WQ0005681_Compliance Evaluation Inspection_20221130

ROY COOPER
Governor
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
Daniel Shaw, Complex Manager
Pilgrim's Pride Corporation
484 Zimmerman Road
Sanford, NC 27330
NORTH CAROLINA
Environmental Quality
November 30, 2022
SUBJECT: Compliance Evaluation Inspection
Pilgrim's Pride — Staley WWTP
Permit No. WQ0005681
Randolph County
Dear Mr. Shaw:
On November 17, 2022, Division of Water Resources staff Caitlin Caudle conducted a
routine compliance inspection. Tina Pedley, ORC, and Dennis Sumpter, Back Up ORC,
were present during the entire inspection. A review of the lift stations, treatment facility,
storage ponds, monitoring wells, and irrigation field was completed. A separate in -office
review of records was completed. This review reflected compliance with the subject
permit. The following items of concern were noted:
A. Stormwater erosion around the large lift station has caused a hole to form around
the outlet pipe. Please fill this hole to prevent potential damage to the lift
station tank and piping.
B. Some solids were floating in the clarifier and in the effluent trough behind the weirs.
Ms. Pedley stated that leaves clog the skimmer and prevent proper operation.
Please continue making efforts to prevent leaves from clogging the skimmer
and remove the solids in the effluent trough.
C. An area of sheet metal has rusted through above the feed trough in the clarifier.
The hole is on an interior wall. Ms. Pedley stated that repairing this area and other
components of the package plant have been budgeted for next year. Please
monitor that area and ensure the solids level stays below the hole as solids
are pumped monthly; and make efforts to repair this hole in a timely manner.
North Carolina Department of Environmental Quality I Division of Water Resources
Winston-Salem Regional Office 1 450 W. Hanes Mill Rd, Suite 300 I Winston-Salem, North Carolina 27105
NoanicaaouNn
oep.m.m or em�nmen� Qualm
336.776.9800

Please refer to the enclosed inspection report for additional comments and observations.
If you have any questions, please contact me or Caitlin Caudle at the letterhead address
and phone number, or by email at Ion. snider(a)-ncdenr.gov or caitlin.caudle(a)_ncdenr.gov.
Sincerely,
DocuSiT<
gned by:
%w. l . cJn,l tr
145B49E225CMEA...
Lon T. Snider, Regional Supervisor
Water Quality Regional Operations Section
Division of Water Resources, NCDEQ-WSRO
Enc: Inspection Report
Cc: Tina Pedley, ORC (electronic copy)
Dennis Sumpter, BUORC (electronic copy)
Randolph County Environmental Health Department (electronic copy)
Laserfiche File WQ0005681
WSRO Electronic Files
D North Carolina Department of Environmental Quality I Division of Water Resources
✓ Winston-Salem Regional Office 1 450 W. Hanes Mill Rd, Suite 300 1 Raleigh, North Carolina 27105
NORTH CAROLINA 336.776.9800
naparMeM of EmironmanW 9uallly

Compliance Inspection Report
Permit: WQ0005681 Effective: 11/01/20 Expiration: 11/30/26 Owner: Pilgrim's Pride Corporation
SOC: Effective: Expiration: Facility: Pilgrim's Pride - Staley WWTP
County: Randolph 2607 Old 421 Rd
Region: Winston-Salem
Staley NC 27355
Contact Person: Tina Pedley
Title:
Phone: [phone]
Directions to Facility:
from winston-salem take 1-40 to greensboro and take US 421 south. From US 421, take old US 421 to staley by taking a right off
the exit ramp. The second entrance on the right will take you to the gold kist office, hatchery, and feed mills.
System Classifications: SI, WW2,
Primary ORC: Certification: Phone:
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
NCG060379 Pilgrim's Pride Corporation - Pilgrims Pride Corporation
Inspection Date: 11/17/2022 Entry Time 10:OOAM Exit Time: 11:30AM
Primary Inspector: Caitlin Caudle E
Docusi9�ed by: Phone: [phone]
Secondary Inspector(s): ruV, Cmj&
8B834968199D49D_
11/30/2022
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 -Water
Use Records
Treatment Activated Sludge
Treatment Clarifiers
Storage
(See attachment summary)
Treatment Flow Measurement -Influent Miscellaneous Questions
Treatment Record Keeping
End Use -Irrigation
Treatment Disinfection
Wells
Treatment Influent Pump Station
Treatment Flow Measurement
Page 1 of 6

Permit: WQ0005681 Owner - Facility: Pilgrim's Pride Corporation
Inspection Date: 11/17/2022 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Inspection Summary:
On November 17, 2022, Division of Water Resources staff Caitlin Caudle conducted a routine compliance inspection. Tina
Pedley, ORC, and Dennis Sumpter, Back Up ORC, were present during the entire inspection. A review of the lift stations,
treatment facility, storage ponds, monitoring wells, and irrigation field was completed. A separate in -office review of records
was completed. This review reflected compliance with the subject permit. The following items of concern were noted:
A. Stormwater erosion around the large lift station has caused a hole to form around the outlet pipe. Please fill this hole to
prevent potential damage to the lift station tank and piping.
B. Some solids were floating in the clarifier and in the effluent trough behind the weirs. Ms. Pedley stated that leaves clog
the skimmer and prevent proper operation. Please continue making efforts to prevent leaves from clogging the skimmer and
remove the solids in the effluent trough.
C. An area of sheet metal has rusted through above the feed trough in the clarifier. The hole is on an interior wall. Ms.
Pedley stated that repairing this area and other components of the package plant have been budgeted for next year. Please
monitor that area and ensure the solids level stays below the hole as solids are pumped monthly, and make efforts to repair
this hole in a timely manner.
Other observations:
• Ms. Pedley stated that the limbs in Z5 have been trimmed back.
• All monitoring wells were locked and well caps were recently replaced.
• No floats are used for irrigation. The system is controlled by a timer and a rain sensor. The lanes are set up in zones.
• High water alarms are present in the lift stations. When activated, there is an audible and visual alarm at the lift stations
and in the building.
• The generator at the plant can operate the lift stations.
• There is only one irrigation pump.
• There is an alarm at the wastewater treatment plant, but it is unclear what that alarm is for. Drawings from 1993 state
that the alarm is an F.E.B. Alarm, which may just be the light bulb.
• The lift station supply lines to the package plant have been repaired and there have been no further issues. Ms. Pedley
stated that complete replacement of all lines has been budgeted for next year.
• The residuals removal activities since last inspection were for repair of supply lines to the package plant and repairing
other components of the package plant.
• The residuals are still on a monthly pumping schedule to remove solids from the package plant.
• The transfer pumps in the EQ basin have been repaired. They now alternate when floats are activated.
• There is an existing pipe that can be used to direct effluent to Lagoon 2 if there is an issue in Lagoon 1.
• The farmer managing the crop spread something on the land surrounding the spray fields. It appeared to be chicken litter
or something of that nature. Nothing was applied to the spray field.
• The O&M Plan is updated once a year.
• The irrigation system was calibrated 10/28/2022.
• No lime was applied to the spray field, but all pH's were in an acceptable range.
• The CCCs are located after the package plant and between the lagoons. Both contact chambers are underground.
• The flowmeter was calibrated 8/4/21 and 8/18/2022.
• An antifoaming agent is not used.
• Duckweed was present in Lagoon 2.
• Z1 was irrigated while on site.
• There is a digital freeboard meter for consistent reporting of freeboard if back up operators or other personnel visit the
WWTP.
Follow Up Items:
• Review Z4 irrigating, woods encroach on part of wetted area
• Alarm at EQ basin. High water? Pump failure?
• Review EQ basin transfer pumps in operation
Page 2 of 6

Permit: WQ0005681 Owner - Facility: Pilgrim's Pride Corporation
Inspection Date: 11/17/2022 Inspection Type: Compliance Evaluation
Reason for Visit: Routine
Type
Yes No NA NE
Infiltration System
❑
Reuse (Quality)
❑
Lagoon Spray, LR
❑
Single Family Spray, LR
❑
Activated Sludge Spray, HR
❑
Activated Sludge Drip, LR
❑
Recycle/Reuse
❑
Single Family Drip
❑
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 Influent Pump Station
Yes No NA NE
Is the pump station free of bypass lines or structures?
0
❑ ❑ ❑
Is the general housekeeping acceptable?
❑ ❑ ❑
Are all pumps present?
❑
❑ ❑
Are all pumps operable?
❑
❑ ❑
Are floats/controls operable?
❑
❑ ❑
Are audio and visual alarms available?
0
❑ ❑ ❑
Are audio and visual alarms operational?
❑ ❑ ❑
# Are SCADA/Telemetry alarms required?
❑
❑ ❑
Are SCADA/Telemetry available?
❑
❑ ❑
Are SCADA/Telemetry operational?
❑
❑ 0 ❑
Comment:
Treatment Flow Measurement -Influent
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:
Treatment Flow Measurement -Water Use Records Yes No NA NE
Page 3 of 6

Permit: WQ0005681 Owner - Facility: Pilgrim's Pride Corporation
Inspection Date: 11/17/2022 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Is water use metered? ❑ ❑ 0 ❑
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?
0
❑ ❑ ❑
Does flowmeter monitor continuously?
0
❑ ❑ ❑
Does flowmeter record flow?
0
❑ ❑ ❑
Does flowmeter appear to monitor accurately?
0
❑ ❑ ❑
Comment:
Treatment Activated Sludge
Yes No NA NE
Is the aeration mechanism operable?
❑ ❑ ❑
Is the aeration basin thoroughly mixed?
❑ ❑ ❑
Is the aeration equipment easily accessed?
❑ ❑ ❑
Is Dissolved Oxygen adequate?
❑
❑ 0 ❑
Are Settleometer results acceptable?
❑
❑ 0 ❑
Is activated sludge an acceptable color?
0
❑ ❑ ❑
Comment:
Treatment Clarifiers
Yes No NA NE
Are the weirs level?
❑ ❑ ❑
Are the weirs free of solids and algae?
❑ ❑ ❑
Is the scum removal system operational?
❑ ❑ ❑
Is the scum removal system accessible?
0
❑ ❑ ❑
Is the sludge blanket at an acceptable level?
❑
❑ ❑
Is the effluent from the clarifier free of excessive solids?
❑ ❑ ❑
Comment:
Treatment Disinfection
Yes No NA NE
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?
❑ ❑ ❑
Page 4 of 6

Permit: WQ0005681 Owner - Facility: Pilgrim's Pride Corporation
Inspection Date: 11/17/2022 Inspection Type: Compliance Evaluation
Reason for Visit: Routine
Are the tablets the proper size and type?
0
❑ ❑ ❑
Is contact chamber free of sludge, solids, and growth?
❑
❑ ❑
If UV, are extra UV bulbs available?
❑
❑ 0 ❑
If UV, is the UV intensity adequate?
❑
❑ 0 ❑
# Is it a dual feed system?
❑
❑ 0 ❑
Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)?
❑
❑ 0 ❑
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: Some high fecal values have been reported. Contact chambers are below
ground.
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?
❑ ❑ ❑
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?
0
❑ ❑ ❑
Is a copy of the SOC readily available?
❑
❑ 0 ❑
No treatment units bypassed since last inspection?
0
❑ ❑ ❑
Page 5 of 6

Permit: WQ0005681 Owner - Facility: Pilgrim's Pride Corporation
Inspection Date: 11/17/2022 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Comment:
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?
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: No water supply wells within CB.
Yes No NA NE
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