NC0024538_Authorization to Construct_20170913

Water Resources
ENVIRONMENTAL QUALITY
ROY COOPER
covenrw
MICHAEL S. REGAN
Sea etm y
S. JAY ZIMMERMAN
Dr ecroi
September 13, 2017
Mr David Hux
Water Resources Director
824 West Grover Street
Shelby, North Carolina 28150
SUBJECT: Authorization to Construct
CORRECTED A to C No. 024538A03
City of Shelby
First Broad River WWTP
NPDES No. NCO024538
Dear Mr. Hux:
A letter of request for an Authorization to Construct was received July 28, 2017 by the Division of
Water Resources (Division), and upon further review this corrected permit is being issued to supercede the
permit issued on September 11, 2017. Authorization is hereby granted for the construction of modifications
to the existing 6.0 MGD First Broad River WWP, with discharge of treated wastewater into the First Broad
River in the First Broad 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 new headworks consisting of one (1) inclined manual bar screen in the
bypass channel, one (1) inclined rotary drum bar screen designed for 15.75 MGD,
relocation of existing mechanical rotary drum bar screen, two (2) shaftless screw conveyors
sized at 60 cf/hr, one (1) grit removal system minimum designed for 21 MGD which
includes one (1) forced vortex grit removal chamber, one (1) vacuum primed grit pumping
system, one (1) grit concentrator, one (1) grit washer/classifier, piping and controls;
replacement of exiting 24" influent force main with new 1,100 ft long 30" influent force
main; upgrade of influent pump station which includes installation of two (2) new 5,300
GPM at 68 ft TDH non -clog centrifugal influent pumps with VFD, installation of new
VFDs on existing two (2) pumps, piping and controls; replacement of existing primary
clarifier splitter box with a new splitter box for existing two (2) and two (2) future primary
clanfiers, piping and controls; installation of two (2) enclosed circular 337,500 gallon
anaerobic digesters with total four (4) 5 HP mixers (two per digester) with off gas
removal/processing and with sludge heating system consisting of heat exchangers, sludge
recirculation pumps, hot water boiler system consisting of boilers, hot water circulation
pumps, piping and controls; installation of three (3) 250 GPM at 48.9 ft TDH horizontal
chopper digested sludge recirculation pumps, piping and controls; installation of one (1)
250,000 gallon sludge holding tank with one (1) 8 HP submersible mixer; piping and
controls; installation of two (2) belt filter press systems rated for 2,000 dry lb/hr consisting
of two (2) belt filter presses, polymer feed system consisting of two (2) polymer blenders
with progressive cavity polymer feed pump, dilution water assembly, belt wash system,
solution discharge assembly, piping and controls; installation of three (3) 200 GPM at 46.2
ft TDH progressive cavity belt filter press feed/transfer pumps, piping and controls,
State of North Carolina I Environmental Quality I Water Resources
512 N Salisbury Street 11612 Mail service Center I Raleigh, North Carolina 27699-1612
Phone [phone]

Mr. David Hux Water Resources Director
September 13, 2017
Page 2 of 3
installation of filtrate pump station consisting of two (2) 550 GPM at 50 ft TDH
submersible non -clog filtrate pumps, piping and controls; installation of two (2) 4 HP
submersible mixers in existing two (2) filtrate equalization tanks (one in each), piping and
controls; installation of three (3) 225 GPM at 129 ft TDH vertical turbine non potable
water pumps, piping and controls; installation of one (1) new 6,000 lbs/hr (dry) cake
conveyor and controls; installation of new 7,600 ftz roofed cake storage; demolition of
existing composting facility; in conformity with the project plans, specifications, and other
supporting documentation comprising the ATC Permit Application package submitted to
the Department of Environmental Quality.
This ATC is issued in accordance with Part III, Paragraph A of NPDES Permit No. NC0024538
issued effective December 1, 2013, and shall be subject to revocation unless the wastewater treatment
facilities are constructed in accordance with the conditions and limitations specified in Permit No.
NC000024538
It is the Owner's responsibility to ensure that the as -constructed project meets the requirements of
all applicable regulations and statutes, the ATC Permit Application package, and all of the requirements
contained herem Failure to comply may result in penalties in accordance with North Carolina General
Statute § 143-215.6A through § 143-215 6C.
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 number704-663-1699, 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 in. 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 and the ATC Permit Application package Mail the Certification to:
Division of Water Resources, WQ Permitting — NPDES, 1617 Mail Service Center, Raleigh, NC 27699-
1617
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.

Mr David Hux Water Resources Director
September 13, 2017
Page 3 of 3
A copy of the project 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.
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.
The issuance of this ATC 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.
If you have any questions or need additional information, please contact Trupti Desai at telephone
number [phone].
Sincerely,
S. Jay Zimmerman, P.G.
Director, Division of Water Resources
With Engineer's Certificate attached:
cc: DWR Mooresville Regional Office, Water Quality Programs
Central Files
e -copy: Mr. Will Shull, P.E.
HDR
Email: Will.Shull@hdrinc com
NPDES File
Without Engineer's Certificate attached:
cc* Cleveland County Health
DWI/Mr Ken Pohhg

City of Shelby
First Broad River WWTP NPDES No. NC0024538
CORRECTED Authorization to Construct No. 02453 8A03
Issued September 11, 2017
Page 1 of 2
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 First Broad Wastewater Treatment
Plant, located in Cleveland 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 new headworks consisting of one (1) inclined manual bar screen in
the bypass channel, one (1) inclined rotary drum bar screen designed for 15.75
MGD, relocation of existing mechanical rotary drum bar screen, two (2) shaftless
screw conveyors sized at 60 cf/hr, one (1) grit removal system minimum designed
for 21 MGD which includes one (1) forced vortex grit removal chamber, one (1)
vacuum primed grit pumping system, one (1) grit concentrator, one (1) grit
washer/classifier, piping and controls; replacement of exiting 24" influent force
main with new 1,100 ft long 30" influent force main; upgrade of influent pump
station which includes installation of two (2) new 5,300 GPM at 68 ft TDH non -
clog centrifugal influent pumps with VFD, installation of new VFDs on existing
two (2) pumps, piping and controls; replacement of existing primary clarifier
splitter box with a new splitter box for existing two (2) and two (2) future primary
clarifiers, piping and controls; installation of two (2) enclosed circular 337,500
gallon anaerobic digesters with total four (4) 5 HP mixers (two per digester) with
off gas removal/processing and with sludge heating system consisting of heat
exchangers, sludge recirculation pumps, hot water boiler system consisting of
boilers, hot water circulation pumps, piping and controls; installation of three (3)
250 GPM at 48.9 ft TDH horizontal chopper digested sludge recirculation pumps,
piping and controls; installation of one (1) 250,000 gallon sludge holding tank with
one (1) 8 HP submersible mixer; piping and controls; installation of two (2) belt
filter press systems rated for 2,000 dry lb/hr consisting of two (2) belt filter presses,
polymer feed system consisting of two (2) polymer blenders with progressive
cavity polymer feed pump, dilution water assembly, belt wash system, solution
discharge assembly, piping and controls; installation of three (3) 200 GPM at 46.2
ft TDH progressive cavity belt filter press feed/transfer pumps, piping and controls;
installation of filtrate pump station consisting of two (2) 550 GPM at 50 ft TDH
submersible non -clog filtrate pumps, piping and controls; installation of two (2) 4
HP submersible mixers in existing two (2) filtrate equalization tanks (one in each),
piping and controls; installation of three (3) 225 GPM at 129 ft TDH vertical
turbine non potable water pumps, piping and controls; installation of one (1) new

City of Shelby
First Broad River WWTP NPDES No. NCO024538
Authorization to Construct No. 024538A03
Issued September 11, 2017
Page 2 of 2
6,000 lbs/hr (dry) cake conveyor and controls; installation of new 7,600 ft2 roofed
cake storage; demolition of existing composting facility; in conformity with the
project plans, specifications, and other supporting documentation comprising the
ATC Permit Application package submitted to the Department of Environmental
Quality.
Signature
Date
Registration No.
Mail this Certification to: Attn: Trupti Desai
Complex Permitting Unit
DEQ/DWR/Water Quality Programs
1617 Mail Service Center
Raleigh, NC 27699-1617