NC0026051_Historical information_20051231

Michael F. Easley, Governor
February 14, 2005
SUBJECT: Wastewater/Groundwater Laboratory Certification
Dear Mr. Battle:
Thank you for your time and cooperation. I can be contacted at [phone] (extension 272), if you have questions.
Sincerely,
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper
Review your last inspection report (Inspection date: January 30, 2004), to assure that all cited items have been corrected;
otherwise, enforcement action may be recommended.
We have scheduled an on-site inspection of your field operation for approximately 9:00 a.m., March 1, 2005. The scope of the
inspection will include all methods marked on Attachment I of the field operations current North Carolina Wastewater /Groundwater
Certificate and /or marked on the application for NC Wastewater/Groundwater Laboratory Certification. A copy of the current Attachment I
is enclosed for your reference. The purpose of the inspection will be to verify documented quality control/quality assurance procedures and
adequacy in meeting the requirements of 15A NCAC 2H .0800.
The data review portion of the inspection will require complete data packets including all of the supporting documentation for data
analysis. This requires, but is not limited to: copies of final reports, instrument run logs, bench sheets, standard preparation logs, reagent
preparation logs, calibration curves and sample receipt/chain of custody forms. These data sets will be used to assess the quality of your
data during the inspection. Any parameters for which there is no North Carolina data to review, general examples of samples analyzed by
the certified methods will be reviewed along with any documented allowances in the laboratory's quality system to meet North Carolina
program specific requirements. Please have available all field meters and calibration standards at this time.
cc: James Meyer
Raleigh Regional Office
•Edith Henderson
Laboratory Section
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Quality
Laboratory Section 1623 Mail Sendee Center; Raleigh, NC 27699-1623
4405 Reedy Creek Road; Raleigh, NC 27607
Phone [phone] /FAX [phone] / Internet: www.dwqlab.org
5108
Mr. Tyrone Battle
Woodard & Curran - Triangle WWTF
5926 NC Hwy. 55 East
Durham, NC 27713-
dujct
North Carolina
Naturally
4
March 31, 2005 M&C 01471-0003 (40/60)
GV.
Dear Mr. Schuster:
If you have any questions, please let me know.
Sincerely,
Enclosure
cc:
S:\1471 \0003\40\03315Schuster.DOC
200 MacKenan Court, Cary, North Carolina 2751 1
Tel [phone] Fax [phone] www.mckimcreed.com
AA0002467
Mr. Ken Schuster
NCDENR
Raleigh Regional Office
1628 Mail Service Center
Raleigh, NC 27699-2628
Bob Carter, Durham County Project Manager
Chuck Hill, PE, Durham County Utility Division Manager
Tom Belnick, NCDENR NPDES Unit
Kevin Eberle, PE, McKim & Creed
McKim & Creed will issue partial substantial completions as each train has been made ready to
come on line. At this time, it is anticipated that only two BNR trains will be placed into service
at a capacity of 8 MGD ADE. We understand that neither the Regional Office nor the NPDES
Unit of NCDENR will issue any written approval or acknowledgement of the plant startup.
Bry^X?- Blake, PE
Senior Project Manager
Per the Authorization to Construct and on behalf of Durham County, McKim & Creed is
notifying you of the County's intent to place into service the new process facilities tentatively on
April 6,h or 7th. Based on our conversation on March 30, 2005, please find attached the draft
start-up plan dated February 17, 2005 for the new process facilities. As discussed, the County is
planning to phase in one new BNR train at a time. This will allow the existing plant to stay on
line as the first BNR train is stabilized. After the first train is stabilized, the second train will be
brought on line. As this is being accomplished, the existing plant will start to be taken off line.
Ur :KRE: Triangle Wastewater Treatment Plant Phase II Expansion
ATC No. 026051A01
NPDES Permit No. NC0026051
1.
2.
3.
4.
5.
6.
7.
1C:\Documents and Settings\BBIake\Local SettingsVTemporary Internet Files\OLK3\02175Plan.doc
Woodward & Curran to check and confirm that all chemical bulk storage tanks
have sufficient supply of chemicals.
The State (Regional Office) shall be notified when Loving starts to fill the BNR trains for
leak testing as just about all plant effluent flow will be diverted to fill the BNR trains.
Woodward & Curran to notify the State.
The appropriate RAS/WAS pump on the south side of the new RAS/WAS pump station
shall transfer flow into the new Influent Flow and RAS Distribution Box. RAS flow shall
be measured by the new RAS flow meter. See Sheets C-10 and C-12. Kruger to lock
out WAS Pump No. 2 and RAS Pump No. 3 in their control logic to prevent them
from starting during the sludge seeding operation.
The appropriate weir shall be set to allow RAS/WAS flow to enter the desired BNR Train.
The other two weirs shall be raised to isolate the remaining two BNR Trains. Weirs to
be set by Loving.
RAS and/or WAS will be pumped via the existing RAS or .WAS pumps and an
interconnection between the existing WAS waste line and the new WAS waste line. See
Sheet C-8. Operation of existing RAS/WAS pumps by Woodward & Curran.
TRIANGLE WWTP PHASE II
START-UP PLAN
FEBRUARY 17, 2005
Forward flow shall enter the desired BNR Train by pumping. Two suction lift pumps
each capable of pumping 700 GPM to 2700 GPM shall be set on top of the Influent Flow
and RAS Distribution Box. The discharge of the pumps shall be metered with local read
The new WAS meter vault shall be valved so as to pass flow through the by-pass line
around the meter vault. The WAS shall enter the new RAS/WAS wetwell by isolating
and removing one of the new RAS/WAS pumps on the north side of the station. The
corresponding check valve shall be blocked open to allow flow to enter the wetwell
through the pump discharge piping. See Sheets C-8, C-24, and D-3A. Loving to
remove RAS Pump No. 3 and block the check valve open. Loving to close the
plug valve in the discharge header between RAS Pump No. 3 and No. 4.
*** REVISED DRAFT ***
The start-up plan is based on all process facilities being completed, leak tested, electrical
checked out, SCADA checked out and ready to be placed into service. The plan is also based
on transferring RAS and/or WAS from the existing clarifiers to seed the one new BNR Train.
• potassium hydroxide (supplied by Woodward & Curran)
• sodium aluminate (supplied by Woodward & Curran)
« polymer (supplied by Woodward & Curran, see Item 16)
® methanol (supplied by Loving , see Item 1.6, Page 11501-2)
• sodium hypochlorite (supplied by Woodward & Curran)
The chemical bulk storage tanks shall be checked to confirm that a sufficient supply of
the following chemicals are present:
8.
9.
10.
11.
12.
2S:\1471\0003\60\02175Plan doc
The existing plant process train shall remain on line at all times. The existing 30” sluice
gate at the grit structure effluent box shall remain open such that forward flow not
pumped into the BNR basin shall continue to feed the existing aeration basins.
out of GPM and total flow. Pumps to be furnished and setup by Loving. Woodward
& Curran to maintain operation of the pumps.
Begin seeding system with sludge approximately 24 to 48 hours prior to starting influent
flow: Woodward & Curran to operate existing RAS/WAS pumps to provide seed
sludge.
It is desirable to have seeded the new oxidation ditch with at least 300 to 500 mg/l of
MLSS from the existing system before starting influent flow. If it is possible to have
more than this, so much the better, however, Kruger does not recommend adding
seed sludge more than 48 hours in advance of adding influent. If possible, allow the
MLSS in the existing system to increase several days prior to anticipated startup to
20 or 30 % above your normal target level. Then waste the excess sludge to the
new ditch over first two to four days of seeding.
The amount of sludge needed for a desirable start-up MLSS level of 300-500 mg/l
may be estimated as following:
For example, assuming the concentration of the RAS/WAS flow is about 8,000 mg/l
approximately 170,000 gallons would be required to raise the MLSS level in the new
ditch to 300 mg/l.
Seeding the new ditch with RAS/WAS from the existing system should continue for
several days following introduction of influent until the MLSS reaches between 1000
Where X is the target MLSS level in the new ditch and the total basin
volume for the new ditch inclusive of ditch, anaerobic and anoxic
zones is about 4.5 MG
Volume of Seed Sludge, MG = (X mg/l) x Total Basin Volume(MG)
MLSSinRASor WAS
The Contractor shall leak test each BNR Train one at a time with plant effluent. The
testing water can be pumped from one train to the next such that the desired BNR Train
to be placed into service first receives the test water last. Leak testing is to be
completed prior to transferring RAS/WAS flow into BNR. Leak testing by Loving.
The mixers and weirs should be placed into local or manual control. Raise the ditch
effluent weirs approximately 3 inches above lowest position and set secondary anoxic
effluent weirs at lowest position. Turn on all mixers. Kruger/Loving to set weirs and
place mixers into operation.
After leak testing has been successfully completed, the desired BNR Train to be placed
into service shall have a plant effluent water level in the anaerobic, anoxic zones and
oxidation ditch that reaches the edges of rotors blades (0” rotor submergence). Rotor
blade submergence can be checked physically or read from the PLC. Loving to
provide the effluent water and confirm level.
13.
14.
15.
16.
17.
18.
19.
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Once RAS/WAS flow from the existing clarifiers is not required, then the pumps in the
new RAS/WWAS Pump Station shall be reset and valves adjusted to allow wasting of
sludge from the new process. Loving to reset RAS Pump No. 3, reset check valve
and discharge header valves for normal operation. Kruger to “unlock” RAS Pump
No. 3 and WAS Pump No. 2 in control logic to allow normal operation.
Once flow is entering the secondary clarifier, the RAS pumps should be switched on and
the RAS should be adjusted to 100% of the influent flow. It is not necessary to establish
a sludge blanket during startup, rather keep the RAS rate high to ensure most of the
MLSS solids reside in the aeration basins where there is food and oxygen available for
growth rather than the clarifier. Control of RAS pumping shall be set by Kruger in
the control logic for start-up.
Implement automatic level control at PLC or SCADA and set rotor submergence at
8 inches. Woodward & Curran to set automatic level control.
and 1500 mg/l. At that point, it will be best to let solids accumulate through new
biological growth in the system. Woodward & Curran to provide for testing of
sludge to ensure the desired MLSS levels.
Once the influent flow has raised the water level in the ditch so that the rotor
submergence > 4”, turn on the rotors. If automatic D.O. control is functioning, the DO
set point should be 2.5 mg/l. It will be decreased to 1.3 mg/l when the MLSS reaches
target levels, the major criteria for achieving a stabilized system, before reducing the
D.O. set point. Loving/Kruger to place rotors into operation.
One of the new clarifiers shall be placed into service with the other three off-line. The
clarifier will be empty and allowed to fill with forward flow from the BNR Train.
Woodward & Curran shall have their chemical supplier jar testing the MLSS
entering the clarifier to determine the proper polymer. McKim & Creed would
anticipate the use of a cationic polymer. Once the correct polymer is identified, the
polymer shall be supplied at the proper dosage to the forward flow entering the clarifier.
The first clarifier shall continue to fill and allowed to stabilize establishing the sludge
blanket after the BNR Train has stabilized (see Item 22). As the forward flow is
increased to the first BNR Train, a second clarifier can be brought on line if needed. The
two remaining off-line clarifiers shall serve as storage basins if there is an upset of the
BNR Train. Flow can be diverted into the off-line clarifiers by weir adjustment at the
Clarifier Distribution Box. See Sheet C-21. Woodward & Curran is to bring on-line
the second clarifier as needed.
Monitor MLSS in the oxidation ditch at least once per day (maybe more often) during
seeding. The initial influent flow rate may be estimated as following using the aerobic
F:M as the basis for controlling flow volume. Woodward & Curran to provide for
monitoring of MLSS levels.
Do not turn on the internal recycle pumps until it is verified that the new ditch is fully
nitrifying as evidenced by low ammonia (< 1 mg/l) and a corresponding increase in
nitrate (> 5 to 10 mg/l) in the BNR effluent (see Item 20). Woodward & Curran to
provide testing to ensure ammonia and nitrate levels.
Table 1. Recommended flow, MLSS and F:M ratio during Start-up
1.0to 1.2 600 to 700 0.14
1.5 to 1.7 0.12
2.0 to 2.2 0.10
2.3 to 2.5 0.09
3.0 to 3.2 0.09
3.5 to 4 MGD 0.09
4S:\1471 \0003\60\02175Plan.doc
An aerobic F:M ratio about 0.15 to 0.2 is initially desired in order to accelerate
sludge build-up during start-up. The following table shows the estimation of
influent flow vs. MLSS assuming an influent BOD of about 150 mg/l on average
and a ditch volume of about 3 MG. Continue seeding until MLSS reaches target
levels (about 3,000-4,000 mg/l).
NOTE: The aerobic F:M is estimated using the ditch volume only and does not
include the volume of the anaerobic zones, the anoxic zones, or solids in the
clarifier.
Influent Flow, MGD
0.5 to 0.7
Influent flow, MGD = (t7: M) x 0.7 * MLSS(mg/l) x Ditch Volume(MG)
Infuent BOD(mgZl)
900 to 1,100
1.400 to 1,600
1,900 to 2,200
2.400 to 2,600
3,000 to 3,300
MLSS, mg/l
300 to 400
Approximate F:M
0.17
The values in Table 1 assume the wastewater temperature is 12 to 15 °C and an influent
BOD of approximately 150 mg/l. The values in this table should be considered
approximate. Decrease influent flow if effluent ammonias rise above 2 mg/l or effluent
BOD rises above 15 mg/l., the influent BOD increases significantly, or the MLSS
tejmperature in the oxidation ditch fails below 10 to 11 °C.
A recommended monitoring schedule for process startup is listed in Table 2. As an
absolute minimum, the ditches should be monitored for MLSS and ammonia and the
clarifier effluent composite analyzed for ammonia. Kruger assumes that plant, staff has
the capability onsite to monitor ammonia and MLSS daily. Once the ditch is stabilized,
the frequency of monitoring can be reduced.
Table 2. Recommended Monitoring Schedule during Process Start-up
Influent WAS/RAS
W DC
DC W
DG
DG DG
Once/day
20.
21.
22.
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It may be desirable to begin wasting some sludge from the new system once the MLSS
reaches about 1,500 mg/l to 2,000 mg/l or 15-20 days after seeding, whichever comes
first. The volume of waste sludge can be estimated based on a SRT of 15-20 days and
should be less than net growth of activated sludge in oxidation ditches to allow continued
accumulation of solids. Kruger will advise during startup on when to begin wasting
and how much to waste.
Daily Composite Sample
Daily Grab Sample
Weekly (twice/week)
DC
W
DG
DG
DG
W
DC
Oxidation
Ditches
Secondary
Clarifier Effluent
DC
W
DC:
DG:
W:
Twice/day
DG
Organic
CBOD5 - total
Solids
TSS
VSS
TKN
NH4-N
NO3-N
Operational
Indicators
pH
Alkalinity
Temperature
At MLSS of about 2000 mg/l, adjust RAS flow to maintain a 1-2 ft sludge blanket depth in
secondary clarifiers. The sludge blanket should be checked at approximately the same
time each day in the same location in the clarifier. Woodward & Curran to make
adjustment to RAS pumps and provide for checking of sludge blankets.
Mixed Liquor
Settled Sludge
Volume (5,30,60 Min)
Once nitrification is stabilized, as evidence by effluent ammonias < 1 mg/ and a rise in
effluent nitrates, the internal recycle pumps can be started. The pumps should be set to
return about 100 to 150% of the influent flow rate. Woodward & Curran to start
internal recycle pumps.
23.
24.
25.
26.
6S:\1471\0003\60\02175Plan.doc
As forward flow leaves the first clarifier, one new filter shall be placed into service.
Influent sluice gates for four filters shall be shut and one sluice gate shall be open for the
filter to be placed into service. See Sheet C-25. Woodward & Curran shall set the
sluice gates and place the one filter into service. When the second BNR Train is
placed into service and all forward flow has been diverted from the existing plant into the
new BNR process trains, a second filter shall be placed into service.
After approximately four weeks of operation, begin monitoring the ortho-phosphate in the
selector and the total phosphate concentration in the influent about twice per week to
detect onset of biological phosphorus removal. Chemical addition (sodium aluminate)
will probably be required into the oxidation ditches, particularly during startup if
phosphorus limits must be met. Woodward & Curran to provide for monitoring the
ortho-phosphate level.
After the first BNR Train has stabilized, the second BNR Train will be started up. The
startup process shall be as outlined above except seed sludge shall be provided from
the new clarifiers and will not be required from the existing clarifiers. The 30” sluice gate
at the grit structure effluent box shall be closed allowing all forward flow to enter the two
BNR Trains. This will eliminate the need for the temporary pumps (Item 5) as the
forward flow will be gravity flow. Once the 30” sluice gate is closed, the existing plant
can be allowed to go off-line. Once the existing plant is off-line, the effluent pump station
can be shut down and the 30” sluice gate at the UV structure influent box can be closed.
See Sheet C-17 of the Phase I plans. Woodward & Curran to place the existing
plant off-line and close the appropriate sluice gates.
BOD removal should begin to occur immediately if seeding is adequate and the influent flow is
not increased too rapidly. Nitrification should also follow rapidly again if the F:M ratio does not
get too high. During the first couple of days of startup, there will be a considerable dilution
effect to offset any delay in onset of nitrification. Sufficient MLSS must be accumulated to see
good nitrogen removal and this may require several weeks. Kruger would recommend holding
off on methanol addition until solids are at target levels and effluent TN levels have stabilized.
Biological phosphorus will require significantly more time and will be very much dependant on
the presence of soluble BOD in the influent. If the soluble BOD is present, biological
phosphorus removal should begin to take place within 6-10 weeks after initial startup and
steadily improve thereafter if the system is suitably loaded. The onset of biological phosphorus
removal is detected by monitoring the ortho-phosphate concentration in the last stage of the
anaerobic selector. Typically, it will be 3 to 5 times the ortho-phosphate concentration in the
Once the MLSS concentration is between 2,500 and 3000 mg/l and nitrification is
stabilized, the RAS Bleed to the second anoxic stage may be started. The RAS bleed
should be incrementally increased daily until the MLSS in the Secondary Anoxic zone is
approximately 800 to 1000 mg/l higher than in the oxidation ditches. During this
adjustment period lasting a few days, collect a sample of MLSS for solids measurement
from the secondary anoxic zone in addition to the sample collected in the oxidation ditch.
Typically the RAS bleed rate will be between 20 and 30 percent of the RAS flow rate and
the target MLSS in the secondary anoxic should be about 700 to 1000 mg/l higher than
in the oxidation ditch upstream. Once the RAS bleed is set, sampling in the secondary
anoxic zone can be reduced to once per week. Lower the DO set point in the oxidation
ditch to 1.3 mg/l. Woodward & Curran to make the RAS bleed adjustment and
provide fortesting MLSS levels.
7S :\ 1471 \0003\60\02175Plan.doc
influent if the release/uptake cycle is established. After approximately four weeks of operation,
begin monitoring the ortho-phosphate in the selector and the total phosphate concentration in
the influent about twice per week.
The County has agreed for Woodward & Curran to provide a designated start-up coordinator.
Woodward & Curran to inform the County of the designated person.
Kruger personnel will visit the site the first few days of startup and will always be available for
consult.
Apt.12. 2005 3:54P No. 5936 P. I
d^McKIM&CREED
FACSIMILE TRANSMITTAL
DESIGNATED RECIPIENT:Ken Schuster FAX NO: 571-4718
DATE: April 12, 2005
SENDER:Bryan F. Blake, PE TIME:
NUMBER OF TRANSMISSION PAGES (Including this page):13
PROJECT NUMBER 01471-0003 PROJECT NAME Triangle WWTP-Phase II
□ THIS IS YOUR ORIGINAL KI HARD COPY TO FOLLOW
COMMENTS:• • IF NOT CORRECTLY RECEIVED OR PAGES FAULTY, PLEASE CALL SENDER AT 919/233-8091 **
REMARKS:
S:\OHCOR\Reopelle\Fax\SchuSter.DOC REV.-042795
200 MacKENAN COURT
SUITE 200
CARY, N.C. 27511
TEL: [phone]
FAX: [phone]
ATTENTION
THE INFORMATION CONTAINED IN THIS FACSIMILE MESSAGE IS PRIVILEGED AND CONFIDENTIAL INFORMATION INTENDED ONLY FOR THE USE OF THE INDIVIDUAL OR ENTITY NAMED
ABOVE. IF THE READER Of THIS MESSAGE IS NOT THE INTENDED RECIPIENT. OR THE EMPLOYEE OF/OR AGENT RESPONSIBLE TO DELIVER IT TO THE INTENDED RECIPIENT, YOU ARE HEREBY
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INCURRED.
COMPANY: NCDENR - Raleigh Regional Office
XT 70^
P. 2
April 12,2005 M&C 01471-0003 (40/60)
RE:
Dear Mr. Belnick:
If you need additional information, please let me know.
Sincerely,
McKIM & CREED, P.A.
I I.Q
/der
Enclosures
cc:
$:\l4n\00C3\4O\Ml25B«lnick.d<x
Bryan F. Blake, PE
Senior Project Manager
Bob Carter, Durham County
Chuck Hill, PE, Durham County
Ken Schuster, NCDENR Regional Office
Kevin Eberle, McKim & Creed, P.A.
Mr. Tom Belnick
NCDENR NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
200 macKenan Court, cary, North Carolina 27511
TEL [phone] Fax [phone] www.mckifficreed.com
AA0002647
Triangle Wastewater Treatment Plant Phase II Expansion
ATC No. 026051A01
NPDES Permit No. NC0026051
McKim & Creed will process partial certifications for each of the two remaining BNR trains as
the contractor achieves substantial completion.
Please find attached the Partial Certification for the referenced project as we discussed. The
Partial Certification is basically for placing into service one of the five stage biological nutrient
removal trains. Train No. 2, with the other process structures as noted. This provides for 4.0
MGD ADF capacity in the new plant.
Apt.1 2. 2005 3:No.5 9 36
Also attached is the current start-up plan dated April 12, 2005 for your files. It is now
anticipated that the new process trains will be placed into service some time this week.
Location:
.ONE>
>
Registration No,11570
te
>
>
>
>
>
Ap r • 12 •_ 2_005 L3 '• 54P^k Caro^M
Department EnviWment
and Natural Resources
Division of Water Quality
r8EAL ■
Pi
has been 1
wi<x the
uafed in
completed in substantial conformance with the Authorization to Construct and with the approve^gn'
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E,„ Director
Date APR 11^^^2005 __________________________________j
Upon completion of construction and prior to operation of the modified facility. I
Division with a certification from a professional engineer certifying that the permits
accordance with the NPDES Permit, this Authorization to Construct, and the approve
The Certification should be submitted to: f.
NCDENR/DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolin^^O^- 7
a No.5 9 36 P- 3
NCDENR
PARTIAL CERTIFICATION
Professional Engineer’s Certification
For
Construction of Wastewater Treatment Facilities
ATC PROJECT NUMBER: 026051API
Durham-Triangle WWTP
NPDES Permit No. NC0026051
____BRYAN F. BLAKE_____________________am a duly registered Professional Engineer
(please print)
ill the State of North Carolina and have been authorized to observe (circle one: fall time) the
construction of the subject project for the Permittee;
Project: Durham/Triangle WWTP
Phase JI Expansion
Intersection of Hwy 55 and Alexander Drive
Durham County
The project consists of:
Installation of a new five stage biological nutrient removal system (three treatment trains) including the following:
r ..... ...._______z
Three 16* x 36* x 18.5’ (79706 gallons) anaerobic selectors
Th«&36’ x 67.5’ x 1825’ (331709 gallons) primary anoxic reactors
Three-339’ x 36’ x 18’ (1,643,366 gallons) oxidation ditch aerobic reactors
Thr-e^36’ x 45.5’ x 17’ (208,315 gallons) second stage anoxic reactors
♦ BNR system flow distribution box
ONE ♦ "
ONE ♦
ONE ♦
ONE ♦
ONE ♦ Three-15’ x 36’ x 16.5’ (66,656 gallons) reaeration tanks
> Secondary clarifier flow distribution
Four 110’ diameter x 16’ high secondary clarifiers
wetwenUni aCtivated sludge wetwells with two hi8h volume (3,475 gpm) and one low volume (350 gpm) pumps per
Retum-actoaiedkludge.PLG~ba$ed-fkw Gontrol pump control system
Tertiary filter weir type flow distribution
Five train traveling bridge tertiary sand filter with effective sand particle size of 0.55 to 0.65 nun and a unifonnity
coefficient (D60/D10) less than or equal to 1.5
> Filter backwash system consisting of one 7.5 hp centrifugal pump per filter train (five pumps total)
Sodium Aluminate Chemical feed system with application points located secondary clarifier influent distribution
chamber and the tertiary sand filter distribution channel
> Polymer feed system with application points located secondary clarifier influent distribution chamber
> Sodium hypochlorite feed system with application points located at the tertiary sand filter distribution channel and
the reuse water trough at the ultraviolet disinfection unit effluent
> Effluent flow metering system consisting of a compound rectangular sharp crested weir and a ultrasonic level sensor
> Installation of any appurtenances associated with the referenced modifications
I hereby certify that I did regularly observe this project with due care and diligence and that the construction was
and
specifications.
Signature /C
No • 5 9 3 6 P. 4
1,
2.
3.
4.
5.
6.
7.
1S:\i471\0003W\04075Plan.<Joc
The State (Regional Office) shall be notified when Loving starts to fill the BNR trains for
leak testing as just about all plant effluent flow will be diverted to fill the BNR trains.
Woodward & Curran to notify the State.
RAS and/or WAS will be pumped via the existing RAS or WAS pumps and an
interconnection between the existing WAS waste line and the new WAS waste line. See
Sheet C-8. Operation of existing RAS/WAS pumps by Woodward & Curran.
The appropriate RAS/WAS pump on the north side of the new RAS/WAS pump station
shall transfer flow into the new Influent Flow and RAS Distribution Box. RAS flow shall
be measured by the new RAS flow meter. See Sheets C-10 and C-12. Kruger to lock
out WAS Pump No. 1 and RAS Pump No. 1 in their control logic to prevent them
from starting during the sludge seeding operation. (Note: In manual operation,
the pumps must be monitored and not allowed to run dry.)
The appropriate weir shall be set to allow RAS/WAS flow to enter the desired BNR Train
(Train No. 2). The other two weirs shall be raised to isolate the remaining two BNR
Trains. Weirs to be set by Loving.
Forward flow shall enter the desired BNR Train (Train No. 2) by pumping. Two suction
lift pumps each capable of pumping 500 GPM to 2700 GPM shall be set on top of the
potassium hydroxide (supplied by Woodward & Curran)
sodium aluminate (supplied by Woodward & Curran)
polymer (supplied by Woodward & Curran, see Item 16)
methanol (supplied by Loving , see Item 1.6, Page 11501-2)
sodium hypochlorite (supplied by Woodward & Curran)
TRIANGLE WWTP PHASE II
START-UP PLAN
APRIL 12, 2005
The new WAS meter vault shall be valved so as to pass flow through the by-pass line
around the meter vault. The WAS shall enter the new RAS/WAS wetwell by isolating
and removing one of the new RAS/WAS pumps on the south side of the station. The
corresponding check valve shall be blocked open to allow flow to enter the wetwell
through the pump discharge piping. See Sheets C-8, C-24, and D-3A. Loving to
remove RAS Pump No. 1 and block the check valve open. Loving to close the
plug valve in the discharge header between RAS Pump No. 1 and No. 2 and close
the 8” WAS valve in the discharge header at WAS Pump No. 2.
APr.12- 2 0 05 3:54P^
The start-up plan is based on all process facilities being completed, leak tested, electrical
checked out, and ready to be placed into service. The plan is also based on transferring RAS
and/or WAS from the existing clarifiers to seed the one new BNR Train.
Woodward & Curran to check and confirm that all chemical bulk storage tanks
have sufficient supply of chemicals.
The chemical bulk storage tanks shall be checked to confirm that a sufficient supply of
the following chemicals are present:
No • 5 93 6 P. 5
8.
9.
10.
11.
12.
13.
2S:\147-\0003\50\04076P|on.doe
L
The BNR train will be started and run manually without the Kruger PLC Control
Panel. See the attachment “Manual Operation Train No. 2”.
Volume of Seed Sludge, MG = (X mg/1) x Total Basin Volume(MG)
MLSS in RAS or WAS
Where X is the target MLSS level in the new ditch and the total basin
volume for the new ditch inclusive of ditch, anaerobic and anoxic
zones is about 4.5 MG
After leak testing has been successfully completed, the desired BNR Train (Train No. 2)
to be placed into service shall have a plant effluent water level in the anaerobic, anoxic
zones and oxidation ditch that reaches the edges of rotors blades (0” rotor
submergence). Rotor blade submergence can be checked physically or read from the
PLC. Loving to provide the effluent water and confirm level.
Begin seeding system with sludge approximately 24 to 48 hours prior to starting influent
flow: Woodward & Curran to operate existing RAS/WAS pumps to provide seed
sludge.
The existing plant process train shall remain on line at all times. The existing 30" sluice
gate at the grit structure effluent box shall remain open such that forward flow not
pumped into the BNR basin shall continue to feed the existing aeration basins.
The mixers and weirs should be placed into local or manual control. Raise the ditch
effluent weirs approximately 3 inches above lowest position and set secondary anoxic
effluent weirs at lowest position. Turn on all mixers. Kruger/Loving to set weirs and
place mixers into operation.
The amount of sludge needed for a desirable start-up MLSS level of 300-500 mg/l
may be estimated as following:
It Is desirable to have seeded the new oxidation ditch with at least 300 to 500 mg/l of
MLSS from the existing system before starting influent flow. If it is possible to have
more than this, so much the better, however, Kruger does not recommend adding
seed sludge more than 48 hours in advance of adding influent. If possible, allow the
MLSS in the existing system to increase several days prior to anticipated startup to
20 or 30 % above your normal target level. Then waste the excess sludge to the
new ditch over first two to four days of seeding.
Apt. 1 2 . 2005 3:5 5P^
Influent Flow and RAS Distribution Box. The discharge of the pumps shall be metered
with local read out of GPM and total flow. Pumps to be furnished and setup by
Loving. Woodward & Curran to maintain operation of the pumps. (Note: The
temporary pumps are manually controlled without floats and must not be allowed
to run dry.)
The Contractor shall leak test each BNR Train one at a time with plant effluent. The
testing water can be pumped from one train to the next such that the desired BNR Train
to be placed into service first receives the test water last. Leak testing is to be
completed prior to transferring RAS/WAS flow into BNR. Leak testing by Loving.
P. 6No • 5936
14.
15.
Forward Flow
16.
17.
3S\147l\O0OJi60\O4075Plwi.doc
Table 1, Initial Chemical Dosage Recommendations
(Durham Only - Not Including Cary Flow)
For example, assuming the concentration of the RAS/WAS flow is about 8,000 mg/l
approximately 170,000 gallons would be required to raise the MISS level in the new
ditch to 300 mg/l.
Seeding the new ditch with RAS/WAS from the existing system should continue for
several days following introduction of influent until the MLSS reaches between 1000
and 1500 mg/l. At that point, it will be best to let solids accumulate through new
biological growth in the system. Woodward & Curran to provide for testing of
sludge to ensure the desired MLSS levels.
Verify that chemical feed systems are functional and ready for operation (sodium
aluminate, potassium hydroxide, and cationic polymer initially and methanol). Methanol
will likely be required one or two weeks later, after biological nitrification has been
established. Adjust initial feed rates per Table 1 based on actual influent flow rate.
Start the appropriate chemical feeds simultaneously with starting influent flow to the
BNR.
Once RAS/WAS flow from the existing clarifiers is not required, then the pumps in the
new RAS/WWAS Pump Station shall be reset and valves adjusted to allow wasting of
sludge from the new process. Loving to reset RAS Pump No. 1, reset check valve
and discharge header valves for normal operation. Kruger to “unlock0 RAS Pump
No. 1 and WAS Pump No. 1 in control logic to allow normal operation. (Note: RAS
Pump No, 1 to remain locked out until pump has been replaced.)
Do not turn on the internal recycle pumps until it is verified that the new ditch is fully
nitrifying as evidenced by low ammonia (< 1 mg/l) and a corresponding increase in
nitrate (> 5 to 10 mg/l) in the BNR effluent (see Item 22). Woodward & Curran to
provide regular testing to track ammonia and nitrate levels. Once nitrification has
been established, start methanol feed at the rate indicated in Table 1 to the second
anoxic zone.
Chemical____________
Sodium Aluminate______
Potassium Hydroxide
Emulsion Cationic Polymer
Methanol
1 MOD
mg/l
17.2
115.7
___1_
3
gal/hr
2.5
____7
0.04
0.47
2MGD
mg/l
17.2
115.7
___1_
3
gal/hr
5
___14
0.08
0.94
gal/hr
___10
'__28
0.16
1.88
Apr-12- 2 0 0 5 3:5 5|^
3MGD
mg/l
17.2
115.7
___1_
3
4MGD
mg/l
17.2
115.7
__1
3
gal/hr
7.5
__21
0.12
1.41
Once the influent flow has raised the water level in the ditch so that the rotor
submergence > 4”, turn on the rotors. If automatic D O. control is functioning, the D.O.
set point should be 2.5 mg/l. It will be decreased to 1.3 mg/l when the MLSS reaches
target levels, the major criteria for achieving a stabilized system, before reducing the
D.O. set point. Loving/Kruger to place rotors into operation. (Note: Automatic D.O.
control will not be functioning at start up.)
No.5 9 3 6 P. 7
18.
19.
20.
21.
4SAI 471 \0003\80W075Plan.doc
Influent flow, MGD = (F: M) x 0.7 * MLSS(mgZl) x Ditch Volume(MG)
Infuent B0D(mg /1)
Implement automatic level control at PLC or SCADA and set rotor submergence at
8 inches. Woodward & Curran to set automatic level control. The ditch weir shall
be manually adjusted at start up in accordance with the attachment.
An aerobic F:M ratio about 0.15 to 0.2 is initially desired in order to accelerate
sludge build-up during start-up. The following table shows the estimation of
influent flow vs. MLSS assuming an influent BOD of about 150 mg/l on average
and a ditch volume of about 3 MG. Continue seeding until MLSS reaches target
levels (about 3,000-4,000 mg/l).
NOTE: The aerobic F:M is estimated using the ditch volume only and does not
include the volume of the anaerobic zones, the anoxic zones, or solids in the
clarifier.
Once flow is entering the secondary clarifier and HAS flow can be discharged from the
clarifier, the RAS pumps should be switched on and the RAS should be adjusted to
100% of the influent flow. It is not necessary to establish a sludge blanket during
startup, rather keep the RAS rate high to ensure most of the MLSS solids reside in the
aeration basins where there is food and oxygen available for growth rather than the
clarifier. Control of RAS pumping shall be set by Kruger in the control logic for
start-up. (Note: However at start up the RAS pumps shall be manually operated.
In manual operation, the pumps must be monitored and not allowed to run dry.)
APr.1 2- 2 00 5 3:5 ^
One of the new clarifiers (Clarifier No. 3) shall be placed into service with the other three
off-line. The clarifier will be empty and allowed to fill with forward flow from the BNR
Train. Start sodium aluminate feed when forward flow is initiated to the clarifier.
Woodward & Curran shall have their chemical supplier jar testing the MLSS
entering the clarifier to determine the proper polymer. McKim & Creed would
anticipate the use of a cationic polymer. Once the correct polymer is identified, the
polymer shall be supplied at the recommended dosage to the forward flow entering the
clarifier. The first clarifier shall continue to fill and allowed to stabilize establishing the
sludge blanket after the BNR Train has stabilized (see Items 19 and 24). As the forward
flow is increased to the first BNR Train, a second clarifier (Clarifier No. 2) can be brought
on line if needed. The two remaining off-line clarifiers (Clarifier No. 1 and No. 4) shall
serve as storage basins if there is an upset of the BNR Train. Flow can be diverted into
the off-line clarifiers by weir adjustment at the Clarifier Distribution Box. See Sheet C-
21. Woodward & Curran is to bring on-line the second clarifier as needed.
Monitor MLSS in the oxidation ditch at least once per day (maybe more often) during
seeding. The initial influent flow rate may be estimated as following using the aerobic
F;M as the basis for controlling flow volume. Woodward & Curran to provide for
monitoring of MLSS levels.
No-5 9 36 P. 8
Table 2. Recommended flow, MLSS and F:M ratio during Start-up
0.09
0.09
5S \1471\0003W7M075Plan OOC
A recommended monitoring schedule for process startup is listed in Table 3. As an
absolute minimum, the ditches should be monitored for MLSS and ammonia and the
clarifier effluent composite analyzed for ammonia. Kruger assumes that plant staff has
the capability onsite to monitor ammonia and MLSS daily. Once the ditch is stabilized,
the frequency of monitoring can be reduced.
0.10
0.09
Influent Flow, MOD
0.5 to 0.7
1.0 to 1,2
1.5 to 1.7
2.0 to 2.2
2.3 to 2.5
3.0 to 3 2
3.5to4MGD
MLSS, mg/l
300 to 400
600 to 700
900 to 1,100
1.400 to 1,600
1,900 to 2,200
2.400 to 2,600
3,000 to 3,300
Approximate F:M
0.17
0.14
0.12
Apr• 12- 20 0 5 3:5 |^
The values in Table 2 assume the wastewater temperature is 12 to IS^C and an influent
BOD of approximately 150 mg/l. The values in this table should be considered
approximate. Decrease influent flow if effluent ammonias rise above 2 mg/l or effluent
BOD rises above 15 mg/l., the influent BOD increases significantly, or the MLSS
temperature in the oxidation ditch falls below 10 to 11 °C.
No • 5 9 36 P. 9
Table 3. Recommended Monitoring Schedule During BNR Process Start-up
DC’DC DC
DC W
DG
DG
Once/day
0 DG
22.
23.
24.
25.
6S'\1471\0003«CW407&Plan.dOC
It may be desirable to begin wasting some sludge from the new system once the MISS
reaches about 1,500 mg/l to 2,000 mg/l or 15-20 days after seeding, whichever comes
first. The volume of waste sludge can be estimated based on a SRT of 15-20 days and
should be less than net growth of activated sludge in oxidation ditches to allow continued
accumulation of solids. Kruger will advise during startup on when to begin wasting
and how much to waste.
At MLSS of about 2000 mg/l, adjust RAS flow to maintain a 1-2 ft sludge blanket depth in
secondary clarifiers. The sludge blanket should be checked at approximately the same
time each day in the same location in the clarifier. Woodward & Curran to make
adjustment to RAS pumps and provide for checking of sludge blankets.
As forward flow leaves the first clarifier, one new filter (Filter No. 1) shall be placed into
service. Influent sluice gates for four filters shall be shut and one sluice gate shall be
open for the filter to be placed into service. See Sheet C-25. Woodward & Curran
DC’
w
DC*
DC’
DC*
O
DC’
DG
DG
DG
DG
DC
DG
DG
DG
DG
DC
W
W
w
DC
O
DG
OG
Oxidation
Ditches
DG
DG
Secondary
Clarifier
Effluent
DC
DC
WAS/
RAS
DG
DG
DG
DG
(Raw
Influent
(pre
screening)
BNR
Influent
(post
screening)
Anaerobic
Selector
(3r<> stage)
Twice/day
DG
DG
DG
DG
DG
DC
DC
DC
DC
Apr.12- 20 05
Once nitrification is stabilized, as evidence by effluent ammonias < 1 mg/ and a rise in
effluent nitrates, the internal recycle pumps can be started. The pumps should be set to
return about 100 to 150% of the influent flow rate. Woodward & Curran to start
internal recycle pumps.
Parameters
Organic
CBOD5-Total
Solids
TSS
VSS_________
Nitrogen
TN
TKN
NH4-N
no3-n_____
Phosphorus
TP
PO4-P_______
Operational
Indicators
PH
Alkalinity
Temperature____
Mixed Liquor
Settled Sludge
Volume (5,30,60
Min)_________
TP In Mixer Liquor _____________________________________________________
DC: Daily composite sample
DC*: Manual daily composite sample minimum of 5 samples taken to correlate with the post
screening samples
DG: Daily grab sample
W: Weekly (twice/week)
O; Occasional
Apr.12. 2 0 0 5 3:No-5 9 3 6 P. 10
26.
27.
28.
7S:\1471\0003\80\0407SPIan.doe
BOD removal should begin to occur immediately if seeding is adequate and the influent flow is
not increased too rapidly. Nitrification should also follow rapidly again if the F:M ratio does not
get too high. During the first couple of days of startup, there will be a considerable dilution
effect to offset any delay in onset of nitrification. Sufficient MISS must be accumulated to see
good nitrogen removal and this may require several weeks. Kruger would recommend holding
off on methanol addition until solids are at target levels and effluent TN levels have stabilized.
After the first BNR Train (Train No. 2) has stabilized, the second BNR Train (Train No. 1)
will be started up. The startup process shall be as outlined above except seed sludge
shall be provided from the new clarifiers and will not be required from the existing
clarifiers. The 30" sluice gate at the grit structure effluent box shall be closed allowing all
forward flow to enter the two BNR Trains. This will eliminate the need for the temporary
pumps (Item 7) as the forward flow will be gravity flow. Once the 30" sluice gate is
closed, the existing plant can be allowed to go off-line. Once the existing plant is off-line,
the effluent pump station can be shut down and the 30” sluice gate at the UV structure
influent box can be closed. See Sheet C-17 of the Phase I plans. Woodward & Curran
to place the existing plant off-line and close the appropriate sluice gates.
After approximately four weeks of operation, begin monitoring the ortho-phosphate in the
selector and the total phosphate concentration in the influent about twice per week to
detect onset of biological phosphorus removal. Chemical addition (sodium aluminate)
will probably be required into the clarifiers, particularly during startup if phosphorus limits
must be met. Woodward & Curran to provide for monitoring the ortho-phosphate
level.
shall set the sluice gates and place the one filter into service. When the second
BNR Train is placed into service and all forward flow has been diverted from the existing
plant into the new BNR process trains, a second filter (Filter No. 2) shall be placed into
service.
Once the MLSS concentration is between 2,500 and 3000 mg/l and nitrification is
stabilized, the RAS Bleed to the second anoxic stage may be started. The RAS bleed
should be incrementally increased daily until the MLSS in the Secondary Anoxic zone is
approximately 800 to 1000 mg/l higher than in the oxidation ditches. During this
adjustment period lasting a few days, collect a sample of MLSS for solids measurement
from the secondary anoxic zone in addition to the sample collected in the oxidation ditch.
Typically the RAS bleed rate will be between 20 and 30 percent of the RAS flow rate and
the target MLSS in the secondary anoxic should be about 700 to 1000 mg/l higher than
in the oxidation ditch upstream. Once the RAS bleed is set, sampling in the secondary
anoxic zone can be reduced to once per week. Lower the DO set point in the oxidation
ditch to 1.3 mg/l. Woodward & Curran to make the RAS bleed adjustment and
provide for testing MLSS levels.
Biological phosphorus will require significantly more time and will be very much dependant on
the presence of soluble BOD in the influent. If the soluble BOD is present, biological
phosphorus removal should begin to take place within 6-10 weeks after initial startup and
steadily improve thereafter if the system is suitably loaded. The onset of biological phosphorus
removal is detected by monitoring the ortho-phosphate concentration in the last stage of the
anaerobic selector. Typically, it will be 3 to 5 times the ortho-phosphate concentration in the
influent if the release/uptake cycle is established. After approximately four weeks of operation,
No.5 93 6 P. 11
8S:\1471 \0003W3\Q4075Plan.doc
begin monitoring the ortho-phosphate in the selector and the total phosphate concentration in
the influent about twice per week.
The County has agreed for Woodward & Curran to provide a designated start-up coordinator.
Woodward & Curran to Inform the County of the designated person.
Kruger personnel will visit the site the first few days of startup and will always be available for
consult.
Apr-12- 2 0 0 5 3 ^
P. 12No-5 936
MANUAL OPERATION TRAIN #2
Initial Manual Mode Start-up
0
8.2 8.4 8.5 8.5 8.5 8.0 8.4 8.8
9SAI 471 VOOOaWKMOZSPian.dfje
1.0
12
v
5.0
Ta
To
6.0
To
"o’
7.0
44
8.0
48
"o’
2.0
19
Z5
3.0
15
~T
4.0
To
15
BEFORE TURN ON ROTORS, MAKE SURE ROTOR SUBMERGENCE 4”
Apr.1 2. 2 0 0 5 3:^
• After leak testing, water levels in the ditch should reach the edges of rotor blades. Tum on
all mixers
• Drop secondary anoxic effluent weir down to the lowest position
• Under manual operation mode, adjust weir position according to the flow rates listed in
Table 1 The flow rates listed here are the anticipated start-up raw influent plus RAS flow.
For example, assume the start-up flow rate of 2.0 MGD and RAS flow of 1.0 MGD, the total
influent to the ditch would be 3.0 MGD, then the ditch effluent weir would be raised 2.0
inches from its lowest position. If the total flow rate to the ditch is more than 6.0 MGD, the
effluent weir would be in the lowest position.
Table 1 Rotor submergence and weir position at different flowrate
Flow rate, MGD*
Water head over weir, inch
Initial weir elevation, inch*
Approx, rotor
submergence, inch
’ Including RAS flow
+ Measured from the lowest weir position
• Add seeding sludge, and turn on re-aeration blowers. Once rotor submergence > 4”, tum on
all rotors.
• Pump raw influent to the BNR train when mixed liquor concentrations reach above 500
mg/1.
• If necessary, re-adjust the ditch effluent weir position to maintain an optimal rotor
submergence of 8.5 inches.
• Adjust secondary effluent weir positions so that the water levels (read from water level
sensors) in secondary anoxic zones are 3” inches lower than in the ditch.
• Once fully nitrification has been established, tum on internal recycle pumps and set flow
rate about 100 - 200%of influent flow rate or based on effluent quality.
No ■ 59 36 P. 13
Switch from Auto Control Mode to Manual control
10$:\147 t\0003\80\04075PIan.doc
Switch mixers, rotors and internal recycle pumps to manual mode.
All mixers should be ON
Adjust weir position according to Table 1. Please note that the weir positions are
determined by the peak flow. For example, if the daily peak flow is 4 MOD and RAS is 3.0
MGD, then the weir will be drop down to the lowest position.
Turn on all rotors manually or use the following equations to estimate the number of rotor in
operation.
Adjust secondary effluent weir positions so that the water levels (read from water level
sensors) in secondary anoxic zones are 3” inches lower than in the ditch.
Set the internal recycle pumps flow as 100-200% of influent flow.
AOR, lbsO2/day=1.2BOD (Ibs/day) + 4.6 NH3 (Ibs/day)
SOR, lbsO2/day =1.4*AOR
Number of rotors required = SOR (lbsO2/hr)Z176 lbsO2/hr.rotor
APr-12. 2005 3:^1
Memo
End
Ken Schuster and I visited the plant on April 7, 2005, arriving at 10:00 AM and meeting
with Dennis A. Brown, Area Manager for Woodard & Curran, the contracted operators
for the facility. This visit was in response to the letter from McKim and Creed, Bryan
Blake, PE, advising of the intent to start new process facilities, as required by the
Authorization to Construct.
McKim and Creed submitted a start-up plan dated February 17, 2005 with their letter of
March 31 advising that start-up would take place on April 6 or 7. On our arrival, we
were advised that preparations were being made for start-up, but the actual start date
had been put off until Monday, April 11. We toured the facility starting with the new
clarifiers, one of which was filled for leak testing. All work was essentially complete with
the exception of SCADA - - We were advised that the facility would be started without
SCADA and run in the manual mode. The completion date for SCADA is set for late
April. Most of the instrumentation was installed and operational, but communication
links had not yet been established.
The BNR basins were complete and filled for leak testing. Kruger was on site servicing
the basin rotors and performing other start-up checks. The MCC’s were installed, main
feeds pulled, but still in the process of making terminations. Local panels were still
open and in need of finalizing wire runs and completing terminations. The travelling
bridge filters were complete and had previously been tested. The UV system was
operational. Effluent was clear and free of foam.
The current plant operation showed sludge bulking in the clarifier. This is primarily due
to the intentional storing of sludge to use as seed sludge during start-up. During start­
up, the existing facility and treatment units will remain on line at all times. Start-up will
be at an approximate rate of 1 MOD, and should begin the week of April 11,2005.
Date:
To:
From:
Subject:
April 13, 2005
File
Barry Herzberg
Durham Triangle WWTP
Durham County
NC0026051
Recon Visit
April 12, 2005 M&C 01471-0003 (40/60)
RE:
Dear Mr. Belnick:
If you need additional information, please let me know.
Sincerely,
McKIM & CREED, P.A.
I
/der
Enclosures
cc:
S: \ 1471 \0003 \ 40 \ 04125Belnick.doc
I
Please find attached the Partial Certification for the referenced project as we discussed. The
Partial Certification is basically for placing into service one of the five stage biological nutrient
removal trains. Train No. 2, with the other process structures as noted. This provides for 4.0
MGD ADF capacity in the new plant.
Bob Carter, Durham County
Chuck Hill, PE, Durham County
Ken Schuster, NCDENR Regional Office
Kevin Eberle, McKim & Creed, P.A.
200 MacKenan Court, Cary, North Carolina 2751 1
Tel [phone] Fax [phone] www.mckimcreed.com
AA0002667
Mr. Tom Belnick
NCDENR NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Triangle Wastewater Treatment Plant Phase II Expansion
ATC No. 026051A01
NPDES Permit No. NC0026051
McKim & Creed will process partial certifications for each of the two remaining BNR trains as
the contractor achieves substantial completion.
Also attached is the current start-up plan dated April 12, 2005 for your files. It is now
anticipated that the new process trains will be placed into service some time this week.
Bryan F. Blake, PE
Senior Project Manager
I,
Location:
>
>
Signature Registration No.11570
Date
>
>
>
>
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E.„ Director
ATC PROJECT NUMBER: 026051A01
Durham-Triangle WWTP
NPDES Permit No. NC0026051
the
Sed in
&.
ONE ♦
ONE ♦
ONE ♦
ONE ♦
ONE ♦
>
>
>
The project consists of:
> ]
NCDENR
PARTIAL CERTIFICATION
Professional Engineer’s Certification
For
Construction of Wastewater Treatment Facilities
APKTT,^?, 2005 __________________________________________j
Upon completion of construction and prior to operation of the modified facility, f
Division with a certification from a professional engineer certifying that the permit}
accordance with the NPDES Permit, this Authorization to Construct, and the approve
The Certification should be submitted to:
NCDENR/DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina
State of North Caroli^
Department of ^/irdjnent
and Natural Resources
Division of Water Quality
BRYAN F. BLAKE , am a duly registered Professional Engineer
(please print)
in the State of North Carolina and have been authorized to observe (circle one: full time) the
construction of the subject project for the Permittee:
Project: Durham/Triangle WWTP
Phase II Expansion
Intersection of Hwy 55 and Alexander Drive
Durham County
(—
Installation of a new five stage biological nutrient removal system (three treatment trains) including the following:
♦ BNR system flow distribution box
Three 16’ x 36’ x 18.5’ (79706 gallons) anaerobic selectors
Three-36’ x 67.5’ x 18.25’ (331709 gallons) primary anoxic reactors
Three.339’ x 36’ x 18’ (1,643,366 gallons) oxidation ditch aerobic reactors
Thr-ee-36’ x 45.5’ x 17’ (208,315 gallons) second stage anoxic reactors
Three 15’ x 36’ x 16.5’ (66,656 gallons) reaeration tanks
Secondary clarifier flow distribution
Four 110’ diameter x 16’ high secondary clarifiers
Two return activated sludge wetwells with two high volume (3,475 gpm) and one low volume (350 gpm) pumps per
wetwell
ReLu En-acxivated. -sludge- PLG-based-flow -proportioniU- eomrol pump-con treLsy-stem
> Tertiary filter weir type flow distribution
Five train traveling bridge tertiary sand filter with effective sand particle size of 0.55 to 0.65 mm and a unifonnity
coefficient (D60/D10) less than or equal to 1.5
Filter backwash system consisting of one 7.5 hp centrifugal pump per filter train (five pumps total)
Sodium Aluminate Chemical feed system with application points located secondary clarifier influent distribution
chamber and the tertiary sand filter distribution channel
Polymer feed system with application points located secondary clarifier influent distribution chamber
Sodium hypochlorite feed system with application points located at the tertiary sand filter distribution channel and
the reuse water trough at the ultraviolet disinfection unit effluent
> Effluent flow metering system consisting of a compound rectangular sharp crested weir and a ultrasonic level sensor
> Installation of any appurtenances associated with the referenced modifications
I hereby certify that I did regularly observe this project with due care and diligence and that the construction was
completed in substantial conformance with the Authorization to Construct and with the approve4-hl<|s and
specifications^
he I&rmfl$$fyll pQivii
1.
2.
3.
4.
5.
6.
7.
1S:\1471 \0003\60\04075Plan. doc
• potassium hydroxide (supplied by Woodward & Curran)
• sodium aluminate (supplied by Woodward & Curran)
• polymer (supplied by Woodward & Curran, see Item 16)
• methanol (supplied by Loving , see Item 1.6, Page 11501-2)
• sodium hypochlorite (supplied by Woodward & Curran)
The appropriate RAS/WAS pump on the north side of the new RAS/WAS pump station
shall transfer flow into the new Influent Flow and RAS Distribution Box. RAS flow shall
be measured by the new RAS flow meter. See Sheets C-10 and C-12. Kruger to lock
out WAS Pump No. 1 and RAS Pump No. 1 in their control logic to prevent them
from starting during the sludge seeding operation. (Note: In manual operation,
the pumps must be monitored and not allowed to run dry.)
The appropriate weir shall be set to allow RAS/WAS flow to enter the desired BNR Train
(Train No. 2). The other two weirs shall be raised to isolate the remaining two BNR
Trains. Weirs to be set by Loving.
The State (Regional Office) shall be notified when Loving starts to fill the BNR trains for
leak testing as just about all plant effluent flow will be diverted to fill the BNR trains.
Woodward & Curran to notify the State.
Forward flow shall enter the desired BNR Train (Train No. 2) by pumping. Two suction
lift pumps each capable of pumping 500 GPM to 2700 GPM shall be set on top of the
Woodward & Curran to check and confirm that all chemical bulk storage tanks
have sufficient supply of chemicals.
RAS and/or WAS will be pumped via the existing RAS or WAS pumps and an
interconnection between the existing WAS waste line and the new WAS waste line. See
Sheet C-8. Operation of existing RAS/WAS pumps by Woodward & Curran.
The chemical bulk storage tanks shall be checked to confirm that a sufficient supply of
the following chemicals are present:
TRIANGLE WWTP PHASE II
START-UP PLAN
APRIL 12, 2005
The start-up plan is based on all process facilities being completed, leak tested, electrical
checked out, and ready to be placed into service. The plan is also based on transferring RAS
and/or WAS from the existing clarifiers to seed the one new BNR Train.
The new WAS meter vault shall be valved so as to pass flow through the by-pass line
around the meter vault. The WAS shall enter the new RAS/WAS wetwell by isolating
and removing one of the new RAS/WAS pumps on the south side of the station. The
corresponding check valve shall be blocked open to allow flow to enter the wetwell
through the pump discharge piping. See Sheets C-8, C-24, and D-3A. Loving to
remove RAS Pump No. 1 and block the check valve open. Loving to close the
plug valve in the discharge header between RAS Pump No. 1 and No. 2 and close
the 8” WAS valve in the discharge header at WAS Pump No. 2.
8.
9.
10.
11.
12.
13.
2S \1471\0003\60\04075Plan doc
Begin seeding system with sludge approximately 24 to 48 hours prior to starting influent
flow: Woodward & Curran to operate existing RAS/WAS pumps to provide seed
sludge.
The BNR train will be started and run manually without the Kruger PLC Control
Panel. See the attachment “Manual Operation Train No. 2”.
The existing plant process train shall remain on line at all times. The existing 30” sluice
gate at the grit structure effluent box shall remain open such that forward flow not
pumped into the BNR basin shall continue to feed the existing aeration basins.
The amount of sludge needed for a desirable start-up MLSS level of 300-500 mg/l
may be estimated as following:
It is desirable to have seeded the new oxidation ditch with at least 300 to 500 mg/l of
MLSS from the existing system before starting influent flow. If it is possible to have
more than this, so much the better, however, Kruger does not recommend adding
seed sludge more than 48 hours in advance of adding influent. If possible, allow the
MLSS in the existing system to increase several days prior to anticipated startup to
20 or 30 % above your normal target level. Then waste the excess sludge to the
new ditch over first two to four days of seeding.
Where X is the target MLSS level in the new ditch and the total basin
volume for the new ditch inclusive of ditch, anaerobic and anoxic
zones is about 4.5 MG
Volume of Seed Sludge, MG = (X mg/l) x Total Basin Volume(MG)
MLSS in RASor WAS
After leak testing has been successfully completed, the desired BNR Train (Train No. 2)
to be placed into service shall have a plant effluent water level in the anaerobic, anoxic
zones and oxidation ditch that reaches the edges of rotors blades (0” rotor
submergence). Rotor blade submergence can be checked physically or read from the
PLC. Loving to provide the effluent water and confirm level.
Influent Flow and RAS Distribution Box. The discharge of the pumps shall be metered
with local read out of GPM and total flow. Pumps to be furnished and setup by
Loving. Woodward & Curran to maintain operation of the pumps. (Note: The
temporary pumps are manually controlled without floats and must not be allowed
to run dry.)
The Contractor shall leak test each BNR Train one at a time with plant effluent. The
testing water can be pumped from one train to the next such that the desired BNR Train
to be placed into service first receives the test water last. Leak testing is to be
completed prior to transferring RAS/WAS flow into BNR. Leak testing by Loving.
The mixers and weirs should be placed into local or manual control. Raise the ditch
effluent weirs approximately 3 inches above lowest position and set secondary anoxic
effluent weirs at lowest position. Turn on all mixers. Kruger/Loving to set weirs and
place mixers into operation.
14.
15.
1 MGD 3 MGD 4 MGDForward Flow 2 MGD
16.
17.
3S \1471 \0003\60\04075Plan. doc
Once the influent flow has raised the water level in the ditch so that the rotor
submergence > 4", turn on the rotors. If automatic D.O. control is functioning, the D.O.
set point should be 2.5 mg/l. It will be decreased to 1.3 mg/l when the MLSS reaches
target levels, the major criteria for achieving a stabilized system, before reducing the
D.O. set point. Loving/Kruger to place rotors into operation. (Note: Automatic D.O.
control will not be functioning at start up.)
Once RAS/WAS flow from the existing clarifiers is not required, then the pumps in the
new RAS/WWAS Pump Station shall be reset and valves adjusted to allow wasting of
sludge from the new process. Loving to reset RAS Pump No. 1, reset check valve
and discharge header valves for normal operation. Kruger to “unlock” RAS Pump
No. 1 and WAS Pump No. 1 in control logic to allow normal operation. (Note: RAS
Pump No. 1 to remain locked out until pump has been replaced.)
For example, assuming the concentration of the RAS/WAS flow is about 8,000 mg/l
approximately 170,000 gallons would be required to raise the MLSS level in the new
ditch to 300 mg/l.
Seeding the new ditch with RAS/WAS from the existing system should continue for
several days following introduction of influent until the MLSS reaches between 1000
and 1500 mg/l. At that point, it will be best to let solids accumulate through new
biological growth in the system. Woodward & Curran to provide for testing of
sludge to ensure the desired MLSS levels.
Table 1. Initial Chemical Dosage Recommendations
(Durham Only - Not Including Cary Flow)
Chemical______________
Sodium Aluminate_______
Potassium Hydroxide____
Emulsion Cationic Polymer
Methanol
mg/l
17.2
115.7
____1_
3
mg/l
17,2
115.7
___1_
3
gal/hr
____5
__14
0.08
0.94
mg/l
17.2
115.7
____1_
3
mg/l
17.2
115.7
____1_
3
gal/hr
10
___28
0.16
1.88
gal/hr
__2.5
____7
0.04
0.47
gal/hr
7.5
___21
0.12
1.41
Verify that chemical feed systems are functional and ready for operation (sodium
aluminate, potassium hydroxide, and cationic polymer initially and methanol). Methanol
will likely be required one or two weeks later, after biological nitrification has been
established. Adjust initial feed rates per Table 1 based on actual influent flow rate.
Start the appropriate chemical feeds simultaneously with starting influent flow to the
BNR.
Do not turn on the internal recycle pumps until it is verified that the new ditch is fully
nitrifying as evidenced by low ammonia (< 1 mg/l) and a corresponding increase in
nitrate (> 5 to 10 mg/l) in the BNR effluent (see Item 22). Woodward & Curran to
provide regular testing to track ammonia and nitrate levels. Once nitrification has
been established, start methanol feed at the rate indicated in Table 1 to the second
anoxic zone.
18.
19.
20.
21.
4S \1471\0003\60\04075Plan doc
Implement automatic level control at PLC or SCADA and set rotor submergence at
8 inches. Woodward & Curran to set automatic level control. The ditch weir shall
be manually adjusted at start up in accordance with the attachment.
NOTE: The aerobic F:M is estimated using the ditch volume only and does not
include the volume of the anaerobic zones, the anoxic zones, or solids in the
clarifier.
An aerobic F:M ratio about 0.15 to 0.2 is initially desired in order to accelerate
sludge build-up during start-up. The following table shows the estimation of
influent flow vs. MLSS assuming an influent BOD of about 150 mg/l on average
and a ditch volume of about 3 MG. Continue seeding until MLSS reaches target
levels (about 3,000-4,000 mg/l).
Once flow is entering the secondary clarifier and RAS flow can be discharged from the
clarifier, the RAS pumps should be switched on and the RAS should be adjusted to
100% of the influent flow. It is not necessary to establish a sludge blanket during
startup, rather keep the RAS rate high to ensure most of the MLSS solids reside in the
aeration basins where there is food and oxygen available for growth rather than the
clarifier. Control of RAS pumping shall be set by Kruger in the control logic for
start-up. (Note: However at start up the RAS pumps shall be manually operated.
In manual operation, the pumps must be monitored and not allowed to run dry.)
One of the new clarifiers (Clarifier No. 3) shall be placed into service with the other three
off-line. The clarifier will be empty and allowed to fill with forward flow from the BNR
Train. Start sodium aluminate feed when forward flow is initiated to the clarifier.
Woodward & Curran shall have their chemical supplier jar testing the MLSS
entering the clarifier to determine the proper polymer. McKim & Creed would
anticipate the use of a cationic polymer. Once the correct polymer is identified, the
polymer shall be supplied at the recommended dosage to the forward flow entering the
clarifier. The first clarifier shall continue to fill and allowed to stabilize establishing the
sludge blanket after the BNR Train has stabilized (see Items 19 and 24). As the forward
flow is increased to the first BNR Train, a second clarifier (Clarifier No. 2) can be brought
on line if needed. The two remaining off-line clarifiers (Clarifier No. 1 and No. 4) shall
serve as storage basins if there is an upset of the BNR Train. Flow can be diverted into
the off-line clarifiers by weir adjustment at the Clarifier Distribution Box. See Sheet C-
21. Woodward & Curran is to bring on-line the second clarifier as needed.
Monitor MLSS in the oxidation ditch at least once per day (maybe more often) during
seeding. The initial influent flow rate may be estimated as following using the aerobic
F:M as the basis for controlling flow volume. Woodward & Curran to provide for
monitoring of MLSS levels.
Influent flow, MGD = (F: M)x Q-7 * MLSS(mg/l) x Ditch Volume(MG)
Infuent BOD(mgZI)
Table 2. Recommended flow, MLSS and F:M ratio during Start-up
t.Oto 1.2 600 to 700 0.14
1.5 to 1.7 0.12
2.0 to 2.2 0.10
2.3 to 2.5 0.09
3.0 to 3.2 0.09
3.5 to 4 MGD 0.09
5S:\1471\0003\60\04075Plan.aoc
Influent Flow, MGD
0.5 to 0.7
900 to 1,100
1.400 to 1,600
1,900 to 2,200
2.400 to 2,600
3,000 to 3,300
MLSS, mg/l
300 to 400
Approximate F:M
0.17
The values in Table 2 assume the wastewater temperature is 12 to 15°C and an influent
BOD of approximately 150 mg/l. The values in this table should be considered
approximate. Decrease influent flow if effluent ammonias rise above 2 mg/l or effluent
BOD rises above 15 mg/l., the influent BOD increases significantly, or the MLSS
temperature in the oxidation ditch falls below 10 to 11 °C.
A recommended monitoring schedule for process startup is listed in Table 3. As an
absolute minimum, the ditches should be monitored for MLSS and ammonia and the
clarifier effluent composite analyzed for ammonia. Kruger assumes that plant staff has
the capability onsite to monitor ammonia and MLSS daily. Once the ditch is stabilized,
the frequency of monitoring can be reduced.
Table 3. Recommended Monitoring Schedule During BNR Process Start-up
DC DCDC*
DC W
DG
DG
Once/day
DG0
22.
23.
24.
25.
6S \1471\0003\60\04075Plan.doc
It may be desirable to begin wasting some sludge from the new system once the MLSS
reaches about 1,500 mg/l to 2,000 mg/l or 15-20 days after seeding, whichever comes
first. The volume of waste sludge can be estimated based on a SRT of 15-20 days and
should be less than net growth of activated sludge in oxidation ditches to allow continued
accumulation of solids. Kruger will advise during startup on when to begin wasting
and how much to waste.
(Raw
Influent
(pre
screening)
DC*
DC*
DC*
O
DC*
DG
DC*
W
DG
DG
DG
DC
DG
DG
DG
DG
W
W
DC
O
DC
W
DG
DG
Oxidation
Ditches
DG
DG
DG
DG
DG
DG
Secondary
Clarifier
Effluent
DC
DC
DC
DC
DC
DC
WAS/
RAS
DG
DG
DG
DG
DG:
W:
O:
BNR
Influent
(post
screening)
Twice/day
DG
At MLSS of about 2000 mg/l, adjust RAS flow to maintain a 1-2 ft sludge blanket depth in
secondary clarifiers. The sludge blanket should be checked at approximately the same
time each day in the same location in the clarifier. Woodward & Curran to make
adjustment to RAS pumps and provide for checking of sludge blankets.
Anaerobic
Selector
(3rd stage)
As forward flow leaves the first clarifier, one new filter (Filter No. 1) shall be placed into
service. Influent sluice gates for four filters shall be shut and one sluice gate shall be
open for the filter to be placed into service. See Sheet C-25. Woodward & Curran
Parameters
Organic
CBOD5 - Total
Solids
TSS
VSS_________
Nitrogen
TN
TKN
NH4-N
NO3-N________
Phosphorus
TP
PO4-P________
Operational
Indicators
PH
Alkalinity
Temperature_____
Mixed Liquor
Settled Sludge
Volume (5,30,60
Min) ______
TP in Mixer Liquor
DC: Daily composite sample
DC*: Manual daily composite sample minimum of 5 samples taken to correlate with the post
screening samples
Daily grab sample
Weekly (twice/week)
Occasional
Once nitrification is stabilized, as evidence by effluent ammonias < 1 mg/ and a rise in
effluent nitrates, the internal recycle pumps can be started. The pumps should be set to
return about 100 to 150% of the influent flow rate. Woodward & Curran to start
internal recycle pumps.
26.
27.
28.
7S \1471\0003\60\04075Plan doc
After approximately four weeks of operation, begin monitoring the ortho-phosphate in the
selector and the total phosphate concentration in the influent about twice per week to
detect onset of biological phosphorus removal. Chemical addition (sodium aluminate)
will probably be required into the clarifiers, particularly during startup if phosphorus limits
must be met. Woodward & Curran to provide for monitoring the ortho-phosphate
level.
shall set the sluice gates and place the one filter into service. When the second
BNR Train is placed into service and all forward flow has been diverted from the existing
plant into the new BNR process trains, a second filter (Filter No. 2) shall be placed into
service.
After the first BNR Train (Train No. 2) has stabilized, the second BNR Train (Train No. 1)
will be started up. The startup process shall be as outlined above except seed sludge
shall be provided from the new clarifiers and will not be required from the existing
clarifiers. The 30’’ sluice gate at the grit structure effluent box shall be closed allowing all
forward flow to enter the two BNR Trains. This will eliminate the need for the temporary
pumps (Item 7) as the forward flow will be gravity flow. Once the 30” sluice gate is
closed, the existing plant can be allowed to go off-line. Once the existing plant is off-line,
the effluent pump station can be shut down and the 30” sluice gate at the UV structure
influent box can be closed. See Sheet C-17 of the Phase I plans. Woodward & Curran
to place the existing plant off-line and close the appropriate sluice gates.
BOD removal should begin to occur immediately if seeding is adequate and the influent flow is
not increased too rapidly. Nitrification should also follow rapidly again if the F:M ratio does not
get too high. During the first couple of days of startup, there will be a considerable dilution
effect to offset any delay in onset of nitrification. Sufficient MLSS must be accumulated to see
good nitrogen removal and this may require several weeks. Kruger would recommend holding
off on methanol addition until solids are at target levels and effluent TN levels have stabilized.
Biological phosphorus will require significantly more time and will be very much dependant on
the presence of soluble BOD in the influent. If the soluble BOD is present, biological
phosphorus removal should begin to take place within 6-10 weeks after initial startup and
steadily improve thereafter if the system is suitably loaded. The onset of biological phosphorus
removal is detected by monitoring the ortho-phosphate concentration in the last stage of the
anaerobic selector. Typically, it will be 3 to 5 times the ortho-phosphate concentration in the
influent if the release/uptake cycle is established. After approximately four weeks of operation,
Once the MLSS concentration is between 2,500 and 3000 mg/l and nitrification is
stabilized, the RAS Bleed to the second anoxic stage may be started. The RAS bleed
should be incrementally increased daily until the MLSS in the Secondary Anoxic zone is
approximately 800 to 1000 mg/l higher than in the oxidation ditches. During this
adjustment period lasting a few days, collect a sample of MLSS for solids measurement
from the secondary anoxic zone in addition to the sample collected in the oxidation ditch.
Typically the RAS bleed rate will be between 20 and 30 percent of the RAS flow rate and
the target MLSS in the secondary anoxic should be about 700 to 1000 mg/l higher than
in the oxidation ditch upstream. Once the RAS bleed is set, sampling in the secondary
anoxic zone can be reduced to once per week. Lower the DO set point in the oxidation
ditch to 1.3 mg/l. Woodward & Curran to make the RAS bleed adjustment and
provide for testing MLSS levels.
8S \1471 \0003\60\04075Plan.doc
begin monitoring the ortho-phosphate in the selector and the total phosphate concentration in
the influent about twice per week.
The County has agreed for Woodward & Curran to provide a designated start-up coordinator.
Woodward & Curran to inform the County of the designated person.
Kruger personnel will visit the site the first few days of startup and will always be available for
consult.
MANUAL OPERATION TRAIN #2
BEFORE TURN ON ROTORS, MAKE SURE ROTOR SUBMERGENCE >4”
Initial Manual Mode Start-up
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
1.2 1.9 2.5 3.0 3.5 4.0 4.4 4.8
0 032.5 2 1.5 1.0 0
8.2 8.4 8.5 8.5 8.5 8.0
8.4 8.8
9S:\1471\0003\60\04075Plan.doc
After leak testing, water levels in the ditch should reach the edges of rotor blades. Turn on
all mixers
Drop secondary anoxic effluent weir down to the lowest position
Under manual operation mode, adjust weir position according to the flow rates listed in
Table 1. The flow rates listed here are the anticipated start-up raw influent plus RAS flow.
For example, assume the start-up flow rate of 2.0 MGD and RAS flow of 1.0 MGD, the total
influent to the ditch would be 3.0 MGD, then the ditch effluent weir would be raised 2.0
inches from its lowest position. If the total flow rate to the ditch is more than 6.0 MGD, the
effluent weir would be in the lowest position.
Table 1. Rotor submergence and weir position at different flowrate
Flow rate, MGD*
Water head over weir, inch
Initial weir elevation, inch+
Approx, rotor
submergence, inch
* Including RAS flow
+ Measured from the lowest weir position
Add seeding sludge, and turn on re-aeration blowers. Once rotor submergence > 4”, turn on
all rotors.
Pump raw influent to the BNR train when mixed liquor concentrations reach above 500
mg/l.
If necessary, re-adjust the ditch effluent weir position to maintain an optimal rotor
submergence of 8.5 inches.
Adjust secondary effluent weir positions so that the water levels (read from water level
sensors) in secondary anoxic zones are 3” inches lower than in the ditch.
Once fully nitrification has been established, turn on internal recycle pumps and set flow
rate about 100 - 200%of influent flow rate or based on effluent quality.
Switch from Auto Control Mode to Manual control
10S\1471\0003\60\04075Plan.doc
AOR, lbsO2/day=1.2BOD (Ibs/day) + 4.6 NH3 (Ibs/day)
SOR, lbsO2/day =1.4*AOR
Number of rotors required = SOR (lbsO2/hr)/176 lbsO2/hr.rotor
Adjust secondary effluent weir positions so that the water levels (read from water level
sensors) in secondary anoxic zones are 3” inches lower than in the ditch.
Set the internal recycle pumps flow as 100-200% of influent flow.
Switch mixers, rotors and internal recycle pumps to manual mode.
All mixers should be ON
Adjust weir position according to Table 1. Please note that the weir positions are
determined by the peak flow. For example, if the daily peak flow is 4 MOD and RAS is 3.0
MOD, then the weir will be drop down to the lowest position.
Turn on all rotors manually or use the following equations to estimate the number of rotor in
operation.
Memo
Date:April 21,2005
To:File
From:Barry Herzberg
Subject:
End
A follow-up visit was made to this facility now that start-up of the new BNR trains is
underway. Contacts on site included Charles Hill, Utility Division Manager and Bob
Carter, Project Manager for Durham County, and Don Hancock, Construction
Administrator for McKim and Creed.
The first of the three new BNR trains was on line. Seed sludge had been taken from the
existing plant clarifiers, and the process appeared to be functioning according to plan.
Equipment was working satisfactorily, although the SCADA system is still not functional.
Influent flow is being split so as to maintain 1.0 to 1.5 MOD to the new system with the
balance going to the existing plant. Process color and odor were unremarkable.
Foaming was minimal in the ditch. The Kruger equipment was operating smoothly.
Secondary clarifier was clear of surface contaminants, and effluent over the weirs was
clean. At the time of my visit, the traveling bridge tertiary filters had been taken off line
to allow installation of a catwalk along the overflow weir in the effluent chamber
downstream of the UV system.
A significant amount of site work has been completed in the two weeks since my last
visit.
Once the first BNR train has stabilized, the second train will be put into service. The
third train will remain serviceable, but will not be put into operation until necessary to
meet flow demands. Target project completion date is June 5, 2005.
Durham Triangle WWTP
Durham County
NC0026051
Recon Visit
r
«
April 27, 2005 M&C 01471-0003 (40/60/70
RE:
Dear Mr. Belnick:
remaining BNR train as the
It is anticipated that BNR Train No. 1 will be placed into service some time next week.
If you need additional information, please let me know.
Sincerely,
McKIM & CREED, P.A.
/der
Enclosures
cc:
1
Please find attached another Partial Certification for the referenced project as we discussed.
This Partial Certification is for placing into service the second five stage biological nutrient
removal train. Train No. 1. This provides for an additional 4.0 MGD ADE capacity in the new
plant for a total of 8.0 MGD.
Bob Carter, Durham County
Chuck Hill, PE, Durham County
Ken Schuster, NCDENR Regional Office
Kevin Eberle, McKim & Creed, P.A.
Ty Edmondson, III, PE, T. A. Loving Co.
Mr. Tom Belnick
NCDENR NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Triangle Wastewater Treatment Plant Phase II Expansion
ATC No. 026051A01
NPDES Permit No. NC0026051
/
Bryan f. Blake, PE
Senior Project Manager
McKim & Creed will process a partial certification for the one
contractor achieves substantial completion.
S:\1471\0003\40\04275BelnickDOC 200 MACKENAN COURT, CARY, NORTH CAROLINA 2751 1
Tel [phone] Fax [phone] www.mckimcreed.com
AA0002667
NCDENR
Location:
The project consists of: BNR Train No. 1
id with the approved plans and
11570
State of Not
Department 1
and Natural Resouro
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E.„ Director
> Installation of a new five stage biological nutrient removal system (one treatment
train) including the following:
■ One Anaerobic Selector with three cells each 15'-9"x36'x18' (total volume 229,000
gallons)
■ One Primary Anoxic Reactor with two cells each 67’x36'xl8’ (total volume 649,500
gallons)
■ One Oxidation Ditch Aerobic Reactor 72'x339'xl8' (total volume 3,200,000 gallons)
■ One Second Stage Anoxic Reactor with two cells each 36'x45'xl7' (total volume
412,000 gallons)
■ One-Re-Aeration Stage 15'x36'xl6.9' (total volume 68,000 gallons)
^Carolina
t®Envir^nent
I Resources
aid mligence and that the construction was
j®jct |nd with the approved plans and
Professional Engineer’s Certification
For
Construction of Wastewater Treatment Facilities
ATC PROJECT NUMBER: 026051A01
Durham-Triangle WWTP
NPDES Permit No. NC0026051
I, Bryan F. Blake •, am a duly registered Professional Engineer
(please print) . ,
in the State of North Carolina and have been authorized to observe (circle one: jXXii&kSHy, full time) the
construction of the subject project for the Permittee:
Project: Durham/Triangle WWTP
Phase II Expansion
Intersection of Hwy 55 and Alexander Drive
Durham County
I hereby certify that I did regularly observe thisfcroj^fwigg^afe $pc
completed in substantial conformance with the jkutIwrizatLon^feCons1
specification^----y s W

sisna“re
Date April_27f 2005
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division with a certification from a professional engineer certifying that the permitted facility has been installed m
accordance with the NPDES Permit, this Authorization to Construct, and the approved plans and specif cations.
The Certification should be submitted to:
NCDENR/DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617
f
May 17, 2005
RE:
Dear Mr. Belnick:
If you need additional information, please let me know.
Sincerely,
McKIM & CREED, P.A.
/der
Enclosures
cc:
Please find attached another Partial Certification for the referenced project as we discussed.
This Partial Certification is for substantial completion of the third and final five stage biological
nutrient removal train, Train No. 3. This provides for an additional 4.0 MGD ADF capacity in
the new plant for a total of 12.0 MGD.
It is anticipated that BNR Train No. 3 will not be placed into service until such time as the
additional capacity is needed.
Please note that McKim & Creed has issued three partial certificates to date which cover all the
process units and equipment per the Authorization to Construct except for the inplant SCADA
system. A fourth and final partial certificate will be issued for this component.
Bob Carter, Durham County
Chuck Hill, PE, Durham County
Ken Schuster, NCDENR Regional Office
Kevin Eberle, McKim & Creed, P.A.
Ty Edmondson, III, PE, T. A. Loving Co.
Mr. Tom Belnick
NCDENR NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Triangle Wastewater Treatment Plant Phase II Expansion
ATC No. 026051 AO 1
NPDES Permit No. NC0026051
M&C 01471-0003 (40/60/70)
Bry^h F. Blake, PE
Senior Project Manager
S:\1471\OOO3\4O\O5175Belnick.DOC 200 MACKENAN COURT, CARY, NORTH CAROLINA 2751 1
TEL [phone] Fax [phone] www.mckimcreed.com
AA0002667
r
i
NCDENR
Location:
The project consists of: BNR Train No. 3
igistration No.11570Signature
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E.„ Director
> Installation of a new five stage biological nutrient removal system (one treatment
train) including the following:
■ One Anaerobic Selector with three cells each 15'-9"x36'xl8' (total volume 229,000
gallons)
■ One Primary Anoxic Reactor with two cells each 67'x36'xl8' (total volume 649,500
gallons)
■ One Oxidation Ditch Aerobic Reactor 72'x339zxl8' (total volume 3,200,000 gallons)
■ One Second Stage Anoxic Reactor with two cells each 36'x45'x17' (total volume
412,000 gallons)
■ One-Re-Aeration Stage IS'xSO'xlb.O' (total volume 68,000 gallons)
State of N Ai Cardia
Departmen^f ErrflBnment
and Natural Resources
Division of Water Quality
ATC PROJECT NUMBER: 026051A01
Durham-Triangle WWTP
NPDES Permit No. NC0026051
I,Bryan F, Blake _____________________, am a duly registered Professional Engineer
(please print)
in the State of North Carolina and have been authorized to observe (circle one-^peri®riicalhV55®ckJy, full time) the
construction of the subject project for the Permittee:
Project: Durham/Triangle WWTP
Phase II Expansion
Intersection of Hwy 55 and Alexander Drive
Durham County
I i
I hereby certify that I did regularly olfserVe this'H^
completed in substantial conformancd^ithyihe Autho
specifications. J
Professional Engineer’s Certification
For .
Construction of Wastewater Treatment Facilities
Date May 17 , 2005 _________•
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division 'with a certification 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.
The Certification should be submitted to:
NCDENRJDWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617
□ B
J10 witlj du&care and diligence and that the construction was
rorizati&n ti/Construct and with the approved plans and
Michael F. Easley, Governor
’ M . »j
June 20, 2005
Floor
Dear Mr. Hill:
Sincerely,
50% Recycled/10% Post Consumer PaperAn Equal Opportunity/Affirmative Action Employer -
The facility was operating normally at the time of the inspection, with an influent flow of approximately 5.0
MGD. There were no objectionable odors anywhere on the facility grounds.
North Carolina Division of Water Quality
Internet: h2o.enr.state.nc.us
On June 7, 2005, Mr. Barry Herzberg of the Raleigh Regional Office conducted an annual Compliance
Evaluation Inspection of the subject facility. The attached checklist reflects those areas evaluated during
this inspection, and includes comments where appropriate at the end of each section.
We are pleased to advise that the Durham Triangle Water Reclamation Facility is in compliance with the
NPDES permit, NC0026051. Should you have any questions regarding this evaluation, please contact
me at 919-571-4700 extension 238, or by e-mail to [e-mail].
Barry Herzberg 1/
Environmental Engineer
Raleigh Regional Office
1628 Mail Service Center
William G. Ross, Jr., Secretary
North Carolina Department of Environment and Natural Resources
Phone[phone]
FAX [phone]
Alan W. Klimek, P.E., Director
Division of Water Quality
Subject: Compliance Evaluation Inspection
Durham Triangle Water Reclamation Facility
Durham County
NPDES Permit No. 0026051
Surface Water Protection
Raleigh. NC 27699-1628
NorthCarolinaNaturally
Customer Service
1-877-623-6748
?puch
Mr. Charles N. Hill, Jr., P.E.
Utility Division Manager
Durham County
120 E. Parrish Street, T1
Durham, NC 27701
JUN 2 0 2305
2J d
EPA
NPDES
3l NC0026051
21| I I I I I I | | | | I | I I I I I I I Illi66
Entry Time/Date Permit Effective Date
04/03/01
Triangle WWTP
Exit Time/Date Permit Expiration Date5926 NC Hwy 55 E
06/04/30Durham NC 27701
Other Facility Data
Gerald Tyrone Battle/ORC/919-544-8831/
Ronald Glenn Ketteman/ORC/919-544-8280/
Name, Address of Responsible Official/Title/Phone and Fax Number
Effluent/Receiving Waters
Section D; Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s)Agency/Office/Phone and Fax Numbers Date
RRO WQ///HerzbergBarry
Agency/Office/Phone and Fax Numbers DateSignature of Management Q A Reviewer
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
12L
United States Environmental Protection Agency
Washington, D C. 20460
yr/mo/day
05/06/07
Operations & Maintenance | Records/Reports
Laboratory
Contacted
No
QA
72 LJ
Jerry F Rimmer,120 E Parrish St Durham NC 27701/Plant
Manager/919-544-8280/9195448590
Facility Self-Monitoring Evaluation Rating
7° Lil
Form Approved.
OMB No. 2040-0057
Approval expires 8-31-98
Fac Type
20 LJ
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Inspection Type
18l£jJ 11
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
M Flow Measurement
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
J 17
Inspector
19l±|
Inspection Work Days
671 .5 | 69
Remarks
I I I I I I I I I I I I I I I I I I I | | | |
Bl
71 U 73 LU74
m Permit
m Facility Site Review
Water Compliance Inspection Report
Section A: National Data System Coding (i.e., PCS)
—Reserved---------------------
75| | | | | | | | 80
Transaction Code
1 Ld 2 LI
09:00 AM 05/06/07
12:30 PM 05/06/07
Permit
(If the present permit expires in 6 months or less). Has the permittee submitted a new application?
Is access to the plant site restricted to the general public?
Comment:
NA NEBar Screens
b.Mechanical
Are the bars adequately screening debris?
Is the screen free of excessive debris?
Is disposal of screening in compliance?
Is the unit in good condition?
Comment: There was a minor amount of debris collecting on the inside of the units rear access panel.
NA NEGrit Removal
Type of grit removal
a.Manual
b.Mechanical
NA NE
Comment:
NA NE
Is the site free of excessive buildup of solids in center well of circular clarifier?
Are weirs level?
Is the site free of weir blockage?
Is the site free of excessive floating sludge?
Is the drive unit operational?
Is disposal of grit in compliance?
Comment: An odor control system is operational in both the barscreen and grit removal areas. There were no
objectionable odors anywhere in the immediate area.
Grease Removal
Secondary Clarifier
Is the clarifier free of black and odorous wastewater?
Is the facility as described in the permit?
Are there any special conditions for the permit?
Type of bar screen
a.Manual
Is the grit free of excessive organic matter?
Is the grit free of excessive odor?
Is automatic grease removal present?
Is grease removal operating properly?
Is the site free of evidence of short-circuiting?
Is scum removal adequate?
Is the sludge blanket level acceptable?
Is the return rate acceptable (low turbulence)?
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
Is the inspector granted access to all areas for inspection?
Comment: This facility is now operating the completed expansion to 12.0 MGD, with the following treatment components:
Mechanical barscreens and grit removal, 5 stage BNR system, secondary clarifiers, tertiary sand filters and UV
disinfection. Sludge is wasted to a holding lagoon for annual processing. The permit limits for 12.0 MGD operation are
included in the current permit.
Operations & Maintenance
Is the plant generally clean with acceptable housekeeping?
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge,
and other that are applicable?
Yes No
Yes No
Yes No
Yes No NA NE
Yes No
Secondary Clarifier
Is the overflow clear of excessive solids/pin floc?
NENA
Are pumps in place?
Type
Is chemical feed required to sustain process?
NA NEFiltration (High Rate Tertiary')
Type of operation:
Is the filter free of growth?
Is the air scour operational?
Comment:
NA NEDisinfection - UV
Are extra UV bulbs available on site?
Are UV bulbs clean?
Is UV intensity adequate?
Is transmittance at or above designed level?
Is effluent clear?
Is there a backup system on site?
Is effluent clear and free of solids?
Comment:
NA NE
Is the generator tested by interrupting primary power source?
Is the generator tested under load?
Is there an emergency agreement with a fuel vendor for extended run on back-up power?
NENA
Is the surface free of bulking ?
Is the sludge blanket level acceptable? (Approximately 'A of the sidewall depth)
Comment: Only one of the four clarifiers was in operation during the inspection. Sludge troughs were clean and
operating normally.
Rumps-RAS-WAS
Is the generator fuel level monitored?
Comment: There are three standby generators on site. All are operational, but were not tested during this inspection.
This facility also has dual power feeds from Duke Power.
Laboratory
Are pumps operational?
Are there adequate spare parts and supplies on site?
Is nutrient removal process operating properly?
Comment:
Was generator tested & operational during the inspection?
Do the generator(s) have adequate capacity to operate the entire wastewater site?
Is total nitrogen removal required?
Is total phosphorous removal required?
Is the filter media present?
Is the filter surface free of clogging?
Is the scouring acceptable?
Is the clear well free of excessive solids and filter media?
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
Comment: One pump had been removed due to failure on start-up caused by faulty wiring.
Nutrient Removal
Standby Power
Is automatically activated standby power available?
Biological
■
■
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No NA NF
Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)?
Incubator (Fecal Coliform) set to 44 5 degrees Celsius*/- 0.2 degrees?
Record Keeping
Are records kept and maintained as required by the permit?
Is the chain-of-custody complete?
O&M Manual
■
Dates, times and location of sampling
Dates of analysis
Name of person performing analyses
Is the backup operator certified at one grade less or greater than the facility classification?
Is a copy of the current NPDES permit available on site?
Effluent Pipe
Are all other parameters(excluding field parameters) performed by a certified lab?
Is the facility using a contract lab?
Incubator (BOD) set to 20.0 degrees Celsius +/-1.0 degrees?
Comment:
Is all required information readily available, complete and current?
Are all records maintained for 3 years (lab. reg. required 5 years)?
Are analytical results consistent with data reported on DMRs?
Transported COCs
Are DMRs complete: do they include all permit parameters?
Has the facility submitted its annual compliance report to users and DWQ?
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift?
Is the ORC visitation log available and current?
Is the ORC certified at grade equal to or higher than the facility classification?
Facility has copy of previous year's Annual Report on file for review?
Comment:
As built Engineering drawings
Schedules and dates of equipment maintenance and repairs
Name of individual performing the sampling
Results of analysis and calibration
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
Laboratory
Are field parameters performed by certified personnel or laboratory?
Is right of way to the outfall properly maintained?
Are the receiving water free of foam other than trace amounts and other debris?
If effluent (diffuser pipes are required) are they operating properly?
Comment: Very clean effluent discharge to Northeast Creek. Several large catfish and numerous smaller fishes in area.
Advised plant personnel to try to determine if catfish were the flathead (invasive) species.
Yes No NA NE
July 7, 2005
Re:
Dear Mr. Schuster:
If you have any questions or need additional information, please call me at 560-7992.
cc:
CH/jld
■5 /
Glen E. Whisler, P.E., County Engineer
Adrienne Fancher, Project Manager-United Water
120 E. Parrish Street, Law Bldg., 1st Floor, Durham, N.C. 27701 [phone] Fax [phone]
Equal Employment/Affirmative Action Employer
NCDENR - Raleigh Regional Office
Kenneth Schuster, P.E.
Water Quality Regional Supervisor
Division of Water Quality
Water Quality Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Sincerely,
Chuck Hill, P.E.
Utility Division Manager
Effective July 1, 2005, United Water assumed the operations and maintenance
responsibilities for the TWWTP (NC0026051) and collection system (WQC00038) under
a five (5) year contract with Durham County. The new Project Manager is Adrienne
Fancher and she can be reached at 544-8280. Tyrone Battle will remain as IPP
Coordinator and Plant ORC and will be backed up by Ron Ketteman. The collection
system ORC will remain as Ron Ketteman and he will be backed up by Victor Cozart.
' ^1
‘ I
■ ■?./
WWTP and Collection Systems Operations Change Notification for the
Triangle Wastewater Treatment Plant (TWWTP) at 5926 Hwy 55
NA
COUNTY OF DURHAM
ENGINEERING DEPARTMENT
/ii
■
^vfCEJM&(?RSED
August 17, 2005 M&C 01471-0003 (40/60/70)
RE:
Dear Mr. Belnick:
If you need additional information, please let me know.
Sincerely,
McKIM & CREED, P.A.
/der
Enclosure
cc:
S:\1471\0003\40\08175Beinick.DOC
Bob Carter, Durham County
Chuck Hill, PE, Durham County
Ken Schuster, NCDENR Regional Office
Kevin Eberle, McKim & Creed, P.A.
Ty Edmondson, III, PE, T. A. Loving Co.
Mr. Tom Belnick
NCDENR NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Triangle Wastewater Treatment Plant Phase II Expansion
ATC No. 026051A01
NPDES Permit No. NC0026051
200 MacKenan Court, Cary, North Carolina 2751 1
Tel [phone] Fax [phone] www.mckimcreed.com
AA0002667
Bry/m F. Blake, PE
Senior Project Manager
Please note that McKim & Creed has now issued four partial certificates which cover all the
process units and equipment per the Authorization to Construct.
Please find attached the fourth and last Partial Certification for the referenced project as we
discussed. This Partial Certification is for substantial completion of the in-plant SCADA
system.
NCDENR
I,
Location:
This certification is for substantial completion of the in-plant SCADA system.
itration No.11570
Date
I hereby certify that I did regularly c
completed in substantial conformam
specifications,
Signature!
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E.„ Director
Project: Durham/Triangle WWTP
Phase II Expansion
Intersection of Hwy 55 and Alexander Drive
Durham County
ATC PROJECT NUMBER: 026051A01
Durham-Triangle WWTP
NPDES Permit No. NC0026051
Bryan F. Blake , am a duly registered Professional Engineer
(please print)
in the State of North Carolina and have been authorized to observe (circle one: periodically, weekly, full time) the
construction of the subject project for the Permittee:
State of NorthA^roy^
Department oHznvi™ment
and Natural Resources
Division of Water Quality
witH du&care and diligence and that the construction was
tlie^^^Qzati(Mi toJSonstruct and with the approved plans and
July 2005
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division with a certification 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.
The Certification should be submitted to:
NCDENRJDWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617
7$ 2005
PROFESSIONAL ENGINEER’S CERTIFICATION
FOR
Construction of Wastewater Treatment Facilities
cQ. . ft n K. J» . a sep
: wi
Michael F. Easley, Governor
September 22, 2005
Subject:
Dear Mr. Hill:
We regret the extreme delay in providing you with these comments.
Sincerely,
You are reminded of the Division’s December 10, 2004, letter requires all POTWs to make
various revisions to their SUOs and submit them by December 1, 2006. Please review our web­
site for details.
Mr. Chuck Hill
Division Head, Durham County Env. Eng. Office
Durham County
120 E. Parrish St., Suite 110
Durham, NC 27701
Pretreatment Review of Sewer Use Ordinance (SUO)
Program: Durham County
Durham County NPDES Number NC0026051.
1617 Mail Service Center
512N. Salisbury St.
Phone[phone]
FAX [phone]
Alan W. Klimek, P.E. Director
Division of Water Quality
Raleigh, NC 27699-1617
Raleigh, NC 27604
NC DWQ/PERCS
Internet: h2o.enr.state.nc.us/Pretrcat/index.html
Thank you for your continued support of the Pretreatment Program. If you have any questions or
comments, please contact Dana Folley at [phone] ext. 523 [email:
[e-mail]] or Jeff Poupart, Supervisor of the Pretreatment, Emergency Response,
and Collection Systems Unit (PERCS) at ext 527 [email: [e-mail]].
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
The review indicates that the SUO is adequate and the minimum requirements of 15A NCAC
2H .0900 and 40 CFR 403 are met. The SUO was adopted by the local governing body on
September 1, 2003.
The Pretreatment, Emergency Response and Collection Systems Unit (PERCS) of the Division
of Water Quality has reviewed the Sewer Use Ordinance (SUO) for Durham County. This SUO
was received by the Division on March 1, 2004, with additional information received on
November 22, 2004.
NorthCarolina
-------------Naturally
Customer Service
1-877-623-6748
pZ,
co/rI j
Q \ Alan W. Klimek, P.E.
DRF / durhamcounty_suo_003
cc: Tyrone Battle, United Water, consultant for Durham County
Central Files
Chris Wu, Raleigh Regional Office
Dana Folley, PERCS Unit
1 ItaXZ 1111 r
Michael F. Easley, Governor
ft ft
Date: October 17, 2005
Subject: Notice of Incomplete Discharge Monitoring Report
Dear Permittee:
cc:
An Equal Opportunity/Affirmative Action Employer
Raleigh Regional Office
Central Files
Charles N. Hill, Jr.
120 East Parrish Street
Durham, NC 27701
Attention: Michele Phillips
Division of Water Quality
Central Files
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Raleigh, North Carolina 27699-1617
Raleigh. NC 27604
Phone: [phone]
Fax: [phone]
Alan W. Klimek, P, E. Director
Division of Water Quality
N. C. Division of Water Quality
Internet: http://h2o.enr.state.nc.us
Future DMR submittals with the same or similar problems will be unacceptable. If you have any questions
about the proper completion of DMRs, please contact Michele Phillips at 919-733-5083 Ext. 225. Thank
you for your assistance in this matter.
1617 Mail Service Center
512 N. Salisbury St.
The purpose of this letter is to call your attention to problems with the recent submittal of the Discharge
Monitoring Report (DMR) from your facility. As you may know, the data recorded on your DMR is keyed
into the Division’s database. Our data entry staff has informed me of problems with your recent DMR
submittal. Until these problems have been corrected, your DMR will be considered incomplete. Please
see the attached form along with a copy of the problem DMR for details regarding the DMR’s deficiency.
North Carolina____ Naturally
Customer Service
1-877-623-6748
At7 rGO
>
o
Incomplete or illegible DMRs affect our staffs ability to provide a timely and effective evaluation of DMR
submittals. Please be aware that until the Division receives a corrected DMR, you may be considered
noncompliant with your NPDES permit and 15A NCAC 02B .0506, and you may be subject to further
enforcement action. Please take the necessary steps to correct the problems and submit two copies of the
amended DMR within fifteen (15) days of the date of this letter to the following address:
William G. Ross Jr., Secretary
Nonh Carolffroepanment of Environment and Natural Resources
Sincerely,
W. Klimek, P.E.
Notice of Incomplete Discharge Monitoring Report
Q The written values are illegible.
%
Q The Average, Maximum, and/or the Minimum data points have been omitted.
O The Units of Measure have been omitted or are incorrect
U The DMR Parameter Codes have been omitted.
The Division of Water Quality deems the aforementioned DMR as incomplete due to the
following reason(s): (Please see the highlighted areas on the attached DMR for details.)
Facility:
County.
DMR Month and Year
Other ..
C-oppcjn

r\c T5 .
plaj'-e.
-fee
UrsuZ "Qifm ~fznv|
Permit Number |\^ 06 3^05-1
Michael F. Easley. Governor
October 28, 2005
Subject:
Dear Ms. Tian:
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper
On July 13, 1995, the Environmental Management Commission approved the Town of Cary's
request for full delegation authority to issue sanitary sewer extension permits. In conjunction
with that delegation, this office has been allowing the Town to issue sewer extension permits
based upon a block flow approval process. Previously, the Raleigh Regional Office has granted
block flow approvals for the North Cary WWTF totaling 5,000,000 GPD. As requested in your
letter dated October 14, 2005, the Raleigh Regional Office hereby grants an additional block
flow allocation of 500,000 GPD for the North Cary WWTF yielding a total of 5,500,000 GPD
granted for that facility. The North Cary WRF has a current capacity of 10.0 MGD.
North Carolina Division of Water Quality
Internet h2o.enr.state.nc.us
Ms. Shuyan Tian, PE
Development Review Engineer
Town of Cary
Post Office Box 8005
Cary, N. C. 27512-8005
1)
2)
3)
4)
5)
6)
Permit No.
Permit Issue Date
Permit Holder
Name of Project
Project Wastewater Flow
Total Project Wastewater Flow for the Month
Summary of Activities for Violations of the Permitting Process
Town of Cary
Sanitary Sewer Flow Allocation
North Cary WRF - Block Flow Approval No. 23
Wake County
Raleigh Regional Office
1028 Mail Service Center
William G. Ross. Jr.. Secretary
North Carolina Department of Environment and Natural Resources
Phone [phone]
FAX [phone]
Alan W Klimek. P.E., Director
Division of Water Quality
Surface Water Protection
Raleigh, NC 27699-1628
As permits are issued by the Town, the wastewater flow associated with those projects will be
subtracted from the block flow allocation. When the issued permits have almost depleted the
flow allocation, the Town will request that it be granted an additional allocation. The Raleigh
Regional Office (RRO) requires that the Town submit a quarterly report for each WWTF. The
reports should be received by the Raleigh Regional Office before the end of each of the months
of January, April, July and October, and must provide the following information for the permits
that have been issued:
North Caroli nu___Naturally
Customer Service
877-623-6748
/DWGC° ..
Additionally, the report must provide the following information:
D
4)
5)
6)
Sincerely,
Copies:
According to our records, the addition of this block flow allocation to your remaining block flow
balance will provide the Town of Cary with a total of 578,255 gpd in unpermitted block flow
allocation. Our records also show a remaining paper flow capacity for your treatment facility of
1,773,280 gpd, not including the expansion of the North Cary facility to 12.0 MOD. This amount
removes all the Kit Creek Pump Station service area tributary and permitted flows from the Cary
North facility and redirects these flows to Durham Triangle WWTP, as stated in Glen Harrell’s
letter of October 13, 2005.
If you have any questions regarding this matter, please contact Barry Herzberg at
919-791-4249, or via E-Mail to [e-mail].
Ms. Shuyan Tian, P. E.
Page 2
October 28, 2005
2)
3)
Running Total of Flow Allocated to the Town by the Raleigh Regional Office, to
Date
Running Total of Flow From Permits Issued, to Date
Flow Which Remains From Allocation From RRO (flow allocated but not yet
depleted by issued permits)
Running Total of Flow Which has Been Depleted From the Allocation by Issued
Permits, but Which has not yet Become Tributary to the WWTF
Total Flow (also includes flow for permits issued prior to the implementation of the
block flow approval process) not yet Tributary to the WWTF
Most Recent Twelve Month Flow Average of the WWTF
Kenneth Schuster, P. E.
Regional Water Quality Supervisor
Durham Triangle file - NC0026051
Cary North file - NC0048879
Please be advised that the Raleigh Regional Office reserves the right to suspend this block flow
approval process if problems occur with the operation of this program, if problems occur with the
compliance status of the WWTF, or if other situations occur which might jeopardize the
successful operation of this program.
1
October 27, 2005
Dear Mr. Herzberg:
cc: Glen E. Whisler, P.E., County Engineer
CH/kt
You are cordially invited to an Open House at the Triangle Wastewater Treatment Plant,
located at 5926 NC Highway 55 on November 8, 2005, 2:00 P.M. to 4:00 P.M. We look
forward to showing you our newly upgraded and expanded treatment facility.
120 E. Parrish Street, Law Bldg., 1st Floor, Durham, N.C. 27701 [phone] Fax [phone]
Equal Employment/Affirmative Action Employer
5%
Sincerely,
CU
Chuck Hill, P.E.
Utility Division Manager
NCDENR - Pretreatment Unit
Barry Herzberg, Environmental Engineer, I
Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
\ <
\w
If you have any questions, please contact me by telephone at 560-7992 or e-mail at
[e-mail].
COUNTY OF DURHAM
ENGINEERING DEPARTMENT
2
Dear Mr. Hill:
Sincerely,
)
cc:
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper
1617 Mail Service Center
512 N. Salisbury St.
Phone[phone]
FAX [phone]
Alan W. Klimek, P.E. Director
Division of Water Quality
North Carolina Division of Water Quality
Internet: h2o.enr.state.nc.us
Raleigh. NC 27699-1617
Raleigh, NC 27604
Mr. Chuck Hill, P.E.
Durham County
120 E. Parrish Street, Suite 110
Durham, NC 27701
Customer Service
1-877-623-6748
CENTRAL FILES
Raleigh Regional Office/Surface Water Protection
NPDES Unit
Subject: Receipt of permit renewal application
NPDES Permit NC0026051
Triangle WWTP
Durham County
Frances Candelaria
Point Source Branch
Michael F. Easley, Governor
I
8
?!
NorthCarolina
Naturally
The NPDES Unit received your permit renewal application on November 2, 2005. 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. The requirements in your existing permit will remain in effect until the
permit is renewed (or the Division takes other action).
il
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
lirv' l j
November 2, 2005
If you have any additional questions concerning renewal of the subject permit, please contact me at
[phone], extension 520.
2 IM 14 > I L/VUv-Z
November 1, 2005
Renewal Application for Permit NC0026051 Triangle WWTPRe:
Dear Mr. Weaver:
120 E. Parrish Street, Law Bldg., 1st Floor, Durham, N.C. 27701 [phone] Fax [phone]
Equal Employment/Affirmative Action Employer
Mr. Charles H. Weaver, Jr.
NCDENR/Division of Water Quality
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
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> The number of clarifiers has doubled to four with an increase in the overall diameter
of each and treatment capacity.
Durham County respectfully submits this permit renewal application for consideration. Since
the last permit issuance, we have, in essence, built a new plant. The new facility is capable of
removing nitrogen and phosphorous through biological processes, and can treat an average
daily flow of 12 MGD.
> The Influent Pumping Station (IPS) was designed with the intent of a more efficient
and less odorous removal of screenings and grit.
COUNTY OF DURHAM
ENGINEERING DEPARTMENT
> Instead of using two extended aeration basins that could treat 6 MGD, the new facility
boasts three Biological Nutrient Removal (BNR) trains that doubled our treatment
capacity to 12 MGD. The new facility is geared to the removal of the nutrients Totals
Nitrogen and Total Phosphorus in an effort to meet mandates prescribed by the Sta^
and EP A. Previously, we could not treat for Total Nitrogen but the BNR System j/qw7
offers that capability. The previous configuration relied heavily on chemical a
precipitation for the treatment of Total Phosphorus. The BNR system allows us the /
benefit of treating biologically for Total Phosphorus thus decreasing our depepde^cy
on chemicals. We are pleased to report that there has been a significant reductidh in ‘
the two parameters as well as Ammonia since the start up of the system.
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Enclosure
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The County is proceeding with the design of sludge management facilities to produce a Class
A sludge within the next few years. The current schedule has this process on line in 2008.
The current lagoon will continue to be utilized and annual removals will continue until the
new processes are completed.
Finally, there is a serpentine chamber outfitted with multiple diffusers for post aeration
before discharge to the creek.
Glen E. Whisler, P.E., County Engineer
Adrienne Fancher, Project Manager - United Water
The walls of the aforementioned structures were built above the one hundred year
flood plane. We think that this will help us maintain efficiencies during periods of
excessively high flow.
Three (3) emergency generators have been installed that permit 100% coverage in the
event of an electrical failure.
The chosen form of disinfection is Ultraviolet (UV) instead of chlorine. It allows for
more consistent disinfection and is exponentially safer for the operators.
There are now five sand filters instead of two. There is not only an increase in
treatment capacity, but it offers a maintenance bonus. The filters can be rotated
periodically and serviced more often without sacrificing run time.
Sincerely,
MJ
Chuck Hill, P.E.
Utility Division Manager
The County is currently contracting with Bionomics for sludge removal. Each year, sludge is
removed from the lagoon, equivalent to or exceeding the amount produced during that year, as
anticipated in the Interim Biosolids Management Plan approved by the Division of Water
Quality June 10, 2002 (copy attached). This contract includes dredging from the lagoon,
dewatering on site, and hauling dewatered sludge to a composting facility permitted by the
state for this purpose. The County is not using land application for the disposal of sludge at
this time.
FOR ADDITIONAL INFORMATION CONTACT THE DURHAM COUNTY ENGINEERING DEPARTMENT AT
560-0735
NOVEMBER 8, 2005
2:00PM to 4:00PM
INVITATION
TO AN
OPEN HOUSE
AT THE
TRIANGLE WASTEWATER TREATMENT PLANT
5926 Highway 55
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Directions to Triangle Wastewater Treatment Plant (TWWTP) from [-40.
The address of the plant is 5926 Highway 55.
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1. Get off 1-40 at exit 279A (heading away from downtown Durham)
Turn left onto Alexander Dr.
Proceed through the light at Hwy. 55 into Treatment Plant
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