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Home My WebLink AboutNC0006548_Compliance Evaluation Inspection_20200116ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Director NORTH CAROLINA Environmental Quality January 16, 2020 Mr. Jeremy Kilburn, VP and General Council Wayne Farms LLC 4110 Continental Drive Oakwood, Georgia 30566 Subject: Compliance Evaluation Inspection Wayne Farms Dobson Fresh Plant WWTP NPDES Permit # NC0006548 Surry County Dear Ms. Kilburn: A Compliance Evaluation Inspection was performed by North Carolina Division of Water Resources (NC DWR) staff person, Justin Henderson on January 10, 2020. Mr. Jeremy Bowlin, ORC was present during this inspection. This type of inspection consists of two basic parts: an in - office review of the facility files and self -monitoring data and an on -site inspection of the facility. While, this inspection mostly reflects compliance with the subject permit, the following items of concern warrant your attention and action: 1) The thermometer located in the effluent composite sampler was overdue for annual calibration. Mr. Bowlin indicated, at the time of this inspection, that he would have this thermometer sent for calibration on Tuesday January 14, 2019, to address this finding. 2) There is a monitoring well network present at the facility. This network consists of one up -gradient monitoring well and three down -gradient monitoring wells. Groundwater monitoring from these monitoring wells is not actively being conducted. These monitoring wells were evaluated for structural integrity and location as part of this inspection. The up -gradient monitoring well's casing has been compromised, reportedly due to being hit or "backed" into by a vehicle associated with the facility's operations. 15A NCAC 02C .0112 (d) states: Broken, punctured, or otherwise defective or unserviceable casing, screen, fixtures, seals, or any part of the well head shall be repaired or replaced, or the well shall be permanently abandoned in accordance with 15A NCAC 02C .0113 (b). Please specify if repair or permanent abandonment of the up -gradient monitoring well will be pursued to comply with this regulation. NORTH CAROLINAD_E Q�� o.�ro�em m e�w��vi nu.i� North Carolina Department of Environmental Quality I Division of Water Resources Winston-Salem Regional Office 1 450 West Hanes Mill Road, Suite 300 I Winston-Salem, North Carolina 27105 336.776.9800 3) As noted above, groundwater monitoring is not actively being conducted for the monitoring well network present at the facility. The Division would recommend that permanent abandonment of these monitoring wells be considered to reduce/prevent the potential for groundwater contamination occurring due to improper maintenance of these wells. Prior to permanent abandonment procedures, the Division would encourage that each monitoring well be sampled for the standard groundwater parameters (i.e. Water Level; Fecal; pH; TDS; Chloride; NH3; NO3; TP) to demonstrate compliance with 15A NCAC 02L standards. The Division requests a written response providing details of the facility's plans to repair and/or permanently abandoned the up -gradient monitoring well, as well as the facility's preference in the consideration of permanent abandonment for all the monitoring wells existing at the facility. This response is requested to be submitted within 30-days of receipt of this inspection letter. If you have any questions concerning this report, please contact Justin Henderson or me at (336) 776-9800. y» Low T JMatt W-81itZ,. Asst. Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ enc: Inspection Report cc: Jeremy Bowlin, ORC- jeremy.bowlin@waynefarms.com Laserfiche Files (electronic copies) United States Environmental Protection Agency Form Approved. EPA Washington, D.C. 20460 OMB No. 2040-0057 Water Compliance Inspection Report Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 IN 1 2 15 I 3 I NC0006548 111 12 I 20/01/10 I17 18 I S J 19 L G] 201 I 211111 I I I I I I II I I I I I I I I I I I I I I I I I I I I I I I II I I I I I f6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 671 70 I I 71 I I 72 I r I 73 I I 174 751 I I I I I I I80 u ty I I i Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include Entry Time/Date Permit Effective Date POTW name and NPDES oermit Number) 09:30AM 20/01/10 19/09/01 Dobson Plant 802 E Atkins St Exit Time/Date Permit Expiration Date Dobson NC 27017 12:OOPM 20/01/10 23/12/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Jeremy Elden Bowl in/ORC/336-386-5867/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Paul Nordin,PO Box 383 Dobson NC 27017//336-386-5867/3363868822 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self -Monitoring Program Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Justin L Henderson DocuSigned by: DWR/WSRO WQ/336-776-9701/ Dt,tsh t, hA&k 6V' 1/13/2020 51F3525961`8113496.. Signature of Management Q A Review rpocusigned by: Agency/Office/Phone and Fax Numbers Date T 1/16/2020 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type (Cont.) NC0006548 111 121 20/01/10 117 18 ICI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Dear Ms. Kilburn: A Compliance Evaluation Inspection was performed by North Carolina Division of Water Resources (NC DWR) staff person, Justin Henderson on January 10, 2020. Mr. Jeremy Bowlin, ORC was present during this inspection. This type of inspection consists of two basic parts: an in -office review of the facility files and self -monitoring data and an on -site inspection of the facility. While, this inspection mostly reflects compliance with the subject permit, the following items of concern warrant your attention and action: 1) The thermometer located in the effluent composite sampler was overdue for annual calibration. Mr. Bowlin indicated, at the time of this inspection, that he would have this thermometer sent for calibration on Tuesday January 14, 2019, to address this finding. 2) There is a monitoring well network present at the facility. This network consists of one up -gradient monitoring well and three down -gradient monitoring wells. Groundwater monitoring from these monitoring wells is not actively being conducted. These monitoring wells were evaluated for structural integrity and location as part of this inspection. The up -gradient monitoring well's casing has been compromised, reportedly due to being hit or "backed" into by a vehicle associated with the facility's operations. 15A NCAC 02C .0112 (d) states: Broken, punctured, or otherwise defective or unserviceable casing, screen, fixtures, seals, or any part of the well head shall be repaired or replaced, or the well shall be permanently abandoned in accordance with 15A NCAC 02C .0113 (b). Please specify if repair or permanent abandonment of the up -gradient monitoring well will be pursued to comply with this regulation. 3) As noted above, groundwater monitoring is not actively being conducted for the monitoring well network present at the facility. The Division would recommend that permanent abandonment of these monitoring wells be considered to reduce/prevent the potential for groundwater contamination occurring due to improper maintenance of these wells. Prior to permanent abandonment procedures, the Division would encourage that each monitoring well be sampled for the standard groundwater parameters (i.e. Water Level; Fecal; pH; TDS; Chloride; NH3; NO3; TP) to demonstrate compliance with 15A NCAC 02L standards. The Division requests a written response providing details of the facility's plans to repair and/or permanently abandoned the up -gradient monitoring well, as well as the facility's preference in the consideration of permanent abandonment for all the monitoring wells existing at the facility. This response is requested to be submitted within 30-days of receipt of this inspection letter. If you have any questions concerning this report, please contact Justin Henderson or me at (336) 776-9800. Page# Permit: NC0006548 Owner - Facility: Dobson Plant Inspection Date: 01/10/2020 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ ❑ 0 ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: Pump Station - Effluent Yes No NA NE Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? ❑ ❑ 0 ❑ Is audible and visual alarm available and operational? ❑ ❑ ❑ Comment: Equalization Basins Yes No NA NE Is the basin aerated? 0 ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the basin free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Are audible and visual alarms operable? ❑ ❑ ❑ # Is basin size/volume adequate? 0 ❑ ❑ ❑ Comment: Page# 3 Permit: NC0006548 Inspection Date: 01/10/2020 Owner - Facility: Dobson Plant Inspection Type: Compliance Evaluation Secondary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Some pin floc was observed in the overflow assoicated with the smaller clarifier. Mr. Bowlin indicated this was due to the presence of Ceriodaphnia bacteria. He indicated that a super -chlorination would be necessary to control its growth. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? ❑ ❑ 0 ❑ Are the diffusers operational? 0 ❑ ❑ ❑ Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? 0 ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑ Comment: Nutrient Removal Yes No NA NE # Is total nitrogen removal required? ❑ ❑ 0 ❑ # Is total phosphorous removal required? ❑ ❑ 0 ❑ Type Biological # Is chemical feed required to sustain process? ❑ ❑ 0 ❑ Is nutrient removal process operating properly? 0 ❑ ❑ ❑ Comment: Page# 4 Permit: NC0006548 Owner - Facility: Dobson Plant Inspection Date: 01/10/2020 Inspection Type: Compliance Evaluation Nutrient Removal Yes No NA NE Lagoons Yes No NA NE Type of lagoons? Aerated # Number of lagoons in operation at time of visit? 1 Are lagoons operated in? # Is a re -circulation line present? ❑ ❑ 0 ❑ Is lagoon free of excessive floating materials? 0 ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? ❑ ❑ 0 ❑ Are dike slopes clear of woody vegetation? 0 ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? 0 ❑ ❑ ❑ Are dikes free of seepage? 0 ❑ ❑ ❑ Are dikes free of erosion? 0 ❑ ❑ ❑ Are dikes free of burrowing animals? 0 ❑ ❑ ❑ # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ 0 ❑ Is the lagoon surface free of weeds? 0 ❑ ❑ ❑ Is the lagoon free of short circuiting? 0 ❑ ❑ ❑ Comment: Disinfection -Liquid Yes No NA NE Is there adequate reserve supply of disinfectant? 0 ❑ ❑ ❑ (Sodium Hypochlorite) Is pump feed system operational? 0 ❑ ❑ ❑ Is bulk storage tank containment area adequate? (free of leaks/open drains) 0 ❑ ❑ ❑ Is the level of chlorine residual acceptable? 0 ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? 0 ❑ ❑ ❑ Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ Page# 5 Permit: NC0006548 Owner - Facility: Dobson Plant Inspection Date: 01/10/2020 Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: Effluent composite sampler thermometer was overdue for calibration. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and 0 ❑ ❑ ❑ sampling location)? Comment: Page# 6