WQ0000961_Final Permit_20090715

A F.X MA
NCDENR
North Carolina Department of Environment and
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins
Governor Director
July 15, 2009
Max E. Hopkins, Senior Staff Engineer
R.J. Reynolds Tobacco Company
Post Office Box 2959
Winston-Salem, North Carolina 27102-2959
Dear Mr. Hopkins:
Natural Resources
Dee Freeman
Secretary
Subject: Permit No, WQ0000961
R.J. Reynolds Tobacco Company
Davie County Storage Facility
Wastewater Irrigation System
Forsyth County
In accordance with your permit modification request received April 27, 2009, we are forwarding
herewith Permit No. WQ0000961, dated July 15, 2009, to R.J. Reynolds Tobacco Company for the
continued operation of the subject wastewater treatment and surface irrigation facilities.
The subject permit has been modified to reflect a change in the effluent limit from 60,000 gallons
per day to 10,000 gallons per day as a result of the combined waste stream of domestic and industrial
waste being reduced to only domestic waste. Please note that the frequency of effluent sampling for most
parameters is being reduced from monthly to three times a year as a result of the decreased flow rate.
Please note that a future resumption of the previous flow rate will require a separate permit modification
that may entail an engineering review.
This permit shall he effective from the date of issuance until August 31, 2013, shall void Permit
No. WQ0000961 issued September 30, 2008 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.
Please note the setback distances described under Permit Condition I1.10. It is the Division's
understanding that all of these setbacks have been met. If there appears to be a conflict, please contact the
Aquifer Protection Section.
Please also note that since the last permit issuance, the Division has instituted a new
monitoring policy for all non -discharge systems and created a new permit shell, Please pay careful
attention to the monitoring frequencies and parameters listed in Attachment A, as they may differ
from the requirements and frequencies in the last permit issuance
AQUIFER PROTECTION SECTION
1636 Mail Service Center, Raleigh, North Carolina 27699-1636
Location: 2728 Capital Boulevard, Raleigh, North Carolina 27604
Phone: [phone] FAX 1: 919-795-0588; FAX 2: 919-71560481 Customer Service: 1-877-623-6748
Internet: Wrrruv,ncau8tereual0.o!2
An Equal Opportunity 1 Affirmative Action Employer
One
Nor thCarolina
NaA M711Y

Max E. Hopkins, P.F.
July 15, 2009
Page 2 of 2
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 150B 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 contact David Goodrich at (919) 715-
6162 or [e-mail].
Sincerely,
for Co een H. Sullins
cc: Forsyth County Health Department
Winston-Salem Regional Office, Aquifer Protection Section
Gail G. Licayan, P.E., Kleinfelder, 313 Gallimore Dairy Road, Greensboro, NC 27409
Christopher W. Hay, E.I., Kleinfelder, 313 Gallimore Dairy Road, Greensboro, NC 27409.
Technical Assistance and Certification Unit
APS Central Files
LAU Files

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
WASTEWATER 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
R.J. Reynolds Tobacco Company
Forsyth County
FOR THE
continued operation of a 10,000 gallon per day (GPD) wastewater treatment and surface irrigation
disposal facility consisting of approximately 135 linear feet of 4 -inch force main, a 20,000 gallon
equalization basin with dual lift pumps, an aeration basin, a clarifier, a sludge holding tank, chlorination
facilities, an effluent holding pond, and spray irrigation facilities to apply treated wastewater to a three
acre spray irrigation field, as 1.05 million gallon holding lagoon with a synthetic liner, a 227 GPM
centrifugal pump with approximately 2,900 linear feet of 4 -inch force main, a 24 -acre irrigation field with
233 sprinklers, 62.5 ft. off center, and all associated piping, valves, and appurtenances to serve the
domestic wastewater stream of the Davie County Storage Facility, with no discharge of wastes to the
surface waters, pursuant to the application received April 27, 2009, 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 August 31, 2013, shall void Permit No.
WQ0000961 issued September 30, 2008, and shall be subject to the following specified conditions and
limitations:
I. SCHEDULES
No later than six months prior to the expiration of this permit, the Permittee shall request renewal of
this permit on official Division forms. Upon receipt of the request, the Division will review the
adequacy of the facilities described therein, and if warranted, will renew the permit for such period of
time and under such conditions and limitations as it may deem appropriate. Please note that Rule 15A
NCAC 02T .0105(d) requires an updated site map to be submitted with the permit renewal
application.
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11. 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 contravention of groundwater or surface water
standards. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions due to improper operation and maintenance, 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, 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 ground
or surface waters resulting from the operation of this facility.
3. The wastewater collection facilities shall be properly maintained and operated at all times. The
Permittee shall maintain compliance with an individual system -wide collection system permit for the
operation and maintenance of these facilities as required by 15A NCAC 02T .0400. If an individual
permit is not required, the following performance criteria shall be met as provided in 15A NCAC 02T
.0403.
a. The sewer system shall be effectively maintained and operated at all times to prevent discharge to
land or surface waters, and any contravention of the groundwater standards or surface water
standards.
b. A map of the sewer system shall be developed and shall be actively maintained.
c. An operation and maintenance plan shall be developed and implemented.
d. Pump stations that are not connected to a telemetry system shall be inspected every day (i.e., 365
days a year). Pump stations that are connected to a telemetry system shall be inspected at least
once per week.
e. High-priority sewers shall be inspected at least once per every six-month period of time.
f. A general observation of the entire sewer system shall be conducted at least once per year.
g. Overflows and bypasses shall be reported to the appropriate Division regional office in
accordance with 15A NCAC 02B .0506(a), and public notice shall be provided as required by
North Carolina General Statute § 143-215.1 C.
h. A grease control program is in place.
i. Right-of-ways and easements are maintained.
j. Inspection and maintenance records shall be maintained for a period of at least three years.
4. Effluent limitations shall not exceed those specified in Attachment A.
5. Application rates, whether hydraulic, nutrient, or other pollutant shall not exceed those specified in
Attachment B.
The Compliance Boundary for the disposal system is specified by rules in 15A NCAC 02L .0100,
Groundwater Classifications and Standards. This disposal system was individually permitted prior to
December 30, 1983; therefore, the Compliance Boundary is established at either 500 feet from the
waste disposal area, or at the property boundary, whichever is closest to the waste disposal area. An
exceedance of groundwater standards at or beyond the Compliance Boundary is subject to
remediation action according to 15A NCAC 02L .0106(d)(2) as well as enforcement actions in
accordance with North Carolina General Statute 143-215.6A through 143-215.6C.
7. The Permittee shall apply for a permit modification prior to any sale or transfer of property that
affects a compliance boundary to establish a new compliance boundary.
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8. In accordance with 15A NCAC 02L .0107(d), no wells, other than monitoring wells, shall be
constructed within the compliance boundary except as provided by 15A NCAC 02L .0107(g).
9. 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 Review
Boundary shall require action in accordance with 15A NCAC 02L .0106.
10. The facilities permitted herein must be constructed according to the following setbacks:
a. The setbacks for Irrigation Sites shall be as follows (all distances in feet):
L Any habitable residence or place of public assembly under separate ownership:
400
ii. Any habitable residence or place of public assembly owned by the Permittee:
200
iii. Any private or public water supply source:
100
iv. Drainage ways or surface waters:
100
v. Groundwater lowering ditches:
100
vi. Surface water diversions:
25
vii. Any well with exception of monitoring wells:
100
viii.Any property line:
150
ix. Top of slope of embankments or cuts of two feet or more in vertical height:
15
x. Any water line from a disposal system:
10
xi. Subsurface groundwater lowering drainage systems:
100
xii. Any swimming pool:
100
xiii. Public right of way:
50
xiv. Nitrification field:
20
xv. Any building foundation or basement:
15
b. The setbacks for Treatment and Storage Units shall be as follows (all distances in feet):
i. Any habitable residence or place of public assembly under separate ownership: 100
ii. Any private or public water supply source: 100
iii. Surface waters: 50
iv. Any well with exception of monitoring wells: 100
v. Any property line: so
III. OPERATION AND MAINTENANCE REQUIREMENTS
1. The facilities shall be properly maintained and operated at all times. The facilities shall be effectively
maintained and operated as. a non -discharge system to prevent the discharge of any wastewater
resulting from the operation of this facility. The Permittee shall maintain an Operation and
Maintenance Plan pursuant to 15A NCAC 02T .0507 including operational functions, maintenance
schedules, safety measures, and a spill response plan.
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 08G .0200. The ORC shall visit
the facilities in accordance with 15A NCAC 08G .0200 or as specified in this permit and shall comply
with all other conditions specified in these rules.
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3. A suitable year round vegetative cover shall be maintained such that crop health is optimized, allows
for even distribution of effluent, and allows inspection of the irrigation system.
4. Adequate measures shall be taken to prevent wastewater ponding or runoff from the irrigation field.
5. Irrigation shall not be performed during inclement weather or when the ground is in a condition that
will cause ponding or runoff.
6. All waste application equipment must be tested and calibrated at least once per permit cycle. Records
of the calibration must be maintained for five years.
7. No type of wastewater other than that from the Davie County Storage Facility 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.
9. 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.
10. The residuals generated from these treatment facilities must be disposed / utilized in accordance with
15A NCAC 02T .1100. The Permittee shall maintain a residual management plan pursuant to 15A
NCAC 02T.0509.
11. Diversion or bypassing of the untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in the wastewater storage facilities shall not be less than two feet at any time.
13. A waste -level gauge to monitor waste levels in the storage pond shall be provided. 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 the lowest point on top of the dam elevations.
14. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum allowable temporary storage elevation on the inside of the
embankment), 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.
W. MONITORING AND REPORTING REQUIREMENTS
1. Any monitoring (including groundwater, surface water, soil or plant tissue analyses) deemed
necessary by the Division to ensure surface and ground water protection will be established and an
acceptable sampling reporting schedule shall be followed.
2. All laboratory analyses for effluent, ground waters, or surface waters shall be made by a laboratory
certified by the Division for the required parameter(s) under 15A NCAC 02H.0800.
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3. Flow through the treatment facility shall be continuously monitored and daily flow values shall be
reported on Form NDMR.
The Permittee shall install and maintain an appropriate flow measurement device consistent with
approved engineering and scientific practices to ensure the accuracy and reliability of flow
measurement. blow 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, and
c. Percent from true flow.
4. The effluent from the subject facilities shall be monitored by the Permittee at the frequencies and
locations for the parameters specified in Attachment A.
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 for each field,
f. Continuous monthly and year-to-date loadings for any non -hydraulic parameter specifically
limited in Attachment B for each field,
g. Weather conditions, and
h. Maintenance of cover crops.
6. Freeboard (waste level to the lowest elevation on the top of the embankment) in the storage lagoon
shall be recorded weekly.
7. A record shall be maintained of all residuals removed from this facility. This record shall include the
name of the hauler, permit authorizing the disposal or a letter from a municipality agreeing to accept
the residuals, date the residuals were hauled, and volume of residuals removed.
S. A maintenance log shall be maintained at this facility including but not Iimited to the following items:
a. Visual observations of the plant and plant site.
b. Record of preventative maintenance (i.e., changing of equipment, adjustments, testing,
inspections and cleanings, etc.).
c. Date of calibration of flow measurement device.
d. Date and results of power interruption testing on alternate power supply.
9. Three (3) copies of all monitoring data [as specified in Conditions IV.3. and TV.4.1 on Form NDMR
for each PPI and three (3) copies of all operation and disposal records [as specified in Conditions IV.5
and TV.6] on Form NDAR-1 for every field shall be submitted on or before the last day of the
following month. If no activities occurred during the monitoring month, monitoring reports are still
required documenting the absence of the activity. 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
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10. 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
Exchangeable Sodium Percentage
11. Noncompliance Notification.
The Permittee shall report by telephone to the Winston-Salem Regional Office, telephone number
[phone], 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 including ponding in the irrigation field or runoff
from the irrigation fields.
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 disposal system resulting in a by-pass directly to receiving waters.
d. Any time that self-monitoring information indicates that the facility has gone out of compliance
with its permit limitations including, but not limited to, freeboard measurements, effluent
limitations, exceedances of groundwater standards, or overloading of any field.
For any emergency that requires immediate reporting (e.g., discharges to surface waters, imminent
failure of a storage structure, etc.) outside normal business hours must be reported to the Division's
Emergency Response personnel at telephone number [phone], [phone], 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.
V. INSPECTIONS
1. Adequate inspection and maintenance shall be provided by the Permittee to ensure 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 Pbrmittee shall keep an
inspection log or summary including at least the date and time of inspection, observati6bs 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 five years from the date of the inspection and shall be
made available upon request to the Division or other permitting authority.
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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 permit; 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. 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.
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.
This. permit is effective only with respect to the nature and volume of wastes described in the
application and other supporting data. No variances to applicable rules governing the construction
and / or operation of the permitted facilities are granted unless specifically requested and granted in
this permit.
4. 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 (local, state,
and federal) that have jurisdiction. Of particular concern to the Division are applicable river buffer
rules in 15A NCAC 02B .0200, erosion and sedimentation control requirements in 15A NCAC
Chapter 4 and under the Division's General Permit NCGO 10000, and any requirements pertaining to
wetlands under 15A NCAC 02B .0200 and 02H.0500.
5. 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 on official Division form(s),
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. The
Permittee of record shall remain fully responsible for compliance until a permit is issued to the new
owner.
6. The Permittee shall retain a set of approved plans and specifications for the life of the facilities
permitted herein.
7. The Permittee shall maintain this permit until all permitted facilities herein are properly closed or
permitted under another permit issued by the appropriate permitting authority.
8. The Permittee must pay the annual 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
pursuant to 15A NCAC 02T .0105(c).
Permit issued this the 15"' day of July, 2009
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
r Cole H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0000961
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ATTACHMENT A - LIMITATIONS AND MONITORING REQUIREMENTS Permit Number: WQ0000961 Version: 3.1
PPI 001— WWTF Influent
EFFLUENT CHARACTERISTICS
EFFLUENT LIMITS
MONITORING
REQUIREMENTS
Parameter Description - PCS Code
Monthly Average
Mean Monthly Geometric
Daily Minimum
Daily Maximum
Measurement
Frequency
Sample
Type
Flow, in conduit or thru treatment plant - 50050
10,000
gpcl
Continuous
Recorder
1.179 11II1YRSIAiAN 1.2Alil
EFFLUENT CEIARACTERISTICS
EFFLUENT LIMITS
MONITORING
REQUIREMENTS
Parameter Description -FCS Code
Monthly Average
Mean Monthly Geometric
Daily Minimum
Daily Maximum
Measurement
Frequency
Sample
Type
Coliform, Fecal MF, M -FC Broth,44.5C - 31616
3 X year
Grab
Nitrite plus Nitrate, Total (as N) - 00630
3 X year
Grab
Phospboroixs, Total (as P) — 00665
3 X year
Grab
SOD, 5 -Day (20 Deg. C) — 00310
3 X year
Grab
Solids, Total Suspended — 00530
3 X year
Grab
Nitrogen, Ammonia Total (as N) — 00610
3 X year
Grab
Nitrogen, Kjeldal, Total (as N) — 00625
3 X year
Grab
pli — 00400
5 X week
Grab
Chlorine, Total Residual — 50060
5 X week
Grab
3 X year sampling wilt he performed in March, July, and November.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
WQ0000961 Version 3.1 Attachment A Page I of 1

ATTACHMENT B - APPROVED LAND APPLICATION SITES AND LIMITATIONS
R.J. Reynolds Tobacco Company — Davie County Storage Facility
Permit Number: WQ0000961 Version: 3.1
IRRIGATION AREA INFORMATION
APPLICATION LIMITA'T'IONS
Field
Owner
County
Latitude Longitude
Net
Acreage
Dominant
Soil Series i
Parameter
Hourly
Rate
Yearly
Max
Units
01
R J R Tobacco — Davie County Stemmery
Davie
35°57'42" 80028'14"
3.00
Enon fine sandy loam
01284 -- Application Surface Irrigation
0.2
52
inches
Total
3.00
WQ0000961 Version 3.1 Attachment B Page I of 1

ID
Ci! R. J. R. Tobacco Company 1O7 `<<
4r Davie County Stemmery
NPDES Permit No. WQ0000351
�\• .
Land Application Site
/ Spray Irrigation Fields
USGS Quad No. D17NW
USQS Quad Name: Advance J_�\
I
FIGURE I
R.J. REYNOLDS TOBACCO COMPANY
DAVIE COUNTY STORAGE FACILITY
GROUNDWATER TREATMENT SYSTEM
DAVIE COUNTY
W00000961
SITE LOCATION MAP
I �
vvn7a
FIGURE I
R.J. REYNOLDS TOBACCO COMPANY
DAVIE COUNTY STORAGE FACILITY
GROUNDWATER TREATMENT SYSTEM
DAVIE COUNTY
W00000961
SITE LOCATION MAP

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FIGURE, 2
Ir
c , R.J. REYNOLDS TOBACCO COMPANY
pT / l7AVIE COUNTY STORAGE FACILITY
GROUNDWATER TREATMENT SYSTEM
DAYIE COUNTY
W 0000961
SITE DETAIL MAP