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HomeMy WebLinkAboutWQ0003760_Final Permit_19950228State of North Carolina Department of Environment, Health and Natural Resources ` MI.WTVA IT Division of Environmental Management James B. Hunt, Jr., Governor !L1 ��� Jonathan B. Howes, Secretary p E H N Ft A. Preston Howard, Jr., P.E., Director February 28, 1995 Mr. Arthur J. Toompas, Manager, Water and Air Resources Cone Mills Corporation 1201 Maple Street Greensboro, North Carolina 27405 Subject: Permit No. WQ0003760 Cone Mills Corporation Guilford County Farm Site Residuals Spray Irrigation Guilford County Dear Mr. Toompas: In accordance with the amendment request received February 14, 1995 from Mr. John L. Hodges with the Cone Mills Corporation, we are forwarding herewith Permit No. WQ0003760, dated February 28, 1995, to the Cone Mills Corporation for the continued operation of a wastewater residuals land application program. The permit amendment was requested to correctly identify the fields which the hog waste and prison sanitary waste could be applied under Permit No. WQ0000949. The fields numbers have been changed in Condition No. VI from Fields 9 and 10 to Fields 5 and 6. No other conditions in this permit have been amended. This permit shall be effective from the date of issuance until February 29, 1996, shall hereby void Permit No. WQ0003760 issued March 31, 1993, 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 30 days following receipt of this permit. This request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447, Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding. If you need additional information concerning this matter, please contact Mr. Michael D. Allen at (919) 733-5083. Sincerely, Oak& A. Prest Howard, Jr., P.E. cc: Guilford County Health Department Winston-Salem Regional Office, Water Quality Winston-Salem Regional Office, Groundwater Groundwater Section, Jack Floyd Training and Certification Unit (no revised rating) Facilities Assessment Unit P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone 919-733-5083 FAX 919-733-9919 An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES RALEIGH SPRAY 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 Cone Mills Corporation Guilford County FOR THE continued operation of a 0.1 MGD waste sludge land disposal facility consisting of two 3 MG aerated holding lagoons, irrigation pumps, and approximately 591 acres of disposal area to serve Cone Mills Corporation with no discharge of wastes to the surface waters, pursuant to the amendment request received February 14, 1995 from Mr. John L. Hodges with the Cone Mills Corporationqw, and in conformity with the project plan, specifications, and other supporting data subsequently filed and approved by the Department of Environment, Health and Natural Resources and considered a part of this permit. This permit shall be effective from the date of issuance until February 29, 1996, shall hereby void Permit No. WQ0003760 issued March 31, 1993, and shall be subject to the following specified conditions and limitations: I. PERFORMANCE STANDARDS 1. The spray 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 perform satisfactorily, including the creation of nuisance conditions or failure of the irrigation area to adequately absorb the wastewater, the Permittee shall take such immediate corrective action to correct the problem, including actions as may be required by the Division of Environmental Management. 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. Diversion or bypassing of the untreated wastewater from the treatment facilities is prohibited. 4. 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 drainageways or surface water bodies, e) 50 feet between wetted area and public right of ways, f) 100 feet between wastewater treatment units and wells, g) 50 feet between wastewater treatment units and property lines, h) 10 feet from upslope interceptor drains and surface water diversions, i) 25 feet from downslope interceptor drains, surface water diversions, groundwater drainage systems and surface drainage ditches. 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 which 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 spray 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. 5. This permit shall become voidable if the soils fail to adequately absorb the wastes and may be rescinded unless the sites are maintained and operated in a manner which will protect the assigned water quality standards of the surface waters and ground waters. 6. In the event that the land application program is not operated satisfactorily, including the creation of nuisance conditions, the Permittee shall cease applying sludge to the sites and take any immediate corrective actions, including the construction of additional or replacement wastewater treatment or disposal facilities. 7. No crops for direct human consumption shall be raised on these sites for a period of 18 months following sludge application. 8. Maximum slope for liquid sludge application shall be 6% unless terraces are constructed to prevent runoff. 9. A copy of this permit shall be kept at the land application site when sludge is being applied during the life of this permit. A spill prevention and control plan shall be kept in all sludge transport and application vehicles. 10. All sludges included in this permit must be stabilized by a process to significantly reduce pathogens (as described in 40 CFR Part 257, Appendix II) prior to application or incorporation. An evaluation of all sludges as specified in condition HA must be conducted as to their ability to demonstrate compliance with this requirement. Condition I. 10 of the April 4, 1991 permit requires that this report be submitted to the Division within six (6) months of the permit issue date. This due date for this report was October 4, 1991, and it has not been received. A copy of this report must be submitted to the Assistant Chief for Operations, Division of Environmental Management, Water Quality Section, Operations Branch, PO Box 29535, Raleigh, NC 27626-0535 within 30 days of your receipt of this permit. 11 _ Specific sludge application area boundaries shall be clearly marked on each site prior to and during sludge application. 2 II. OPERATION AND MAINTENANCE REQUIREMENTS 1. The facilities shall be properly maintained and operated at all tunes. 2. Upon classification of the facility by the Certification Commission, the Permittee shall employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the wastewater treatment facilities. The operator must hold a certificate of the type and grade at least equivalent to or greater than the classification assigned to the wastewater treatment facilities by the Certification Commission. The Permittee must also employ a certified back-up operator of the appropriate type and grade to comply with the conditions of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at least weekly and each Class II, III, and IV facility at least daily, excluding weekends and holidays, and must properly manage and document daily operation and maintenance of the facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202. 3. A suitable vegetative cover shall be maintained. 4. The application rates shall not exceed the following for the specified crops: Cron PAN (lb./acrelyr) Alfalfa 250 Blue Grass 220 Coastal Bermuda Grass 350 Corn (Silage & Grain) 200 Cotton 100 Fescue 250 Forest (Hardwood & Softwood) 75 Small Grain (Wheat, barley, mild, oats) 100 Sorghum 120 Soybeans 150 Sudex (Hay) 160 Sudex (Silage) 200 Timothy, Orchard, & Rye Grass 200 5. Irrigation shall not be performed during inclement weather or when the ground is in a condition that will cause runoff. 6. Adequate measures shall be taken to prevent wastewater runoff from the spray field. 7. 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. 8. The application rate shall not exceed: a) 1 inch per hour on cultivated crop land, b) 0.75 inch per hour on forage/pasture land, and c) 1 inch per acre per week on all sites. 9. No type of wastewater other than that from Cone Mills Corporation and hog waste from the Guilford County Farm shall be sprayed onto the irrigation area. 10. No traffic or equipment shall be allowed on the disposal area except while installation occurs or while normal maintenance is being performed. 11. 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. 12. The lifetime heavy metal loadings shall not exceed the following for the corresponding Cation Exchange Capacities (CEC): Lifetime Loadinzs 1 acre Parameter CEC < 5 CEC 5 - 15 CEC > 15 Lead 500 1000 2000 Zinc 250 500 1000 Copper 125 250 500 Nickel 125 250 500 Cadmium 4.5 9 18 13. Adequate procedures shall be provided to prevent surface runoff from carrying any disposed or stored sludge material into any surface waters. 14. Animals shall not be grazed on sludge applied land within a 30-day period following the sludge application. Application sites that are to be used for grazing shall have fencing that will be used to prevent access after each application. 15. Surface applied sludge will be plowed or disced within twenty-four (24) hours after application on lands with no cover crop established. 16. For areas that are prone to flooding or within the 100-year flood elevation, sludge may be applied only during periods of dry weather. The sludge must be incorporated into the soil within twenty-four (24) hours of application. 17. Appropriate measures must be taken to control public access to the land application sites during active site use and for the 12-month period following the last sludge application event. Such controls may include the posting of signs indicating the activities being conducted at each site. 18. Adequate provisions shall be taken to prevent wind erosion and surface runoff from conveying pollutants from the sludge application area onto the adjacent property or into the surface waters. 19. Sludge shall not be applied in inclement weather or until 24 hours following a rainfall event of 1/2-inch or greater in 24 hours. Any emergency sludge disposal measures must first be approved by the Division of Environmental Management. 20. The site shall be adequately limed to a soil pH of at least 6.5 prior to sludge application. Sludge may be applied to sites with a pH of less than 6.5 provided a sufficient amount of lime is also applied to achieve a final pH of the lime, sludge and soil mixture of at least 6.5. 21. A compacted clay liner of at least four to six inches in thickness shall be maintained over the protruding rock formation on the sides and bottom of the holding basins. MONITORING AND REPORTING REQUIREMENTS i . Any monitoring (including groundwater, surface water, soil or plant tissue analyses) deemed necessary by the Division of Environmental Management to insure surface and ground water protection will be established and an acceptable sampling reporting schedule shall be followed. 4 2_ Adequate records shall be maintained by the Permittee tracking the amount of wastewater from Cone Mills Corporation and the amount of hog waste from the Guilford County Farm disposed. These records shall include, but are not necessarily limited to, the following information: a) date of irrigation, b) volume of sludge applied in gallons/acre and dry tons/acre, 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) weather conditions, g) soil conditions, h) type of crop or crops to be grown on field, i) annual and cumulative totals of dry tons/acre of sludge, annual and cumulative pounds/acre of each heavy metal (which shall include, but not be limited to, lead, nickel, cadmium, copper, and zinc), annual pounds/acre of plant available nitrogen (PAN), and annual poundslacre of phosphorus applied to each field. 3. The digester shall be monitored once per month, prior to sludge removal, during any calendar month that sludge is removed for transport to the Guilford County Farm. The analysis shall include, but is not limited to, the following parameters: Ammonia Zinc Total K}eldhal Nitrogen Copper Phosphorus Nickel Cadmium Suspended Solids - analysis three times per week when sludge is withdrawn 4. Each lagoon shall be sampled on a quarterly basis for a total of eight samples per year. The sludge analysis shall include but is not necessarily limited to the following parameters: total solids Magnesium Chlorides Sulfate Phosphorus Potassium Lead Zinc Copper Nickel Cadmium Chromium Sodium Calcium Total Nitrogen Ammonia Nitrogen Nitrate/Nitrite Nitrogen pH Plant Available Nitrogen (by calculation) The samples from the two lagoons shall not be intermixed. 5. An annual Toxicity Characteristics Leaching Procedure (TCLP) analysis for the digester shall be conducted by the Permittee and the results maintained on file by the Permittee for a minimum of five years. A representative sample shall be collected and analyzed. The TCLP analysis shall include the following parameters: Arsenic Barium Benzene Cadmium Carbon tetrachloride Chlordane Chlorobenzene Chloroform Chromium o-Cresol m-Cresol p-Cresol Cresol 2,4-D 1,4-Dichlorobenzene 1,2-Dichloroethane 1,1-Dichloroethylene Endrin Hexachlorobenzene Hexachloroethane Lindane Methoxychlor Nitrobenzene Pyridine Silver Toxaphene 2,4,5-Trichlorophenol 2,4,5-TP (Silvex) 2,4-Dinitrotoluene Heptachlor (and its hydroxide) Hexachloro-1,3-butadiene Lead Mercury Methyl ethyl ketone Pentachlorophenol Selenium Tetrachloroethylene Trichloroethylene 2,4,6-Trichl orophenol Vinyl chloride 6. A representative annual soils analysis (Standard Soil Fertility Analysis) shall be conducted of each site receiving sludge in the respective calendar year 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: % Base Saturation Magnesium Phosphorus Potassium Leadl Zinc pH Manganese Cation Exchange Capacity Sodium Nickell Cadmiuml Copper Calcium 1 Soils analysis for these parameters shall be conducted once prior to permit renewal on soils from each site which has received sludge during the permit cycle. 7. Surface waters shall be monitored once per month for three months following an application of sludge. A sample should also be collected following a significant rainfall event that may cause runoff. The samples should be analyzed for the following parameters: Total Kjeldhal Nitrogen Zinc Nitrite Copper Nitrate Nickel Phosphorus Cadmium pH Chromium 8. Three copies of all monitoring and reporting requirements as specified in conditions III 1, 1112, 1113, III 4,1115, III 6, and III 7 shall be submitted annually on or before March 1 of the following year to the following address: NC Division of Environmental Management Water Quality Section Facility Assessment Unit PO Box 29535 Raleigh, NC 27626-0535 0 IV. 9. Noncompliance Notification: The Permittee shall report by telephone to the Winston-Salem Regional Office, telephone no. (919) 761-2351, 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 with the land application program which results in the land application of significant amounts of wastes which are abnormal in quantity or characteristic- b. Any failure of the land application program resulting in a release of sludge material to receiving waters. c. Any time that self -monitoring information indicates that the facility has gone out of compliance with the conditions and limitations of this permit or the parameters on which the system was designed. d. Any process unit failure, due to known or unknown reasons, that renders the facility incapable of adequate sludge treatment. e. Any spillage or discharge from a vehicle or piping system transporting sludge to the application site. Persons reporting such occurrences by telephone shall also file a written report in letter form within 15 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. GROUNDWATER REQUIREMENTS As specified in Permit No. WQ0003760 issued April 4, 1991, four (4) monitor wells, one (1) upgradient and three (3) downgradient, shall be installed to monitor groundwater quality. The wells shall be constructed such that the water level in the well is never above or below the screened (open) portion of the well at any time during the year. The wells shall be constructed generally in the locations shown on the map attached to the April 4, 1991 permit, however, the exact location and construction details for these wells shall be approved by the Winston-Salem Regional Office, from which a well construction permit must be obtained. 2. The monitor wells must be sampled initially after construction and thereafter every April, August, and December for the following parameters: NO3 TOC Ammonia Nitrogen Water Level S 04 NO2 Nickel Zinc Volatile Organic Compounds - TDS pH Chlorides Total Coliforms Total Suspended Solids Cadmium Fecal Coliforms In December only (by Method 1 or Method 2 below) Method 1: Method 6230D (Capillary - Column), "Standard Methods for the Examination of Water and Wastewater", 17th edition, 1989 Method 2: Method 502.2 " Methods for the Determination of Organic Compounds in Drinking Water", United States Environmental Protection Agency - 600/4-88/039 The measurement of water level must be made prior to sampling for the remaining parameters. The measuring points (top of well casing) of all monitoring wells shall be surveyed to provide relative elevations of the measuring point for each of the monitoring wells. The depth of water in each well shall be measured from the surveyed point on the top of the casing. If TOC concentrations greater than 10 mg/1 are detected in any downgradient 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 mgll, this concentration will be taken to represent the naturally occurring TOC concentration. Any exceedances of this naturally occurring TOC concentration in the downgradient wells shall be subject to the additional sampling and analysis as described above. If any volatile organic compounds are detected by method 6230D, or the equivalent method 502.2, then EPA methods 604 and 611 must also be run to detect other organic compounds which may be present. The results of all analysis specified in the monitoring requirements, including 604 and 611 if required, must be submitted simultaneously. The results of the sampling and analysis shall be sent to the N.C. Division of Environmental Management on Form GW-59 (Compliance Monitoring Report Form) every May, September, and January 3. The Compliance Boundgy delineated on the attached site plan for the disposal system is specified by regulations in 15A NCAC 2L, Classifications and Water Quality Standards applicable to the groundwater of North Carolina. An exceedance of Groundwater Quality Standards beyond the Compliance Boundary is subject to penalty provisions applicable under General Statute 143-215.6A. The sale of property, by the Permittee, which is within or contiguous to the disposal system site may alter location of the Compliance Boundary. For facilities permitted prior to December 30, 1983, the Compliance Boundary is established at the lesser of 500 feet from the waste disposal area, or the property boundary, whichever is less. If the title to any property which may affect the location of the Compliance Boundary is changed, the permittee shall notify the Division Director within 14 days. The Director shall then establish a modified Compliance Boundary which will be done as a modification to the Permit. The REVIEW BQUNDARY. for the disposal system is specified by regulations in 15A NCAC 2L, Groundwater Classifications and Standards. A REVIEW_ BOUNDARY is established around disposal systems midway between the Compliance Boundary and the perimeter of the waste disposal area. When the concentration of any substance equals or exceeds the maximum allowable concentration of that substance at the REVIEW BOUNDARY, as determined by monitoring, the permittee shall either (i) demonstrate, through predictive calculations or modeling, that natural site conditions, facility design and operational controls will prevent a violation of standards at the Compliance Boundary; or, (ii) submit a plan for the alteration of existing site conditions, facility design or operational controls that will prevent a violation of standards at the Compliance Boundary, and implement that plan upon its approval by the Director. 4. No land application of waste activities shall be undertaken when the seasonal high water table is less than three (3) feet below land surface. 5. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided. V . INSPECTIONS 1. 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 of Environmental Management or other permitting authority. 3. Any duly authorized officer, employee, or representative of the Division of Environmental Management may, upon presentation of credentials, enter and inspect any property, premises or place on or related to the disposal site and facility at any reasonable time for the purpose of determining compliance with this permit; may inspect or copy any records that must be kept under the terms and conditions of this permit; or may obtain samples of groundwater, surface water, or leachate. VL GENERAL CONDITIONS This permit is effective only with respect to the nature and volume of wastes described in the application and other supporting data. 2. This permit shall become voidable unless the land application activities are carried out in accordance with the conditions of this permit and in the manner approved by this Division, 3. This permit shall become voidable unless the agreements between the Permittee and the landowners/lessees are in full force and effect. 4. The following are approved sites for sludge application (see approved map submitted with the April 4, 1991 permit). Application area is listed in acres, excluding buffers. Site No. Owner/Lessee Application Area 1 Guilford County Farm 30 2 Guilford County Farm 18 3 Guilford County Farm 52 4A & 4B Guilford County Farm 51 5* Guilford County Farm 35 6* Guilford County Farm 20 7A & 7B Guilford County Farm 10 S Guilford County Farm 12 11 Guilford County Farm 6 12A & 12B Guilford County Farm 22 13 Guilford County Farm 3 14A & 14B Guilford County Farm 8 15A & 15B Guilford County Farm 36 16 Guilford County Farm 17 17 Guilford County Farm 6 Site No. Owner/Lessee Application Area 18A & 18B Guilford County Farm 21 19 Guilford County Farm 15 20 Guilford County Farm 15 21 Guilford County Farm 12 22 Guilford County Farm 30 23 Guilford County Farm 10 24 Guilford County Farm 17 25 - 29 Guilford County Farm 49 30 Guilford County Farm 14 31 Guilford County Farm 2 32 Guilford County Farm 56 33 Guilford County Farm 2 34 Guilford County Farm 5 35 Guilford County Farm 7 36 Guilford County Farm 10 Total Available Acres 591 * Sites 5 and 6 are not approved for application of sludge by Cone Mills Corporation. They are utilized for hog production and domestic waste sludge application by the Guilford County Farm. 5 . Over the road tankers or transport vehicles shall not be utilized to apply sludge. Only the permitted spray system or vehicles approved by the Division's Winston-Salem Regional Office shall be utilized for application. 6. A set of approved documents for the subject project must be retained by the applicant for the life of the permit. 7. This permit may be modified, or revoked and reissued to incorporate any conditions, limitations and monitoring requirements the Division of Environmental Management deems necessary in order to adequately protect the environment and public health. 8. 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 of Environmental Management 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. 9. Failure to abide by the conditions and limitations contained in this permit may subject the Permittee to an enforcement action by the Division of Environmental Management in accordance with North Carolina General Statute 143-215.6A to 143-215.6C. 10. The issuance of this permit does not preclude 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) which have jurisdiction. 11. Prior to any transfer of this land, a notice shall be given to the new owner that gives full details of the materials applied at this site. 12. The annual administering and compliance fee must be paid by the Permittee within thirty 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). 10 13. 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. Permit issued this the twenty-eighth day of February, 1995 NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION LU A. Preston ward, Jr., P.E. Director Division of aviroamental Management By Authority of the Environmental Management Commission Permit Number WQ0003760 11