WQ0005603_NOV2009LV0499_20090605

NCDENR•
ffItE COPY
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
June 5, 2009
CERTIFIED MAIL 7006 2150 0005 2458 8856
RETURN RECEIPT REQUESTED
Jerry Sisk, Facility Engineer
Coats American, Inc.
Post Office Box 368
Marion, NC 28752
Subject: NOTICE OF VIOLATION
NOV-2009-PC-0499
Compliance Evaluation Inspection
Coats American-Sevier Plant
Recycle system
Permit No. WQ0005603
McDowell County
.Dear Mr. Sisk:
Enclosed please find a copy of the Inspection Report from the inspection conducted 2009-05-
27. Beverly Price of the Asheville Regional Office conducted the Compliance Evaluation Inspection.
The treatment facility was found to be in violation of Permit WQ0005603 for the following:
Inspection Area Compliance Issue
Record Keeping The well construction record (Form GW-1) for Monitoring Well
(MW) #15 has not been submitted. (See Permit Condition 35.)
MW#2 is missing the tag/data. (See Permit Condition 23.) The
scaled site map (see Permit Condition 10.) has not been
submitted.
Storage The ash basin dam has an excessive amount of small
trees/woody vegetation. (See Permit Condition 13.)
AQUIFER PROTECTION SECTION—Asheville Regional Office(ARO)
2090 U.S.70 Highway,Swannanoa,NC 28778-8211
Phone:[phone] FAX:[phone] One
Customer Service:1-877-623-6748 NorthCarolina
Internet:www.unii✓%Affirrna ve rq
Acton
Naturally
M Equal OppoNnitylAffirniafive Aclian Employer Naturally

J
• I 4
Mr. Sisk
June 5, 2009
Page 2
The issues noted above were all referenced in the 2008 inspection. Please refer to the
enclosed Inspection Report for any additional observation and comments.
To prevent further action, carefully review these violations and deficiencies and respond in
writing to this office within fifteen (15) working days of receipt of this letter. You should address
the causes of noncompliance and all actions taken to prevent the recurrence of similar situations.
If you should have any questions, please do not hesitate to contact Beverly Price at 828/296-
4500.
Sincerely,
.A..e1)‘cl
G. Landon Davidson, L.G.
Regional Supervisor
Aquifer Protection
Attachment
cc: Phillip Pittman, ORC w/ attachment
APS Central Files w/ attachment
APS Enforcement w/ attachment
APS ARO Files

•
•
Compliance Inspection Report
Permit: WQ0005603 Effective: 06/21/06 Expiration: 05/31/11 Owner. Coats American Inc
SOC: Effective: Expiration: Facility: Coats American-Sevier Plant
County: McDowell 630 American Thread Rd
Region: Asheville
Marion NC 28752
Contact Person: Jerry W Sisk Title: Facility Engineer Phone: [phone]
Directions to Facility:
Hwy.221 N from Marion.Turn right on American Thread Road(SR 1556). Facility is located approximately 1 mile on the right.
System Classifications:
Primary ORC: Certification: Phone:
Secondary ORC(s):
On-Site Representative(s): •
24 hour contact name Phillip Charles Pittman Phone: [phone]
On-site representative Phillip Charles Pittman Phone: [phone]
Related Permits:
Inspection Date: 05/27/2009 Entry Time: 10:00 AM Exit Time: 11:30 AM
Primary Inspector: Beverly Price Phone:[phone]
Secondary Inspector(s):
Reason for Inspection: Routine Inspection Type:Compliance Evaluation
Permit Inspection Type: Wastewater Recycling
Facility Status: 0 Compliant ■ Not Compliant
Question Areas:
III Miscellaneous Questions I.Treatment 1111 Record Keeping •Storage
•
(See attachment summary)
Page: 1

Permit:WQ0005603 Owner-Facility:Coats American Inc
Inspection Date:05/27/2009 , Inspection Type:Compliance Evaluation Reason for Visit:Routine
Inspection Summary:
The inspection included a data review and a tour of the facility.
The monitoring data appeared to be complete and accurate.
There are 2L violations:April 2009 GW-59: MW#2:Mn, Pb; MW#10:TDS, SO4; MW#11:Mn; MW#12:Mn; MW#14:Pb;
MW#15:Mn-these issues will be addressed separately from this inspection.
Issues noted in the 2008 Inspection that were not addressed include: •
1) The well construction record (Form GW-1)for MW#15 has still not been submitted. '
2) MW#2 still missing tag/data.
3) The scaled site map (Permit Condition 10.) has still not been submitted.
4)t The ash basin dam still has an excessive amount of small trees/woody vegetation. (vegetation removal was started
after the 2006 inspection).
A Notice of Violation will be issued for the issues noted above
The permit is written as a Wastewater Recycle System but the facility does not and has never recycled water from the ash
basin. According to Phillip Pittman, the system was not designed as a recycle system. The permittee should request an
Ash Distribution Permit or the current system should be designed/used as a Recycle System.
Page: 2

•
•
Permit:WO0005803 Owner-Facility:Coats American Inc
Inspection Date:05/27/2009 Inspection Type:Compliance Evaluation Reason for Visit:Routine
Type • Yes No NA NE
Reuse(Quality) 0
Single Family Spray, LR 0
Infiltration System 0
Lagoon Spray,LR 0
Activated Sludge Drip, LR 0
Activated Sludge Spray,HR 0
Activated Sludge Spray, LR ❑ •
Single Family Drip ❑
Recycle/Reuse ■
Treatment Yes No NA NE
Are Treatment facilities consistent with those outlined in the current permit? 0 • 0 0
Do all treatment units appear to be operational?(if no,note below.) ❑ • ❑ 0
Comment: This facility does not recycle and has never recycled. System consists of
an ash basin only with no piping for recycling.
Record Keeping Yes No NA NE
Is a copy of current permit available? ■ ❑ ❑ ❑
Are monitoring reports present: NDMR? 0 0 • 0
NDAR? ❑ ❑ ■ 0
Are flow rates less than of permitted flow? ❑ 0 ■ ❑
Are flow rates less than of permitted flow? 0 ❑ ■ 0
Are application rates adhered to? 0 0 ■ 0
Is GW monitoring being conducted,if required(GW-59s submitted)? ■ ❑ ❑ ❑
Are all samples analyzed for all required parameters? ■ ❑ ❑ ❑
Are there any 2L GW quality violations? MOOD
Is GW-59A certification form completed for facility? ■ ❑ ❑ ❑
Is effluent sampled for same parameters as GW? 0 0 ■ ❑
Do effluent concentrations exceed GW standards? 0 0 ■ 0
Are annual soil reports available? 0 0 ■ 0
#Are PAN records required? 0 0 ■ 0
#Did last soil report indicate a need for lime? 0 0 ■ 0
Page: 3

•
Permit:W00005603 Owner-Facility:Coats American Inc
Inspection Date: 05/27/2009 Inspection Type:Compliance Evaluation Reason for Visit:Routine
If so,has it been applied? ❑ ❑ ■ ❑
Are operational logs present? ■ ❑ ❑ ❑
Are lab sheets available for review? ■ ❑ ❑ ❑
Do lab sheets support data reported on NDMR? 0 0 ■ 0
Do lab sheets support data reported on GW-59s? ■ ❑ ❑ ❑
Are Operational and Maintenance records present? ■ ❑ ❑ ❑
Were Operational and Maintenance records complete? ■ ❑ ❑ ❑
Has permittee been free of public complaints in last 12 months? ■ ❑ ❑ ❑
Is a copy of the SOC readily available? ❑ ❑ ■ ❑
No treatment units bypassed since last inspection? ■ ❑ ❑ ❑
Comment:
ASH SETTLING BASIN -
Storage Yes No NA NE
Storage Type? Pond
Storage amount?
#At what point is side-stream wastewater returned to treatment?
Is there a Spill Control Plan? 0 0 ■ 0
Aerated or Mixed? NONE
If aeration is present,is it adequate? 0 0 ■ 0
If present,are diffusers cleaned regularly? 001110
Is influent structure acceptable? ■ ❑ ❑ ❑
Are banks/berms free of seepage and erosion? ■ ❑ ❑ ❑
Are banks/berms free of excessive vegetation? 0 ■ 0 0
Is pond lined? 0 ■ 0 0
Liner Type Unknown
Is liner acceptable? 0 0 ■ 0
Are baffles/curtains acceptable ' G '' ❑ ■ ❑
Does the pond have a freeboard marker? ■ ❑ ❑ ❑
Required freeboard? 2
Page: 4

Permit WO0005603 Owner-Facility:Coats American Inc
Inspection Date: 0527/2009 Inspection Type:Compliance Evaluation Reason for Visit Routine
Feet
Actual freeboard? 5
Feet
Is there suitable grassed vegetation? 0 • 0 0
Is the vegetation maintained? 0 ■ ❑ ❑
Is the area free of excessive weeds and/or woody species? - 0 • 0 0
Is the area free from signs of overflow? 111300
Is color acceptable? 0 0 • 0
Are floating mats acceptable? 0 0 ■ ❑
No excessive buildup of solids? 0 0 • 0
Are aerators/mixers acceptable? 0 0 • 0
Is effluent structure acceptable? ❑ ❑ ■ ❑
If present,is pond cover acceptable? 0 0 • 0
Comment: Excessive amount of small trees/shrubs/vegetation on the pond dam.
Page: 5