WQ0005555_Final Permit_20011019

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D., Acting Director
October 19, 2001
MR. JEFFREY D. FICKETT, GENERAL MANAGER
WEYERHAEUSER COMPANY
POST OFFICE Box 590
ELKIN, NORTH CAROLINA 28621
A41IT - ]w
V r
ik"o •
f
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AM> NAruRAL RE50URCE5
Subject: Permit No. WQ0005555
Weyerhaeuser Company
Elkin, NC Oriented Strand Board (OSB)
Manufacturing Facility
Wastewater Treatment and
Spray Irrigation System
Surry County
Dear Mr. Fickett:
In accordance with your application for a minor permit modification received on May 23, 2001 as well as
the additional information received on August 10, 2001 and October 9, 2001, we are forwarding herewith Permit
No. WQ0005555, dated October 19, 2001, to the Weyerhaeuser Company for the modification and continued
operation of the subject wastewater treatment and spray irrigation facilities.
This permit is being modified to approve the connection of two new unit processes associated with new air
pollution control facilities recently installed at Weyerhaeuser Company's Elkin, NC Oriented Strand Board
Manufacturing Facility to the permitted wastewater treatment and spray irrigation facilities:
♦ A maximum of 7,200 gallons per day of wastewater will be contributed by a unit that "dernists" water -
saturated air after it exits a wet electrostatic precipitator. This demisting unit will not result in a net
increase of wastewater requiring treatment and disposal because wastewater effluent is currently being
recycled for use in the wet electrostatic precipitator (i.e., the demisting unit removes and creates water
that was previously wastewater effluent).
♦ Following the demisting unit, dehumidified air enters into a regenerative thermal "oxidizer (RTO) for
additional treatment prior to exhausting. An approximate maximum of 20,000 gallons of water is
required to wash down each side of the RTO on a periodic basis (i.e., currently every four months, but
expected to decrease in frequency). Since the wash -down process must use clean water, this
connection will result in a net increase of wastewater requiring treatment and disposal.
The wastewater from both sources will be collected in an existing 1,250-sump and then conveyed by one of
two existing 200-gallon per minute pumps to an existing 20,000-gallon holding tank. An existing 10-gallon per
minute pump (i.e., a spare pump is on -hand for immediate installation should this simplex operation fail) will be
used to transfer the wastewater from the holding tank directly into the existing flocculating clarifier that is approved
for operation as part of the wastewater treatment and spray irrigation facilities. Note that the facilities are still
permitted for a maximum wastewater treatment/spray irrigation capacity of 28,800 gallons per day and that
the additional wastewater flow volume to be contributed by the two new connections shall not exceed this
approved limit.
1617 Mai( Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/10% post -consumer paper

Please take time review this permit thoroughly. Pay particular attention to the monitoring requirements,
as failure to establish an adequate system for collecting and maintaining the required operational information will
result in future compliance problems. Of special interest is the fact that one additional parameter (i.e., fecal
coliform) and four additional parameters (i.e., chemical oxygen demand, chromium, formaldehyde, and mercury)
have been added to the list of those parameters for which samples taken from the wastewater effluent and the
existing groundwater monitoring wells, respectively, must be analyzed (i.e., see Condition III. 4. and Condition IV.
1. for additional details). The Permittee has historically monitored groundwater samples for the above -listed
parameters, and it has been Division of Water Quality (Division) policy to monitor fecal coliform density in the
wastewater effluent if it is being monitored as part of the groundwater monitoring program. However, these
monitoring parameters were inadvertently omitted from the language of Permit No. WQ0005555 that was issued on
July 12, 2000. These omissions were realized during the review of this minor modification request, and, therefore,
the permit is being corrected accordingly.
This permit shall be effective from the date of issuance until ,dune 30, 2005; shall void Permit No.
WQ0005555, issued on July 12, 2000; and shall be subject to the conditions and limitations as specified therein.
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 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 Ms. Shannon Mohr Thornburg at
[phone], extension 353.
Since ly
.Gregory J. Thorp , Ph.D.
cc: Mr. Gary Ribblett, P.E., Delta Environmental Consultants, Inc.
Surry County Health Department
Winston-Salem Regional Office, Water Quality Section
Winston-Salem Regional Office, Groundwater Section
Central Office, Groundwater Section
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
2

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
WASTEWATER TREATMENT AND 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
Weyerhaeuser Company
Surry County
FOR THE
continued operation of 28,800-gallon per day wastewater treatment .and spray irrigation facilities for the treatment
and disposal of cooling tower blow -down, clean-up waters from the wet electrostatic precipitators, domestic
wastewater, wastewater from the operation of a biofilter, non -contact cooling water, mobile equipment washwater,
demister drop -out box wastewater, and periodic wash -down water from the regenerative thermal oxidizer. The
facilities consist of the following minimum components: three side hill screens; a pH control system to buffer pH
up or down; a defoaming system; a 4,800-gallon surge tank; a polymer addition system for solids removal; a static
mixer•, a 93,508-gallon flocculating clarifier; a 1,400-gallon sludge storage tank; a centrifuge for solids dewatering;
a stand-by vacuum filter system for solids dewatering; a 230,000-gallon anoxic reactor lagoon with a synthetic tarp
cover; a 190,000-gallon aerated pond; a 420,000-gallon storage pond; an additional 840,000-gallon storage pond
with aeration available if needed; a 250-gallon per minute vertical chopper pump; 16 fixed spray nozzles; a portable
irrigation system; 20.4 acres of spray irrigation fields; and all associated piping, valves, and other appurtenances
required to make complete and operational wastewater treatment and spray irrigation facilities to serve
Weyerhaeuser Company's Elkin, NC Oriented Strand Board Manufacturing Facility, with no discharge of wastes to
the surface waters, pursuant to the application received on May 23, 2001 as well as the additional information
received on August 10, 2001 and October 9, 2001, 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 June 30, 2005; shall void Permit No.
WQ0005555, issued July 12, 2000; and shall be subject to the following specified conditions and limitations:
I. PERFORMANCE STANDARDS
The Division of Water Quality's (Division) Winston-Salem Regional Office, telephone number (336)
771-4600, shall be notified at least 48 hours in advance of the initial introduction of wastewater from
the two unit processes associated with new air pollution control facilities that are approved to be
connected to the wastewater treatment and spray irrigation facilities so that an in -place inspection can
be made. Such notification to the Water Quality Supervisor shall be made duringMnormal office hours
(i.e., from 8:00 a.m. until 5:00 p.m.) on Monday through Friday, excluding State Holidays.

2. The wastewater treatment and 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 groundwater that
will render them unsatisfactory for normal use. In the event that these facilities fail to perform
satisfactorily, including the creation of nuisance conditions or failure of the irrigation areas to
assimilate the wastewater effluent adequately, 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.
3. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to surface
waters or groundwater resulting from the operation of the wastewater treatment and spray irrigation
facilities.
4. The residuals generated from the wastewater treatment facilities shall be disposed in accordance with
North Carolina General Statute § 143-215.1 and in a manner approved by the Division.
5. Diversion or bypassing of the untreated wastewater from the wastewater treatment and/or spray
irrigation facilities shall be prohibited.
6. The following buffers shall be maintained by the wastewater treatment and spray irrigation facilities:
a. 400 feet between the wetted area and any residence or place of public assembly under separate
ownership,
b. 150 feet between the wetted area and any property line,
c. 100 feet between the wetted area and any well,
d. 100 feet between the wetted area and any drainageway or surface water body,
e. 50 feet between the wetted area and any public tight -of -way,
f. 100 feet between wastewater treatment units and any well, and
g. 50 feet between wastewater treatment units and any property line.
Some of the buffers specified above may not have been included in previous permits for the wastewater
treatment and spray irrigation facilities. The Permittee does not have to modify previously -approved
facilities to comply with these buffers unless specifically required by the Division to do so, nor are
these buffers intended to prohibit or prevent modifications that may be required by the Division to
improve the performance of the existing facilities. These buffers do, however, apply to modifications
of the system that are for the purpose of increasing the wastewater flow that is tributary to the facilities.
These buffers do apply to any expansion or modification of the facilities and apply in instances in
which the sale of property would cause any of the buffers with which the facilities now comply to be
violated. The Permittee shall be advised that any modification to the existing facilities will require a
permit modification.
II. OPERATION AND MAINTENANCE REQUIREMENTS
The wastewater treatment and spray irrigation facilities shall be properly maintained and operated at all
times.

2. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall employ a
certified wastewater treatment plant operator to be in responsible charge (ORC) of the facilities. The
operator shall hold a certificate of the type and grade at least equivalent to or greater than the
classification assigned to the facilities by the WPCSOCC. The Permittee shall also employ a certified
back-up operator of the appropriate type and grade to comply with the conditions of 15A NCAC 8G
.0202. The ORC shall visit Class I facilities at least weekly and Class 11, 111, and IV facilities at least
daily, excluding weekends and holidays; shall properly manage and document daily operation and
maintenance of the facilities; and shall comply with all other conditions of 15A NCAC 8G .0202.
3. Collected wastewater from washing down of the regenerative thermal oxidizer shall be introduced into
the wastewater treatment and spray irrigation facilities such that the permitted flow limit of the
facilities (i.e., 28,800 gallons per day) is not violated at any time.
4. Freeboard in any lagoon shall not be less than two feet at any time.
S. A suitable year-round vegetative cover shall be maintained.
6. Irrigation shall not be performed during inclement weather or when the ground is in a condition that
will cause runoff.
7. Adequate measures shall be taken to prevent wastewater effluent runoff from the wetted area of the
spray irrigation facilities.
8. The wastewater treatment and spray irrigation facilities shall be effectively maintained and operated as
a non -discharge system to prevent the discharge of any wastewater or wastewater effluent resulting
from the operation of these facilities.
9. The application rate onto the wetted area of the spray irrigation facilities shall not exceed a cumulative
loading of 52.0 inches over any 12-month period at an instantaneous application rate not to exceed 0.25
inches per hour.
10. No type of wastewater effluent other than that from the wastewater treatment facilities serving
Weyerhaeuser Company's Elkin, NC Oriented Strand Board Manufacturing Facility shall be sprayed
onto the wetted area of the spray irrigation facilities.
11. No traffic or equipment shall be allowed on the wetted area of the spray irrigation facilities except
while installation occurs or while normal maintenance is being performed.
12. Public access to the wetted area of the spray irrigation facilities shall be controlled during active use.
Such controls may include the posting of signs that describe the activities being conducted at the
facilities.
III. MONITORING AND REPORTING RE UIREMENTS
I. Any monitoring (i.e., including groundwater, surface water, soil or plant tissue analyses) deemed
necessary by the Division to ensure surface water and groundwater protection shall be established and
an acceptable sampling reporting schedule shall be followed.

2. Influent wastewater flow to the wastewater treatment facilities shall be continuously monitored and
recorded. Daily flow values shall be reported on Form NDMR-I. The Permittee shall install an
appropriate flow measurement device consistent with approved engineering and scientific practices to
ensure the accuracy and reliability of flow measurement. Selected 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.
Calibration records for flow measurement devices shall be kept on file by the Permittee for a period of
at least three years. At a minimum, data to be included in this documentation shall include:
a. Date of device calibration,
b. Name of person performing device calibration, and
c. Percent from true flow that was calculated during device calibration
3. Adequate records shall be maintained by the Permittee tracking the amount of wastewater effluent
disposed onto the wetted area of the spray irrigation facilities. These records shall include, but are not
necessarily limited to, the following information:
a. Date of irrigation;
b. Volume of wastewater effluent irrigated;
c. Field irrigated;
d. Length of time that each field is irrigated;
e. Continuous weekly, monthly, and year-to-date hydraulic (i.e. in inches per acre) loadings for each
field;
f Weather conditions; and
g. Maintenance of cover crops.
4. The wastewater effluent from the wastewater treatment facilities shall be monitored by the Permittee at
the point following all wastewater treatment processes and prior to irrigation every March, July, and
November for the following parameters:
Ammonia -Nitrogen (NH;-N)
Chemical Oxygen Demand (COD)
Calcium
Chlorides
Chromium
Fecal Coliform
Formaldehyde
Magnesium
Mercury
Nitrate -Nitrite -Nitrogen (NO3-NO2-N)
PH
Phenol
Plant Available Nitrogen (By Calculation)
Sodium
Sodium Adsorption Ratio (By Calculation)
Total Dissolved Solids (TDS)
Total Kjeldahl Nitrogen (TKN)
Total Organic Carbon (TOC)
Total Phosphorus
Total Suspended Solids
5. A representative annual soils analysis (i.e., Standard Soil Fertility Analysis) shall be conducted by the
Permittee on soil sample(s) from each field of the spray irrigation facilities. The results of this analysis
shall be maintained on file by the Permittee for a minimum of five years. The Standard Soil Fertility
Analysis shall include, but shall not necessarily be limited to, the following parameters:
Acidity
Base Saturation (by calculation)
Calcium
Cation Exchange Capacity
Copper
Exchangeable Sodium Percentage
Magnesium
Manganese
Percent Hunvc Matter
PH
Phosphorus
Potassium
Sodium
Zinc
4

6. Three copies of all operation and irrigation records (i.e., as specified in Condition III. 3.) shall be
submitted on Form NDAR-1 on or before the last day of the month following the irrigation event.
Three copies of all monitoring data (i.e., as specified in Condition III. 2. and Condition III. 4.) shall be
submitted on Form NDMR-1 on or before the last day of the month following the monitoring/sampling
month. All information shall be submitted to the following address:
NCDENR-DWQ
Water Quality Section
Non -Discharge Compliance/Enforcement Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
7. Noncompliance Notification:
The Permittee shall report by telephone to the Water Quality Section of the Division's 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 facilities that 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 renders the wastewater treatment
and spray irrigation facilities incapable of adequate treatment and disposal such as mechanical or
electrical failures of pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer lint:, or other facility resulting in a bypass 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 wastewater treatment and spray
irrigation facilities have gone out of compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letterform within five
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
Each existing groundwater monitoring well (i.e., MW-4, MW-5, MW-6, MW-7, MW-8, MW-9, MW-
10, MW-11, and MW-12) shall be sampled every March, July, and November for the following
parameters.
Ammonia -Nitrogen (NH3-N) Nitrate -Nitrogen (NO3-N)
Chlorides pH
Chemical Oxygen Demand (COD) Total Dissolved Solids (TDS)
Chromium Total Organic Carbon (TOC)
Fecal Coliform Total Phosphorus
Formaldehyde Water Level
Mercury
Volatile Organic Compounds (VOCs) in November only, which shall be analyzed using one of the
following methods:
(A) Standard Method 6230D (PQL at 0.5 µg/L or less),
(B) Standard Method 6210D (PQL at 0.5 µglL or less),
(C) EPA Method 8021 (Low Concentration, PQL at 0.5 µg/L or Iess),

(D) EPA Method 8260 (Low Concentration, PQL at 0.5 µg/L or less), or
(E) Another method with prior approval by the Groundwater Section Chief.
Any method used shall meet the following qualifications:
(1) The laboratory shall be Division -certified to run any method used.
(2) The method used shall, at a minimum, include all the constituents listed in Table
VIII of Standard Method 6230D.
(3) The method used shall provided a PQL at 0.5 µg/L or less, which shall be
supported by laboratory proficiency studies as required by the Division's
Laboratory Certification Unit. Any constituents detected above the MDL, but
below the PQL at 0.5 µg/L, shall be qualified (estimated) and reported.
If any VOCs are detected by the methods listed, then the Winston-Salem Regional Office Groundwater
Supervisor, telephone number [phone], shall be contacted immediately for further instructions
regarding any additional follow-up analyses required. The results of all initial and follow-up analyses
shall be submitted simultaneously.
If TOC concentrations greater than 10 milligrams per liter are detected in any downgradient
groundwater monitoring well, additional sampling and analysis shall be conducted to identify the
individual constituents comprising this TOC concentration. If the TOC concentration as measured in
the background groundwater monitoring well exceeds 10 milligrams per liter, the concentration shall 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.
The measurement of water levels shall be made prior to sampling the groundwater for the remaining
parameters. The depth to water in each groundwater monitoring well shall be measured from the
surveyed point on the top of the casing.
The measuring points (i.e., top of well casing) of each groundwater monitoring well shall be surveyed
to provide the relative elevation of the measuring point for each well.
The results of the sampling and analysis shall be received on GW-59 Form (i.e., "Groundwater Quality
Monitoring -Compliance Report Form) on or before the last working day of the month following the
sampling month at the following address:
NCDENR-DWQ
Groundwater Section
Permits and Compliance Unit
1636 Mail Service Center
Raleigh, North Carolina 27699-1636
2. The COMPLIANCE BOUNDARY for disposal systems shall be as specified by regulations in 15A
NCAC 2L (i.e., "Groundwater Classifications and Standards"). The Compliance Boundary for disposal
systems individually permitted after December 31, 1983 shall be established at either (1) 250 feet from
the waste disposal area, or (2) 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
shall be subject to immediate remediation action in addition to the penalty provisions applicable under
North Carolina General Statute § 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY shall be established around the disposal
system midway between the Compliance Boundary and the perimeter of the waste disposal area. Any
exceedance of standards at the Review Boundary shall require remediation action on the part of the
Permittee.

Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
V. INSPECTIONS
Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to ensure proper
operation of the wastewater treatment and spray irrigation facilities.
2. The Permittee or his designee shall inspect the wastewater treatment and spray irrigation 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 wastewater treatment
and/or spray irrigation facilities 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. This permit shall become voidable unless the wastewater treatment and spray irrigation facilities are
constructed in accordance with the conditions of this permit, the approved plans and specifications, and
other supporting data.
2. This permit shall be effective only with respect to the nature and volume of wastes described in the
application and other supporting data.
This permit shall not be transferable. In the event there is a desire for the wastewater treatment and
spray irrigation facilities to change ownership, or there is a name change of the Permittee, a formal
permit request shall be submitted to the Division accompanied by documentation from the parties
involved and other supporting materials as may be appropriate. The approval of this request shall be
considered on its merits and may or may not be approved.
4. Failure to abide by the conditions and Iimitations contained in this permit may subject the Permittee to
an enforcement action by the Division in accordance with North Carolina General Statutes § 143-
215.6A through § 143-215.6C.
5. The issuance of this permit shall not preclude the Permittee from complying with any and all statutes,
rules, regulations, or ordinances that may be imposed by other government agencies (i.e., local, state,
and federal) which have jurisdiction, including, but not limited to, applicable river buffer rules in 15A
NCAC 2B .0200, soil erosion and sedimentation control requirements in 15A NCAC Chapter 4 and
under the Division's General Permit NCG0100000, and any requirements pertaining to wetlands under
15A NCAC 2B .0200 and 15A NCAC .0500.
6. A set of approved plans and specifications for the subject project shall be retained by the Permittee for
the life of the wastewater treatment and spray irrigation facilities.
The annual administering and compliance fee shall be paid by the Permittee within 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 months prior to the expiration of this permit, shall request its extension.
Upon receipt of the request, the Division shall review the adequacy of the wastewater treatment and
spray irrigation facilities described therein, and if warranted, shall extend the permit for such period of
time and under such conditions and limitations as it may deem appropriate.
Permit issued this the nineteenth of October, 2001.
NORT AROLINA NVIRONMENTAL MANAGEMENT COMMISSION
,;I-- Gregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0005555