HomeMy WebLinkAboutWQ0005217_Final Permit_19930330State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27604
James B. Hunt, Jr., Governor
March 30, 1993
Mr. David A. Smith,
Sr. Vice President, Manufacturing
Holr,axri, Incorporated
15215 Day Road
Dund ,e, NAI. 48131
Jonathan B. Howes, Secretary
Subject: Permit No. WQ0005217
Holnam, Incorporated
Ideal Cement Facility
Groundwater Remediation
New Hanover County
Dear Mr. Smith:
In accordance with your application received December 30, 1992, we are forwarding herewith
Pemit No. WQ0005217 dated March 30, 1993, Holnam, Incorporated for the modification and continued
operation of the subject groundwater remediation system and infiltration pond. This permit modification is
to a1ld an iron removal system prior to the existing influent settling tank.
This permit shall be effective from the date of issuance until September 30, 1996, 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. Issuance of this
pe,Tnit hereby voids .Permit No. WQ0005217 issued June 24, 1992.
If aa7y ts, requirements, or limitations contained in this permit are unacceptable to you, you have
the ,_a nti to �m adjudicatory hearing upon written request within 30 days following receipt of this
perrnt�. Thi,, ri� qucst must be in the form of a written petition, conforming to Chapter 150B of North
C,volira Cone; J, Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447,
NC 21-611-7447. Unless such demands are made this permit shall be final and binding.
Regional Offices
1sheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
r04/251-6208 919/486-1541 704/663-1699 919/571-4700 919/946-6481 919/395-3900 9191761-2351
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone 919-733-7015
An Equal Opportunity Affirmative Action Employer
One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact W. John Seymour at 919/ 733-5083.
Sincerely,
A. Prest Howard, Jr., P.E.
Director
cc: New Hanover County Health Department
Wilmington Regional Office, Water Quality
Wilmington Regional Office, Groundwater
Groundwater Section, Jack Floyd
Training and Certification Unit
Facilities Assessment Unit
Westinghouse Environmental & Geotechnical Services, Inc.
NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
INFILTRATION GALLERY 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
Holnam, Incorporated
New Hanover County
FOR THE
modification and continued operation of an existing 21,600 GPD groundwater remediation facility
consisting of a new four tray iron removal system using drip aeration of influent through trays of coke
filter media totaling 9 square feet (located above the existing holding tank), a new backwash system for the
existing lead carbon absorption unit, an existing 10 GPM 6 inch recovery well, an existing 6,200 gallon
holding tank, an existing 15 GPM transfer pump, an existing 20 GPM bag filter, an existing continuous
recording chart flow meter and a digital totalizing flow meter, two (2) existing 1,050 pound carbon
absorption units in series, an existing 200 foot by 200 foot infiltration pond, and all associated piping,
valves, controls, and appurtenances to serve Holnam Incorporated's Ideal Cement Facility with no
discharge to the surface waters, pursuant to the amendment received December 30, 1992 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 September 30, 1996, 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 modified portions of this
permitted facility, a certification must be received from a professional engineer certifying
that the permitted facilities have been installed in accordance with this permit and the
approved plans and specifications. Mail the Certification to the Permits and Engineering
Unit, P.O. Box 29535, Raleigh, NC 27626-0535.
2. The Wilmington Regional Office, telephone number 919/ 395-3900 shall be notified at least
forty-eight (48) hours in advance of operation of the newly 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. 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. 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
treatment or disposal facilities.
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.
6. Any 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 groundwater from the treatment facilities is
prohibited.
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. Once
the facility is classified, the Permittee must submit a letter to the Certification Commission
which designates the operator in responsible charge.
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.
III. MONITORINQ AND REPORTING -REQUIREMENTS
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. Noncompliance Notification:
The Permittee shall report by telephone to the Wilmington Regional Office, telephone
number 919/ 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
2
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 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.
IV. GROUNDWATER REQUIREMENTS
The monitor well (MW-10) shall be sampled every April, August and December for the
following parameters:
Volatile Organic Compounds using EPA Method 610
Water Level
pH
TOC
The measurement of water Ivel 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 the water in each well shall be measured from the surveyed point on the top of the
well casing.
The results of the sampling and analysis shall be sent to the North Carolina Division of
Environmental Management on Form GW-59 [Compliance Monitoring Report Form] every
May, September, and January.
2. All components of the groundwater recovery, treatment and disposal system shall be
properly weather -proofed to prevent freezing and failure of the system.
3. The influent and effluent from the treatment system shall be sampled once every two (2)
weeks for the first three (3) months and monthly thereafter for the parameters specified
below:
pH
Volatile Organic Compounds -using EPA Method 610
The results of the sampling and analysis shall be sent to the Groundwater Section in the
Wilmington Regional Office and the Groundwater Section, Permits Unit, P.O. Box 29535,
Raleigh, N.C. 27626-0535, within 30 days of sample collection.
3
4, Two (2) weeks prior to system start-up, the Permittee shall notify the Division of
Environmental Management's Wilmington Regional Office that operation is about to
commence.
5. The groundwater recovery treatment and disposal system shall be inspected weekly. If it is
determined that the system is malfunctioning, all repairs should be made as soon as
possible and reported to the Wilmington Regional Office.
6. Any additional groundwater quality monitoring as deemed necessary by the Division of
Environmental Management shall be provided.
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 groundwater recovery and treatment
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.
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 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
Permittee for the life of this project.
5. 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.
4
6. 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)-
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.
8. The Permittee, at least six (6) months prior to the expiration of this permit, shall request ifs
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.
10. Issuance of this permit hereby voids Permit No. WQ0005217 issued June 24, 1992.
Permit issued this the 30th day of March, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
� J " - - C.rqC
A. Presto oward, Jr., .E., Director
Division of -Environmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0005217
0
Permit No. WQ0005217
March 30, 1993
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,
Project Name
Location
for the
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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CEMENT FACILITY
7 -HoLNAM, INC. (IDEAL
R nEMEDIATION FACILITY
GROUNDWATER
PERMIT No. WQ0005217
IN. C -
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RATING SCALE FOR CLASSIFICATION OF FACILITIES
Name of Plant: ;
Owner or Contact Person:
Mailing Address:___ f Szc
i
�/ l C'h
County: L--_, &/?r.E>r_�r'/ Telephone:��/��
NPDES Permit No NCB Nondisc. Per. No.,LJ,�&1719r7
IssueDate: Expiration Date: c e 1
Existing Facilit V.7 s New Facility
Rated By: r- Date:-� —� -
Reviewed (Train. & Cert.) Reg. Office_
Reviewed (Train. & Cert.) Central Office
ORC Grade
zl 6__ -7
Plant Class: (circle one) 1
II
111 IV Total Points-2i
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)
1 N FLOW OF PLANT IN GPD
floating or rotor) .......... _ ...
8
(not applicable to non -contaminated cooling waters, sludge
Separate Sludge Reaeration .....
3
handling facilities for water purification plants, totally
(ii) Trickling Filter
closed cycle systems (def. No. 11), and facilities
High Rate ...................
7
consisting only of Item (4) (d) or Items (4) (d) and (11) (d))
Standard Rate ...............
5
0 -- 20,000..........................
20.001 -- 50,000 ............. _ ....... , ....
2
Packed Tower .............
(iii) Biological Aerated Filler or Aerated
5
50,001 100.000 .
Biological Filter .................... _ .
10
100,001 250,000 ..........................
4
(iv) Aerated Lagoons ..................... .
10
250,001 - 500,000..........................
5
500,001--1,000,000 ..........................
8
(v) Rotating 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 /
C Design Flow
/ C
recirculating biological .....
3
(gpd) . - _ _F-
(vu) Stabilization Lagoons ........ . ........ .
5
(3)
PRELIMINARY UNITS (see definition no. 32)'
(viii)Cfarifier ..............................
5
(a) Bar Screens ............................ . . . .
1
(ix) Single stage system for combined
or
carbonaceous removal of BOO 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 -
O through (5) (a) (vini) .................
8
(d) Mechanical or Aerated Grit Removal ...........
2
(x) Nutrient additions to enhance BOD
(e) Flaw Measuring Device ..... . .................
1
removal ...............................
5
or
(1) Instrumented Flow Measurement ..............
il�
(xi) Biological Culture ('Super Bugs') addition
to enhance organic compound removal .....
5
(g) Preaeralion................................
(b) Nitrogenous Stage
(i) Aeration - High Purity Oxygen System .....
20
(h) Influent Flow -Equalization ...................
2
Diffused Air System ...........
10
O Grease or Oil Separators - Gravity ..........
2
Mechanical Air System (fixed,
Mechanical ..........
3
floating, or rotor) ...... ......
13
Dissolved Air Flotation.
8
dge udge Reaeration .....
Separate Slu
3
G Prechlo6mlion ..............................
5
(ii) Trickling Filter -
High Rate ..............
7
(4)
PRIMARY TREATMENT UNITS
Standard Rate ............
5
(a) Septic Tank (see definition no. 43) ..............
2
Packed Tower ............
5
(b) Imhoff Tank ..................................
5
(lii) Biological Aerated Filler or Aerated
(c) Primary Clarifiers ... .. .. .. ......... ...
5
Biological Filter .........................
10
d) Settling Ponds or Settling Tanks for Inorganic
(iv) Rotating Biological Contaclors ............
10
Nontoxic Materials (sludge handling facilities
(v) Sand Filter -
for water purification plants, sand, gravel,
intermittent biological ... _ ....
2
stone, and other mining operations except
recirculating biological ........
3
recreational activities such as gem or gold
(vi) Clarifier ................................
5
mining) ......................................
2
(6) TERTIARY OR ADVANCED TREATMENT UNIT 1
{a) Activated Carbons Beds - (u r �', r!cl h r34C r- d5i
without carbon regenerationeration -with carbon regen.. j .,... .
(b) Powdered or Granular Activated Carbon Feed -
without carbon regeneration ................. 5
with carbon regeneration ................... is
(c) Air Stripping ............. . ............... 5
(d) Denitrification Process (separate process) ..... 10
(e) Electrodialysis ............................. 5
(q Foam Separation ............................. 5
(g) son Exchange ................................ 5
(h) Land Application or Treated Elfluent
(see definition no. 22b) (not applicable for
sand, gravel, stone and other similar mining
operations)
(i) on agriculturally managed sites (See del.
No-4) ........................ I.......... 10
{� (ii) by high rate Infiltration on non -agriculturally
1"r managed siles (includes rotary distributors
and similar fixed nozzle systems) ........... 4
(W) by subsurface disposal (includes low pressure
pipe systems and gravity systems except at
plants consisting or septic lank and nitrifica-
tion lines only) ......... _ ............. . ..... 4
(� Microscreens.................................. 5
{j) Phosphorus Remoial by Biological Processes
(See der. No. 26) 20
(k) Polishing Ponds - without aeration ....... 2
with aeration .......... 5
(1) Post Aeration - cascade .............. 0
diffused or mechanical ... 5
(m) Reverse Osmosis .... 5
(n) Sand or Mixed -Media Filters - low rate ........... 2
high rate .......... 5
,) Treatment processes for removal of metal or
cyanide.................................... is
(p) Treatment processes for removal of toxic
1 materials other than metal or cyanide ......... S
1 SLUDGE TREATMENT
(4) Sludge Digestion Tank -Heated ............... 10
`'A i L' Aerobic ............... 5
Unheated ............. 3
rryl� Sludge Stabilization (chemical or thermal) ....... 5
YA (c) Sludge Drying Beds - Gravity ................. 2
�? r, Vacuum Assisted ....... 5
(d� Sludge Elulriation ....... . ........... - ••.....: 5
J Sludge Conditioner (chemical or thermal) ...5
f) Sludge Thidmner (gravity) ...................... 5
Dissolved Air Flotation Unit
f�. 4r LR not applicable to a unit rates as 3 c .........
S
� IIL () Sludge Gas Utilization (including gas storage) .... 2
[�4�(i) Sludge Holding Tank - Aerated ................ 5
Non-aeraled ............ 2
Sludge Incinerator - (not including activated
carbon regeneration) ... 10
(k) Vacuum Filter. Centrifuge or Filler Press or other
similar dewatering devices. ........... 10
(8) SLUDGE DISPOSAL [including incinerated ash)
(a) Lagoons..._ ................................. 2
(b) Land Application (surface and subsurlace)
(see definition 22a)
where the facility holds the land Opp. permit ... 10
-by contracting to a land applical'uon operator who
holds the land application permit ................ 2
-land application of sludge by a contractor who does
not hold the permit for the wastewater treatment
facility where the sludge is generated ......... 10
(c) Landfilled (burial ............................. 5
:9) DISINFECTION
(a) Chlorination ............................. 5
(b) Dechlorinalion ........................ 5
(c) Ozone .............................. 5
(d) Radiation .......................... 5
(10) -CHEMICAL ADDITION SYSTEM (S) (See definition No. 9)
(not applicable to chemical addilion . rated as ilern
(3) 6). (5) (a) (xi), (6) (a), (6) (b). (7) (b). (7) (e),
(9) (a), (9) (b), or (9) (c) 5 points each: List:
5
5
.... 5
(11) MISCELLANEOUS UNITS
(a) Holding Ponds, I•ioldi Tanks or Settling Ponds
for Organic or Toxic Materials including wastes
from mining operations containing nitrogen and/or
phosphorous compounds in amounts significantly
greater than is common for domestic wastewater ..........4
(b) Effluent Flow Equalization (not applicable to storage
basins which are inherent in land application systems). 2
(c) Stage Discharge (not applicable to storage basins
inherent in land application systems..._.....». __..........
(d) Pumps...
(e) Stand -By Power Supply_......_ 3
(1) Thermal Pollution Control Device...... 3
TOTAL POINTS
CLASSIFICATION
L..
5 - 25 Points
2asiss,q- _. _
26- 50 Points
111 _ __.. _
51- 65 Points
Class IV.. r __ . _...
66- Up Points
Facilities having a rating of one through four points, Inclusive,
d❑ not require a certified operator. Classification of all other
facilities requires a comparable grade operator in responsible
charge.
Facilities having an activated sludge process will be assigned
a minimum classification of Class 11.
Facilities having treatment processes for the removal of metal
or cyanide will be assigned a minimum classification of Class 11.
Facilities having treatment processes for the biological removal
of phosphorus will be assigned a minimum classification of Class
Ill.
In -plant processes and related control equipment which are an
Integral part of industrial production shall not be considered waste
treatment. Likewise, discharges of wastewater from residences
having a design flow of 1.000 gpd or less, shall not be subject to
rating.
ADDITIONAL COMMENTS:
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