WQ0002648_Final Permit_20000512

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Bill Holman, Secretary
Kerr T. Stevens, Director
May 12, 2000
Darius Luck, Vice President/Plant Manager
Luck's Inc.
PO Box 510
Seagrove, North Carolina 27341
Dear Mr. Luck:
mom
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Permit No. WQ0002648
Wastewater Treatment and
Wastewater Spray Irrigation
Randolph County
In accordance with your application received January 29, 2000 we are forwarding herewith Permit No.
WQ0002648, dated May 12, 2000, to Luck's Inc for the continued operation of the subject wastewater
treatment and spray irrigation facilities. It is understood that should the existing wet weather pond be filled, the
Luck's, Inc., Seagrove Plant has agreed to shut down or slow down operations to prevent any over flow of the
storage pond or runoff from the spray field. This requirement must be met.
Please note the most recent soil scientist report (by Toney C. Jacobs, dated January 12, 1995) allows a
loading rate of 38.4 inches/acre/year for the existing subject 40 acre spray irrigation field. The 300,000 GPD
allowed in the previous wastewater permits far exceeds the 38.4 inches/acre/year loading rate. The submitted
application package indicates a total treatment capacity of 120,000 GPD from the 30,000 GPD sanitary
package treatment plant, the 60,000 GPD process waste package treatment plant, and the estimated 30,000
GPD of contact cooling water. This only allows approximately 5 days of storage, for the 588,000 gallon
capacity of the wet weather storage pond. By calculation for a 365 day work year, the existing 40 acre spray
field can handle an approximate average of 114,261 gallons per day. By calculation, for the 120,000 GPD rate,
the 38.4 inches/acre/year spray field loading rate could accommodate approximately 346 work days per year.
The Division has been assured the subject Luck's Inc. plant will take all steps necessary to prevent any over
flow of the storage pond or runoff from the spray field. Therefore, this permit must reduce the previously
allowed 300,000 GPD flow to the 120,000 GPD total treatment capacity. Luck's Inc. is cautioned that it would
be a violation of this permit to allow any over flow of the storage pond or runoff from the spray field.
This permit shall be effective from the date of issuance until April 30, 2005, shall void Permit No.
WQ0002648 issued September 26, 1995, 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.
1617 Mail Service center, Raleigh, North Carolina 27699-1617 Telephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/10% post -consumer paper

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. //
Kerr T. Stevens
cc: Randolph County Health Department
Winston-Salem Regional Office, Water Quality Section
Winston-Salem Regional Office, Groundwater Section
Groundwater Section, Central Office
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
ra

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
SPRAY IRRIGATION SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as amended, and
other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Luck's Inc.
Randolph County
FOR THE
continued operation of flow equalization facilities following the preliminary screening of the Process Cooking and
Canning and Clean-up operations, and prior to the existing DAF Unit, consisting of a 30,000 gallon flow equalization
tank with 80 cfm blower units and all associated pumps, piping, controls, and appurtenances; and the continued
operation of the existing 120,000 GPD spray irrigation treatment and disposal facility, for combined sewage and
industrial wastes, consisting of a 30,000 GPD domestic wastewater package treatment plant (employees and floor
washing) using aerobic digestion, clarification and disinfection, a 60,000 GPD process cooking and canning and clean-
up process wastewater package treatment plant using aerobic digestion, clarification proceeded by preliminary
screening and preliminary diffused air floatation unit process, a non -contact cooling water & produce washing
wastewater screening facilities, a 588,000 gallon wet weather storage pond with irrigation pump station, a 40 acre
spray field area, and all associated piping, pumps, valves, controls and appurtenances to serve Luck's Inc., Seagrove
Plant with no discharge of wastes to the surface waters, pursuant to the application received January 29, 2000, 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 shall be effective from the date of issuance until April 30, 2005, shall void Permit No. WQ0002648
issued September 26, I995, and shall be subject to the following specified conditions and Iimitations:
I. PERFORMANCE STANDARDS
The spray 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 Genera]
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 drainageways or surface water bodies,
e) 50 feet between wetted area and public right of ways,
f) 100 feet between wastewater treatment units and wells, and
g) 50 feet between wastewater 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 which 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 spray 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 facility by the Water Pollution Control System Operators Certification
Commission (WPCSOCC), the Permittee shall employ a certified wastewater treatment plant operator to
be in responsible charge (ORC) of the wastewater treatment facilities. The operator must hold a certificate
of the type and grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the WPCSOCC. The Permittee must also employ a certified back-up operator of the
appropriate type and grade to comply with the conditions of 15A NCAC 8G .0202. The ORC of the
facility must visit each Class I facility at least weekly and each Class II, III, and IV facility at least daily,
excluding weekends and holidays, and must properly manage and document daily operation and
maintenance of the facility and must comply with all other conditions of 15A NCAC 8G .0202
A suitable year round vegetative cover over the spray irrigation field of shall be maintained.
4. Irrigation shall not be performed during inclement weather or when the ground is in a condition that will
cause runoff.
5. Adequate measures shall be taken to prevent wastewater runoff from the spray field.
b. 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.
7. The application rate shall not exceed a cumulative loading of 38.4 inches over any twelve (12) month
period at an instantaneous application rate not to allow any runoff from the spray field.
No type of wastewater other than that from Luck's, Inc., Seagrove Plant, shall be sprayed onto th,
irrigation area.
2

9. 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 wet weather storage pond shall not be less than two feet at any time.
III. MONITORING AND REPORTING REQUIREMENTS
1. 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. 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, weather conditions, and
g. maintenance of cover crops.
3. The effluent from the subject facilities shall be monitored by the Permittee at the point prior to irrigation
every March, Judy, and November for the following parameters:
BOD5
TSS
Fecal Coliform
pH
NH3 as N
Sodium
Magnesium
Calcium
Sodium Adsorption Ratio by Calculation
4. Three (3) copies of all operation and disposal records (as specified in condition III 2) on Form NDAR-1
shall be submitted on or before the last day of the following month. Three (3) copies of all effluent
monitoring data (as specified in condition III 3) on Form NDMR-1 shall be submitted on or before the last
day of April, August, and December. 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
S. A representative annual soils analysis (Standard Soil Fertility Analysis) shall be conducted on each spray
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)

6. Noncompliance Notification:
The Permittee shall report by telephone to the Winston-Salem Regional Office, telephone number 33
771-4600 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.
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.
IV. GROUNDWATER REQUIREMENTS
1. The three (3) existing monitor wells (MW-1, MW-2, and MW-3) shall be sampled every March, July, and
November for the following parameters:
NO3 TDS
TOC Chloride
Sulfate Sodium
pH Water Level
Volatile Organic Compounds - In November only using one of the following methods:
(A) Standard Method 62301), PQL at 0.5 ug/L or less
(B) Standard Method 6210, PQL at 0.5 ug(L or less
(C) EPA Method 8021, Low Concentration, PQL at 0.5 ug/L or less
(D) EPA Method 8260, Low Concentration, PQL at 0.5 ug/L or less
(E) Another method with prior approval by the Groundwater Section Chief
The spray irrigation field shall be tested once every four (4) months for sodium content and the results
submitted to the Division's Winston-Salem Regional Office.
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be measured from the surveyed point on the top of the casing.
If TOC concentrations greater than 10 mg/1 are detected in any downgradient 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 I0 mg/1,
this concentration will be taken to represent the naturally occurring TOC concentration. Any exceedances
of this naturally occurring TOC concentration in the downgradient wells shall be subject to the additional
sampling and analysis as described above.

1f any volatile organic compounds are detected by Method 6230D, or the equivalent Method 502.2, then
the Winston-Salem Regional Office Groundwater Supervisor, telephone number 910/ 771-4600 must be
contacted immediately for further instructions regarding any additional follow-up analyses required. The
results of all initial and follow-up analyses must be submitted simultaneously.
The results of the sampling and analysis shall be sent to the Groundwater Section, Permits and
Compliance Unit,1636 Mail Service Center, Raleigh, N.C. 27699-1636 on Form GW-59 [Compliance
Monitoring Report Form] every April, August, and December.
2. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary is for the disposal system
constructed prior to December 31, 1983 is established at either (1) 500 feet from the waste disposal area,
or (2) at 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 in addition to the penalty provisions applicable under General Statute 143-
215.6A(a)(1).
In accordance with 15A NCAC 2L, a 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 re -mediation action on the part of the permittee.
4. No land application of waste activities shall be undertaken when the seasonal high water table is less than
three feet below the land surface.
V. INSPECTIONS
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
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.

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 accompanir
by an application fee, documentation from the parties involved; and other supporting materials as may L
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 Permittee 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 preclude the Permittee 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.
6. 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
revolve 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 12`' day of May, 2000
NORTH ROLINA E , O ENTAL MANAGEMENT COMMISSION
Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0002648

• F
ah+ Ch � •, � .
ram•- J��'�•'rlL a.o �rPO 'r2
! .(:ram• :! i..�=
5•�as.t;' T. ' - 1 !� �l-. •lnd�zteiii srslc .-1-•�� . .
r �Yi - 111 :'i; I��r �. / •, •;C.`'� j ���'+ - - r •��• ` • •1, _
'�� .- ��:_< -V - i • - `�_ .�: , --`� 1 Imo._-� � ,-
s: Luc <s :"Ecr,
tr , .1'O '/ 1_• _,.�.: ::lc I �21cF+-i—iph'� •` f;' :i
Ir: .
.�-'�` ( ;�� �\ .f• !}, ' .1 o NDOJ-F'`rs: cQ
_ c• !_ �.i _ i /S ri,r Figure I
Luck's Inc.
Spray Irrigation
c:
-Asbury ., • � �:�� Randolph County
.. _ --- - ..... __ WQ00026�8 I GW00029
,>
'' Site Location Map

0 C-0
U
-11 ,�, >-, 0 C) g:I
10 C)
g- a co
'A ft �41 cu- 34
t
......... . ......... .. ...... .
-------------
ILI
0 �r
F f Lu
----------
W E�
;2:
51 0
71, -
611
CIL
bl.-J
.4�1•Cy
VOO
✓CIA
6
LUCK'S INCORPORATED
jCeO WASIC MMSq,