NC0004987_Authorization to Construct_20100427

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NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue
Governor
Mr. Rom Lewis
Duke Energy
Mail Code EC13K
526 S. Church Street
Charlotte, North Carolina 28202
Dear Mr. Lewis:
Coleen H. Sullins
Director
April 27, 2010
SUBJECT: Authorization to Construct
A to C No. 004987A04
Duke Energy
Marshall Steam Station
Dee Freeman
Secretary
Flue Gas Desulfurization WWTP Improvements
Phase 2: Selenium Reduction System
Catawba County
A letter of request for an Authorization to Construct was received February 12, 2010, by
the Division of Water Quality (Division), and final plans and specifications for the subject
project have been reviewed and found to be satisfactory. Authorization is hereby granted for the
construction of modifications to the existing Flue Gas Desulfurization (FGD) Wastewater
Treatment Plant, with discharge of treated wastewater into the Ash Settling Basin (via Internal
Outfall 004), which discharges into the Catawba River (Lake Norman, Outfall 002) in the
Catawba River Basin.
This authorization results in no increase in design or permitted capacity and is awarded
for the construction of the following specific modifications:
Installation of a new 6 -way inlet flow splitter box; 8 -inch gravity distribution piping; six
(6) Vertical Flow Wetlands for selenium removal (to replace existing wetland cells 1A,
1B and 1C) designated as VFW cells IA, 1B, 1C, 1D, IE and 1F, with each cell
consisting of a geosynthetic clay liner, 18 inches of liner cover material, 15 inches of
coarse underdrain material with 8 -inch perforated pipe, and 3.75 feet of spent mushroom
compost (97,500 f0); 18 -inch and 24 -inch gravity drain pipe to a new 3 -way outlet flow
splitter box; 12 -inch gravity drain pipe to existing 2A, 2B and 2C wetland cells; and
removal of the temporary 18 -inch HDPE gravity bypass pipe between the equalization
basins and wetland cells 2A, 2B, and 2C (installed under ATC #004987A03, issued
February 18, 2010); in conformity with the project plans, specifications, and other
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer
Nne
orthCarolina
Naturally

A
Mr. Ron Lewis
April 27, 2010
Page 2
supporting data subsequently filed and approved by the Department of Environment .and
Natural Resources.
This Authorization to Construct is issued in accordance with Part III, Paragraph A of
NPDES Permit No. NC0004987 issued June 15, 2009, and shall be subject to revocation unless
the wastewater treatment facilities are constructed in accordance with the conditions and
limitations specified in Permit No. NC0004987.
The sludge generated from these treatment facilities must be disposed of in accordance
with G.S. 143-215.1 and in a manner approved by the Division.
In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as may
be required by the Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
The Mooresville Regional Office, telephone number [phone], shall be notified at
least forty-eight (48) hours .in advance of operation of the installed facilities so that an on site
inspection can be made. Such notification to the regional supervisor shall be made during the
normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State
Holidays.
Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from'a professional engineer certifying that the permitted facility
has been installed in accordance with the NPDES Permit, this Authorization to Construct and the
approved plans and specifications. Mail the Certification to: Construction Grants & Loans,
DWQ/DENR, 1633 Mail Service Center, Raleigh, NC 27699-1633.
Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at
least equivalent to or greater than the classification assigned to the wastewater treatment
facilities by the Certification Commission.
The Permittee must also employ a certified back-up operator of the appropriate type and
grade to comply with the conditions of T15A:8G.0202. The ORC of the facility must visit each
Class I facility 'at least weekly and each Class II, III and IV facility at least daily, excluding
Weekends and holidays, must properly manage the facility, must document daily operation and
maintenance of the facility, and must comply with all other conditions of T15A:8G.0202.
A copy of the approved plans and specifications shall be maintained on file by the
Permittee for the life of the facility.

Mr. Ron Lewis
April 27, 2010
Page 3
During the construction of the proposed additions/modifications, the permittee shall
continue to properly maintain and operate the existing wastewater treatment facilities at all times,
and in such a manner, as necessary to comply with the effluent limits specified in the NPDES
Permit.
- You are reminded that it is mandatory for the project to be constructed in accordance
with the North Carolina Sedimentation Pollution Control Act, and when applicable, the North
Carolina Dam Safety Act. In addition, the specifications must clearly state what -the contractor's
responsibilities shall be in complying with these Acts.
Prior to entering into any contract(s) for construction, the recipient must have obtained all
applicable permits from the State.
Failure to abide by the requirements contained in this Authorization to Construct may
subject the Permittee to an enforcement aciion-by the Division in accordance with North
Carolina General Statute 143-215.6A to 143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from
complying with any and all statutes, rules, regulations, or ordinances which may be imposed by
other government agencies (local, state, and federal) which have jurisdiction.
One (1) set of approved plans and specifications is being forwarded to you. If you have
any questions or need additional information, please contact Seth Robertson, P.E. at telephone
number [phone].
Sincerely,
Coleen H. Sullins
kp:sr
cc: Jesse G. Hite, Jr., P.E. — Gannet Fleming, Inc., Suite 1008, 301 S. McDowell St.,
Charlotte, NC 28204-2622
Catawba County Health Department
DWQ Mooresville,Regional Office, Surface Water Protection
DWQ, Technical Assistance and Certification Unit
DWQ, Point Source Branch, NPDES Program
Ken Pohlig, P.E.
ATC File No. 004987A04

Duke Power
Marshall Steam Station
Flue Gas Desulfurization WWTP Improvements
Phase 2: Selenium Reduction System
A To C No. 004987A04
Issued April 27, 2010
Engineer's Certification
I, , as a duly registered Professional Engineer in
the State of North Carolina, having been authorized to observe (periodically/weekly/full time)
the construction of the modifications and improvements to the Marshall Steam Station Flue Gas
Desulfurization WWTP, located at the intersection of NC Highway 150 and NCSR 1841 in
Catawba County, hereby state that, to the best of my abilities, due care and diligence was used in
the observation of the following construction:
Installation of a new 6 -way inlet flow splitter box; 8 -inch gravity distribution piping; six
(6) Vertical Flow Wetlands for selenium removal (to replace existing wetland cells IA,
1B and 1C) designated as VFW cells 1A, 1B, 1C, 1D, IE and 1F, with each cell
consisting of a geosynthetic clay liner, 18 inches of liner cover material, 15 inches of
coarse underdrain material with 8 -inch perforated pipe, and 3.75 feet of spent mushroom
compost (97,500 ft); 18 -inch and 24 -inch gravity drain pipe to a new 3 -way outlet flow
splitter box; 12 -inch gravity drain pipe to existing 2A, 2B and 2C wetland cells; and
removal of the temporary 18 -inch HDPE gravity bypass pipe between the equalization
basins and wetland cells 2A, 2B, and 2C (installed under ATC #004987A03, issued
February 18, 2010); in conformity with the project plans, specifications, and other
supporting data subsequently filed and approved by the Department of Environment and
Natural Resources.
I certify that the construction of the above referenced project was observed to be built within
substantial compliance and intent of the approved plans and specifications.
Signature
Date
Registration No.
Send to: Construction Grants & Loans
DENR/DWQ
1633 Mail Service Center
Raleigh, NC 27699-1633
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I i` l • r
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins
Governor Director
February 18, 2010
Mr. Ron Lewis
Duke Energy
Mail Code EC13K
526 S. Church Street
Charlotte, North Carolina 28202
SUBJECT: Authorization to Construct
A to C No. 004987A03
Duke Energy
Marshall Steam Station
Dee Freeman
Secretary
Flue Gas Desulfurization WWTP Improvements
Phase 1: Bypass Piping and Dewatering Plan
Catawba County
Dear Mr. Lewis:
A letter of request for an Authorization to Construct was received January 14, 2010, by
the Division of Water Quality (Division), and final plans and specifications for the subject
project have been reviewed and found to be satisfactory. Authorization is hereby granted for the
construction of modifications to the existing Flue Gas Desulfurization (FGD) Wastewater
Treatment Plant, with discharge of treated wastewater into the Ash Settling Basin (via Internal
Outfall 004), which discharges into the Catawba River (Lake Norman, Outfall 002) in the
Catawba River Basin.
This authorization results in no increase in design or permitted capacity and is awarded
for the construction of the following specific modifications:
Installation of an 18 -inch HDPE gravity bypass pipe between the equalization basins and
wetland cells 2A, 2B, and 2C, to allow removal of material in wetland cells IA, 1B and
1C for wetland conversion in a future authorization to construct, in conformity with the
project plans, specifications, and other supporting data subsequently filed and approved
by the Department of Environment and Natural Resources.
This Authorization to Construct is issued in accordance with Part III, Paragraph A of
NPDES Permit No. NC0004987 issued June 15, 2009, and shall be subject to revocation unless
the wastewater treatment facilities are constructed in accordance with the conditions and
limitations specified in Permit No. NC0004987.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 One
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604 NorthCarolina
Phone: [phone] \ FAX: [phone] \ Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org Aatuy+
i a!!ff
An Equal Opportunity \ Affirmative Action Employer

Mr. Ron Lewis
February 18, 2010
Page 2
The sludge generated from these treatment facilities must be disposed of in accordance
with G.S. 143-215.1 and in a manner approved by the Division.
In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as may
be required by the Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
The Mooresville Regional Office, telephone number [phone], shall be notified at
least forty-eight (48) hours in advance of operation of the installed facilities so that an on site
inspection can be made. Such notification to the regional supervisor shall be made during the
normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State
Holidays.
Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted facility
has been installed in accordance with the NPDES Permit, this Authorization to Construct and the
approved plans and specifications. Mail the Certification to: Construction Grants & Loans,
DWQ/DENR, 1633 Mail Service Center, Raleigh, NC 27699-1633.
Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator .to be in responsible charge (ORC) of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at
least equivalent to or greater than the classification assigned to the wastewater treatment
facilities by the Certification Commission.
The Permittee must also employ a certified back-up operator of the appropriate type and
grade to comply with the conditions of T15A:8G.0202. The ORC of the facility must visit each
Class I facility at least weekly and each Class II, III and IV facility at least daily, excluding
weekends and holidays, must properly manage the facility, must document daily operation and
maintenance of the facility, and must comply with all other conditions of T15A:8G.0202.
A copy of the approved plans and specifications shall be maintained on file by the
Permittee for the life of the facility.
During the construction of the proposed additions/modifications, the permittee shall
continue to properly maintain and operate the existing wastewater treatment facilities at all times,
and in such a manner, as necessary to comply with the effluent limits specified in the NPDES
Permit.

Mr. Ron Lewis
February 18, 2010
Page 3
You are reminded that it is mandatory for the project to be constructed in accordance
with the North Carolina Sedimentation Pollution Control Act, and when applicable, the North
Carolina Dam Safety Act. In addition, the specifications must clearly state what the contractor's
responsibilities shall be in complying with these Acts.
Prior to entering into any contract(s) for construction, the recipient must have obtained all
applicable permits from the State.
Failure to abide by the requirements contained in this Authorization to Construct may
subject the Permittee to an enforcement action by the Division in accordance with North
Carolina General Statute 143-215.6A to 143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from
complying with any and all statutes, rules, regulations, or ordinances which may be imposed by
other government agencies (local, state, and federal) which have jurisdiction.
One (1) set of approved plans and specifications is being forwarded to you. If you have
any questions or need additional information, please contact Seth Robertson, P.E. at telephone
number [phone].
Sincerely,
�/ Gw"c,e�� •
Coleen H. Sullins
kp: sr
cc: Jesse G. Hite, Jr., P.E. — Gannet Fleming, Inc., Suite 1008, 301 S. McDowell St.,
Charlotte, NC 28204-2622
Catawba County Health Department
DWQ Mooresville Regional Office, Surface Water Protection
DWQ, Technical Assistance and Certification Unit
DWQ, Point Source Branch, NPDES Program
Ken Pohlig, P.E.
ATC File No. 004987A03

Duke Power
Marshall Steam Station
Flue Gas Desulfurization WWTP Improvements
Phase 1: Bypass Piping and Dewatering Plan
A To C No. 004987A03
Issued February 18, 2010
Engineer's Certification
I, , as a duly registered Professional Engineer in
the State of North Carolina, having been authorized to observe (periodically/weekly/full time)
the construction of the modifications and improvements to the Marshall Steam Station Flue Gas
Desulfurization WWTP, located at the intersection of NC Highway 150 and NCSR 1841 in
Catawba County, hereby state that, to the best of my abilities, due care and diligence was used in
the observation of the following construction:
Installation of an 18 -inch HDPE gravity bypass pipe between the equalization basins and
wetland cells 2A, 2B, and 2C, to allow removal of material in wetland cells 1A, 1B and
1C for wetland conversion in a future authorization to construct, in conformity with the
project plans, specifications, and other supporting data subsequently filed and approved
by the Department of Environment and Natural Resources.
I certify that the construction of the above referenced project was observed to be built within
substantial compliance and intent of the approved plans and specifications.
Signature Registration No.
Date
Send to: Construction Grants & Loans
DENR/DWQ
1633 Mail Service Center
Raleigh, NC 27699-1633