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Home My WebLink AboutWQ0000485_Compliance Evaluation Inspection_20220929DocuSign Envelope ID: 51868996-51 D7-4800-899C-A7D8AEB114DC ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Larry Holt 469 Yellow Cut Road Rose Hill NC 28458 NORTH CAROLINA Environmental Quality September 29, 2022 SUBJECT: Compliance Inspection Report Darling Ingredients (formerly Valley Proteins - Rose Hill Division) Non -discharge Permit No. WQ0000485 Duplin County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of Darling Ingredients WWTF on 9/27/2022. 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 Geoff Kegley with the Water Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215 or via email at g eoff. keg ley@ncdenr.gov. Sincerely, DocuSignedby: E3ABA14AC7DC434... Morella Sanchez -King, Regional Supervisor Water Quality Regional Operations Section Wilmington Regional Office Division of Water Resources, NCDEQ ATTACHMENTS Cc: Corey Lanier, ORC - Darling Ingredients (via email) Matt Haynes - Darling Ingredients (via email) DWR Laserfiche files D_E North Carolina Department of Environmental Quality 1 Division of Water Resources Wilmington Regional Office 1127 Cardinal Drive Extension I Wilmington. North Carolina 28405 910.796.7215 nwaow.a Ernhenn.re..." e'd DocuSign Envelope ID: 7DE9ADEF-C6FB-476B-BA78-36A25B35CA09 Compliance Inspection Report Permit: WQ0000485 Effective: 11 /01 /19 SOC: Effective: County: Duplin Region: Wilmington Contact Person: Matthew A Haynes Expiration: 03/31/25 Expiration: Owner : Valley Proteins Inc Facility: Valley Proteins - Rose Hill Div. 469 Yellowcut Rd Rose Hill NC 28458 Title: District Environmental Manager Phone: 540-431-9210 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 Secondary ORC(s): On -Site Representative(s): Related Permits: Inspection Date: 09/27/2022 Primary Inspector: Geoff Kegley Secondary Inspector(s): Entry Time 10:30AM DocuSigned by: 44/ "-CD17E2515D3B417... Reason for Inspection: Routine Permit Inspection Type: Wastewater Irrigation Facility Status: II Compliant ❑ Not Compliant Question Areas: ▪ Treatment Flow Measurement -Effluent ▪ Treatment Flow Measurement -Water Use Records ▪ Treatment Lagoons ▪ Treatment Flow Measurement (See attachment summary) Exit Time: 12:30PM Phone: 910-289-2083 Phone: Inspection Type: Compliance Evaluation ▪ Treatment Flow Measurement -Influent Miscellaneous Questions ▪ Treatment Record Keeping ▪ End Use -Irrigation ▪ Standby Power Treatment Disinfection Page 1 of 6 DocuSign Envelope ID: 7DE9ADEF-C6FB-476B-BA78-36A25B35CA09 Permit: WQ0000485 Owner - Facility: Valley Proteins Inc Inspection Date: 09/27/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Inspection Summary: A routine compliance inspection of the Darling Ingredients (formerly Valley Proteins) wastewater treatment and spray irrigation disposal system was conducted on September 27, 2022. The purpose of the inspection was to verify that the facility is operating in compliance with the conditions specified within Permit W00000485. Corey Lanier, operator for the system was present during the inspection and was very helpful providing assistance throughout the inspection and follow-up. 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: • 0.084 MG process wastewater EQ tank • 1.5 MG anaerobic reactor tank (constructed, but inactive) • dissolved air flotation unit (DAF) • 3.5 MG aeration basin with surface aerators • 1.72 MG complete mixed activated sludge (CMAS) basin with jet aerators • DAF clarifier cell • three irrigation storage lagoons (two 2.9 acre and one 4.65 acre) • 0.35 MGD reverse osmosis system for internal process wastewater recycle • hexane extraction system • sodium hypochlorite feed system at irrigation pump station • spray irrigation fields 2, 3, 4, 5, 6, 7, 8, and 9 totaling 79 acres Sanitary wastewater generated from the bathroom facilities at the plant flows into the Town of Rose Hill sewer collection system. Discussions are underway to connect to the Town of Wallace to receive flow from the industrial wastewater plant in times of need (upsets, wet irrigation fields, etc.). During the recent inspection, freeboard in all the lagoons were well below two feet. Regarding the groundwater monitoring program, sampling results have indicated consistent exceedances of TDS and chloride limits in samples obtained from monitoring wells MW-10A and MW-14A. Site map indicates these wells are located within the designed sprayfields. Site inspection confirmed that these wells are in very close proximity to several spray heads. Due to landscape position, property lines, and ditches, it seems impractical to relocate these wells further away from the sprayfield. Therefore, it was recommended to limit or discontinue use of several spray irrigation heads that are immediately adjacent to these wells. Please note that this slightly reduces the designed acreage available for irrigation and associated nutrient/hydraulic loading. Records were readily available for review, well organized and complete. The facility is deemed compliant with Permit WQ0000485. Please review the comment sections of the inspection report for more details. Page 2 of 6 DocuSign Envelope ID: 7DE9ADEF-C6FB-476B-BA78-36A25B35CA09 Permit: WQ0000485 Owner - Facility: Valley Proteins Inc Inspection Date: 09/27/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Type Reuse (Quality) Infiltration System Single Family Spray, LR Activated Sludge Spray, LR Activated Sludge Drip, LR Activated Sludge Spray, HR Recycle/Reuse 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.) Comment: 1.5 MG anaerobic reactor tank is constructed, but not in use. 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? Comment: Treatment Flow Measurement -Water Use Records Is water use metered? Are the daily average values properly calculated? Comment: Yes No NA NE • Yes No NA NE • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE ❑ ❑ ❑ • ❑ ❑ ❑ • Treatment Flow Measurement -Effluent Yes No NA NE Is flowmeter calibrated annually? • ❑ ❑ ❑ Is flowmeter operating properly? • ❑ ❑ ❑ Does flowmeter monitor continuously? • ❑ ❑ ❑ Does flowmeter record flow? • ❑ ❑ ❑ Does flowmeter appear to monitor accurately? • ❑ ❑ ❑ Comment: Calibration was performed by AMS services on 12/30/2021 Standby Power Is automatically activated standby power available? Yes No NA NE ❑ ❑ • ❑ Page 3 of 6 DocuSign Envelope ID: 7DE9ADEF-C6FB-476B-BA78-36A25B35CA09 Permit: WQ0000485 Owner - Facility: Valley Proteins Inc Inspection Date: 09/27/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Is generator tested weekly by interrupting primary power source? • ❑ ❑ ❑ Is generator operable? • ❑ ❑ ❑ Does generator have adequate fuel? ❑ ❑ ❑• Comment: Facility now owns a large portable generator located on -site and is capable of running all essential units. Generator is tested weekly. Treatment Disinfection Is the system working? 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? (1000- 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 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? Are there any 2L GW quality violations? Is GW-59A certification form completed for facility? Is effluent sampled for same parameters as GW? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑• • ❑ ❑ ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑ ❑• ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page 4 of 6 DocuSign Envelope ID: 7DE9ADEF-C6FB-476B-BA78-36A25B35CA09 Permit: WQ0000485 Owner - Facility: Valley Proteins Inc Inspection Date: 09/27/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine 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: Sampling results have indicated consistent exceedances of TDS and chloride limits in samples obtained from monitoring wells MW-10A and MW-14A. Site map indicates these wells are located within the designed sprayfields. Site inspection confirmed that these wells are in very close proximity to several spray heads. Due to landscape position, property lines, and ditches, it seems impractical to relocate these wells further away from the sprayfield. Therefore, it was recommended to limit or discontinue use of several spray irrigation heads that are immediately adjacent to these wells. Please note that this slightly reduces the designed acreage available for irrigation and associated nutrient/hydraulic loading. Immediately after the inspection, the operator capped these irrigation heads and sent pictures documenting this action. 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? 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? Yes No NA NE • ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑• ❑ ❑ ❑• ❑ ❑ ❑• Page 5 of 6 DocuSign Envelope ID: 7DE9ADEF-C6FB-476B-BA78-36A25B35CA09 Permit: WQ0000485 Owner - Facility: Valley Proteins Inc Inspection Date: 09/27/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine 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: Crop planting and harvesting are conducted by a third party. No evidence of ponding or runoff was observed during the inspection. Monitoring wells were observed to have stick-up casings and were locked. Page 6 of 6