HomeMy WebLinkAboutWQ0000485_Final Permit_20051107o�oF w� r�RQG Michael F, Easley, Governor
William G. Ross Jr., Secretary
r North Carolina Department of Environment and Natural Resources
'C Alan W. Klimek, P.E. Director
Division of Water Quality
November 7, 2005
Tom A. Gibson, Director of Environmental Affiars
Valley Proteins, Inc.
PO Box 3588
Winchester, VA 22604
Subject: Permit No. WQ0000485
Carolina By -Product, Rose Hill
Wastewater Surface Irrigation
Duplin County
Dear Mr. Gibson.
In accordance with your renewal request received September 1, 2005, we are forwarding herewith
Permit No, WQ0000485, dated November 7, 2005, to Valley Proteins, Inc. for the continued operation of
the subject wastewater treatment and surface irrigation facilities.
This permit shall be effective from the date of issuance until October 31, 2010, shall void Permit
No. WQ0000485 issued October 16, 2001, 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 150E 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
(919) 715-6173 or miranda.williams@ncmail.net.
W. Klimek,
cc: Duplin County Health Department
Wilmington Regional Office, Aquifer Protection Section
Art Riddick, PE — Reid Engineering Company, Inc.
Technical Assistance and Certification Unit
APS Central Files
LAU Files
Miranda Williams at
North Carolina
Natura!!ry
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone (919) 733-3221 Customer Service
Internet: h2o.enr.state. ne.us 2728 Capital Boulevard Raleigh, NC 27604 FAX (919) 715-6048 1-877-623-6748
An Equal Opportunity/Affirmative Action Employer — 50% Recycled110% Past Consumer Paper
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, General Statutes of North Carolina as
amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Valley Proteins, Inc.
Duplin County
FOR THE
continued operation of a 300,000 gallon per day (GPD) wastewater treatment and disposal facility with
138,000 GPD disposed by spray irrigation and an additional 162,000 GPD evaporated in a cooling tower
and recycled Back into the facility.
The existing 243,000 -GPD wastewater treatment facility consists of a raw wastewater collection pump
station, a screen surge tank, a Sweco mechanically -cleaned bar screen, a screen effluent wet well and a
dissolved air flotation (DAF) cell influent pump station, a DAF cell with an effluent pump station, a 3.5 -
million -gallon, seven-day aerated flow equalization lagoon (Lagoon No. 1) with four 20 -HP surface
aerators, four 30 -HP surface aerators, and three 15 -HP surface aerators, a 200 -GPM flow equalization
pump station with dual pumps, force main, and flow meter, a 1.67 -million -gallon, completely -mixed
activated sludge (CMAS) basin with two 50 -HP jet aerator manifolds and two 200 -HP centrifugal
corepressors, one 500 -gallon polymer flocculent solution mix storage tanks with a 1 -HP tank mixer and
one polymer solution pump, a flotation clarifier with dual 75 -GPM recycle pressure pumps and a
magnetic flow meter, sludge collection tank with dual 30 -GPM progressive cavity sludge return pumps, a
1.3 -million -gallon waste sludge aerobic digester with a 60 -HP aerator and chemical feed equipment
consisting of a a 4,000 gallon magnesium hydroxide tank with mixer and pump, an effluent flow meter, a
146 -GPM clarifier effluent pump station with dual pumps, two 2.8 -acre unlined, non-aerated lagoons, a
7.2 -million -gallon recirculation lagoon, and a gaseous chlorine chemical feed system.
The 138,000 GPD spray irrigation disposal system consists of the operation of a spray irrigation pump
station with an existing 650 -GPM pump, four existing spray irrigation fields (Fields #I, 2, 3, and 5) and
four previously permitted spray irrigation fields (Field #6, 47, 98 and 49) totaling 70.44 acres.
The wastewater treatment and spray irrigation disposal system will serve the Carolina By -Product, Rose
Hill Division, with no discharge of wastes to the surface waters, pursuant to the application received
September 1, 2005, and subsequent additional information received by the Division, 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 October 31, 2010, shall void Permit
No. WQ0000485 issued October 16, 2001, and shall be subject to the following specified conditions and
limitations:
I. PERFORMANCE STANDARDS
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 perforin 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, 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.
3. 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
1. 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 and winter rye shall be maintained. Fescue
may also continue to be used on a trial basis on Field 6.
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 irrigation field.
6. The facilities small 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 the following:
a. An instantaneous application rate of 0.2 inches per hour.
b. A maximum nitrogen loading of 350 pounds of Plant Available Nitrogen (PAN) per acre per year
for fields containing coastal bermuda grass (300 lbs./acre PAN) overseeded with winter rye (50
lbs./acre PAN) and a maximum nitrogen loading of 250 pounds of PAN per acre per year for
fields containing corn (silage) (150 lbs./acre) overseeded with winter rye (100 lbs./acre). If any
other crops are to be grown on the subject irrigation fields, a crop management plan outlined by
the local Extension Office, the Department of Agriculture, the Natural Resource Conservation
Service, or other agronomist should be maintained and PAN loading rates shall not exceed the
realistic yield expectation for those crops.
c. The following cumulative hydraulic loadings should not be exceeded for the appropriate spray
irrigation held over any twelve-month period:
Cumulative Loadings
Field _# Acres (inches per twelve month period)
1 6.84
26.0
2 3.59
26.0
3 8.44
36.4
5 13.83
46.8
6 12.9
31.2
7 5.86
65.0
8 7.55
65.0
9 11.43
31.2
8. No type of wastewater other than that from Carolina By -Product, Rose Hill shall be irrigated onto the
irrigation area.
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 all treatment and storage lagoons shall not be less than two feet at any time.
12. If not already installed, a waste-Ievel gauge, to monitor waste levels in the storage ponds, 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 darn
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.
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. Influent flow shall be continuously monitored and daily flow values shall be reported on Form
NDMR.
The Permittee shall install an appropriate flow measurement device consistent with approved
engineering and scientific practices to ensure the accuracy and reliability of influent flow
measurement. 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. The Permittee shall keep records of flow measurement
device calibration on file 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
The effluent from the subject facilities shall be monitored by the Permittee at the point prior to
irrigation every Marcia, July, and November for the following parameters:
NH3 as N
NO2-NO3
Total Coliform
BODS
TKN
Total Phosphorous
TSS
Sodium
Magnesium
H
Calcium
Sodium Adsorption Ratio by Calculation
Chloroform
Total Organic Carbon
JPlant Available Nitrogen (PAN) (by calculation}
4. Samples shall be collected monthly from the surface waters at the four Iocations previously identified
as VP -I, VP -2, VP -3, and VP -4 and analyzed by a certified laboratory for the following parameters:
NH3 as N
Total Coliform
Total Organic Carbon (TOC)
TKN
Nitrate
5. The Permittee tracking the amount of wastewater disposed shall maintain adequate records. 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 and nitrogen (lbs
PAN/acre) loadings for each field,
f. Weather conditions,
g. Maintenance of cover crops,
h. Abnormalities for each field (e.g., ponding, runoff, etc.),
i. Collection of samples (wastewater and/or surface water) for analysis,
j. Any maintenance performed on the wastewater treatment and/or irrigation system, and
k. The solids level within each lagoon shall be .measured and recorded annually.
4
6. Three (3) copies of all monitoring data [as specified in Conditions III(2) and I11(3)] on Form NDMR-
I and three (3) copies of all operation and disposal records [as specified in Conditions IU(4) and
HI(5)] on Form ND.A_R-1 shall be submitted on or before the last day of the following month. All
information shall be submitted to the following address:
Division of Water Quality
Information Processing Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
7. An annual representative 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
Base Saturation (by calculation) Phosphorus
Cation Exchange Capacity
I Exchangeable Sodium Percentage
8. The exchangeable sodium percentage (ESP) shall be monitored on the spray irrigation sites using the
results from the annual soils analysis. The local Extension Office, the Department of Agriculture, the
Natural Resource Conservation Service or a North Carolina Licensed Soil Scientist will review the
results and make recommendations to adjust the spray irrigation fields as necessary to ensure they
continue to function properly.
9. Noncompliance Notification:
The Permittee shall report by telephone to the Wilmington Regional Office, telephone number (9 10)
796-7215, 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 (800) 662-7956, (800) 858-0368, or (919) 733-3300.
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. Sampling Criteria:
a. Monitor well(s) MW -1, MW -2, MW -4, MW -6, MW -7, and MW -8 (in the vicinity of spray fields 1,2,3,5)
and monitor wells MW -10, MW -11, MW -12, and MW -13 (in the vicinity of spray fields 6,7,8,9), as
depicted on the attached site maps, shall be sampled every March, July, and November 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.
Chloride Total Ammonia
Fecal Coliforms Total Dissolved Solids (TDS)
Nitrate (NO3 as N) Total Organic Carbon (TOC)
PH Total Phosphorus
Sodium Water Level
Sulfate
Volatile Organic Compounds (VOS) — In November only
b. For Total Organic Carbon (TOC), if concentrations greater than 10 mg/l 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/l, 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.
c. For Volatile Organic Compounds (VOCs) sampled in November, 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.
d. Any laboratory selected to analyze parameters must be Division of Water Quality (DWQ) certified for
those parameters required.
2. Reporting / Documentation:
a. Ail reports and documentation (GW -1, GW -30, GW -59) shall be mailed to the following address:
Division of Water Quality
Information Processing Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Updated blank forms (GW -1, GW -30, GW -59) may be downloaded from the Groundwater Section's
website at ht -HRw.ehnr.state.nc.us/ or requested from the address mentioned above.
b. The results of the sampling and analysis must be received on Form GW -59 (Groundwater Quality
Monitoring: Compliance Report Foran) 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 tb-
permit conditions must be reported using the most recent GW -59 form along with attached copies of th,
laboratory analyses.
3. Vertical Separation Requirements:
a. Industrial waste shall not be applied or discharged onto or below the land surface when the vertical
separation between the waste and the seasonal high water table is less than three (3) feet, unless the
permittee has demonstrated to the Director or his delegate, by using predictive calculations or modeling
methods acceptable to the Director or his delegate, that such placement will not result in the contravention
of classified groundwater standards. Verification of the water table elevation can be confirmed by water
level readings obtained from the monitor wells at the sites, within 24 hours prior to application of
wastewater.
4. Applicable Boundaries:
a. 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
remediation action according to 15A NCAC 2L .0106(d)(2).
b. 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 Revie-
Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
5. Additional Requirements:
a. 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 pen -nit; 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 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 exempt the Permittee from complying with any and all statutes,
rules, regulations, or ordinances which may be imposed by other government agencies (Iocal, 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.
6. The Permittee shall retain a set of approved plans and specifications for the life of the project.
7. The Permittee must pay the annual administering and compliance 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 as specified by 15A NCAC 2H.0205 (c)(4).
8. 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.
9. The Permittee shall advise the Wilmington Regional Office in writing of the name of the designated
farm manager and the alternate farm manager. Any change in these assignments shall be promptly
reported in writing to the Wilmington Regional Office.
10. The farm manager shall be provided with a copy of this permit and shall keep the permit updated with
any and all modifications or changes as they occur.
Permit issued this the/fth day of November, 2005
NORTH
AL MANAGEMENT COMMISSION
,,Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0000485
i
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