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WQ0016376_More Information (Received)_20200908
September 8, 2020 Vivien Zhong, P.E. NCDEQ Division Of Water Resources 1617 Mail Service Center Raleigh, North Carolina 27699-1617 Subject: Response for Permit No. WQ0016376 S&J Villari Processing Facility - Warsaw Wastewater Irrigation System Duplin County Dear Ms. Zhong, L�1 CAVANAU G H Stewardship Through Innovok. Cavanaugh & Associates, P.A., on behalf of S&J Villari Livestock (Villari), has reviewed your comments dated August 20, 2020, and has developed responses and additional supporting information to address each item in your comments. For your convenience, we have repeated the comments below in bold font, followed by the responses in italicized font. 1. The soils report included only 5 zones: Northwest of Zone 14, Zone 15, 16, 17 and 14. NW Zone 14 does not seem to be permitted right now. For Zone 14 - 17, the areas of each zone in the water balance sheets are not consistent with what were provided in the submitted soils report. For Zone 17, it was permitted in the Attachment B that the soils series is Bibby, whereas it shows as Lynchburg in the water balance sheet. Please clarify and provide the soils report that covers all zones. As we discussed on the phone Monday 8/10, the discrepancy between Bibby and Lynchburg in Zone 17 originates from the 2012 soils report. 'New Area 4' in the soils report is the same area as Zone 17, and the description of 'New Area 4'states that the "area consists of fill material over an original Lynchburg soil series" and that the 'fill material appears to be from... fine loamy soils" and 'fine sandy loam and loamy fine sand". While Zone 17 was ultimately permitted to label the dominant soil series as 'Bibby Sandy Loam'. the 2012 water balance listed 'Lynchburg, - no matter the designation of the soil series, the 'New Area 4' Ksat value of 0.043 in/hr will apply, so the numbers used in the water balance are accurate. Additionally, as we discussed, the values used in the updated water balance use the values from the 2012 soils report for the corresponding soil series for each zone; for example, Zone 1 is permitted as Norfolk, so the 2012 soils report Ksat value of 0.075 in/hr for Norfolk was used in the updated water balance. Lastly, as we discussed, the 2012 soils report area numbers do not correspond to the Zone numbers in the permit; i.e., as previously mentioned, 'New Area 4' is the same area as Zone 17. 2. The minimum required storage calculated on Page 29 of the response package was 8,570,580 gallons. However, about only 5.53 million gallons were permitted. Please clarify. As stated in our DWR response to Erick Saunders dated July 9, 2019: As was the case for the WWIS permit approved in 2013, the water balance shows a 'Minimum Required Storage' greater than the 5.53 MG existing storage on site (3.65 MG lagoon and 1.88 MG storage tank totaling to 5.53 MG), however, as was indicated in the May 17, 2013 DEQ cover letter for that approval, "the fields hydraulic and nutrient loading limits are the limiting factor for this facility'; so storage expansion was not considered. In other words, there were previous discussions with DWR that ultimately led to the 2013 approval based on the understanding that storage was not the issue and that the permit was limited by how much wastewater the irrigation fields could take. The referenced approval letter from 2013 has been included with this response. 3. Please provide the reference for the design daily flow (influent) of 99,080 gpd, located on the page 6 of the response package. The existing permit allows for a monthly average of 100,260 gpd total flow to all irrigation zones, so the 99,080 gpd is a back -calculation accounting for the gains and losses from precipitation and evaporation. Related to the answer to Comment #2 regarding storage, the 100,260 gpd was approved in 2013 based on how much wastewater the irrigation fields could take, Villari does not consistently utilize the full 100,260 gpd that their permit allows, but due to seasonality and the varying nature of the food production at the Villari facility, as well as sanitation restrictions imposed by USDA and NCDA, the flow varies, so it's permitted by the (near) maximum flow that can be supported by the irrigation fields. 4. Please update the site map to reflect Zones 14W and 14E. Zones 14W and 14E are labeled on the existing sheet, but they were not as obvious as they could be, so we've updated the plan sheet and it's attached with this response. Additionally, we noticed that we had erroneously deleted the "Zone 17" in a previous response, so it's been added back to the sheet. Additionally, per the inspection from Helen Perez on August 5, 2020, the size of the chlorine contact chamber that is directly downstream of the 1.88 MG aboveground storage tank has been labeled on the plans (the previous version of the plans labeled the tank, but didn't include it's size), and is attached with this response. It's our understanding that the chlorine contact chamber needs to be added to the description of the permit. Also as a result of the inspection, we have added to the plans the proposed pump station and forcemain that Villari is installing on the northern side of the lagoon. The lagoon currently operates by wastewater flowing into the lagoon on the north(west) side, and then it's removed from the lagoon using the pumps on the south(east) side that pumps to the 1.88 MG aboveground storage tank; Villari is adding a pump station with a single pump on the north side of the lagoon, as well as new piping and valves on the south(west) side of the lagoon, so that the wastewater flows into the lagoon at the south(west) and exits the lagoon at the north by the new pump station. They will keep the existing infrastructure in place as a back-up plan to the new pump station. The pump station calculations are included with this response, as well as the cut sheets from the pump manufacturer. Please do not hesitate to contact our office should you have any questions, comments, or require any additional information. Regards, Cavanaugh & Associates, P.A. Jeff P. Cappadona, P.E. Attachments cc: Sam Villari, Owner, S&J Villari Livestock 4*a rAfts NCDENR North Carolina Department of Environment and Natura Division of Water Quality Pat McCrory Charles Wakild, P.E. Governor Director May 17, 2013 Joseph P. Villari, Owner The Pork Company 892 Penny Branch Road Warsaw, North Carolina 28398 Dear Mr. Villari: Resources John E. Skvarla, III Secretary Subject: Permit No. WQ0016376 S&J Villari Livestock Processing Facility -Warsaw Wastewater Irrigation System Duplin County In accordance with your permit major modification request received August 28, 2012 and permit renewal request received May 8, 2013, and subsequent additional information received January 28, April 30 and May 8, 2013 we are forwarding herewith Permit No. WQ0016376 dated May 17, 2013, to the Pork Company for the continued operation of the subject wastewater treatment and irrigation facilities. The modifications to the subject permit are as follows: • Proper abandonment of existing monitoring well #4 in accordance with applicable well abandonment requirements of 15A NCAC 02C .0111 and relocation of this monitoring well. • The installation of monitoring well #9. • Increasing the capacity of the facilitative lagoon treatment system from 45,000 gallons per day to 100,260 gallons per day. Please note that the fields hydraulic and nutrient loading limits are the limiting factor for this facility. • Reduction of the center pivot acreage from 23.11 acres to 20.56 acres through the elimination of the end -gun use for certain areas. • Addition of 3.12 acres of new spray irrigation area. This permit shall be effective from the date of issuance until April 30, 2018, shall void Permit No. WQ0016376 issued November 4, 2008 and shall be subject to the conditions and Iimitations as specified therein. Please pay particular attention to the monitoring requirements listed in Attachments A, B and C for they may differ from the previous permit issuance. Failure to establish an adequate system for collecting and maintaining the required operational information shall result in future compliance problems. For your convenience, customized electronic copies of your facility's NDMR, and NDAR-1 reporting forms are available for download at: http://portal.ncdenr.or web/wq/aps/tau/repoi-ring. AQUIFER PROTECTION SECTION 1636 Mail Service Center, Raleigh, North Carolina 27699-1636 Location: 512 N. Salisbury St., Raleigh, North Carolina 27604 One Phone: 919-807-6464 l FAX: 919-807-6480 L FAX: 919-807-5496 NorthCau olina Internet: www.ncwaterguality.vn An Equal OpparluMy 1 Affirmative Aclion Employer Adia'ally Mr. Villari May 17, 2013 Page 2 of 2 Please note the following permit conditions are new since the last permit issuance: • Condition I.1. The Wilmington Regional Office shall approve the location of the monitoring well prior to installation. • Condition I.2_ The Permittee shall submit a site map including the new monitoring well. • Condition L3. The Permittee shall properly abandon monitoring well #4 (MW4). • Condition II.11. The Permittee shall ensure any landowner who is not the Permittee and owns land within the compliance boundary shall execute and file with the Duplin County Register of Deeds an easement. •. Condition IV.9. A record shall be maintained of all residuals removed from this facility. • Condition IV.10. A maintenance log shall be maintained at this facility. • Condition VI.8. The permit is subject, to revocation or unilateral modification upon 60 days notice. • Condition VI.9. Expansion of the permitted facilities shall not be granted if the Permittee exemplifies any of the criteria in 15A NCAC 02T .0120(b). • Acreages and LongitudeslLatitudes were updated on all existing fields. • The existing Zone CP has been separated in to Zones 14 E (cast) and 14 W (west). The Division has concerns regarding the quality of the current crops on the irrigation fields. It is recommended that the Permittee continue to seek recommendations from an agronomist. The Permittee shall be responsible for ensuring adequate measures are taken to provide the best conditions for suitable crop growth and nutrient uptake. If any parts, requirements or limitations contained in this permit are unacceptable, the Permittee has the right to request an adjudicatory hearing upon written request within 30 days following receipt of this permit. This request shall be in the form of a written petition, conforming to Chapter ISOB of the North Carolina General Statutes, and filed with the Office of Administrative Hearings at 6714 Mail Service Center, Raleigh, NC 27699-6714. Unless such demands are made, this permit shall be final and binding. One set of approved plans and specifications is being forwarded to you. If you need additional information concerning this permit, please contact Alice M. Wessner at (919) 807-6425 or alice.wessncr@ncdenr.gov. Sincerely, Charles Wakild, P.E. cc: Duplin County Health Department Wilmington Regional Office, Aquifer Protection Section William G. Simmons, Jr. P.E., 1904 Eastwood Road, Suite 205, Wilmington, NC, 28403 Beth Buffington, Aquifer Protection Section Permit File WQ0016376 Notebook File WQ0016376 CAVANAUGH Pump System Design Spreadsheet - C = 120 Project: S&J Villari Processing Facility- Warsaw Location: Duplin County, NC Design By: JPC Project No: 41.10.007 Client: S & J Villari Livestock Checked By: WGS Date: 2020-9-8 Description: Lagoon Pump System Requirements System Pipe 1 Length of Pipe 343 Pipe Diameter 4 Elevation Difference 25.00 Pipe Area 0.087 C 120 Velocity At Selected Flow (ft/sec) 6.13 Duty Points: Pi e 2 in Pi e 3 R R Daily Flow Rate = 100,260 Design Period = 24 gpm gpm Average Flow = 70 (additional Row) (additional Row) Peaking Factor = 1.00 Peak Flow = 70 Nozzle Head = 0.00 Pressure Head = 0.00 Duty Points: �pm @ 44 ft, 6.1 ftlsec - gpd hrs gpm BASIS OF DESIGN gpm R Pump Chosen: R EBARA EFQT3, 1,470 RPM Step: - Manufacturer's System Curve Pump Curve Data Flow Rate Flow Rate Velocity Elevation Head Friction Head Friction Head Friction Pipe 1 Pipe 2 Head Velocity Head Pipe 3 I(Not Submerged) FittingNalve Head Nozzle Head Pressure Head TDH TDH (GPM) R3/sec 0 fUsec ft R (R) 0.0 (R) 0.0 R ft ft ft 25 0.1 �.1 0.6 25.00 0.2 0.0 0.0 0.0 0.1 0.0 0.0 0.0 25.3 26.0 75 0.2 - 0.2 1.9 2.6 25.00 1.8 3.0 0.1 .1 0.3 0.5 0.0 0.0 0.0 0.0 27.1 28.6 54 52 125 0.3 - 0.3 3.2 3.8 25.00 4.6 6.4 0.2 .2 0.8 1.1 0.0 0.0 0.0 0.0 30.5 32.7 49 48 175 0.4 2� 0.4 4.5 5.1 25.00 8.5 10.9 0.3 0.4 1.5 2.0 0.0 0.0 0.0 0.0 35.3 38.3 47 46 225 0.5 250 _.6 5.7 6.4 25.00 13.5 16.5 - 0.5 - 0.6 2.5 3.1 0.0 0.0 0.0 0.0 41.5 45.1 44 43 275 0.6 300 EMW 325 0.7 7.0 7.7 8.3 25.00 ' 25.00 19.6 23.- 26.7 - 0.8 - 0.9 1.1 3.7 4.4 5.2 0.0 0.0 0.0 0.0 0.0 0.0 49.1 53.4 58.0 41 40 38 350 0.8 375 0.8 400 0.9 8.9 9.6 10.2 25.00 3 34.8 39.� 1.2 1.4 1.6 6.0 6.9 7.8 0.0 0.0 0.0 0.0 0.0 0.0 62.9 68.1 73.7 1 35 33 32 425 0.9 450 y.0 10.9 11.5 25.00 43.9 48.8 1.8 2.0 8.8 9.9 0.0 0.0 0.0 0.0 79.6 85.8 30 475 1.1 500 " 12.1 12.8 25.00 53.9 59.3 - 2.3 - 2.5 11.1 12.2 0.0 0.0 0.0 0.0 92.3 99.1 1 525 1.2 550 - 1.2 13.4 14.0 25.00 i 64.9 70.7 - 2.8 - 3.1 13.5 14.8 0.0 0.0 0.0 0.0 106.2 113.6 575 1.3 600 - 1.3 14.7 15.3 25.00 76.8 83.1 - - - 3.3 - 3.6 16.2 17.6 0.0 0.0 0.0 0.0 121.4 129.4 625 1.4 650 1.4 16.0 16.6 25.00 89.6 - 96.4 - - 4.0 - 4.3 19.1 20.7 0.0 0.0 0.0 0.0 137.7 146.3 1 675 1.5 700 -1.6 17.2 17.9 25.00 103.3 - 110.5 - - 4.6 - 5.0 22.3 24.0 0.0 0.0 0.0 0.0 155.3 164.5 725 1.6 750 -1.7 775 1.7 18.5 19.1 19.8 25.00 i 25.00 117.9 - 125.6 - 133.4 - 5.3 - 5.7 6.1 25.8 27.6 29.4 0.0 0.0 0.0 0.0 0.0 0.0 174.0 183.8 193.9 1 800 -1.8 20.4 - 141.5 - - - 6.5 31.4 0.0 0.0 204.3 825 1.8 850 , 1.9 21.1 21.7 25.00 149.8 - 158.3 - - 6.9 - 7.3 33.3 35.4 0.0 0.0 0.0 0.0 215.0 226.0 875 1.9 900 , 2.0 22.3 23.0 25.00 167.0 - 175.9 - - 7.8 - 8.2 37.5 39.7 0.0 0.0 0.0 0.0 237.3 248.8 1 925 2.1 2.1 23.6 24.3 25.00 i 185.1 - 194.5 - - 8.7 - 9.1 41.9 44.2 0.0 0.0 0.0 0.0 260.7 272.8 975 2.2 1,000 `2.2 24.9 25.5 25.00 204.0 - 213.8 - - 9.6 - 10.1 46.6 49.0 0.0 0.0 0.0 0.0 285.2 297.9 1:025 2.3 050 I2.3 26.2 26.8 25.00 223.8 - 234.0 - - 10.6 - 11.2 51.5 54.0 0.0 0.0 0.0 0.0 310.9 324.2 1,075 2.4 27.4 25.00 244.4 11.7 56.6 0.0 0.0 337.7 1,100 2.5 28.1 255.0 12.2 59.3 0.0 0.0 351.6 1,125 2.5 28.7 25.00 265.9 12.8 62.0 0.0 0.0 365.7 1,150 2.6 29.4 i 276.9 13.4 64.8 0.0 0.0 380.1 1,175 2.6 30.0 25.00 288.1 - - 14.0 67.6 0.0 0.0 394.8 1 Pump 240 FittinaNalve Head, Size (in) Description K Factor Q1ty Total K 4 Gate Valve 0.14 0 0.00 4 Check Valve 0.85 0 0.00 4 Ball Valve 0.05 0 0.00 4 Butterfly Valve 0.77 0 0.00 4 Plug Valve 0.31 0 0.00 4 90, Elbow 0.51 6 3.06 4 45. Elbow 0.27 0 0.00 4 Tee (Branch) 1.02 0 0.00 4 Tee (Run) 0.34 0 0.00 4 Pipe Entrance 0.78 1 0.78 4 Pipe Exit 1.00 1 1.00 Total K: 4.84 0.0 44.0 FittingNalve Head = K (v2 / 2g) ME a= Y Z Q QU E E m Q c �+ O cn cm ui m > J Q E 7 a 0 0 0 0 0 0 0 0 0 0 CO L ('M N 009 0g-� 00-� 09£ ON E Q ogz L O FL ON 091 001 09 0 Q E 7 d U (D U) N O N (4881) peaH 3iweuA(] le;ol EBARA Self Priming Trash Pump EFQT/EFQU Performance Curves Project: GPM: TDH: EFF: HP: Chk'd: Date: EFQT3 Impeller Diameter: 8.75" S.G.. 1.0 TOTALNFAQ PERFORMANCE CURVE 30OX3" man PSI FT 60 -140 40 56- 130 -. 36 52- 120 48 110 32 -3 44 - 100 - 28 40 - so- 36 - 24 60 32 - 70 20 - 28 - 60 - 24 - 16. 50 20 - 12 16 - 40 e 12 30 e- 20 4 4— 10 0 0 0 (US) GPM • f N VA PON 0 FLOW17 R n +l a �F V 7i Us m3%lr O b O q O b O b O b O b O b O b O �y O olf C b O N N Nf of ♦ f b b •O .D n n .0 O P P O G r Data Sheet Net Weight: 404 lbs. (183kg) Shipping Weight: 452 lbs. (205kg) Impeller Dia.: 8-3/4" (222.3mm) R.P.M.: From 650 RPM to 2150 RPM Max. Solids: 2-1 /2" (63.5mm) Repriming Lifts 5 FT 4 Fr 2 FT I Fr RPM 650 1 750 1 850 1 950 1 1050 1 1150 1 1250 1 1350 I 1450 I 1550 1650-17501850-2150 FEET 5 5 8 1 10 13 1 16 1 18 1 19 20 21 1 22 25 METERS 1.5 1.8 2.4 1 3.1 4.0 1 4.9 1 5.5 1 5.8 6.1 6.4 1 6.7 7.6 Figure NPSH prior to using above chart. DO NOT use as NPSH Suction Lift. 2.5" Dia. Max. Spherical Solids. EBARA Fluid Handling www.pumpsebara.com EBARA (803) 327-5005 (p) , (803) 327-5097 (f) 11 rev. 02113 EBARA Self Priming Trash Pump EFQT/EFQU Dimensions Project: Model: Chk'd: Date: Model EFQT 2, 3, 4, 6 SUCTION REQUIR D FOI REMOVALOF BACK PLATE x 4 HOLES Unit: Inches If e FLANGE n)OTY - (h)HOLES dxlg w 'WAY SHAFT ��0000©faro©o©o©©orao©000© ©fo�f�®��f�f�fafafo®faaf�®mfo�®f�fo �a�rf�am��®rar��fofafo©off�fa®��®®ff ofof��rf�r:�raf��raraforora®®omra©®®ro o�ff�r��r��r�r�faff�fof�fa0®ff��a©®�fo Unit: mm ��fa000©afar©o©o©foorao©o®®© ©���®�®®�m�®�mafa�fafofomro o�far�rrf�fa®raram®��0a���m®mra Unit: Inches S12E 0 MODEL FLANGE TYPE e f n h RAISED FACE RAISED FACE 2 EFQT2 2" ANSI 150W 4 3/4 6 4 3/4 YES 1 3 518 3 EFQT3 3" ANSI 1504 6 7 1/2 4 3/4 NO 4 EFQT4 4" ANSI 1504 7 1/2 9 8 3/4 VES 6 M 6 EFQT6 6" ANSI 15011 9 V2 11 8 7/B YE 8 112 Unit: mm S12E 0 MODEL FLANGE TYPE e ( n I h I RAISED FACE I RAISED FACE 50 EFQT2 2" ANSI 150H 121 152 302 19 YES 92 80 EFQT3 3"ANSI 150N 152 191 102 19 NO 1D0 EFQT4 4"ANSI 150N 191 229 203 19 1 YES 1 157 150 EFQT6 6"ANSI 150W 241 279 203 22 1 YES 1 216 EBARA Fluid Handling www.pumpsebara.com EBARA (803) 327-5005 (p) a (803) 327-5097 (f) KEYWAY w d Ig 3/8 3/8 3/8 �3/164 3/8 20 rev. 04 15 EBARA Self Priming Trash Pump EFQT/EFQU Dimensions Project: Model: Chk'd: Date: EFQT/EFQU Skid Package - Side By Side Model Model EFQT 2, 3, 4, 6 ON M11C ONE Unit: inches PUMP MODEL NEMA MOTOR FRAME A B C D E F G H J K L M ON EFQT2 145T 32 24 1/4 28 24 15 518 9 7/16 4 114 2 3/4 23 20 N/A 6 9/16 za4T 256T 34 27 25 3/4 22 EFQT3 145T 41 1 /2 32 11 /16 31 1/4 21 114 11 7/8 7 118 25 5/8 25 1/2 8 184T 5T 256T 44 28 27 318 32 5/8 26 286T 46 29 114 27 7/8 30 EFQT4 43 28 1/4 35 5/16 33 1/2 23 718 12 7/8 8 14 26 7/8 27 184T 33 5/16 215T 28 3/8 135 7/16 27 256T 44 28 1/4 35 5/16 26 7/8 28 286T 46 29 3/8 35 7/16 28 30 EFQT6 145T 47 29 37 3/8 3813/16 26 9116 1415/16 913/16 27 5/8 31 184T 47 1 /4 31 1/4 215T 47 1/2 31 112 256T 49 2815/16 37 5/16 27 9/16 33 16 1/2 286T 49 1/2 29 1 /8 27 3/4 33 1/2 16 3/4 326T 52 32 1/2 38 7/16 31 1781 36 1 18 Unit- mm PUMP MODEL NEMA MOTOR FRAME A B C D E F G H J K L M ON EFQT2 145T 813 616 711 610 397 240 108 70 584 508 N/A 152 14 184T 256T 864 686 654 559 EFQT3 1054 830 794 540 302 181 651 648 203 184T 215T 1118 711 256T 695 660 286T 1168 743 708 762 EFQT4 1092 718 897 851 606 327 210 683 686 184T d 215T 721 686 256T 1118 718 683 711 286T 1168 746 711 762 EFQT6 145T 1194 737 949 986 675 379 249 702 787 184T 1200 794 215T 1207 800 256T 1245 735 948 700 838 419 286T 1257 740 705 851 425 326T 1321 826 976 791 914 1 457 S EBARA EBARA Fluid Handling www.pumpsebara.com (803) 327-5005 (p) • (803) 327-5097 (f) 32 rev. 04115 z.a naz no. mmm Z�9b rez 'col Iwux 'va ni3tl.lnz 'co o�x no.wo� ww .i r wog ;cVaib '��zsbs-uVo�S mzN ciz� dd ii ro . r 4310N SM dVW N011VOM S uopenouul y6noLy1 dlyspae,lna>S 713M ONI21011NOW MNOdV H1dON W 0J NNOLL H E3In v N V A V O 1881 NOISNVdX3 W31sAs NO11V91?Jdl �,�ols3nn 1bv-nln r -Y s \- { �4":......���'"", OZOZ V d39M3 d3s �M .lax 0 4 '5s u q4H gog . o "ash -N.6% W 11 E",yd GW�3 I e"y $u : G 8>« .80.k a, w i ` iH 3 �a �4 Wysg$ 3S WO or �um8's d SWRn ao,s d ' €a 8 g6.W' 8 rn oaf=a�n5��� Z � 333333333333333333 � z $000so9888888RR8�.^. 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