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HomeMy WebLinkAboutWQ0000485_Final Permit_20051107o�oF w� r�RQG Michael F, Easley, Governor William G. Ross Jr., Secretary r North Carolina Department of Environment and Natural Resources 'C Alan W. Klimek, P.E. Director Division of Water Quality November 7, 2005 Tom A. Gibson, Director of Environmental Affiars Valley Proteins, Inc. PO Box 3588 Winchester, VA 22604 Subject: Permit No. WQ0000485 Carolina By -Product, Rose Hill Wastewater Surface Irrigation Duplin County Dear Mr. Gibson. In accordance with your renewal request received September 1, 2005, we are forwarding herewith Permit No, WQ0000485, dated November 7, 2005, to Valley Proteins, Inc. for the continued operation of the subject wastewater treatment and surface irrigation facilities. This permit shall be effective from the date of issuance until October 31, 2010, shall void Permit No. WQ0000485 issued October 16, 2001, and shall be subject to the conditions and limitations as specified therein. Please pay particular attention to the monitoring requirements in this permit. Failure to establish an adequate system for collecting and maintaining the required operational information will result in future compliance problems. If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This request must be in the form of a written petition, conforming to Chapter 150E of the North Carolina General Statutes, and filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714. Unless such demands are made this permit shall be final and binding, If you need additional information concerning this matter, please (919) 715-6173 or miranda.williams@ncmail.net. W. Klimek, cc: Duplin County Health Department Wilmington Regional Office, Aquifer Protection Section Art Riddick, PE — Reid Engineering Company, Inc. Technical Assistance and Certification Unit APS Central Files LAU Files Miranda Williams at North Carolina Natura!!ry Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone (919) 733-3221 Customer Service Internet: h2o.enr.state. ne.us 2728 Capital Boulevard Raleigh, NC 27604 FAX (919) 715-6048 1-877-623-6748 An Equal Opportunity/Affirmative Action Employer — 50% Recycled110% Past Consumer Paper NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES RALEIGH SURFACE IRRIGATION SYSTEM PERMIT In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as amended, and other applicable Laws, Rules, and Regulations PERMISSION IS HEREBY GRANTED TO Valley Proteins, Inc. Duplin County FOR THE continued operation of a 300,000 gallon per day (GPD) wastewater treatment and disposal facility with 138,000 GPD disposed by spray irrigation and an additional 162,000 GPD evaporated in a cooling tower and recycled Back into the facility. The existing 243,000 -GPD wastewater treatment facility consists of a raw wastewater collection pump station, a screen surge tank, a Sweco mechanically -cleaned bar screen, a screen effluent wet well and a dissolved air flotation (DAF) cell influent pump station, a DAF cell with an effluent pump station, a 3.5 - million -gallon, seven-day aerated flow equalization lagoon (Lagoon No. 1) with four 20 -HP surface aerators, four 30 -HP surface aerators, and three 15 -HP surface aerators, a 200 -GPM flow equalization pump station with dual pumps, force main, and flow meter, a 1.67 -million -gallon, completely -mixed activated sludge (CMAS) basin with two 50 -HP jet aerator manifolds and two 200 -HP centrifugal corepressors, one 500 -gallon polymer flocculent solution mix storage tanks with a 1 -HP tank mixer and one polymer solution pump, a flotation clarifier with dual 75 -GPM recycle pressure pumps and a magnetic flow meter, sludge collection tank with dual 30 -GPM progressive cavity sludge return pumps, a 1.3 -million -gallon waste sludge aerobic digester with a 60 -HP aerator and chemical feed equipment consisting of a a 4,000 gallon magnesium hydroxide tank with mixer and pump, an effluent flow meter, a 146 -GPM clarifier effluent pump station with dual pumps, two 2.8 -acre unlined, non-aerated lagoons, a 7.2 -million -gallon recirculation lagoon, and a gaseous chlorine chemical feed system. The 138,000 GPD spray irrigation disposal system consists of the operation of a spray irrigation pump station with an existing 650 -GPM pump, four existing spray irrigation fields (Fields #I, 2, 3, and 5) and four previously permitted spray irrigation fields (Field #6, 47, 98 and 49) totaling 70.44 acres. The wastewater treatment and spray irrigation disposal system will serve the Carolina By -Product, Rose Hill Division, with no discharge of wastes to the surface waters, pursuant to the application received September 1, 2005, and subsequent additional information received by the Division, and in conformity with the project plan, specifications, and other supporting data subsequently filed and approved by the Department of Environment and Natural Resources and considered a part of this permit. This permit shall be effective from the date of issuance until October 31, 2010, shall void Permit No. WQ0000485 issued October 16, 2001, and shall be subject to the following specified conditions and limitations: I. PERFORMANCE STANDARDS The surface irrigation facilities shall be effectively maintained and operated at all times so that there is no discharge to the surface waters, nor any contamination of ground waters, which will render them unsatisfactory for normal use. In the event that the facilities fail to perforin satisfactorily, including the creation of nuisance conditions or failure of the irrigation area to adequately assimilate the wastewater, the Permittee shall take immediate corrective actions including those actions that may be required by the Division of Water Quality, such as the construction of additional or replacement wastewater treatment and disposal facilities. 2. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to surface or groundwaters resulting from the operation of this facility. 3. The residuals generated from these treatment facilities must be disposed in accordance with General Statute 143-215.1 and in a manner approved by the Division.. 4. Diversion or bypassing of the untreated wastewater from the treatment facilities is prohibited. 5. The following buffers shall be maintained: a) 400 feet between wetted area and any residence or places of public assembly under separate ownership, b) 150 feet between wetted area and property lines, c) 100 feet between wetted area and wells, d) 100 feet between wetted area and drainage ways or surface water bodies, e) 50 feet between wetted area and public right of ways, f) 100 feet between treatment/storage units and any wells, and g) 50 feet between treatment units and property lines_ Some of the buffers specified above may not have been included in previous permits for this waste treatment and disposal system. These buffers are not intended to prohibit or prevent modifications, which are required by the Division, to improve performance of the existing treatment facility. These buffers do, however, apply to modifications of the treatment and disposal facilities that are for the purpose of increasing the flow that is tributary to the facility. These buffers do apply to any expansion or modification of the irrigation areas and apply in instances in which the sale of property would cause any of the buffers now complied with, for the treatment and disposal facilities, to be violated. The applicant is advised that any modifications to the existing facilities will require a permit modification. II. OPERATION AND MAINTENANCE REQUIREMENTS 1. The facilities shall be properly maintained and operated at all times. 2. Upon classification of the wastewater treatment and irrigation facilities by the Water Pollution Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to be back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit the facilities in accordance with 15A NCAC 8G.0204 or as specified in this permit and shall comply with all other conditions specified in these rules. 3. A suitable year round vegetative cover of coastal bermuda and winter rye shall be maintained. Fescue may also continue to be used on a trial basis on Field 6. 4_ Irrigation shall not be performed during inclement weather or when the ground is in a condition that will cause runoff. 5. Adequate measures shall be taken to prevent wastewater runoff from the irrigation field. 6. The facilities small be effectively maintained and operated as a non -discharge system to prevent the discharge of any wastewater resulting from the operation of this facility. 7. The application rate shall not exceed the following: a. An instantaneous application rate of 0.2 inches per hour. b. A maximum nitrogen loading of 350 pounds of Plant Available Nitrogen (PAN) per acre per year for fields containing coastal bermuda grass (300 lbs./acre PAN) overseeded with winter rye (50 lbs./acre PAN) and a maximum nitrogen loading of 250 pounds of PAN per acre per year for fields containing corn (silage) (150 lbs./acre) overseeded with winter rye (100 lbs./acre). If any other crops are to be grown on the subject irrigation fields, a crop management plan outlined by the local Extension Office, the Department of Agriculture, the Natural Resource Conservation Service, or other agronomist should be maintained and PAN loading rates shall not exceed the realistic yield expectation for those crops. c. The following cumulative hydraulic loadings should not be exceeded for the appropriate spray irrigation held over any twelve-month period: Cumulative Loadings Field _# Acres (inches per twelve month period) 1 6.84 26.0 2 3.59 26.0 3 8.44 36.4 5 13.83 46.8 6 12.9 31.2 7 5.86 65.0 8 7.55 65.0 9 11.43 31.2 8. No type of wastewater other than that from Carolina By -Product, Rose Hill shall be irrigated onto the irrigation area. 9. No traffic or equipment shall be allowed on the disposal area except while installation occurs or while normal maintenance is being performed. 10. Public access to the land application sites shall be controlled during active site use. Such controls may include the posting of signs showing the activities being conducted at each site. 11. Freeboard in all treatment and storage lagoons shall not be less than two feet at any time. 12. If not already installed, a waste-Ievel gauge, to monitor waste levels in the storage ponds, shall be installed within 60 days of issuance of this permit. This gauge shall have readily visible permanent markings indicating the maximum liquid level at the top of the temporary liquid storage volume, minimum liquid level at the bottom of the temporary liquid storage volume, and top of the darn elevations. Caution must be taken not to damage the integrity of the liner when installing the gauge. 13. A protective vegetative cover shall be established and maintained on all earthen basin embankments (outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas, and surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or otherwise controlled and accessible. III. MONITORING AND REPORTING REQUIREMENTS 1. Any monitoring (including groundwater, surface water, soil or plant tissue analyses) deemed necessary by the Division to insure surface and ground water protection will be established and an acceptable sampling reporting schedule shall be followed. 2. Influent flow shall be continuously monitored and daily flow values shall be reported on Form NDMR. The Permittee shall install an appropriate flow measurement device consistent with approved engineering and scientific practices to ensure the accuracy and reliability of influent flow measurement. Flow measurement devices selected shall be capable of measuring flows with a maximum deviation of less than 10 percent from true flow, accurately calibrated at a minimum of once per year, and maintained to ensure that the accuracy of the measurements is consistent with the accepted capability of that type of device. The Permittee shall keep records of flow measurement device calibration on file for a period of at least three years. At a minimum, data to be included in this documentation shall be: a. Date of flow measurement device calibration b. Name of person performing calibration c. Percent from true flow The effluent from the subject facilities shall be monitored by the Permittee at the point prior to irrigation every Marcia, July, and November for the following parameters: NH3 as N NO2-NO3 Total Coliform BODS TKN Total Phosphorous TSS Sodium Magnesium H Calcium Sodium Adsorption Ratio by Calculation Chloroform Total Organic Carbon JPlant Available Nitrogen (PAN) (by calculation} 4. Samples shall be collected monthly from the surface waters at the four Iocations previously identified as VP -I, VP -2, VP -3, and VP -4 and analyzed by a certified laboratory for the following parameters: NH3 as N Total Coliform Total Organic Carbon (TOC) TKN Nitrate 5. The Permittee tracking the amount of wastewater disposed shall maintain adequate records. These records shall include, but are not necessarily limited to, the following information: a. Date of irrigation, b. Volume of wastewater irrigated, c. Field irrigated, d. Length of time field is irrigated, e. Continuous weekly, monthly, and year-to-date hydraulic (inches/acre) loadings and nitrogen (lbs PAN/acre) loadings for each field, f. Weather conditions, g. Maintenance of cover crops, h. Abnormalities for each field (e.g., ponding, runoff, etc.), i. Collection of samples (wastewater and/or surface water) for analysis, j. Any maintenance performed on the wastewater treatment and/or irrigation system, and k. The solids level within each lagoon shall be .measured and recorded annually. 4 6. Three (3) copies of all monitoring data [as specified in Conditions III(2) and I11(3)] on Form NDMR- I and three (3) copies of all operation and disposal records [as specified in Conditions IU(4) and HI(5)] on Form ND.A_R-1 shall be submitted on or before the last day of the following month. All information shall be submitted to the following address: Division of Water Quality Information Processing Unit 1617 Mail Service Center Raleigh, North Carolina 27699-1617 7. An annual representative soils analysis (Standard Soil Fertility Analysis) shall be conducted on each irrigation field and the results maintained on file by the Permittee for a minimum of five years. The Standard Soil Fertility Analysis shall include, but is not necessarily limited to, the following parameters. Acidity Manganese Potassium Calcium Percent Humic Matter Sodium Copper PH Zinc Magnesium Base Saturation (by calculation) Phosphorus Cation Exchange Capacity I Exchangeable Sodium Percentage 8. The exchangeable sodium percentage (ESP) shall be monitored on the spray irrigation sites using the results from the annual soils analysis. The local Extension Office, the Department of Agriculture, the Natural Resource Conservation Service or a North Carolina Licensed Soil Scientist will review the results and make recommendations to adjust the spray irrigation fields as necessary to ensure they continue to function properly. 9. Noncompliance Notification: The Permittee shall report by telephone to the Wilmington Regional Office, telephone number (9 10) 796-7215, as soon as possible, but in no case more than 24 hours or on the next working day following the occurrence or first knowledge of the occurrence of any of the following: a. Any occurrence at the wastewater treatment facility which results in the treatment of significant amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents of a sludge digester; the known passage of a slug of hazardous substance through the facility; or any other unusual circumstances. b. Any process unit failure, due to known or unknown reasons, that render the facility incapable of adequate wastewater treatment such as mechanical or electrical failures of pumps, aerators, compressors, etc. c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to receiving waters without treatment of all or any portion of the influent to such station or facility. d. Any time that self-monitoring information indicates that the facility has gone out of compliance with its permit limitations. Occurrences outside normal business hours may also be reported to the Division's Emergency Response personnel at telephone number (800) 662-7956, (800) 858-0368, or (919) 733-3300. Persons reporting such occurrences by telephone shall also file a written report in letter form within five (5) days following first knowledge of the occurrence. This report must outline the actions taken or proposed to be taken to ensure that the problem does not recur. IV. GROUNDWATER REQUIREMENTS 1. Sampling Criteria: a. Monitor well(s) MW -1, MW -2, MW -4, MW -6, MW -7, and MW -8 (in the vicinity of spray fields 1,2,3,5) and monitor wells MW -10, MW -11, MW -12, and MW -13 (in the vicinity of spray fields 6,7,8,9), as depicted on the attached site maps, shall be sampled every March, July, and November for the parameters listed below. Prior to sampling the parameters, the measurement of water levels must be taken. The depth to water in each well shall be measured from the surveyed point on the top of the casing. The measuring points (top of well casing) of all monitoring wells shall be surveyed relative to a common datum. Chloride Total Ammonia Fecal Coliforms Total Dissolved Solids (TDS) Nitrate (NO3 as N) Total Organic Carbon (TOC) PH Total Phosphorus Sodium Water Level Sulfate Volatile Organic Compounds (VOS) — In November only b. For Total Organic Carbon (TOC), if concentrations greater than 10 mg/l are detected in any down - gradient monitoring well, additional sampling and analysis must be conducted to identify the individual constituents comprising this TOC concentration. If the TOC concentration as measured in the background monitor well exceeds 10 mg/l, this concentration will be taken to represent the naturally occurring TOC concentration. Any exceedances of this naturally occurring TOC concentration in the down -gradient wells shall be subject to the additional sampling and analysis as described above. c. For Volatile Organic Compounds (VOCs) sampled in November, use only one of the following methods: 1) Standard Method 6230D, Practical Quantitation Limit (PQL) at 0.5 ug/L or less 2) Standard Method 6210, PQL at 0.5 ug/L or less 3) EPA Method 8021, Low Concentration, PQL at 0.5 ug/L or less 4) EPA Method 8260, Low Concentration, PQL at 0.5 ug/L or less 5) Another method with prior approval by the Groundwater Section Chief. Any of the referenced methods used for VOCs must at a minimum, include all the constituents listed in Table VIII of Standard Method 6230D. Any method used must provide a PQL of 0.5 ug/L or less, which must be supported by laboratory proficiency studies as required by the DWQ Laboratory Certification Unit. Any constituents detected above the Method Detection Limit (MDL) but below the PQL of 0.5 ug/L must be qualified (estimated) and reported. d. Any laboratory selected to analyze parameters must be Division of Water Quality (DWQ) certified for those parameters required. 2. Reporting / Documentation: a. Ail reports and documentation (GW -1, GW -30, GW -59) shall be mailed to the following address: Division of Water Quality Information Processing Unit 1617 Mail Service Center Raleigh, North Carolina 27699-1617 Updated blank forms (GW -1, GW -30, GW -59) may be downloaded from the Groundwater Section's website at ht -HRw.ehnr.state.nc.us/ or requested from the address mentioned above. b. The results of the sampling and analysis must be received on Form GW -59 (Groundwater Quality Monitoring: Compliance Report Foran) by the Groundwater Section (address listed in the "Reporting / Documentation" section of the Groundwater Requirements), on or before the last working day of the month following the sampling month. The data of all groundwater sampling analyses required by tb- permit conditions must be reported using the most recent GW -59 form along with attached copies of th, laboratory analyses. 3. Vertical Separation Requirements: a. Industrial waste shall not be applied or discharged onto or below the land surface when the vertical separation between the waste and the seasonal high water table is less than three (3) feet, unless the permittee has demonstrated to the Director or his delegate, by using predictive calculations or modeling methods acceptable to the Director or his delegate, that such placement will not result in the contravention of classified groundwater standards. Verification of the water table elevation can be confirmed by water level readings obtained from the monitor wells at the sites, within 24 hours prior to application of wastewater. 4. Applicable Boundaries: a. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L, Groundwater Classifications and Standards. The Compliance Boundary for the disposal system individually permitted on or after December 30, 1983 is established at either 250 feet from the waste disposal area, or 50 feet within the property boundary, whichever is closest to the waste disposal area. An exceedance of Groundwater Quality Standards at or beyond the Compliance Boundary is subject to remediation action according to 15A NCAC 2L .0106(d)(2). b. The REVIEW BOUNDARY is established around the disposal systems midway between the Compliance Boundary and the perimeter of the waste disposal area. Any exceedance of standards at the Revie- Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1). 5. Additional Requirements: a. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided. V. INSPECTIONS L Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper operation of the subject facilities. 2. The Permittee or his designee shall inspect the wastewater treatment and disposal facilities to prevent malfunctions and deterioration, operator errors and discharges which may cause or lead to the release of wastes to the environment, a threat to human health, or a nuisance. The Permittee shall keep an inspection log or summary including at least the date and time of inspection, observations made, and any maintenance, repairs, or corrective actions taken by the Permittee. This log of inspections shall be maintained by the Permittee for a period of three years from the date of the inspection and shall be made available upon request to the Division or other permitting authority. 3. Any duly authorized officer, employee, or representative of the Division may, upon presentation of credentials, enter and inspect any property, premises or place on or related to the disposal site or facility at any reasonable time for the purpose of determining compliance with this pen -nit; may inspect or copy any records that must be maintained under the terms and conditions of this permit, and may obtain samples of groundwater, surface water, or leachate. VI. GENERAL CONDITIONS 1. This permit shall become voidable unless the facilities are constructed in accordance with the conditions of this permit, the approved plans and specifications, and other supporting data. 2. This permit is effective only with respect to the nature and volume of wastes described in the application and other supporting data. 3. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there is a name change of the Permittee, a formal permit request must be submitted to the Division accompanied by an application fee, documentation from the parties involved, and other supporting materials as may be appropriate. The approval of this request will be considered on its merits and may or may not be approved. 4. Failure to. abide by the conditions and limitations contained in this permit may subject the Permittee to an enforcement action by the Division in accordance with North Carolina General Statute 143- 215.6A to 143-215.6C. 5. The issuance of this permit does not exempt the Permittee from complying with any and all statutes, rules, regulations, or ordinances which may be imposed by other government agencies (Iocal, state, and federal) which have jurisdiction, including but not limited to applicable river buffer rules in 15A NCAC 2B .0200, erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General Permit NCG010000, and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 2H.0500. 6. The Permittee shall retain a set of approved plans and specifications for the life of the project. 7. The Permittee must pay the annual administering and compliance fee within thirty (30) days after being billed by the Division. Failure to pay the fee accordingly may cause the Division to initiate action to revoke this permit as specified by 15A NCAC 2H.0205 (c)(4). 8. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its extension. Upon receipt of the request, the Commission will review the adequacy of the facilities described therein, and if warranted, will extend the permit for such period of time and under such conditions and limitations as it may deem appropriate. 9. The Permittee shall advise the Wilmington Regional Office in writing of the name of the designated farm manager and the alternate farm manager. Any change in these assignments shall be promptly reported in writing to the Wilmington Regional Office. 10. The farm manager shall be provided with a copy of this permit and shall keep the permit updated with any and all modifications or changes as they occur. Permit issued this the/fth day of November, 2005 NORTH AL MANAGEMENT COMMISSION ,,Alan W. Klimek, P.E., Director Division of Water Quality By Authority of the Environmental Management Commission Permit Number WQ0000485 i 1. 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