WQ0000485_Final Permit_19910517

V
State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27626-0535
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Mr. Kirby D. Brown
Valley Proteins, Incorporated
Route Two, Box 156
Winchester, Virginia 22601
Dear Mr. Brown:
George T. Everett, Ph.D.
Director
May 17, 1991
Subject: Permit Number WQ0000485
Valley Proteins, Incorporated
Rose Hill, NC Facility
Spray Irrigation System
Duplin County
In accordance with your application received October 22, 1990, we are forwarding
herewith Permit No. WQ0000485, dated May 17, 1991, to Valley Proteins, Incorporated for the
continued operation of and additions to an existing spray irrigation wastewater treatment and
disposal system.
This permit shall be effective from the date of issuance until December 31, 1993, shall
void Permit Number WQ0000485 issued January 12, 1989, 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 to you,
you have the right to request an adjudicatory hearing upon written request within 30 days
following receipt of this permit- This request must be in the form of a written petition, conforming
to Chapter 150B of North Carolina General Statutes, and filed with the Office of Administrative
Hearings, P.O. Drawer 27447, Raleigh, NC 27611-7447. Unless such demands are made this
permit shall be final and binding.
One set of approved plans and specifications is being forwarded to you. If you need
additional information concerning this matter, please contact Mr. Dana Bolden at 919/ 733-5083.
CC. Duplin County Health Department
Wilmington Regional Office
Groundwater Section
)orated
lratning and C:erbtifcation Unit
Facilities Assessment Unit
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

03" NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
1161TOaKean,
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
Valley Proteins, Incorporated
Duplin County
FOR THE
continued operation of existing wastewater treatment and disposal facilities consisting of a
dissolved air flotation (DAF) unit, a 100,000 gallon aerobic holding tank, a 1.4 acre unlined
aerated lagoon, a 2.8 acre unlined aerated lagoon, a 2.8 acre unlined, non-aerated lagoon, an
effluent pumping station with duplex pumps, four spray irrigation fields totaling approximately
25.5 acres, a 7.2 million gallon recycled process water lagoon, two mechanical catch basins, and a
blood collection tank and the construction and operation of additional wastewater treatment and
disposal facilities consisting of an additional 11.7 acre spray irrigation field (Field 5) divided into
four irrigation zones and all associated piping and appurtenances to serve Valley Proteins,
Incorporated with no discharge of wastes to the surface waters, pursuant to the application received
October 22, 1991 and in conformity with the project plan, specifications, and other supporting data
subsequently filed and approved by the Department of Environment, Health and Natural Resources
and considered a part of this permit.
This permit shall be effective from the date of issuance until December 31, 1993, and shall
be subject to the following specified conditions and limitations:
I. PERFORMANCE STANDARDS
1. Upon completion of construction and prior to operation of the additions to this permitted
facility, a certification must be received from a professional engineer certifying that the
permitted facility has been installed in accordance with this permit, the approved plans
and specifications. Mail the Certification to the Permits and Engineering Unit, P.Q. Box
29535, Raleigh, NC 27626-0535.
2. The Wilmington Regional Office, phone no. [phone], shall be notified at least
forty-eight (48) hours in advance of operation of the installed facilities so that an
in-place inspection can be made. Such notification to the regional supervisor shall be
made during the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through
Friday, excluding State Holidays.

3. 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 absorb the wastewater, the Permittee shall take such
immediate corrective action to correct the problem, including actions as may be required
by the Division of Environmental Management.
4. This permit shall become voidable in the event of failure of the soil to adequately absorb
the wastewater. Ponding of wastewater on the surface of an irrigation zone when the
next irrigation cycle commences shall be considered evidence of failure of th(-,-soils to
adequately absorb the wastewater. Additionally, such failure shall be interpreted as a
violation of this pen -nit condition.
5. 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.
5. The sludge generated from these treatment facilities must be disposed of in accordance
with General Statute 143-215.1 and in a manner approved by the North Carolina
Division of Environmental Management.
7. Diversion or bypassing of the untreated wastewater from the treatment facilities is
prohibited.
8. The following buffers shall be maintained:
a) 400 feet between wetted area and any residence 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,
g) 50 feet between wastewater treatment units and property lines.
11. OPERATION AND MAINTENANCE REQUIREMENTS
1. The facilities shall be properly maintained and operated at all times.
2. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade
at least equivalent to the classification assigned to the wastewater treatment facilities by
the Certification Commission. Once the facility is classified, the Permittee must submit a
letter to the Certification Commission which designates the operator in responsible
charge.
3. A suitable vegetative cover shall be maintained on all spray irrigation areas. The crop
management plan developed by Robert Rendall and Associates and submitted as a part
of this application shall be followed in the operation of this facility.
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.
The ground surface shall be scarified as necessary to prevent the sealing of the surface
sufficient to cause ponding on the irrigation site(s).
RN

6. 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 initial application rates shall be as follows:
Area Initial Application Rate
Fief acre inches ptr w ek
1 2.5 0.50
2 2.9 0.50
3 7.5 0.70
4 12.6 0.70
5 11.7 0.90 -
The loading rates may be increased after thorough review and demonstration to the
satisfaction of the Wilmington Regional Supervisor that the system is capable of
operating at an increased loading rate. Increased loading rates, as authorized by the
Wilmington Regional Supervisor, shall not exceed the following maximum hydraulic
loadings:
No type of wastewater other than that from Valley Proteins, Incorporated shall be
sprayed 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. A minimum of two feet of freeboard shall be maintained in all treatment and storage
lagoons at all times.
12. The six spray heads marked with an "X" on Figure 3 of the information submitted by
Robert Kendall and Associates must be properly capped off and removed from service.
III. MONITORING AND -REPQRTIN T REQILIREMENTS
1. Any monitoring (including groundwater, surface water, soil or plant tissue
analyses) deemed necessary by the Division of Environmental Management 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:
3
Area
Maximum Application Rate
Field
acre
(inches per, week)
1
2.5
1.00
2
2.9
1.00
3
7.5
1.40
4
12.6
1.40
5
11.7
1.80
No type of wastewater other than that from Valley Proteins, Incorporated shall be
sprayed 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. A minimum of two feet of freeboard shall be maintained in all treatment and storage
lagoons at all times.
12. The six spray heads marked with an "X" on Figure 3 of the information submitted by
Robert Kendall and Associates must be properly capped off and removed from service.
III. MONITORING AND -REPQRTIN T REQILIREMENTS
1. Any monitoring (including groundwater, surface water, soil or plant tissue
analyses) deemed necessary by the Division of Environmental Management 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:
3

a) date of irrigation, 0.�
b) volume of wastewater irrigated,
c) field irrigated,
d) length of time field is irrigated,
e) volume of water applied to specific field(s)
f) continuous weekly, monthly, and year-to-date hydraulic (inches/acre) loadings
for each field,
g) weather conditions,
h) maintenance of cover crops and activities on fields (mowing, scarifying, etc.),
i) abnormalities on field(s) (ponding, runoff, etc.),
j) collection of samples (wastewater and/or surface water) for analysis), and
k) any maintenance performed on the wastewater treatment and/or irrigation facilities
3. Samples shall be collected twice per month from the storage lagoon and analyzed by a
certified laboratory for the following parameters:
TKN NH3 as N
NO3 Total Coliform
Total Organic Carbon (TOC) BODS
TSS Sodium
Magnesium Calcium
pH Sodium Adsorption Ratio by Calculation
4. Samples shall be collected monthly from the surface waters at the four locations marked
as VP -1, VP -2, VP -3, and VP -4 on Figure 1 (attached). The samples shall be analyzed
by a certified laboratory for the following parameters:
TKN NH3 as N
NO3 Total Coliform
Total Organic Carbon (TOC)
5. Three copies of all operation and disposal records (as specified in condition 111 2),
all effluent monitoring data (as specified in condition 111 3), all surface water quality
monitoring (as specified in condition 111 4), and any other data as may be required shall
be submitted on or before the last day of the month following sampling to the following
address:
NC Division of Environmental Management
Water Quality Section
Attention: Central Files
PO Box 29535
Raleigh, NC 27626-0535
6_ Noncompliance Notification:
The Permittee shall report by telephone to the Wilmington Regional Office,
telephone no. [phone], 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.
.19

c. Any failure of a pumping station, sewer line�,)ptreatment 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 15 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. A 150 foot buffer shall be maintained between the perimeter of the expansion spray
field and the property line.
2. All buffers as specified in 15A NCAC 2H.0219 shall be observed
3. Within 90 days of permit issuance, three (3) monitor wells, one (1) upgradient and
two (2) downgradient, shall be installed to monitor groundwater quality in the area
of the expansion spray field. The well(s) shall be constructed such that the water
level in the well is never above or below the screened (open) portion of the well at
any time during the year. However, the exact location and construction details for
these wells shall be approved by the Wilmington Regional Office, from which a
well construction permit must be obtained.
4. The three (3) new monitor wells must be sampled initially after construction and
thereafter along with existing monitor wells MW -1, MW -2, and MW -3 every March,
July, and November for the following parameters:
NO3 (10.0) TDS (500.0)
TOC pH ( 6.5-8.5 standard units)
Ammonia Nitrogen Chlorides (250.0)
Water Level Total Coliforms (1/100 ml)
Total Suspended Solids SO4(250.0)
Volatile Organic Compounds - In November only (by Method 1 or Method
2 below)
Method 1: Method 6230D ( Capillary - Column), "Standard Methods for
the Examination of Water and Wastewater", 17th edition, 1989
Method 2: Method 502.2 " Methods for the Determination of Organic
Compounds in Drinking Water", United States Environmental
Protection Agency - 600/4-88/039
The measurement of water level must be made prior to sampling for the remaining
parameters.
The measuring points (top of well casing) of all monitoring wells shall be
surveyed to provide relative elevations of the measuring point for each of the
monitoring wells. The depth of water in each well shall be measured from the
surveyed point on the top of the casing.
5

The numbers in parentheses represent the maximum allowable concentrations in
zroundwater for the various analytical parameters, as specified in 15 NCAC 2L
[Groundwater Classifications and Standards]. Unless otherwise noted, the
concentrations are given in parts per million.
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 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 downgxadient
wells shall be subject to the additional sampling and analysis as described above.
If any volatile organic compounds are detected by method 6230D, or the equivalent
method 502.2, then EPA methods 604 and 611 must also be run to detect other
organic compounds which may be present, The results of all analysis specified in
the monitoring requirements, including 604 and 611 if required, must be submitted
simultaneously.
The results of the sampling and analysis shall be sent to the N.C. Division of
Environmental Management on Form GW -59 (Compliance Monitoring Report
Form) every April, August, and December.
2. The Compliance Boundary delineated on the attached site plan for the disposal
system is specified by regulations in 15 NCAC 2L, Groundwater Classifications and
Standards. An exceedance of Groundwater Quality Standards beyond the
Compliance Boundary is subject to penalty provisions applicable under General
Statute 143-215.6(1)a. The sale of property, by the Permittee, which is within or
contiguous to the disposal system site may alter location of the Compliance
Boundary.
For facilities permitted on or after December 30, 1983, the Compliance Boundary is
established at the lesser of 250 feet from the waste disposal area, or 50 feet within
the property boundary.
If the title to any property which may affect the location of the Compliance Boundary
is changed, the permittee shall notify the Division Director within 14 days. The
Director shall then establish a modified Compliance Boundary which will be done as
a modification to the Permit.
The REVIEW BOUNDARY delineated on the attached site map for the disposal
system is specified by regulations in 15 NCAC 2L, Groundwater Classifications
and Standards. A REVIEW BOUNDARY is established around disposal systems
midway between the Compliance Boundary and the perimeter of the waste disposal
area. When the concentration of any substance equals or exceeds the maximum
allowable concentration of that substance at the REVIEW BOUNDARY, as
determined by monitoring, the permittee shall either (i) demonstrate, through
predictive calculations or modeling, that natural site conditions, facility design and
operational controls will prevent a violation of standards at the Compliance
Boundary; or, (ii) submit a plan for the alteration of existing site conditions, facility
design or operational controls that will prevent a violation of standards at the
Compliance Boundary, and implement that plan upon its approval by the Director.
Any additional groundwater quality monitoring, as deemed necessary by the
Division, shall be provided.

�r� � V. INSPECTIONS
1. 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 in cluding--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 of Environmental Management or other permitting
authority.
3. Any duly authorized officer, employee, or representative of the Division of
Environmental Management may, upon presentation of credentials, enter and inspect
any property, premises or place on or related to the disposal site and facility at any
reasonable time for the purpose of determining compliance with this permit; may inspect
or copy any records that must be kept under the terms and conditions of this permit; or
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, 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 chanL-e
ownership, or there is a name change of the Permittee, a formal permit request must b--
submitted
esubmitted to the Division of Environmental Management 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 of Environmental Management in
accordance with North Carolina General Statute 143-215.6.
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. Prior to any transfer of this land, a notice shall be given to the new owner that gives full
details of the materials applied at this site.
7. The permittee shall advise the Wilmington Regional Office in writing of the name of the
designated Farm Manager and an alternate Farm Manager. Any change in these
assignments shall be promptly reported in writing to the Wilmington Regional Office.
8. The farm manager shall be provided with a copy of this permit and shall keep it updated
with any and all changes/modifications to this permit as they occur.
7

9. The permittee shall submit plans and specifications for disinOe facilities on or before
July 31, 1991 and shall complete construction of and place in operation the disinfection
facilities within 90 days of receiving approval from the Division.
10. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of the project.
11. The annual administering and compliance fee must be paid by the Permittee within thirty
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 15 NCAC 2H .0205
(c)(4).
12. 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 17th day of May, 1991
TH CAROLINA
George T. E nett, it
Division of E ironmc
By Authority of t
Permit Number WQ0000485
AL MANAGEMENT COMMISSION
agement
ital Management Commission

Permit No. WQ0000485
May 17, 1991
Engineer's Certification
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project, , for the
Project Name Location
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the
observation of the construction such that the construction was observed to be built within substantial
compliance and intent of the approved plans and specifications.
Signature
Date
Registration No

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FIGURE 1. LOCATION MAP ROBERT KENDAL L
VALLEY PROTEINS, INC. & ASSOCIATES

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