WQ0000484_Final Permit_20030121

W A
Michael F. Easley, Governor
CO 7 William G. Ross Jr., Secretary
r North Carolina Department of Environment and Natural Resources
d Alan W. Klimek, P.E-, Director
Division of Water Quality
January 21, 2003
Michael Tirrell, Vice President of Processing Operations
Mountaire Farms LLC
PO Box 339
Lumber Bridge, NC 28357
Subject: Permit No. WQ0000484
Mountaire Farms Processing Plant
Wastewater Surface Irrigation
Robeson County
Dear Mr. Tirrell:
In accordance with your request for renewal received October 8, 2002, we are forwarding herewith Permit
No. WQ0000484, dated January 21, 2003, to Mountaire Farms LLC for the continued operation of the subject
wastewater treatment and surface irrigation facilities.
This permit shall be effective from the date of issuance until December 31, 2007, shall void Permit No.
WQ0000484 issued June 30, 1998, and shall be subject to the conditions and limitations as specified therein.
Please pay particular attention to the monitoring requirements in this permit. Failure to establish an adequate
system for collecting and maintaining the required operational information will result in future compliance
problems.
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 thirty (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 Sue Homewood at (919) 733-
5083 extension 502. If
Alan W. Klimek, P.E.
cc: Robeson County Health Department
Fayetteville Regional Office, Water Quality Section
Fayetteville Regional Office, Groundwater Section
Groundwater Section, Central Office
Technical Assistance and Certification Unit
Water Quality Central Files
NDPU Files -
Non -Discharge Permitting Unit Internet http://h2o.enr,state.nc.us/ndpu NTDENR
1617 Mail Service Center, Raleigh, NC 27699-1617 Telephone [phone] Fax [phone]
DENR Customer Service Center Telephone [phone]
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NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
SURFACE IRRIGATION SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, Genera] Statutes of North Carolina as amended,
and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Mountaire Farms LLC
Robeson County
FOR THE
continued operation of a process wastewater treatment, facility to treat wastewater from two kill shifts and one
cleanup shift (Average daily production flow of 1.56 MGD over a five day week with the seven day average flow
not to exceed 1.114 MGD) consisting of a flow equalization basin with floating aerator, feed forward pumping
station with high water alarm, two DAF units each with nitrogen removal system and a clarifier (Sorin Treatment
System), a 19.79 MG aerated storage lagoon with a 30 mil synthetic liner, four aerators and 1.18 million gallons
of permanent storage, a spray irrigation pumping station consisting of vertical turbine pumps, four through sixteen
inch force main extensions, a 640 foot long Valley Model 8000 center pivot corner irrigation system with a 268
food corner arm, a 298 foot long Valley Model 8000 center pivot irrigation system, a 527 foot Valley Model 8000
center pivot irrigation system, and a total of 282.14 available acres, and all necessary pipes, pumps, valves, and
appurtenances required for proper operation.
Continued operation of an infiltration gallery disposal system consisting of 493 linear feet of eight inch gravity
sewer, a 225 GPM pump station ("Field C") with duplex pumps, high water alarms, manual power transfer switch
and an emergency generator hookup, and approximately 3,670 linear feet of six inch force main; a 35 GPM pump
station ("Field F" with duplex pumps, high water alarms, manual power transfer switch and an emergency
generator hookup, five individual infiltration basins each with a square footage of 22,500 square feet with all
necessary pipes, pumps, valves, and appurtenances required for proper operation. -
Continued operation of a 20,000 GPI) extended aeration domestic wastewater treatment facility, and the
continued operation of a 570,000 GPD industrial wastewater treatment system consisting of rotary screens, an air
flotation/grease trap unit, grit removal, a 1.6 MG two stage lagoon with stage two lined, chlorine disinfection
facilities, a 4 MG lined storage lagoon, instrumented flow measurement, dual irrigation pumps and 282.14 acres
of spray irrigation area to serve
Mountaire Fames Processing Plant, with no discharge of wastes to the surface waters, pursuant to the application
received October 8, 2002, 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 shaII be effective from the date of issuance until December 31, 2007, shall void Permit No.
WQ0000484 issued June 30, 1998, and shall be subject to the following specified conditions and limitations:

I. PERFORMANCE STANDARDS
1. The surface 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 ground waters which will render them
unsatisfactory for normal use. In the event that the facilities fail to perform satisfactorily, including
the creation of nuisance conditions or failure of the irrigation area to adequately assimilate the
wastewater, the Permittee shall take immediate corrective actions including those actions that may be
required by the Division of Water Quality (Division), such as the construction of additional or
replacement wastewater treatment and disposal facilities.
2. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to surface
or groundwaters resulting from the operation of this facility.
The residuals generated from these treatment facilities must be disposed in accordance with General
Statute 143-215.1 and in a manner approved by the Division.
4. Diversion or bypassing of the untreated wastewater from the treatment facilities is prohibited.
5. The following buffers shall be maintained:
a) 400 feet between wetted area and any residence or places of public assembly under separate
ownership,
b) 150 feet between wetted area and property lines,
c) 100 feet between wetted area and wells,
d) 100 feet between wetted area and drainage ways or surface water bodies,
e) 50 feet between wetted area and public right of ways,
f) 100 feet between treatment/storage units and any wells, and
g) 50 feet between treatment units and property lines.
Some of the buffers specified above may not have been included in previous permits for this waste
treatment and disposal system. These buffers are not intended to prohibit or prevent modifications,
which are required by the Division, to improve performance of the existing treatment facility. These
buffers do, however, apply to modifications of the treatment and disposal facilities that are for the
purpose of increasing the flow that is tributary to the facility. These buffers do apply to any
expansion or modification of the irrigation areas and apply in instances in which the sale of property
would cause any of the buffers now complied with, for the treatment and disposal facilities, to be
violated. The applicant is advised that any modifications to the existing facilities will require a permit
modification.
II. OPERATION AND MAINTENANCE REQUIREMENTS
The facilities shall be properly maintained and operated at all times.
2. Upon classification of the wastewater treatment and irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to
be back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit
the facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply
with all other conditions specified in these rules.
3. A suitable year round vegetative cover of Coastal Bermuda Grass and Winter Grain (Wheat, oats, rye,
etc) shall be maintained on the irrigation fields. Other crops may not be grown on the irrigation area
without requesting and receiving a modification to this permit.
4. Irrigation shall not be performed during inclement weather or when the ground is in a condition that
will cause runoff.
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Adequate measures shall be taken to prevent wastewater runoff from the irrigation field.
The facilities shall be effectively maintained and operated as a non -discharge system to prevent the
discharge of any wastewater resulting from the operation of this facility.
The application rates on the irrigation fields shall not exceed either rate listed below:
a. The application rate shall not exceed a cumulative loading over any twelve month period as listed
below or an instantaneous application rate not to cause ponding or runoff.
Field Acres wetted area Application Rate
A
8.25
78.0 inches/acre/year
B
6.75
78.0 inches/acre/year
C
35.03
78.0 inches/acre/year
D
3.50
78.0 inches/acre/year
E
4.70
91.0 inches/acre/year
F
26.53
78.0 inches/acre/year
G
47.49
91.0 inches/acre/year
H
14.19
91.0 inches/acre/year
1
13.59
9 1. 0 inches/acre/year
r
58.22
9 1. 0 inches/acre/year
K
9.72
91.0 inches/acre/year
L
24.79
91.0 inches/acre/year
M 1
0.60
91.0 inches/acre/year
M2
3.80
91.0 inches/acre/year
M3
1.23
91.0 inches/acre/year
M4
5.12
91.0 inches/acre/year
M5
18.23
52.0 inches/acre/year
Total acres 282.14
b. The application rate shall also be limited by Nitrogen per acre per year as Iisted in the table
below:
Crop PAN (lb/acre/year)
Bermuda Grass Hay 300
Milo 100
Small Grain 100
Timothy, Orchard, & Rye Grass 200
If the approved spray irrigation sites are to be double cropped (i.e., a crop in the spring and a second
crop in the fall, with BOTH crops to receive wastewater), then the second crop shall receive an
application of nutrients at a rate of no greater than 50 lb/acre/year. This practice will be allowed as
long as the second crop is harvested. If the second crop is to be planted for erosion control only, and
is to be tilled into the soil, then no wastewater shall be applied to these fields because the nitrogen
will essentially be returned to the soil.
No type of wastewater other than that from Mountaire Farms Processing Plant shall be irrigated onto
the irrigation area.
No traffic or equipment shall be allowed on the disposal area except while installation occurs or while
normal maintenance is being performed.
10. Public access to the land application sites shall be controlled during active site use. Such controls
may include the posting of signs showing the activities being conducted at each site.

11. Freeboard in the storage lagoons shall not be less than two feet at any time.
12. A waste -level gauge, to monitor waste levels in the storage pond, shall be installed within 60 days of
issuance of this permit. This gauge shall have readily visible permanent markings indicating the
maximum liquid level at the top of the temporary liquid storage volume, minimum liquid level at the
bottom of the temporary liquid storage volume, and top of the dam elevations. Caution must be taken
not to damage the integrity of the liner when installing the gauge.
13. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas,
and surface water diversions_ Trees, shrubs, and other woody vegetation shall not be allowed to grow
on the earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or
otherwise controlled and accessible.
14. The application of chemicals to the rapid infiltration basins is expressly prohibited.
15. The rapid infiltration basins shall be operated and maintained to prevent the surface of the beds from
becoming sealed and vegetative growth from becoming established. Vegetative growth must be kept
out of the bottom of the rapid infiltration basins at all times. All vegetation must be removed
manually so that minimal disturbances will occur to the disposal area. At a minimum the basins shall
be raked once per month.
M. MONITORING AND REPORTING_REOUIREMENTS
L Any monitoring (including groundwater, surface water, soil or plant tissue analyses) deemed
necessary by the Division to insure surface and ground water protection will be established and an
acceptable sampling reporting schedule shall be followed.
2. Effluent flow from the industrial waste stream and effluent flow from the domestic waste stream shall
be continuously monitored and daily flow values shall be reported on Form NDMR. The flows shall
be reported separately on the NDMR.
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. Records of flow measurement device calibration 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 be:
a. Date of flow measurement device calibration
b. Name of person performing calibration
c. Percent from true flow
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5.
The effluent from the subject facilities shall be monitored by the Permittee at a point prior to
irrigation every month for the following parameters:
BOD5
TSS
Fecal Coliform
pH
% Solids
PAN by Calculation;
NH3 as N
NO2-NO3 as N
TKN
Total Phosphorous
Sodium
Magnesium
Calcium
Sodium Adsorption Ratio by Calculation
Copper
Zinc
Cadmium
Lead
Nickel
Adequate records shall be maintained by the Permittee tracking the amount of wastewater disposed.
These records shall include, but are not necessarily limited to, the following information:
a. date of irrigation,
b. volume of wastewater irrigated,
c. field irrigated,
d. length of time field is irrigated,
e. continuous weekly, monthly, and year-to-date hydraulic (inches/acre) loadings for each field,
f. continuous weekly, monthly, and year-to-date PAN (pounds/acre) loadings for each field and
crop,
g. nitrogen balance for each field and crop after an application event,
h. any ponding or runoff of wastewater from the irrigation fields,
i. maintenance of cover crops,
j. maintenance performed on the wastewater treatment and irrigation facilities, and
k. wastewater and surface water sample collection activities.
Freeboard in the storage lagoons shall be recorded weekly.
6. A representative annual soils analysis (Standard Soil Fertility Analysis) shall be conducted on each
irrigation field and the results maintained on file by the Permittee for a minimum of five years. The
Standard Soil Fertility Analysis shall include, but is not necessarily limited to, the following
parameters:
Acidity Manganese Potassium
Calcium Percent Humic Matter Sodium
Copper pH Zinc
Magnesium Exchangeable Sodium Percentage Phosphorus
Cation Exchange Capacity Base Saturation (by calculation)
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The Standard Soil Fertility Analysis and an analysis for the following pollutants shall be conducted
once prior to permit renewal on soils from each site which has received wastewater during the permit
cycle.
Nickel Cadmium Lead
A report from a Soil Scientist shall accompany the above required analysis to determine site soils
efficiency.
7. Scheduled maintenance of the irrigation fields shall be performed as needed. The maintenance shall
include actions on the permitted acreage to ensure that ponding does not occur and shall include an
annual report by an agronomist or agricultural expert concerning crops and operation for the up
coming year. A written report including this information shall be submitted to the Fayetteville
Regional Office, Water Quality supervisor, 225 Green Street, Suite 714, Fayetteville, NC 28301, by
March 151 of each year.
Three (3) copies of all monitoring data (as specified in condition III 2 and 111 3) on Form NDMR-1
and three (3) copies of all operation and disposal records (as specified in condition IIi 4 and III 5) on
Form NDAR-I, and three (3) copies of all reporting information as specified in conditions 1116 and
1117, shall be submitted monthly on or before the last day of the following month. All information
shall be submitted to the following address:
NC Division of Water Quality
Water Quality Section
Non -Discharge Compliance/Enforcement Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
9. Noncompliance Notification:
The Permittee shall report by telephone to the Fayetteville Regional Office, telephone number (910)
486-1541, 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 facility which 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 render the facility incapable of
adequate wastewater treatment such as mechanical or electrical failures of pumps, aerators,
compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass 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 facility has gone out of compliance
with its permit limitations.
Occurrences outside normal business hours may also be reported to the Division's Emergency
Response personnel at telephone number [phone], [phone], or [phone].
Persons reporting such occurrences by telephone shall also file a written report in letter form within
five (5) 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.
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IV. GROUNDWATER REQUIREMENTS
1. Monitor well(s) MW-8, MW-13, MW-14, MW-15, MW-16, MW-17, MW-18, MW-19, MW-20,
MW-24, MW-25, MW-26, MW-27, MW-28, MW-29, MW-31, MW-32, MW-33, MW-34, MW-35,
and MW-36 shall be sampled every April, August, and December for the parameters listed below.
Prior to sampling the parameters, the measurement of water levels must be taken. The depth to water
in each well shall be measured from the surveyed point on the top of the casing. The measuring
points (top of well casing) of all monitoring wells shall be surveyed relative to a common datum.
Water Level pH
Total Ammonia Nitrogen (NH3-N) TotaI Dissolved Solids (TDS)
Total Organic Carbon (TOC) Fecal Coliforms
Volatile Organic Compounds (in December only) Nitrate Nitrogen (NO3-N)
2. For Total Organic Carbon (TOC), if concentrations greater than 10 mg/1 are detected in any down -
gradient monitoring well, additional sampling and analysis must be conducted to identify the
individual constituents comprising this TOC concentration. If the TOC concentration as measured in
the background monitor well exceeds 10 mg/I, this concentration will be taken to represent the
naturally occurring TOC concentration. Any exceedances of this naturally occurring TOC
concentration in the down -gradient wells shall be subject to the additional sampling and analysis as
described above.
For Volatile Organic Compounds (VOCs) sampled in December, use only one of the following
methods:
1) Standard Method 6230D, Practical Quantitation Limit (PQL) at 0.5 ug/L or less
2) Standard Method 6210, PQL at 0.5 ug/L or less
3) EPA Method 8021, Low Concentration, PQL at 0.5 ug/L or less
4) EPA Method 8260, Low Concentration, PQL at 0.5 ug/L or less
5) Another method with prior approval by the Groundwater Section Chief.
Any of the referenced methods used for VOCs must at a minimum, include all the constituents listed
in Table VIII of Standard Method 6230D. Any method used must provide a PQL of 0.5 ug/L or less,
which must be supported by laboratory proficiency studies as required by the DWQ Laboratory
Certification Unit. Any constituents detected above the Method Detection Limit (MDL) but below the
PQL of 0.5 ug/L must be qualified (estimated) and reported.
4. Any laboratory selected to analyze parameters must be Division of Water Quality (DWQ) certified
for those parameters required.
5. All reports and documentation (GW-59) shall be mailed to the following address:
Groundwater Section
Permits and Compliance Unit
1636 Mail Service Center
Raleigh, NC 27699-1636
Updated blank forms (GW-59) may be downloaded from the Groundwater Section's website at
http://gw.ehnr.state.nc.us/ or requested from the address mentioned above.
6. The results of the sampling and analysis must be received on Form GW-59 (Groundwater Quality
Monitoring: Compliance Report Form) by the Groundwater Section (address listed in the "Reporting
/ Documentation" section of the Groundwater Requirements), on or before the last working day of the
month following the sampling month. The data of all groundwater sampling analyses required by the
permit conditions must be reported using the most recent GW-59 form along with attached copies of
the laboratory analyses.

7. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC
2L, Groundwater Classifications and Standards. The Compliance Boundary for the disposal system
individually permitted on or after December 30, 1983 is established at either 250 feet from the waste
disposal area, or 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 is subject
to immediate remediation action according to 15A NCAC 2L .0106(d)(2).
The REVIEW BOUNDARY is established around the disposal systems midway between the
Compliance Boundary and the perimeter of the waste disposal area. Any exceedance of standards at
the Review Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
9. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
V. INSPECTIONS
L Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities.
2. The Permittee or his designee shall inspect the wastewater treatment and disposal 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 disposal site or
facility 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 facilities are constructed in accordance with the
conditions of this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the
application and other supporting data.
3. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or
there is a name change of the Permittee, a formal permit request must be submitted to the Division
accompanied by an application fee, documentation from the parties involved, and other supporting
materials as may be appropriate. The approval of this request will be considered on its merits and
may or may not be approved.
4. Failure to abide by the conditions and limitations contained in this permit may subject the Perrrtittee
to an enforcement action by the Division in accordance with North Carolina General Statute 143-
215.6A to 143-215.6C.

5. The issuance of this permit does not exempt the Permttee from complying with any and all statutes,
rules, regulations, or ordinances which may be imposed by other government agencies (local, state,
and federal) which have jurisdiction, including but not limited to applicable river buffer rules in 15A
NCAC 2B .0200, erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under
the Division's General Permit NCG010000, and any requirements pertaining to wetlands under 15A
NCAC 2B .0200 and 2H .0500.
A set of approved plans and specifications for the subject project must be retained by the Permittee
for the life of the project.
7. The annual administering and compliance fee must be paid by the Permittee within thirty (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).
The Permittee, at least six (6) months prior to the expiration of this permit, shall request its extension.
Upon receipt of the request, the Commission will review the adequacy of the facilities described
therein, and if warranted, will extend the permit for such period of time and under such conditions
and limitations as it may deem appropriate.
Permit issued this the 2 1 " day of January, 2003
NOR AROLIN NV ON IENTAL MANAGEMENT COMMISSION
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0000484
O