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Home My WebLink AboutWQ0000884_Compliance Evaluation Inspection_20210322DocuSign Envelope ID: C3CB6E51-582C-4B30-9BFE-7CE0D328E87A ROY COOPER Governor MICHAEL 5. REGAN Secretary S. DANIEL SMITH Director Joshua Batchelor Butterball LLC 1628 Garner Chapel Rd Mount Olive, NC 28365 NORTH CAROLINA Environmental Quality March 19, 2021 SUBJECT: Compliance Inspection Report Butterball - Mt. Olive WWTF Non -discharge Permit No. WQ0000884 Duplin County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Butterball - Mt. Olive WWTF on 3/11/2021. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in Non -discharge Permit No. WQ0000884. 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 bryan.lievre@ncdenr.gov. Sincerely, ,—DocuSigned by: waft&5o —Lit4 `— E3ABA14AC7 DC434... Morel a Sanchez -King, Regional Supervisor Water Quality Regional Operations Section Wilmington Regional Office Division of Water Resources, NCDEQ ATTACHMENT Cc: Laserfiche D E North CaroLna Department of Enwonmental Quality 1 Division of Water Resources Wilmington R g nai Dtfic! 1 127 Cetd�nel Drive Extlnpon 1 WSknineon, North Groins 28405 ^- -- • -- '^� 910 796-7215 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Compliance Inspection Report Permit: WO0000884 SOC: County: Duplin Region: Wilmington Effective: 05/11/18 Effective: Expiration: 09/30/22 Expiration: Owner : Butterball LLC Facility: Butterball - Mt. Olive VWVTF 1628 Garner Chapel Rd Contact Person: Joshua Batchelor Title: Wastewater Manager Directions to Facility: System Classifications: SI, WW3., Primary ORC: Joshua Tray Batchelor Secondary ORC(s): On -Site Representative(s): Related Permits: Certification: 987940 Inspection Date: 03/11/2021 Entry Time 09:30AM ,—DocuSigne by: Primary Inspector: Bryan Lievre Secondary Inspector(s): '-74249ABED37443E... Tyler G Benson Reason for Inspection: Routine ,—DocuSigned by: fii�� t V fjt,lit,SOIA, `-06DCAE2DD754468... Permit Inspection Type: Wastewater Irrigation Facility Status: Compliant El Not Compliant Question Areas: ▪ Treatment Flow Measurement -Effluent ▪ Treatment Flow Measurement -Water Use Records ▪ Record Keeping ▪ Treatment Sludge Storage/Treatment ▪ Treatment Disinfection ▪ Standby Power (See attachment summary) Mount Olive NC 28365 Exit Time: 12:15PM Phone: 919-658-6743 Phone: 919-658-6743 Phone: 910-796-7215 Inspection Type: Compliance Evaluation ▪ Treatment Flow Measurement -Influent ▪ Treatment ▪ Treatment Lagoons ▪ End Use -Irrigation ▪ Treatment Flow Measurement ▪ Wells ▪ Miscellaneous Questions ▪ Treatment Barscreen ▪ Treatment Activated Sludge ▪ Treatment Clarifiers ▪ Treatment Return pumps ▪ Coastal Requirements Page 1 of 8 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Permit: WQ0000884 Owner - Facility: Butterball LLC Inspection Date: 03/11/2021 Inspection Type : Compliance Evaluation Reason for Visit: Routine Inspection Summary: An inspection of the Butterball Turkeys Wastewater Treatment Facility (WWTF), Permit Number WQ0000884, was performed on March 11, 2021 in order to verify compliance with the existing permit. Present during the meeting were Joshua Batchelor (system ORC) and Lankford Ruffin with the Butterball, as well as Tyler Benson and myself (Bryan Lievre) with NCDEQ, DWR. The facility is permitted for the operation of a 2,000,000 gallon per day (gpd) wastewater treatment and irrigation facility which includes a 100,000 gpd domestic wastewater pretreatment facility, a stormwater capture system, an industrial wastewater treatment plant and an irrigation system. The major components of each of the systems are provided below. The major components of the 100,000 gpd wastewater pretreatment facility (with flow in sequence below) include: - Mechanical shaftless spiral bar screen with 1/4" screen - Flow control box with V-notched weir and 1/2" openings in a plate screen - 25,000-gallon flow equalization basin with: o Liquid level sensors for dual 185 gpm pumps o A 70 cfm PD blower - Dual train 37,500 gallon aeration basins with o dual 590 cfm PD blowers (also used for air lift of WAS & RAS) - Dual train 11,000 gallon hopper -bottom type clarifiers - 700 gallon collection box tank - Effluent pump station with: o Liquid level switches o Two effluent pumps o One emergency dry prime pump A stormwater capture system consisting of: - A 350,000 gallon lined eastern stormwater pond - A 245,000 gallon lined western stormwater pond The major components of the industrial wastewater treatment plant include: - A 1 million gallon (MG) flow equalization tank with two PD blowers and coarse air diffuser - Coagulant injection system - Two dissolved air floatation (DAF) units operating in parallel with polymer feed station - A DAF sludge pump station with dual pumps - A DAF sludge storage tank with hopper bottom to enable decant removal - A 13 MG aerated lagoon with five 60 hp high-speed surface aerators - A 41 MG holding lagoon with three 20 hp surface aerators - A 1,500 gallon plastic tank with liquid chlorine and metering injection pump mixing system The irrigation system includes: - Four 100 hp irrigation pumps - Two 50 hp booster irrigation pumps - Approximately 556.88 acres of spray irrigation with 35 fields, whereas six fields (15A, 15B, 17A, 17b, 17C, and 17D) with a cumulative area of 25.04 acres have not been constructed. Captured stormwater from the eastern pond as well as the effluent from the domestic wastewater pretreatment system are pumped to a 13 MG aerated lagoon. Stormwater from the western pond as well as the treated industrial wastewater from the plant are also both separately piped to the 13 MG aerated lagoon. The combined wastewater then flows from the 13 MG lagoon into a 41 MG facultative lagoon. Chlorine is added to the effluent and the wastewater is then pumped to the irrigation fields. The wastewater pretreatment system was recently replaced and placed into operation in 2019. Although repairs were being Page 2 of 8 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Permit: WQ0000884 Owner - Facility: Butterball LLC Inspection Date: 03/11/2021 Inspection Type : Compliance Evaluation Reason for Visit: Routine performed on the controls for the system during the site visit, operations seem to have not been hindered and the system appeared to be operating properly with no issues observed. The stormwater basins did not contain substantial amounts of water during the visit and appeared to be in good condition. Similarly the lagoon had 48 inches of freeboard. Levels of nitrate appear to be problematic in select monitoring wells, most notably downgradient wells MW-38 and MW-39 as well as upgradient well MW-22. The system is concerned about the possibility to roadside release(s) negatively affecting the groundwater quality in well MW-22 and for this reason, DWR staff advised system staff to contact our office in the event of suspicious activities. The system has taken actions to reduce levels of nitrate in downgradient wells including the replacement of the domestic wastewater system and remedial actions to some of the fields. The system will need to continue to be concerned with nitrate levels within the effluent of the industrial wastewater system Records were well organized and complete. The facility is compliant with Permit WQ0000884. Messrs. Batchelor and Ruffin were extremely knowledgeable of plant operations and were very helpful during the inspection. Please review the comment sections of the inspection report for more details. Page 3 of 8 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Permit: WQ0000884 Owner - Facility: Butterball LLC Inspection Date: 03/11/2021 Inspection Type : Compliance Evaluation Reason for Visit: Routine Type Infiltration System Reuse (Quality) Activated Sludge Spray, HR Single Family Spray, LR Activated Sludge Spray, LR Recycle/Reuse Activated Sludge Drip, LR Single Family Drip Lagoon Spray, LR Treatment Are Treatment facilities consistent with those outlined in the current permit? Do all treatment units appear to be operational? (if no, note below.) Yes No NA NE • Yes No NA NE ❑•❑ ❑ • ❑ ❑ ❑ Comment: The permit issued 5/11/2018 lists dual train 22,000 gallon clarifiers within the domestic wastewater pretreatment facility, however the capacity of each of these units is approximately 11,000 gallons. Treatment Flow Measurement -Influent Is flowmeter calibrated annually? Is flowmeter operating properly? Does flowmeter monitor continuously? Does flowmeter record flow? Does flowmeter appear to monitor accurately? Yes No NA NE ❑ ❑ ❑• ❑ ❑ ❑• ❑ ❑ ❑• ❑ ❑ ❑• ❑ ❑ ❑ • Comment: Potable water is provided by and metered by Duplin County, PWS 04-31-085. Production water is provided by five production wells, each of which are equipped with flowmeters that are calibrated annuallyy. The facility has permitted it's water supply wells with the Central Plain Coastal Capacity Use Area (CCPCUA), Permit CU3019. According to the CCPCUA, the average flow for the production wells in 2020 was 1,026,529 gpd. Stormwater flow is estimated based on total effluent less production wells less potable consumed. Treatment Flow Measurement -Water Use Records Is water use metered? Are the daily average values properly calculated? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: An ultrasonic flow meter is located on the effluent line from the domestic watewater pretreatment system and two in -line flow meters are present for the industrial wastewater treatment system, all of which were calibrated on 4/21/2021 by Atlantic Process Instrumentation & Consulting. Treatment Flow Measurement -Effluent Is flowmeter calibrated annually? • Yes No NA NE ❑ ❑ ❑ Page 4 of 8 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Permit: WQ0000884 Owner - Facility: Butterball LLC Inspection Date: 03/11/2021 Inspection Type : Compliance Evaluation Reason for Visit: Routine Is flowmeter operating properly? Does flowmeter monitor continuously? Does flowmeter record flow? Does flowmeter appear to monitor accurately? • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • Comment: The system has two effluent flow meters - an east and a west meter. The meters were calibrated on 4/21/2021 and 4/22/2021 by Atlantic Instrumentation & Consulting. Standby Power Is automatically activated standby power available? Is generator tested weekly by interrupting primary power source? Is generator operable? Does generator have adequate fuel? Yes No NA NE ❑ • ❑ ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ Comment: The domestic wastewater pretreatment system is equipped with a diesel -powered effluent backup pump. Otherwise, the system would rely on portable emergency generators in the event of power outage. Treatment Barscreen Is it free of excessive debris? Is disposal of screenings in compliance? Are the bars spaced properly? Is the unit in good condition? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The shaftless spiral bar screen was osberved to be operating properly during the inspection. Debris collected within the structure is deposited into a dumpster and taken to a landfill for disposal. Treatment Activated Sludge Is the aeration mechanism operable? Is the aeration basin thoroughly mixed? Is the aeration equipment easily accessed? Is Dissolved Oxygen adequate? Are Settleometer results acceptable? Is activated sludge an acceptable color? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ Comment: Significant and even air distribution was observed within each of the equalization and aeration basins. Treatment Clarifiers Are the weirs level? Are the weirs free of solids and algae? Is the scum removal system operational? Is the scum removal system accessible? Is the sludge blanket at an acceptable level? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page 5 of 8 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Permit: WQ0000884 Owner - Facility: Butterball LLC Inspection Date: 03/11/2021 Inspection Type : Compliance Evaluation Reason for Visit: Routine Is the effluent from the clarifier free of excessive solids? • ❑ ❑ ❑ Comment: Flow was observed to evenly flow over the weirs and the weirs were found to have been very clean with little to no solids buildup. Treatment Return pumps Are they in place? Are they operational? Comment: Return pumps are all air lift pumps and include both sludge ad skimmer returns. Treatment Sludge Storage/Treatment Is the aeration operational? Is the aeration pattern even? If required, are Sanitary "Ts" present in tankage? Comment: Residuals are removed by Valley Proteins with no storage on -site. Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ Treatment Disinfection Yes No NA NE Is the system working? • 0 0 0 Do the fecal coliform results indicate proper disinfection? • ❑ ❑ 0 Is there adequate detention time (>=30 minutes)? 0 0 0 • Is the system properly maintained? • ❑ ❑ ❑ If gas, does the cylinder storage appear safe? 0 0 • 0 Is the fan in the chlorine feed room and storage area operable? 0 0 • 0 Is the chlorinator accessible? 0 0 • 0 If tablets, are tablets present? 0 0 • ❑ Are the tablets the proper size and type? 0 0 • 0 Is contact chamber free of sludge, solids, and growth? 0 0 • 0 If UV, are extra UV bulbs available? 0 0 • 0 If UV, is the UV intensity adequate? 0 0 • 0 # Is it a dual feed system? 0 0 • 0 Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)? 0 0 • 0 If yes, then is there a Risk Management Plan on site? 0 0 0 0 If yes, then what is the EPA twelve digit ID Number? (1000- - ) If yes, then when was the RMP last updated? Comment: Sodium hypochlorite is fed from a 1,500 gallon plastic tank into the line prior to discharge onto the spray fields. Record Keeping Is a copy of current permit available? Are monitoring reports present: NDMR? NDAR? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page 6 of 8 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Permit: WQ0000884 Owner - Facility: Butterball LLC Inspection Date: 03/11/2021 Inspection Type : Compliance Evaluation Reason for Visit: Routine 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? Are there any 2L GW quality violations? Is GW-59A certification form completed for facility? Is effluent sampled for same parameters as GW? Do effluent concentrations exceed GW standards? Are annual soil reports available? # Are PAN records required? # Did last soil report indicate a need for lime? If so, has it been applied? Are operational logs present? Are lab sheets available for review? Do lab sheets support data reported on NDMR? Do lab sheets support data reported on GW-59s? Are Operational and Maintenance records present? Were Operational and Maintenance records complete? Has permittee been free of public complaints in last 12 months? Is a copy of the SOC readily available? No treatment units bypassed since last inspection? • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ •❑ ❑ ❑ ❑ • Comment: The on -site lab is certified for pH and chlorine with Permit #5420. Envirochem is their contract laboratory. GW Nitrate violations reported in wells MW-22, MW-38 and MW-39 in 2020. Effluent levels also appear to have an (inconsistant) increasing nitrate trend for 2020 which the system needs to investigate. System subcontracts to other to put together sample plan, perform sampling and report on results. Copy of past report was available at facility and system anticipates 2021 sampling within the next month. End Use -Irrigation 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? Yes No NA NE ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page 7 of 8 DocuSign Envelope ID: 506C2AED-BE2D-43BA-BA62-9C306FABC279 Permit: WQ0000884 Owner - Facility: Butterball LLC Inspection Date: 03/11/2021 Inspection Type : Compliance Evaluation Reason for Visit: Routine 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? # Info only: Does the permit call for monitoring wells? Are GW monitoring wells located properly w/ respect to RB and CB? Are GW monitoring wells properly constructed, including screened interval? Are monitoring wells damaged? • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ ❑ Comment: Staff were questioned about possible issues identified on several fields, based on 3/209/2019 aerial imagery. Staff indicated that the fields in question had sustained damage resulting from the 2018 hurricane season, noteably most dominantly due to Hurricane Florence which produced disastrous flooding. No issues were noted on any of the many fields observed during the inspection. Monitoring wells MW-22, MW-27, MW-38 were inspected and found to have a secured stick-up outer cover with concrete pad. Coastal Requirements Are essential treatment units provided in duplicate? Is an adequately sized aerated equalization basin present? If so, is it operable? If present, are diffusers cleaned regularly? Is the equalization capacity adequate? Comment: Yes No NA NE • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑• ❑ ❑ ❑• ❑ ❑ ❑• Page 8 of 8