WQ0000485_Compliance Evaluation Inspection_20200921

DocuSign Envelope ID: AAE61 FB1 -C247-440B-9E1 9-851 BDF235CB9
ROY COOPER
Governor
MICHAEL S. REGAN
secretary
S. DANIEL SMITH
Dlreetor
Toby John Schlink
Valley Proteins Inc
PO Box 1026
Rose Hill, NC 28458
NORTH CAROLINA
Envrraningatal Quality
September 21, 2020
SUBJECT: Compliance Inspection Report
Valley Proteins - Rose Hill WWTF
Non -discharge Permit No. WQ0000485
Duplin County
Dear Permittee:
The North Carolina Division of Water Resources conducted an inspection of the Valley Proteins - Rose Hill
WWTF on 9/16/2020. This inspection was conducted to verify that the facility is operating in
compliance with the conditions and limitations specified in Non -discharge Permit No. WQ0000485. The
findings and comments noted during this inspection are provided in the enclosed copy of the inspection
report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the
inspection and therefore, a response to this inspection report is not required.
If you should have any questions, please do not hesitate to contact Bryan Lievre with the Water
Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215 or via email at
[e-mail].
ATTACHMENT
Sincerely,
EW
DocuSigned by:
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Morella Sanchez -King, Regional Supervisor
Water Quality Regional Operations Section
Wilmington Regional Office
Division of Water Resources, NCDEQ
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WilfningtanRegonaIOffiice 1127 CarMaai Dive Extension I Wilra ngton, North Caroina2d34D5
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Compliance Inspection Report
Permit: WQ0000485 Effective: 11/01/19 Expiration: 03/31/25 Owner: Valley Proteins Inc
SOC: Effective: Expiration: Facility: Valley Proteins - Rose Hill WWTF
County: Duplin 469 Yellowcut Rd
Region: Wilmington
Rose Hill NC 28458
Contact Person: Toby John Schlink Title: District Manager Phone: [phone]
Directions to Facility:
From Rose Hill, take Hwy 117 North approx. 0.8 miles to Yellowcut Rd., left to end of road
System Classifications: SI, WW2,
Primary ORC: Corey Myles Lanier Certification: 1007689 Phone: [phone]
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
Inspection Date: 09/16/2020 Entry Time 09:OOAM Exit Time: 11:OOAM
Primary Inspector: Bryan Lievre Phone: [phone]
Secondary Inspector(s):
Reason for Inspection: Routine Inspection Type: Compliance Evaluation
Permit Inspection Type: Wastewater Irrigation
Facility Status: Compliant ❑ Not Compliant
Question Areas:
Treatment Flow Measurement -Effluent Treatment Flow Measurement -Influent Miscellaneous Questions
Treatment Flow Measurement -Water Treatment Record Keeping
Use Records
Treatment Lagoons End Use -Irrigation Treatment Disinfection
Treatment Flow Measurement Standby Power
(See attachment summary)
Page 1 of 6

Permit: WQ0000485 Owner - Facility: Valley Proteins Inc
Inspection Date: 09/16/2020 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Inspection Summary:
A routine compliance inspection of the Valley Protein's wastewater treatment and spray irrigation disposal system was
conducted on September 16, 2020. The purpose of the inspection was to verify that the facility is operating in compliance
with the conditions specified within Permit WQ0000485. Present during the inspection were Corey Lanier, operator for the
system, and myself (Bryan Lievre).
The facility is a rendering plant located at 469 Yellow Cut Road, Rose Hill, NC. The wastewater system is permitted for the
treatment of up to 350,000 gallons per day. The system includes an 0.084 million gallon (MG) process water equalization
tank; 0.05 MG anaerobic reactor tank with floating modular membrane for odor control and heat retention; a dissolved air
flotation (DAF) unit; a 3.5 million gallon (MG) aeration basin (Lagoon 1) with surface aerators; a 1.72 MG complete mixed
activated sludge (CMAS) basin with jet aerators; a secondary DAF unit; a 0.01 MG DAF clarifier cell effluent tank that
pumps to the cooling towers or irrigation storage lagoons; a 0.35 million gallon per day (MGD) reverse osmosis system for
treating internal process recycle wastewater; a sodium hypochlorite feed system at the irrigation pump station; two 2.9 acre
(Lagoon 2 and 3) and one 4.65 acre (Lagoon 4) storage lagoons; and, an 78.99 acre spray irrigation area which is split into
eight fields.
The types of industrial wastewater generated at the facility is either from wash down and truck drainage or cooker
condensate. The effluent from the wastewater treatment system is either disposed of by spray irrigation or evaporated in the
cooling towers. The facility also utilizes recycled wastewater for wash down. Sanitary wastewater generated from the
bathroom facilities at the plant flows into the Town of Rose Hill sewer collection system.
During the recent inspection, freeboard in all of the lagoons was below two feet (2.1' in Lagoon 1, 2.5' in Lagoon 2, 2.4' in
Lagoon 3, and 2.5' in Lagoon 4). Wastewater is pumped from Lagoon 3 to any of the existing eight (8) spray fields (Fields 2
through 9, whereas Field 1 has been closed with the expansion of the process facility) which are located at and in the
vicinity of the site. An updated site map and a water/wastewater flow diagram are recommended.
Records were readily available, organized and complete. The facility is in compliance with Permit WQ0000485. Please
review the comment sections of the inspection report for more details.
Page 2 of 6

Permit: WQ0000485 Owner - Facility: Valley Proteins Inc
Inspection Date: 09/16/2020 Inspection Type: Compliance Evaluation
Reason for Visit: Routine
Type
Yes No NA NE
Recycle/Reuse
❑
Single Family Drip
❑
Activated Sludge Drip, LR
❑
Activated Sludge Spray, HR
❑
Infiltration System
❑
Lagoon Spray, LR
❑
Single Family Spray, LR
❑
Reuse (Quality)
❑
Activated Sludge Spray, LR
Treatment Yes No NA NE
Are Treatment facilities consistent with those outlined in the current permit? 0 ❑ ❑ ❑
Do all treatment units appear to be operational? (if no, note below.) 0 ❑ ❑ ❑
Comment:
Treatment Flow Measurement -Influent
Yes No NA NE
Is flowmeter calibrated annually?
0
❑ ❑ ❑
Is flowmeter operating properly?
❑
❑ ❑
Does flowmeter monitor continuously?
❑ ❑ ❑
Does flowmeter record flow?
❑ ❑ ❑
Does flowmeter appear to monitor accurately?
❑ ❑ ❑
Comment:
Treatment Flow Measurement -Water Use Records Yes No NA NE
Is water use metered? ❑ ❑ ❑
Are the daily average values properly calculated? ❑ ❑ 0 ❑
Comment:
Treatment Flow Measurement -Effluent Yes No NA NE
Is flowmeter calibrated annually? 0 ❑ ❑ ❑
Is flowmeter operating properly? ❑ ❑ ❑
Does flowmeter monitor continuously? ❑ ❑ ❑
Does flowmeter record flow? ❑ ❑ ❑
Does flowmeter appear to monitor accurately? 0 ❑ ❑ ❑
Comment: Magnetic continous flow measuring flowmeters present at clarifier and a second for sprayfields.
Both meters were calibrated 12/18/2019 by AMS Services. The meter at the clarifier was
subsequently replaced 3/24/2020.
Page 3 of 6

Permit: WQ0000485 Owner - Facility: Valley Proteins Inc
Inspection Date: 09/16/2020 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Standby Power Yes No NA NE
Is automatically activated standby power available? ❑ 0 ❑ ❑
Is generator tested weekly by interrupting primary power source? ❑ ❑ ❑
Is generator operable? ❑ ❑ ❑
Does generator have adequate fuel? ❑ ❑ 0 ❑
Comment: Staff indicated that generators sufficiently capable of operating wastewater plant are rented prior
to significant storm events.
Treatment Disinfection
Yes No NA NE
Is the system working?
0
❑ ❑ ❑
Do the fecal coliform results indicate proper disinfection?
❑ ❑ ❑
Is there adequate detention time (-30 minutes)?
❑
❑ ❑
Is the system properly maintained?
❑ ❑ ❑
If gas, does the cylinder storage appear safe?
❑
❑ ❑
Is the fan in the chlorine feed room and storage area operable?
❑
❑ ❑
Is the chlorinator accessible?
❑ ❑ ❑
If tablets, are tablets present?
❑
❑ ❑
Are the tablets the proper size and type?
❑
❑ ❑
Is contact chamber free of sludge, solids, and growth?
❑
❑ ❑
If UV, are extra UV bulbs available?
❑
❑ ❑
If UV, is the UV intensity adequate?
❑
❑ ❑
# Is it a dual feed system?
❑
❑ ❑
Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)?
❑
❑ ❑
If yes, then is there a Risk Management Plan on site?
❑
❑ ❑
If yes, then what is the EPA twelve digit ID Number? (1 000-- )
If yes, then when was the RMP last updated?
Comment: The system utilizes a 12-15% sodium hypochlorite solution which is fed
before it is irrigated
onto
the spray fields.
Record Keeping
Yes No NA NE
Is a copy of current permit available?
❑ ❑ ❑
Are monitoring reports present: NDMR?
❑ ❑ ❑
NDAR?
❑ ❑ ❑
Are flow rates less than of permitted flow?
❑ ❑ ❑
Are flow rates less than of permitted flow?
❑ ❑ ❑
Are application rates adhered to?
❑ ❑ ❑
Is GW monitoring being conducted, if required (GW-59s submitted)?
❑ ❑ ❑
Are all samples analyzed for all required parameters?
❑ ❑ ❑
Page 4 of 6

Permit: WQ0000485 Owner - Facility: Valley Proteins Inc
Inspection Date: 09/16/2020 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Are there any 2L GW quality violations?
❑
❑ ❑
Is GW-59A certification form completed for facility?
0
❑ ❑ ❑
Is effluent sampled for same parameters as GW?
0
❑ ❑ ❑
Do effluent concentrations exceed GW standards?
0
❑ ❑ ❑
Are annual soil reports available?
0
❑ ❑ ❑
# Are PAN records required?
0
❑ ❑ ❑
# Did last soil report indicate a need for lime?
❑
❑ 0 ❑
If so, has it been applied?
❑
❑ 0 ❑
Are operational logs present?
0
❑ ❑ ❑
Are lab sheets available for review?
0
❑ ❑ ❑
Do lab sheets support data reported on NDMR?
0
❑ ❑ ❑
Do lab sheets support data reported on GW-59s?
0
❑ ❑ ❑
Are Operational and Maintenance records present?
0
❑ ❑ ❑
Were Operational and Maintenance records complete?
0
❑ ❑ ❑
Has permittee been free of public complaints in last 12 months?
0
❑ ❑ ❑
Is a copy of the SOC readily available?
❑
❑ 0 ❑
No treatment units bypassed since last inspection?
❑
❑ 0 ❑
Comment: Sampling results have indicated the presence of TDS in samples obtained within wells MW-10A
MW-11A, MW-12B & MW-14A at levels above permit limits from sampling
event performed
7/2020, 11/2019, 7/2019 & 3/2019. Intermittently chlorine and sulfate exceedences were also
encountered in samples obtained from wells MW-12B & MW-14A. Monthly monitoring
reports
for 8/2020 & 9/2020 were checked during the inspection. Soil samplig
was most recently
performed by Corey Lanier 11/14/2019.
End Use -Irrigation
Yes No NA NE
Are buffers adequate?
❑
❑ ❑
Is the cover crop type specified in permit?
❑
❑ ❑
Is the crop cover acceptable?
❑ ❑ ❑
Is the site condition adequate?
❑ ❑ ❑
Is the site free of runoff / ponding?
❑ ❑ ❑
Is the acreage specified in the permit being utilized?
❑ ❑ ❑
Is the application equipment present?
❑ ❑ ❑
Is the application equipment operational?
❑ ❑ ❑
Is the disposal field free of limiting slopes?
❑ ❑ ❑
Is access restricted and/or signs posted during active site use?
❑ ❑ ❑
Are any supply wells within the CB?
❑
❑ ❑
Are any supply wells within 250' of the CB?
❑
❑ ❑
How close is the closest water supply well?
❑
❑ ❑
Is municipal water available in the area?
0
❑ ❑ ❑
Page 5 of 6

Permit: WQ0000485 Owner - Facility: Valley Proteins Inc
Inspection Date: 09/16/2020 Inspection Type: Compliance Evaluation Reason for Visit: Routine
# Info only: Does the permit call for monitoring wells? 0 ❑ ❑ ❑
Are GW monitoring wells located properly w/ respect to RB and CB? ❑ ❑ ❑
Are GW monitoring wells properly constructed, including screened interval? 0 ❑ ❑ ❑
Are monitoring wells damaged? ❑ 0 ❑ ❑
Comment: Wastewater was being applied to Field 7 during the recent inspection and Field 9 was not being
used due to an overgrowth of weeds. Crops are planted in the fields and harvested by others.
No evidence of ponding or runoff was observed during the recent inspection. During the recent
inspection monitoring wells MW-&7A, MW-9 and MW-13A were located and found to have
secured stick-up casings, well tags and a concrete pad.
Page 6 of 6