Clarifier/Sludge Pumping Station
Number of process pumps: two primary sludge pumps, 2 scum pumps
Type: Progressing Cavity
Design Operating Capacity (gpm): Primary sludge pumps are 200 gpm at 97-ft. total dynamic
head
Scum pumps are 100 gpm at 107-ft. total dynamic head
Operation: Primary Sludge pumps are variable speed, manual control; scum pumps are
constant speed with float -switch control
Note: The pumps are designed such that sludge in the primary clarifiers can develop to 5%
solids. With the addition of this pump station equipment, each clarifier will have a dedicated
primary sludge pump.
I checked all pump curves and total dynamic head calculations
Gravity Thickener:
Solids Loading Rate (lb/day/ft2): Total: Average-20 Max Month - 22
Firm: Average - 30 Max Month - 33
Diameter: 45 feet
Sidewater depth: 14 feet
Note: This thickener is nearly identical to two thickeners currently operating on -site. The
addition of this third gravity thickener allows provision of firm capacity for existing and future
sludge flows. The target solids concentration for the gravity thickeners is 5%.
Raw Sewage Pumping Station (North Plant):
Number of process pumps: one variable speed, 400-hp pump at 99.6-ft. total dynamic head
Firm Capacity: 19.2 MGD
Note: This pump station was originally designed to accommodate a total of five pumps. There
are four in operation right now. The above described pump will be installed in the last open
space in the existing pump station.
Effluent Filters:
The scope of this project includes replacement of the gravel support and sand in all filters. Due
to problems with loss of media, a dual trough system will be installed for filters 1-8. The drain
lines will be cleaned and assorted maintenance and repairs will be performed on the drain
valves and air compressor system.
Screen and Grit Facility Additions
The portion of the screening and grit facility which sends flow to the north and south plants
will have one 50MGD mechanically cleaned bar screen and one 50 MGD vortex grit removal
Page 4

unit added. The portion of the pretreatment works that sends flow to equalization will have one
50 MGD mechanically cleaned bar screen added.
Odor Control
Wet scrubbing odor control facilities
The odor control facility built to handle odors from the North Plant clarifiers will have an air
flow rate of 6600 scfm per clarifier. This system will be a 28000-scfm two -stage packed tower
chemical scrubber.
The odor control facility for the airflow from the sludge silos and thickening/dewatering
complex will be an 8000 scfm three -stage packed tower chemical scrubber with a flow rate of
5600 scfm for the North Plant sludge silos and 2000 scfm for the North Plant Centrifuge Unit
fans.
Review Notes:
For pump stations:
Checked design calculations (including verification of head loss calculations) and pump curves.
Reviewed design plans to ensure that no bypass can occur. Sufficient standby power exists on -
site to meet mostto an AC generator unit. Duality is achieved since there are two individual
units of each of the two types of pumps.
Flow meter and all associated controls have been included in the plans and specs.
Odor Control:
Wastewater is generated in the form of blowdown water. The North Plant odor control facility is
expected to generate 5 gpm of wastewater that will be send to the North Plant manhole. From
there, it will go to the North Plant primary clarifiers for treatment. The sludge silo odor control
facility is expected to generate 2 gpm of wastewater which will be directed into a drain line
leading to the South Plant raw sewage pump station where it will continue on for treatment.
In general, I checked the sizing and design of the clarifiers, gravity thickeners, filter backwash
troughs and screen and grit facility additions.
An erosion control plan has been included which includes construction of a silt fence, rock dam
and sediment trap around the construction site.
There are no instances of bypass, and all treatment components provide additional reliability to
the system. A review of the construction schedule provided in the specifications gives
maximum allowable times for tie-ins for the different parts of the project, most of which are
between 4 and 6 hours. More importantly, the construction schedule includes a clause that
the plant must continue to meet all NPDES permit requirements at the effluent filters.
Backup Power: Sufficient backup power exists on -site for all proposed treatment units. Please
see attached June 20, 2001 memo from HDR.
Chemical Storage: The odor control system requires chemical storage. The design plans
include a separate building in which these chemicals will be housed and secondary
containment has been provided around the storage containers within the building. .
Material Compatibility: Materials are compatible with the proposed application.
Compatibility with existing equipment: The proposed project is compatible with the existing
treatment system.
Recommendations
I recommend that the Authorization to Construct be issued in order to increase system
capacity and reliability.
Page 5

SOC PRIORITY PROJECT: No
To: Permits and Engineering Unit
Water Quality Section
Attention: Natalie Sierra
Date: July 24, 2001
AUTHORIZATION TO CONSTRUCT
NPDES PERMIT
REPORT AND RECOMMENDATIONS
County: Mecklenburg
MRO No.: 01-95
Permit No. NC0024970
Application No. 024970ACH
PART I - GENERAL INFORMATION
1. Facility and address: McAlpine Creek WWTP
CMUD
5100 Brookshire Boulevard
Charlotte, N.C. 28216
RECEIVED
WATER QUALITY SECTION
JUL 3
Non -Discharge Permitting
2. Date of on -site investigation (if conducted): Not conducted.
3. Report prepared by: Michael L. Parker, Environ. Engr. II
4. Persons contacted and telephone number: N/A.
5. Discharge point(s):
Latitude: 35° 03' 55" Longitude: 80° 52' 20" USGS Quad No.: G 15 SE
6. Site size and expansion area consistent with application? Yes. Sufficient area exists for
the proposed WWTP modifications.
7. Topography (relationship to flood plain included): Portions of the WWTP site may be
located within the 100 year flood plain, however, all WWT facilities appear to be
adequately protected from flooding.
8. Location of nearest dwelling: None within 500 feet of the site.

Page Two
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. Existing treatment facility
a. Current permitted capacity: 64.0 MGD
b. Date(s) and construction activities allowed by previous ATCs issued in the
previous two (2) years: 024970ACG was issued to CMUD for modifications to
the existing chlorine contact lagoon to optimize operation during heavy flows.
c. Actual treatment capacity of the current facility (design volume): 64.0 MGD.
d. Description of existing or substantially constructed WWT facilities: The
McAlpine Creek WWTP is divided up into two (2), parallel train WWTPs (North
and South Plants) having a combined treatment capacity of 64.0 MGD. The
activated sludge treatment components consist of equalization, screening, grit
removal, primary clarifiers, aeration basins, secondary clarifiers, chlorination,
anaerobic sludge digestion, gravity sand filters and sodium bisulfite
dechlorination.
2. Proposed treatment facilities: Modifications proposed for this facility include the addition
of two (2) primary clarifiers to the North Plant to bring the rated capacity up to 32 MGD,
an additional gravity thickener (for a total of 3), an additional pump at the North Plant
raw sewage pumping station, modifications to the effluent filters, additional 50 MGD
screening and grit removal equipment, and a new odor control system for the North Plant
primary clarifiers, sludge silos, and thickening/dewatering complex.
3. Residuals handling and utilization/disposal scheme:
a. If land applied, please specify DWQ Permit No. WQ000057
Residuals Contractor: WheelabratorBio Gro Systems, Inc.
Telephone No. 704-752-8673
b. Residuals Stabilization: Class B
c. Other disposal/utilization scheme: Advanced Alkaline Stabilization, Composting.
4. Treatment plant classification : Class IV (The proposed modifications/additions will not
affect this facility's current classification).
5. SIC Code(s): 4952 Wastewater Code(s): 01 Main Treatment Unit Code: 01003
6. Important SOC/JOC or Compliance Schedule Dates: This facility is not currently under
an SOC or JOC.

Page Three
PART III - EVALUATIONS AND RECOMMENDATIONS
The Charlotte Mecklenburg Utility Department (CMUD) requests approval to construct
modifications to the subject WWTP to improve operational efficiency and treatment reliability.
Pending a technical review by P&E of the plans and specifications, it is recommended
that an ATC be issued.
Signature of Report Preparer l Date
/
Quality Regi
Water uali ' Supervisor / Date
g
h:\ate\atc01\mcalpinc.atc

'06-20-01 09:04 From -NOR Enid neerins 3386760 T-029 P.02/02 F-156
June 20, 2001
Ms. Natalie Sierra
North Carolina Deparanent of Environment and Natural Resources
Division of Water Quality
512 North Salisbury Street
Raleigh, North Carolina 27604
Re: Charlotte -Mecklenburg Utilities, Charlotte, NC
McAlpine Creek Wastewater Management Facility
Primary Treatment Improvements and Effluent Filter Rehabilitation
HDR Project No. 0121-500-018 (File MCFR-6)
Dear Ms. Sierra.
HR
In reference to our telephone conversation on Friday, June 15, 2001, liDR Engineering, Inc. of the
Carolinas (1IDR) is forwarding to you information on the backup power considerations for the project
referenced above_ Each of the project systems is discussed separately below:
1. North phut Primary Clarifiers and Sludge Pumping Station: The motor control center (MCC204)
for the clarifier drives, sludge pumps, and scum pumps is fed ilrom switchgear SRSR as shown on
Drawing E-9. Switchgear SKSR, in turn, is backed up by an existing 750-kW diesel -powered
generator (GEN L4). The load calculation for MCC 204 on Drawing 1T-9 reports a Total
eoruiected load of 243 AMPS or 202 KVA. Switchgear SRSR. will have a maximum operating
load of 563 KVA. See load tabulation Drawing E10. Thus, the existing generator produces
adequate power for the new system.
2. North Plant Odor Control Facility — This facility is also fed from Switchgear SRSR.. See Item
No. 1 above.
3. North Plant Raw Sewage Pumpmg Station — 400 HP Pump #5 will be fed from switehgear SMP
as shown on Drawing E-29. Switchgear SMP is backed up by a 1000 kw diesel generator (gen 3)
Switchgear SMP has a maximum operating load of 1040 KVA.
4, Screen and Gra Facility Modifications — All equipment in the Screen and Grit Facility is backed
up by the 400 kW diesel generator as shown on Drawing E-24.
5. Effluent Filter Modifications — Not Applicable.
6. Gravity Thickener No. 3 The gravity thickener complex does not currently have backup power
capability.
7_ Sludge Storage Facility Odor Control System -- The new odor control system, described by
Drawing Series 800, does not have backup power.
If you need additional information or have any questions, please call me at [phone].
Best regard,
HDR Engineering, Inc. of the Carolinas
Scott M. Alpert, PE
Project Eriguicc r
Emp/oyew Owned
vwsit .fran Strew
Cnariotte. North Carolina
20202-5001
%WNW,
704 338.6760

TO:
FROM: Kevin Mosteller, PE
DATE: May 1, 2001
LQ ItyLmi-4;:a
f'1tKL—C'1—O
CMUD Design Review Project Team
NC DENR — ATC Review fir•
H p- f a 9 600 HDR Engineering, Inc.
of the Carolinas
Sicli41) 131MEMORANDUM
141AN
SUBJECT: Design Memorandum
McAlpine Creek Wastewater Management Facility
Primary Treatment Improvements and Effluent Filter Rehabilitation
HDR Project No. 00121-500-018
INTRODUCTION
The McAlpine Creek Wastewater Management Facility (WWMF) is owned and operated by
Charlotte -Mecklenburg Utilities (CMUD). The plant has a current rated maximum month
capacity of 64 million gallons per day (MGD) and provides tertiary treatment. Plant unit
processes include screening and grit removal, primary clarifiers, activated sludge aeration
basins, secondary clarifiers, effluent filters, sodium hypochlorite disinfection, and sodium
bisulfite dechlorination. The plant has equalization storage for wet weather and diumal
peak storage, anaerobic digesters for solids treatment, and high -solids centrifuges for
dewatering plant residuals. After screening and grit removal, the flow is split into two
parallel trains, referred to as the North and the South Plants, for primary and secondary
treatment. Flow from each train is combined prior to filtration. The rated capacity of each
train is shown in Table 1.
Table 1: Capacities of Individual Trains at the McAlpine Creek WWMF
r lr _Tajo ;: 1
'gnu a { ` r b 0
r'i Pam 11" C }
North Plant
32
45
South Plant
32
64
TOTAL
64
109
HDR Engineering, Inc. of the Carolinas (HDR) has been contracted by CMUD to design
improvements at the plant to increase treatment reliability. Upgrades will take place in four
separate design packages:
Package No. 1: Primary Treatment Improvements and Effluent Filter Rehabilitation
Package No. 2: Biosolids Management Improvements
Package No. 3: RAS/WAS and W3/W1 Improvements
Package No. 4: Primary Clarifier Rehabilitation.
The purpose of this memo is to summarize the improvements that are included in Package
No. 1: Primary Treatment Improvements and Effluent Filter Rehabilitation. Additions and
improvements that are part of this package include:

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1, 2001
Page 2
• Construction of two North Plant primary clarifiers and associated
station.
• Construction of one gravity thickener.
• Installation of a fifth pump in the North Plant Raw Sewage Pumping
• Replacement of Effluent Filter media and miscellaneous backwash
• Installation of additional screens and grit removal equipment at the
Facility.
• Construction of one odor control facility to serve the North Plant and
facility for the biosolids processing and storage area.
NORTH PLANT PRIMARY CLARIFIER ADDITIONS
sludge pumping
Station.
retrofits.
Screen and Grit
one odor control
Primary clarifiers remove readily settleable solids from the influent wastewater stream and
reduce solids loading to the activated sludge system. There are currently two 130-FT
diameter primary clarifiers in the North Plant. To achieve desired treatment at the plant's
rated capacity of 32 MGD, both of these clarifiers must be online. In order to increase
treatment reliability, two additional primary clarifiers will be constructed as part of this
project.
A summary of the design parameters of the existing and proposed new clarifiers is shown in
Table 2.
Table 2: Summary of Design Criteria for North Plant Primary Clarifiers
Parameter
Existing
New
Total
Number of Clarifiers
2
2
4
Diameter
130 FT
130 FT
130 FT
Sidewall Depth
8 FT — 0 IN
13 FT — 6 IN
-
Total Volume
1.59 MG
2.69 MG
4.27 MG
Surface Area per Clarifier
13,200 FT2
13,200 FT2
13,200 FT2
Total Surface Area
26,400 FT2
26,400 FTC
52,800 FT2
Firm Surface Areal
13,200 Fr
-
39,600 FT2
NOTES:
1 Assumes one clarifier out of service.
The new clarifiers are sized to provide more reliable primary treatment capacity in the North
Plant until 2010. By that time, it is expected that the total plant capacity will be increased to
80 MGD and that the North Plant capacity will increase to 48 MGD. With the proposed
additional clarifiers, firm overflow rates at maximum month flows will be within accepted
criteria. At an expected North Plant peak hydraulic flow of 64 MGD in 2010, peak overflow
rates will also be within accepted criteria for peak conditions. A summary of the resulting
operational parameters for all North Plant clarifiers under present and expected future flow
conditions is shown in Table 3.

Vic;lm 10AO
Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1, 2001
Page 3
Table 3. Operational Parameters - North Plant Primary Clarifiers (Existing + New)
Present and Future Flow Conditions (200
Flow (MGD)
Detention
Time (hr)
Firm
Detention
Time (hr)'
Overflow
Rate
(gpd/ft2)
Firm Overflow
Rate (gpdift2)'
Present Avg. Day
Flow = 24 MGD
4.3
2.9
450
600
Current Max.
Month Flow = 32
MGD
3.2
2.2
600
800
Current Peak
Hyd Flow = 45
MGD
2.3
1.6
850
1,100
Future Max
Month Flow = 48
MGD
2.1
1.5
900
1,200
Future Peak Flow
= 64 MGD
1.6
1.1
1,200
1,600
Notes:
1 Assumes one new clarifier out of service.
The new North Plant primary clarifiers will be located adjacent to the existing clarifiers and
across from the administration building at the plant. Flow to the clarifiers will be split equally
among all clarifiers by fixed weirs placed in existing Manhole No. 1. Effluent from the
primaries will be conveyed to the abandoned Trickling Filter Pump Station by new 48-IN and
64-IN lines. Effluent lines from the existing primary clarifiers will be relocated to allow for
future digester construction. Flow from the Trickling Filter Pump Station is combined with
Retum Activated Sludge (RAS) flow from the North Plant and flows by gravity to Aeration
Basins 1-9 and 26-28.
Primary sludge from the existing clarifiers is removed through telescoping valves and
conveyed by gravity to the gravity thickeners. Sludge from the new clarifiers will be handled
in one of two ways:
1. Dilute sludge will be removed by telescoping valves and conveyed by gravity to the
gravity thickeners.
2. Sludge will be thickened to 5% solids concentration in the new clarifiers and will be
pumped to the existing digesters.
Operators will be able to select the mode of sludge handling based on preference and on
operational conditions.

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1,2001
Page 4
New sludge overflow boxes will be constructed on each clarifier to allow for gravity
conveyance of dilute sludge to the gravity thickeners. Telescoping valves will be installed in
each box to allow operator control of sludge removal rates. When sludge is to be conveyed
by gravity to the thickeners, collected scum from the clarifiers will be removed by a surface
skimmer and then combined with the dilute sludge for thickening at the gravity thickeners.
To accommodate thickening of primary sludge in the new clarifiers, a new Primary Sludge
Pumping Station will be constructed between the two new clarifiers. The pump station will
include two sludge pumps and two scum pumps. The rated capacities and description of
the pump operation are shown in Table 4:
Table 4: Proposed North Plant Primary Sludge Pump Station Equipment
—`�� � a,3-: L.:: .�'
r7c""`' t'".. 7 � ►�Ia fs-:q �:I ,b
[ .' "��.'��'.]�a'� - .�"{"� r+'je �_ `�,'�td�YT ram:: y r�
il, MR ISKIII1�1�1GR .
� � ?., f w im.. - �, .
Lx .�+�x. #.L[_._ Ks..b.- d..�"L,
Number of Pumps & Type
2 — Progressing Cavity
2 — Progressing Cavity
Rated Capacity (Each)
200 GPM © 97 FT TDH
100 GPM CO 107 FT TDH
Operation
Variable Speed, Manual
Control (ON/OFF, Speed)
Constant speed, Float -switch
control
Under this mode of operation, sludge blankets will be developed in the clarifiers to thicken
the primary sludge to a target concentration of 5% solids. The thickened sludge will then be
pumped by progressing cavity pumps. Each clarifier will have a dedicated primary sludge
pump. Scum collected by the surface skimmers will be collected in overflow boxes adjacent
to the pump station. Dedicated scum pumps will then pump the primary sludge to the
digesters through a dedicated force main. Piping and valves will be provided to allow
pumping from either scum box. In addition, piping and valves will be provided to allow
pumping from either clarifier in the event of equipment downtime.
The clarifier mechanisms that were selected for use on the new primary clarifiers are spiral
scraper type. The geometry of spiral scrapers transports sludge to the central hopper area
faster than conventional plow type mechanisms. Based on CMUD preference, grease
lubricated, precision bearing type drives are specified for the additions.
In order to minimize odors released from the new primary clarifiers, odor control covers will
be constructed over the clarifier tanks. Low profile type aluminum covers with exterior
trusses will be used. Scum boxes and sludge wet wells will be covered with aluminum
checkerplate. The headspace between the covers and the water surface will be exhausted
at a rate of 6,600 cfm per clarifier, corresponding to an air exchange rate of six air changes
per hour. Foul air will be conveyed to a new odor control scrubber to be located near the
proposed primary clarifiers. The proposed odor control scrubber system will be discussed
in a later section.

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1, 2001
Page 5
GRAVITY THICKENER C;SOID 6_44:09
The McAlpine Creek WWMF currently has two gravity thickeners. The gravity thickeners
currently receive dilute primary sludge from the existing North Plant primary clarifiers and
primary sludge from the Sugar Creek WWTP. Normal influent sludge concentrations range
from 0.5 to 1.0% solids. Influent sludge is screened and then fed to the gravity thickeners.
Thickened sludge at a target concentration of 5% is pumped from the gravity thickeners to
the plant anaerobic digesters for further treatment.
In order to provide firm capacity for existing and future primary sludge flows, an additional
gravity thickener will be constructed. The new gravity thickener will be similar to the
existing, having a diameter of 45 feet and a sidewater depth of 14 feet. The expected future
operating parameters at the gravity thickener complex after the addition of the third gravity
thickener are shown in Table 5.
Table 5: Future Operating Conditions — Three Gravity Thickeners
Flow Rate
to North
Plant
(MGD)
Flow Rate to
Gravity
Thickeners1'2
(MGD)
Solids Loading Rate
Hydraulic
Loading Rate
(GPD/FT2)
(LB/Day/FT2)
Total
Firm
Total
Firm
Average
29
2.23
20
30
466
700
Max. Month
32
2.38
22
33
498
747
Notes:
1 Includes 500 GPM of primary sludge from the Sugar Creek WWTP.
2 Assumes all flow from new primaries goes to gravity thickeners.
Scum from the new gravity thickener will be collected in a box constructed common -wall
with the new thickener. A chopper pump will be used to convey the scum to the waste
activated sludge (WAS) pump station. At the WAS pump station, the scum will be
combined with waste activated sludge and then pumped to the digesters.
Similar to the new primary clarifiers, a low profile aluminum cover will be constructed over
the new gravity thickener for odor control. Foul air will be exhausted from the new gravity
thickener by a new centrifugal fan. Exhaust rates will provide six air exchanges per hour.
The foul air will be conveyed to the existing plant odor control scrubber for treatment.
No additions are being made to the gravity thickener pump station or to the existing influent
screening area. The two existing sludge pumps, each rated at 200 gpm, have sufficient
capacity for future conditions. Likewise, the existing screen and associated screenings
compactor are of sufficient size for future conditions.
Effluent from the gravity thickeners is currently conveyed by gravity to Aeration Basin Nos.
7-9. A gravity thickener effluent pump station was constructed previously for the purpose of
conveying the effluent to the Trickling Filter Recirculation Pump Station for combination with

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1, 2001
Page 6
the entire North Plant flow. Because of the addition of Sugar Creek sludge to the gravity
thickeners, the pump does not have sufficient capacity for current effluent flowrates. To
accommodate future flows, a new pump station is under consideration for addition to the
Package No. 2 design project.
NORTH PLANT RAW SEWAGE PUMPING STATION f
The North Plant Raw Sewage Pumping Station lifts a portion of the effluent from the
Screen and Grit facility (SGF) to the North Plant primary clarifiers through a 36-IN force
main. The remaining portion of the flow is handled by the South Plant. Currently, there
are four centrifugal pumps in the station with a total capacity of 50 MGD. The peak
hydraulic flow in the North Plant is 45 MGD. In order to provide firm capacity during
peak conditions, a fifth pump will be added to the station. The existing capacities of the
individual pumps and expected capacities after addition of the fifth pump are shown in
Table 6. The station was originally designed to accommodate a total of five pumps.
The proposed pump will be installed in the location of the last open slot in the station.
Therefore, no major structural or piping changes will be required. Since the pump
discharge is below the discharge header, a pump control butterfly valve will be installed
to prevent backflow through the pump. The control system for the valve will be similar
to those that have been constructed for the existing pumps.
Table 6. Proposed North Plant Raw Sewage Pumping Station Capacity
Pump
Existing
New
Drive
Rated
Capacity
HP
Drive
Peak
Capacity
Firm Capacity
HP
1
Constant
15 MGD
400
Constant
15.9 MGD
17.8 MGD
400
2
Constant
10 MGD
300
Constant
10.4 MGD
11.3 MGD
300
3
Constant
5 MGD
150
Constant
4.0 MGD
4.7 MGD
150
4
Variable
20 MGD
500
Variable
20.5 MGD
---
500
5
Variable
17.0 MGD
19.2 MGD
400
Station Capacity
50 MGD
67.8 MGD
53 MGD
EFFLUENT FILTERS
The McAlpine Creek WWMF currently has 10 effluent filters used for effluent polishing. The
filters are mono -media, declining rate filters. The system consists of a universal underdrain
system, approximately 12-IN gravel for support of the media, and 48-IN deep uniformly
graded sand. Each filter is 20 FT x 40 FT in plan area. Filters are backwashed based on
time of filter run with a combination of air, effluent and air, and then effluent only. Backwash
water exits the filters through a backwash trough. The trough empties into a backwash
equalization tank and is then pumped to the South Plant aeration basins.

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1,2001
Page 7
Over the last 10 years, operations staff has noted loss of media during backwash. In some
filters, it is suspected that as much as 50% of the sand has been lost. The modifications
proposed at the filter complex are intended to accomplish the following:
• Reduce media loss in the filters.
• Rehabilitate aging equipment.
• Enhance operator access to the filters.
• Improve reliability of effluent quality.
To reduce media loss, several improvements are proposed. First, the existing backwash
trough in Filter Nos. 1-8 will be replaced with a dual trough system. The dual trough system
will reduce the approach velocity of the backwash water, thereby reducing the potential for
sand carryover in the filters. Additionally, two 8-IN pneumatic butterfly valves will be added
to the backwash troughs in each filter. The purpose of the valves is to allow the water level
in the filters to be lowered below the elevation of the backwash weir prior to backwash.
Other modifications to the filters include the following:
• Replacement of gravel support and mono -media sand in each filter.
• Installation of a second backwash drain pump.
• Cleaning of the external drain lines.
• Replacement of the external drain valves for Filters 1, 3, 5, 7, and 9.
• Replacement of pneumatic actuators on existing valves.
• Installation of a stand-alone air compressor for local instrument air.
• Replacement of existing blower vent valve actuators with electric actuators.
• Installation of a new master control panel.
• Replacement of the filter console panels for Filters 1-8.
• Addition of variable frequency drives (VFDs) to the filter influent pumps.
SCREEN AND GRIT FACILITY ADDITIONS
The Screen and Grit Facility (SGF) handles influent flow to the plant. The facility consists of
bar screens for large solids removal, vortex grit removal units for removal of inorganic
solids, grit classifiers for washing and dewatering of removed grit, screening presses for the
dewatering of removed screenings, and enclosed dumpsters for collection of grit and
screenings.
The facility was designed to allow screening and grit removal for flow that would be sent to
the North and South treatment trains. In addition, the capability to screen and bypass
excess flow during wet weather periods was provided. Bypassed flow is sent to the plant's
equalization basins for storage and retumed to the plant during lower flow periods. Some of
the current equipment housed in the SGF and existing capacities are shown in Table 7.

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1,2001
Page 8
Table 7: Current Equipment and Capacities in SGF
kalqf,ynS mr-.v Ysar:i ,
� , «ww .w 4 . " 9
.yW' �7sr.
taat 5.ia7
To North and South Plants
Screening
2 - 30 MGD Mechanically Cleaned Bar Screens
1 — 50 MGD Mechanically Cleaned Bar Screen
110 MGD total / 60 MGD firm'
Grit Removal
2 — 30 MGD Vortex Grit Removal Basins
1 — 50 MGD Vortex Grit Removal Basin
110 MGD total / 60 MGD firm.'
To Flow Equalization
Screening
1 — 50 MGD Mechanically Cleaned Bar Screen
50 MGD total
1 Firm capacity assumes largest unit out of service.
The SGF was designed to allow expansion for both treatment and bypass trains by
installation of additional equipment in existing channels. In order to increase the capacity of
the SGF to handle flows more reliably, an additional 50-MGD screen and 50-MGD vortex
grit removal unit will be added to the facility in the channels carrying flow to the North and
South plant. Further, a second 50-MGD bar screen will be added to the bypass channels at
the facility. The proposed additions and resulting facility capacities are shown in Table 8.
Table 8: Proposed Equipment Additions and Resulting Capacities in the SGF
it' OW -
To North and South Plants
Screening
1 — 50 MGD Mechanically Cleaned Bar Screen
160 MGD Total / 110 MGD Firm.'
Grit Removal
1 — 50 MGD Vortex Grit Removal Unit
160 MGD Total / 110 MGD Firm.'
To Flow Equalization
Screening
1 — 50 MGD Mechanically Cleaned Bar Screen
100 MGD Total / 50 MGD Firm.'
1 Firm capacity assumes largest unit out of service.
An additional grit pump will be added at the facility to accommodate the additional vortex grit
removal unit.
ODOR CONTROL FACILITIES
There are currently two odor control facilities at the McAlpine Creek plant. One is located
near the SGF. The other is located at the Residuals Management Facility (RMF). The SGF
odor control system currently treats odorous air exhausted from the following locations at
the plant:

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1,2001
Page 9
• Screening and Grit Facility.
• North Plant Primary Clarifiers (#1 and #2).
• Gravity Thickeners.
• North Plant Raw Sewage Pumping Station Wetwell.
• Influent Junction Box.
• RAS/WAS #3 Wetwell.
• Flow Equalization Return Weir Box.
• South Plant Primary Clarifiers (#3 - #6).
The RMF scrubber currently handles air exhausted from the biosolids storage hoppers and
the thickening/dewatering building centrate line.
The existing odor control scrubber at the SGF does not have additional airflow capacity to
accommodate the new unit processes that are proposed on the project. Additionally,
CMUD would like the option of rerouting the foul air currently collected from the
Thickening/Dewatering Building and the Sludge Silos since monthly fees must be paid to
the contract operator of the RMF. Therefore, two additional odor control facilities are
proposed.
A new 28,000-scfm two -stage packed tower chemical scrubber is proposed to handle
airflow from the North Plant primary clarifiers (new + existing) and nearby process units, if
necessary. The removal of the existing clarifiers from the odor control scrubber system at
the SGF will allow for the tie-in of the proposed third gravity thickener to the SGF system. A
summary of the airflow rates expected for the new scrubber is shown in Table 8.
Table 8: New North Plant Two -Stage Odor Control System - Air Source Contributions
Source
Expected Air
Flowrates
Resulting Air
Changes per Hour
North Plant Primary Clarifier Nos. 1 and 2
6,600 scfm per clarifier
6
North Plant Primary Clarifiers Nos. 7 and 8
6,600 scfm per clarifier
6
North Plant Digesters (if necessary)
400 scfm
To be determined
Reserve Capacity
1,200 scfm
N/A
The second proposed odor control facility is an 8,000-scfm three -stage packed tower
chemical scrubber to handle airflow from the Sludge Silos and Thickening/Dewatering
Complex centrifuge unit fans. A summary of the airflow rates expected from the process
units to be tied to the new scrubber is shown in Table 9.

Primary Treatment Improvements and Effluent Filter Rehabilitation
May 1,2001
Page 10
Table 9: New Three -Stage Odor Control System Air Source Contributions
Source
Expected Flow Rate
North Plant Sludge Silos
5,600 scfm
North Plant Centrifuge Unit Fans
2,000 scfm
Reserve Capacity
400 scfm
ELECTRICAL AND CONTROLS
Electrical and controls will be included for all of the improvements listed above.

Apr-12-01 08:09
From-HDR Engineering
T-564 P.02/02 F-038
Apnl 12, 200I
Ms. Christie Jackson
North Carolina Department of Environment an
Wetter Quality Division
512 North Salisbury Street
Raleigh, North Carolina 27611-7887
esources
Re: Charlotte -Mecklenburg Utilities, Charlotte, NC
McAlpine Creek Wastewater Management Facility
Primary Treatment Improvements and ]affluent Filter Rehabilitation
HDR Project No. 0121-500-018 (File MCFR-6)
> *6--Q:
Dear Ms. Jackson: fit'
Evros O r> C
As mentioned during our telephone conversation on Wednesday, April 11, 2001,HDR Engineering, Inc
of the Carolinas (HDR), on behalf of Charlotte -Mecklenburg Utilities (CMUD), soon will be submitting
the project referenced above for an Authorization -to -Construct permit review. We would appreciate it if
you would review the scope of the project below and start the process of assigning a reviewer to the
project. We would like to set up a meeting with the reviewer (aridlor others as necessary) to present the
design documents and discus:, any preliminary concerns or issues. We would be open to having the
meeting at your office or we could host the reviewer here for a plant tour and discussion of the proposed
improvements. As we discussed briefly, the scope of the project is as follows-
McAI Treatment Primary Tt Im rovemN
ine Creek WWMF , rr nts and Effluent Filter Rehabilitation
P
1. Twu new Primary Clantiers, 130-1 ' DLL, 13 FT-6 IN SWA
2. New Primary Clarifier Pumping Station w/ 2 primary sludge pumps (200 GPM @ I25 FT) and 2 scum pumps
(100 GPM @ 104T)
3. One new Gravity Thickener, 45 FT DIA, 14 FT SWD
4. Modifications to existing Raw Sewage Pumping Station (Adduion of one new 17 MGD. 400 HP pump)
5. Effluent Filter Rehabilitation (Rrplacem,,nt of media and construction of new nackwash effluent troughs)
6. Modifications to Screen and Grit Facility (Addition of 2 mechanically cleaned bar screens, 1 vortex grit
removal unit, ;ind 1 get pump)
7. One new two -stage wet scrubber odor Control Facility
6 Onc new three -stet a wet scrubber Odor Control Facility
The plant is currently rated for a maximum month capacity of 64 million gallons per day (MGD). The
project described above is designed to increase the treatment reliability of the plant, but not increase the
rated capacity_
If you need additional information or have any questions, plea.se call me at [phone]. In any case,1
would appreciate a phone call from you or the assigned reviewer so that we can schedule a meeting to
submit this project. Thank you for your help on this project and we look forward to working with you on
This and future projects.
Best regards,
HDR Engineering, Inc_ of the Carolinas r
AO
Scott M. Alpert, PE
Project Engineer
MDR Engineering, Inc.
of the Carolinas
Empioyee Owned
128 S Tryon Street Telephone
Suite 1400 704 338-6700
Charlotte, North Carolina Fax
26202-5001 704 338-6760

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