WQ0012709_Final Permit_20010920

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph. D., Acting Director
September 20, 2001
EARL WELLS, JR., PRESIDENT
PORK PRODUCTS, INC.
750 CROOMSBRIDGE ROAD
BURGAW, NC 28425
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NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Permit No. WQ0012709
Pork Products, Inc.
Wastewater Spray Irrigation
Pender County
Dear Mr. Wells:
In accordance with your renewal request, received June 21, 2001; we are forwarding herewith Permit
No. WQ0012709, dated September 20, 2001, to Pork Products, Inc. for the continued operation of the subject
wastewater treatment and spray irrigation facilities.
This permit shall be effective from the date of issuance until August 31, 2006, shall void Permit No.
WQ0032709, issued November 27, 2000, 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.
Please take time to review this permit thoroughly. Of special interest are the following items:
• Condition I.5.: Regarding applicable buffer areas to observe.
• Condition II.3.: Regarding the timely harvest and off -site removal of the vegetative cover crop
growing on the spray area.
• Condition II.7.: Regarding the allowable irrigation application rate, and avoidance of run-off or
ponding conditions resulting from improper irrigation application.
• Condition 11.10.: Regarding avoidance of non -maintenance traffic and equipment on the spray
field area, and exercising extreme care to avoid soil compaction in this area, at all times, including
during routine maintenance.
• Condition IIL 3.: Regarding sampling parameter additions to the required effluent monitoring.
TKN, NOZ-N, NO3-N, and PAN by calculation.
• Condition III.4.: Regarding the utilization of Annual soil analysis results to determine the
appropriate application rate of lime and/or gypsum soil amendments.
• Condition III.5.: Regarding the appropriate soil sampling windows to establish, in order to use the
annual soil analysis results for planning purposes.
• Condition III. 6.: Regarding timely submittal of required permit monitoring and operation records
to the Division.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Teiephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/10% post -consumer paper

Condition IV. 4.: Regarding no application of wastewater to the permitted spray area, when the
water table is less than three feet from the land surface.
• Condition V. 2.: Regarding Permittee responsibility to keep an on -going inspection log and/or
summary of facility maintenance, repairs, problems and associated corrective actions.
• Condition VT. 9. Regarding timely connection to operational publicly owned wastewater collection
system, upon availability to the subject facility.
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 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.
If you need additional information concerning this matter, please contact Theresa Nartea at (919) 733-
5083 extension 375.
Sincer
Gregory J. Thorpe, Ph.D.
cc: Pender County Health Department
Wilmington Regional Office, Water Quality Section
Wilmington Regional Office, Groundwater Section
Groundwater Section, Central Office
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
NDPU files
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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
Pork Products, Inc.
Pender County
FOR THE
continued operation and maintenance of a wastewater treatment and disposal facility program for the spray irrigation
of up to 2,100 gallons per day (GPD) of wastewater generated from meat processing activities conducted at the Pork
Products, Inc. facility, consisting of: one-1,500 gallon grease trap; three-1,500 gallon holding tanks; one-1,500 gallon
pump tank with dual 1/2 horsepower submersible pumps; one -high water alarm system; four-17,000 gallon covered,
above ground steel storage tanks; one-159,000 square foot irrigation area, with associated solid set spray irrigation
equipment, to include 20-Senniger 7025-1 spray nozzles and one -five horsepower irrigation pump; and all associated
valves, piping, and appurtenances to serve the slaughterhouse operation facility of Pork Products, Inc., with no
discharge of wastes to the surface waters, pursuant to the renewal request, received June 21, 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 August 31, 2006, shall void Permit No.
WQ0012709, issued November 27, 2000, and shall be subject to the following specified conditions and limitations:
I. PERFORMANCE STANDARDS
1. 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.
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.
The residuals generated from these treatment facilities must be disposed in accordance with North
Carolina General Statute 143-215.1 and in a manner approved by the Division.
4. Diversion or bypassing, of the untreated wastewater from the treatment facilities is prohibited.

The following buffers shall be maintained:
a) 400 feet between wetted area and any residence or places of public assembly under separ
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.
II. OPERATION AND MAINTENANCE REQUIREMENTS
1. The facilities shall be properly maintained and operated at all times
2. Upon classification of -the facility by the Water Pollution Control System Operators Certifieatior
Commission (WPCSOCC), the Permittee shall employ a certified wastewater treatment plant operator
be in responsible charge (ORC) of the wastewater treatment facilities. The operator must hold a certifica
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, 111, 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.
A suitable year round vegetative cover of Coastal Bermuda pasture and a winter cover crop shall be
maintained. Required maintenance shall include the timely harvest, and immediate off -site removal of the
harvested hay product.
4. Irrigation shall not be performed during inclement weather or when the ground is in a condition that will
cause runoff.
Adequate measures shall be taken to prevent wastewater runoff from the spray field.
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 a cumulative loading of 52.0 inches over any 12-month period, at an
instantaneous application rate of up to 1/ inch per hour, and not to exceed 1/4 inch per hour. At no time
shall the instantaneous application rate (inches applied per hour-IPH) result in surface run-off conditions.
Nor shall the instantaneous application rate (IPH) result in ponded wastewater conditions.
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The application of plant available nitrogen (PAN) shall not exceed a cumulative loading rate of 300
pounds PAN per acre per year for Coastal Bermuda, and 50 pounds PAN per acre per year for the winter
cover crop. Application of nitrogen shall be credited to the actively growing crop at the time of
application. PAN shall be calculated using a 0.40 mineralization rate coefficient, due to the unstabilized
nature of the waste product. In order to receive PAN credit for the crop(s) grown, the receiving crop(s)
trust be removed from the spray application area (See Condition H. 3.).
9. No type of wastewater other than that from the Pork Products, Inc. facility shall be sprayed onto the
irrigation area.
10. No traffic or equipment shall be allowed on the disposal area except while installation occurs or while
normal maintenance is being performed. Extreme care should be taken by Permittee to avoid causing
excessive soil compaction conditions during routine maintenance of the spray application area.
11. 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.
12. Only those cleaning agents and soaps which are bio-degradable, will not harm the cover crop, and will not
contravene the groundwater standards listed in 15A NCAC 2L may be utilized in the subject truck
washing facility.
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.
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. Weather conditions; and
g. Maintenance of cover crops.
3. The effluent from the subject facilities shall be monitored by the Permittee at the point prior to irrigation
every MARCH, JULY, and NOVEMBER for the following parameters:
BOD5 TSS
Fecal Coliform pH
NH3 as N Sodium
Magnesium Calcium
Sodium Adsorption Ratio by Calculation
TKN NO,,-N and NO N
PIant Available N (PAN) by Calculation

4. Results from the soils analysis required in Permit Condition III.. 5., shall be utilized to determine tl
appropriate amount of lime and/or gypsum to be incorporated into the spray irrigation field to neutralize
potential salts buildup from the cleaning agents and disinfectants. Salts accumulation shall not be allowed
to build to a point that inhibits the soils ability to absorb the spray irrigated wastewater.
5. An ANNUAL representative soils analysis (Standard Soil Fertility Analysis) shall be conducted during the
months of April 15`h to September 15`h (after initial sampling date is established, future annual sampling,
thereafter, shall occur on or near the date of the initial sampling (+/- up to seven days)) on each permitted
spray field area, and the results shall be 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 Manganese Potassium
Calcium Percent Humic Matter Sodium
Copper pH Zinc
Magnesium Exchangeable Sodium Percentage Phosphorus
Cation Exchange Capacity Base Saturation (by calculation)
6. Three copies of all operation and disposal records (as specified in Condition III. 2.) on Form NDAR-1
(Hydraulic data) and Form IRR-2 (Nutrient Balance data) shall be SUBMITTED ON OR BEFORE THE
LAST DAY OF APRIL, AUGUST, AND DECEMBER. Three copies of all effluent monitoring data (as
specified in Condition III. 3.) on Form NDMR-1 shall be SUBMITTED ON OR BEFORE THE LAST
DAY OF APRIL, AUGUST, AND DECEMBER. Three copies of the representative soils analysis shall
be submitted ANNUALLY on or before March 1" of the following year. 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

7. Noncompliance Notification:
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 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 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
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 RE UIREMENTS
The Groundwater Section shall be furnished with copies of the analyses of the periodic sampling of the
slaughterhouse water supply well (as required by the Pender County Health Department). The analyses
shall be mailed to:
Groundwater Section
Permits and Compliance Unit
1636 Mail Service Center
Raleigh, NC 27699-1636
2. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary is for the disposal system
constructed after December 31, 1983 is established at either (1) 250 feet from the waste disposal area, or (2)
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 in accordance with 15A NCAC 2L .0106(d)(2), in addition to the penalty provisions applicable under
North Carolina General Statute 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a 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 remediation action on the part of the Permittee, in
accordance with 15A NCAC 2L .0106(d)(1).
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4. Waste application activities shall not occur when the vertical separation between the depth of application and
the water table is less than three feet. Verification of the water table elevation can be confirmed by on-si
auger borings, which must be done within 24 hours prior to the wastewater application event. When aug
boring investigations are conducted, ensure that all open borings are properly re -filled with native soil, pnOL
.to the application event, to decrease the chance of any waste contaminating the groundwater.
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.
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
1. 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 limitations 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 15A NCAC Ch. 4 and under the Division's General
Permit NCG0100000, 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 th
Iife of the project.
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The annual administering and compliance fee must be paid by the Permittee within 30 days after bein8
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).
8. The Permittee, at least six 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.
The subject wastewater treatment and disposal facilities shall be connected to an operational publicly
owned wastewater collection system within 180 days of its availability to the subject facilities, if the
subject wastewater treatment or disposal facilities are in noncompliance with the terms and conditions of
this non -discharge permit or the governing statutes or regulations. Prior to the initiation of these
connection activities, appropriate approval must be received from this Division.
Permit issued this the twentieth day of September, 2001
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Gregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0012709
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