NC0084573_Renewal (Application)_20140922

Alm
NCDENR
North Carolina Department of Environment and Natural Resources
Pat McCrory John E. Skvarla, III
Governor Secretary
September 29, 2014
Mr. Chris Henderson, Senior Utility Engineer
City of Lincoln
115 West Main Street, 2 °a Fl.
Lincolnton, NC 28092
Subject: Acknowledgement of Permit Renewal
Permit NCO084573
Lincoln County
Dear Mr. Henderson:
The NPDES Unit received your permit renewal application on September 22, 2014. A member of the
NPDES Unit will review your application. They will contact you if additional information is required to
complete your permit renewal. You should expect to receive a draft permit approximately 30 -45 days
before your existing permit expires.
If you have any additional questions concerning renewal of the subject permit, please contact Bob
Sledge (919) 807 -6398.
Sincerely,
�/�J�Q,vv T�n,20�DYDL
Wren Thedford
Wastewater Branch
cc: Central Files
Mooresville Regional Office
NPDES Unit
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.ncwater.orq
An Equal Opportunity�Afflrmative Action Employer

O CO
yo COUNTY OF LINCOLN, NORTH CAROLINA
C A R 1 1 5 WEST MAIN STREET, 2ND FLOOR CITIZENS CENTER, LINCOLNTON, NORTH CAROLINA 28092
DEPARTMENT OF PUBLIC WORKS
PHONE [phone]
FAX [phone]
W W W. LI NCOLNCOUNTY.ORG
Mr. Bob Sledge
NC DENR/DWR/NPDES Unit
1617 Mail Service Center RECEIVED /DENR/DWR
Raleigh, NC 27699 -1617
September 10, 2014
sEP 2 2 2014
Water Quality
Re: NPDES Permit NCO084573 Renewal Request Permitting Section
Dear Mr. Sledge,
I am writing this letter to you to formally request the renewal of our WTP NPDES Permit,
NC0084573. You should find the permit application filled out completely with all pertinent
information and diagrams requested. Since our last NPDES permit renewal, a new Huber
Screw Press has been installed to process the Alum Sludge. The Operator in Responsible
Charge is Mr. Adam Jolicoeur and his contact information is:
Adam Jolicoeur
7674 Tree Farm Road
Denver, NC 28037
(704) 483 —7070 Office
(704) 483 —7072 Fax
[e-mail]
If you have any further questions, please feel free to contact me at your convenience.
Sincerely,,
Chris Henderson
Senior Utility Engineer
[e-mail]

9
NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699 -1617
NPDES Permit Number NC0084573
If you are completing this form in computer use the TAB key or the up - down arrows to move from one
field to the next. To check the boxes, click your mouse on top of the box. Otherwise, please print or type.
1. Contact Information:
Owner Name
Facility Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
e -mail Address
Lincoln County
Lincoln County WTP
115 West Main Street
Lincolnton
NC 28092
(704)736 -8497 RECEIVEDI \NR
(704)736 -8499 SEP 2 2 20
dchambleeClincolncounty.org Water (�
.� n
2. Location of facility producing discharge:
Check here if same as above ❑
Street Address or State Road
City
State / Zip Code
County
7674 Tree Farm Lane
Denver
NC 28037
Lincoln
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name Lincoln County
Mailing Address 115 West Main Street
City Lincolnton
State / Zip Code NC 28092
Telephone Number (704)736 -8497
Fax Number (704)736 -8499
4. Ownership Status:
Federal ❑ State ❑ Private ❑ Public
Page] of 3 Version 5/2012

NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
5. Type of treatment plant:
® Conventional (Includes coagulation, flocculation, and sedimentation, usually followed by
filtration and disinfection)
❑ Ion Exchange (Sodium Cycle Cationic ion exchange)
❑ Green Sand Filter (No sodium recharge)
❑ Membrane Technology (RO, nanofiltration)
Check here if the treatment process also uses a water softener ❑
6. Description of source water(s) (i.e. groundwater, surface water)
Surface Water
7. Describe the treatment process(es) for the raw water:
Conventional Treatment. The raw water is taken from Lake Norman and injected with alum
and sodium hypochlorite (Minx). It then passes through the flocculators, across
sedimentation basins. Then it's filtered through multi -media filters. Prior to the filters,
sodium hypochlorite (Miox) is injected. The finished water is injected with sodium
hypochlorite (Miox), sodium hydroxide, fluoride, and orthophosphate.
8. Describe the wastewater and the treatment process(es) for wastewater generated by the
facility:
The backwash water and sludge from the sedimentation basins are sent to the thickeners.
The solids are settled out; the supernate is discharged to the lake. From the thickeners,
the sludge is mixed with polymer, and then it's processed through the Huber screw press.
The dried cake is transferred by conveyor to a dumpster, once full; it is sent to the
Lincoln County Landfill for fill dirt.
9. Number of separate discharge points: 1
Outfall Identification number(s) 1
10. Frequency of discharge: Continuous ❑ Intermittent
If intermittent:
Days per week discharge occurs: Daily Duration: 2 hours
11. Plant design potable flowrate 3.99 MGD
Backwash or reject flow 0.06 MGD
12. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Little Creek Cove- Lake Norman /Catawba
13. Please list all water treatment additives, including cleaning chemicals or disinfection
treatments that have the potential to be discharged.
Alum / aluminum sulfate Yes X No
Page 2 of 3 Version 5/2012

NPDES PERMIT APPLICATION - SHORT FORM C - WTP
For discharges associated with water treatment plants
Iron sulfate / ferrous sulfate Yes No X
Fluoride Yes X No
Ammonia nitrogen / Chloramines Yes No X
Zinc- orthophosphate or sweetwater CP1236 Yes No X
List any other additives below:
Orthophosphate, Sodium Hypochlorite, Sodium Hydroxide, Sodium Thiosulphate
14. Is this facility located on Indian country? (check one)
Yes ❑ No
15. Additional Information:
Provide a schematic of flow through the facility, include flow volumes at all points in
the water treatment process. The plan should show the point(s) of addition for
chemicals and all discharges routed to an outfall [including stormwater].
Solids Handling Plan
16. NEW Applicants
Information needed in addition to items 1 -15:
New applicants are highly encouraged to contact a permit coordinator with the
NCDENR Customer Service Center.
Was the Customer Service Center contacted? ❑ Yes ❑ No
Analyses of source water collected
Engineering Alternative Analysis
Discharges from Ion Exchange and Reverse Osmosis plants shall be evaluated using a
water quality model.
17. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Q 1 L. L L Ann T. Sp.Cj�<Sc;, ,_1 . CA V �i�1 (VI A►J pcC -�
Printed name of Person Signing Title
Signature of Applicant Date
North Carolina General Statute 143 -215.6 (b)(2) provides that: Any person who knowingly makes any false statement representation, or certification in any application,
record, report, plan, or other document files or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that
Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or monitoring device or method required to be operated or maintained under Article 21
or regulations of the Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $25,000, or by
imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5
years, or both, for a similar offense.)
Page 3 of 3 Version 5/2012

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Latitude: 35 -31 -45 NC0084573 N
Longitude: 80 -59 -33
Quad # E15SW
Receiving Stream: Lake Norman Lincoln County V TP
Stream Class: WS -IV & B CA
Subbasin: 30832
SCALE 1:24,000
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WTP LOCATION
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PRE -MIOX
ALUM
PRE - CAUSTIC
PRE - FILTER MIOX
ORTHOPHOSPHATE
FLOURIDE
CAUSTIC
POST MIOX
LINCOLN COUNTY WATER TREATMENT PLANT
PROCESS FLOW SCHEMATIC DIAGRAM
LAKE NORMAN
WATER INTAKE &
PUMP STATION
3.9 MGD
RAPID MIX
FLOCCULATION
SEDIMENTATION BASINS
500,000 gallons
FILTRATION
4 Filters
Clearwells
1 (:i)
Million Gallon
HIGH SERVICE PUMPS
(2) H.S. Pump 3 mgd
I
TO LINCOLN COUNTY
WATER DISTRIBUTON SYSTEM
WASTE (Alum Sludge)
SOLIDS
FILTER
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THICKENERS
189,0000 189,0000
Gallons Gallons
SOLIDS DEWATERING
HUBER SCREW PRESS
LANDFILL OR LAND APPLICATION
DISPOSAL
NPDES Permit No. NCO084573
Sodium Thiosulphate
DISCHARGE TO LAKE
(Average flow 59,000 GPD)
Department of Public Works
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Water Treatment

LINCOLN COUNTY
WATER TREATMENT PLANT
RESIDUALS MANAGEMENT PLAN
June 2012
'?ECEIVEDM[
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Wafer k,
perminino
Prepared by
GOODWYN, MILLS AND CAWOOD, INC.
2660 EastC6se Lane, Suite 200
Montgomery, Alabama 36117
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1.11 FIS RA':U Ii IS, I P I Irlt% PROVIN SOL VI 10 -45

TREATMENT MODIFICATIONS
The intent of the design of the proposed improvements is to comply with all requirements of DENR - Public Water
Supply Section 15Ar 18C.0300 - 18C.0700. The improvements do not modify the direct flow of the water through the
process, and will continue to follow the conventional surface water filtration process. The notable improvements to the
sludge handling facility are modifications to the gravity thickeners, new polymer feed system, installation of progressive
cavity pumps with smart stator technology followed by an energy - efficient screw press, and conveyors to transfer
dewatered solids to a dumpster or open bed truck. All filtrate and process wastewater is returned to the existing yard
drain pump station to be treated through the solids handling process. All decant from the gravity thickeners exits
through the floating decant arms and flow is hydraulically controlled by electrically actuated valves. Prior to final
discharge, all decant is dechlorinated with a dechlorinating agent to comply with current chlorine residual concentrations
per the existing NDPES permit.
Gravity Thickeners
The existing gravity thickeners are being retrofitted with a center column cage with two steel rake arms driven by a
continuous torque standard shaft # HP drive. The rake arms will have adjustable 304 stainless steel squeegees to
scrape the bottom of the tank. The existing tanks will 6e grouted to submerge the 8" withdrawal line and provide a
sump for sludge removal. The gravity thickeners will also receive floating decanters which consist of an 8" diameter
schedule 40, 304 stainless steel pipe with twenty (20) 2" diameter orifices with foam core floats attached to the
decant pipe. The decant pipe will float with the water level and primarily controlled by the electrically actuated valve.
The low water and high water level in the gravity thickener shall be 799.22' and 812.60, respectively, providing 1' of
free board in each thickener.
Progress ive_Cavity Pumps
A sludge handling building will be constructed to house the dewatering feed pumps, dewatering mechanism and
conveyance system. As sludge exits the gravity thickeners, sludge can either enter the existing dewatering system
for redundancy or enter the new dewatering system 6y simply operating two manual valves outside the existing
sludge dewatering building. Sludge will enter the new sludge handling building into a header reducing down to 3"
prior to entering the feed pumps. The design will utilize progressive cavity pumps to pump the settled sludge from
the thickeners to a screw press. The progressive cavity pumps are designed to pump 6 to 20 GPM at a solids
content of 0.8 to 1.2% with a 3 HP motor.
Screw Press and Conveyance System
The screw press was piloted and studied extensively on -site at the Lincoln County Water Treatment Plant using
alum sludge from the current process in place for treated potable water. During the pilot, the feed solid
concentration to the screw press ranged from 0.8 to 1.2 %. It was determined that at a flow rate of 4 GPM, the
screw handled 20 pounds per hour of dry solids. The cake produced was 24.6% dry solids. The maximum
throughput of the screw press is 45 pounds per dry solids at 8 GPM; however, the cake produced was only 20% dry

solids. The screw press will be rated to handling 40 to 90 pounds per hour of dry solids at 8 to 16 GPM producing
20 to 25% dry solids. After the dewatering process, cake solids will be conveyed through a series of four (4) shafted
screw conveyors to lift the solids to be discharged into a dumpster in a cover bay.
Chemical Feed System
Prior to sludge entering the screw press, polymer is introduced to assist with dewatering. Neat polymer will be
dosed into an aging tank with a peristaltic pump. A 500- gallon aging tank will 6e utilized to create batches of dilute
polymer. The chemical feed system is outfitted with a mixer to provide a complete mix system as well as a site glass
to monitor consistency of dilute polymer make up. Dilute polymer will then be fed to the screw press with a
duty /standy -6y progressive cavity pump solely used for dilute polymer. The polymer will be injected downstream of
the sludge feed polymer pumps and prior to a 2 *' check valve designed specifically for mixing. A detention time of
45 seconds has been provided between the point of polymer injection and the screw press inlet so that the polymer
can activate and optimally assist in dewatering.
CONCLUSION
All aforementioned equipment was installed to improve the current process of dewatering solids. The existing gravity
thickeners did not have a mechanical thickening mechanism; therefore, with this addition, it can be assumed that the feed
solids from the thickeners will be greater than the range observed in the pilot. Furthermore, the decanting arm will assist
in assuring that a quality clarified supernate in the thickener is decanted. Previously, the peripheral decant lines were
fixed withdrawing at a fixed elevation with no indication to the location of the sludge blanket. The progressive cavity and
screw press tandem was selected due to the performance displayed in the pilot, efficiency and reliable operation as well
as ease of operation and maintenance. A shafted conveyor was selected to lift solids because of the simplicity of the
conveyors. The designed system provides redundancy as well as flexibility. All unit operations have a minimum of two
installations or the ability to be expanded to two installations. The sludge handling facility will be expandable and can
receive two additional progressive cavity pumps and screw presses as the need for solids handling increases. For the
interim, the existing sludge handling system will be left in full working order if back up is needed.
The proposed system was designed to meet the clients need with regard to redundancy, capacity, efficiency and
reliability for current and future demands. With this proposed system, the Lincoln County Public Works Lincoln
County Water Treatment Plant will 6e able to produce the desired 3.999 MGD with a method for sludge dewatering
to handle the volume of sludge being produced by the sedimentation and filtration processes.
Also, the existing vacuum drying bed will remain intact for redundancy of sludge removal. The existing quick disconnect
from the sludge thickeners will also remain in place. Thus, the operator can utilize the drying bed as necessary or may
haul wet sludge. The design will allow for a system where the operator has three (3) options of processing sludge.

Sludge Handling System
Lincoln County Water Treatment Plant Recommended Operations Protocol
1.0 OBJECTIVE
The intent of the sludge handling operations at the Lincoln County Water Treatment Plant is to
provide solids handling of alum sludge in an efficient manner. In addition, the sludge handling
system protocol shall provide the operations staff methods and recommended procedures to
properly and efficiently operate the system described herein.
2.0 SCOPE
The sludge handling system provided is a combination of unit operations including two solids
thickeners, one positive displacement feed pump, a polymer system, and one dewatering press,.
The previous method of dewatering was a vacuum drying bed; however the County determined
that it was critical that the process no longer be weather dependent. The new sludge handling
system provides a process that requires minimal power and delivers processed solids at a percent
solids concentration acceptable for delivery to the local landfill. The sludge must meet the
requirements of the landfill and pass the paint filter liquids test. Additional optimization of the
solids handling system shall be as determined to be sensible by the operator.
3.0 SYSTEM DESCRIPTION
The equipment basis of design for the sludge handling system consists of the following unit
operations:
1. Thickeners ( Westech)
a. The thickeners allow the operator to improve the consistency and solids content of
the sludge prior to conveyance to the dewatering process
2. Progressive Cavity Pump ( Seepex)
a. The progressive cavity pump provides the required positive displacement,
metered flow pattern required for sludge processing
3. Polymer Feed System ( Acrison)
a. The polymer system is a batch makeup system that is controlled locally by level
b. The Huber programmable logic control (PLC) provides a signal for startup and for
the feed pumps to deliver the necessary polymer dose to the sludge
4. Screw Press (Huber)
a. The screw press dewaters the sludge to a cake product
5. Conveyance (Custom Conveyors)
a. The conveyors transport dewatered cake to an owner selected dewatering bin
The Westech thickeners, Seepex feed pump, Acrison polymer system, Huber screw press, and
Huber conveyors work together to provide a complete process.
4.0 OPERATION
2

Sludge Handling System
Lincoln County Water Treatment Plant Recommended Operations Protocol
4.1 Thickeners
The sludge thickener mechanisms and their operation are critical in the success of the solids
dewatering process. The thickeners are fit with mechanical thickening devices at the bottom of
the conical tanks. The bottom of the conical tanks, where the 8 inch diameter effluent sludge
pipe is located, is at approximate elevation of 780 feet. The grade elevation at the tanks is
approximately 798 feet, thus the depth at which sludge can accumulate is upward of 18 vertical
feet. In addition, the decant mechanism for the water allows for the decanting of the tank to a
low water level (LWL) of near elevation 799. The top of wall of the sludge thickeners is near
814.8 allowing for over 13 feet of wastewater from the water treatment plant to accumulate from
the backwashing of filters and the removal of solids in the sedimentation process.
The operation of the sludge thickeners is critical to the dewatering process. The operator
controls the thickness of the solids with the rotating thickener and the available pressure (head)
in the tanks. The water level in the tank feeding the sludge dewatering process provides
backpressure on the sludge feed pumps. The 8 inch diameter sludge feed line operated at flow
rates between 8 and 20 gallons per minute provides little frictional headless in the pipe due to
velocity. The velocity of the sludge in the 8 inch pipe at 20 gallons per minute is near 0.13 feet
per second. However, the thixotropic properties of the sludge may create difficulties when
starting the dewatering process, specifically when it has not been operational for periods greater
than 12 hours.
4.2 Progressive Cavity Pump and Polymer System
The sludge feed pump suction is located at approximate elevation of 801.5 feet. Thus, the
operator shall, at a minimum, allow for the pumps to have a flooded suction. For operation of
the dewatering system, the tank from which the operator elects to process solids should have a
water level sufficient to overcome the head loss, which is minimal due to the low velocity in the
8 inch pipe, and the viscous /thixotropic properties of the sludge._ The pressure of the tanks
should read on the pressure gauge on the suction side of the pump to indicate to the operator that
sufficient head is present for beginning the dewatering process. It is recommended that the tank
water level be at a minimum elevation of 805 feet for the startup of the dewatering system.
Continuous use by the operator and logging of startup data should allow the operator to increase
or decrease this water level for startup dependent upon the comfort level with the sludge
consistency and backpressure on the pump.
Upon process initiation, the sludge (plug) valve from the thickener which is to be utilized for
sludge dewatering shall be opened. The operator shall fluidize the influent sludge line by turning
on the water connection at the suction of the pump. The water will provide lubrication of the pipe
for improved sludge conveyance.
3

Sludge Handling System
Lincoln County Water Treatment Plant Recommended Operations Protocol
The pressure gauge on the suction side of the pump shall be utilized to determine when sufficient
head pressure has built up behind the pump for startup. The operator may replace the existing
pressure gauge with a combination vacuum gauge to insure that a vacuum has not been created,
thereby protecting the progressive cavity pumps from running dry. The operator may elect to
wait until adequate sludge consistency is being conveyed to the screw press before initiating
polymer system injection.
Reducing the polymer injection prior to the sludge becoming consistency may waste costly
polymer. Once the sludge is actively being conveyed in the piping system, the polymer injection
can be initiated. All water and inconsistent sludge content prior to polymer injection and the
dewatering of the sludge shall flow as designed to the yard drain pump station that recycles the
contents to the thickener.
Additional flushing quick connections near the thickener on the conveyance piping are
recommended should plugging of the line become frequent during shut down periods. Existing
connections to the 8 inch pipe make this connection easily constructed and the conveyance line
cleared with the water pressure of the line. The thickener level must be elevated to force the
water pressure to move and lubricated around the sludge travelling toward the pump, in lieu of
simply filling the tank where the pressure may be lower.
4.3 Screw Press and Conveyance
After initiation of the process and confirmation of active sludge movement with consistency, the
process may then be operated and controlled by the Huber controller. The controller is designed
to operate the polymer system, dewatering system and dried -solids conveyance system.
5.0 SYSTEM TERMINATION
Process termination is another critical component of the operations. Due to the known properties
of water treatment sludge, issues may develop in the feed piping that cause difficulties during the
subsequent startup. Operators shall fluidize the sludge feed line, and process sludge to the drain
through the screw press._ The wasted water and sludge will then be recycled back to the
thickener through the yard drain pump station. The feed line pressure gauge shall be monitored
and the pressure supplied by the water should increase the pressure in the line to indicate good
fluidization.
6.0 TESTING AND REPORTING
It is recommended that multiple data entries be logged with each startup. These factors will aid
in the optimization of the process not only by present operators but by future operations staff.
The entries should include, but not be limited to:
1. Thickener utilized for dewatering process (1 or 2);
4

■ 4�
Sludge Handling System
Lincoln County Water Treatment Plant Recommended Operations Protocol
2. Water elevation in thickener at startup;
3. Time between shutdown and startup;
4. Percent solids influent;
5. Polymer usage;
6. Average sludge flow rate;
7. Percent solids processed;
8. Process run time;
9. Faults encountered during processing;
10. Total sludge volume processed;
11. Thickener run times; and
12. Sludge line pressure.
Data logging, whether in the PLC or in tabular form, allows operators to constructively
troubleshoot. Process optimization is made more efficient, and quality information becomes
readily accessible to management purposes.- Many other data points should also be evaluated
and the operator should use good judgment in determining the necessary additional points to
monitor.
The operator shall utilize the data log to make decisions on the run times for the thickener
mechanisms._ It is likely that the thickener should not be run at all times, as the thickening of the
alum sludge when not processing solids may create a consistency that is difficult to convey and
process. -In addition, the solids may be forced into the lower elevations of the pipe between the
thickener and the feed pump and become consolidated creating problems for the subsequent
startup. Other actions that aids in the clearing of this sludge line are the flushing of the line prior
to process termination and utilizing the available head pressure in the tanks to feed the pumps.
Modifications to the sludge handling process operations protocol shall be made as data becomes
available for analysis. Improved comprehension of the specific installation through the data
collected shall provide improved operations.
7.0 SUMMARY
The sludge handling system shall be operated to meet the requirement for delivery of the
dewatered product to the local landfill. The operations staff must be cognizant of the
aforementioned items to provide a system that functions properly and efficiently as designed.
Data shall be recorded and tracked so that changes can be made to the sludge handling system. It
is recommended that process changes be made immediately when the sludge handling system is
not operating as intended. These changes shall be at the discretion of the operator responsible
for the system at that time. Efficient sludge handling operations at the Lincoln County Water
Treatment Plant is an integral process to the overall treatment process and shall be operated with
the recommendations provided, data collected and experience gained while the sludge handling
system is in operation.
5