NC0056391_Authorization to Construct_20041015

Michael F. Easley, Governor
State of North Carolina
O G
UP
:e;..
Mr. Jerry H. Tweed, Vice President
Heater Utilities
202 MacKenan Court
Cary, NC 27511
October 15, 2004
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
Subject: Authorization to Construct Permit Issuance
ATC Number 0056391A01
Cross Creek Mobile Estates WWTP
NPDES Permit NCO056391
Wake County
Dear Mr. Tweed:
A request for an Authorization to Construct (ATC) was received by the Division and final
plans and specifications for this project have been reviewed and found to be satisfactory.
Authorization is hereby granted for construction of ultraviolet disinfection system at the Cross Creek
Mobile Estates WWTP. Specifically, this ATC allows:
• Installation of a single 200,000 gpd ultraviolet disinfection system
• Installation of a new liquid feed dechlorination system between existing plant outlet and a new UV
system
• Removal of the existing tablet chlorination system from operation to be retained for back-up disinfection
• Installation of a new SCADA monitoring system to notify the operator of power failures
Once construction under this ATC has been completed and an Engineer's Certificate has
been submitted, the permittee is authorized to operate the units listed above, with permitted limits
as specified in the NPDES permit issued July 31, 2003. The Division of Water Quality approves
this project in terms of compliance with NPDES limits; we defer to Heater Utilities and their
consultants for approval of distribution system, adequate mechanical design, structural integrity,
etc. of the entire disinfection treatment system.
This Authorization to Construct is issued in accordance with NPDES Permit No.
NCO056391 issued July 31, 2003, and shall be subject to revocation unless the treatment system is
.constructed in accordance with the conditions and limitations specified in the permit.
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 North Carolina Division of Water Quality.
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 this Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
The Raleigh Regional Office, telephone number (919) 571 - 4700, shall be notified at
North Carolina Division of Water Quality [phone]
1617 Mail Service Center FAX [phone]
Raleigh, North Carolina 27699-1617 On the Internet at http://h2o.enr.state.nc.us/

Cross Creek Mobile Estates WWTP
Permit No. NCO056391
Page 2
least forty-eight (48) hours in advance of operation of the installed facilities so that an in -place
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 classification of the facility by the Certification Commission, the Permittee shall
employ a certified water pollution control treatment system operator to be in responsible charge
(ORC) of the water pollution control treatment system. The operator must hold a certificate of the
type and grade at least equivalent to or greater than the classification assigned to the water
pollution control treatment system 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, .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 weekends and
holidays, and must properly manage and document daily operation and maintenance of the facility
and must comply with all other conditions outlined in Title 15A, Chapter 8G, .0204. Once the
facility is classified, the Permittee must submit a letter to the Certification Commission which
designates the operator in responsible charge within: (A) Sixty calendar days prior to wastewater
being introduced into a new system or (B) within 120 calendar days of the following, (i) after
receiving notification of a change in the classification of the system requiring the designation of a
new ORC and back-up ORC or (ii) a vacancy in the position of ORC or back-up ORC.
A copy of the approved plans and specifications shall be maintained on file by the Permittee
for the life of the facility.
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
by 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.
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 the NPDES Unit, Division of Water
Quality, 1617 Mail Service Center, Raleigh, NC 27699-1617.
2

Cross Creek Mobile Estates WWTP
Permit No. NCO056391
Page 3
One (1) set of approved plans and specifications is being forwarded to you. If you have any
questions or need additional information, please contact Mr. Sergei Chernikov, Ph.D., telephone
number [phone], extension 594.
Sincerely,
/ A an W. Klimek, P.E.
cc: Central Files
NPDES Unit, Permit File
Raleigh Regional Office, Water Quality
W. Lee Fleming, Jr. Engineering
503 Oberlin Rd., Suite 204
Raleigh, NC 27605
3

ATC SUMMARY Cross Creek Mobile Estates WWTP
ATC No. 0056391A0I
UT to Neuse River, class C-NSW water
Neusea River Basin
Wake County
04IQ_9 4
The scope of the project includes installation of a new 200,000 gpd ultraviolet disinfection system, new
liquid feed dechlorination system, new SCADA monitoring system, and the removal of the existing tablet
chlorination system from operation to be retained for back-up disinfection at the existing 70,000 gpd Cross
Creek Mobile Estates wastewater treatment plant.
REVIEW SUMMARY
Executive Summary
The Cross Creek Mobile Estates WWTP has a designed capacity of 70,000 gpd and treat 100% domestic
water. This facility consists of a sludge storage chamber, single aeration chamber, single clarifier, single
tablet chlorination system, and an effluent flow meter. The plant does not have an on -site generator; but does
have a quick disconnect facility for the connection of a portable generator.
Applicant:
Mr. Jerry H. Tweed, Vice -President
Heater Utilities
202 MacKenan Court
Cary, NC 27519
Application/Plans Prepared by:
W. Lee Fleming, Jr. Engineering
503 Oberlin Road, Suite 204
Raleigh, NC 27605
Significant Dates:
Received: 06/07/04
Acknowledged: 06/21/04
RO comments: 07/21/04
Reviewed: 08/04/04
Project Location:
Wake County
Facility status: Existing
Wastewater source: 100% Domestic.
Funding Source: private
Estimated Project Schedule:
To start construct immediately upon receiving the ATC
Page 1

Submissions:
• Letter of Transmittal
• Engineering Plans / Specs
• Description of the Treatment System
Regional Office comments:
Regional office identified several deficiencies that were addressed by the applicant through written and oral
communications.
Review Notes:
The project has been reviewed at the ATC review on August 6, 2004 and October 14, 2004, no significant
deficiencies were found. Applicant has submitted response to the unresolved issues. Monthly average TSS
values during the last year were consistently below 5.0 mg/L. The system is designed to treat 150,000 gpd,
the number was probably calculated using peaking factor of 3, which is slightly below recommended range of
3.5-4.1.
Specifications:
Fecal coliforms 200/100 mL
Flow 0.2 MGD
BOD5 10.0 mg/L
TSS 30 mg/L
UV system Model UV3150K (Trojan Technologies, Inc.)
Page 2

CROSS CREEK MOBILE HOME ESTATES TREATMENT PLANT
MODIFICATION
ULTRAVIOLET DISINFECTION SPECIFICATIONS
JUN 7 20�4
DE9dR — y`fAtE�7 QUr�L1TY
pCy1NT SO��CE gRr:NCH
Plans & Specifications Prepared By:
W. Lee Fleming, Jr. Engineering
503 Oberlin Road, Suite 204
Raleigh, N.C. 27605
Phone: [phone]
Facsimile: 919/833-1105
Prepared: May, 2004

CROSS CREEK MOBILE HOME'ESTATES TREATMENT PLANT MODIFICATION
ULTRAVIOLET DISINFECTION SPECIFICATIONS
I. GENERAL
All construction shall be as shown on Sheet UV -IC of the detailed drawings and as specified in this
document. Field modifications and adjustments shall be documented and a report maintained of these
changes. Work shall be planned so as not to interfere with other treatment plant operation.
The Contractor shall hold harmless the Owner or the Engineer for damages or injuries during all phases
of construction and plant installation. All testing, repairs or replacements shall be provided at the
Contractor's expense.
At the conclusion of construction, the existing grade shall be restored unless otherwise illustrated or
instructed. All disturbed areas shall be seeded and mulched at the completion of backfilling and testing
operations.
The Contractor is responsible for location of all existing utilities and lines and is responsible for the
notification of the Engineer prior to consecution if interferences are found.
The Contractor is responsible for the relocation of all interferences at his expense.
The Owner or Engineer is not responsible for damages to existing utilities during construction.
The Contractor will repair, or have repaired, all damages at his expense. Trees, fences, poles, and all
other property shall be protected unless their removal is authorized, and any property not authorized for
removal but damaged by the Contractor shall be restored by the Contractor to the Owner's satisfaction.
The Contractor shall be responsible for securing all Local, State, and Federal permits required for the
utility construction.
Signs, barricades, warning lights, guards, and flagmen shall be employed by the Contractor when
necessary if construction endangers either vehicular or pedestrian traffic. These devices shall remain in
place until the traffic may proceed normally again. The Contractor shall save the Owner and the Engineer
harmless for any damage or injury realized during construction.
The Contractor and any Subcontractors shall be responsible for the total compliance with all Federal,
State, and Local Ordinances, Laws, and Regulations as they relate to safe construction practices and to
protecting their employees and the public's general health.
The Contractor shall ensure that all occupational safety and health administration (OSHA) regulations
and standards are followed during all phases of construction. All electrical wiring, conduit, and junction
boxes shall be constructed and. installed in accordance with the materials and standards of the N.C.
Electrical Code.

The Contractor and Equipment Suppliers shall guarantee all materials, equipment, and workmanship for a
period of one year after receipt of a letter of acceptance from the Owner.
Detailed shop drawings and operational information shall be provided to the Engineer prior to placement
of purchase orders for UV equipment, control panel, and landing system.
A final inspection shall be required with the Owner, Engineer, Contractor, Equipment Supplier and the
State's Division of Water Quality.
H. WASTEWATER TREATMENT PLANT MODIFICATION
A single 150,000 gallon per day disinfection wastewater treatment plant ultraviolet system shall be
provided as a modification to the existing plant. This system shall be capable of treating domestic
wastewater to a level of 200/100 ml fecal coliform. The system shall be as illustrated on Sheet UV-1C.
All steel used in the manufacturing of the chamber and all other components shall be a minimum of 0.250
inches thick and shall be ASTM A36 structural low carbon steel. The design and installation shall be
made in such a manner at to prevent leakage and to support the chamber. The chamber shall be placed
on a concrete foundation as illustrated on the detailed drawings and shall be provided with connectors
which can be used to connect the chamber to the concrete slab. Before installation of the chamber, the
contractor shall provide the Engineer with the weight of the chamber for flotation check and slab sizing
for flotation prevention.
The wastewater treatment plant manufacturer shall provide adequate reinforcement to withstand
maximum external loads to the chamber when soil is backfilled to the top of the walls and the chamber is
empty and when the chamber is full and the soil is removed completely around the chamber.
Additionally, all walls shall be braced so as not to allow wall deformation. Any bending or
buckling shall be repaired at the plant contractor's expense.
All metallic surfaces shall be coated to prevent corrosion or rusting. Immediately upon completion of
installation, but before operation, the UV system and piping shall be filled with water to check for leaks.
The existing chlorine contact system shall be supplemented by the addition of a liquid drip dechlorination
system on the existing plant's chlorine contact chamber. The new UV system shall provide the plant's
disinfection treatment. The remaining chlorine and dechlorination equipment shall be maintained and only
be used during loss of UV system operation. The installation of the new UV system shall not interrupt
with the operation of the existing wastewater treatment plant components through the existing chlorine
chamber.
The ultraviolet disinfection unit shall be capable of providing disinfection for waste strengths of 10 mg/1
BOD5 and 30 mg/l TSS at the average daily flow rate of 150,000 gpd. The unit shall be constructed of a
module for holding the sleeves with the UV bulbs and shall be made in such a manner as to allow the
removal:of individual modules while the system continues to operate. Prior to ordering the UV unit,
2

certified test results shall be submitted to the Project Engineer of fecal coliform reductions of similar
wastes. The complete UV systems shall be Model UV3150K as made by Trojan Technologies, Inc.
The UV system shall consist of two transition boxes, a UV bulb channel, and all other components to
make the system complete. The complete UV system shall be constructed of stainless steel and shall be
sized to prevent overflow from the UV system chambers during peak flows. Adequate support brackets
and braces shall be provided to attached the UV systems to the new tank interior walls. The UV systems
shall be attached to these brackets using stainless steel bolts, nuts, and washers.
The UV system's control panels shall be constructed of NEMA IVX fiberglass, shall be UL listed, and
shall be fitted with a hasp and lock. The control panels shall be fitted with a 110 volt receptacle and shall
be ground fault to prevent electrical shock. The panels shall have visual gauges which indicate the proper
operation of the UV systems and shall indicate the effectiveness of the system. A support post shall be
provided for the control panels which is of the height which will allow opening of the panels at a height
which is acceptable without bending. The post shall be constructed of SCH 40 steel and shall be coated
the same as the other steel used in the landing and stairs.
Grating panels shall be provided as a walkway to service the UV systems and their electrical equipment.
Grating panels shall be supported as to have a safe uniform load carrying capacity of 80 pounds per
square foot. An anti-skid surface, designed for skid proof resistance in all directions, and shall be
provided with a protective coating to prevent rust and corrosion. All grated 'areas and stairs shall be
protected with handrails as required by OSHA standards. Grating shall be galvanized after punching.
All exposed steel used in the landing, stairs, grating, braces, and all other metal surfaces shall receive a
chlorinated rubber prime coat of Pro Chem Primer (3691-PC-1) to a thickness of 3 mil. The finish coat
shall be PRO Chem Enamel (3690-PC-5) with a color selected by the Owner and a thickness of 6 to 8
mil. The finished coat shall be of a chlorinated rubber and shall be satisfactory for metal protection with
plant walls exposed to the atmosphere. Prior to painting, the metal surface area shall be sandblasted to a
white metal finish. No rust, oil, or other surface impurity shall be present when the protective coating is
applied. All field welds shall be cleaned with a wire brush or other grinding equipment to bare metal prior
to priming and coating. All shipping and installation scrapes shall be coated with the same protective
coating as the plant received. All welds shall be scraped or sanded to bare metal and coated the same as
the structure finish. An alternate primer and paint may be used to match the existing wastewater plant
paint scheme. The owner will inform the contractor of the selected paint requirements.
The Plant Contractor is responsible for all field mounting and erection necessary to make the UV system
and service landing complete and operational. Prior to manufacturing of the tank, the elevation of the
inlet and outlet pipes and the UV mounting elevations shall be confirmed by the Contractor based on the
elevations of the existing outlet and outfall pipes. A sketch shall be provided, during the shop drawing
process, which illustrates the locations of all units and pipes.
Handrails shall be provided around all open areas. The handrails shall be fabricated of 1 1/2 inch schedule
40 steel pipe or galvanized iron, shall be constructed using a top and middle rail of the same material, and
shall be bolted to the plant. All attachments shall be made to protect dissimilar materials at the point of
3

connection. Handrails shall comply with all OSHA requirements for safety protection. The handrails
shall be coated with the same coating as the plant.
A ladder shall be provided which are safe for access on the inside of the tank and will meet or surpass all
OSHA standards for loads and safety shall be provided. The ladder steps shall be protected with the
same coating as the plant. If required, a set of wooden stairs, platform, and handrails shall be provided
on the outside of the tank. The platform shall be the same elevation as the top of the tank wall and it
shall be sized to allow access to the chamber.
The steel containment chamber shall be fitted with a sump pump for the removal of accumulated
rainwater. The bottom of the vault shall be fitted with a submersible sump pump for transfer of
accumulated water from the vault to the treatment plant equalization chamber. The force main from the
pump to the treatment plant shall be 1 1/2" Schedule 40 PVC and the end of the force main shall be fitted
with a check valve to prevent water from flowing from the treatment plant to the vault in high water
conditions. The sump pump shall be fitted with an on -off float switch and the pump shall be capable of
pumping 3/4 inch solids at a rate of 20 gpm.
The treatment plant shall be equipped with a monitoring and notification system as manufactured by
Motorola. This system shall be of the MOSCAD-L SCADA remote thernal unit. The system shall be of
the radio signal type. The system shall monitor the following elements: loss of primary power to the
plant, low intensity of the UV system, and any other alarm or power supply for the plant. Heater
Utilities, Inc. will be responsible for the installation of this system once the UV system is installed. The
system shall be fitted with a battery backup system for continuos operation even with primary power and
generator loss. This backup system shall be provided with a continuous charge.
The SCADA monitoring system shall be provided with 120 volt ac power and the system shall be
equipped with a battery backup system. The processor shall be Mortorola 58CLC302 CMOS, 15.6 Mhz
clock. The system shall be located in a NEMA IVX fiberglass control panel. The system shall utilize a
wireless communications system which is consistent with the existing Heater Utilities, Inc. SCADA
system.
The new dechlorination system, to be used as a backup system in the case of the loss of the UV system,
shall consist of 55 gallon drum located at the flow metering chamber of the existing treatment plant. This
system shall consist of a plastic or other non-metallic drum and a drip valve and shall be filled with
calcium thio-sulfite to be used for dechlorination. The drip valve shall be sized to permit the adjustment
of the liquid dispensing at a rate specified by the liquid chemical manufacturer for the design flow rate of
the plant. This system shall be mounted on the plant with sufficient supports and braces to maintain the
full 55 gallon drum at the desired location. The complete system shall provide treatment of the plant's
chlorine to a 28 ug/1 level during periods when the UV system is not working.