WQ0016376_Final Permit_20050518

O0F WA �F9Q� Michael F. Easley, Governor
� William G. Ross Jr., Secretary
UJ r North Carolina Department of Environment and Natural Resources
. Lu. , -a-)
C) Alan W. Klimek, P.E. Director
Nq=r Division of Water Quality
May 18, 2005
Joseph P. Villari
S & J Villari Livestock
892 Penny Branch Road
Warsaw, NC 28398
Subject: Permit No. WQ0016376
The Pork Company d.b.a.
S & J Villari Livestock Processing Facility
Wastewater Surface Irrigation
Duplin County
Dear Mr. Villari:
In accordance with your permit renewal request received February 4, 2005, and subsequent
additional information received February 21, 2005, we are forwarding herewith Permit No. WQ0016376,
dated May 18, 2005, to The Pork Company d.b.a. S & J Villari Livestock for the continued operation of
the subject wastewater treatment and surface irrigation facilities.
This permit shall be effective from the date of issuance until April 30, 2010, shall void Permit No.
WQ0016376 issued April 2, 2004, and shall be subject to the conditions and limitations as specified
therein. Please pay particular attention to the monitoring requirements in this permit. New conditions
include the use of chlorine tablets (if applicable) consistent with approved design specifications
(Condition II(17)). Failure to establish an adequate system for collecting and maintaining the required
operational information will result in future compliance problems.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the
right to request an adjudicatory hearing upon written request within thirty (30) days following receipt of
this permit. This request must be in the form of a written petition, conforming to Chapter 150B of the
North Carolina General Statutes, and filed with the Office of Administrative Hearings, 6714 Mail Service
Center, Raleigh, NC 27699-6714. Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact David Goodrich at (919)
715-6162.
Sincere
.Alan W. Klimek, P.E.
cc: Duplin County Health Department
Wilmington Regional Office, Aquifer Protection Section
Technical Assistance and Certification Unit
f. APS Central Files one
T, -0 Files N Carolina
a%rally
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer service
Internet: h2o.ennstate.ne,us 2728 Capital Boulevard Raleigh, NC 27604 FAX [phone]
An Equal OpportunitylAffirmative Action Employer 50% Recycledl10% Post Consumer Paper

NORTH t::AROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
SURFACE IRRIGATION SYSTtM 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
The Pork Company
d.b.a.
S & J Villari Livestock
Duplin County
FOR THE
continued operation of a 45,000 GPD (based on operation 5.5 days per week, for a maximum total of
247,500 gallons per week) surface irrigation treatment facility consisting of a T-R Solids Separator, a
curbed 20 feet by 24 feet solids collection area with leachate collection and daily solids rendering
collection, a 10,000 gallon storage tank, a 2,000 gallon pump tank with dual solids handling pumps, a
3,650,428-gallon (volume corrected based on field measurements) synthetically -lined aerobic lagoon, a
1.88 million gallon above -ground stainless steel storage tank, and continued operation of a solid set
irrigation system to consist of 80 sprinklers in 13 irrigation zones covering approximately 16 effectively
irrigated acres, and continued operation of a new center pivot irrigation system effectively irrigating 23.11
acres, to serve S & 7 Villari Livestock Processing Facility, with no discharge of wastes to the surface
waters, pursuant to the application received February 4, 2005, and subsequent additional information
received by the Division, 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 April 30, 2010, shall void Permit No.
WQ0016376 issued April 2, 2004, and shall be subject to the following specified conditions and
limitations:
I. PERFORMANCE STANDARDS
The surface 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, such as the construction of additional or replacement
wastewater treatment and disposal facilities.

The Division has concerns regarding the quality of the current crops on both irrigation fields. It is
recommended that the Permittee continue to seek recommendations from an agronomist. The
Permittee shall be responsible for ensuring adequate measures are taken to provide the best conditions
for suitable crop growth and nutrient uptake.
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,
/A: The residuals generated from these treatment facilities must be disposed in accordance with General
Statute 143-215.1 and in a manner approved by the Division.
Diversion or bypassing of the untreated wastewater from the treatment facilities is prohibited.
6. The following buffers shall be maintained:
i
400 feet between wetted area and any residence or places of public assembly under separate
ownership,
__b) 150 feet between wetted area and property lines,
� 100 feet between wetted area and wells,
,d 100 feet between wetted area and drainage ways or surface water bodies,
50 feet between wetted area and public right of ways,
100 feet between treatment/storage units and any wells, and
50 feet between 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 that 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 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.
11. OPERATION AND MAINTENANCE REQUIREMENTS
I The facilities shall be properly maintained and operated at all times.
"Upon classification of the wastewater treatment and irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to
be back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit
the facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply
with all other conditions specified in these rules.
3: A suitable year round vegetative cover shall be maintained.
,_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 irrigation 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.

r
To ensure that the poor soils on site adequately assimilate the wastewater, the Operator in
Responsible Charge will carefully inspect the spray site every hour, paying particular attention to
areas under nozzles previously identified as A and B in Zones 2-5. Should saturated conditions exist,
or ponding water occur, the irrigation event will be stopped and further inspection on the rest of the
spray area will occur. Should the Operator in Responsible Charge determine that the other spray area
can adequately assimilate additional wastewater, the above -mentioned nozzles will be closed and the
irrigation event may continue with proper supervision.
The application rate on the existing solid set irrigation system shall not exceed a cumulative loading
of 45.33 inches over any twelve (12) month period at an instantaneous application rate not to exceed
0.6 inches per hour.
y
,9:"The application rate on the new center pivot irrigation system shall not exceed a cumulative loading
of 16.0 inches over any twelve (12) month period at an instantaneous application rate not to exceed
0.6 inches per hour.
�rThe application of plant available nitrogen (by calculation) shall not exceed a cumulative loading of
300 pounds per acre per growing season of Coastal Bermuda grass (March — September) and a
cumulative loading of 50 pounds per acre per growing season of a winter cover crop (October —
March).
,1+ No type of wastewater other than that from S & J Villari Livestock processing Facility shall be
irrigated onto the irrigation area.
12 No traffic or equipment shall be allowed on the disposal area except while installation occurs or while
normal maintenance is being performed.
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.
1,4.Freeboard in the lagoon shall not be less than two feet at any time.
�.15'. If not already installed, a waste -level gauge, to monitor waste levels in the storage pond, shall be
installed within sixty (60) days of issuance of this permit. This gauge shall have readily visible
permanent markings indicating the maximum liquid level at the top of the temporary liquid storage
volume, minimum liquid level at the bottom of the temporary liquid storage volume, and top of the
dam elevations. Caution must be taken not to damage the integrity of the liner when installing the
gauge.
y
,16. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas,
and surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow
on the earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or
otherwise controlled and accessible.
If applicable, the chlorine tablets used in the disinfection facility shall be of the kind and type
specified in the plans and specifications approved by the Division.

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: Influent flow shall be continuously monitored and daily flow values shall be reported on Form
° NDMR. `
If not already installed, the Permittee shall install an appropriate flow measurement device consistent
with approved engineering and scientific practices to ensure the accuracy and reliability of influent
flow measurement. Flow measurement devices selected shall be capable of measuring flows with a
maximum deviation of less than 10 percent from true flow, accurately calibrated at a minimum of
once per year, and maintained to ensure that the accuracy of the measurements is consistent with the
accepted capability of that type of device, The Permittee shall keep records of flow measurement
device calibration on file for a period of at least three years. At a minimum, data to be included in
this documentation shall be:
a. Date of flow measurement device calibration
b. Name of person performing calibration
c. Percent from true flow
If not already constructed, plans and specifications for the flow measuring device shall be prepared by
a licensed Professional Engineer and submitted to the appropriate regional office 30 days prior to
installation. The flow measuring device shall be installed within 1 year of the date of this permit.
- 3. The effluent from the subject facilities shall be monitored by the Permittee at a point after
chlorination every rnont�i for the following parameters: � JT
Plant Available Nitrogen (PAN) by calculation
,7
Surface monitoring of the adjacent Unnamed Tributary to Turkey Creek at the point where the
tributary first enters the property (to be referred to as Upstream SW on monitoring reports) and at the
downstream point where the tributary leaves the property (to be referred to as Downstream SW on
monitoring reports) shall be conducted monthly for the following parameters:
BOD5
TSS
NO2-NO3
_ Fecal Coliform
NH3 as N
TKN
pH
Total Phosphorous
NO3 — as N TKN
NH3 — as N - Fecal Coliform
Total Phosphorous
Monitoring and analyses shall be conducted in accordance with 15A NCAC 2B .0505(e)(4) and
analyses must be conducted by a DWQ Certified Laboratory as per 15A NCAC 211.0800,
4

The Permittee tracking the amount of wastewater disposed shall maintain adequate records. 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.
fr. Freeboard in the lagoon shall be recorded weekly.
,,7.' Three (3) copies of all monitoring data [as specified in Conditions 111(2), 111(3) and III(4)] on Form
NDMR-1 and three (3) copies of all operation and disposal records [as specified in Conditions III(5)
and III(6)] on Form NDAR-1 shall be submitted on or before the last day of the following month. All
information shall be submitted to the following address:
Division of Water Quality
Information Processing Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
.Fr An annual representative soils analysis (Standard Soil Fertility Analysis) shall be conducted on each
irrigation field and the results maintained on file by the Permittee for a minimum of five years. The
Standard Soil Fertility Analysis shall include, but is not necessarily limited to, the following
parameters:
Acidity
Manganese
Potassium
Calcium
Percent Humic Matter
Sodium
Copper
pH
Zinc
Magnesium
Base Saturation (by calculation)
Phos horns
Cation Exchange Capacity
Exchangeable Sodium Percentage
An annual report shall be submitted to the Division, on or before March I" of the following year,
outlining the operation and maintenance teclrniques used to prevent nuisance conditions. This report
shall be submitted to the Division of Water Quality, Wilmington Regional Office, 127 Cardinal Drive
Extension, Wilmington, NC 28405-3845 and shall include, but not be limited to:
Operation. and Maintenance Schedule(s)
Equipment repair and replacement
Odor Control measures
Complaints lodged by citizens
10. Noncompliance Notification:
Annual Soils Analysis
Lime Application Records, if applicable
Cover Crop Harvest Dates & Yields
Other Field Maintenance Activities
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.
Occurrences outside normal business hours may also be reported to the Division's Emergency
Response personnel at telephone number [phone], [phone], or [phone].
Persons reporting such occurrences by telephone shall also file a written report in Ietter form within
five (5) days following first knowledge of the occurrence. This report must outline the actions taken
or proposed to be taken to ensure that the problem does not recur.
IV. GROUNDWATER REQUIREMENTS
I-: Sampling Requirements: (provided the new wells 5, 6,7,&8 have been installed, etc)
a. Groundwater monitoring wells MW-1, MW-2, MW-3, MW-4, MW-5, MW-6, MW-7, and MW-8
shall be sampled every April, August, and December for the parameters listed below:
Water Level
Total Ammonia Nitrogen (NH3-N)
- Nitrate Nitrogen (NO,-N)
,-Total Dissolved Solids (TDS).
Total Phosphorous
pH
Fecal Coliforms
Total Organic Carbon (TOC)
Chloride
-Volatile Organic Compounds — in December only
Water levels in the groundwater monitoring wells shall be measured prior to sampling the
groundwater for the remaining parameters. The depth to water in each well shall be measured
from the surveyed point on the top of the casing, which shall be surveyed relative to a common
datum.
/b. Volatile Organic Compounds (VOCs) sampled in December shall be analyzed using one of the
following methods:
(A) Standard Method 6230D, PQL at 0.5 ug/L or less
(B) Standard Method 621 OD, PQL at 0.5 ug/L or less
(C) EPA Method 8021, Low Concentration, PQL at 0.5 ug/L or less
(D) EPA Method 9260, Low Concentration, PQL at 0.5 ug/L or less
(E) Another method with prior approval by the Division.

Any method used shall, at a minimum, include all of the constituents listed in Table VIII of
Standard Methods 6230D. The method, used shall provide a PQL at 0.5 ug/L or less, which shall
be supported by laboratory proficiency studies as required by the Division's Laboratory
Certification Unit. Any constituents detected above the MDL, but below the PQL at 0.5 ug/L,
shall be qualified (i.e., estimated) and reported.
If total organic carbon (TOC) concentrations greater than 10 milligrams per liter are detected in
any downgradient groundwater monitoring well, additional sampling and analysis shall be
conducted to identify the individual constituents comprising this TOC concentration. If the TOC'
concentration as measured in the background well exceeds 10 milligrams per liter, this
concentration shall be taken to represent the naturally -occurring TOC concentration. Any
exceedances of this naturally -occurring TOC concentration in downgradient wells shall be subject
to the additional sampling and analysis as described in this permit.
,.d. Any laboratory selected to analyze parameters shall be Division -certified for those parameters
required.
2. Reporting /Documentation Requirements:
The results of the sampling and analyses shall be received on the most -recent version of
"Groundwater Quality Monitoring: Compliance Report Form" (i.e., GW-59 Form) with copies of
the laboratory analyses attached by the Division's information Processing Unit on or before the
last working day of the month fallowing the sampling month.
b: All reports, maps, and other documents required in the "Groundwater Requirements" section of
this permit shall be mailed to the following address:
NCDENR-DWQ
Information Processing Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Updated blank reporting and other forms may be downloaded from the web site for the Division's
Aquifer Protection Section at http://gw.ehnr.state.ne.us/ or requested from the address listed
above. ! j
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�3- Vertical Separation Requirements:
a. Industrial waste shall not be applied or discharged onto or below the land surface when the
vertical separation between the waste and the seasonal high water table is less than three (3) feet,
unless the permittee has demonstrated to the Director or his delegate, by using predictive
calculations or modeling methods acceptable to the Director or his delegate, that such placement
will not result in the contravention of classified groundwater standards.
4. Applicable Boundary Requirements:
,ar. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A
NCAC 2L, Groundwater Classifications and Standards. The Compliance Boundary for the
disposal system individually permitted on or after December 30, 1983 is established at either 250
feet from the waste disposal area, or 50 feet within the property boundary, whichever is closer to
the waste disposal area. An exceedance of Groundwater Quality Standards at or beyond the
Compliance Boundary is subject to remediation action according to 15A NCAC 2L .0106(d)(2).

The REVIEW BOUNDARY is established around the disposal systems midway between the
v Compliance Boundary and the perimeter of the waste disposal area. Any exceedance of standards
at the Review Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
Other Reguire_m_ents:
a. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
V. INSPECTIONS
.. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities.
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 Pennittee 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.
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
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 Chapter 4 and under
the Division's General Permit NCG010000, and any requirements pertaining to wetlands under 15A
NCAC 2B .0200 and 2H .0500.
8

„6-. The Permittee shall retain a set of approved plans and specifications for the life of the project.
7. The Permittee must pay the annual administering and compliance fee within thirty (30) days after
being billed by the Division. Failure to pay the fee accordingly may cause the Division to initiate
action to revoke this permit as specified by 15A NCAC 2H .0 20 5 (c)(4).
,8:” 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 18"' day of May, 2005
NORTH OLINNA E IRONMENTAL MANAGEMENT COMMISSION
.."Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0016376
9

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