WQ0000902_Final Permit_19931112

State of North Carolina
Department of Environment,
Health and Natural Resources
D visio-n of Environmental Management
.lames B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
November 12, 1993
Mr. Ernest Hardison, Plant Manager
Washington Packaging Company, Inc.
Post Office Box 753
Washington, North Carolina 27889
&T0'J.9VVA
74
C)EHNF1
Subject: Permit No. WQ0000902
Washington Packaging Company, Inc.
Wastewater Recycle System
Beaufort County
Dear Mr. Hardison:
In accordance with your application for permit renewal received August 19, 1993, we are
forwarding herewith Permit No. WQ0000902, dated November 12, 1993, to Washington Packaging
Company, Inc. for the continued operation of the subject wastewater recycle system.
This permit shall void Permit No. WQ0000902 issued May 17, 1989 and shall be effective from
the date of issuance until October 31, 1998, 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 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.
If you need additional information concerning this matter, please contact Ms. Angela Y. Griffin at
9191733-5083.
cc:
Sincerely,
(�
a
A. Prest Howard, Jr., P.E.
Beaufort County Health Department
Washington Regional Office, Water Quality Section
Washington Regional Office, Groundwater Section
Mr. ,lack Floyd, Groundwater Section, Central Office
Training and Certification Unit
Facilities Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
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
Washington Packaging Company, Inc.
Beaufort County
FOR THE
continued operation of a 5,000 GPD wastewater recycle system consisting of a grease trap and a 0.5 acre
holding lagoon to serve Washington Packaging Company, Inc. with no discharge of wastes to the surface
waters, pursuant to the application received August 19, 1993 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 void Permit No. WQ0000902 issued May 17, 1989 and shall be effective from
the date of issuance until October 31, 1998, and shall be subject to the following specified conditions and
limitations:
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. The facilities shall be properly maintained and operated at all times.
4. 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 of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.

5. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORQ 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 Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .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 Title 15A, Chapter 8A, .0202.
6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. 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.
8. 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.
9. 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.
10. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
11. Freeboard in the 0.5 acre holding lagoon shall not be less than two feet at any time.
12. Any monitoring 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.
13. A staff gauge, for the purpose of determining liquid waste levels, shall be installed in the
waste lagoon.
14. The Permittee shall maintain monthly monitoring reports which include weekly readings of
the staff gauge and the gallons of water used each month by Washington Packaging
Company, based on water readings.
15. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
16. The Permittee or his designee shall inspect the wastewater 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 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.
2

17. 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 recycle system 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.
18. 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 15 NCAC 2H .0205
(c)(4).
19. 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 143-215.6A to 143-215.6C.
20. 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.
21. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
22. Noncompliance Notification:
The Permittee shall report by telephone to the Washington Regional Office, telephone
number [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 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 Iine, 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 is not in
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.
23. Any groundwater quality monitoring, as deemed necessary by the Division shall be
provided.
24. Upon the availability of a municipal or regional sewerage collection system, the subject
wastewater treatment facilities shall be abandoned and all wastewater discharged into the
municipal or regional sewerage system.
3

25. An Engineering and Economic Feasibility Study as to the possibility of connecting to the
Chocowinity/Washington sewerage system shall be conducted by the Permittee and
submitted to the Division within one (1) year on permit issuance.
26. 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 12th day of November, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
L�L or�o-"- -1
A. Prestonward, Jr., .E., Director
Division ofOnvironmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0000902
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_PHOTOREVISED 1983
DMA 5555 it BE -SERIES V842

Name of Plant: rf1�a��,w r>� c ' fiu '►�
Owner or Contact Person- Fnll
Mailing Address: ?-akOc
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County: as C(A Telephone:
NPDES Permit No. NC00 -f Nondisc.
Per. No. WD,%00�01-
IssueDate: S 17 Expiration
Date: 30 9
Existing Facility Z New Facility nfi
Rated By: �l+��i, �; � Date:
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Reviewed (Train, & Gert.) Reg. Office^.
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Reviewed (Train. & C rt.) Central Office
O R C Grade
Plant Class. (circle orae) 0 11 111
IV Total Points
ITEM POINTS (5) SECONDARY TREATMENT UNITS
(a) Carbonaceous Stage
(1)
Industrial Pretreatment Units and/or
(i)Aeration - High Purity Oxygen System .....
20
Industrial Pretreatment Program
Diffused Air System ...........
10
(see definition No. 33) 4
Mechanical Air System (fixed,
(2)
DESIGN FLOW OF PLANT IN GPD
floating or rotor) ..............
8
(not applicable to non-conlaminated cooling waters, sludge
Separate Sludge Reaeration .....
I
handling facilities for water purification plants, totally
(ii) Trickling Filter
closed cycle systems (del. No. 11), and facilities
High Rate ...................
7
consisting only of Item (4) (d) or Items (4) (d) and (11) (d,)l
Standard Rale .
5
0 - 20,000.......................... (1
Packed Tower...............
5
20,001 — 50,000.......................... 2
(iii) Biological Aerated Filler or Aerated
50,001 - 100,000 .......................... 3
Biological Filter ......................
10
100,001 — 250,000 .......................... 4
(iv) Aerated Lagoons ..................... .
10
250,001 - 500,000.......................... 5
500,001 --1,000,000 .................... I ... I - 8
(v) Rotaling Biological Contactors ..........
10
1,000,001 — 2,000,000 ........................ 10
2,000,001 (and up) - rate 1 point additional for each
(vi) Sand Filters-
200,000 gpd capacity up to a
intermittent biological .....
2
maximum of 30
recirculating biological .. ...
3
Design Flow (gpd)
(v`n) Stabilization Lagoons ...................
(�
(3)
PRELIMINARY UNITS (see definition no. 32)
(viii)Clarifier ..............................
(a) Bar Screens................................ 1
(ix) Single stage system for combined
or
carbonaceous removal of BOD and
(b) Mechanical Screens, Static Screens or
nitrogenous removal by nitrification
Comminuting Devices ........... ............. 2
(see def. No. 12) (Points for this item
(c) Grit Removal ............................... 1
have to be in addition to items (5) (a)
or
(i) through (5) (a) (viii) .......... . ......
8
(d) Mechanical or Aerated Grit Removal ........... 2
(x) Nutrient additions to enhance SOD
(e) Flow Measuring Device ....................... 1
removal ...............................
5
or
(xi) Biological Culture (`Super Bugs') addition
{f) instrumented Flow Measurement .............. 2
to enhance organic compound removal .....
5
{g) Pmaeration .. - ............................. 2
(b) Nitrogenous Stage
(i7 feralion - High P.,•ity 0.:yg2n System .....
20
(h) Influent Row-LLj,,a;ization ................... 2
Diffused Air System .... I ......
10
(i) Grease or Oil Separators - Gravity ..........Mechanical
Air System (fixed,
Mechanical ..........
floating, or rotor) ...... .. _ ...
8
Dissolved Air Flotation. 8
Separate Sludge Reaeration .....
3
Prechlorination .......................... 5
"(il) Trickling Filler -
High Rate ..............
7
(4)
PRIMARY TREATMENT UNITS
Standard Rale ............
5
(a) Seplic Tank (see delinilion no. 43) .............. 2
Packed Tower ............
5
(b) ImhotfTank. ._.................. -......... . 5
(iii) Biological Aerated Filler or Aerated
(c) Primary Clarifiers ............................ 5
Biological Filler .........................
10
(d) Settling Ponds or Settling Tanks for Inorganic
(iv) Rotating Biological Contactors ............
10
Non-toxic Materiats {sludge handling facilities
(v) Sand Filler-
for water purilicalion plants, sand, gravel,
intermittent biological ........
2
stone, o-id other mining operations except
recirculating biological .. ......
3
recreational activities such at gem or gold
(vi) Ctarifier , , , ............ . ... . ....... . ....
5
mining)...................................... 2

(L) TERTIARY OR ADVANCEDTREATMENT UNIT
(1 p) CHEMICAL ADDITION SYSTEM (5) (See definition No. 9)
Ea) Activated Carbons Beds -
(not applicable to chemical additions rated as ilen
without carbon regeneration .................. 5
(3) (j), (5) (a) (xi), (6) (a), (6) (b), (7) (b), (7) (e},
with carbon regeneration .................... 15
(9) (a), {9} (b), or (9) (C) 5 paints each: List:
(b} Powdered or Granular Activated Carbon Feed -
5
`
without carbon regeneration ................. 5
with carbon regeneration .................... 15
5
;) Air Stripping ..................... .. . .. ' 5
... 5
(d) Denitrification Process (separate process) 10
(e) Electrodalysis ..............................5
(11) MISCELLANEOUS UNITS
(f) Foarn Separation ............................. 5
(a) Holding Ponds, Holding Tanks or Settling Ponds
(g) Ion Exchange ................................ 5
for Organic or Toxic Materials 'Including wastes
(h) Land Application oI Treated Effluent
from mining operations containing nitrogen and/or
(see definition no. 22b) (not applicable for
phosphorous compounds In amounts significantly
sand, gravel. stone and other similar mining
greater than is common for domestic wastewater .......... 4
operations)
(b) Eff)uenl Flow Equalization (not applicable to storage
(i) on agriculturally managed sites (See def,
basins which are inherent in land appiicalion systems)- 2
No. 4) ................................... 10
(c) Stage Discharge (not applicable to storage basins
(ii) by high rale infiltration on non-agricullurally
inherent in land application systems ....................................... 5
managed sites (includes rotary distributors
(d) Pumps._ ...:... -. •-�•-•--�--••—•-•--•••-�-•_�..._...._..._.._.r..... 3
and similar fined nozzle systems) .......... 4
(e) Stand -By Power Supply........_ ......................................_....... 3
(iii) by subsurface disposal (includes low pressure
(f) Thermal Pollution Control device........ ..................................... 3
pipe systems and gravity systems except at
plants consisting of septic lank and nitrifica-
tion lines only) ............................. 4
TOTAL POINTS
(a) Mirroscreens.................................. 5
E!) Phosphorus Removal by Biological Processes
CLASSIFICATION
(See dsf. No. 26) ............................ 20
(k) Polishing Ponds - without aeration ....... 2
~•—Class I ............... __._....... 5 - 25 Points -�--
wilh aeration .......... 5
Class 11 ........ ................... ......... _. _ 26- 50 Points
(1) Post Aeration - cascade .............. 0
Class III.................................. 51. 65 Points
diffused or mechanical ... 5
Class iV......._ .. _. _ 66- Up Points
(m) Reverse Osmosis ............................... 5
(n) Sand or Mixed -Media Fillers - low rate ........... 2
Facilities having a rating of one through four points, inclusive,
high rate .......... 5
do not require a certilied operator. Classification of all other
(o) Treatment processes for removal of metal or
facilities requires a comparable grade operator in responsible
cyanide ............ . ...................... 15
charge.
Treatment processes for removal of toxic
materials other than metal or cyanide ......... 15
Facilities having an activated sludge process will be assigned
a minimum classification of Class Il.
SLUDGETREATMENT
Facilities having treatment processes for the removal of metal
(a) Sludge Digestion Tank . Heated ...............
10 or cyanide will be assigned a minimum classification or Class Il.
Aerobic ...............
5
Unheated.............3
Facilities having treatment processes for the biological removal
(b) Sludge Stabilization (chemical or thermal) .......
5 of phosphorus will be assigned a minimum classification of Class
(c) Sludge Drying Beds - Gravity .................
2 f 1 f .
Vacuum Assisted .......
5
(d) Sludge Efutrialion .............................
5 In -plant processes and related control equipment which are an
(e) Sludge Conditioner (chemical or thermal) ........
5 integral part of Industrial production shall not be considered waste
(f) Sludge Thid;ener (gravity) ......................
5 treatment. Likewise, discharges of wastewater from residences
(g) Dissolved Air Flotation Unit
having a design flow of 1,000 gpd or less, shall not be subject to
(not applicable to a unit rales as (3) (1) .........
8 rating
(h) Sludge Gas Utilization (including gas storage) ....
2
(i) Sludge holding Tank - Aerated ................
5 ADDITIONAL COMMENTS:
Non-aeraled ............
2
(j) Sludge Incinerator - (not including activated
carbon regeneration) .....
10
(k) Vacuum Filter, Centrifuge or Filler Press or other
Similar dewatering devices ....................
10
SLUDGE DISPOSAL (including incinerated ash)
(a) Lagoons ....... .................. .............
2
(b) Land Application (surface and subsurface)
(see definition 22a)
-where the facility holds the land app. permit ..
10
-by conGactiing to a land application operator who
holds the land application permit ................
2
-land application of sludge by a conlraclor who does
not hold the permit for the wastewater treatment
facility where the sludge is generated .........
10
tL;) Landfilled (burial) ............. _ ...............
5
DISINFECTION
(a) Chlorination ....................... .....
5
(b) Derlhlorination ........................
5
(c) Ozone ..............................
5
(d) Radiation ..........................
5