WQ0020410_Final Permit_20031112

aF 1fVA Michael F. Easley, Governor
William G. Ross Jr., Secretary
��} G North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
S- °-�i Division of Water Quality
U C Coleen H. Sullins, Deputy Director
Division of Water Quality
November 12, 2003
The Honorable Robert S. Matheny, Mayor
Town of Zebulon
100 N. Arendell Avenue Al . I 2003
Zebulon, North Carolina 27597-2837 'j
SUBJECT: Town of Zebulon
Modified Permit
Permit No. WQ0020410
Conjunctive Use
Reclaimed Water Generation and Distribution System
Project Number: E-SRG-T-00-0096
Dear Mayor Matheny:
In accordance with your application received October 15, 2003, we are forwarding
herewith Modified Permit Number WQ0020410, dated November 12, 2003, to The Town of
Zebulon for the construction and operation of the subject Wastewater Treatment Reclaimed
Water Generation and Distribution System.
This permit shall void Permit WQ0020410 previously issued on December 11, 2002,
shall be effective from the date of issuance until December 11, 2007, or until rescinded, and shall
be subject to the conditions and limitations as specified therein. Please pay particular attention to
the monitoring requirements in this permit. Failure to establish an adequate system for collecting
and maintaining the required operational information will result in future compliance problems.
The Conjunctive Use Permit application and supporting documentation has been
evaluated by the Division, and it has been determined that flow equalization at the Town of
Zebulon Wastewater Treatment facility is not required to meet the limitations of Section 111.2 in
Permit No. WQ0020410. Accordingly, this permit is issued pursuant to T15A.2H.0219(p), with
the inclusion of condition VI.3.
If any parts, requirements, or limitations contained in this permit are unacceptable, you
have the right to request an adjudicatory hearing upon written request within thirty (30) days
following receipt of this permit. This request must be in the form of a written petition,
conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of
Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714. Unless such
demands are made, this permit shall be final and binding.
Upon completion of construction and prior to operation of this permitted facility, a
certifcation must be received from a professional engineer certifying that the permitted facility
M i3E%q
N. C. Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 [phone] Customer Service
1-877-623-6748

Honorable Robert S. Matheny, Mayor
Page 2
November 12, 2003
has been installed in accordance with the approved plans and specifications. Mail the
Certification to the Construction Grants & Loans Section, 1633 Mail Service Center, Raleigh,
North Carolina 27699-1633. (Engineer's Certification Form is attached.)
One set of approved plans and specifications is being forwarded to you. if you need
additional. Information concerning this matter, please contact Mr. Cecil G. Madden, Jr., P.E. at
[phone].
Sincerely
Alan W. Klimek, P.E.
CGM
Attachment
cc: Green Engineering (Attn: E. Leo Green, Jr., P.E.)
Wake County Health Department
Raleigh Regional Office, Water Quality Section
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
Sue Homewood
Daniel Blaisdell, P.E.
Amy Simes, P.E.
Cecil G. Madden, Jr., P.E.
SRG

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECLAIMED WATER GENERATION AND DISTRIBUTION PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North
Carolina as amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO THE
Town of Zebulon
Wake County
FOR THE
continued construction and operation of a 250,000 GPD reclaimed water generation and
distribution system, consisting of one (1) reclaimed water pump station with duplex 500 GPM,
50 -HP vertical turbine pumps and one (1) 250 GPM, 25 -HP submersible motor -driven vertical
turbine jockey pump with an audio and visual high-water alarm; a telemetry system; turbidity
monitor and supervisory control and data acquisition (SCADA) system; approximately 850
linear feet of 3 -inch and 3,300 linear feet of 12 -inch reclaimed water force main with an
associated air release valve; approximately 150 linear feet of 24 -inch steel casing with 12 -inch
reclaimed water force main; approximately 1,316 linear feet of 8 -inch gravity sewer with
associated manholes; approximately 50 linear feet of 16 -inch steel casing with 8 -inch gravity
sewer; and one (1) 250,000 -gallon elevated reclaimed water storage tank to serve the Town of
Zebulon with no discharge of wastes to the surface waters, pursuant to the application received
August 28, 2001, and in conformity with the project plan, specifications, and other supporting
data subsequently filed and approved by the Department of Environment and Natural Resources.
Permission is also granted for the construction and operation of an additional 1300 lineal feet of
12 -inch reclaimed water force main, and 700 lineal feet of 3 -inch reclaimed water force main,
pursuant to the application received October 15, 2003, and in conformity with the project plan,
specifications, and other supporting data subsequently filed and approved by the Department of
Environment and Natural Resources and considered a part of this modified permit.
This permit shall be effective from the date of issuance until December 11, 2007, or until
rescinded, and shall be subject to the following specified conditions and limitations:

Modified Permit
Permit No. WQ0020410
Town of Zebulon
I. PERFORMANCE STANDARDS
I . 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 this permit, the approved
plans and specifications, and other supporting materials. If this project is to be
completed in phases and partially certified, you shall retain the responsibility to track
further construction approved under the same permit, and shall provide a final
Certificate of Completion once the entire project has been completed. Mail the
Certification to the Construction Grants & Loans Section, 1633 Mail Service Center,
Raleigh, NC 27699-1633.
2. The DWQ Raleigh 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 in-place inspection can be made. Such notification to the regional
supervisor shall be made during the normal office hours from 8:00 a.m. until
5:00 p.m. on Monday through Friday, excluding State Holidays.
3. The reclaimed water utilization facilities shall be effectively maintained and operated
at all times so that there is no discharge to the surface waters, nor any contamination
of ground waters which will render them unsatisfactory for normal use. In the event
that the facilities fail to perform satisfactorily, including the creation of nuisance
conditions or failure of the irrigation area to adequately assimilate the wastewater, the
Permittee shall take immediate corrective actions including those actions that maybe
required by,the Division of Water Quality (Division), such as the construction of
additional or replacement wastewater treatment and disposal facilities.
4. The issuance of this permit shall not relieve the Pennittee of the responsibility for
damages to surface or ground waters resulting from the operation of this facility.
5. The residuals generated from these treatment facilities must be disposed in
accordance with General Statute 143-215.1 and in a manner approved by the
Division.
6. Diversion or bypassing of the untreated wastewater from the treatment facilities is
prohibited.
7. The following buffers shall be maintained:
a. 100 feet between wetted areas and water supply wells,
b. 100 feet between wetted areas and waters classified as SA,
c. 25 feet between wetted areas and surface waters not classified as SA,
d. 100 feet between wastewater treatment units and wells,
e. 50 feet between reclaimed water storage/irrigation ponds and property lines, and
f. 50 feet between wastewater treatment units and property lines.

Modified Permit
Permit No. WQ0020410
Town of Zebulon
8. All reclaimed water valves, storage facilities, outlets shall be tagged or labeled to warn
the public or employees that the water is not intended for drinking. Where appropriate, such
warning shall inform the public or employees to avoid contact with the water.
9. All reclaimed water piping, valves, outlets and other appurtenances shall be color -coded,
taped, or otherwise marked to identify the source of the water as being reclaimed water.
a. All reclaimed water piping and appurtenances shall be either colored purple (i.e.,
Pantone 522) and embossed, or integrally stamped or marked, "CAUTION:
RECLAIMED WATER - DO NOT DRINK", or be installed with a purple (i.e.,
Pantone 522) identification tape or polyethylene vinyl wrap. The warning shall be
stamped on opposite sides of the pipe and repeated every three feet or Iess.
b. Identification tape shall be at least three inches wide and have white or black
lettering on purple (i.e., Panton 522) field stating, "CAUTION: RECLAIMED
WATER - DO NOT DRINK." Identification tape shall be installed on top of
reclaimed water pipelines, fastened at least every 10 feet to each pipe length and run
continuously the entire length of the pipe.
c. Existing underground distribution systems retrofitted for the purpose of distributing
reclaimed water shall be taped or otherwise identified as in items (a) or (b) above. --
This identification need not extend the entire length of the distribution system but shall
be incorporated within 10 feet of crossing any potable water supply line or sanitary
sewer line.
10. All reclaimed water valves and outlets shall be of a type, or secured in a manner that
permits operation by authorized personnel only.
11. Above -ground hose bibs (i.e., spigots or other hand -operated connections) shall not be
present. Hose bibs shall be located in locked below -grade vaults that shall be clearly labeled
as being of non -potable quality. As an alternative to the use of locked below -grade vaults
with standard hose bibs services, hose bibs, which can only be operated by a special tool,
may be placed in non -lockable underground service boxes clearly labeled as non -potable
water_
12. The Permittee shall maintain an active cross -connection control program that shall have the
following minimum requirements:
a. No direct cross -connections shall be allowed between the reclaimed water and
potable water systems.

Modified Permit
Permit No. WQ0020410
Town of Zebulon
b. A reduced pressure principle backflow preventer, an approved air gap separation,
or other device approved by the Division of Environmental Health, shall be
installed at the potable water service connection to the use area where both
reclaimed water and potable water are supplied to a reclaimed water use area.
The installation of the reduced pressure principle backflow prevention device
shall allow proper testing.
C. An air gap separation, approved and regularly inspected by the potable water
supplier, shall be provided between the potable water and reclaimed water
systems where potable water is used to supplement a reclaimed water system.
II. OPERATION AND MAINTENANCE REQUIREMENTS
1. The facilities shall be properly maintained and operated at all times.
2. Upon classification of the wastewater treatment and spray irrigation facilities by the Water
Pollution Control System Operators Certification Commission (WPCSOCC), the Permittee shall
designate and employ a certified operator to be in responsible charge (ORC), and one or more
certified operator(s) to be back-up ORC(s) of the facilities in accordance with 15A NCAC 8G
.0201. The Permittee shall submit the ORC and back-up ORC designations to the WPCSOCC at
least 60 days prior to the introduction of waste into the system. The designated ORC shall visit the
facilities in accordance with 15A NCAC SG .0204, and shall comply with all other conditions
specified in these rules.
I The facilities shall be effectively maintained and operated as a non -discharge system to prevent the
discharge of any wastewater resulting from the operation of this facility.
4. Should the limit for fecal coliform (daily maximum concentration of 25 per 100 ml) or turbidity
(instantaneous maximum of 10 NTU) be exceeded, all wastewater shall be handled in one of three
ways, until the levels have stabilized below these maximum levels. The Town of Zebulon may
further treat the wastewater to bring it into compliance with reclaimed water standards without
returning the water to the facility's headworks, may re-route it to the headworks of the wastewater
treatment facility for treatment to reuse standards, or may discharge it in strict accordance with the
conditions of the facility's existing NPDES Permit.
III. MONITORING AND REPORTING RE UIREMENTS
1. Any monitoring (including groundwater, surface water, soil or plant tissue analyses)
deemed necessary by the Division to ensure surface and ground water protection will
be established, and an acceptable sampling reporting schedule shall be followed.
2. As an indicator of proper operation and maintenance, the facility shall produce an
effluent in compliance with the following limitations:

Modified Permit
Permit No. WQ0020410
Town of Zebulon
Parameter
BODS (5 -day, 20°C)
NH3 as N
TSS
Fecal Coliform
Turbidity
Monthly Average a
10 mg/l
4 mg/l
5 mg/1
14 per 100 ml b
Daily (Instantaneous) Maximum c
15 mg/l
6 mg/l
10 mg/l
25 per 100 m1
10 NTU
a. Monthly averages for all but fecal coliform shall be the arithmetic mean of all
samples collected during the reporting period.
b. Monthly average for fecal coliform shall be the geometric mean of all samples
collected during the reporting period.
c. Daily maximum shall be the maximum value of all samples collected during the
reporting period.
The effluent from the subject facilities shall be monitored by the Permittee, at the
point prior to discharge to the distribution system, for the following parameters.
Parameter
Sampling_Point
Sampling Frequency
Tpe of Sample
Flow
Effluent
As Used
Recording
Turbidity
Effluent
Continuous
Recording
Settleable Matter
Effluent
Daily
Grab
Residual Chlorine
Effluent
Daily
Grab
Fecal Coliform
Effluent
*2/Month
Grab
BODS (5 -day, 200C)
Effluent
*2/Month
Composite
TSS
Effluent
*2/Month
Composite
NH3 as N
Effluent
*2/Month
Composite
NO3
Effluent
*2/Month
Composite
TKN
Effluent
*2/1\4onth
Composite
TDS
Effluent
**Triannually
Grab
TOC
Effluent
**Triannually
Grab
Chloride
Effluent
**Triannually
Grab
pH
Effluent
**Triannually
Grab
The effluent pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
2/Month sampling frequency only during the months of April through October. During the
remainder of the year, these parameters shall be monitored monthly.
** Triannually sampling shall be conducted during March, July, and November.
If Groundwater sampling indicates or predicts problems with the compliance with Groundwater
Standards, this permit will be modified to include additional and/or more restrictive Iimitations.

Modified Permit
Permit No. WQ0020410
Town of Zebulon
3. Three (3) copies of all effluent monitoring data (as specified in condition III 2) on Form
NDMR-1 shall be submitted on or before the last day of the following month. All
information shall be submitted to the following address:
NC Division of Water Quality
Water Quality Section
Non -Discharge Compliance/Enforcement Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
4. A maintenance log shall be maintained at this facility including but not limited to the
following items:
a. Daily sampling results of dissolved oxygen in the aeration basin and at the clarifier weir.
b. Visual observations of the plant and plant site,
c. Record of preventative maintenance (changing of filters, adjusting belt tensions, alarm
testing, diffuser inspections and cleanings, etc.).
d. Date of calibration of flow measurement device.
e. Date and results of power interruption testing on alternate power supply.
5. Noncompliance Notification:
The Permittee shall report by telephone to the DWQ Raleigh Regional Office, telephone number
[phone], as soon as possible, but in no case more than 24 hours, or on the next working day
following the occurrence or first knowledge of the occurrence of any following:
a. Any occurrence at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the
contents of a sludge digester; the known passage of a slug of hazardous substance through the
facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that renders the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures of pumps,
aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a
by-pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self-monitoring information indicates that the facility has gone out of
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in
letter form within five (5) days following first knowledge of the occurrence. This
report must outline the actions taken or proposed to be taken to ensure that the
problem does not recur.

Modified Permit
Permit No. WQ0020410
Town of Zebulon
IV. GROUNDWATER REOUIREMENTS
1. Any groundwater quality monitoring, as deemed necessary by the Division., shall be
provided.
V. INSPECTIONS
1. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to ensure proper
operation of the subject facilities.
2. The Permittee or his designee shall inspect the wastewater treatment and disposal
facilities to prevent malfunctions and deterioration, operator errors and discharges
which may cause or lead to the release of wastes to the environment, a threat to human
health, or a nuisance. The Permittee shall keep an inspection log or summary
including at least the date and time of inspection, observations made, and any
maintenance, repairs, or corrective actions taken by the Permittee. This log of
inspections shall be maintained by the Permittee for a period of three years from the
date of the inspection and shall be made available upon request to the Division or
other permitting authority.
3. Any duly authorized officer, employee, or representative of the Division may, upon
presentation of credentials; _enter and inspect any property, premises, or place, on or related
to the disposal site or facility, at any reasonable time for the purpose of determining
compliance with this permit; may inspect or copy any records that must be maintained under
the Terms and Conditions of this permit, and may obtain samples of ground water, surface
water, or leachate.
VI. GENERAL CONDITIONS
1. This pen -nit shall become voidable unless the facilities are constructed in accordance with the
conditions of this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the
application and other supporting data.
3. This permit is issued pursuant to T15A:2H.0219(p) for the construction and operation of a reclaimed
water utilization facility without flow equalization. In the event that non-compliance with any
permit limitation results from the absence of flow equalization, this permit may be administratively
reopened, and a requirement for the construction of a flow equalization basin may be incorporated
into the permit.
4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or
there is a name change of the Permittee, a formal permit request must be submitted to the Division
accompanied by an application fee, documentation from the parties involved, and other supporting
materials as may be appropriate. The approval of this request will be considered on its merits and
may or may not be approved.

Modified Permit
Permit No. WQ0020410
Town of Zebulon
5. Failure to abide by the conditions and limitations contained in this permit 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.
6. The issuance of this permit does not exempt the Permittec 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, including but not limited to applicable river buffer rules in 15A
NCAC 2B.0200, erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under
the Division's General Permit NCG010000, and any requirements pertaining to wetlands under 15A
NCAC: 2B.0200 and 2H.0500.
7. A set of approved plans and specifications for the subject project must be retained by the Permittee
for the life of the project.
8. This permit, in no way, negates, precludes, or invalidates the most recent reissuance of
NPDES Permit No. NC0024368, and the Permitted shall continue to comply with all
conditions provided for therein.
9. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Commission will review the adequacy of the facilities
described therein, and if warranted, will extend the permit for such period of time and under such
conditions and limitations as it may deem appropriate.
Modified Permit issued this 12`h day of November 2003
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Klimek, PE., Di c"tor
ion of Water Quali
Authority of the Environmental Management Commission
Modified Permit Number WQ0020410

Modified Permit
Permit No. WQ0020410
Town of Zebulon
Engineer's Certification
1, , 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 Conjunctive Use Reclaimed Wastewater System serving the Town of
Zebulon, located in Wake County, hereby state that to the best of my abilities, due care and
diligence was used in the observation of the following construction:
A 250,000 GPD reclaimed water generation and distribution system, consisting of one (1)
reclaimed water pump station with duplex 500 GPM, 50 -HP vertical turbine pumps and one (1)
250 GPM, 25 -HP submersible motor -driven vertical turbine jockey pump with an audio and
visual high-water alarm; a telemetry system; turbidity monitor and supervisory control and data
acquisition (SCADA) system; approximately 850 linear feet of 3 -inch and 3,300 linear feet of
12 -inch reclaimed water force main with an associated air release valve; approximately 150
linear feet of 24 -inch steel casing with 12 -inch reclaimed water force main; approximately 1,316
linear feet of 8 -inch gravity sewer with associated manholes; approximately 50 linear feet of 16 -
inch steel casing with 8 -inch gravity sewer; and one (1) 250,000 -gallon elevated reclaimed water
storage tank, pursuant to the application received August 28, 2001, and in conformity with the
project plan, specifications, and other supporting data subsequently filed and approved by the
Department of Environment and Natural Resources.
And an additional 1300 lineal feet of 12 -inch reclaimed water force main, and 700 lineal feet of
3 -inch reclaimed water force main, pursuant to the application received October 15, 2003, and in
conformity with the project plan, specifications, and other supporting data subsequently filed and
approved by the Department of Environment and Natural Resources.
1 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.:
Mail this Certification to: DENR/DWQ
Construction Grants & Loans Section
1633 Mail Service Center
Raleigh, NC 27699-1633