WQ0000884_Final Permit_20020412

F WaT�
CSO 9Q Michael F. Easley, Governor
9 William G. Ross Jr., Secretary
> North Carolina Department of Environment and Natural Resources
—i
Gregory I Thorpe. Ph.D., Acting Director
Division of Water Quality
April 12, 2002
Dan Blackshear, President
Carolina Turkeys
PO Box 589
Mt. Olive, NC 28365
Subject: Permit No. WQ0000884
Carolina Turkeys
Wastewater Spray Irrigation
Duplin County
Dear Mr. Blackshear:
In accordance with your application received August 1, 2001, we are forwarding herewith Permit No. WQ0000884, dated
April 12, 2002, to Carolina Turkeys for the continued operation of the subject wastewater treatment and spray irrigation
facilities.
This permit shall be effective from the date of issuance until March 31, 2007, shall void Permit No. WQ0000884 issued
February 24, 1997, 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 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.
Please note Condition I.1 requiring submittal of a permit modification to address future nutrient limits. Please note
Condition II. 12 and Condition 11.13. requiring maintenance of lagoon embankments and a waste -level gauge to be
installed in the lagoon.. Please also note the monitoring and recording Section III that has been modified from the
previous version of Permit Number WQ0000884.
If you need additional information concerning this matter, please contact Sue H ewood at [phone] extension 502.
Sinc r y,
Gregory J. Thorpe, Ph -D.
cc: Duplin County Health Department
Wilmington Regional Office, Water Quality Section
Wilmington Regional Office, Groundwater Section
Groundwater Section, Central Office
Reid Engineering Company, Inc.
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
Water Quality Central Files
NDPU Files
Non -Discharge Permitting Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
DENR Customer Service Center
An Equal Opportunity Action Employer
Internet http://h2o.enr.state.nc.us/ndpu
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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
Carolina Turkeys
Duplin County
• ; "11
continued operation of a 1,500,000 GPD spray irrigation treatment and disposal facility consisting of a 36,400
GPD extended aeration package wastewater treatment plant for domestic waste with a bar screen, a 10,000 gallon
aerated equalization tank, a 36,4000 gallon aeration tank with dual blowers, an aerobic digestor, a 6,000 gallon
clarifier, and chlorine contact chamber, a 41 MG holding lagoon, a 15 MG aerated lagoon with four (4) 60 HP
high speed surface aerators, a flow equalization basin with mixing equipment, two (2) dissolved air floatation
units operated in parallel, a sludge pump station, a sludge storage tank, a sludge decant observation tank, chlorine
disinfection facilities, and approximately 392 acres of spray irrigation disposal area to serve Carolina Turkeys,
with no discharge of wastes to the surface waters, pursuant to the renewal request received August 1, 2001, 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 March 31, 2007, shall void Permit No.
WQ0000884 issued February 24, 1997, and shall be subject to the following specified conditions and limitations:
I. PERFORMANCE STANDARDS
The Permittee shall submit a request to the Division level& -by August 1, 2002 to modify the
wastewater treatment system to include a Biological Nutrient Removal Upgrade to reduce effluent
Plant Available Nitrogen (PAN). The upgrade to the system will be designed so that the wastewater
treatment system will not exceed a cumulative loading of 350 lbs per acre per active growing season
of Coastal Bermuda and a cumulative loading of 50 lbs per acre per active growing season of small
grain overseed. Construction of the approved wastewater treatment system upgrade shall be complete
within six months of permit issuance.
2. 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.

3. 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.
4. 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.
5. Diversion or bypassing of the untreated wastewater from the treatment facilities is prohibited.
6. 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.
7. The name of the farm manager and designated alternate farm manager shall be provided to the
Wilmington Regional Office in writing. Any change in these assignments shall be promptly reported
in writing to the Wilmington Regional Office.
H. 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.
3. A suitable vegetative cover of Coastal Bermuda Grass overseeded with a small grain 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.
2

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 application rate shall not exceed the following cumulative loadings over any twelve (12) month
period at an instantaneous application rate not to cause runoff:
Cumulative Loading
Zone (inches per twelve month period
IA, 1B, IC, 2A, 213, 2C, 3 50.0
5,7
I1 1
7A (Application shall not exceed the minimum necessary for crop maintenance)
8A
40.0
8B
30,0
8C
25.0
9A
40.0
9B
10.0
9C
25.0
IOA
35.0
I OB
30.0
lOC
35.0
Areas previously designated as Zone 4 and Zone 6 shall not be used for wastewater irrigation.
8. No type of wastewater other than that from Carolina Turkeys shall be sprayed onto the irrigation area.
9. No traffic or equipment shaII 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 lagoons shall not be less than two feet at any time.
12. A waste -level gauge, to monitor waste levels in the storage pond, 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 dam 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
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.
3

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. continuous weekly, monthly, and year -to -late PAN (pounds/acre) loadings for each field and
crop,
g. nitrogen balance for each field and crop after an application event,
h. any ponding or runoff of wastewater from the irrigation fields,
i. maintenance of cover crops,
j. maintenance performed on the wastewater treatment and irrigation facilities, and
k. wastewater and surface water sample collection activities.
3. 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. Records of flow measurement device calibration shall be
kept on file by the Permittee 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
Plans and specifications for the flow measuring device shall be prepared by a licensed Professional
Engineer and submitted to the appropriate regional office 30 days prior to installation. The flow
measuring device shall be installed within 1 year of the date of this permit.
4. The effluent from the subject facilities shall be monitored by the Permittee at the point prior to
irrigation twice per month for the following parameters:
BODS TSS
Total Coliform pH
NH3 as N Total Kjeldahl Nitrogen
NO3 as N Oil and Grease
Total Organic Carbon Sodium
Magnesium Calcium
Sodium Adsorption Ratio by Calculation
5. Samples shall be collected monthly from the surface waters at the five locations marked by an "X" on
Figure 1 and analyzed by a certified laboratory for the following parameters:
Total Organic Carbon Total Kjeldahl Nitrogens
Nitrates Total Coliform
NH3 pH
6. The Permittee shall maintain records of all cutting and harvesting events on the irrigation fields.
These shall include the date of cutting or harvesting, how many acres are harvested, and the amount
of hay harvested.
4

IV.
7. Three (3) copies of operation and disposal records (as specified in condition 1112) on Form NDAR-1
(hydraulic information) and Form IRR -2 (nutrient information), three (3) copies of all effluent
monitoring data (as specified in condition 1113 and 111 4) on Forza NDMR-1, and three (3) copies of
surface water monitoring data (as specified in condition 111 5) shall be submitted on or before the last
day of the following month. 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
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
Calcium
Copper
Magnesium
Cation Exchange Capacity
9. Noncompliance Notification:
Manganese Potassium
Percent Humic Matter Sodium
PH Zinc
Exchangeable Sodium Percentage Phosphorus
Base Saturation (by calculation)
The Permittee shall report by telephone to the Wilmington Regional Office, telephone number (910)
395-3900, 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.
GROUNDWATER REQUIREMENTS
Within ninety (90) days of permit issuance, monitor wells MW -19 and MW -20 shall be installed to
monitor groundwater quality. The wells 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. The
general location and name for each well is marked on Figure 3. Each monitoring well shall be
constructed in accordance with this permit and approved by the Wilmington Regional Office.

The wells must be constructed by either a North Carolina Certified Well Contractor, the property
owner, or the property lessee according to General Statutes 87-94.4(b)(2). If the construction is not
performed by a certified well contractor, the property owner or lessee must physically perform the
actual well construction activities, and the well must be constructed according to the North Carolina
Well Construction Standards (15A NCAC 2C _0108) and the Iocal county rules.
Within sixty (60) days of permit issuance, monitor wells MW -7 and MW -8 shall be permanently
abandoned. Within thirty (30) days of abandonment, a Well Abandonment Record (GW -30 form)
shall be completed for each well abandoned and mailed to the address listed in the "Reporting /
Documentation' section of the Groundwater Requirements. The wells must be abandoned by either a
North Carolina Certified Well Contractor, the property owner, or the property lessee according to
General Statutes 87-94.4(b)(2). If the abandonment is not performed by a certified well contractor,
the property owner or lessee must physically perform the actual well abandonment activities and the
wells must be abandoned according to the North Carolina Well Construction Standards (15A NCAC
2C .0113) and local county rules.
4. The Wilmington Regional Office, telephone number [phone], shall be notified at least forty-
eight (48) hours prior to the construction of any monitor well so that an inspection can be made of the
monitoring well location. Such notification to the regional groundwater 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.
5. Within thirty (30) days of completion of all well construction activities, a certification must be
received from a professional engineer or a Iicensed geologist certifying that the monitoring wells are
located according to this permit.
6. Monitor wells MW -4, MW -9, MW -15, MW -18, MW -19 and MW -20 shall be sampled every
January, May, and September 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.
Nitrate Nitrogen (NO3-N)
Total Organic Carbon (TOC)
Water Level
Chemical Oxygen Demand (COD)
Total Phosphorous
Total Ammonia Nitrogen (NH3-N)
Total Dissolved Solids (TDS)
pH
Chloride
Fecal Coliform
Oil & Grease
For Total Organic Carbon (TOC), if concentrations greater than 10 mg/1 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.
Any laboratory selected to analyze parameters must be Division of Water Quality (DWQ) certified
for those parameters required.
The results of the sampling and analysis must be received on Form GW -59 (Groundwater Quality
Monitoring: Compliance Report Form) by the Groundwater Section (address listed in the "Reporting 1
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 the
permit conditions must be reported using the most recent GW -59 form along with attached copies of
the laboratory analyses.
6

7. Al[ reports and documentation (GW -1, GW -30, GW -59) shall be mailed to the following address:
Groundwater Section
Permits and Compliance Unit
1636 Mail Service Center
Raleigh, NC 27699-1636
Updated blank farms (GW -1, GW -30, GW -59) may be downloaded from the Groundwater Section's
website at http:Hgw.ehnr.state.nc.us/ or requested from the address mentioned above.
8. 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 after December 31, 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 immediate remediation action according to 15A NCAC 2L .0106(d)(2).
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 Review Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
9. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
10. Two of the wells that supplies water to the plant processes (near Spray Area No. 5) are situated inside
of the Compliance Boundary. Within sixty (60) days of permit issuance, construction details for both
wells, and any other potable wells situated within the Compliance Boundary, shall be furnished to
the Groundwater Section at the Wilmington Regional Office, 127 Cardinal Drive Extension,
Wilmington, NC 28405-3845. Water withdrawn from these wells must meet the 15A NCAC 2L
Groundwater Quality Standards.
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
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 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.
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) which have jurisdiction, including but not limited to applicable river buffer rules in 15A
NCAC 2B .0200, erosion and sedimentation control requirements in ISA NCAC Chapter 4 and under
the Division's General Permit NCGO10000, and any requirements pertaining to wetlands under 15A
NCAC 2B .0200 and 2H .0500.
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 revoke 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`s day of April, 2002
hi,
NORTY AROLINA NMENTAL MANAGEMENT COMMISSION
r -
Gregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0000884

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FIGURE 1
SCALE IN FEET �—� CAROUNA TURKEYS —
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1539 (SPRAY 1MGATION SYSTM
DUPLIN COUNTY
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SCA[ E 1:24 000 SITE LOCATION MAP

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FI7-G��URE 2
CAROLINA TURKEYS
SPRAY IRRIGATION SYSTEM
DUPLIN COUNTY
WQ0000884/GWOI149
SITE DETAIL MAP

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FIGURE 3
CAROLINA TURKEYS
SPRAY IRRIGATION SYSTEM
DUPLIN COUNTY