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HomeMy WebLinkAboutNC0021903_Application Form & Calcs (ATC)_20190923McDAVIDAssoCIATES, Engineers • Planners . Land Surveyors CORPORATE OFFICE (252) 753-2139 • Fax (252) 753-7220 E-mail: mai@mcdavid-inc.com 3714 N. Main Street - P.O. Drawer 49 Farmville, NC 27828 September 20, 2019 Ms. Julie Grzyb, Supervisor NPDES Complex Permitting Unit NC Division of Water Resources 512 N. Salisbury Street, 91 Floor Raleigh, NC 27604 Subject: Dear Ms. Grzyb: GOLDSBORO OFFICE (919) 736-7630 • Fax (919) 735-7351 E-mail: maigold@mcdavid-inc.com 109 E. Walnut Street • P.O. Box 1776 Goldsboro, NC 27533 Town of Warsaw Request for Authorization to Construct Warsaw WWTP NCO021903 Duplin County The Town is requesting an Authorization to Construct associated with NC0021903. This is a modification of the existing facility. The modifications include increasing the capacity of the influent pump station, building a new flow splitter box ahead of the filters, adding two new 12' x 12' filter cells, and replacing the two existing mud well pumps. This design is not intended to increase the average daily flow of the WWTP. It is being constructed to address the peak hourly flows at the WWTP. Enclosed please find the following: • Application for Authorization to Construct • One copy of Plans and Specifications • One copy of Design Basis • One CD with all Documents Should you have questions related to this matter, please give me a call. Sincerely, McDAVID ASSOCIATES, INC. �,f �- %74P. ec . Madden, ,1 i Goldsboro Office Cc: Scotty Summerlin (w/o attachments) State of North Carolina r l. Department of Environmental Quality Division of Water Resources Water Resources ENVIRONIIENTAL QUALITY APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT (FORM ATC-12-14) SECTION 1: INSTRUCTIONS AND INFORMATION A. The Division of Water Resources will accept this application package for review only if all of the items are provided and the application is complete. Failure to submit all of the required items will result in the application package being returned as incomplete per 15A NCAC 02T .0105(b). B. Plans and specifications must be prepared in accordance with 15 NCAC 02H. 0100, 15A NCAC 02T, North Carolina General Statute 133-3, North Carolina General Statute 143-215.1, and Division of Water Resources Minimum Design Criteria for NPDES Wastewater Treatment Facilities. C. The plans and specifications submitted must represent a completed final design that is ready to advertise for bid. D. Any content changes made to this Form ATC-12-14 shall result in the application package being returned. E. The Applicant shall submit ONE ORIGINAL and ONE DIGITAL COPY (CD) of the application, all supporting documentation and attachments. All information must be submitted bound or in a 3-ring binder, with a Section tab for each Section, except the Engineering Plans. F. Check the boxes below to indicate that the information is provided and the requirements are met. G. If attachments are necessary for clarity or due to space limitations, such attachments are considered part of the application package and must be numbered to correspond to the item referenced. H. For any project that requires review under the State Environmental Policy Act (SEPA), an Authorization to Construct cannot be issued prior to the completion of a State Clearinghouse advertisement period for a FONSI, EIS, etc. unless the project qualifies for a Determination of Minor Construction Activity. 1. For more information, visit the Division of Water Resources web site at: https://deg.nc.gov/about/divisions/water resources/water-resources-permits/wastewater-branch/npdes-wastewater/authorization-to-construct. J. In addition to this Authorization to Construct, the Applicant should be aware that other permits may be required from other Sections of the Division of Water Resources (for example: reclaimed water facilities permits; Class A or B biosolids residuals permit). SECTION 2: APPLICANT INFORMATION AND PROJECT DESCRIPTION A. APPLICANT Applicant's name Town of Warsaw Signature authority's name per 15A NCAC 02T .0106(b) A. J. Connors Signature authority's title Mayor Complete mailing address 121 S. Front St., Warsaw, NC 28398 Telephone number (910) 293-7814 Email address manager@townofwarsawnc.com B. PROFESSIONAL ENGINEER Professional Engineer's name Cecil G. Madden, Jr. Professional Engineer's title Senior Engineer North Carolina Professional Engineer's License No. 16593 Firm name McDavid Associates, Inc. Firm License number C-131 Complete mailing address P. 0. Box 1776, Goldsboro, NC 27533 Application for Authorization to Construct Permit (FORM ATC-12-14) Page 1 Water Resources ENVIRONMENTAL GUAUTY State of North Carolina Department of Environmental Quality Division of Water Resources APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT (FORM ATC-12-14) Telephone number (919) 736-7630 Email address cgm@mcdavid-inc.com C. NPDES PERMIT NPDES Permit number NCO021903 Current Permitted flow (MGD) — include permit 0.915 MGD flow phases if applicable D. PROJECT DESCRIPTION Provide a brief description of the project: Expansion of influent wetwell and influent pump station pumps to accommodate the instantaneous pumping rate, a new flow splitter box to feed the tertiary filters, two new 12' by 12' tertiary filter cells, compatible with the two existing filter cells, and the replacement of two existing mudwell pumps with similar mudwell pumps. SECTION 3: APPLICATION ITEMS REQUIRED FOR SUBMITTAL FOR ALL PROJECTS A. Cover Letter ® The letter must include a request for the Authorization to Construct; the facility NPDES Number; a brief project description that indicates whether the project is a new facility, facility modification, treatment process modification, or facility expansion; the construction timeline; and a list of all items and attachments included in the application package. ❑ If any of the requirements of 15 NCAC 02H. 0100, 15A NCAC 02T, North Carolina General Statute 133-3, North Carolina General Statute 143-215.1, and Division of Water Resources Minimum Design Criteria for NPDES Wastewater Treatment Facilities are not met by the proposed design, the letter must include an itemized list of the requirements that are not met. B. NPDES Permit ® Submit Part I of the Final NPDES permit for this facility that includes Part A (Effluent Limitations and Monitoring Requirements) for the monthly average flow limit that corresponds to the work that is requested for this project. C. Special Order by Consent ❑ If the facility is subject to any Special Orders by Consent (SOC), submit the applicable SOC. ® Not Applicable. D. Finding of No Significant Impact or Record of Decision ❑ Submit a copy of the Finding of No Significant Impact or Record of Decision for this project. ® Provide a brief description of any of the mitigating factors or activities included in the approved Environmental Document that impact any aspect of design of this project, if not specified in the Finding of No Significant Impact or Record of Decision. The or000sed work will occur on the site of the existing wastewater treatment alant. TODoRraohv will be returned to the original grade. An Erosion and Sedimentation Control Permit will be obtained. Heavy equipment will have air emissions controls. Construction will start no earlier than 7:00 AM. Spill prevention will be implemented. Water will be used to reduce dust. ❑ Not Applicable. Application for Authorization to Construct Permit (FORM ATC-12-14) Page 2 State of North Carolina 8 Department of Environmental Quality Division of Water Resources E. Engineering Plans ® Per 15A NCAC 02T .0504(c)(1), submit one set of detailed plans that have been signed, sealed and dated by a North Carolina Licensed Professional Engineer. ® Per 21 NCAC 56 .1103(a)(6), the name, address and License number of the Licensee's firm shall be included on each sheet of the engineering drawings. ® Plans must be labeled as follows: FINAL DRAWING — FOR REVIEW PURPOSES ONLY— NOT RELEASED FOR CONSTRUCTION. ® 15A NCAC 02H .0124 requires multiple (dual at a minimum) components such as pumps, chemical feed systems, aeration equipment and disinfection equipment. Is this requirement met by the design? ® Yes or ❑ No. If no, provide an explanation: Plans shall include: ® Plans for all applicable disciplines needed for bidding and construction of the proposed project (check as appropriate): ® Civil ❑ Not Applicable ® Process Mechanical ❑ Not Applicable ® Structural ❑ Not Applicable ® Electrical ❑ Not Applicable ® Instrumentation/Controls ❑ Not Applicable ❑ Architectural ® Not Applicable ❑ Building Mechanical ® Not Applicable ❑ Building Plumbing ® Not Applicable ® Plan and profile views and associated details of all modified treatment units including piping, valves, and equipment (pumps, blowers, mixers, diffusers, etc.) ® Are any modifications proposed that impact the hydraulic profile of the treatment facility? ® Yes or ❑ No. If yes, provide a hydraulic profile drawing on one sheet that includes all impacted upstream and downstream units. The profile shall include the top of wall elevations of each impacted treatment unit and the water surface elevations within each impacted treatment unit for two flow conditions: (1) the NPDES permitted flow with all trains in service and (2) the peak hourly flow with one treatment train removed from service. ® Are any modifications proposed that impact the process flow diagram or process flow schematic of the treatment facility? ® Yes or ❑ No. If yes, provide the process flow diagram or process flow schematic showing all modified flow paths including aeration, recycle/return, wasting, and chemical feed, with the location of all monitoring and control instruments noted. F. ® Engineering Specifications ® Per 15A NCAC 02T .0504(c)(2), submit one set of specifications that have been signed, sealed and dated by a North Carolina Licensed Professional Engineer. ® Specifications must be labeled as follows: FINAL SPECIFICATIONS — FOR REVIEW PURPOSES ONLY — NOT RELEASED FOR CONSTRUCTION. Specifications shall include: ® Specifications for all applicable disciplines needed for bidding and construction of the proposed project (check as appropriate): ® Civil M Not Applicable ® Process Mechanical Q Not Applicable Application for Authorization to Construct Permit (FORM ATC-12-14) Page 3 IN Water Resources ENVIRONMENTAL GU A! ITY State of North Carolina Department of Environmental Quality Division of Water Resources APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT (FORM ATC-12-14) ® Structural ❑ Not Applicable ® Electrical ❑ Not Applicable ® Instrumentation/Controls ❑ Not Applicable ❑ Architectural ® Not Applicable ❑ Building Mechanical ® Not Applicable ❑ Building Plumbing ® Not Applicable ® Detailed specifications for all treatment units and processes including piping, valves, equipment (pumps, blowers, mixers, diffusers, etc.), and instrumentation. ® Means of ensuring quality and integrity of the finished product including leakage testing requirements for structures and pipelines, and performance testing requirements for equipment. ® Bid Form for publicly bid projects. G. Construction Sequence Plan ® Construction Sequence Plan such that construction activities will not result in overflows or bypasses to waters of the State. The Plan must not imply that the Contractor is responsible for operation of treatment facilities. List the location of the Construction Sequence Plan as in the Engineering Plans or in the Engineering Specifications or in both: On the Cover Sheet H. Engineering Calculations ® Per 15A NCAC 02T .0504(c)(3), submit one set of engineering calculations that have been signed, sealed and dated by a North Carolina Licensed Professional Engineer; the seal, signature and date shall be placed on the cover sheet of the calculations. For new or expanding facilities and for treatment process modifications that are included in Section 4.C, the calculations shall include at a minimum: ® Demonstration of how peak hour design flow was determined with a justification of the selected peaking factor. ❑ Influent pollutant loading demonstrating how the design influent characteristics in Section 4.B.2 of this form were determined. ❑ Pollutant loading for each treatment unit demonstrating how the design effluent concentrations in Section 4.8.2 of this form were determined. ® Hydraulic loading for each treatment unit. ® Sizing criteria for each treatment unit and associated equipment (blowers, mixers, pumps, etc.) ® Total dynamic head (TDH) calculations and system curve analysis for each pump specified that is included in Section 4.C.6. ® Buoyancy calculations for all below grade structures. ® Supporting documentation that the specified auxiliary power source is capable of powering all essential treatment units. I. Permits ® Provide the following information for each permit and/or certification required for this project: Permit/ If Not Issued Provide Not Date Date Certification Status and Expected Permit/Certification Applicable Submitted Approved Number Issuance Date Dam Safety N/A Application for Authorization to Construct Permit (FORM ATC-12-14) Page 4 Water Resources ENVIRONMENTAL QUALITY State of North Carolina Department of Environmental Quality Division of Water Resources APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT (FORM ATC-12-14) Soil Erosion and Sediment Control 9/20/19 USCOE / Section 404 Permit N/A Water Quality Certification (401) N/A USCOE / Section 10 N/A Stormwater Management Plan N/A CAMA N/A NCDOT Encroachment Agreement N/A Railroad Encroachment Agreement N/A Other: N/A J. Residuals Management Plan ❑ For all new facilities, expanding facilities, or modifications that result in a change to sludge production and/or sludge processes, provide a Residuals Management Plan meeting the requirements of 15A NCAC 02T .0504(j) and 15A NCAC 02T .0508; the Plan must include: ❑ A detailed explanation as to how the generated residuals (including trash, sediment and grit) will be collected, handled, processed, stored, treated, and disposed. ❑ An evaluation of the treatment facility's residuals storage requirements based upon the maximum anticipated residuals production rate and ability to remove residuals. ❑ A permit for residuals utilization or a written commitment to the Applicant from a Permittee of a Department approved residuals disposal/utilization program that has adequate permitted capacity to accept the residuals or has submitted a residuals/utilization program application. ❑ If oil, grease, grit or screenings removal and collection is a designated unit process, a detailed explanation as to how the oil/grease will be collected, handled, processed, stored and disposed. ® Not Applicable. No change in annual sludge loading is expected to occur. Application for Authorization to Construct Permit (FORM ATC-12-14) Page 5 Plant Flows Existing Plant Design 0.915 MGD Current Annual Average (past 12 months) 0.573 MGD For Past 12 Months: Start Date: August 2018 For Past 24 Months: Start Date: August 2017 Application for Authorization toConstruct Permit (FORM ATC'1Z'14) Page B. WASTEWATER TREATMENT FACILITY DESIGN INFORMATION —COMPLETE FOR NEW OR EXPANDING FACILITIES AND 1. Have all of the requirements of 15 NCAC 02H. 0100, 15A NCAC 02T, North Carolina General Statute 133-3, North Carolina General Statute 143-215.1, and Division of Water Resources Minimum Design Criteria for NPDES Wastewater Treatment Facilities been met by the proposed design and specifications? ❑ Yes or ❑ No. If no, provide justification as to why the requirements are not met, consistent with 15A NCAC 02T .0105(n): 2. Provide the design influent and effluent characteristics that are used as the basis for the project design, and the NPDES permit limits for the following parameters: Project Basis of Design Design Influent Design Influent Influent Concentration Load Concentration - (Must be (Must be Current Annual supported by supported by Design Effluent Average (past Engineering Engineering Concentration and/or NP DES Permit Limits 12 months) if Calculations Calculations Load (monthly average) Parameter Available [Section 3.H]) [Section 3.H]) Ammonia Nitrogen 1 mg/L Summer 1 mg/L Summer (NH3-N) 25 mg/L 25 mg/L 191 lb/day 2 mg/L Winter 2 mg/L Winter Biochemical 5 mg/L Summer 5 mg/L Summer Oxygen Demand 200 mg/L 200 mg/L 1,526 lb/day (BODS) 10 mg/L Winter 10 mg/L Winter Fecal Coliform 4 per 100 mL 200 per 100 mL Nitrate + Nitrite Nitrogen (NO3-N + NA mg/L NA mg/L NO,-N) Total Kjeldahl 40 mg/L Nitrogen 27 mg/L NA mg/L Total Nitrogen 75,204 lb/year NA lb/year 3 mg/L NA mg/L Total Phosphorus 8 mg/L 8 mg/L 61 lb/day 8,365 lb/year NA lb/year Total Suspended 749 mg/L 750 mg/L 5,723 lb/clay 10 mg/L 30 mg/L Solids (TSS) 3. Based on the "Project Basis of Design" parameters listed above, will the proposed design allow the treatment facility to meet the NPDES Permit Limits listed above? ® Yes or ❑ No. If no, describe how and why the Permit Limits will not be met: Application for Authorization to Construct Permit (FORM ATC-12-14) Page 7 State of North Carolina Department of Environmental Quality Division of Water Resources 4. Per 15A NCAC 02T .0505(i), by-pass and overflow lines are prohibited. Is this condition met by the design? ® Yes or ❑ No If no, describe the treatment units bypassed, why this is necessary, and where the bypass discharges: 5. Per 15A NCAC 02T .0505(k), multiple pumps shall be provided wherever pumps are used. Is this condition met by the design? ® Yes or ❑ No. If no, provide an explanation: 6. Per 15A NCAC 02T .0505(I), power reliability shall be provided consisting of automatically activated standby power supply onsite capable of powering all essential treatment units under design conditions, or dual power supply shall be provided per 15A NCAC 02H. 0124(2)(a). Is this condition met by the design? ® Yes or ❑ No. If no, provide (as an attachment to this Application) written approval from the Director that the facility: ➢ Has a private water supply that automatically shuts off during power failures and does not contain elevated water storage tanks, and ➢ Has sufficient storage capacity that no potential for overflow exists, and ➢ Can tolerate septic wastewater due to prolonged detention. Per 15A NCAC 02T .0505(o), a minimum of 30 days of residual storage shall be provided. Is this condition met by the design? ® Yes or ❑ No. If no, explain the alternative design criteria proposed for this project in accordance 15A NCAC 02T .105(n): 8. Per 15A NCAC 02T .0505(g), the public shall be prohibited from access to the wastewater treatment facilities. Explain how the design complies with this requirement: Site has a fence. 9. Is the treatment facility located within the 100-year flood plain? ® Yes or ❑ No. If yes, describe how the facility is protected from the 100-year flood: The structures are 2 feet above the 100 year flood elevation. C. WASTEWATER TREATMENT UNIT AND MECHANICAL EQUIPMENT INFORMATION —COMPLETE FOR NEW OR EXPANDING FACILITIES AND FOR MODIFIED TREATMENT UNITS 1. PRELIMINARY AND PRIMARY TREATMENT (i.e., phvsical removal operations and flow equalization): No. of _F Plan Sheet Specification Calculations Treatment Unit Units Type Size per Unit Reference Reference Provided? (Yes or No) Manual Bar Screen 1 Existing 3.5 MGD at peak hourly flow Mechanical Bar 1 Existing 3.5 MGD at peak hourly flow Screen Grit Removal 1 Existing 3.5 MGD at peak hourly flow Flow Equalization NA NA gallons Primary Clarifier NA Circular ft diameter; ft side water depth Primary Clarifier NA Rectangular square feet; ft side water depth Other NA Application for Authorization to Construct Permit (FORM ATC-12-14) Page 8 Wa ter Resources ENVIRONMENTAL QUALITY State of North Carolina Department of Environmental Quality Division of Water Resources APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT (FORM ATC-12-14) 2. SECONDARY TREATMENT (BIOLOGICAL REACTORS AND CLARIFIERS) (i.e., biological and chemical processes to remove organics and nutrients) No. of Plan Sheet Specification Calculations Treatment Unit Units Type Size per Unit Reference Reference Provided? (Yes or No) Aerobic Zones/ 3 OX. Ditches 457,500 gallons Yes in Tanks Existing Discussion Anoxic Zones/ NA gallons Tanks Anaerobic NA gallons Zones/Tanks Sequencing Batch NA -- gallons Reactor (SBR) Membrane NA -- gallons Bioreactor (MBR) Secondary Clarifier 2 Circular 40 ft diameter; 14 ft side water Yes in Existing depth Discussion Secondary Clarifier 2 Circular 30 ft Diameter; 10 ft side water Yes in Existing depth Discussion Other NA 3. TERTIARY TREATMENT No. of Plan Sheet Specification Calculations Treatment Unit Units Type Size per Unit Reference Reference Provided? (Yes or No) ft diameter; ft side water Tertiary Clarifier NA depth square feet; ft side Tertiary Clarifier NA water depth Tertiary Filter 4 Square 144 square feet 8 & 9 13220 Yes in Discussion Tertiary Membrane NA square feet Filtration Post -Treatment NA -- gallons Flow Equalization Yes in Post -Aeration 1 Existing 3,804 gallons Discussion Other NA 4. DISINFECTION No. of Plan Sheet Specification Calculations Treatment Unit Units Type Size per Unit Reference Reference Provided? (Yes or No) gal/day per bank at peak Ultraviolet Light NA (Parallel; in hourly flow; number of series) banks; number of lamps/bank Application for Authorization to Construct Permit (FORM ATC-12-14) Page 9 Wetter Resources ENVIRONMENTAL GU ;LITY State of North Carolina Department of Environmental Quality Division of Water Resources APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT (FORM ATC-12-14) Gas (Gas; 85,016 gallons of contact Yes in Chlorination 1 tablet; liquid) tank/unit clear well plus Cl discussion contact tank Existing Dechlorination 1 Gas (Gas; 3,804 gallons of contact Yes in tablet; liquid) tank/unit Existing Post Air tank Discussion 5. RESIDUALS TREATMENT No. of Plan Sheet Specification Calculations Treatment Unit Units Type Size per Unit Reference Reference Provided? (Yes or No) Gravity Thickening square feet; ft side Tank NA water depth Mechanical Thickening/ NA dry lb/hour Dewatering Existing no Aerobic Digestion Existing No change gallons change in annual loading Anaerobic NA gallons Digestion Composting NA dry lb/hour Drying NA dry lb/hour Other NA 6. PUMP SYSTEMS (include influent, intermediate, effluent, major recycles, waste sludge, thickened waste sludge and plant drain pumps) Location No. of Pumps purpose Type Capacity of each pump plan Sheet Reference Specification Reference GPM TDH Influent Pumps 3 Influent Raw waste Submersible Complete new design 1250 37.1 6&7 13328 & 16021 Mud Well Pumps 2 Return backwash back to WWTP Suction Lift Just replacing with like pumps and motors 125 29 11 7. MIXERS Application for Authorization to Construct Permit (FORM ATC-12-14) Page 10 Water Resources ENVIRONMENTAL QUALITY State of North Carolina Department of Environmental Quality Division of Water Resources APPLICATION FOR AUTHORIZATION TO CONSTRUCT PERMIT (FORM ATC-12-14) Location No. of Mixers Purpose Type Power of eac{hFMixer plan Sheet Reference Specification Reference 8. BLOWERS Location No. of Blowers purpose Type Capacity of each Blower (Clo plan Sheet Reference Specification Reference NA Location No. of Units purpose Type Plan Sheet Reference Specification Reference NA D. SETBACKS— COMPLETE FOR NEW WASTEWATER TREATMENT STRUCTURES The minimum distance for each setback parameter to the wastewater treatment/storage units per 15A NCAC 02T .05 are as follows: Minimum Distance Is Minimum Distance Required from Nearest Requirement met by the Setback Parameter TreatmentitStorage Design? If "No", identify Unit Setback Waivers in Item D.2 Below Any habitable residence or place of assembly under separate 100 ft ®Yes No ❑ ownership or not to be maintained as part of the project site Any private or public water supply source 100 ft ® Yes ❑ No Surface waters (streams — intermittent and perennial, perennial 50 ft ® Yes ❑ No waterbodies, and wetlands) Any well with exception of monitoring wells 100 ft ®Yes ❑ No Application for Authorization to Construct Permit (FORM ATC-12-14) Page 11 2. Have any setback waivers been obtained per El Yes or M No. If yes, have these waivers been written, notarized and signed by all parties involved and recorded with the County Register of Deeds? El Yes or [:] No. If no, provide anexplanation: Application for Authorization toConstruct Permit (FORM ATC- 2-14) Page12 SECTION 5: APPLICATION CERTIFICATION BY PROFESSIONAL ENGINEER Professional Engineer's Certification per 15A NCAC 02T .0105: I, Cecil G. Madden, Jr., attest that this application package for an Authorization to Construct (Typed Name of Professional Engineer) for the Town of Warsaw WWTP - Contract No. 42 — WWTP Improvements (Facility and Project Name) was prepared under my direct supervisory control and to the best of my knowledge is accurate, complete and consistent with the information supplied in the engineering plans, specifications, calculations, and all other supporting documentation for this project. I further attest that to the best of my knowledge the proposed design has been prepared in accordance with all applicable regulations and statutes, 15 NCAC 02H. 01001, 15A NCAC 02T, North Carolina General Statute 133-3, North Carolina General Statute 143-215.11 and Division of Water Resources Minimum Design Criteria for NPDES Wastewater Treatment Facilities, and this Authorization to Construct Permit Application, except as provided for and explained in Section 4.B.1 of this Application. I understand that the Division of Water Resources' issuance of the Authorization to Construct Permit may be based solely upon this Certification and that the Division may waive the technical review of the plans, specifications, calculations and other supporting documentation provided in this application package. I further understand that the application package may be subject to a future audit by the Division. Although certain portions of this submittal package may have been prepared, signed and sealed by other professionals licensed in North Carolina, inclusion of these materials under my signature and seal signifies that I have reviewed the materials and have determined that the materials are consistent with the project design. I understand that in accordance with General Statutes 143-215.6A and 143-215.6B, any person who knowingly makes any false statement, representation, or certification in any application package shall be guilty of a Class 2 misdemeanor, which may include a fine not to exceed $10,000, as well as civil penalties up to $25,000 per violation. North Carolina Professional Engineer's seal with written signature placed over or adjacent to the seal and dated: t% A R p S10 a SEAL 16359 � i'MpOID \` Application for Authorization to Construct Permit (FORM ATC-12-14) Page 13 SECTION 6: APPLICATION CERTIFICATION BY APPLICANT Applicant's Certification per |, attest that this application package for an Authorization to Construct (Typed Name of Signature Authority and Title) for the Town of Warsaw WWTP - Contract No. 42 — WWTP Improvements (Facility and Project Name) has been reviewed by me and is accurate and complete to the best of my knowledge. | also understand that ifall required parts of this application package are not completed and that if all required supporting information and attachments are not included, this application package will be returned to me as incomplete. | further certify that in accordance with the Applicant or any affiliate has not been convicted of environmental crimes, has not abandoned a wastewater facility without proper closure, does not have an outstanding civil penalty where all appeals have been abandoned or exhausted, are compliant with any active compliance schedule, and does not have any overdue annual fees. | understand that the Division nfWater Resources' issuance ofthe Authorization 10Construct Pennitnnaybebesed solely upon acceptance of the Licensed Professional Engineer's Certification contained in Section 5, and that the Division may waive the technical review of the plans, specifications, calculations and other supporting documentation provided in this application package. I further understand that the application package may be subject to a future audit. I understand that in accordance with General Statutes 143-215.6A and 143-215.613 any person who knowingly makes any false statement, representation, or certification in any application package shall be guilty of a Class 2 misdemeanor, which may include a fine not to exceed $10,000, as well as civil penalties up to $25,000 per violation. Signature: Date: THE COMPLETED APPLICATION AND SUPPORTING INFORMATION SHALL BE SUBMITTED TO: NORTH CAROLINADEPARTMENT OFENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER RESOURCES/NPDES BY U.S. Postal Service BY Courier/Special Deliver : 1617 MAIL SERVICE CENTER 512 N. SALISBURY STREET, 9TH FLOOR TELEPHONE NUMBER: (919)707-3644 Application for Authorization to Construct Permit (FORM ATC-12-14) Page 14 i m 1 INC. Warsaw Design Basis Contract No. 42 — WWTP Improvements CWSRF Project No. CS370474-05 Cecil G. Madden, Jr., P.E. McDAVID ASSOCIATES, INC. Corporate License C-131 P.O. Box 1776 Goldsboro, NC 27533 Tel: (919) 736-7630 Fax: (919) 735-7351 CA ��� �'�'•ESS�•O�/ ��i ;a SEAL 16359 �,•. N�INE� � �. The Town of Warsaw operates an existing 0.915 MGD wastewater treatment facility with discharge into Stewarts Creek in accordance with NPDES Permit No. NC0021903. It is described as follows: • A three foot wide mechanical bar screen with 1/ 2" clear spaces. In the event of screen failure the flow rises to a bypass channel where the flow is screened by a manual bar screen with 1" clear spaces. • An influent pump station with three 25 HP 800 GPM pumps. Any two are capable of delivering 1600 GPM with the third pump out of service. • A 12' by 12' Aerated grit chamber with two 3 HP blowers, and a grit washer. A flow splitter box that uses weirs to equally split the flow to three oxidation ditches. • Three oxidation ditches with rotors and weirs. Ditch one and two each have one dual speed 30 HP / 20HP rotor. Ditch three has two dual speed 30 HP / 20 HP rotors. The weirs allow the operator to adjust the depth of submergence of the rotors in order to increase or decrease oxygen transfer. • There are four clarifiers. The flow from Ditch One is split between Clarifier One and Clarifier Two. These Clarifiers are 30' diameter clarifiers. The flow from Ditch Two and Ditch Three are combined and split between Clarifiers Three and Four. These two clarifiers are 40' diameter clarifiers. • Effluent from all clarifiers is routed through a splitter box and directed to dual tertiary filters. Each filter is a 12' by 12' filter bed with wheeler style underdrains. There is a single clear well with dual 3,350 GPM backwash pumps. There is a single mudwell with dual 125 GPM mudwell pumps. Backwash from the filters is directed to the splitter box at the head of the oxidation ditches. • Effluent from the filters is directed to the chlorine contact tank. Disinfection is via gaseous chlorine. • Effluent from the chlorine contact tank is directed to the dechlorination / post aeration tank. • Dechlorination is accomplished with gaseous sulfur dioxide. There is a 1 HP and a 2 HP floating aerator in the post aeration tank. Discharge is to Stewarts Creek. • Sludge from the bottom of the clarifiers is routed via telescopic valves to the Sludge Pump Station where two 900 GPM pumps are used to recirculate the sludge back to the flow splitter box which distributes flow to the oxidation ditches. A single 200 GPM pump is used to direct waste sludge to the aerobic digester and aerobic sludge holding tank. The aerobic digester is a 50' diameter, 193, 500 gallon tank with a decant mechanism and a two speed 30 HP / 12.7 HP floating aerator. The aerobic sludge holding tank is a 48' diameter, 153, 000 gallon tank with a decant mechanism and a two speed 25 HP / 10.5 HP floating aerator. • Polymer feed is available to aid settling under high flow conditions. The Town of Warsaw is experiencing overflows of the collection system right outside of their WWTP site at a low point in the collection system. A detailed analysis of seven years of NPDES flow data was conducted. Below is a graph of flow data. Warsaw WWTP, NCO021903 ---oallyFlow 3 - Monthly Average Flow 2.8 2.6 2.4 2.2 2 1.8 1.6 3 1.4 0 1.2 1 g h- 0.8 0.6 0.4 0.2 0 Jan-11 Jan-12 Jan-13 Jan-14 Jan-15 Jan-16 Jan-17 Jan-18 Warsaw WWTP, NCO021903 4 3.5 L C Cr 3 2.5 0 u 2 lL 00 Y 1.5 m a a > 1 0 0.5 0 Jan-11 Jan-12 Jan-13 Jan-14 Jan-15 Jan-16 Jan-17 Jan-18 Warsaw WWTP, Flow data from Jan 2011 to April 2018 4 3.5 o 4+ v 3 . LL Y 2.5 a 1.$ • •� i• '•• i{f.: •. • 16 •N • 1lip ! � 0.5 �• t , , 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 Monthly Average Flow (MGD) Warsaw WWTP, Flow data from Jan 2011 to April 2018 3 2.5 p 2 - 3 1.5 LL 0.5 0 ' 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Monthly Average Flow (MGD) Day Peaking Factor = 2.5. Hourly Peaking Factor = Approximately 2.5 x 1.3 = 3.25 say 3.3.The existing WWTP is designed with an NPDES flow capacity of 0.915 MGD. Based on a 3.3 peaking factor, the Influent Pumps should have the capacity to deliver 3.0195 MGD with one of the largest pumps out of service. With two pumps operating the Influent Pumps should deliver 2,100 gpm or 1,050 gpm per pump. The existing pumps are only able to pump 1,600 gpm with one out of service or 800 gpm each. Discussion of Design Pollutant Loadings Influent monitoring of existing WWTP only monitors BOD and TSS. Below is a table of 12 months of data for BOD and TSS along with Metcalf and Eddy's suggested influent concentrations. Warsaw's Existing Influent August 2018 - July 2019 Month BOD TSS Total N Total P NH3-N TKN mg/I mg/1 mg/1 mg/1 mg/1 mg/1 July 31, 2019 276.1 1133.3 June 152.5 165.0 May 118.4 142.4 April 111.8 1827.5 March 88.0 609.8 February 107.8 894.6 January 96.8 406.3 December 74.8 264.7 November 139.4 766.8 October 193.5 1012.8 September 94.7 665.2 August 1, 2018 120.7 1105.0 Annual Avg 131 749 M&E (Strong) 400.0 350.0 85 15 50 85 M&E (Weak) 110.0 100.0 20 4 12 20 M&E (Medium) 220.0 220.0 40 8 25 40 Below is a table of the effluent monitoring reported for 12 consecutive months that demonstrates the capacity of existing treatment facility. Warsaw's Existing Effluent August 2017 - July 2019 Month Flow Flow Flow BOD NH3N TSS F coli Tot N Tot P DO ADF Max Min AVG AVG AVG AVG AVG AVG AVG July 1, 2019 0.247 0.367 0.134 0.38 0.18 1.03 3.40 50.05 5.08 7.34 June 0.262 0.354 0.198 0.24 0.15 0.00 8.05 7.52 May 0.310 0.390 0.172 0.17 0.10 0.00 2.25 7.69 April 0.632 1.186 0.371 0.22 0.02 0.00 1.00 16.98 1.77 8.68 March 0.616 1.146 0.400 0.78 0.02 0.00 1.00 9.56 February 0.578 1.288 0.380 0.00 0.09 0.00 1.22 17.72 1.07 9.37 January 0.675 1.138 0.493 0.00 0.28 0.00 1.00 9.33 December 0.909 1.786 0.448 0.22 0.08 0.00 1.10 8.61 November 0.513 1.027 0.282 0.68 0.02 0.52 1.05 8.08 October 0.395 0.621 0.235 0.00 0.00 0.00 6.46 20.18 1.52 7.50 September 0.782 2.495 0.327 0.00 0.04 0.00 10.09 6.62 August 1, 2018 0.952 2.073 0.409 0.53 0.23 0.00 2.60 6.64 max 0.952 2.490 9.56 Annual Avg 0.573 0.27 0.10 0.13 3.27 26.23 2.36 8.08 Min 6.62 Based on the above tables the following is a discussion of the anticipated project loadings used in the design basis: Ammonia NH3-N 25 mg/1 per M&E at 0.915 mgd 191 lbs/day of NH3-N Lbs/day NH3-N = 0,915 x 25 x 8.34 = 191 Ibs of NH3-N. The existing facility has historically achieved less than 1.0 mg/l NH3-N. This should not change. The summer limit is 1 mg/1 NH3-N. The winter limit is 2 mg/I NH3-N. This remains achievable. The influent BOD5 monitored was an annual average of 131 mg/l, M&E suggest a weak strength waste of 110 mg/I and a medium waste of 220 mg/l. Based on the actual observed concentration we are conservatively assuming 200 mg/l. The existing facility has historically achieved less than 1 mg/l BOD5. This should not change. The summer limit is 5 mg/1 BOD5 and winter limit is 10 mg/1 BOD5. This remains achievable. Fecal Coliform monitored in the effluent is averages less than 4 count per 100 ml. The high was 10 and the low was 1 count per 100 ml. The design effluent concentration is 4 count per 100 ml. We see no reason for change. Chlorine will be fed to the splitter box just prior to the filters. Adequate contact time is afforded to reduce the Fecal Coliform count. The limit of 200 count/l00 ml remains achievable. TKN has not been monitored. M&E suggests a medium strength waste would have a TKN concentration of 40 mg/l. There is no limit for TKN. Total nitrogen in the influent has not been monitored and does not have an effluent limit. It has been monitored quarterly in the effluent and averaged 27 mg/l. At 0.91 mgd, annual poundage of total nitrogen would be calculated as follows: Lbs Total Nitrogen/Yr = 27mg/I x 0.915 MGD x 8,34 x 365 = 75,204 lbs/yr. (There is no limit.) Total phosphorus is not monitored in the influent and does not have an effluent limit. M&E suggest a medium influent of 8 mg/l. In NC due to the phosphate ban, one might be able to justify 6 mg/1 in the influent. Using 8 mg/l and 0.915 MGD the phosphorus loading would be 8mg/l x 0.915 mgd x 8.34 = 61 lbs/day. The effluent has been monitored quarterly and averaged less than 3 mg/l. There is no reason to expect that to change. At 0,915 mgd, annual poundage of total phosphorus would be calculated as follows: Lbs Total Phosphorus/Yr = 3mg/l x 0915 MGD x 8.34 x 365 = 8,365 lbs/yr. (There is no limit.) TSS monitored in the influent over a 12 month period has been 749 mg/l, (say 750 mg/1). M&E suggest a strong waste would have 350 mg/I TSS. At 0.915 MGD the loading to the plant would be calculated as follows: TSS Loading = 0.915 MGD x 750 mg/I x 8.34 = 5,723 lbs/day The TSS concentration has been monitored in the effluent and is routinely less than 1 mg/l. The limit is 30 mg/l. It is reasonable to assume a design basis of 2 mg/1 or less. The facility will be able to continue complying with the existing limit. Project Basis of Design Design Influent Design Influent Influent Concentration Concentration Load (Must be Annual Average Supported by supported by Design Effluent NPDES permit (past 12 months) if Engineering Engineering Concentration Limits (monthly Parameter Available Calculations Calculations and/or Load average) Ammonia Nitrogen 25 mg/1 25 mg/1 191 Ibs/day 1 mg/t Sum. I mg/1 Sum. (NH3-N) 2 mg/1 Win. 2 m 1 Win. Biochemical 5 mg/1 Sum. 5 mg/I Sum Oxygen Demand 200 mg/I 200 mg/I 1,526 Ibs/day 10 mg/I Win. 10 mg/I Win. (SODS Fecal Coliform 4 Ct / 100 ml 200 Ct/ 100 ml Nitrate + Nitrite Nitrogen (NO2-N + NA NA NO2-N) TKN 40 mg/I NA NA Total Nitrogen 27 mg/1 NA 75,204 ib/yr NA Total Phosphorus 8 mg/1 8 mg/1 61 lb/day 3 mg/I NA 8,365lb/yr NA Total Suspended 749 mg/I 750 mg/I 5,723 lb/day 2 mg/1 30 mg/1 Solids (TSS) Influent Pump Station Design The existing pump station has two wetwells. In order to maintain operation of the existing influent pump station while under construction, it is proposed to construct a new pump station and interconnect their wetwells. The first existing wetwell has an interior of 15' by 8.5'. It has a stage storage of 953.7 gallons per foot. The second existing wetwell has an interior of 15' by 7', with a stage storage of 785.4 gallons per foot. The newly proposed wetwell has an interior of 10' by 10', with a stage storage of 748 gallons per foot. They have a combined stage storage of 2,487.1 gallons per foot. The three of these wetwells have a surface area of 332.5 square feet or the equivalent of one wet well with the dimensions of 10' by 33.25'. SUBMERSIBLE SEWAGE PUMP STATION DESIGN PROJECT AND STATION INFORMATION Project Name Town of Warsaw Influent Pump Station Project Number. Owner Warsaw Owner Contact: Telephone Number: Station Name Influent Pump Station Station Number: Case Number: Three V I Case Description: Submersible - Three Pumps with Two Meeting the Peak 1, Calculated By. Madden with Lewis DESIGN CAPACITY Average Daily Flow = 915,000 gpd 635 42 gpi-n Peaking Factor Wthod i Manigid Entry CJ Service Flupulatiur! Peaking Factor Entry 1.65 DWQ PS -FM MDC, 2.02 A 4.c, requires a minimum peaking factor of 2.50. Design Peaking Factor = 1,65 (manually entered) Peak Hourly Flow = 1,048 44 gpm Design Pumping Capacity = 1.250.00 gpm t 1 OxxAcriZI 0 1 x,-cxcai3O 101 2_9en_oxceI1,CGMMarsaM2- I 7-W29-3400-IP"aSe W3 XIS 1 of 12 8:24 AAA &12,-2019 WET WELL DESIGN DWQ PS -FM MDC, 2,04 A,2, requires that the wet well volume be set to provide 2 to 8 pumping cycles per hour at average daily flow. In order to reduce equipment wear, the wet well volume should be set to minimize the number of pumping cycles per hour at maximum cycling. Maximum cycling occurs at peak hourly flow or when the influent flow rate is exactly equal to one-half the pumping rate, whichever s smaller. Not more than eight (8) pumping cycles per hour at maximum cycling is recommended for des1n. Minimum cycles per hour at average daily flow = 2 DWQ PS -FM MDC, 204 A.2. Maximum cycles per hour at average daily fkwil = a DWQ PS -FM MDC, 2-04 A.2. Maximum cycles per hour at maximum cycling = 8 Average Daily Flow = 636,42 9pm Peak Hourly Flow = 1,048.44 gpm Design Pumping Capacity 1,250.00 gpm Maximum Wet Well Volume = 9,372.40 gallons at Average Daily Flow Minimum Wet Well Voluryte = 2,34110 gallons at Average Daily Flow Minimum Wet Well volume = 2,34175 gallons at maximum cycling which occurs when the influent flow rate is one-half the pumping rate We'r Well Type Re"'tangular Wet Welt Inside Width = 10 00 feet Wet Well inside Length = 33 25 feet Wet Well Volume - 2,487 27 gallons per vertical foot Maximum Cycle Depth m 3.77 feet Minimum Cycle Depth = 0.94 feet Design Cycle Depth = 1.25 feet Design Wet Well Volume = 3,109 09 gallons Cycles per hour at average flow = 6 03 [complies with DWQ PS -FM MDC, 2,04 A 2 Cycles per hour at max- cycling = 6.03 (influent flow at one-half Design Pumping Capacity) Minimum Wet Well Liquid Depth = 3-50 feet (invert to pumps off) influent Pipe Invert Elevation = 126.00 feet High Water Alarm Elevation = 126.90 feet Alarm level is above the influent pipe invert. Lag Pump On Elevation = 126.50 feet Lead Pump On Elevation = 126.00 feet Pumps Off Elevation = 124.75 feet Wet Well Invert Elevation = 121.25 feet lOxc_genDlOix-excai,DlUl2_gon_cxcetCGMtOlarsaW,2-',7-6029-3AGC-IPS-Case 003 Xis 2 Of 12 8:24 AM WV2019 PUMP DISCHARGE PIPING Pipe Material: Flanged Ductile Iron Pipe, Class 53 Nominal Diameter = 8 inches Inside Diameter = 8.205 inches C-Factor = 120 Equivalent Length Calculations item Description Quantity I Eq. Length Per Unit (feet) Equivalent Length (feet ETe 30 1 30 9W Bend 145' Bend 2-2 Bend/- 3 21 63 11 Y4* Bend Tee (run) 0 jttSrun to branch) 1 45 45 Check Valve 1 74 74 Plug Valve 1 31 31 Total Equivalent Length = 243:] DISCHARGE HEADER PIPING Pipe Material: Nominal Diameter Inside Diameter C-Factor = Equivalent Length Calculations Eq- Length Equivalent Item Description Quantity Per Unit Length I I (feet) (feet' Pipe 0 9W Bend 45' Send 0 22W Bend 11 %." Bend Tee (run) 0 Tee (run to branch) Check Valve Pis Valve rTotal Equivalent Length Vif 5D I Oxx — FWD 101 001xis Page 3 of 12 8 24 MA 610 W019 FORCE MAIN PIPING IlMateriallSize I Pipe Material: Ductile Iron Pipe. Class 350 Nominal Diameter 12 inches Inside Diameter = 12.515 inc-ftes, C-Factor = 120 Item Description Quantity Eq. Length Per Unit (feet) Equivalent Length (feet) Pie 85 1 85 ,90" Bend 0 P.46' Bend 22W Bend 11 1/4, Bend Tee (run) 1 16 16 Tee (run to branch) Check Valve 'N—Ugvalve Total Equivalent Length ffi 101 FORCE MAIN PIPING (MaterlaIISE-re 2) Pipe Material: Nominal Diameter Inside Diameter C-Factor = Ductile Iran Pipe, Class 360 12 inches 12.515 inches 120 Equivalent Length Calculations Item Description I Quantity Eq. Length Per Unit Equivalent Length (feet) Pie 790 1 790 90' Bend 4 32 128 128 !i 1 Bend 1 '16 16 22 Y2'B end r 111/4' Bend ; - k45' Tee (run) Tee (run to branch) Check Valve PI Valve ITotal Equivalent Length ,= 77=L-9-34-� W3-xis Page 4 of 12 8 74 AM 61'€V2019 FORCE MAIN PIPING (Material/Size 3) Pipe Matenal: NOT USED Nominal Diameter Inside Diameter C-Factof = 120 Equivalent Length Calculations Item escriptVan Eq. Length Per Unit (feet) FORCE MAIN PIPING tMaterLaLI&O-4j Pipe Material: NOT USED Nominal Diameter Inside Diameter C-Factor = Eauivalent Length Calculations Item Description Quantity Length r Unit t Eq. Length Equivalent Per Per Unit Length (feet Pipe 90' Bend 45' Send 22Y2' Bend 111/4Bend Tee (run) Tee (run to branch) Check Valve Plug Valve [Total Equivalent Lena Eta = FORCE MAIN DISCHARGE Discharge Elevation = 151,00 feet W:NDI Oxx_gen01 0 1 x exce,01 0'2 tell 7-6029-3400-IPS-Case 003 xis Page 5 of 12 $24 Am 61 2=1 9 SYSTEM HEAD CALCULATIONS Flow Increment = 50.00 gprn Safety Head = 0.00 feet F-Mbon Piping Section F actor ac Pump Discharge Friction Factor 0,000013 Force Main Friction Factor 0000007 Force Main Velocity Factor 0,002608 g Pump On Elevation = 126.50 feet Lead Pump On Elevation = 126.6-0 feet Pumps Off Elevation = 124.75 feet Discharge Elevation = 151,00 feet Design Capacity Heads si' Design Ca2acrty 1,250.00 gpm lir Minimum Static Head Minimum Irxf 25,00 feet Maximurn Static Head 26.25 feet M M Inir jpj�l �ic Head irirnyM 35.81 feet Maximum Total gyname Head = Maximum M 37,06 feet Pump Specification, 1.260 00 gpm at 37 06 feet {includes safety head) 003 x1s, Page 6 of 12 &24 AM 6112W19 SYSTEM TABLE - Sin ie Pump Op ration Isafety head not included) FIOV, :R7t:e Rate Apm 0 50 min. TDH feet 25.00 25.03 M Ti H feet 2625 2628 100 2510 2635 150 25.21 26,46 200 25,36 26,611 250 25,55 26�80 300 26-77 27,02 350 400 25.02 267— 27.27 --17—.56 450 26.63 27.88 500 26.98 28.23 550 27,36 28.61 600 2717 2902 650 700 750 2812 28.69 29.19 29.47 2994 30.44 800 29.73 30.98 850 30,29 31.54 900 30,88 32,13 950 31.50 32,75 1,000 32.15 33.40 LM 1100 32.82 33.53 34.07 34.78 1,150 3416 35.51 1,200 36.02 36617 1,250 35,81 3706 1,300 36.62 3787 1,350 37A7 3872 1,400 1,450 38.34 39.23 3959 --'40—,48 1,500 40.16 41,41 1,550 41.11 4236 1,600 42.08 4133 1,650 4309 44,34 1,,700 4412 45,37 1,750 1,800 45-17 46,25 46,42 47.50 1,850 47-36 48.61 1,900 48-50 49.75 1,950 4966 50.91 2,000 50.84 52 M 2,050 62,05 5330 2,100 2,150 2,200 63,29 54.55 55.84 rA 54 55.80 57,09 2,250 57.15 58.40 2.300 58,49 59,74 2,350 5985 61,10 2,400 61.24 62A9 W:Zio)cx_gen'Dioix—excel%DIC12_ger—"cePLOWWarsaw�2-17-6020-3ACO-IPS-Case 003.xis Page 7 of 12 814 AM M 2)2019 nVt:LUGI I Y I AtlLt - bin ie vurnp uperation Flow Rate (gpm) Pump Discharge Ifos) Discharge Header (fps) Force Main MtS I Force Main WS 2 --qLSL- Force Mam MfS 3 Force Main WS 4 0 000 0.00 0.00 50 0.30 0,13 0.13 100 OV 026 0,26 160 OV 0,39 0.39 200 1,21 052 052 250 300 350 1.52 1.82 2.12 0.66 038 0.91 065 0,78 091 400 243 1.04 1,04 450 233 1,17 1.17 Soo 103 1,30 1.30 550 334 1.43 1.43 600 3-64 166 1.56 650 394 1 70 1.70 700 425 1,83 1.83 750 455 1,96 1,96 800 4,85 209 2,09 850 5,16 222 222 904i 5.46 2,35 235 950 1,000 5,76 6.07 2,48 -'1.61 2,48 261 1,050 6.37 2.74 2-74 1,100 6,67 2,87 2.87 1,150 698 3,00 300 1,200 7,28 313 3.13 1.250 7 58 326 3,26 1,300 1,350 1,400 7.89 8.19 849 3,39 152 3�65 3.65 3.39 152 3 165 1,450 8,80 3,78 3.78 1,500 9,10 391 391 1,560 9,41 4,04 4.04 600 9.71 417 4.17 1,700 1,750 laol 10.32 10.62 4,30 4.43 4.56 4,30 4.43 4.56 1,800 10.92 4.69 4.69 1,850 1123 4.83 4.83 1,900 1153 4,96 4,96 1,950 11.83 3 509 5.09 2,550 12.14 522 1 5 22 2,050 12.44 5.35 ! 5,35 2,100 12.74 548 5.48 1105 5.61 5.61 2200 13.35 5.74 534 W 21250 13,65 5,87 587 1 L2,150 2300 00 1196 6.00 600 - 2,35PO 1426 6� 13 613 400 2 00 1456 626 626 003.XIS Page 8 of 12 8,24 AM 01212019 SYSTEM TABLE - Dual Pump Operation (safety head not included) Flow Rate m Min, TDH feet Max, TOH (feet) 0 25,00 26 25 50 25,01 26 26 100 25,06 28,30 150 25,11 26.36 200 25.19 26.44 250 25.29 26.54 300 2541 26.66 350 25,55 2680 400 450 500 25,70 2s. f38 � 26.06a����, M27.52 550 26.27 600 26,49650 2673 . 700 2699 28,24 75t3 27.26 28.51 800 850 27.55 27.85 28.80 29.10 900 28.17 29.42 950 28,50 29,75 1,000 28,85 30.10 1,050 29.22 30A7 1,100 29,60 30,85 1,150 29.99 31.24 1,200 30A0 31.65 1,250 30.83 32.08 1,300 31,27 32.52 1,350 31,72 32,97 1,400 32,19 3344 1,450 32,68 33.93 1,500 33.18 34.43 1,550 33.69 1,600 34.22 _34,94 35.47 1,650 3476 36.01 1,700 35.31 36,56 1,750 35.88 37.13 1,800 36,47 37,72 1,850 1,900 1,950 37.07 37.68 38,31 38,32 38.93 39.56 2,000 38.95 40.20 2,050 39.60 40-85 2,100 40,27 41.52 2,150 40,95 42,20 2.200 2,250 41.65 42.35 42,90 43.60 2,300 43.08 44.33 2,350 43.81 45.06 2,400 44.56 45.81 W:�Dflc_gn401x_+L7Ot2agan,mexc?GiAtWrror-5a254Q0 PS -Case 003 xks Page 9 of 12 8`24 Ate W12 19 VELOCITY TABLE - Dual Puma ODeration Flow Rate (pm ) 0 50 Rump Discharge S!P�J 0.00 0.15 Distharce i= harge Header Header He der f s .Jts�.. Force Main Force Main S1 WS I (f s .2S.L. 0.00 0.13 Force Main WS 2 (fps) 0.00 0.13 Force am mis 3 (fps) Force Main MIS 4 (fps) 100 0.30 0-26 0,26 150 0,46 0-39 U9 200 0,61 0,52 0.52 260 076 0.65 065 300 0,91 078 078 350 106 0,91 091 400 1.21 1,64- 1,04 450 1.37 1.17 117, 500 1,52 1.30 1.30 560 1 1,67 1.43 1 A3 600 1.82 1.66 1,56 650 1,97 1,70 130 700 2.12 1.83 1,83 750 128 196 1,96 800 850 1 2.43 258 2-09 2-22 -2:69- 222 900 273 235 2.35 950 2.88 2A8 248 1,000 103 2,61 261 050 3.19 2.74 2.74 1,100 3.34 2.87 287 1,150 3,49 Ii�0� OW 310 1,200 164 3.13 3.13 1,250 3,79 3,26 3,26 1,300 3,94 139 3.39 1,350 4.10 3.52 352 1,400 4,25 3 65 365 1,450 4.40 3.78 3-78 1,500 4,55 3.91 3-91 1,550 4,70 4.04 4.04 1,600 4.85 417 417 1,650 5.01 4.30 4,30 1,700 5.16 4,43 4.43 1,750 5.31 4.56 4,56 1,800 5.46 4.69 4.69 1,850 5.61 4.83 4,83 1,900 5.76 4.96 4,96 1,950 592 5.09 6.019 2,000 607 5,22 5,22 2,050 622 635 535 2.100 6-37 5.48 5 48 2,150 6.52 5.61 561 2,200 6.67 5.74 5.74 2,250 613 5.87 5,87 2.300 698 6.00 6.00 2,350 7.13 6,13 613 2,400 7.28 6,26 6.26 W,%Dl oxx_ge�notti! ii-excehDl N 2_gen__Pxceit;;GVtViasa-k�2-17-602a-3400-IPS-Caw 033 x1s Page to of 12 8 24 AM 6112f201 9 TRIALL -PUMP Manufacturer: Fairbanks Model Number, 6" 5433 MV Ffrrmromm- elm Curve Number T6CIC Imeetter Diameter 11. 3000 inches Irn Iter S ed = 1, 183 rpm Characteristic Curve Pants Head OeeEE�E Capacity Left Sole of Curve W 7OO Middle of Curve Right Side of Curve 37 2 60 1 960 OD I 1,600,00 j Pamn anpratino Parameters Impeller Diameter = 113000 inOes Impeller Sp d = 1,183 rem Head ( et Capacity (gpm) Equation Factors 4820 70000 A= 5813737 10 1 1,250,00 B=-0,0112i10 28.60 1 1,600-00 C = -4 560E:b6 Pump capacity is within design toierance. Impeller diameter is acceptabte. esign Capacity = 1,250.00 gpm Design Tolerance 1.04 gpm Intare-pnt Pnints fnr Svstpm and PUMD Curves - Sina;e PUMD ODeration system Curve capacity Total Pump Pump Pump Brake System Curve Capacity I Capacity Head Efficiency Power (gpm} (pm} (feet) (HP) Minimum TDH Curve 'P'mum T' 2,149,23 1,074,62 40,94 7T0% 14-43 rM:ax:im`umTDH Curve 2,09738 1,048,69 41,48 77.0 W6D10xx_oen'D101x_excetOiOl2_gen—exc,e?CGM'i%Varsmv',2-17-6029-3400-IPS-Case W3.x4 Pa" 11 of 12 &24 AM W212019 Custot P E N TA I R P ojectlnemD 20 a t5 r y lU d ti go 72 e4 5n 49 .tn 2 32 24 16 a 0 � 1e Ne a z D 0 200 400 UUC Item number Default Service Quantity :1 Quote number Dale last saved : 12 Jun 2019 0 19 AM Flow, rated : 1,250.0 USgpm Differential head 1 : 37.10 fl pressure, rated Flud density, rated 1 me) : 1.0001 1.000 SG 'Ni, PENTAIP Pump Performance Curve ncompoiu 2.0 - 19.1 S 000 t.CW I,7fiu 1.4M 1.ouu Flow - USgpm Sae Stages Speed, rated Based on curve number Effiaency Power, rated NPSH required Viscosity Cg1Ch/Ce1Cn [ANSIM196.7-2010) IBLAU now 18210 2000 6` 5433MV 1 1 t 83 rpm 64433MV-1800-W 1 C 78.91 % 14.85 hp 8.45 ft 1.00 cP 1 001 1.00 11.001 1.DO FAIRBANKS WHIMS PHONE -1.913.371-5000 • FAX: 3501 PAIRIiNJKS AVENUE KANSAS CRY. KANSAS661015 Custoer P E N TA I R P n)e ttnam Item number Dufuull Service Quantity : t Quote number Performance Data Head, maximum diameter, rated flow 45.41 It Head, minimum diwneter rated fkyv 13.58 ft Head, maximum, rated diameter . 63.15 ri Efficiency adjustment factor, total 1.00 Power adjustment. total : 0.00 hp Head adjustment factor, lntal . 1.00 Flow adjustment factor. total 1.00 NPSHR adjustment facto-, total 1.0D NPSH margin dictated try pump suppler 0 001t NPSH margin dictated by user 0.00 It NPSH margin used (added to'requvec' values) : 0.00 It Mechanical limits Torque, rated power, rated speed 1.26 hpr`1100 rpm Torque, maxmum power, rated speed 1.34 hpM 00 rpm Torque, driver power, full load speed 1.67 hpt100 rpm Torque, driver power, rated speed 1.69 hpf100 rpm Torque, pump shaft limit 1.000 hobo rpm Rad al load, worst case Radial toad IInNt Impeller peripheral speed, rated Impeller peripheral staved limit various Perlormance Date Flow (l Sgpm) Shutoff, rated diameter 0.00 Shutoff, maximum diameter 0.00 Minimum Continuous Stable Flow i99.9 Rated flow, minarum diameter 1,250.0 Rated flow, maximum diameter 1,250.0 SEP flow, rated diameter 1,191,3 120% rated fbw. rated d ametur 1,5Q0.0 End of curve rated diameter 1,698.7 End of curve, minimum c iametw 1 253.6 End of curve, maximum diameter 1.799.5 Maximum value rated diameter Maximum value, maximum diameter System differential pressure Differential pressure, rated flow, rated diameter (psi) Differential pressure. shutoff, rated diameter (psi) Differential pressure, shutoff, maximum diameter (psi) Discharge pressure Discharge pressure, rated flow, rated diameter (psi.g) Discharge pressure, shutoff, rated diameter (pal.g) Discharge pressure, shutoff, maximum diameter (psi.g) Ratios Maximum flow I rated 0c1n. rated 6arneter Pump Songs Series All Construction Pump Performance - Additional Data EmwipOsb 2.0 - 19 1.5 Sue Stages Speed, rated Frame size Date last saved Stage, Speed and Solids limits Stages, maximum Stages, minimum Pump speed limt, maximum Pump speed limt, minimum Curve speed knit, maxln>✓m Curve speed tent, minimum Variable speed Imit, minimum Solids dameler Itmt Typical Diner Data Driver speed, fur bad Driver speed, rated bad Driver officiency, 100% load Driver efficiency, 75% bad Driver efficiency, 50% load 6. 5433Mv 1 1183 rpm 12 Jun 2019 8:19 AM i 1800 rpm 875 rpm 1800 rpm 695 rpm 180 rpm 3.00 in 1200 rpm 12D0 rpm N)A WA N(A Head (ft) Efficiency I.%) NPSHr (RI Power Ihp) 63.15 8.83 73.28 - - 10,98 67.86 30.47 9.35 9.59 13.58 67.35 - 6.37 4541 79.44 16.04 38.46 79.02 8,32 14.64 31.15 76.02 9.73 15.52 26.14 70.71 12.44 15.86 12.87 66.26 8.55 6.30 30.97 70,31 14.81 20.01 63.15 19.02 15.56 79.46 20.D1 tv Density. rated F4 Density, mar 16,07 1607 27.33 2733 31.71 31.71 'fr Suction iw Suctrun 0 Sur.t on Suction pressure, rated pressure_rnax pressure. rated pressure, max 16,07 16.07 1607 16.07 27.33 27.33 27.33 27.33 31.71 31.71 31.71 31.71 134.33 % Head rated dwmetar I head minimum diameter, rated flow : 273.41 % Time In Air : Short Time In fur Closed loop C:ioling No Certified Test Grades Want certified test Unite- : No Select certified test grade NIA FAIRBANKS NIJHUIS PHONE, •1.913-371.5000 FAX: ►!�►j3501 I P E N TO 10 KANSAS CITY. KANSAS 661D5 Buoyancy Calculations SUBMERSIBLE SEWAGE PUMP STATION DESIGN RECTANGULAR WET WELL BUOYANCY CALCULATIONS PROJECT AND STATION INFORMATION Project Name: Warsaw Project Number: Owner- Warsaw (>nner Contact: Telephone Number Station Name- Influent Station Number, Case Number: 001 Case Description: Calculated By Madden RECTANGULAR WET WELL DIMENSIONS Ground Elevation = 137.00 feet Top Elevation = 137 00 feet Invert Elevation = 12125 feet Water Surface Elevation 137 00 feet Inside Width = 10.00 feet Inside Length = 10 00 feet Wall Thickness = 8.00 inches = 0 67 feet Top Slab Thickness = 12,00 inches = 1,00 feet Base Slab Thickness -- 12.00 inches = 1.00 feet Base Slab Extensions Short Side = 12.00 inches = 1,00 feet Long Side = 12.00 inches = 1.00 feet Top Rectangular Opening No 1 Width = 4800 inches = 400 feet Length = 108,00 inches = 9,00 feet Top Rectangular Opening No 2 Width = 0 00 inches = 0.00 feet Length = 0,00 inches = 0 00 feet Top Circular Opening Diameter = 400 inches = 0 33 feet Fillet Volume = 50.00 cubic feet Outside Width = 11.33 feet Top Slab Width = 11,33 feet Outside Length = 11.33 feet Top Slab Length = 11 33 feet Base Slab Width = 13,33 feet Inside Height = 14.75 feet Base Slab Length = 13.33 feet Soil Height Over Base = 15.75 feet MATERIAL DENSITIES Dry Soil Density = 110.00 lb/cf Concrete Density 140.00 tbacf Water Density = 62.40 Vcf Net Soil Densty 47 60 Iblcf DOWNWARD FOACESAO-r—avlt Base Stab = 24,889 lbs Walls m 58,738 lbs Top Stab = 12,930 lbs, Fillet = 7,000 lbs Total Wet Well Concrete = 1,33,557 it Soil Over Extended Base = 85,470 Ins UPWARD FORCES (Bu2yancy) Base Slab = 11,093 ibs Wall Prism 118,220 ibs Top Slab w ----8 015 lbs Total Wet Weil 137,329 lbs FACTOR OF $AFEj"DWQAA" Required Factor of Safety = 1,0000 Total Wet Well Concrete 7r 103,557 Itis Net Soil Downward Forces 36,985 tbs Total Downward Forces = 140.542 lbs Upward Forces on Wet Well = 137,329 itis Factor of Safety = 1.0234 FACTOR OF SAFETY (MAI Method Required Factor of Safety w 1.0000 Total Downward Forces = 189 027 lbs Total Upward Forces = 186,811 lbs Factor of Safety z 1,0173 Buoyancy is OK Buoyancy is OK SUBMERSIBLE SEWAGE PUMP STATION DESIGN RECTANGULAR VALVE VAULT BUOYANCY CALCULATIONS PROJECT AND STATION INFORMATION Project Name: Warsaw Project Number - Owner: Warsaw Owner Contact: Telephone Number: Station Name Influent PS Station Number Case Number: One Case Description Calculated By Madden RECTANGULAR VALVE VAULT DIMENSIONS Ground Elevation = 137.00 feet Top Elevation = 137 00 feet Invert Elevation = 130.50 feet Water Surface Elevation 137.00 feet Inside Width = 8,00 feet Inside Length = 10.00 feet Wall Thickness = 6.00 inches = 01,50 feet Top Slab Thickness 6,00 Inches = 0.50 feet Base Slab Thickness = 6.00 inches - 0.50 feet Base Slab Extensions Short Side = 1100 inches = 1.00 feet Long Side = 12.00 inches = 100 feet Top Rectangular Opening No 1 Width = 48 00 inches = 4 00 feel, Length = 108 00 inches = 9 00 feet Top Rectanguiar Opening No 2 Width = 0.00 inches = 0 00 feet Length = 0.00 inches = 0.00 feet Top Circular Opening Diameter = 0.00 inches = 0.00 feet Fillet Volume = 5.00 cubic feet Outside Width = 9,00 feet Too Slab Width = 9.00 feet Outside Length = 11.00 feet Top Slab Length = 11 00 feet Base Slab Width = 1100 feet Instde Height = 6,00 feet Base Slab Length = 13 0,0 feet Soil Height Over Base = 6.60 feet MATERIAL DENSITIES Dry Soil Density = 110.00 1b)cf Concrete Density 140,00 lbfcf Water Density = 62,40 lbfcf Net Soil Density = 47,60 lbicf DOWNWARD FQRCES-LQjjy:1W Base Stab = 10,01010S Walls = 15,960 lbs Top Stab = 4 410 lbs Fillet = 700 lbs Total Valve Vault Concrete = 31 080 ibs Soil Over Extended Base = 31,4610 lbs PWARD FORCES t8uovanc Base Slab = 4,462 Ins Wall Prism 37,066 lbs Top Slab r 3,089 lbs Total Valve Vault - 44,676 IbS Soil Over Extended Base = 17,846 lbs FACTOR OF SAFETY iDWO Method Required Factor of Safety = 1.000 Total Value Vault Concrete 31,080 lbs Net Soil Downward Force:; 13,614 ibs Total Downward Forces = 44,694 lbs Upward Forces on Vault = 44,616 lbs Factor of Safety = 1 0017 Buoyancy is OK FACTOR OF SAFETY (MAI Method Required Factor of Safety = I LOW Total Downward Forces = 62,640 lbs Total Upward Forces = 62,462 tbs Factor of Safety = 1.0012 HEMM b O O N C/] K O CD CD At N CD Q >y 6'" C C CD O 0 0 Cl. CD CD C O No Mrq-s:S.317. erg r` 'A �or 3 �� a. I2 128:7 WF taxtng-a5t.6s6. asnrg-2173.6t; Page of NordlrxJ-a:t.:s9.Eatwng-Z 71tis b �n a1RtlH wq d � porllon d b �Cw� +IoeW 0uW map 7hb �pYawpur•1W trrnplb a rsNm��b -1,aA mp r..ra tww+ nW. wbw�.+rd 14 t/w d.la �n !n rnb W...l Gam, rw tN�l pWW mlwml��+ a+d kdpw�l food Inwwc- MW��n Ib.A �V. �hcl e� FEAu FMm MAD 9br, r ��.-,ex fe.�Jw -1141hmd Rase F:nod Flevation (Rii) lYth BFF or Dcp1 F.cgrlatoa Floodway 0 2'. Annual Cnance Hood Hazard FutileConeitiens i1i Annual Chance �! Flood Hazard Areas Deterntired to be Outside Me 0.2 Annual Cnanceflood Hazard Juriscic'ion Bounds) FIRM Party Bounda-) North Carolina State Mane Projection Feet (Zone 3200) Datum: NAD 1983 (Horizontal), NAVD 1988 (Vertical) 11�-SOOhN low rrr ONrlen E NATIONAL. FLOOD INSURANCE PROGRAM CC -1000'KS'UPANCE RAZE MAP QPanel(s):2464 Q- CONTAINS: COMMUNITY CID = TOWN OF WARSAW 370633 CC Notice to User. The Map Number(s) shown below should be used when lacing map to orders: the Community Numbers) shown above should be used on insurance appiicatiorts for the subject community. O SELECTED PANELS: O LL MAP NUMBER EFFECTIVE DATE 37_0:4ta00J id2006 CC O Z w - 11T -41C C 0 Water To" N , East Best fStreet 7, _ i NC 50 \4- V, utfall 0011 J_ 117 Q Town of Warsaw Warsaw WWTP NPDES Permit NCO021903 Receiving Stream; Stewarts Creek Stream Class: C; Sw Stream Segment: 18-68-2-10 Sub -Basin 0: 03-06-19 River Basin: Cape Fear HUC: 0303000605 County: Duplin ti 1:24,000 Facility Location wale noR shown 34,9930560, USGS Quad Warsaw South Discussion of peak hourly flows through Grit Removal, Oxidation Ditch, Clarifiers Chlorine Contact Tank and Post Aeration is addressed as follows: Flows Current Flows ADF based on NPDES Permit = 0.915 MGD or 635.4 GPM. Current Peak Hour Flow based on two of 3 Influent Pumps Pumping = 1,600 GPM. After Project Future Flows ADF = 0.915 MGD or 635.4 GPM. After Project Future Peak Hour Flows = 2,100 GPM Aerated Grit Removal The existing Aerated Grit Removal is 12' by 12' with a 12' sidewater depth and was manufactured by Lakeside Equipment Corporation. Their recommended maximum peak hydraulic loading is 3.5 MGD. The volume of the grit removal structure is 12' x 12' x 12' x 7.48 gal/cf = 12,925 gallons. Per Metcalf and Eddy the recommended detention time is 3 to 5 minutes at peak flow. This structure's detention time at peak flow is calculated as follows: Detention Time = 12,925 gal / 2,100 gpm = 6.15 minutes. Using the recommended detention time recommended by Metcalf and Eddy the facility would be able to handle the following range: 12,925 gal / 5 min = 2,585 gpm or 3.72 MGD (Low end) 12,925 gal / 3 min = 4,308 gpm or 6.20 MGD (High end) Clearly the grit removal can handle the newly proposed peak flow. Oxidation Ditches There are three oxidation ditches. Flows are split evenly among the ditches. Each ditch has a volume of 457,500 gallons for a total volume of 1,372,500 gallons. This provides a nominal ditch holding time of 36 hours at average daily flow which is conservative. This number is not changed by the proposed project. If one ditch is removed from service for repairs the resulting capacity provides 24 hours of holding time which is still adequate for extended aeration. At Current peak hourly flow it provides a holding time of 14.3 hours. After construction of the project, holding time at peak hourly flow will be 10.89 hours. Clarifiers There are four clarifiers. Two are 40 foot diameter clarifiers with 14 foot sidewater depths. Two are 30 foot diameter clarifiers with 10 foot sidewater depths. Two of the oxidation ditches send their flow to the two 40 foot diameter clarifiers. One of the oxidation ditches sends its flow to the two 30 foot diameter clarifiers. Flow to the 40 foot diameter clarifiers are as follows: (1/3) Plant ADF = Clarifier ADF = (1/3)(635.4 gpm) = 211.8 gpm or 305,000 gpd. (1/3) Plant Peak Hourly Flow = Clarifier Peak Hourly Flow = (1/3)(1,600 gpm) = 533.33 gpm or 768,000 gpd per Clarifier. After the project, peak hourly flow to the 40 foot Clarifiers will be (1/3)(2,100 gpm) = 700 gpm or 1,008,000 gpd per Clarifier. The 40 foot clarifiers each have a surface area of 1,256 square feet. Their ADF loading rate is 305,000/1,256 = 242.8 gpd/sf Their Current Peak Hourly Loading Rate = 768,000/1,256 = 611.5 gpd/sf Their Peak Hourly Loading Rate after the Project = 1,008,000/1,256 = 802.5 gpd/sf Flow to the 30 foot diameter clarifiers are as follows: (1/6) Plant ADF = Clarifier ADF = (1/6) (635.4 gpm) = 105.9 gpm or 152,500 gpd (1/6) Plant Peak Hourly Flow = (1/6) (1,600 gpm) = 266.67 gpm or 384,000 gpd After Project (1/6) (2,100 gpm) = 350 gpm or 504,000 gpd The 30 foot diameter clarifiers each have a surface area of 707 square feet. Their ADF Loading rate is 152,500/707 = 215.7 gpd/sf Their Current Peak Hourly Loading Rate = 384,000/707 = 743.1 gpd/sf Their Peak Hourly Loading Rate after the Project = 504,000/707 = 712.9 gpd/sf The primary problem with the 30' diameter clarifiers is the shallow 10' sidewater depth. We are currently working to obtain funding to replace the 30' diameter clarifiers Chlorine Contact Tank The Chlorine is fed at the splitter box prior to filtration. This way the chlorine assists in reducing algal growth on top of the filters and increases chlorine contact time. Once the effluent travels through the filters it travels to the clear well and the chlorine contact chamber. Contact time is based on the clear well volume and the chlorine contact volume. Clear well volume is 67,943 gallons. Chlorine contact tank volume is 17,073 gallons. Total volume of chlorinated water = 67,943 + 17,073 = 85,016 gallons. Contact Time at ADF = 85,016/635.4 = 133.8 Minutes Contact Time at Current Peak Hour Flow = 85.016/1,600 = 53.13 Minutes. Contact Time at New Projects Peak Hour Flow = 85,016/2,100 = 40.48 Minutes. Only 15 Minutes is required at peak Hour Flow. Post Aeration According to Metcalf and Eddy post aeration typically uses a detention time of 10 to 20 minutes at peak hourly flow. Post aeration at the existing treatment facility provides the following detention time: Detention time @ current peak = (13' x 12' x 3.26' x 7.48)/ 1600 gpm = 2.3 8 minutes. Detention time @ proposed peak = (13' x 12' x 3.26' x 7.48)/2100 gpm = 1.8 minutes. The single basin has one 1 HP floating aerator and one 2 HP Floating aerator. The NPDES Permit has a limit of 6.0 mg/l. A review of 12 consecutive months' worth of DMR's shows the average DO to be 8.08 mg/l. The low monthly DO occurred in September at 6.62 mg/l. This is not surprising because the high quality effluent has previously satisfied most of the oxygen demand. Post aeration should remain satisfactory under the proposed peak flows of 2,100 gpm. Tertiary Filter Design Discussion of peak hourly flows through the Filters is addressed as follows: The existing filters consist of two 12' by 12' dual media conventional filter cells with wheeler bottom underdrains. Flows Current Flows ADF based on NPDES Permit = 0.915 MGD or 635.4 GPM. Current Peak Hour Flow based on two of 3 Influent Pumps Pumping = 1,600 GPM. After Project Future Flows ADF = 0.915 MGD or 635.4 GPM. After Project Future Peak Hour Flows = 2,100 GPM Surface area of the existing filters is 2(12' by 12') = 288 sf At ADF loading rate 635.4/288 = 2.2 gpm/sf At current peak loading rate 1600/288 = 5.56 gpm/sf After upgrade of the influent pump station the peak loading rate would be as follows: Peak Loading Rate = 2100/288 = 7.29 gpm/sf (This is too high. Therefore this design doubles the filter size.) Proposed filter size after project = 4(12' by 12') = 576 sf After Project the loading will be as follows: Proposed peak loading = 2100/576 = 3.65 gpm/sf With one filter out of service the loading rate would be 4.87 gpm/sf Metcalf & Eddy third edition page 681 Table 11-6 suggest the loading range of 2 — 10 gpm/sf with 5 gpm/sf being typical for dual media filter. The existing backwash pumps backwash each filter cell one time per day for a period of 7 minutes each filter cell. They currently operate for only 14 minutes per day. These existing backwash pumps can be used to backwash each of the new filter cells with no changes in conditions. Their operation will go from 14 minutes per day to 28 minutes per day. They backwash at the rate of 3,350 gpm. Each backwash cycle produces backwash as follows: Backwash volume = 3,350 gpm x 7 minutes x 4 filters = 93,800 gallons per cycle of 4 filters. The mud well is 50' x 50' x 8.5'. Its stage storage is 18,700 gallons per foot. If the mud well pumps did not pump, the mudwell would rise to 5.01' deep after the backwash of 4 filter cells. This yields more than 3 feet of freeboard. The existing mud well pumps are 125 GPM 29' TDH Gorman Rupp Model A3-B 4" flanged suction lift pumps driven by 5HP 3/60/460 1,750 RPM motors. Both of the pumps and both of the motors need to be replaced due to wear. The only condition that will change is the duration of operation. At 125 GPM, they will pump 12.5 hours per day and will tend to even the backwash surge loading to the plant. The pumps can be replaced with like size pumps and motors. Splitter Box DesijEn Rectangular Weir with End Contractions Q (in gpm) = 1495 ^ (L - 0.2 ^ H) ' H41.5 (Land H in feet) Flow Splitter Welm 11.6owsover welr#I(IengN=Lr) Lr= 3.5 feel Qr 6owsaverweir#2(length=LJ Lr= 3.5 Met Q36owsoverweir#30ength=Ls) (dumps Into EQ Basin) Ls= 0 Met Height of Weir 03 above Wei.#1 and #2 = 1 feet Height of Water Level above W.I. #F1 6 #2 H Height of Water Level above Weir #4 H Q7 OZ Q3 eMtal Ratio of Q7 Ratio of Q2 Ratio o1 Q3 (inches (gpml (gpm) (Inches) (gpm) (gpm) to Total to Total Io Total 0.0" n.00 0.00 0.000 0." 0.01 0.50 0.50 OAO 0.251 15.81 15.81 0.000 0.01 31.62 0.50 0.51 0.00 0.501 44.53 44.53 0,000 0.00 89.06 0.50 0.51 a00 0.751 81.63 81.63 0.000 cot 163.26 0.50 0.50 0.00 1.001 125.46 12546 0.000 cot 250.92 050 0.50 0.00 1.251 175.08 175.08 0.000 cot 350.15 0.50 0.50 0.00 1.501 229.82 229. 0.000 0.00 459.61 0.50 0.50 0.00 1.751 289.22 289.2 MODO 0.00 578.44 0.50 0.50 0.00 2.001 352.90 35290 0.000 0.0D 705. 0.50 0.50 0.00 1251 420.55 420.55 0.OD0 0.00 841.11 0.50 0.50 800 2.501 491.93 491e3 _ 0.000 0.00 983.86 0.50 0.50 0.00 2718 556.74 556.74 OAOD 0.00 1113.48 0.50 0.50 one 3.001 645.04 645.04 _ O.00D 0. 1290.08 0.50 0. 0.00 1251 726.42 726.42 0.ODO 0. 1452.84 0.50 0.50 0.00 3.5M 810.82 510.82 0.000 0.00 1621.64 0.50 0.50 0.00 3.751 898.11 698.11 0.000 0.00 1796.22 _ 0.50 0.50 0. 4.001 988.18 988.18 0.000 0.00 1976.36 0. 0.50 0. 4.251 10B0.92 1080.92 0.000 0.00 2161.83 0. 0.50 0.00 _ 4.501 1176.23 1176.23 0.000 0. 2352.45 0.50 MM 0.01 4.751 1274.02 _ 1774.02 _ _ O.00D 0. 2548.04 0.60 0.50 0.01 5001 1374.22 1374. OoDO 0. 274843 0.50 c50 0.00 5.251 1476.74 1476.74 _ 0.000 0.00 2953.47 - - 0.60 0.50 0.00 5.501 1681.51 1581.51 0000 oo( 3163.02 0.50 0.50 0.D0 5.751 1688.47 1688.47 0.000 0.00 3376.94 0.50 0.Of 0.D0 6.001 1797.55 1797.55 0.000 cat 3595.10 0.50 0.so ODD 6.251 1908.70 1908.70 0.000 0.00 3817.40 0.50 0.50 0.00 6.501 2021.86 2021.86 O.ODO co( 4043.72 0.50 0.60 0.00 6.751 2136.97 2136.97 _ O.ODO 0.00 4273.94 0.50 0.50 0.00 7A01 225199 2253.99 0.000 0.00 4507.98 0.50 0.50 0.00 7.251 2372.87 2372.87 0.000 0.00 4745.74 0.50 0.50 0.00 7.501 ---2493.55 2493.56 0.000 0.00 4987.12 0.50 0.50 0.00 _ 7.751 2616.02 2616.02 QODO 0.00 5232.04 0.50 0.50 0.00 8.001 _ 2740.21 2740.21 QOOD 0.00 5480.42 0.50 0.50 0.00 8.251 2866.09 2866.09 oODO 0.00 5732.17 0.50 0.50 0.00 8.501 2993.62 2993.62 OoDO 0.00 W87.23 0.50 0. 0.00 8,751 3122.76 3122.76 O.DDD 0.00 6245.52 0.60 0. 0.00 9.001 3253.48 3253.48 Q000 0.00 6506,96 0.50 0.50 0.00 9.251 _ 3385.75 3385.75 0.000 0.00 6771.49 0.50 0.50 0.00 9.501 3519.53 3519.53 0.000 0." _ 703905 0. O.W 0.00 9751 3654.79 3654.79 0.000 0.od 7309.58 0. 0.50 0.00 Flaw Spllner Weirs: Qi flows over weir #1 (length = L1), and 02 flows over weir #2 (length = Lr): Rectangular Weirwlih End Contractions: Q(in gpm) = 1495•(L - 0.2-H) - H-1.5 (Land Hin Met) Lr = 3.6 feel Lr= 3.5 feet Ls= 0 feet _Tohl Flow fQi. 012) Rectangular Weir With End Contraction �01 Flowowr Weir#1 1000 - t 03 Flow over Weir #2 900 -Q3 Flow over Weir#3 E 800 a rn 700 - 600 % 500 n Q 400 a 366 200 4 too 0 0 1 2 3 4 5 6 7 Head above Weir (inches) Rectangular Weir with End Contractions, of Flow Proportion 0.9 0 0.6 0.7 ` 0.6 0 0.5 it 0.4 3 0.3 u 0.2 0.1 Q 0 0 1 2 3 4 5 6 7 Head above Weir (Inches) At design the head over 4 weirs (Each 3.5' long) will be 2.72 inches. Standby Power The WWTP has an existing standby power generator with automatic transfer switch capable of powering the whole WWTP. The three newly proposed 25 HP submersible influent pumps will be replacing the function of three existing 25 HP suction lift influent pump stations. There will be no net increase in WWTP HP starting requirements; therefore, the existing generator and transfer switch are adequate. Water Resources INVIRONMtNt ^L GUALITY June 30, 2017 The Honorable Russell Eason Town of Warsaw P.O. Box 464 Warsaw, NC 28398 ROY COOPER ("O"Vxx MICHAEL S REGAN S JAY ZIMMERMAN bt-�A� Subject: NPDES PERMIT ISSUANCE NPDES Permit NCO021903 Warsaw WWTP Class WW-3 Duplin County Dear Mayor Eason: Division personnel have reviewed and approved your application for renewal of the subject pennit. Accordingly, we are forwarding the attached final NPDES discharge permit. This permit is issued pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina and the U.S. Environmental Protection Agency dated October 15, 2007 (or as subsequently amended). The final permit includes the following significant changes from the existing permit: Section A. (4) has been added to require electronic submission of effluent data. Federal regulations require electronic submittal of all discharge monitoring reports (DMRs). Regulatory citations have been added to the permit. > An updated outfall map has been included. The final permit includes the following significant changes from the draft permit: > Monthly average flow in Section A. (1) has been correded to 0.915 MGD, which is consistent with the previous permit. Thank you for submitting comments on the draft permit, which were received -via phone call from Mr. Greg Hughes (in February 7, 2017. Mr. I lughes stated that the monthly average flow limit in the effluent table read 0.07 MGD, but should have a limit of 0.915 MGD, After review of the permit history, the monthly average flow has been changed to 0915 MGD, as it was in the previous permit. If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable to you, you have the fight to an adjudicatory hearing upon written request within thirty (30) days following receipt of this letter. This request must be in the form of a written petition, conforming to Chapter I SOB of the North Carolina General Statutes, and filed with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless, such demand is made, this permit shall be final and binding. State of North 0141ilina I Frivironmental Ouality! Water ResOutces 1617 Mail Semce C-Ma i Raleigh, NC 2709-1617 919 807 6300 911).807-6389 FAX Mips lideq nc Mayor Russell Eason NCO021903 Renewal p, 2 Please note that this permit is not transferable except after notice to the Division. The Division may require modification or revocation and reissuance of the permit. This permit does not affect the legal requirements to obtain any other Federal, State, or Local governmental permit that may be required. If you have any questions or need additional information, please (to not hesitate to contact Brianna Young of my staff at (919) 807-6333 or via email [Brianna.Young*cdenr.gov]. -Qi9 crely, S. Jay rimierman, P. cc: NPDES Files Central files Wilmington Regional Office V I STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENTAL QUALITY DIVISION OF WATER RESOURCES PERMIT TO DISCHARGE WASTEWATER UNDER THE NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM In compliance with the provisions of North Carolina General Statute 143-215. 1, other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Federal Water Pollution Control Act, as amended, the Town of Warsaw is hereby authorized to discharge wastewater from a facility located at the Warsaw WWTP 384 East Best Street Warsaw Duplin County to receiving waters designated as StewartS Creek in subbasin 03-06-19 of the Cape Fear River Basin in accordance with effluent limitations, monitoring requirements, and other conditions set forth in Parts 1, 11, 111 and IV hereof, This permit shall become effective August 1, 2017. This permit and authorization to discharge shall expire at midnight on January 31, 2022, Signed this day June 30, 2017. S,/ Zimmerman, P.G Director, Division of Water Resources By Authonty of the Environmental Management Commission Page 1 of 6 Permit NCO021903 SUPPLEMENT TO PERMIT COVER SHEET All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked, and as of this issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the permit conditions, requirements, terms, and provisions included herein. Town of Warsaw is hereby authorized to: 1. Continue to operate an existing 0.915 MGD wastewater treatment system with the following components: * Mechanical & manual bar screen * Triplex influent pump station * Aerated grit chamber # Flow splitter 0 Three (3) 305,000 gallons per day oxidation ditches- 0 Four (4) secondary, clarifiers * Dual tertiary filters * Gas chlorine disinfection * Post -aeration * Continuous flow measurement * Aerated sludge digester 4 Aerated sludge holding tank * Two (2) of seven (7) sludge drying beds # Standby electrical generator The facility is located at the Town of Warsaw WWTP (384 East Best Street) southeast of Warsaw in Duplin County. 2. Discharge from said treatment works via Outfall 001, at the location specified on the attached map into Stewarts Creek [stream ID: 18-68-2-101 currently classified C; Swamp waters in subbasin 03-06-19 [HUC: 03030006051 of the Cape Fear River Basin. Page 2 of 6 Permit NCO021903 Part I A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS 115A NCAC 02B.0400 et seq., 15A NCAC 02B.0500 et seq.] Beginning with the effective date of this permit and lasting until expiration, the Permittee is authorized to discharge treated wastewater from Outfall 001, Such discharges shall be limited and monitoredt by the Permittee as specified below: EFFLUENT LIMITATIONS MONITORING REQUIREMENTS EFFLUENT CHARACTERISTICS Weekly Measurement Sample Sample ParameterCod 1Monthly Average Avenge Frequency Type Location Flow 50050 0.915 MGD Continuous Recording ent or InfEluffluent SOD, "ay, (20°C) I - Summer' C0310 5,0 mgIL 7.5 mg/L 3NVeek Composite Inand fluent Effluent SOD, 5-day. (200C) 7 - Winter' C03101 10.0 mgt. 15.0 a9l I'Week Composite and Influent Effluent Total Suspended Solids 1 C0530 30,0 mg1L 45.0 mgIL 3/Week Composite Influent and Effluent NH, as N - Summer' C0610 1.0 mg mg/L —!Week Corn ate Effluent NH, as N - Winter, C0610 2.0 mg1L _3,0 6.0 mg&— 3/Week Composite Effluent Dissolved OMe;— 00300 Daily average > 6.0 mg/L 3/Week Grab Effluent -Fecal Coliform (geometric mean) 31616 2001100 ml 4001100 ml 31Week Grab Effluent Total Residual Chlorine 50060 M8-)tnnu-m 3ANeek Grab Effluent 00010 Monitor & Report Day Grab I Effluent .1 Total Nitro C0600 Monitor & !!pd Quarterly Composite Effluent Total Phosphor is Monitor & Report Quarterly Composite Effluent PH 00400 > 6.0 and < 9 0 steridard units 3/Week Grab Effluent Dissolved Oxygen 00300 Monitor & Report Variable Grab UpstreamDownstream 4 Temperature (a C) 00010 Monitor & Report Variable Grab Upstream & DownstreaM4 *Sijynmr- April 1- October 31 *WWW November 1- March 31 1. The permitter: shall submit discharge monitoring reports electronically using the NC DWR's eDMR application system Isee A, (4)], 2. The monthly average. BOD,, and TSS concentrations shall not exceed 15% of their respective influent values (85% removal). 3. The Division shall consider all effluent TRC values reported below 50 pgll to be in compliance with the permit. However. the Permittee shall continue to record and submit all values reported by a North Carolina certified laboratory (including field certified), even if these values fall below 50 gg/ 1. 4. Upstream = at Meadowbrook Lane. Downstream - at US Hwy 117. Upstream and downstream samples shall be collected three times per week from June through September and weekly from October to May. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS Page 3 of 6 Permit NCO021903 A. (2) INSTREAM MONITORING WAIVER 115A NCAC 0213.0500 et seq.] Instream sampling requirements are waived as long as the permittee maintains membership in the Lower Cape Fear Monitoring program. If membership is terminated, the permitte.e must notify the Division and immediately resume the instream monitoring requirements described in Part A. (I.) above. A. (3) PERMIT RE -OPENER: SUPPLEMENTARY NUTRIENT MONITORING [NCGS 143-215.1 (b)] Pursuant to N.C. General Statutes Section 143-215.1 and the implementing rules found in the North Carolina Administrative Code at I SA NCAC 2H.0 112 (b) (1) and 2H.0 114 (a) and Part II sections B- 12 and B- 13 of this permit, the Director of l,)WQ may reopen this permit to require supplemental nutrient monitoring of the discharge. The purpose of the additional monitoring will be to support water quality modeling efforts within the Cape Fear River Basin and shall be consistent with a monitoring plan developed jointly by the Division and affected stakeholders. In addition, the results of water quality modeling may require that limits for total nitrogen and total phosphorus be imposed in this permit upon renewal. AL (4) ELECTRONIC REPORTING OF MONITORING REPORTS (NCGS 143-215.1 (b)) Federal regulations require electronic submittal of all discharge monitoring reports (DMRs) and program reports. The final NPDES Electronic Reporting Rule was adopted and became effective on December 21, 2015. NOTE: This special condition supplements or supersedes the following sections within Part 11 of this permit (Standard Conditions for NPDES Permits): • Section B. (11.) Signatory Requirements • Section D. (2.) Reporting • Section D. (6.) Records Retention • Section E. (5.) Monitoring Reports The permittee shall report discharge monitoring data electronically using the NC DWR's Electronic Discharge Monitoring Report (eDMR) internet application. Monitoring results obtained during the previous month(s) shall be summarized for each month and submitted electronically using eDMR. The eDMR system allows permitted facilities to enter monitoring data and submit DMRs electronically using the internet. Until such time that the state's eDMR application is compliant with EPA's Cross -Media Electronic Reporting Regulation (CROMERR), permittees will be required to submit all discharge monitoring data to the state electronically using eDMR and will be required to complete the eDMR submission by printing, signing, and submitting one signed original and a copy of the computer printed eDMR to the following address: Page 4 of 6 Permit NCO021903 NC DEQ / Division of Water Resources / Water Quality Permitting Section ArrENTION: central Files 1617 Mail Service Center Raleigh, North Carolina 27699-1617 If a permittee is unable to use the eDMR system due to a demonstrated hardship or due to the facility being physically located in an area where less than 10 percent, of the households have broadband access, then a temporary waiver from the NPDES electronic reporting requirements may be granted and discharge monitoring data may be submitted on paper DMR forms (MR 1, 1. 1, 2, 3) or alternative forms approved by the Director. Duplicate signed copies shall be submitted to the mailing address above, See "How to Request a Waiver from Electronic Reporting" section below. Regardless of the submission method, the first DMR is due on the last day of the month following the issuance of the permit or in the case of a new facility, on the last day of the month following the commencement of discharge. Starting on December 21, 2020, the permittee must electronically report the following compliance monitoring data and reports, when applicable: • Sewer Overflow /Bypass Event Reports; • Pretreatment Program Annual Reports; and • Clean Water Act (CWA) Section 316(b) Annual Reports. The permittee may seek an electronic reporting waiver from the Division (see 'How to Request a Waiver from Electronic Reporting" section below). 2. Electronic Su4m s-SiOus In accordance with 40 CFR 122.410)(9), the permittee must identify the initial recipient at the time of each electronic submission. The permittee should use the EPA's website resources to identify the initial recipient for the electronic submission. Initial recipient of electronic NPDES information from NPDES-regulated facilities means the entity (EPA or the state authorized by EPA to implement the NPDES program) that is the designated entity for receiving electronic NPDES data [see 40 CFN 127.2(b)]. EPA plans to establish a website that will also link to the appropriate electronic reporting tool for each type of electronic submission and for each state. Instructions on how to access and use the appropriate electronic reporting tool will be available as well. Information on EPA's NPDES Electronic Reporting Rule is found at: litt �Jjwwa.&O compliancelfinal-national_-pollutant-di!�chyygtLtlimi�tL- -nat� ---R. ---- w'2.e2, - _yj systel-n-np4es-electronic-r!Mttmitag:n4lc. Electronic submissions must start by the dates listed in the "Reporting Requirements* section above. 3. How to Request a Waiver from Elgectronic Reporting the Division. To The permittee may seek a temporary electronic reporting waiver from obtain an electronic reporting waiver, a permittee must first submit an electronic reporting waiver request to the Division. Requests for temporary electronic reporting waivers must be submitted in writing to the Division for written approval at least sixty Page 5 of 6 Permit NC0021903 (60) days prior to the date the facility would be required under this permit to begin submitting monitoring data and reports. The duration of a temporary waiver shall not exceed 5 years and shall thereupon expire. At such time, monitoring data and reports shall be submitted electronically to the Division unless the permittec re -applies for and is granted a new temporary electronic reporting waiver by the Division. Approved electronic reporting waivers are not transferrable. Only permittees with an approved reporting waiver request may submit monitoring data and reports on paper to the Division for the period that the approved reporting waiver request is effective. Information on eDMR and the application for a temporary electronic reporting waiver are found on the following web page: Littp-1 4. Signatory Requirements [ Hp2le Section a. (11-11 All cDMRs submitted to the permit issuing authority shall be signed by a person described in Part 11, Section B. (I l.)(a) or by a duly authori7ed representative of that person as described in Part 11, Section B. (1 1.)(b). A person, and not a position, must be delegated signatory authority for eDMR reporting purposes. For eDMR submissions, the person signing and submitting the DMR must obtain an eDMR user account and login credentials to access the el MR system. For more information on North Carolina's eDTJR system, registering for eDMR and obtaining an eDMR user account, please visit the following web page: hjW,itj j_/deq.nc-Zov abo,-_djvisio4sj':�y j _ Certification. Any person submitting an electronic DMR lasing the state's eDMR system shall make the following certification 140 CFR 122.221, NO OTHER STATEMENTS OF CERTIFICATION WILL BE ACCCEPTED- 7 certib, under penalty of lau), that this document and all attachments were prepared under my direction or supervision in accordance with a systern designed to assure that qualified personnel property gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or, those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false iitfbrmation, including the possibility of fines and imprison ment for knowing violations. " S. Records Retention [Suvolements Section 6. The permittee shall retain records of all Discharge Monitoring Reports, including eDMR submissions. These records or copies shall be maintained for a period of at least 3 years from the date of the report. This period may be extended by request of the Director at any time [40 CFR 122.41 J. Page 6 of 6 _7 7 Toni, A J W N,m A A...... • VftMt C NC 50 IS4 East Best Street M Outfall 00t,, 0" A us 7 andpit Town of Warsaw Warsaw WWTP NPOES Permit NCO021903 Receiving Stream. Stewarts Creek Stream Class C; Sw Stream Segment 1"B-2-10 Sub -Basin # 03-06-19 River Basw Cape Fear HUC 0303000605 County Duplm N A SCALE 124,000 Fa6ity Location =It not ftwr 34 993056°, -78080 USGS Quad, Warsaw South �, - -- - -----ram -der ••4. '�)r Tf�/n .- •1�! /• /� i a r.Mal • ••J NM �� 1, � Y� (�� - East Best Street 4m �'�• `- A �'✓ Outfal1001 I �/I US 117 Town of Warsaw Warsaw WWTP NPDES Permit NCO021903 Receiving Stream: Stewarts Creek Stream Class: C; Sw Stream Segment:18.68-2-10 Sub -Basin 8:03.06-19 River Basin: Cape tear HUC 0303000605 County: Duptrn Facility Location $Cal* MCA shown 34,"3GS6'0. USGS Quad