WQCSD0287_CSD Repair/Retrofit from Spring ARPA Funding 2022_20221006

Cliffside Sanitary District Repair/Retrofit from
Spring funding cycle of 2022
Cliffside Sanitary District (CSD) wastewater acceptance and treatment are provided to 88
customers in the region includin 85 residential/commercial users (rate codes 301, 302, and
303), 1 industrial user (rate code 304), and 2 institutional users (rate codes 305 and 306).
On average the daily usage is 0.018 MGD, and the average annual usage is 6.74 million
gallons (MG). Flows coming into the CSD WWTP spike to over 0.09 MGD (50 times the flow)
due to excessive infiltration and inflow (I&I). Water service is no longer provided by CSD
and now comes through Broad River Authority.
Per the US Census Bureau data updated in 2020, the Cliffside community has a total
population of 530 with a median household income (MHI) of $54,792, while Rutherford
County has MHI of $42,608. In 2010, the Census population was 611, a loss of 81
residents. The current employment rate is 33% with a total of 234 housing units.
Approximately 30% of homes in the area are on central sewer while the remainder of
homes are on septic systems (onsite wastewater treatment systems).
The Cliffside WWTP was designed in 1971 by Alley, Williams, Carmen, & King, Inc.
Engineers, and Architects and was built in 1973 to primarily serve Cone Mills and the
residents who lived and worked in the area. The WWTP is located at the intersection of
Boiling Springs Road and Cliffside Street (35.2388 Latitude, -81.7653 Longitude) along the
Second Broad River. The original design capacity and permit was able to treat 1.75 MGD.
Cone Mills closed in 2003 and ended up filing for bankruptcy in 2005. After Cone Mills
closed, the area began to see a decline in tax base and revenue for CSD. It was taken over
by LGC in 2019 and declared a distressed utility in 2020.
The purpose of this project is to retrofit, repair, add, remove, replace, and/or rehabilitate
the Cliffside Sanitary District sanitary sewer system (gravity lines and manholes), pump
stations, and upfit the wastewater treatment plant as identified in the AIA report completed
in March 2022 by Tetra Tech. These revisions and repairs to the system will not exceed the
current approved permitted capacity of the Cliffside Sanitary District. Each project will be
size-like replacements, retrofits, or repairs and will not increase the capacity at the
wastewater treatment plant.
Sanitary Sewer System: Clean, repair, and/or replace 38 existing aging sanitary sewer
manholes that are failing and have increased flow due to inflow and infiltration (I&I) from
groundwater and stormwater increases into the sanitary sewer system. Bypass former Cone
Mill Sanitary Sewer loop with direct connection between manholes with 600 LF of new 8”
gravity sanitary sewer line and 2-manhole. This bypass will additionally reduce I&I and
long-term maintenance costs. CCTV and as builts for entire system. I would increase the
number of manholes to clean and repair to 50, there are 155 active manholes;
would also add service laterals to this , as a lot of the I & I comes from.
Bridge Lift Station: Retrofit, repair, and/or replace Bridge Lift Station pumps 1 & 2,
motors 1 & 2, replace/relocate generator away from failing stream bank, and stabilize
approximately 150 LF of stream bank at aerial crossing at lift station at unnamed tributary
to Second Broad River. Install lift station level controller, alarm autodialer, and cooling for
the electrical equipment (HVAC unit). Am currently in process of rebuilding both 1 & 2
pumps, and checking motor maintenance. Plan to rebuild motor that was replace
in 2021, and keep for spare for pump station. Have replace window A/C unit, and
plan to add portable heat for winter months and replace exhaust fan. Would like
to add a ‘Channel Monster FLEX’ to existing headworks, and get a 2 nd opinion for
streambank stabilization. Also, have already installed ‘Mission’ cellular raido
dialers.
Haynes Lift Station: Replace pumps and motors 1, 2, and 3 check valve spring loaded
4x6, install 6” gate valves, install emergency generator fuel tank and supply and return
piping, replace equalizer pond aerator and tether system, clean out pond, install alarm
autodialer, and building repairs. Have started new maintenance program, and have
checked motors out. Have added a ‘Mission’ cellular radion for alarm notification,
and repaired existing fuel tank. Would add supplemental fuel tank for fuel
supplier. Have removed EQ pond aerators, would like to install modified diffused
aeration system to pond with retrievable diffuser’s. Also working on generator to
crank and would install supplemantal fuel tank to work with existing fuel tank.

Wastewater Treatment Plant Repairs: Replace for main MCC Electrical Panel and RAS
building at 600V, reconnect main backflow preventer, add alarm autodialer, service air
compressor, install plant influent flowmeter, repair/replace influent grit chamber slide gates,
replace grit chamber mixer, replace autosampler unit and enclosure, Structural – replace
lighting, roof, and doors to RAS building, structural repairs to grounds (outfall steps,
railings), administration building repairs, demolish or remove unused equipment or
structures. Am working on replacing main breaker in existing MCC, along with
digital A-C amp readouts. Could then tie in readings to supplemental HMI and link
through Mission units with their monitoring to work with the 2 and pump stations.
Would add cellular radio to submit effluent flow meter reading to HMI for
monitoring purposes.
Wastewater Treatment Retrofit: Aeration basin retrofit to utilize aeration lagoon as main
treatment – plug north inlet influent pipe, add floating baffle curtains (500 LF long x 15 LF
deep), relocate/repair 4 aerators. Clarifier By-Pass Piping - Add 210 LF-12” SDR 35 Pipe,
core and seal new inlet in splitter box (12” diameter), plug existing outlets in splitter box.
UV Disinfection System – Demo sludge return pumps and piping, convert chlorine
disinfectant to UV (contact flume, lights/ballasts, controls), electrical upgrades (including
step down transformer), and add plumbing connections through the building including DI
pipe. Chlorine Bypass Tank Backup/Emergency Holding Pond - Clean out chlorine contact
tank for bypass treatment if UV fails, add new tablet feeder, motor actuated control valve
and vault including electrical. Add small scale SCADA system. Demo/remove/abandon in
place old equipment. Create new as builts and revise O&M manual for retrofit facility CSD.
Am currently having 6 aerators rebuilt/retrofitted to install in existing aeration
basin; have also received pricing for addition of ‘2’ curtain Baffles to get basin
split into 3 cells and operated like a ‘Partial-Mix Lagoon’; would also retrofit a
spare flotation buoy from previous with 3 inch submersible pumps and pipe back
into influent for internal recycle. Would bypass existing secondary clarifiers with
line and 2 valves at exposed manhole below current aeration basin and install a
‘static screen’ in bypass line with tablet chlorinator; and additional tablet feeder
for de-chlorination could be installed on a new fiberglass slide gate at effluent
flow meter. Would repair, paint and install new roofs, doors and windows, on
existing RAS and Chlorine buidings.
These repairs will not increase wastewater treatment plant permitted capacity and will be
replaced with similar components to current industry standards in accordance with
regulations and permitting approved by NCDEQ, and applicable state, federal laws rules,
and regulations. These repairs will not increase the size of the carrying capacity of the
system and will be replaced with size-like components to carry the existing design flow.
8a. Project Budget (for Construction Projects and Pre-Construction Planning Grants only)
Division Funding
Requested
Other Secured
Funding Source(s)
Total Cost Amount
Indicate construction costs by line item (e.g., linear feet
of different-sized lines)
Construction Costs
Cleaning out sewer pipes/manholes $61,000 $0 $61,000
Smoke testing sewer pipe system $49,900 $0 $49,900
Replacement/Repair of Manholes - 38 $137,700 $0 $137,700
Replace SS Main, Check Values, and Misc. Repairs $164,500 $0 $164,500
Collection System Diagram As Built $10,000 $0 $10,000
Bypass Cone Mill Loop gravity sewer with a new
sanitary sewer gravity mainline - 600 LF of 8" Ductile
Iron, 2 Manholes
$170,000 $0 $170,000
Bridge Lift Station Pump and Motor 1 Rebuild $5,000 $0 $5,000
Bridge Lift Station Pump and Motor 2 Rebuild $5,000 $0 $5,000
Bridge Lift Station Shoreline Stabilization - 150 LF $360,000 $0 $360,000
Bridge Lift Station Relocate Generator $65,000 $0 $65,000
Bridge Lift Station Level Controller $1,000 $0 $1,000
Provided As-built drawings $10,000 $0 $10,000
Bridge Lift Station Alarm Auto Dialer $2,000 $0 $2,000
Bridge Lift Station Cooling for Electrical Equipment
(HVAC unit) $7,500 $0 $7,500
Haynes Lift Station Pump and Motor 1 - Repair $5,000 $0 $5,000
Haynes Lift Station Pump and Motor 2 - Repair $5,000 $0 $5,000
Haynes Lift Station Pump and Motor 3 - Repair $5,000 $0 $5,000
Haynes Lift Station Check Valve 4x6 Spring Loaded
Pump 1 - Replace $2,500 $0 $2,500
Haynes Lift Station Check Valve 4x6 Spring Loaded
Pump 2 - Replace $2,500 $0 $2,500
Haynes Lift Station Check Valve 4x6 Spring Loaded
Pump 3 - Replace $2,500 $0 $2,500
Haynes Emergency Generator Fuel Tank, Supply and
Return Piping $1,500 $0 $1,500
Haynes Equalization Pond Aerator Replacement and
Tether System $26,000 $0 $26,000
Haynes Lift Station Building Repairs $2,500 $0 $2,500
Haynes Lift Station 6-inch Gate Valves $7,000 $0 $7,000
Provided As-built drawings $7,500 $0 $7,500
Haynes Lift Station Clean out Aeration Pond $10,000 $0 $10,000
Haynes Lift Station Auto Dialer $2,000 $0 $2,000
WWTP Repairs - MCC Electrical panel replacement (like
for like at 600V) $349,180 $0 $349,180
WWTP Repairs - Main Backflow Preventor - reconnect $250 $0 $250
WWTP Repairs - Admin Building Repairs $3,000 $0 $3,000
WWTP Repairs – Auto Dialer $2,000 $0 $2,000
WWTP Repairs - Service Air Compressor $1,500 $0 $1,500
WWTP Repairs - Influent Flowmeter $5,000 $0 $5,000
WWTP Repairs - Influent/Grit Chamber Slide Gates $5,000 $0 $5,000
WWTP Repairs - Grit Chamber Mixer - Replace $7,500 $0 $7,500
WWTP Repairs - Autosampler Unit and Enclosure -
Replace $10,000 $0 $10,000
WWTP Repairs - Structure Repairs - outfall steps and
railings $8,000 $0 $8,000
WWTP Repairs - MCC RAS Building Power Panel
Replacement $75,000 $0 $75,000
WWTP Repairs - RAS Building Repairs - lighting, roof,
doors, windows, HVAC $10,000 $0 $10,000
WWTP Repairs – 4-inch Check Valves Pumps 1, 2, & 3 -
Replace $4,500 $0 $4,500
WWTP Retrofit - Plug/isolate North Influent Distribution
Pipe $1,500 $0 $1,500
WWTP Retrofit - Clean out Aeration Pond $150,000 $0 $150,000
WWTP Retrofit - Floating Baffles (500 LF installed, 15
FT deep, no slope) $119,000 $0 $119,000
WWTP Retrofit - Relocate/Replace Existing Aerators (up
to 4 repairs) $83,000 $0 $83,000
WWTP Retrofit - 12" SDR 35 Pipe (Standard Dimension
Ratio) $36,750 $0 $36,750
WWTP Retrofit - Core and Seal New Inlet in Splitter Box
(12" dia.) $7,000 $0 $7,000
WWTP Retrofit - Plug Existing Outlets in Splitter Box $3,000 $0 $3,000
WWTP Retrofit - Demo Sludge Return Pumps and Piping $16,000 $0 $16,000
WWTP Retrofit - Convert Chlorine Disinfectant to UV -
Contact Flume, Lights/Ballasts, Controls $70,000 $0 $70,000
WWTP Retrofit - Electrical Upgrades (Including Step
Down Transformer for UV) $30,000 $0 $30,000
WWTP Retrofit - Plumbing Connections Through the
RAS Building Including DI Pipe $15,000 $0 $15,000
WWTP Retrofit - Clean Out Chlorine Contact Tank for
Bypass Treatment if UV Fails $3,000 $0 $3,000
WWTP Retrofit - New Chlorine Tablet Feeder $250 $0 $250
WWTP Retrofit - Motor Actuated Control Valve and
Vault Including Electrical $10,000 $0 $10,000
WWTP Retrofit - Small Scale SCADA Alarm System $25,000 $0 $25,000
WWTP Retrofit - Demo/Remove/Abandon In Place Old
Equipment $25,000 $0 $25,000
As Built and New O&M Manual $50,000 $0 $50,000
Contingency (10% of construction costs):$225,303 $0 $225,303
Construction Subtotal:$2,506,333 $0 $2,506,333
Engineering Costs
Engineering Design $250,633 $0 $250,633
Permitting $10,000 $0 $10,000
Land Surveying Costs $25,000 $0 $25,000
Engineering Subtotal:$285,633 $0 $285,633
Administration Costs
Planning (pre-construction costs)$0 $0 $0
Easement Preparation $5,000 $0 $5,000
Engineering Report Preparation $10,000 $0 $10,000
Environmental Documentation Preparation (if applicable)$50,000 $0 $50,000
Legal Costs $5,000 $0 $5,000
Compensation for Connection Fees and System
Development Fees that will not be charged after
connecting residences in disadvantaged, underserved
areas (if applicable)
$0 $0 $0
Project Funding Administration (if applicable)$0 $0 $0
Administration Subtotal:$70,000 $0 $70,000
TOTAL PROJECT COST:$2,861,966 $0 $2,861,966
Priorities should be place on 1) Collection System to reduce and eliminate I
& I from system including sewer system at Haynes Pump Station. 2) Both
Haynes and Main/Bridge pump stations to get back to operational status
and PM program that maintains operator ability's and reliability of the
stations and appurtenances; 3) the existing WWTP, some of the items
listed have already been started and in process of working on; the needed
equipment to complete all maintenance and retrofitting needs to be
secured.