WQ0009826_Inspection letter_20220912

ROY COOPER
Governor
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
Kevin McDaniel — Vice President
Wayne Farms LLC
4110 Continental Drive
Oakwood, Georgia 30566
NORTH CAROLINA
Environmental Quality
September 12, 2022
SUBJECT: Compliance Evaluation Inspection
Wayne Farms — Dobson Hatchery WWTF
Permit No. WQ0009826
Surry County
Dear Mr. McDaniel:
On September 8, 2022, Division of Water Resources staff Caitlin Caudle conducted a compliance
evaluation inspection. Jeremy Bowlin, ORC, and David Benge, Hatchery Manager, were present
during the entire inspection. A separate in -office review of records was completed. An on -site
review of records, treatment facilities, monitoring wells, storage facilities, and irrigation fields was
completed. This review reflected compliance with the subject permit. The following item of
concern was noted:
Mr. Bowlin stated that there have been no solids removed from the transfer tank and
settling tank since the new tanks have been installed. There is a filter in the transfer tank
that is checked weekly. The Operation and Maintenance Plan stated that the scum layer
in the transfer tank and settling tank at the fields will be measured at least monthly until
solids build up is understood. Please measure the scum layer in the transfer tank and
settling tank to ensure that pumping is not needed and continue to monitor the
scum layer as needed.
Please refer to the enclosed inspection report for additional comments and observations. If you
have any questions, please contact me or Caitlin Caudle at the letterhead address or phone
number, or by email at lon.snider(abncdenr.gov or caitlin.caudle(a�ncdenr.gov.
Sincerely,
DocuSiTgned by:
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Lon T. Snider, Regional Supervisor
Water Quality Regional Operations Section
Division of Water Resources, NCDEQ-WSRO
Cc: Jeremy Bowlin, ORC (electronic copy) Enc: Inspection Report
David Benge, Hatchery Manager (electronic copy)
Surry County Environmental Health (electronic copy)
Laserfiche File WQ0029190
WSRO electronic Files
DffNorth Carolina Department of Environmental Quality I Division of Water Resources
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Winston-Salem Regional Office 1 450 W. Hanes Mill Rd, Suite 300 1 Winston-Salem, North Carolina 27105
M336.776.9800
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Compliance Inspection Report
Permit: WQ0009826 Effective: 09/16/20 Expiration: 04/30/24 Owner: Wayne Farms LLC
SOC: Effective: Expiration: Facility: Wayne Farms - Elkin Hatchery WWTF
County: Surry 10949 NC 268 E
Region: Winston-Salem
Elkin NC 28621
Contact Person: Paul Nordin Title: Phone: [phone]
Directions to Facility:
System Classifications: SI,
Primary ORC:
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
Inspection Date: 09/08/2022
Primary Inspector: Caitlin Caudle
Secondary Inspector(s):
Certification:
Phone:
Entry Time 09:OOAM Exit Time: 11:OOAM
Phone: [phone]
Reason for Inspection: Routine Inspection Type: Compliance Evaluation
Permit Inspection Type: Wastewater Irrigation
Facility Status: Compliant ❑ Not Compliant
Question Areas:
Treatment Flow Measurement -Effluent Treatment Flow Measurement -Influent Miscellaneous Questions
Treatment Flow Measurement -Water Treatment Treatment Filters
Use Records
Record Keeping End Use -Irrigation Treatment Influent Pump Station
Treatment Disinfection Treatment Flow Measurement Storage
Wells
(See attachment summary)
Page 1 of 7

Permit: WQ0009826 Owner - Facility: Wayne Farms LLC
Inspection Date: 09/08/2022 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Inspection Summary:
On September 8, 2022, Division of Water Resources staff Caitlin Caudle conducted a compliance evaluation inspection.
Jeremy Bowlin, ORC, and David Benge, Hatchery Manager, were present during the entire inspection. A separate in -office
review of records was completed. An on -site review of records, treatment facilities, monitoring wells, storage facilities, and
irrigation fields was completed. This review reflected compliance with the subject permit. The following item of concern was
noted:
1. Mr. Bowlin stated that there have been no solids removed from the transfer tank and settling tank since the new tanks
have been installed. There is a filter in the transfer tank that is checked weekly. The Operation and Maintenance Plan stated
that the scum layer in the transfer tank and settling tank at the fields will be measured at least monthly until solids build up
is understood. Please measure the scum layer in the transfer tank and settling tank to ensure that pumping is not needed,
and continue to monitor the scum layer as needed.
A follow up inspection may be scheduled to review the irrigation fields after mowing and review the length of the forcemain.
Other observations:
• Hatchery ❑ back chamber at lift station ❑ Foowmeter ❑ Sweco ❑ Transfer tank inlet chamber ❑ Baffle wall ❑ Transfer
tank outlet chamber ❑ CCC ❑ Transfer tank inlet chamber ❑ Baffle wall ❑ Outlet chamber ❑ Forcemain ❑ Settling tank ❑
Storage tanks OR Transfer tank ❑ overflow to old transfer tank ❑ Storage pond
• Mr. Bowlin visits the facility once a week to discuss the system with Mr. Benge and two maintenance workers who
regularly monitor the system and perform repairs. Mr. Benge and the maintenance workers are planning to take the operator
exams. Mr. Bowlin will walk the system and review it in operation.
• There is a Sweco vibrating screen separating solids from the effluent. All screenings are sent to a facility which recycles
the solids as protein sources.
• The only open atmosphere tanks are the old transfer tank and the storage pond. The old transfer tank has two
chambers, one with a float tree that sends effluent to the storage pond and a smaller chamber where wastewater from the
hatchery enters and is transferred to the Sweco.
• There have been past exceedances of NH3, Fecal, and TDS of groundwater limits in the effluent. This does not
constitute a violation of the effluent quality based on the Attachment A.
• Fecal values were >5 MPN/100mL for the 7/22 monitoring well sampling event.
• Ammonia in the effluent has been high for the past few sample events. This is likely due to the cleaners used in the
hatchery and the nature of the wastewater as feces and urine from the chicks will be present.
• The flows on all PPI are reported from the flow meter at the Sweco.
• Mr. Bowlin stated that the transfer pumps at the hatchery are likely powered by the generator for the hatchery. All other
components of the system do not have back up power.
• No solids have been removed from the system since the new tanks have been installed.
• All meters were calibrated 4/26/2022 (Sweco flowmeter, three meters at new field).
• There have been some high fecal values in the past few sampling events.
• Flow on NDMRs is measured by the meter at the Sweco. Flow on the NDARs is measured by the 3 flow meters at the
new fields.
• All monitoring wells were in good condition.
• The water supply well at the house at the new fields has been abandoned, and a well beside the hatchery.
• The hatchery does receive public water.
• The fields had not been mowed yet. They are waiting on dry weather.
New fields:
• The new transfer tank has an inlet and outlet chamber with a baffle wall separating them. The baffle wall allows for
additional solids separation. There is a float tree in the outlet chamber with a chlorination float which engages a pump to
send effluent in the outlet chamber through the chlorinator back into the inlet chamber. There is also a transfer float which
transfers effluent to the storage tanks.
• There is a filter in the pump vault that is checked weekly.
• The transfer tank can gravity flow into the old transfer tank if any mechanical failure occurs.
• Irrigation is controlled by floats. Once the float is engaged the next zone in the irrigation cycle will be irrigated for a
Page 2 of 7

Permit: WQ0009826 Owner - Facility: Wayne Farms LLC
Inspection Date: 09/08/2022 Inspection Type: Compliance Evaluation Reason for Visit: Routine
certain amount of time and switch to the next zone, and so on, until the off flow is engaged. Pump 3 was reviewed in
operation.
• The forcemain is all below ground with no above ground stream crossings. There are two stream crossings.
• There are three pumps in the 14,000 gallon dose tank for irrigation.
• The control panel will call out when there are issues at the new fields.
• There are three meters at the spray fields measuring irrigation volumes. There is a meter for Z1 and 4, Z2 and 5, and Z3
and 6.
• There is approximately 2-2 1/2 weeks of storage in the tanks. They are all hydraulically connected on the bottom of the
tanks.
• A rain sensor was on the roof of the control panel shelter.
• The high water alarm was not reviewed in operation.
• A back-up meter is present.
Old Fields:
• The old transfer tank has a large compartment with two pumps and a float tree present. The high water alarm was
operational and one pump was operational. There is a smaller compartment where wastewater flow from the hatchery enters
and is transferred to the Sweco screen. The entire tank sits in a concrete containment area that is even with the top of the
tank. See photos.
• There has been no flow to the storage pond since the new tanks were installed in 2020.
• There is a--3,000 gallon dose tank at the storage pond with a tablet chlorinator in it.
• Two pumps are present for irrigation.
• Antifoaming agents are not used.
• The storage pond is clay lined.
Follow up items:
:1 Review the forcemain from the hatchery to the new fields. Weather conditions and vegetation prevented a review at the
time of inspection.
Confirm backup power for the transfer pumps at the hatchery.
How is flow at the storage pond measured if irrigated? Saw a chart there.
:1 Review filter in transfer tank
Page 3 of 7

Permit: WQ0009826 Owner - Facility: Wayne Farms LLC
Inspection Date: 09/08/2022 Inspection Type: Compliance Evaluation
Reason for Visit: Routine
Type
Yes No NA NE
Reuse (Quality)
❑
Infiltration System
❑
Single Family Spray, LR
❑
Activated Sludge Spray, LR
❑
Activated Sludge Spray, HR
❑
Activated Sludge Drip, LR
❑
Recycle/Reuse
❑
Single Family Drip
❑
Lagoon Spray, LR
Treatment Yes No NA NE
Are Treatment facilities consistent with those outlined in the current permit? 0 ❑ ❑ ❑
Do all treatment units appear to be operational? (if no, note below.) 0 ❑ ❑ ❑
Comment:
Treatment Influent Pump Station
Yes No NA NE
Is the pump station free of bypass lines or structures?
0
❑ ❑ ❑
Is the general housekeeping acceptable?
❑ ❑ ❑
Are all pumps present?
❑ ❑ ❑
Are all pumps operable?
❑ ❑ ❑
Are floats/controls operable?
❑ ❑ ❑
Are audio and visual alarms available?
0
❑ ❑ ❑
Are audio and visual alarms operational?
❑ ❑ ❑
# Are SCADA/Telemetry alarms required?
❑
❑ ❑
Are SCADA/Telemetry available?
❑
❑ ❑
Are SCADA/Telemetry operational?
❑
❑ 0 ❑
Comment:
Treatment Flow Measurement -Influent
Yes No NA NE
Is flowmeter calibrated annually?
❑ ❑ ❑
Is flowmeter operating properly?
❑ ❑ ❑
Does flowmeter monitor continuously?
❑ ❑ ❑
Does flowmeter record flow?
❑ ❑ ❑
Does flowmeter appear to monitor accurately?
❑ ❑ ❑
Comment:
Treatment Flow Measurement -Water Use Records Yes No NA NE
Page 4 of 7

Permit: WQ0009826 Owner - Facility: Wayne Farms LLC
Inspection Date: 09/08/2022 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Is water use metered? ❑ ❑ 0 ❑
Are the daily average values properly calculated? ❑ ❑ 0 ❑
Comment:
Treatment Flow Measurement -Effluent
Yes No NA NE
Is flowmeter calibrated annually?
0
❑ ❑ ❑
Is flowmeter operating properly?
0
❑ ❑ ❑
Does flowmeter monitor continuously?
0
❑ ❑ ❑
Does flowmeter record flow?
0
❑ ❑ ❑
Does flowmeter appear to monitor accurately?
0
❑ ❑ ❑
Comment:
Treatment Filters
Yes No NA NE
Is the filter media present?
0
❑ ❑ ❑
Is the filter media the correct size and type?
0
❑ ❑ ❑
Is the air scour operational?
❑
❑ 0 ❑
Is the scouring acceptable?
❑
❑ 0 ❑
Is the clear well free of excessive solids?
❑
❑ 0 ❑
Is the mud well free of excessive solids and filter media?
❑
❑ 0 ❑
Does backwashing frequency appear adequate?
❑
❑ 0 ❑
Comment:
Treatment Disinfection
Yes No NA NE
Is the system working?
0
❑ ❑ ❑
Do the fecal coliform results indicate proper disinfection?
❑
❑ ❑
Is there adequate detention time (>=30 minutes)?
❑ ❑ ❑
Is the system properly maintained?
❑ ❑ ❑
If gas, does the cylinder storage appear safe?
❑
❑ ❑
Is the fan in the chlorine feed room and storage area operable?
❑
❑ ❑
Is the chlorinator accessible?
❑ ❑ ❑
If tablets, are tablets present?
❑ ❑ ❑
Are the tablets the proper size and type?
❑ ❑ ❑
Is contact chamber free of sludge, solids, and growth?
❑
❑ ❑
If UV, are extra UV bulbs available?
❑
❑ ❑
If UV, is the UV intensity adequate?
❑
❑ ❑
# Is it a dual feed system?
❑
❑ ❑
Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)?
❑
❑ ❑
If yes, then is there a Risk Management Plan on site?
❑
❑ ❑
Page 5 of 7

Permit: WQ0009826 Owner - Facility: Wayne Farms LLC
Inspection Date: 09/08/2022 Inspection Type: Compliance Evaluation
Reason for Visit: Routine
If yes, then what is the EPA twelve digit ID Number? (1 000-- )
If yes, then when was the RMP last updated?
Comment: Some high fecal values during past sampling events.
Record Keeping
Yes No NA NE
Is a copy of current permit available?
❑ ❑ ❑
Are monitoring reports present: NDMR?
❑ ❑ ❑
NDAR?
❑ ❑ ❑
Are flow rates less than of permitted flow?
❑ ❑ ❑
Are flow rates less than of permitted flow?
❑ ❑ ❑
Are application rates adhered to?
❑ ❑ ❑
Is GW monitoring being conducted, if required (GW-59s submitted)?
❑ ❑ ❑
Are all samples analyzed for all required parameters?
❑ ❑ ❑
Are there any 2L GW quality violations?
❑
❑ ❑
Is GW-59A certification form completed for facility?
❑ ❑ ❑
Is effluent sampled for same parameters as GW?
❑ ❑ ❑
Do effluent concentrations exceed GW standards?
❑ ❑ ❑
Are annual soil reports available?
❑ ❑ ❑
# Are PAN records required?
❑ ❑ ❑
# Did last soil report indicate a need for lime?
❑
❑ ❑
If so, has it been applied?
❑
❑ ❑
Are operational logs present?
❑ ❑ ❑
Are lab sheets available for review?
❑ ❑ ❑
Do lab sheets support data reported on NDMR?
❑ ❑ ❑
Do lab sheets support data reported on GW-59s?
❑ ❑ ❑
Are Operational and Maintenance records present?
❑ ❑ ❑
Were Operational and Maintenance records complete?
❑ ❑ ❑
Has permittee been free of public complaints in last 12 months?
❑ ❑ ❑
Is a copy of the SOC readily available?
❑
❑ ❑
No treatment units bypassed since last inspection?
❑ ❑ ❑
Comment: See comments.
End Use -Irrigation
Yes No NA NE
Are buffers adequate?
0
❑ ❑ ❑
Is the cover crop type specified in permit?
❑ ❑ ❑
Is the crop cover acceptable?
❑ ❑ ❑
Is the site condition adequate?
❑ ❑ ❑
Is the site free of runoff / ponding?
0
❑ ❑ ❑
Page 6 of 7

Permit: WQ0009826 Owner - Facility: Wayne Farms LLC
Inspection Date: 09/08/2022 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Is the acreage specified in the permit being utilized?
Is the application equipment present?
Is the application equipment operational?
Is the disposal field free of limiting slopes?
Is access restricted and/or signs posted during active site use?
Are any supply wells within the CB?
Are any supply wells within 250' of the CB?
How close is the closest water supply well?
Is municipal water available in the area?
# Info only: Does the permit call for monitoring wells?
Are GW monitoring wells located properly w/ respect to RB and CB?
Are GW monitoring wells properly constructed, including screened interval?
Are monitoring wells damaged?
Comment: MWs were not damaged.
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