WQ0000965_Final Permit_19920826

w
State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street - Raleigh, North Carolina 27611
James G. Martin, Governor A. Preston Howard, Jr., P.E_,
William W. Cobey, Jr., Secretary Acting Director
August 26, 1992
Mr. W. C. Howard, Jr., P.E., Manager
R. J. Reynolds Tobacco Company
Water Quality Program
Post Office Box 2959
Winston-Salem, North Carolina 27102-2959
Subject: Permit No. WQ0000965
R. J Reynolds Tobacco Co.
Package Operations Plant 200
Subsurface Disposal System
Forsyth County
Dear Mr. Howard:
In accordance with your application received November 12, 1991, we are forwarding herewith
Permit No. WQ0000965, dated August 26, 1992, to R. J. Reynolds Tobacco Company for the continued
operation of a 14,400 GPD groundwater remediation and recycle facility.
This permit shall void Permit No. WQ0000965 issued March 13, 1990 and shall be effective from
the date of issuance until July 31, 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 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.
Regional Offices
Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
704/251-6208 919/486-1541 704/663-1699 919/5714700 919/946-6481 919/395-3900 919/761-2351
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

If you need additional information concerning this matter, please contact Ms. Angela Y. Griffin at
9191733-5083.
Sincerely,
A. Pres n Howard, Jr., P.E.
cc: Forsyth County Health Department
Winston-Salem Regional Office, Water Quality
Winston-Salem Regional Office, Groundwater
Groundwater Section, Jack Floyd
Training and Certification Unit

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
SUBSURFACE DISPOSAL 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
PERNUSSION IS HEREBY GRANTED TO
R. J. Reynolds Tobacco Company
Forsyth County
FOR THE
continued operation of a 14,400 GPD groundwater remediation facility consisting of 10 GPM air operated
drawdown pumps, a 25 micron input filter with water and air heaters, a 15'-8" high and 14-inch thick air
stripper column unit equipped with a 680 SCFM air blower, a recycle tank with pumps, a 5 micron output
filter with pumps to feed the activated carbon polishing system,an infiltration trench with nutrient feed and
all related valves, pipes and appurtenances to serve the R. J. Reynolds Operation Plant 200 with no
discharge of wastes to the surface waters, pursuant to the application received November 12, 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 void Permit No. WQ0000965 issued March 13, 1990 and shall be effective from
the date of issuance until July 31, 1997, and shall be subject to the following specified conditions and
limitations:
1. 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 construction of additional or replacement
wastewater treatment or 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. This permit shall become voidable if the soils fail to adequately absorb the wastes and may
be rescinded unless the facilities are installed, maintained, and operated in a manner which
will protect the assigned water quality standards of the surface waters and ground waters.
4. Adequate measures shall be taken to divert stormwater from the disposal area and prevent
wastewater runoff from the subsurface disposal field.

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.
6. Diversion or bypassing of the untreated wastewater from the treatment facilities is
prohibited.
7. The following buffers shall be maintained:
a) 100 feet between disposal area and any public or private water supply including
wells
b) 100 feet between disposal area and "SA and SB" classified surface waters
c) 50 feet between disposal area and any stream, lake, river or natural drainageway
d) 50 feet between disposal area and property lines
e) 10 feet between disposal area and surface water interceptor drains or diversions
(upslope)
f) 25 feet between disposal area and surface water interceptor drains or diversions
(downslope) and groundwater drainage systems.
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.
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 (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 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.
3. 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.
4. No traffic or equipment shall be allowed on the disposal area except while installation
occurs or while normal maintenance is being performed.
N

1. 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.
2. A record shall be maintained of all residuals removed from this facility. This record shall
include the name of the hauler, permit authorizing the disposal or a letter from a
municipality agreeing to accept the residuals, date the residuals were hauled, and volume of
residuals removed.
c ►�� ���� ,� \1 1�
The Permittee shall report by telephone to the Winston-Salem 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 basin or tank; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, compressors, etc.
C. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-
pass 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.
I I ►1'* ;a 3 -010101 u. ►
1. The influent and effluent of the treatment system shall continue to be sampled every
January, April, July, and October and analyzed using EPA methods 624 and 625.
2. Monitoring well 1, 2, 4, 6, 8, 12, 14, and 19 shall continue to be sampled every January
and July and analyzed using EPA Methods 624 and 625. Water levels should be measured
prior to sample collection.
3. The results of the sampling and analyses shall be sent to the Groundwater Section using
Form GW-59 no later than 30 days following sample collection.
4. Any additional groundwater quality monitoring as deemed necessary by the Division of
Environmental Management shall be provided.
3

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 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.
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.
PSAIRaWDUKII WK111211 1►
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 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 this request will be considered on its merits and may or may
not be approved.
4. A set of approved plans and specifications for the subject project must be retained by the
applicant for the life of the project.
5. 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).
6. 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.
7. 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.
4

S . 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 26th day of August, 1992
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
j 21 . __ Lo.
A,
A. Preston ward, Jr., P.., Acting Dire or
Division of Environmental Management
By Authority of the Environmental Management Commission
Permit Number WQ0000965
k,

�\!: �, � ��. .. J '• -N,;„+v,,r talk �,ut`Tlx 7 •f
Srh
REYNOL MS
itM.COLLCCi�.�
PAf
,! � { '• f may` • j; . � . ,
"ovj
slat ' ' �. " i l R.J. Reynolds Site
Plant 20D 1i �/;yN,rh ;:
,�• •�'�- �1�';•- ` , n-Salem EaSt 0uad. �- �J'arrrr
S' 1, kinSto ,
Ark
,^ - 1� itN `� `�••'• oven••• �: :1C •,• {'. fr 1• -
- 1
go
em
• { So BM y` ii •l .. �•--�� �''•
k f
.�� � _;- j--. ,.• ., ,'_���.. l ,; . ,{r-am., ,
WL
V.
ff t ., - yC� z- if �Nr;"—jr�.'_•- i��- - �. � �� �Y II I ff,' \••. r�� ,
1 1t, ' - ! I •- t/ ig�l 1 lam. C• 7 ,' f -,f.! \� \�•
fliiew _ -•. r 9X !
70
��(} • (f t ` �f"""''� �i�: , • 1�•.� , • J�-• � � .1f �,•- � - ��• � • ', ;, -cam e
%7•r4.�JL l�Tn3on F?ad�►e ' (�• Ji s(,
r �l• fill. �� f }�\.�•: � / •.1•' � � � � � j
\ -� . X\

RATING SCALE FOR CLASSIFICATION OF FACILITIES
Name of Plant: R.J. Reynolds - Plant 200
Owner or Contact Person: � � ,'_iiam C. Howard and B `?iutt
Mailing Address: P. 0. Box 2.959
Winston-5alerl, North Carolina 27102 - 2959
County:_ Forsyth Telephone: (919) 7,11-1736 or 741-1730
NPDES Permit No. NC00 Nondisc. Per. No.I 0000965
IssueDate:-junc 5, ,,2.89, Expiration Date: may 31, 1991 _
Existing Facility yr-.,_ New Facility
Rated By:. James C. Y,atson Date: December 31, 1991
Reviewed (Train. & Cert.) Reg. Office - - 1
Reviewed (Train. & Cert.) Central Offi
ORC James E.P. Lippard Grade
TEEM POINTS ITEM
(1) Industrial Pretreatment Units and/or
Industrial Pretreatment Program
(see`delin4ion No. 33)
4
(2) DFSJ FLOW OF PLANT IN GPD
(not applicable to non -contaminated cooling
_ waters, sludge handling facilities for water
purification plants, totally closed cycle
"Zystems (del. No. 11). and facilities
nsisling only of Item (4) (d) or Items (4) (d)
.id (11) (d))
0 -- 20.000..........................
Q
20.001 -- 50,000..........................
2
50,001 -• ID0,000..........................
3
100,001 — 250,000..........................
4
250,001 -- 500,000..........................
5
500,001_-1,000.000..........................
B
1.000,001 -- 2,000,000 ....
10
2,000,001 (and up) - rate 1 point additional for each
200,000 gpd capacity up to a
maximum of 30
Design Flow (gpd) : 14,400
(3) PRELIMINARY UNITS (see definition no. 32)
(a) Bar Screens ................................
1
or
(b) Mechanical Screens, Slatic Screens or
Comminuting Devices ........... .............
2
(c) Grit Removal ...............................
1
of
(d) Mechanical or Aerated Grit Removal ...........
2
(e) Flow Measuring Device .......................
1
or
'f) Instrumented Flow Measurement ..............
(D
) Preaeralion ........... . .......
2
(h) Influent Flow Equalization ...................
2
(i) Grease or oil Separators - Gravity ..........
2
Mechanical ...... _ _ ..
3
Dissolved Air Flotation.
8
0) Prechbriir4bon ..............................
5
POIN
(4) PRIMARY TREATMENT UNITS
(a) Septic Tank (see definition no. 43) ..............
(b) Imhoff Tank ..................................
(c) Primary Clarifiers ......... ............. .
(d) Settling Ponds or Settling Tanks for Inorganic
Non -toxic Materials (sludge handling facilities
for water purification plants, sand, grave€,
stone, and other mining operations except
recreational activities such as gem or gold
mining). .......................
(5) SECONDARY TREATMENT UNITS
(a) Carbonaceous Stage
(i)Aeration - High Purity Oxygen System ... • -
Diffused Air System ........ _'. .
Mechanical Air System (fixed,
floating or rotor) ............. .
Separate Sludge Reaeration .... .
(i i) Trickling Filler
High Rate ................ . . .
Standard Rafe ...............
Packed Tower .............. .
(iii) Biological Aerated Filler or Aerated
Biological Filler ......................
(iv) Aerated Lagoons ..................... .
(v) Rotating Biological Conlaclors ......... -
(vi) Sand Filters -
intermittent biological .... -
recirculating biological .. ..
(vii) Stabilization Lagoons ........... . .. • _ .. .
(viii)Clarifier ............ ........... .....
(ix) Single stage system for combined
carbonaceous removal of SOD and
nitrogenous removal by nitrification
(see def. No.. 12) (Points for this item
have to be in addition to items (5) (a)
(i) through (5) (a) (viii) .. _ �......... • • _
(x) Nutrient additions to enhance BOD
removal ...............................
(x€) Biological Culture ('Super Bugs') addition
to enhance organic compound removal ... - -
2
1
1
1
1

ar
(b)
Nitrogenous Stage
(i) Aeration - High Purity Oxygen System .. _ ..
20
(i) Sludge Holding Tank - Aerated ................
Dilfused Air System ........ , ..
10
Non -aerated ..... , .... , .
Mechanical Air System (fixed,
(j) Sludge Incinerator - (not Including activated
floating, or rotor) ...... ......
8
carbon regeneration) ..... 1
Separate Sludge Reaeralion .....
3
(k) Vacuum Filler, Centrifuge or Filter Press or other
pi) , Trickling Fitter -
similar dewatering devices .................. . . 1
High Rate ..............
7
Standard Rate ............
5
(8) SLUDGE DISPOSAL (including incinerated ash)
Packed Tower............
5
(a) Lagoons ........................... I.............
(fii) Biological Aerated Filter or Aerated
(b) Land Application (surface and subsurface)
Biological Fitter .........................
10
(see definition 22a)
(i v) Rotating Biological Conlactors ............
10
-where the facility holds the land app. permit .. , 1 f
(v) Sand Filter-
-by contracting to a land application operator who
intermittent biological ........
2
holds the land application permit ................
recirculating biological ........
3
-land application of sludge by a contractor who does
(vi) Mrifier................................
5
not hold the permit for the wastewater treatment
facility where the sludge is generated ......... 1
(6) TERTIARY OR ADVANCED TREATMENT UNIT
(c) Landfilled (burial) .............................
(a)
Activated Carbons Beds -
(9) DISINFECTION
,without carbon regeneration ..................
(a) Chlorination .............................. 5
With carbon regeneration ....................
15
(b) Dechlorination ........................ 5.
(b)
Powdered or Granular Activated Carbon Feed -
(c) Ozone .............................. 5
without carbon regeneration .................
5
(d) Radiation .......................... 5
with carbon regeneration ........... . .......
15
(10) CHCMICAL ADDITION SYSTEM (S) (See definition No. 9)
(c)
Air Stripping .............................
T,additions(not
applicable to chemical rated as item
(d)
Denitrificalion Process (separate process) ... _ _
(3) 0), (5) (a) (xi), (6) (a), (6) (b), (7) (b), (7) (e),
(e)
Electrodialysis ..............................
5
(9) (a), (9) (b), or (9) (c) 5 points each: List:
(f)
Foam Separation .. . ... . ....................
5
5
(g)
tort Exchange ................................
5
. . . . . 5
(h)
Land Application of Treated Effluent
5
(see definition no. 22b) (not applicable for
5
sand, gravel, stone and other similar mining
(11) MISCELLANEOUS UNITS
operations)
(a) Holding Ponds, Holding Tanks or Settling Ponds
on agriculturally managed sites (See def.
for Organic or Toxic Materials including wastes
No. 4)...................................
10
from mining operations containing nitrogen and/or
(ii) by high rate infiltration on non -agriculturally
phosphorous compounds in amounts significantly
managed sites (includes rotary distributors
greater than is common for domestic wastewater .......... 4
and similar fixed nozzle systems) ...........
4
(b) Effluent Flow Equalization (not applicable to storage
(iii) by subsurface disposal (includes low pressure
basins which are inherent in land application systems). 2
pipe systems and gravity systems except at
(c) Stage Discharge (not applicable to storage basins
plants consisting of septic tank and nitrifica-
tion fines only) . . ....... . ...................
®
inherent in land application systems ....................................... 5
(d) Pumps .......... .............. _............ ..... _........ _....................... ................... 0
(i)
Microscreens..................................
5
(e) Stand -By Power Supply .................... ..................................... ......... 3
(j)
Phosphorus Removal by Biological Processes
(f) Thermal Pollution Control Device ............................................. 3
(See def. No. 26) .............................
20
(k)
Polishing Ponds - without aeration ...... _
2
with aeration ..........
5
(1)
Post Aeration - cascade ..............
0
�Q
ditfused or mechanical ...
5
TOTAL POINTS
(m)
Reverse Osmosis ...... ........................
5
(n)
Sand or Mixed -Media Filters - low rate ...........
2
high rate ..........
5
CLASSIFICATION
(o)
"Treatment processes for removal of metal or
cyanide ....................................
15
Class�1:-.................................................. 5 - 25 Points
(p)
Treatment processes for removal of toxic
ss .................. ......._. 26. 50 Points
.........................
materials other than metal or cyanide ....... _ .
15
Class III ....................................................... 51. 65 Points
Class IV ........................................................ 66• Up Points
(7) SLUDGE TREATMENT
Facilities having a rating of one through four points, inclusive,
(a)
Sludge Digestion Tank - Heated ...............
10
do not require a certified operator. Classification of all other
Aerobic ...............
5
facilities requires a comparable grade operator in responsible
Unheated ...... .......
3
charge.
(b)
Sludge Stabilization (chemical or thermal) .......
5
Sludge Drying Beds - Gravity .................
2
Facilities having an activated sludge process will be assigned
Vacuum Assisted .. , ..: ,
5
a minimum classification of Class it.
Sludge Elutriation . . .......................... .
5
(e)
Sludge Conditioner (chemical or thermal) ........
5
Facilities having treatment processes for the removal of metal
(f)
Sludge Thickener (gravity) ......................
5
or cyanide will be assigned a minimum classification of Class 11.
(g)
Dissolved Air Flotation Unit
(not applicable to a unit rates as (3) (+1) .........
8
Facilities having treatment processes for the biological removal
(h)
Sludge Gas Utilization (inGuding gas storage) . ...
2
of phosphorus will be assigned a minimum classification of Clas!
III,