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HomeMy WebLinkAboutNC0003191_permit issuance_20131122Permit NC0003191 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER RESOURCES PERMIT TO DISCHARGE WASTEWATER UNDER THE NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM In compliance with the provision 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, Weyerhaeuser NR Company is hereby authorized to discharge wastewater from a facility located at New Bern Cellulose Fibers 1785 Weyerhaeuser Road Vanceboro, North Carolina Craven County to receiving waters designated as Neuse River in the Neuse River Basin in accordance with effluent limitations, monitoring requirements, and other applicable conditions set forth in Parts I, II, and III hereof. The permit shall become effective January 1, 2014. This permit and the authorization to discharge shall expire at midnight on April 30, 2018. Signed this day November 22, 2013. Final signed by Tom Belnick Thomas A. Reeder, Director Division of Water Resources By Authority of the Environmental Management Commission 1of13 Permit NC0003191 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. Weyerhaeuser NR Company is hereby authorized to: 1. Continue to operate an existing 32.0 MGD wastewater treatment facility located at the New Bern Cellulose Fibers plant, 1785 Weyerhaeuser Road, Vanceboro, Craven County, and consisting of the following treatment components: ■ bar screen ■ primary clarifier ■ sludge press ■ two aeration ponds with a combined volume of 346 million gallons (98 acres) ■ storage and settling pond with a volume of 332 million gallons (116 acres) ■ reaeration canal ■ side -stream oxygenation system ■ effluent diffuser system (Outfall 001). 2. Continue to operate four existing passive oil/water separators consisting of grit removal, baffled sumps, and piping to the wastewater treatment facility. 3. Continue to discharge bleach plant effluent to the wastewater treatment system via separate acid and alkaline sewers (Internal Outfall 003). 4. Discharge from said treatment works at the locations specified on the attached map into the Neuse River, currently classified SC -Swamp NSW waters in the Neuse River Basin. 2of13 Permit NC0003191 Part i A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS Beginning on the effective date of this permit and lasting until the twelve (12) month average flow exceeds 18 MGD or expiration, the Permittee is authorized to discharge treated wastewater from Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified below: PARAMETER EFFLUENT LIMITATIONS MONITORING REQUIREMENTS Monthly Average Daily Maximum Measurement Frequency Sample Type Sample Location Flow 20.0 MGD Continuous Recording Effluent Total Monthly Flow (MG) Monitor and report Monthly Recorded or calculated Effluent BOD, 5-day, 200C (April 1 —October 31 3550 pounds/day 43.0 m /L 6813 pounds/day 66.0 m /L 3/Week Composite Effluent BOD, 5-day, 200C November 1 — March 31 7100 pounds/day 43.0 m /L 13631 pounds/day 66.0 m /L 3/Week Composite Effluent Total Suspended Solids 8250 pounds/day 26700 pounds/day 3/Week Composite Effluent NH3 as N 900 pounds/day 1720 pounds/day Weekly Composite Effluent D.O. (Summer minimum)1,7 172 pounds/MG Daily Grab Effluent Temperature Daily Grab Effluent Conductivity Daily Grab Effluent pH > 6.0 and < 9.0 standard units Daily Grab Effluent Color Quarterly Grab Effluent TKN Monitor and report Weekly Composite Effluent NO2+NO3 Monitor and report Weekly Composite Effluent Total Nitrogen Monitor and report Weekly Composite Effluent Total Nitrogen Load2 Monitor and report 312,828 pounds/year2 Monthly Annually Calculatedz Calculatedz Effluent Effluent Total Phosphorus 2.0 mg/L (quarterly average)3 Weekly Composite Effluent Pentachlorophen014 3.1 pounds/day Weekly Composite Effluent Trichlorophenol^ 19.4 pounds/day Weekly Composite Effluent AOX5 1254 pounds/day 1914 pounds/day Monthly Composite Effluent Chronic Toxicitys Quarterly Composite Effluent Notes: 1. The minimum summer D.O. shall be reported as the sum of effluent and side -stream oxygenation system. If the automatic oxygen sampler indicates that instream oxygen concentration is above 5.5 mg/L and the river flow is greater than 329 cfs, the facility can discontinue the supplemental oxygen injection during the months of April and May only. 2. See Special Condition A.(6.). Calculation of Total Nitrogen Load. 3. Compliance shall be based upon a quarterly average of weekly composite samples collected during the calendar quarter (Jan. -March, Apr -June, July -Sept., Oct.- Dec.). 4. Monitoring is not required for these compounds if the permittee certifies in writing that chlorophenolic- containing biocides are not used at the facility. 5. AOX monitoring shall be in accordance with the Weyerhaeuser Cluster Rule Sampling Plan (dated 8/11/2000) or subsequent modifications approved by the Division. AOX data shall be submitted on a quarterly basis along with other Cluster Rule chemical data; refer to Special Condition A.(13.). 6. Chronic Toxicity (Ceriodaphnia) at 8.6%; January, April, July, and October [see Special Condition A.(5.)]. 7. (Summer) = April 1- October 31 THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. 3of13 Permit NC0003191 A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS Beginning on the day when the twelve (12) month average flow exceeds 18 MGD and lasting until expiration, the Permittee is authorized to discharge treated wastewater from Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified below: PARAMETER EFFLUENT LIMITATIONS MONITORING REQUIREMENTS Monthly Average Daily Maximum Measurement Frequency Sample Type Sample Location Flow 32.0 MGD Continuous Recording Effluent Total Monthly Flow (MG) Monitor and report Monthly Recorded or calculated Effluent BOD, 5-day, 200C (April 1— October 31 3550 pounds/day 43.0 m /L 6813 pounds/day 66.0 m /L 3/Week Composite Effluent BOD, 5-day, 200C November 1 — March 31 7100 pounds/day 43.0 m /L 13631 pounds/day 66.0 m /L 3/Week Composite Effluent Total Suspended Solids 8250 pounds/day 26700 pounds/day 3/Week Composite Effluent NH3 as N 900 pounds/day 1720 pounds/day Weekly Composite Effluent D.O. (Summer minimum)1,7 172 pounds/MG Daily Grab Effluent Temperature Daily Grab Effluent Conductivity Daily Grab Effluent pH > 6.0 and < 9.0 standard units Daily Grab Effluent Color Quarterly Grab Effluent TKN Monitor and report Weekly Composite Effluent NO2+NO3 Monitor and report Weekly Composite Effluent Total Nitrogen Monitor and report Weekly Composite Effluent Total Nitrogen Load2 Monitor and report 312,828 pounds/year2 Monthly Annually Calculatedz Calculatedz Effluent Effluent Total Phosphorus 2.0 mg/L (quarterly average)3 Weekly Composite Effluent Pentachlorophen014 3.1 pounds/day Weekly Composite Effluent Trichlorophenol^ 19.4 pounds/day Weekly Composite Effluent AOXS 1254 pounds/day 1914 pounds/day Monthly Composite Effluent Chronic Toxicity6 Quarterly Composite Effluent Notes: 1. The minimum summer D.O. shall be reported as the sum of effluent and side -stream oxygenation system. If the automatic oxygen sampler indicates that instream oxygen concentration is above 5.5 mg/L and the river flow is greater than 329 cfs, the facility can discontinue the supplemental oxygen injection during the months of April and May only. 2. See Special Condition A.(6.). Calculation of Total Nitrogen Load. 3. Compliance shall be based upon a quarterly average of weekly composite samples collected during the calendar quarter (Jan. -March, Apr -June, July -Sept., Oct.- Dec.). 4. Monitoring is not required for these compounds if the permittee certifies in writing that chlorophenolic- containing biocides are not used at the facility. 5. AOX monitoring shall be in accordance with the Weyerhaeuser Cluster Rule Sampling Plan (dated 8/11/2000) or subsequent modifications approved by the Division. AOX data shall be submitted on a quarterly basis along with other Cluster Rule chemical data; refer to Special Condition A.(13.). 6. Chronic Toxicity (Ceriodaphnia) at 13%; January, April, July, and October [see Special Condition A.(5.)]. 7. (Summer) = April 1- October 31 THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. 4of13 Permit NC0003191 A. (3.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS Beginning on the effective date of this permit and lasting until expiration, the Permittee is authorized to discharge bleach plant effluent from Internal Outfall 003. Such discharges shall be limited and monitored by the Permittee as specified below: PARAMETER EFFLUENT LIMITATIONS MONITORING REQUIREMENTS' Monthly Average Daily Maximum Measurement Frequency Sample Type3 Sample Locationz Flow Weekly Calculated BPE 2,3,7,8-TCDF 31.9 pg/L4 Annually Composite BPE 2,3,7,8-TCDD < 10 pg/L4 Annually Composite BPE Trichlorosyringol < 2.5 ug/L4 Annually Composite BPE 3,4,5-Trichlorocatechol < 5.0 ug/L4 Annually Composite BPE 3,4,6-Trichlorocatechol < 5.0 ug/L4 Annually Composite BPE 3,4,5-Trichloroguaiacol < 2.5 ugIL4 Annually Composite BPE 3,4,6-Trichloroguaiacol < 2.5 ug/L4 Annually Composite BPE 4,5,6-Trichloroguaiacol < 2.5 ugIL4 Annually Composite BPE 2,4,5-Trichlorophenol < 2.5 ug/L4 Annually Composite BPE 2,4,6-Trichlorophenol < 2.5 ugIL4 Annually Composite BPE Tetrachlorocatechol < 5.0 ug/L4 Annually Composite BPE Tetrachloroguaiacol < 5.0 ugIL4 Annually Composite BPE 2,3,4,6-Tetrachlorophenol < 2.5 ug/L4 Annually Composite BPE Pentachlorophenol < 5.0 ugIL4 Annually Composite BPE Notes: 1. Monitoring and flow calculations shall be in accordance with the Weyerhaeuser Cluster Rule Sampling Plan (dated 8/ 11 /00) or subsequent modifications approved by the Division. Chemical results for Cluster Rule parameters (Internal Outfall 003 parameters + AOX from Outfall 001) shall be reported on a quarterly basis; refer to Special Condition A.(13.). The facility has been exempted from monitoring chloroform in accordance Cluster Rules requirements (see Special Condition A.(14.). 2. Sample locations: BPE (Bleach Plant Effluent) is composed of BPE-acid (acid sewer collected from tap installed on filtrate pump from C102 bleaching stage D), BPE-acid (acid sewer collected from tap installed on filtrate pump from C102 pre -bleaching stage W), and BPE-alkaline (alkaline sewer collected from tap installed on filtrate pump from alkaline extraction stage Eop). 3. Sample Type: Calculated- calculate separate flows for alkaline and acid sewers by water balance, and report total bleach plant flow (acid + alkaline waste streams) in DMRs. Grab- collect separate automated grab samples over a 24-hour period from both the acid and alkaline streams using the ISCO Cluster Rule Volatile Organic Compound sampler (or similar sampler), which will then be composited separately by the lab, and analyzed as separate 24-hr composite acid and alkaline samples. Composite- collect separate automated composite samples over a 24-hour period from both the acid and alkaline streams, then prepare and analyze a single flow -proportioned composite of the acid and alkaline waste stream. 4. Limits are based on Minimum Levels (ML) specified in 40 CFR 430.01. 5of13 Permit NC0003191 A. (4.) INSTREAM MONITORING REQUIREMENTS Beginning on the effective date of this permit and lasting until expiration, the Permittee shall monitor instream conditions as specified below: INSTREAM MONITORING REQUIREMENTS PARAMETER Measurement Frequency Sample Type2 Sample Location' Dissolved Oxygen, (April 1 -October 31) 2/Month Grab U2, D2, D4 Temperature, pH, Conductivity, TN, TP Color Quarterly Grab U 1, D 1, D2, D4 Dissolved Oxygen3,4 Daily Grab U25 Dissolved Oxygen, (November 1 - March 31) Monthly U1, D1 Temperature, pH, Conductivity TN, TP (November 1 - March 31) Monthly U2 Notes: 1. Sample locations: U 1 - Upstream at Spring Garden, U2 - Upstream at Streets Ferry Bridge, D1- Downstream at Monitor, D2- Downstream at Narrows, D4- Downstream at Coast Guard navigation marker M38 located just off the City of New Bern downstream of railway bridge. 2. Grab samples for D.O., Temp, and Conductivity shall be collected at one -meter depth intervals from surface (0.1 m) to bottom. Grab samples for pH and color shall be collected at surface only. 3. This requirement becomes effective on April 1, 2014. 4. If the automatic oxygen sampler indicates that instream oxygen concentration is above 5.5 mg/L and the river flow is greater than 329 cfs, the facility can discontinue the supplemental oxygen injection during the months of April and May only. 5. The alternative sampling location for dissolved oxygen is oil dock on the company property. The location can be used if the automatic oxygen sampler on the Streets ferry Bridge is malfunctioning or being repaired/maintained. A. (5.) CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY) The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia dubia at an effluent concentration of 8.6% for 20 MGD flow or 13% for 32 MGD flow. The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be performed during the months of January, April, July, and October. Effluent sampling for this testing shall be performed at the NPDES permitted final effluent discharge below all treatment processes. If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. 6of13 Permit NC0003191 The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable impairment of reproduction or survival. The definition of "detectable impairment," collection methods, exposure regimes, and further statistical methods are specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the parameter code TGP313 for the pass/fail results and THP313 for the Chronic Value. Additionally, DWR Form AT-3 (original) is to be sent to the following address: Attention: NC DENR / DWR / Environmental Sciences Section 1621 Mail Service Center Raleigh, North Carolina 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30 days after the end of the reporting period for which the report is made. Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream. Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the Environmental Sciences Branch at the address cited above. Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required during the following month. Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water Resources indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring requirements or limits. If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall be included in the calculation & reporting of the data submitted on the DMR & all AT Forms submitted. NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival, minimum control organism reproduction, and appropriate environmental controls, shall constitute an invalid test and will require immediate follow-up testing to be completed no later than the last day of the month following the month of the initial monitoring. A. (6.) CALCULATION OF TOTAL NITROGEN LOADS a. The Permittee shall calculate monthly and annual TN Loads as follows: i. Monthly TN Load (pounds/mo) = TN x TMF x 8.34 where: TN = the average Total Nitrogen concentration (mg/L) of the composite samples collected during the month TMF = the Total Monthly Flow of wastewater discharged during the month (MG/mo) 8.34 = conversion factor, from (mg/L x MG) to pounds ii. Annual TN Load (pounds/yr) = Sum of the 12 Monthly TN Loads for the calendar year b. The Permittee shall report monthly Total Nitrogen results (mg/L and pounds/mo) in the appropriate discharge monitoring report for each month and shall report each year's results (pounds/yr) with the December report for that year. 7of13 Permit NC0003191 A. (7.) ANNUAL LIMITS FOR TOTAL NITROGEN a. Total Nitrogen (TN) allocations and TN Load limits for NPDES dischargers in the Neuse River basin are annual limits and are applied for the calendar year. b. For any given calendar year, the Permittee shall be in compliance with the annual TN Load limit in this Permit if: i. the Permittee's annual TN Load is less than or equal to said limit, or ii. the Permittee is a Co-Permittee Member of a compliance association. The TN Load limit in this Permit (if any) may be modified as the result of allowable changes in the Permittee's TN allocation. i. Allowable changes include those resulting from purchase of TN allocation from the Wetlands Restoration Fund; purchase, sale, trade, or lease of allocation between the Permittee and other dischargers; regionalization; and other transactions approved by the Division. ii. The Permittee may request a modification of the TN Load limit in this Permit to reflect allowable changes in its TN allocation. Upon receipt of timely and proper application, the Division will modify the permit as appropriate and in accordance with state and federal program requirements. iii. Changes in TN limits become effective on January 1 of the year following permit modification. The Division must receive application no later than August 31 for changes proposed for the following calendar year. iv. Application shall be sent to: NCDWR / NPDES Programs Attn: Neuse River Basin Coordinator 1617 Mail Service Center Raleigh, NC 27699-1617 d. If the Permittee is a member and co-permittee of an approved compliance association, its TN discharge during that year is governed by that association's group NPDES permit and the TN limits therein. i. The Permittee shall be considered a Co-Permittee Member for any given calendar year in which it is identified as such in Appendix A of the association's group NPDES permit. ii. Association roster(s) and members' TN allocations will be updated annually and in accordance with state and federal program requirements. iii. If the Permittee intends to join or leave a compliance association, the Division must be notified of the proposed action in accordance with the procedures defined in the association's NPDES permit. (1) Upon receipt of timely and proper notification, the Division will modify the permit as appropriate and in accordance with state and federal program requirements. (2) Membership changes in a compliance association become effective on January 1 of the year following modification of the association's permit. e. The TN monitoring and reporting requirements in this Permit remain in effect until expiration of this Permit and are not affected by the Permittee's membership in a compliance association. A. (8.) TOTAL NITROGEN ALLOCATIONS The following table lists the Total Nitrogen (TN) allocation(s) assigned to, acquired by, or transferred to the Permittee in accordance with the Neuse River nutrient management rule (T15A NCAC 02B .0234) and the status of each as of permit issuance. For compliance purposes, this table does not supercede any TN limit(s) established elsewhere in this permit or in the NPDES permit of a compliance association of which the Permittee is a Co- Permittee Member. ALLOCATION TYPE SOURCE DATE ALLOCATION AMOUNT Ill STATUS Estuary Discharge (pounds/yr) (pounds/yr) Base Assigned by Rule 12/7/97; 312,828 312,828 Active (T15A NCAC 02B .0234) 4/1/03 Footnote: (1) Transport Factor = 100% 8of13 Permit NC0003191 Any addition, deletion, or modification of the listed allocation(s) (other than to correct typographical errors) or any change in status of any of the listed allocations shall be considered a major modification of this permit and shall be subject to the public review process afforded such modifications under state and federal rules. A. (9.) INSTREAM DISSOLVED OXYGEN/DISCHARGE RESTRICTION The permittee shall not discharge any wastewater if the depth averaged dissolved oxygen concentration at any stream station is < 3.0 mg/L in the fresh water portion of the river or above the halocline in the saline portion of the river, unless the side -stream oxygenation system is operating and such discharge is authorized by the Director or his/her designee. A. (10.) WASTEWATER STORAGE It is a recommendation, but not a requirement of this permit, that the facility store wastewater when the Neuse River flow is less than 329 cfs. A. (11.) STREAMFLOW DATA The facility will calculate the daily Neuse River flow at Outfall 001 and must maintain this data onsite and available to the Division for review upon request. A. (12.) BEST MANAGEMENT PRACTICES (BMPs) The permittee must implement the BMPs specified in Section I below. The primary BMP objective is to prevent leaks and spills of spent pulping liquors, soap, and turpentine. A secondary objective is to contain, collect, and recover at the immediate process area, or otherwise control, those leaks, spills, and intentional diversions of spent pulping liquor, soap, and turpentine that do occur. BMPs must be developed according to best engineering practices and must be implemented in a manner that takes into account the specific circumstances at the mill. Section I. BMP Implementation Requirements 1. The permittee must return spilled or diverted spent pulping liquors, soap, and turpentine to the process to the maximum extent practicable as determined by the mill, recover such materials outside the process, or discharge spilled or diverted material at a rate that does not disrupt the receiving wastewater treatment system. 2. The permittee must establish a program to identify and repair leaking equipment items. This program must include: (i) Regular daily visual inspections of process area with equipment items in spent pulping liquor, soap, and turpentine service; (ii) Immediate repair of leaking equipment items, when possible. Leaking equipment items that cannot be repaired during normal operations must be identified, temporary means for mitigating the leaks must be provided, and the leaking equipment items repaired during the next maintenance outage; (iii) Identification of conditions under which production will be curtailed or halted to repair leaking equipment items or to prevent pulping liquor, soap, and turpentine leaks and spills; and (iv) A means for tracking repairs over time to identify those equipment items where upgrade or replacement may be warranted based on frequency and severity of leaks, spills, or failures. 3. The permittee must operate continuous, automatic monitoring systems that the mill determines are necessary to detect and control leaks, spills, and intentional diversions of spent pulping liquor, soap, and turpentine. These monitoring systems should be integrated with the mill process control system and may include, e.g., high level monitors and alarms on storage tanks; process area conductivity (or pH) monitors and alarms; and process area sewer, process wastewater, and wastewater treatment plant conductivity (or pH) monitors and alarms. 4. The permittee must establish a program of initial and refresher training of operators, maintenance personnel, and other technical and supervisory personnel who have responsibility for operating, maintaining, or supervising the operation and maintenance of equipment items in spent pulping liquor, soap, and turpentine service. The refresher training must be conducted at least annually and the training program must be documented. 5. The permittee must prepare a brief report that evaluates each spill of spent pulping liquor, soap, or turpentine that is not contained at the immediate process area and any intentional diversion of spent pulping liquor, soap, or turpentine that is not contained at the immediate process area. The report must describe the equipment items involved, the circumstances leading to the incident, the effectiveness of the corrective actions taken to contain and recover the spill or intentional diversion, and plans to develop changes to equipment and operating and maintenance practices as necessary to prevent recurrence. Discussion of the reports must be included as part of the annual refresher training. 6. The permittee must establish a program to review any planned modifications to the pulping and chemical recovery facilities and any construction activities in the pulping and chemical recovery areas before these activities commence. The purpose of such review is to prevent leaks and spills of spent pulping liquor, soap, and turpentine during the planned modifications, and to ensure that construction and supervisory 9of13 Permit NCO003191 personnel are aware of possible liquor diversions and of the requirement to prevent leaks and spills of spent pulping liquors, soap, and turpentine during construction. 7. The permittee must install and maintain secondary containment (i.e., containment constructed of materials impervious to pulping liquors) for spent pulping liquor bulk storage tanks equivalent to the volume of the largest tank plus sufficient freeboard for precipitation. An annual tank integrity testing program, if coupled with other containment or diversion structures, may be substituted for secondary containment for spent pulping liquor bulk storage tanks. 8. The permittee must install and maintain secondary containment for turpentine bulk storage tanks. 9. The permittee must install and maintain curbing, diking or other means of isolating soap and turpentine processing and loading areas from the wastewater treatment facilities. 10. The permittee must conduct wastewater monitoring to detect leaks and spills, to track the effectiveness of the BMPs, and to detect trends in spent pulping liquor losses. Such monitoring must be performed in accordance with Section V. Section II. BMP Plan Requirements 1. The permittee must prepare and implement a BMP Plan. The BMP Plan must be based on a detailed engineering review as described in this section. The BMP Plan must specify the procedures and the practices required for the mill to meet the requirements of Section I, the construction the mill determines is necessary to meet those requirements including a schedule for such construction, and the monitoring program (including the statistically derived action levels) that will be used to meet the requirements of Section V. The BMP Plan also must specify the period of time that the mill determines the action levels established under Section IV may be exceeded without triggering the responses specified in Section V. 2. The permittee must conduct a detailed engineering review of the pulping and chemical recovery operations -- including but not limited to process equipment, storage tanks, pipelines and pumping systems, loading and unloading facilities, and other appurtenant pulping and chemical recovery equipment items in spent pulping liquor, soap, and turpentine service --for the purpose of determining the magnitude and routing of potential leaks, spills, and intentional diversions of spent pulping liquors, soap, and turpentine during the following periods of operation: (i) Process start-ups and shut downs; (ii) Maintenance; (iii) Production grade changes; (iv) Storm or other weather events; (v) Power failures; and (vi) Normal operations. 3. As part of the engineering review, the permittee must determine whether existing spent pulping liquor containment facilities are of adequate capacity for collection and storage of anticipated intentional liquor diversions with sufficient contingency for collection and containment of spills. The engineering review must also consider: (i) The need for continuous, automatic monitoring systems to detect and control leaks and spills of spent pulping liquor, soap, and turpentine; (ii) The need for process wastewater diversion facilities to protect end -of -pipe wastewater treatment facilities from adverse effects of spills and diversions of spent pulping liquors, soap, and turpentine; (iii) The potential for contamination of storm water from the immediate process areas; and (iv) The extent to which segregation and/or collection and treatment of contaminated storm water from the immediate process areas is appropriate. 4. The permittee must amend its BMP Plan whenever there is a change in mill design, construction, operation, or maintenance that materially affects the potential for leaks or spills of spent pulping liquor, turpentine, or soap from the immediate process areas. S. The permittee must complete a review and evaluation of the BMP Plan five years after the first BMP Plan is prepared and, except as provided in Section II.4., once every five years thereafter. As a result of this review and evaluation, the permittee must amend the BMP Plan within three months of the review if the mill determines that any new or modified management practices and engineered controls are necessary to reduce significantly the likelihood of spent pulping liquor, soap, and turpentine leaks, spills, or intentional diversions from the immediate process areas, including a schedule for implementation of such practices and controls. 6. The BMP Plan, and any amendments thereto, must be reviewed by the senior technical manager at the mill and approved and signed by the mill manager. Any person signing the BMP Plan or its amendments must certify to the Division under penalty of law that the BMP Plan (or its amendments) has been prepared in accordance with good engineering practices and in accordance with this regulation. The permittee is not required to obtain approval from the Division of the BMP Plan or any amendments thereto. Section III. BMP Recordkeeping Requirements 1. The permittee must maintain on its premises a complete copy of the current BMP Plan and the records specified in Section III.2 and must make such BMP Plan and records available to the Division for review upon request. 2. The permittee must maintain the following records for three years from the date they are created: (i) Records tracking the repairs performed in accordance with the repair program described in Section I; (ii) Records of initial and refresher training conducted in accordance with Section I; (iii) Reports prepared in accordance with Section I; and (iv) Records of monitoring required by Sections I and V. Section IV. Establishment of Wastewater Treatment System Influent Action Levels 10 of 13 Permit NC0003191 1. The permittee must conduct a monitoring program per Section IV.2, for the purpose of defining wastewater treatment system influent characteristics (or action levels), described in Section IV.3, that will trigger requirements to initiate investigations on BMP effectiveness and to take corrective action. 2. The permittee must employ the following procedures in order to develop the action levels required by Section IV: Monitoring parameters. The permittee must collect 24-hour composite samples and analyze the samples for a measure of organic content (e.g., Chemical Oxygen Demand (COD) or Total Organic Carbon (TOC)). Alternatively, the mill may use a measure related to spent pulping liquor losses measured continuously and averaged over 24 hours (e.g., specific conductivity or color). Monitoring locations. The permittee must conduct monitoring at the point influent enters the wastewater treatment system. For the purposes of this requirement, the permittee may select alternate monitoring point(s) in order to isolate possible sources of spent pulping liquor, soap, or turpentine from other possible sources of organic wastewaters that are tributary to the wastewater treatment facilities (e.g., bleach plants, paper machines and secondary fiber operations). 3. The permittee must maintain an influent action levels monitoring program using the procedures specified in Section IV and must establish initial action levels based on the results of that program. A wastewater treatment influent action level is a statistically determined pollutant loading determined by a statistical analysis of six months of daily measurements. The action levels must consist of a lower action level, which if exceeded will trigger the investigation requirements described in Section V, and an upper action level, which if exceeded will trigger the corrective action requirements described in Section V. 4. The permittee must complete a second six-month monitoring program using the procedures specified in Section IV and must establish revised action levels based on the results of that program. The initial action levels shall remain in effect until replaced by revised action levels. 5. Action levels developed under this Section must be revised using six months of monitoring data after any change in mill design, construction, operation, or maintenance that materially affects the potential for leaks or spills of spent pulping liquor, soap, or turpentine from the immediate process areas. Section V. BMP Monitoring, Corrective Action, and Reporting Requirements 1. The permittee must conduct daily monitoring of the influent to the wastewater treatment system in accordance with the procedures described in Section IV for the purpose of detecting leaks and spills, tracking the effectiveness of the BMPs, and detecting trends in spent pulping liquor losses. 2. Whenever monitoring results exceed the lower action level for the period of time specified in the BMP Plan, the permittee must conduct an investigation to determine the cause of such exceedence. Whenever monitoring results exceed the upper action level for the period of time specified in the BMP Plan, the permittee must complete corrective action to bring the wastewater treatment system influent mass loading below the lower action level as soon as practicable. 3. Although exceedences of the action levels will not constitute violations of an NPDES permit, failure to take the actions required by Section V.2 as soon as practicable will be a permit violation. 4. The permittee must report to the Division the results of the daily monitoring conducted pursuant to Section V. 1. Such reports must include a summary of the monitoring results, the number and dates of exceedences of the applicable action levels, and brief descriptions of any corrective actions taken to respond to such exceedences. Submission of such reports shall be annually, by March 31 st of the following year. Section VI. BMP Definitions 1. Action Level: A daily pollutant loading that when exceeded triggers investigative or corrective action. Mills determine action levels by a statistical analysis of six months of daily measurements collected at the mill. For example, the lower action level may be the 75th percentile of the running seven-day averages (that value exceeded by 25 percent of the running seven-day averages) and the upper action level may be the 90th percentile of the running seven-day averages (that value exceeded by 10 percent of the running seven-day averages). 2. Division: North Carolina DENR, Division of Water Resources, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617. 3. Equipment Items in Spent Pulping Liquor, Soap, and Turpentine Service: Any process vessel, storage tank, pumping system, evaporator, heat exchanger, recovery furnace or boiler, pipeline, valve, fitting, or other device that contains, processes, transports, or comes into contact with spent pulping liquor, soap, or turpentine. Sometimes referred to as "equipment items." 4. Immediate Process Area: The location at the mill where pulping, screening, knotting, pulp washing, pulping liquor concentration, pulping liquor processing, and chemical recovery facilities are located, generally the battery limits of the aforementioned processes. "Immediate process area" includes spent pulping liquor 11 of 13 Permit NC0003191 storage and spill control tanks located at the mill, whether or not they are located in the immediate process area. 5. Intentional Diversion: The planned removal of spent pulping liquor, soap, or turpentine from equipment items in spent pulping liquor, soap, or turpentine service by the mill for any purpose including, but not limited to, maintenance, grade changes, or process shutdowns. 6. Mill: The owner or operator of a direct or indirect discharging pulp, paper, or paperboard manufacturing facility subject to this section. 7. Senior Technical Manager: The person designated by the mill manager to review the BMP Plan. The senior technical manager shall be the chief engineer at the mill, the manager of pulping and chemical recovery operations, or other such responsible person designated by the mill manager who has knowledge of and responsibility for pulping and chemical recovery operations. 8. Soap: The product of reaction between the alkali in kraft pulping liquor and fatty acid portions of the wood, which precipitate out when water is evaporated from the spent pulping liquor. 9. Spent Pulping Liquor: For kraft and soda mills "spent pulping liquor" means black liquor that is used, generated, stored, or processed at any point in the pulping and chemical recovery processes. 10. Turpentine: A mixture of terpenes, principally pinene, obtained by the steam distillation of pine gum recovered from the condensation of digester relief gases from the cooking of softwoods by the kraft pulping process. Sometimes referred to as sulfate turpentine. A. (13.) CLUSTER RULE MONITORING AND REPORTING The bleach plant effluent sample (Outfall 003) shall be analyzed for 2,3,7,8-TCDD in accordance with EPA Method 1613. A single sample may be analyzed to determine compliance with the daily maximum effluent limitation. Alternatively, a sample volume may be collected to enable the sample to be split (duplicate analysis). If the analysis of either split sample is below the Minimum Level (ML), the quantity is considered to be zero for compliance evaluation. If both splits are positive, the results of two analyses shall be averaged to determine compliance. The Minimum Level for 2,3,7,8-TCDD by EPA Method 1613 is 10 pg/L. The bleach plant effluent sample (Outfall 003) shall be analyzed for the 12 chlorinated phenolic compounds in Part I, A(2) in accordance with EPA Method 1653. A single sample may be analyzed to determine compliance with the daily maximum effluent limitation. Alternatively, a sample volume may be collected to enable the sample to be split (duplicate analysis). If the analysis of either split sample is below the Minimum Level (ML), the quantity is considered to be zero for compliance evaluation. If both splits are positive, the results of two analyses shall be averaged to determine compliance. The Minimum Levels for each of the 12 chlorinated compounds are the same as the Daily Maximum concentrations listed in Part I, A(2). The final wastewater treatment plant effluent sample (Outfall 001) shall be analyzed for AOX in accordance with EPA Method 1650, or subsequent test methods approved by the Division. The permittee may request future monitoring modifications to the Cluster Rule requirements, including 1) use of ECF certification in lieu of monitoring for chloroform in the bleach plant effluent (Outfall 003) when this rule is promulgated by EPA; 2) demonstrating compliance using samples collected less frequently than every four hours; 3) using automated composite volatile samplers for chloroform sampling; and 4) using automated composite samplers for chlorophenolic and TCDD/DF sampling. Such future requests will be evaluated in accordance with 15A NCAC 2H.0114. The flow calculations for internal Outfall 003 shall not be subject to accuracy requirements specified under Part II, Section D.3. This exclusion is similar to that provided for pump log flow calculations. Chemical data for Cluster Rule parameters (all Outfall 003 parameters + AOX from Outfall 001) shall be submitted to the Division on a quarterly basis (January- March, April- June, July- September, October - December). Quarterly submissions shall be due 60 days following the last day of each quarter (Due dates = May 31, August 31, November 30, February 28). Chemical data shall be submitted on Division -approved DMR forms, with a separate form provided for each month. A. (14.) CHLOROFORM CERTIFICATION IN LIEU OF MONITORING In accordance with Cluster Rule requirements, Weyerhaeuser has demonstrated compliance with applicable chloroform limitations and is eligible for an exemption from minimum chloroform monitoring requirements. To maintain compliance with this exemption, Weyerhaeuser certifies that they will maintain a record of the following processes and operating conditions from the bleach plant: 1. The pH of the first chlorine dioxide bleaching phase; 2. The chlorine content of chlorine dioxide used on the bleach line; 3. The kappa factor of the first chlorine dioxide bleaching stage; 12 of 13 Permit NC0003191 4. The total bleach line chlorine dioxide application rate. Weyerhaeuser has identified chlorine dioxide as the chlorine containing compound used for bleaching during the collection of samples and certifies that the fiber line does not use elemental chlorine or hypochlorite as bleaching agents. A. (15.) VARIANCE TO 24-HOUR STAFFING BY CERTIFIED OPERATOR The request by Weyerhaeuser for continuation of the variance to 24-hour staffing coverage at your WWTP by certified operators is hereby granted with the following conditions: 1. The facility shall maintain all current systems, operating strategies, monitoring and operator training as outlined in your letter dated June 9, 2000. 2. Maintain and have available for review by Division staff the documentation of the Wastewater Treatment Operator's Training. 3. Failure of the monitoring system to detect and report a malfunction, or the failure of an appropriate person in responding to a problem must be documented and reported to the Washington Regional Office. Failure of a monitoring device or failure to respond to a problem will not be a mitigating factor in any enforcement action. 4. This variance shall remain in effect until April 30, 2018, and will be reviewed with the renewal of the NPDES permit for this facility. A request for renewal of this variance should be submitted with the permit renewal request. 5. The variance may be rescinded at the discretion of the Director in the event that the compliance status or the conditions at the facility change. 13 of 13