NC0001970_Site Visit_20160525

PIC
State of North Carolina
Division of Water Resources
Water Quality Regional Operations Section
Environmental Staff Report
Quality
To: ®NPDES Unit❑Non-Discharge Unit Application No.: (NC0001970)
Attn: (Julie Grzyb) Facility name: Bay Valley Foods-Faison Processing Facility
From: (Tom Tharrington)
Wilmington Regional Office
Note: This form has been adapted from the non-discharge facility staff report to document the review of both non-
discharge and NPDES permit applications and/or renewals. Please complete all sections as they are applicable.
I. GENERAL AND SITE VISIT INFORMATION
RECEIVED/NCDEQ'DWR
I. Was a site visit conducted?® Yes or No
a. Date of site visit: March 30,2016
MAY 252016
b. Site visit conducted by: Tom Tharrington Water Quality
Permitting Section
c. Inspection report attached? ® Yes or No
d. Person contacted: Donovan Brock and their contact information: [phone] ext.251
e. Driving directions: From Wilmington travel west on 1-40 to exit 355,turn right and follow NC-403N to North
Faison Ave and turn left.
2. Discharge Point(s): Effluent
Latitude: 35°.07'.21" Longitude: 78°.08'.28"
3. Receiving stream or affected surface waters: Panther Branch
Classification: C;SW
River Basin and Subbasin No. 03-06-22
Describe receiving stream features and pertinent downstream uses: Small stream with associated marsh
lands in rural,agricultural area.
Proposed-flew.
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FORM: WQROSSR 04-14 Page 1 of 9

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III.EXISTING FACILITIES:MODIFICATION AND RENEWAL APPLICATIONS
1. Are there appropriately certified Operators in Charge(ORCs)for the facility?® Yes ❑No❑N/A
ORC: Donovan W.Brock Certificate if: WW-2: 22276
Backup ORC: Johnny R.Kinetic Certificate#: WW-2:993965
2. Are the design,maintenance and operation of the treatment facilities adequate for the type of waste and disposal
system? ®Yes or❑No
If no,please explain:
Description of existing facilities:
Equipment List
• One(1)Coarse(Gross) Screening Equipment—Automated conveyer
• One(1)Aerated Grit Removal System
• One(1)Influent Pump Station with dual pumps
• One(1)Fine Screening Equipment—Rotary drum screen
• Three(3)Aerated Lagoons with floating surface aerators—(18—30 hp aerators)
• One(1)Secondary Clarifier Unit
• One(1)Polymer Dosing System—Polymer aging tank,chemical pump&associated tubing
• One(1)Tertiary Filter—Traveling bridge sand filter
• Effluent Flowmeter
• Post Aeration- Cascade(Stair Step)Aerator
• Sludge Storage Tank—(Sludge Mix Tank)
• Plate and Frame Sludge Filter
• Five(5)sludge drying beds
• One(1) 1.9 MG Brine Yard Stormwater Retention Pond with return pump
• Two(2)Back-up Generator Units
Proposed flow: 0.50 MGD
Current permitted flow:0.50 MGD
Process wastewater consist of water generated from packaging activities, plant utility systems,collected
stormwater and recovered groundwater.
Headworks& Screening-The process wastewater is screened through a screen conveyor with a coarse mesh to
remove larger items that would cause operational problems with wastewater equipment(i.e. large pieces of glass,
jar lids,plastic). After grit removal an influent pump station with dual,float controlled pumps moves the
wastewater to a fine rotary screening unit just prior to the aeration basins. If a high level occurs in the process
sewer, influent wastewater will over top an internal manhole wall and be directed into the Brine Yard Detention
Pond for storage.This wastewater or any accumulated stormwater collected in the Brine Yard Retention Pond is
then pumped into the aeration basin system for treatment as needed.
FORM: WQROSSR 04-14 Page 2 of 9

ir Aeration Lagoons—Wastewater flows through three(3)aerated lagoons for biological treatment,the first lagoon
has eight(8)30-hp floating surface aerators equipped with small draft tubes to provide both needed aeration and
lagoon mixing. Wastewater from the first lagoon travels to the next via a newly added system of concrete lined
channels at the surface level.These new channels prevent plugging from solids accumulation that occurred with
pipelines located below the surface.Lagoon mixed liquor levels operate the best in the 6,000 mg/I level and as a
result solids accumulation in the bottom of the lagoons had been an on-going issue,over a 3 year period BVF-
Faison has removed over 10,531.35 tons of accumulated biomass from the lagoons. The next two aerated lagoon
each have five(5)30-hp floating aerators identical to those in the first lagoon. Recently added inlet valves,valve
vaults and drop gates will allow operators to take lagoon out of service for maintenance or alter wastewater flow
path as needed between the lagoon series.
Clarification&Filtration—After biological treatment mixed liquor travels to the secondary clarifier unit,where
a polymer dosing system is used to enhance settling of the sludge.A RAS pump station with dual float controlled
RAS pumps returns activated sludge to the aerated lagoons.This RAS pump station is also equipped with an
independent high level alarm float that is connected to an auto-dialer system in case of operational issues.
Clarified effluent is directed to a single down-flow tertiary sand filter before re-aeration and effluent discharge.
Waste Sludge—Wasted sludge is currently pumped into a sludge mix tank before being processed in a plate and
frame sludge press.Originally perlite was added in the mix tank as a filter aid but operations staff have achieved
similar results without the need for the material.The plate and frame press can perform 4 batches a day and is
typically operated 5 days per week.Future plans include replacing this unit with a conventional belt press for
efficiency.
Effluent&In-Stream Chloride Monitoring—The NPDES permit for this site contains a variance from the
water quality standard for chloride in Panther Branch. As a part of this variance the site is required to perform
benthic sampling at upstream and downstream locations at least 6 months prior to the permit expiration date.The
site must also provide annual reports discussing chloride removal technologies,chloride removal methods and a
summary of source reduction activities.
NOTE: During the site inspection Bay Valley staff indicated that recent in-stream chloride monitoring results
had been very low. The lower production rates at the facility and heavy rainfall events were determined to have
contributed to these lower chloride levels. It is expected that production rates at this site are going to increase in
the near future and in turn increase the in-stream chloride levels.
3. Are the site conditions(e.g., soils,topography,depth to water table,etc)maintained appropriately and adequately
assimilating the waste? ®Yes or❑No
If no,please explain:
4. Has the site changed in any way that may affect the permit(e.g.,drainage added,new wells inside the compliance
boundary,new development,etc.)? ❑ Yes or 0 No
If yes,please explain:
5. Is the residuals management plan adequate? ® Yes or❑No
If no,please explain:
.. . . . - . .
liner piease-explaim7. Is the existing groundwater monitoring program adequate? 0 Yes❑No❑N/A
If no,explain and recommend any changes to the groundwater monitoring program:
8. Are there any setback conflicts for existing treatment,storage and disposal sites? El Yes or®No
If yes,attach a map showing conflict areas.
9. Is the description of the facilities as written in the existing permit correct? ® Yes or El No
If no,please explain: More detail description listed above.
10. Were monitoring wells properly constructed and located? 9 Yes❑No❑N/A
If no, please explain:
FORM: WQROSSR 04-14 Page 3 of 9

14. Are the monitoring well coordinates correct in RIMS? ❑Yes®No El N/A
If no,please complete the following(expand table if necessary): locations extrapolated from a digital map
source
Monitoring Well Latitude Longitude
1 35°07'27.97" -78°08'09.28"
2 35°07'20.87" -78°08' 15.73"
3A 35°07'26.82" -78°08'21.13"
4A 35°07'23.69" -78°08'22.95"
5 35°07'28.96" -78°08' 16.43"
8 35°07'21.10" -78°08'27.97"
DW-1 35°07'23.70" -78°08'22.94"
12. Has a review of all self-monitoring data been conducted(e.g.,DMR,141)MK-44026a,GW)? ®Yes or❑No
Please summarize any fmdings resulting from this review:
Since the permit was last issued.BIMS indicates 7 instances of daily maximum violations for BOD,with 1
monthly average violation.This monthly average violation for ROD occurred in 2011.
The site also has thirteen(13)groundwater monitoring wells and three(3)recovery wells used to monitor and
remediate a groundwater contamination area(Groundwater Incident#11105)below the production facility. Six
(6)of these monitoring wells are in place for NPDES permit compliance purposes with an additional well(DW-1)
being included as a deep.topographically downgradient monitoring well. A review of the latest Semi-Annual
Sampling Report was conducted for this staff report and monitoring wells that exceed the NC 2L Standards for
TDS and chloride are away from the wastewater treatment lagoons in the production areas.It appears that the
Recovery Wells are preventing the elevated constituents in the groundwater from migrating off-site to the south.
Provide input to help the permit writer evaluate any requests for reduced monitoring, if applicable.
13. Are there any permit changes needed in order to address ongoing RIMS violations? ❑Yes or®No
If yes,please explain:
14. Check all that apply:
®No compliance issues ❑ Current enforcement action(s) El Currently under JOC
❑Notice(s)of violation ❑ Currently under SOC ❑ Currently under moratorium
Please explain and attach any documents that may help clarify answer/comments(i.e.,NOV,NOD,etc.)
If the facility has had compliance problems during the permit cycle,please explain the status. Has the RO been
working with the Permittee? Is a solution underway or in place?
Have all compliance dates/conditions in the existing permit been satisfied? ❑ Yes El No®N/A
If no,please explain:
15. Are there any issues related to compliance/enforcement that should be resolved before issuing this permit?
❑Yes®No❑N/A
If yes, please explain:
16. Possible toxic impacts to surface waters: Chloride
17. Pretreatment Program(POTWs only):N/A
FORM:WQROSSR 04-14 Page 4 of 9

IV.REGIONAL OFFICE RECOMMENDATIONS
1. Do you foresee any problems with issuance/renewal of this permit? ❑Yes or®No
If yes,please explain:
Rent Reason
Condition Reason
Condition Reason
5. Recommendation: ❑Hold,pending receipt and review of additional information by regional office
❑ Hold,pending review of draft permit by regional office
El Issue upon receipt of needed additional information
® Issue
❑Deny(Please state reasons: )
6. Signature of report preparer. tiv
Signature of regional supervisor:
Date: li r/a-r1/ 0/6
FORM:WQROSSR 04-14 Page 5 of 9

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FORM: WQROSSR 04-14 Page 7 of 9

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tinted States EnvWorvneMal Protection Agency Form Approved.
EPA Washington.D.C.20460 OMB No.2040-0057
Water Compliance Inspection Report Approval expires 8-31-98
Section A:National Data System Coding(i.e.,PCS)
Transaction Code NPDES yr/moidey Inspection Type Inspector Fac Type
1 („ ( 2 IS I 3 I NC0001970 111 121 1ero3/30 117 18141 19I c I 201 I
21111111 1111111 11111111111 1 111111 11111111111 I p8
Inspection Work Days Facility Self-Monitoring Evaluation Rating 131 OA Reserved
-
671 1 701. I 71 I itLJ I 72 I , I 731 1 174 751J 1 1 1 1 1 1 l80
I' I Section 8:Facility Data
Name and Location of Facility Inspected(For Industrial Users discharging to PO-1W,also include Entry Time/Date Permit Effective Date
POTW name and NPDES permit Number) 10:35AM 18/03/30 11/08/01
Bay Valley Foods Faison Processing Facility
354 N Faison Ave Exit Time/Date Permit Expiration Date
Faison NC 28341 01:15PM 18/03/30 18/07/31
Name(s)of Onsite Representative(s)/Titles(s)/P hone and Fax Number(s) Other Facility Data
///
Donovan Wayne BrocWORC/910-287-4711/
Name,Address of Responsible ORntleUTi le/Phone and Fax Number
Contacted
Donovan Wayne Brock,PO Box 158 Faison NC
283410158/ORC/910-2e7-1989/9102874882 NO
Section C:Areas Evaluated During Inspection(Check only those areas evaluated)
Permit • Flow Measurement • Operations 8 Maintenance III Records/Reports
• Self-Monitoring Program •Sludge Handling Disposal •Facility Site Review •Effluent/Receiving Waters
Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s)and Signature(s)of Inspector(s) Agency/Office/Phone and Fax Number, Date
Torn Thamngton WIRD WO///
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
Morella Sanchez-King WIRO GW//910-796-7218/
EPA Form 3580-3(Rev 9-94)Previous editions are obsolete.
Paged 1

NPDES yr/me/day Inspection Type (Cont.) 1
31 NC0001 a70 111 121 16/03/30 111 18 IA
„I
Section a Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
This site is completing recent maintenance/improvements in the aeration basin area. Notable is the
removal of accumulated solids from basin#2(middle basin)removing a total of 10,531 tons of solids,
inspection and repairs of the synthetic liner and installation of channels to move flow through the series
of aeration basins.At the time of inspection this project was nearing completion.This facility is
anticipating increased production rates and as a result it is assumed some increase in effluent chloride
levels may occur with this increase.
The site samples process aeration basins,effluent and downstream locations daily for dissolved
oxygen, pH and temperature. The site maintains NC Laboratory field parameter certification#5263 and
also uses Envirochem Inc(Wilmington)for additional laboratory needs. Laboratory equipment includes
dual YSI 55 dissolved oxygen meters and an Oakton 510 pH/mV/°C meter for field parameter testing.
The final effluent flowmeter(ISCO 4230)was last calibrated on 09/11/15.
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Permit NC0001970 Owner-Facility: Bay Valley Foods Faison Processing Facility
inspection Data: 03/30/2016 Inspection Type: Compliance Evaluation
Permit Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new • 0 0 0
application?
Is the facility as described in the permit? • ❑ 0 0
#Are there any special conditions for the permit? • 0 0 0
Is access to the plant site restricted to the general public? • 0 0 0
Is the inspector granted access to all areas for inspection? • 0 ❑ 0
Comment: Special conditions listed in this permit include items relatina to the chloride variance aranted
to this discharger. such as triennial variance review by the North Carolina Environmental
Management Commission, annual reports submitted by the permittee. Benthic sampling of
receiving waters. Groundwater monitoring reauirements and semolina reauirements in the
event of the brine yard retention pond overflow.
Operations&Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? • 0 0 0
Does the facility analyze process control parameters,for ex:MLSS, MCRT,Settleable U 0 0 0
Solids, pH, DO, Sludge Judge,and other that are applicable?
Comment: The site was clean and well maintained. Construction of wastewater treatment
improvements and liner repairs were near completion at the time of inspection.The center
aeration basin was being slowly filled with wastewater and surface aerators will be installed
when a normal operating level is reached.Aeration basin MLSS levels are typically
maintained around 6.000 ma/I.
Pump Station -Influent Yes No NA NE
Is the pump wet well free of bypass lines or structures? • ❑ 0 0
Is the wet well free of excessive grease? • 0 0 0
Are all pumps present? • 0 0 0
Are all pumps operable? • 0 0 0
Are float controls operable? • 0 0 0
Is SCADA telemetry available and operational? 0 0 • 0
Is audible and visual alarm available and operational? 0 ❑ 0 •
Comment: After the initial screenina device and grit removal,process wastewater moves to the influent
wet well where it is pumped to the first aeration basin. Brine yard retention pit stonnwater
can be pumped into the aeration basin#1 at this point also(seperate pump system). The
operating controls/alarms are maintained by a series for float switches in the influent wet
well.
Bar Screens Yes No NA NE
Type of bar screen
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Penult NC0001970 Owner•Facility: Day Valley Foods Faison Processing Facility
inspection Date: 03/30/2016 Inspection Type: Compliance Evaluation
Bar Screens Yes No NA NE
a.Manual ❑
b.Mechanical •
Are the bars adequately screening debris? ■ 0 0 0
Is the screen free of excessive debris? • 0 0 0
Is disposal of screening in compliance? U 0 ❑ 0
Is the unit in good condition? • 0 0 0
Comment: Initial screening of process wastewater takes place near the influent pump station and is a
mechanical coarse screen. Screened material is stored in a dumpster before being
transported to the Duplin Co. landfill. If a high level occurs in the process sewer due to
excessive screenings or pump failure.wastewater will overtop an internal wall inside the
upstream manhole and flow to the brine yard retention pond for storage until treatment.
Grit Removal Yes No NA NE
Type of grit removal
a.Manual 0
b.Mechanical •
Is the grit free of excessive organic matter? • 0 ❑ 0
Is the grit free of excessive odor? ■ ❑ 0 0
#Is disposal of grit in compliance? • 0 0 0
Comment: No comment
Aeration Basins Yes No NA NE
Mode of operation Ext.Air
Type of aeration system Surface
Is the basin free of dead spots? • 0 0 0
Are surface aerators and mixers operational? • 0 0 0
Are the diffusers operational? 0 0 • 0
Is the foam the proper color for the treatment process? 0 0 • 0
Does the foam cover less than 25%of the basin's surface? • 0 0 0
Is the DO level acceptable? • 0 0 0
Is the DO level acceptable?(1.0 to 3.0 mg/1) • 0 0 0
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Pam It NC0001970 Owner-Facility: Bay Valley Foods Faison Processing Facility
Inspection oats: 03/30/2018 Impaction Type: Compliance Evaluation
Aeration Basins Yes No NA NE
Comment: Prior to entering aeration basin#1.wastewater passes throuah an elevated micro screen
trommel for removal of additional material.The 3 aeration basins total 14 MG volume and
have 18 30-hp surface aerator units.There are 8 aerators in basin#1 and 5 each in basins
#2 and#3. Recent improvements to the aeration basins include liner repair/replacement.
construction of new overflow channels to replace subsurface piping between each aeration
basin and inlet/outlet valve box construction for easier future access.
Chemical Feed Yes No NA NE
Is containment adequate? • 0 0 0
Is storage adequate? • 0 0 0
Are backup pumps available? • 0 0 0
Is the site free of excessive leaking? • 0 0 0
Comment: A polymer solution is iniected prior to the secondary clarifier, a dilute solution is mixed each
week with 20 gallons of polymer added to the dilution vessel.
Secondary Clarifier Yes No NA NE
Is the clarifier free of black and odorous wastewater? • 0 0 0
Is the site free of excessive buildup of solids in center well of circular clarifier? • 0 0 0
Are weirs level? • 0 0 0
Is the site free of weir blockage? • 0 0 0
Is the site free of evidence of short-circuiting? • 0 0 0
Is scum removal adequate? • 0 0 0
Is the site free of excessive floating sludge? • 0 0 0
Is the drive unit operational? • 0 0 0
Is the return rate acceptable(low turbulence)? • 0 0 0
Is the overflow clear of excessive solids/pin floc? • 0 0 0
Is the sludge blanket level acceptable?(Approximately V.of the sidewall depth) 0 0 0 •
Comment: The secondary clarifier was clean with little to no solids loss.
Pumps-RAS-WASYes No NA NE
Are pumps in place? • 0 0 0
Are pumps operational? • 0 0 0
Are there adequate spare parts and supplies on site? • 0 0 0
Comment: Dual RAS/WAS pumps remove activated sludae and return to the aeration basins or sludge
mix tank as needed.The pumps are controlled by a series of floats with an additional float
connected to an auto-dialer for notification in case of high wet well levels.
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• •, Permit NC0001670 Owner-Facility: Bay Valley Foods Faison Processing Facility
Inspection Data: 03/30/2016 inspection type: Compliance Evaluation
Filtration (High Rate Tertiarvt Yes No NA NE
Type of operation: Down flow
Is the filter media present? • 0 0 ❑
Is the filter surface free of clogging? • 0 0 0
Is the filter free of growth? • 0 0 0
Is the air scour operational? 0 0 • 0
Is the scouring acceptable? 0 0 • 0
Is the clear well free of excessive solids and filter media? • 0 0 0
Comment: Down flow type teritiary sand filter with backwash sequence initiated by float controls or
manual action.
Drying Beds Yes No NA NE
Is there adequate drying bed space? • 0 0 0
Is the sludge distribution on drying beds appropriate? • 0 0 0
Are the drying beds free of vegetation? • 0 ❑ 0
#Is the site free of dry sludge remaining in beds? • 0 0 0
Is the site free of stockpiled sludge? • 0 0 0
Is the filtrate from sludge drying beds returned to the front of the plant? 0 0 0 •
#Is the sludge disposed of through county landfill? • 0 0 0
#Is the sludge land applied? 0 • 0 0
(Vacuum filters)Is polymer mixing adequate? 0 0 • 0
Comment: 5 sand drying beds are available for use if needed.
Solids Handling Equipment Yes No NA NE
Is the equipment operational? • 0 0 0
Is the chemical feed equipment operational? 0 0 • 0
Is storage adequate? • ❑ 0 0
Is the site free of high level of solids in filtrate from filter presses or vacuum filters? 0 0 0 •
Is the site free of sludge buildup on belts and/or rollers of filter press? 0 0 • 0
Is the site free of excessive moisture in belt filter press sludge cake? 0 0 • 0
The facility has an approved sludge management plan? • 0 0 0
Comment: Waste sludge is processed through a plate and frame press.This is a manually controlled
process with a maximum of 4 batches of waste sludge Dressed each day.Typically
operated 5 days per week. pressed sludge is transported to the Duplin County Landfill for
disposal.
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Permit NC0001970 Owner-Facility: Bay Valley Foods Faison Processing Facility
Inspection Oats: 03/30/2016 Inspection Type: Compliance Evaluation
Standby Power Yes No NA NE
Is automatically activated standby power available? • 0 0 0
Is the generator tested by interrupting primary power source? 0 0 0 •
Is the generator tested under load? 0 0 0 •
Was generator tested&operational during the inspection? 0 • 0 0
Do the generator(s)have adequate capacity to operate the entire wastewater site? • 0 0 0
Is there an emergency agreement with a fuel vendor for extended run on back-up power? • 0 0 0
Is the generator fuel level monitored? • 0 0 0
Comment: The site has 2 generators that are used to power different areas of the wastewater process,
one unit powers equipment located near the headworks and an additional unit powers
equipment around the secondary darifier and RAS/WAS pumps. Final effluent flows by
gravity to the receiving stream and the influent wastewater can be directed to the 1.9 million
gallon brine yard retention basin if needed.The generators are tested each Tuesday and
operated for 15 mins.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? • 0 0 0
Is sample collected below all treatment units? • 0 0 0
Is proper volume collected? • 0 0 0
Is the tubing clean? • 0 0 0
#Is proper temperature set for sample storage(kept at less than or equal to 6.0 degrees • 0 0 0
Celsius)?
Is the facility sampling performed as required by the permit(frequency,sampling type U 0 0 0
representative)?
Comment: The facility uses a programable ISCO 3710 sampler with a sample refrigerator that is
maintained at 3.0°C. Effluent flow is measured by an ISCO 4230 bubble flow meter
(differential pressure).
Pages 7