WQ0000884_Compliance Evaluation Inspection_20240129

Compliance Inspection Report
Permit:WQ0000884 Effective: 08/30/22 Expiration: 05/31/29 Owner: Butterball LLC
SOC: Effective: Expiration: Facility: Butterball-Mt. Olive WWTF
County: Duplin 1628 Garner Chapel Rd
Region: Wilmington
Mount Olive NC 28365
Contact Person:Joshua Batchelor Title: Wastewater Manager Phone: [phone]
Directions to Facility:
System Classifications: SI, WW3.,
Primary ORC: Joshua Tray Batchelor Certification: 987940 Phone: [phone]
Secondary ORC(s):
On-Site Representative(s):
Related Permits:
Inspection Date: 01/10/2024 Entry Time 09:30AM Exit Time: 12:30PM
Primary Inspector:Bryan Lievre Phone: [phone]
Secondary Inspector(s):
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 Barscreen
Use Records
Record Keeping Treatment Lagoons Treatment Activated Sludge
Treatment Sludge Storage/Treatment End Use-Irrigation Treatment Clarifiers
Treatment Disinfection Treatment Flow Measurement Treatment Return pumps
Standby Power Wells Coastal Requirements
(See attachment summary)
Page 1 of 8

Permit: WQ0000884 Owner-Facility:Butterball LLC
Inspection Date: 01/10/2024 Inspection Type:Compliance Evaluation Reason for Visit: Routine
Inspection Summary:
An inspection of the Butterball—Mt. Olive WWTF Wastewater Irrigation System, Permit Number WQ0000884, was
performed on January 10, 2024 in order to verify compliance with the existing permit. Present during the meeting were
Lankford Ruffin, Joshua Batchelor(system ORC), Ashley Bridenick and Jeff Evers with Butterball.
The facility is permitted for the operation of a 2,000,000 gallon per day(gpd)wastewater treatment and irrigation facility
which incorporates a 100,000 gpd domestic wastewater pretreatment facility, a stormwater capture system, an industrial
wastewater treatment plant and an irrigation system. The major components of each of the systems are provided below.
The major components of the 100,000 gpd wastewater pretreatment facility(in sequence below) include:
- Mechanical shaftless spiral bar screen with 1/4" screen
- Flow control box with V-notched weir and '/2"openings in a plate screen
- 25,000-gallon flow equalization basin with liquid level sensors for dual 185 gpm pumps and a
70 cfm PD blower
- Dual train 37,500 gallon aeration basins with dual 380 cfm PD blowers (also used for air lift of
WAS & RAS)
- Dual train 11,000 gallon hopper-bottom type clarifiers
- 700 gallon collection box tank
- Effluent pump station with:
o Liquid level switches
o Two 300 gpm effluent pumps(to industrial wastewater plant)
o One emergency 300 gpm dry prime diesel-powered backup pump
A stormwater capture system consisting of:
- A 350,000 gallon lined eastern stormwater pond
- A 245,000 gallon lined western stormwater pond
The major components of the industrial wastewater treatment plant include:
- A 1 million gallon (MG)flow equalization tank with two PD blowers and coarse air diffuser
mixing system
- A two (2) MG flow equalization tank with two PD blowers and coarse air diffuser mixing system
(currently under construction and installed in parallel with the 1 MG equalization tank)
- Coagulant injection system
- Two dissolved air floatation (DAF) units operating in parallel with polymer feed station
- A DAF sludge pump station with dual pumps
- A DAF sludge storage tank with hopper bottom to enable decant removal
- A 13 MG aerated lagoon of reported clay construction with five 60 hp high-speed surface aerators- A 41 MG holding
lagoon of reported clay construction with three 20 hp surface aerators
- A 1,500 gallon plastic tank with liquid chlorine and metering injection pump
The irrigation system includes:
- Four 100 hp irrigation pumps
- Two 50 hp booster irrigation pumps
- Approximately 556.88 acres of spray irrigation with 35 fields, whereas six fields (15A, 15B,
17A, 17b, 17C, and 17D)with a cumulative area of 25.04 acres have not been constructed
- Associated controls with software to regulate spray to application areas
The domestic wastewater pretreatment system was replaced and placed into operation in 2019 and was recently observed
to be in good condition with no operational issues. The stormwater basins did not contain substantial amounts of water
during the visit and appeared to be in good condition.
Page 2 of 8

Permit: WQ0000884 Owner-Facility:Butterball LLC
Inspection Date: 01/10/2024 Inspection Type:Compliance Evaluation Reason for Visit: Routine
Concentrations of nitrate in monitoring wells MW-38 through MW-41 are all above their respective limit of 10 mg/L and are
the suspected most downgradient wells upgradient of the Northeast Cape Fear River. Monitoring well MW-22 has also
recently been exceeding 10 mg/L nitrate and this well is believed to be upgradient of the irrigation fields. Monitoring well
MW-24 was just below 10 mg/L(at 9.60 mg/L)during the last sampling event in 9/2023 and has demonstrated an increasing
trend. Surface water samples of nitrate from locations PPI 006, PPI 007 and PPI 009 have inconsistently been above 10
mg/L and historical sampling results indicate an increasing trend. Surface sampling location PPI 008 has also historically
exceeded 10 mg/L, but not since 2/4/2021 and the trend at this location appears to be decreasing.
It is understood that the system has taken actions to reduce levels of nitrate in downgradient monitoring wells including the
replacement of the domestic wastewater pretreatment system and remedial actions to some of the fields. The system
continues to repair approximately 50 to 60 acres of fields each year. The repairs include discing the field, adding appropriate
chemicals (i.e. fertilizer, lime, etc.)to stabilize the soil, and then seeding the field to place it back into operation. The
system will need to continue to decrease levels within the above mentioned sample locations.
It is recommended that the system initiate regular monitoring of sludge levels in the 13 MG aerated lagoon as well as the 41
MG holding lagoon to enable proper planning of future sludge removal from these structures. System staff were advised to
contact the regional office prior to placing the 2 MG tank or any new spray fields into operation and to submit the
engineering certification form as required within the current permit.
System staff were extremely knowledgeable of plant operations and were very helpful during the inspection. The facility is
compliant with Permit WQ0000884. Records were well organized and complete. Please review the comment sections of the
inspection report for more details.
Page 3 of 8

Permit: WQ0000884 Owner-Facility:Butterball LLC
Inspection Date: 01/10/2024 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 ❑
Recycle/Reuse ❑
Activated Sludge Drip, LR ❑
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: The current permit, issued 8/30/2022, lists dual train 27,500 gallon aeration basins and dual
train 22,000 gallon clarifiers within the domestic wastewater pretreatment system: however, the
capacity of each of the aeration basins is 37,500 gallons and each of the clarifiers have a
capacity of approximately 11,000 gallons.
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: Potable water is provided by and metered by Duplin County, PWS O4-31-085. Production
water is provided by five metered production wells that are calibrated annually. The production
wells are permitted under the Central Plain Coastal Capacity Use Area (CCPCUA), Permit
CU3019. According to the CCPCUA, the average daily flow for the production wells in 2023
was 2,937,669 gpd. Stormwater flow is estimated, based on total effluent less production less
Potable water consumption.
Treatment Flow Measurement-Water Use Records Yes No NA NE
Is water use metered? 0 ❑ ❑ ❑
Are the daily average values properly calculated? 0 ❑ ❑ ❑
Comment: The average daily flow in 2023 for the domestic system was -52,200 gpd and for the industrial
system was -1,343,000 gpd.
Treatment Flow Measurement-Effluent Yes No NA NE
Is flowmeter calibrated annually? 0 ❑ ❑ ❑
Is flowmeter operating properly? 0 ❑ ❑ ❑
Page 4 of 8

Permit: WQ0000884 Owner-Facility:Butterball LLC
Inspection Date: 01/10/2024 Inspection Type:Compliance Evaluation Reason for Visit: Routine
Does flowmeter monitor continuously? 0 ❑ ❑ ❑
Does flowmeter record flow? 0 ❑ ❑ ❑
Does flowmeter appear to monitor accurately? ❑ ❑ ❑
Comment: An ultrasonic flow meter is located on the effluent line from the domestic wastewater
Pretreatment system and two in-line flow meters are present for the industrial wastewater
treatment system. The flow meters were last calibrated on 6/5/2023 and 7/12/2023 by
Benchmark Engineering.
Standby Power Yes No NA NE
Is automatically activated standby power available? ❑ 0 ❑ ❑
Is generator tested weekly by interrupting primary power source? ❑ ❑ 0 ❑
Is generator operable? ❑ ❑ 0 ❑
Does generator have adequate fuel? ❑ ❑ 0 ❑
Comment: The domestic wastewater pretreatment system is equipped with a diesel-powered effluent
backup pump, which is set up to automatically operate Mondays &Thursdays, and the unit is
also maintained by diesel mechanics. Otherwise, the system would rely on portable emergency
generators in the event of a local power outage.
Treatment Barscreen Yes No NA NE
Is it free of excessive debris? 0 ❑ ❑ ❑
Is disposal of screenings in compliance? ❑ ❑ ❑
Are the bars spaced properly? ❑ ❑ ❑
Is the unit in good condition? 0 ❑ ❑ ❑
Comment: The shaftless spiral barscreen in the domestic system was observed to be operating properly
during the inspection, even collecting lots of fines adhered to other larger debris. Debris
collected within the structure is automatically deposited within a dumpster and taken to the
county landfill for proper disposal.
Treatment Activated Sludge Yes No NA NE
Is the aeration mechanism operable? ❑ ❑ ❑
Is the aeration basin thoroughly mixed? ❑ ❑ ❑
Is the aeration equipment easily accessed? ❑ ❑ ❑
Is Dissolved Oxygen adequate? ❑ ❑ ❑
Are Settleometer results acceptable? ❑ ❑ ❑
Is activated sludge an acceptable color? 0 ❑ ❑ ❑
Comment: Freeboard within the 41 MG lagoon was at 42 inches during the site inspection. Although a
few surface aerators were down for repairs during the inspection, the 13 MG lagoon still
seemed to be to have significant aeration and the sides of the both of the lagoons seemed to
be well maintained. In the domestic system, significant and even air distribution was observed
within each of the aeration basins.
Treatment Clarifiers Yes No NA NE
Are the weirs level? 0 ❑ ❑ ❑
Are the weirs free of solids and algae? 0 ❑ ❑ ❑
Page 5 of 8

Permit: WQ0000884 Owner-Facility:Butterball LLC
Inspection Date: 01/10/2024 Inspection Type:Compliance Evaluation Reason for Visit: Routine
Is the scum removal system operational? 0 ❑ ❑ ❑
Is the scum removal system accessible? 0 ❑ ❑ ❑
Is the sludge blanket at an acceptable level? 0 ❑ ❑ ❑
Is the effluent from the clarifier free of excessive solids? 0 ❑ ❑ ❑
Comment: A sludge blanket of approximately four feet is reportedly maintained in the dual clarifiers for the
domestic system. Flow was observed to evenly flow over the weirs and the weirs were found to
have been very clean with little to no solids buildup within the domestic system. Weirs are
reportedly cleaned daily with water rinses.
Treatment Return pumps Yes No NA NE
Are they in place? 0 ❑ ❑ ❑
Are they operational? 0 ❑ ❑ ❑
Comment: Return pumps are all air lift pumps and include both sludge and skimmer returns.
Treatment Sludge Storage/Treatment Yes No NA NE
Is the aeration operational? ❑ ❑ ❑
Is the aeration pattern even? ❑ ❑ ❑
If required, are Sanitary"Ts"present in tankage? ❑ ❑ 0 ❑
Comment: Residuals are sent to a container which is owned, removed and disposed by McGill.
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? ❑ ❑ ❑
If yes,then what is the EPA twelve digit ID Number? (1000- - )
If yes,then when was the RMP last updated?
Page 6 of 8

Permit: WQ0000884 Owner-Facility:Butterball LLC
Inspection Date: 01/10/2024 Inspection Type:Compliance Evaluation Reason for Visit: Routine
Comment: Disinfection using liquid sodium hvpochlorite is fed on the effluent line from the industrial
wastewater system prior to the irrigation fields. A leak was discovered on the 1,500 gallon
sodium hvpochlorite tank so multiple 275 plastic tanks were being utilized until a replacement
tank was installed.
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? ❑ 0 ❑ ❑
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? ❑ 0 ❑ ❑
Comment: The current permit was issued 8/30/20222 and expires 5/31/2029. The on-site lab is field
certified for pH and chlorine with Permit#5420. Envirochem is their contract laboratory.
Groundwater total nitrate-nitrogen violations were reported in monitoring wells MW-22, MW-38
through MW-41. Meherrin AG staff obtain soil samples from the spray fields, produce a report
with recommendations and apply lime and fertilizer as recommended. The last report was
reviewed while on-site. Afield book is maintained for both systems and separate field books
are maintained to document freeboard measurement in the lagoons.
End Use-Irrigation Yes No NA NE
Are buffers adequate? ❑ ❑ ❑
Page 7 of 8

Permit: WQ0000884 Owner-Facility:Butterball LLC
Inspection Date: 01/10/2024 Inspection Type:Compliance Evaluation Reason for Visit: Routine
Is the cover crop type specified in permit? 0 ❑ ❑ ❑
Is the crop cover acceptable? 0 ❑ ❑ ❑
Is the site condition adequate? 0 ❑ ❑ ❑
Is the site free of runoff/ponding? 0 ❑ ❑ ❑
Is the acreage specified in the permit being utilized? 0 ❑ ❑ ❑
Is the application equipment present? 0 ❑ ❑ ❑
Is the application equipment operational? 0 ❑ ❑ ❑
Is the disposal field free of limiting slopes? 0 ❑ ❑ ❑
Is access restricted and/or signs posted during active site use? 0 ❑ ❑ ❑
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? 0 ❑ ❑ ❑
# Info only: Does the permit call for monitoring wells? 0 ❑ ❑ ❑
Are GW monitoring wells located properly w/respect to RB and CB? 0 ❑ ❑ ❑
Are GW monitoring wells properly constructed, including screened interval? ❑ ❑ ❑
Are monitoring wells damaged? ❑ 0 ❑ ❑
Comment: Spray fields 8A, 9A, 9C were inspected based on review of 2023 on-line aerial imagery via
Google Earth which identified the possibility of erosional issues in the fields. Each of these
fields were inspected and all were found to be n satisfactory condition. Spray fields 02A and
02B were also inspected as the 2023 on-line imagery identified the fields as being much lighter
in color. According to system staff, these two fields were rehabbed in 2023 and therefore the
lighter color was most likely due to the effects of this process, whereas no vegetation had been
established and lime may have been applied to the area. Although some small areas of
surface ponding were visible during the inspection, none of these fields were being used for
irrigation and heavy rainfall was experienced the prior day. According to system staff, all fields
(except those on which tree's are being sprayed) have been overseeded with rye.
Coastal Requirements Yes No NA NE
Are essential treatment units provided in duplicate? ❑ ❑ ❑
Is an adequately sized aerated equalization basin present? ❑ ❑ ❑
If so, is it operable? ❑ ❑ ❑
If present, are diffusers cleaned regularly? ❑ ❑ ❑
Is the equalization capacity adequate? ❑ ❑ ❑
Comment:
Page 8 of 8