WQ0003380_Final Permit_20090731

Aa
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H, Sullins
Govemor Director
July 31, 2009
Gary S. Joshway, Sr., Dudley Plywood Plant Manager
Georgia-Pacific Wood Products LLC
139 Brewington Road
Dudley, North Carolina 28333
Dear Mr. Joshway:
Dee Freeman
Secretary
Subject: Permit No. WQ0003380
Georgia-Pacific Corporation
Dudley Plywood Plant
Closed -Loop Recycle System
Wayne County
In accordance with your permit renewal and modification request received June 4, 2009, we are
forwarding herewith Permit No. WQ0003380, dated July 31, 2009, to Georgia-Pacific Corporation for the
continued operation of the subject closed -loop wastewater recycle facilities.
Please note that, per your request and changes in the system, Item No. 6 of the previous permit
(issued December 6, 2004), referring to the inclusion of a 15,000 GPD domestic wastewater treatment
system, has not been included in the new permit. Please also note that the description of the log heating
vat water recycle system appearing in Item No. 2 of the previous permit has been modified to reflect that
the biological treatment option has been eliminated from this system.
This permit shall be effective from the date of issuance until June 30, 2014, shall void Permit No.
WQ0003380 issued December 3, 2004, and shall be subject to the conditions and limitations as specified
therein. PIease 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.
Please note that since the last permit issuance, the Division has created a new permit shell. Please
note that on September 1, 2006 State Administrative Code 15A NCAC Subchapter 02T — Waste not
Discharged to Surface Water was adopted. This permit incorporates the requirement of these rules.
Remember to take the time to review this permit thoroughly, as some of the conditions contained
therein may have been added, changed, or deleted from those in previously issued permits.
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,
AQUIFER PROTECTION SECTION
1636 Mail Service Center, Raleigh, North Carolina 27699-1636
Location: 2728 Capital Boulevard, Raleigh, North Carolina 27604
Phone: [phone] V FAX 1: 919-715-0588; FAX 2: 919-715-60481 Customer Semite 1-877-623-6748
Internet: wwripwate[qualfty,org
An Equal Opportunity 1 Affirmative Action Employer
Nne
orthCarohna:
Naturally

Gary S. 3oshway, Sr.
July 31, 2009
Page 2 of 2
If you need additional information concerning this matter, please contact David Goodrich at (919)
715-6162 or [e-mail].
Sincerely,
or ?o1een Sullins
.tF
cc; Wayne County Health Department
Washington Regional Office, Aquifer Protection Section
Technical Assistance and Certification Unit
APS Central Files
LAU Files

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
CLOSED -LOOP RECYCLE 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
Georgia-Pacific Corporation
Wayne County
FOR THE
continued operation of the wastewater recycle facilities located at the Georgia-Pacific Corporation's
Plywood/OWB Plant in Dudley, which consist of:
I, a wastewater recycle system used in conjunction with the control of rotary dryer emissions using an
Electrostatic Precipitation Unit (ESP) consisting of a pre -quench unit which consists of a chamber
and duct, holding tank with integral mixer, two 175 - GPM recycle pumps, one 133 GPM supply
pump; exiting collection systems; a dual compartment 20,000 gallon concentrate sump with a 8,450
gallon clean water compartment, a 4,000 gallon concentrated waste compartment, a spray system, a
drain system, and concentrated sensors; a 60 GPM sprayer system for the ESP unit with a collector
and return piping system; a 20,000 gallon concentrated waste storage tank; a 15 GPM spray pump for
spraying concentrated waste on wood waste to be burned; a wash down system with two (2) 375
GPM pumps used individually to clean the ESP system, and all associated piping, valves, pumps and
appurtenances to allow the transfer of wastewater to the scrubber water discharge recycle system, the
veneer dryer wash down recycle system, the log heating vat water recycle system, the oil/water
separator facility, or the Wet Storage Deck recycle system;
2. a 100,000 GPD log heating vat water recycle system with screen, surge basin and all associated
piping, valves, pumps, controls and appurtenances to allow the transfer of wastewater to the ESP Unit
recycle system, the scrubber water discharge recycle system, the veneer dryer wash down recycle
system, the oil/water separator facility, or the Wet Storage Deck recycle system;
3. a veneer dryer wash down reclaim system with wash down hose systems, storage tank, and all
associated piping, valves, pumps, controls and appurtenances to allow the transfer of wastewater to
the ESP Unit recycle system, the scrubber water discharge recycle system, the log heating vat water
recycle system, the oil/water separator facility, or the Wet Storage Deck recycle system;
4. a scrubber water discharge recycle system with dual ash settling basins, clear water sump, recycle
pump, and all associated piping, valves, pumps, controls and appurtenances to allow the transfer of
wastewater from the ESP Unit recycle system, the veneer dryer wash down recycle system, log
heating vat water recycle system, the domestic wastewater treatment recycle system, the oil/water
separator facility, or the Wet Storage Deck recycle system;"
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5. a 300 GPM oil/water separator with sump and sump pump with ultimate discharge to the ESP Unit
recycle system, the scrubber water discharge recycle system, the veneer dryer wash down recycle
system, the log heating vat water recycle system, or the Wet Storage Deck recycle system;
6. a 706,000 GPD wastewater Wet Storage Deck recycle system consisting of a 78,000 cubic foot
recycle pond, two 40 hp pumps, six wet deck sprinklers, one groundwater supply well, one well float
control, and all associated piping, valves, controls and appurtenances to allow the transfer of
wastewater to the scrubber water discharge recycle system, the veneer dryer wash down recycle
system, the log heating vat water recycle system, the oil/water separator facility, or the ESP Unit
recycle system;
7. a 9,000 gallon dirty water sump with a 2,000 GPM pump, four sidehill screens, a heat exchanger with
a heat transfer rate of 17,800 Btu per hour, a 17,000 gallon clean water sump with a 1,800 GPM
pump, and all associated piping, valves and appurtenances for water distribution,
all to serve the Georgia-Pacific Corporation Plywood/OSB Facility located in Dudley, North Carolina
with no discharge of wastes to the surface waters, pursuant to the application received June 4, 2009, 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 June 30, 2014, shall void Permit No.
WQ0003380 issued December 3, 2004, and shall be subject to the following specified conditions and
limitations:
1. SCHEDULES
No later than six months prior to the expiration of this permit, the Permittee shall request renewal of
this permit on official Division forms. Upon receipt of the request, the Division will review the
adequacy of the facilities described therein, and if warranted, will renew the permit for such period of
time and under such conditions and limitations as it may deem appropriate. Please note that Rule 15A
NCAC 02T .0105(d) requires an updated site map to be submitted with the permit renewal
application.
H. PERFORMANCE STANDARDS
The closed -loop recycle system shall be effectively maintained and operated at all times so that there
is no discharge to the surface waters, nor any contravention of groundwater or surface water
standards. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions due to improper operation and maintenance, the Permittee shall take immediate
corrective actions including those actions that may be required by the Division, such as the
construction of additional or replacement wastewater treatment, recycle, or disposal facilities.
2. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to ground
or surface waters resulting from the operation of this facility.
The COMPLIANCE BOUNDARY for residuals land application programs is specified by regulations in 15A
NCAC 2L (i.e., "Groundwater Classifications and Standards"). The Compliance Boundary for each land
application site is established at either 250 feet from the residuals land application area or 50 feet within the
property boundary, whichever is closest to the residuals land application area. Per 15A NCAC 2T .0105(h),
upon the request by the Permittee the Compliance Boundary may be located closer to the waste disposal area
(provided the groundwater standards can be met- at the newly established Compliance Boundary). An
exceedance of Groundwater Standards at or beyond the Compliance Boundary is subject to rernediation action
according to 15A NCAC 2L .0106(d)(2) as well as enforcement actions in accordance with North Carolini
General Statute 143-215.6A through 143-215.6C.
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4. The REVIEW BOUNDARY shall be established around each land application site midway between the
Compliance Boundary and the perimeter of the residuals land application area. Any exceedance of
Groundwater Quality Standards at the Review Boundary shall require action in accordance with 15A NCAC
2L .0106 (d)(l).
5. The facilities permitted herein must be constructed according to the following setbacks:
a. The setbacks for Treatment and/or Storage Units permitted after September 1, 2006 shall be as
follows (all distances in feet):
i. Any habitable residence or place of public assembly under separate ownership or 100
not to be maintained as part of the project site:
ii. Any private or public water supply source: 100
iii. Surface waters: 50
iv. Any well with the exception of a Division approved groundwater monitoring well: 100
v. Any property line: 50
b. The setbacks for wet decking disposal (wetted) areas permitted after September 1, 2006 shall be
as follows (all distances in feet):
i. Upslope ditches, drains, and surface water diversions: 10
ii. Downslope ditches, drains, and surface water diversions: 25
iii. Any well with the exception of a Division approved groundwater monitoring well: 100
iv. Public right of ways: 50
v. Any property line: 50
Some of the setbacks specified above may not have been included in previous...
III. OPERATION AND MAINTENANCE REQUIREMENTS
The facilities shall be properly maintained and operated at all times. 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 Permittee shall maintain an Operation and
Maintenance Plan pursuant to 15A NCAC 02T .1007 including operational functions, maintenance
schedules, safety measures, and a spill response plan.
2. Upon classification of the wastewater treatment and closed-Ioop recycle 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 08G .0200. The
ORC shall visit the facilities in accordance with 15A NCAC 08G .0200 or as specified in this permit
and shall comply with all other conditions specified in these rules.
3. The residuals generated from these treatment facilities must be disposed / utilized in accordance with
15A NCAC 02T .1100. The Permittee shall maintain a residual management plan pursuant to 15A
NCAC 02T .1008.
4. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
5. Freeboard in the Wet Storage Deck recycle pond shall not be less than two feet at any time.
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6. A waste -level gauge to monitor waste levels in the storage pond shall be provided. 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 the lowest point on top of the dam elevations.
7. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum allowable temporary storage elevation on the inside of the
embankment), 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.
IV. MONITORING AND REPORTING REQUIREMENTS
1. Any monitoring (including groundwater, surface water, soil or plant tissue analyses) deemed
necessary by the Division to ensure surface and ground water protection will be established and an
acceptable sampling reporting schedule shall be followed.
2. All laboratory analyses for effluent, ground waters, or surface waters shall be made by a laboratory
certified by the Division for the required parameter(s) under 15A NCAC 02H .0800.
3. Noncompliance Notification:
The Permittee shall report by telephone to the Washington Regional Office, telephone number (252)
946-6481, 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 basin or tank; 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.
d. Any time that self -monitoring information indicates that the facility has gone out of compliance
with its permit requirements.
For any emergency that requires immediate reporting (e.g., discharges to surface waters, imminent
failure of a storage structure, etc.) outside normal business hours must be reported to the Division's
Emergency Response personnel at telephone number [phone], [phone], or (919) 733-
3 300. 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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V. INSPECTIONS
1. Adequate inspection and maintenance shall be provided by the Permittee to ensure proper operation
of the subject facilities.
2. The Permittee or his designee shall inspect the wastewater treatment and recycle 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 five years from the date of the inspection and shall be
made available upon request to the Division or other permitting authority, upon request.
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. Failure to abide by the conditions and Iimitations 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.
2. 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.
3. This permit is effective only with respect to the nature and volume of wastes described in the
application and other supporting data. No variances to applicable rules governing the construction
and 1 or operation of the permitted facilities are granted unless specifically requested and granted in
this permit.
4. The issuance of this permit does not exempt 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) that have jurisdiction. Of particular concern to the Division are applicable river buffer
rules in I5A NCAC 02B .0200, erosion and sedimentation control requirements in 15A NCAC
Chapter 4 and under the Division's General Permit NCG10000, and any requirements pertaining to
wetlands under 15A NCAC 02B .0200 and 02H .0500.
5. 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 on official Division form(s),
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. The
Permittee of record shall remain fully responsible for compliance until a permit is issued to the new
owner.
6. The Permittee shall retain a set of approved plans and specifications for the life of the facilities
permitted herein.
7. The Permittee shall maintain this permit until all permitted facilities herein are properly closed or
permitted under another permit issued by the appropriate permitting authority.
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8. The Permittee must pay the annual fee 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
pursuant to 15A NCAC 02T .0105(e).
Permit issued this the 3 1 " day of July, 2009
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
r..
or Cohen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0003380
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