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Home My WebLink AboutNC0001970_Compliance Evaluation Inspection_20210707DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E ROY COOPER Governor JOHN NICHOLSON Interim Secretary S. DANIEL SMITH Director Zakary Kissel, Plant Manager Bay Valley Foods 354 North Faison Avenue Faison, NC 28341 rcSTATE r NORTH CAROLINA Environmental Quality July 12, 2021 SUBJECT: Compliance Inspection Report Bay Valley Foods Faison Processing Facility NPDES WW Permit No. NC0001970 Duplin County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Bay Valley Foods Faison Processing Facility on 7/07/2021. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0001970. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the inspection and therefore, a response to this inspection report is not required. If you should have any questions, please do not hesitate to contact Helen Perez with the Water Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215 or via email at helen.perez@ncdenr.gov. Sincerely, DocuSigned by: 1 0- --ma- ri OA. 7F141E7366F3456... Morella Sanchez -King, Regional Supervisor Water Quality Regional Operations Section Wilmington Regional Office Division of Water Resources, NCDEQ ATTACHMENTS Cc: Donovan Brock — electronic copy Upload to Laserfiche DE Q�� North Carolina Department of Environmental Quality I Division of Water Resources Wilmington Regional Office 1 127 Cardinal Drive Extension I Wilmington, North Carolina 28405 mw�amwemwm.n,ia�,� /`� 910.796.7215 DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E 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 I 2 u 3 I NC0001970 I11 121 21/07/07 I17 18I � I 19 I s I 201 I 211IIIII 111111III II III III1 I I IIIII IIIIIIIII II r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 701L—I a I 71 [n LI 72 I n, I 71 I 74 79 I I I I I I I80 L-1 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 Dermit Number) 01:OOPM 21/07/07 11/08/01 Bay Valley Foods Faison Processing Facility 354 N Faison Ave Exit Time/Date Permit Expiration Date Faison NC 28341 03:15PM 21/07/07 16/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Donovan Wayne Brock//910-267-4050 /9102671989 Donovan Wayne Brock/ORC/910-267-4711/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Donovan Wayne Brock,PO Box 158 Faison NC 283410158/ORC/910-267-4050/9102671989 Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran 0 Sludge Handling Dispo: Facility Site Review Effluent/Receiving Wate 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 Helen I Perez Docusigned by: DWR/WIRO WQ/910-796-7387/ 7/12/2021 1D645B4A39694BE... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date DocuSigned by: Tom Tharrington DWR/WIRO WQ/ - - / -roµ -�I� ti o7/12/2021 `/r141 E/J bF;S4bb... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E NPDES yr/mo/day Inspection Type (Cont.) NC0001970 I11 12I 21/07/07 117 18 I c Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) A routine compliance inspection of the Bay Valley Foods -Faison Processing Facility WWTP was conducted on July 7, 2021. The purpose of the evaluation was to verify that the facility is operating in compliance with the conditions and limitations specified in Permit NC0001970. This wastewater facility is a 0.50 MGD, extended aeration biological treatment system. Process wastewater consists of water generated from packaging activities, plant utility systems, collected stormwater from the Brine Yard Retention Pond and recovered groundwater. The facility continues to be well maintained and operated. The permit expired on 07/31/2016 and is currently under review by the NPDES Unit for renewal. A file review of DMRs from 2016 to present shows two daily maximum violations for BOD in April and August of 2017 and a monthly average maximum violation for flow in June 2018. A review of GW-59 reports since sampling began in the mid 1990s has shown elevated levels of TDS and chlorides in all the monitoring wells. Many corrective actions have taken place over the years by the facility, and an apparent downward trend in these contaminant concentrations has been observed with occasional fluctuations. The facility is compliant with NPDES Permit NC0001970. Please review the comment sections of the inspection report for more details. Page# DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E Permit: NC0001970 Owner -Facility: Bay Valley Foods Faison Processing Faci Inspection Date: 07/07/2021 Inspection Type: Compliance Evaluation 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? ■ ❑ ❑ ❑ # Are there any special conditions for the permit? ■ ❑ ❑ ❑ Is access to the plant site restricted to the general public? ■ ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? ■ ❑ ❑ ❑ Comment: The permit renewal is currently under review. The permit contains a variance from the water quality standard for chloride in Panther Branch. As part of this variance, the site is required to perform benthic sampling at upstream and downstream locations at least 6 months prior to the expiration date. The site must also provide annual reports discussing chloride removal technologies, chloride removal methods and a summary of source reduction activities. Groundwater monitoring is required and sampling, in the event of the brine yard retention pond overflow, is required.. Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? ■ ❑ ❑ ❑ Is all required information readily available, complete and current? ■ ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? ❑ ❑ ❑ ■ Are analytical results consistent with data reported on DMRs? ❑ ❑ ❑ ■ Is the chain -of -custody complete? ❑ ❑ ❑ ■ Dates, times and location of sampling ❑ Name of individual performing the sampling ❑ Results of analysis and calibration ❑ Dates of analysis ❑ Name of person performing analyses ❑ Transported COCs ❑ Are DMRs complete: do they include all permit parameters? ■ ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ ■ ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified ❑ ❑ ■ ❑ operator on each shift? Is the ORC visitation log available and current? ■ ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? ■ ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility ■ ❑ ❑ ❑ classification? Is a copy of the current NPDES permit available on site? ■ ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ■ ❑ Page# 3 DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E Permit: NC0001970 Inspection Date: 07/07/2021 Record Keeping Comment: No comment. Owner -Facility: Bay Valley Foods Faison Processing Faci Inspection Type: Compliance Evaluation Laboratory Are field parameters performed by certified personnel or laboratory? Are all other parameters(excluding field parameters) performed by a certified lab? # Is the facility using a contract lab? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? Yes No NA NE Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ Comment: The facility is field lab certified, Certification #5263. All other parameters are tested by Envirochem, Certification #94. Calibration records and bench sheets for pH, DO and temperature were complete. 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: Process control includes MLSS, settleable solids, PH and DO. Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑ Is the wet well free of excessive grease? ■ ❑ ❑ ❑ 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: The influent pump station is located after the course screen conveyor and grit system. Influent is pumped from the wet well into aeration basin #1. High level float is connected to an auto -dialer for high wet well level notification. Bar Screens Type of bar screen a.Manual b.Mechanical Yes No NA NE Page# 4 DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E Permit: NC0001970 Inspection Date: 07/07/2021 Bar Screens Owner -Facility: Bay Valley Foods Faison Processing Faci Inspection Type: Compliance Evaluation Yes No NA NE Are the bars adequately screening debris? 0 ❑ ❑ ❑ Is the screen free of excessive debris? ■ ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Initial screening of the influent is by an automated conveyor mechanical course screen. This screen removes larger items such as glass pieces, jar lids, plastic from the process plant and large food particles. A fine rotary drum screen unit removes the smaller solids just prior to the aeration basins. Screened material is transported to the county landfill. Grit Removal Type of grit removal Yes No NA NE a.Manual ❑ b.Mechanical Is the grit free of excessive organic matter? 0 ❑ ❑ ❑ Is the grit free of excessive odor? E ❑ ❑ ❑ # Is disposal of grit in compliance? 0 ❑ ❑ ❑ Comment: The grit removal system is located between the course screen and the rotary screen. Grit material is transported to the county landfill. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? 0 ❑ ❑ ❑ Are the diffusers operational? ❑ ❑ ■ ❑ Is the foam the proper color for the treatment process? ❑ ❑ 0 ❑ Does the foam cover less than 25% of the basin's surface? ■ ❑ ❑ ❑ Is the DO level acceptable? ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑ Comment: The facility has 3 aeration basins connected in series with a total volume of 14MG There are a total of 18 surface aerators for aeration and mixing. Wastewater flows from the first basin to the next by concrete channels at the suface level. Inlet valves and drop gates allow operators to take a basin out of service for maintenance or to alter wastewater flow path as needed between the basin series. Solid accumulation in the bottom of Basin #2 was removed earlier this year. Page# 5 DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E Permit: NC0001970 Inspection Date: 07/07/2021 Owner -Facility: Bay Valley Foods Faison Processing Faci Inspection Type: Compliance Evaluation Chemical Feed Yes No NA NE Is containment adequate? ■ ❑ ❑ ❑ Is storage adequate? ■ ❑ ❑ ❑ Are backup pumps available? ■ ❑ ❑ ❑ Is the site free of excessive leaking? ■ ❑ ❑ ❑ Comment: A polymer solution is added prior to the secondary clarifier to enhance settling of the sludge. 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) Comment: No comment. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The RAS pump station is equipped with a high level alarm float that is connected to an auto -dialer system for notification. Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Down flow Is the filter media present? ■ ❑ ❑ ❑ Is the filter surface free of clogging? ■ ❑ ❑ ❑ Is the filter free of growth? ■ ❑ ❑ ❑ Is the air scour operational? ❑ ❑ ■ ❑ Page# 6 DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E Permit: NC0001970 Inspection Date: 07/07/2021 Owner -Facility: Bay Valley Foods Faison Processing Faci Inspection Type: Compliance Evaluation Filtration (High Rate Tertiary) Is the scouring acceptable? Is the clear well free of excessive solids and filter media? Comment: The traveling bridge sand filter backwashes when initiated by float controls. Drying Beds Is there adequate drying bed space? Is the sludge distribution on drying beds appropriate? Are the drying beds free of vegetation? # Is the site free of dry sludge remaining in beds? Is the site free of stockpiled sludge? Is the filtrate from sludge drying beds returned to the front of the plant? # Is the sludge disposed of through county landfill? # Is the sludge land applied? (Vacuum filters) Is polymer mixing adequate? Yes No NA NE ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ■ ❑ Comment: Currently the wasted sludge is pumped to the 5 drying beds and removed by a contractor when dried. The plate and frame press is no longer being used. Future plans include purchasing a conventional belt press for efficiency. Standby Power Yes No NA NE Is automatically activated standby power available? ■ ❑ ❑ ❑ Is the generator tested by interrupting primary power source? ❑ ❑ ❑ ■ Is the generator tested under load? ❑ ❑ ❑ Was generator tested & operational during the inspection? ❑ ❑ ❑ Do the generator(s) have adequate capacity to operate the entire wastewater site? ■ ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up ❑ ❑ ❑ ■ power? Is the generator fuel level monitored? 0 ❑ ❑ ❑ Comment: The facility has 2 generators for the wastewater plant. One generator powers the headworks area and an additional generator powers the secondary clarifier and RAS/WAS areas. Both are tested weekly. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ Page# 7 DocuSign Envelope ID: 0533ECD1-4F23-4097-B263-A260EF4DD90E Permit: NC0001970 Inspection Date: 07/07/2021 Flow Measurement - Effluent Owner -Facility: Bay Valley Foods Faison Processing Faci Inspection Type: Compliance Evaluation (If units are separated) Does the chart recorder match the flow meter? Comment: The effluent flowmeter was calibrated by Clearwater Inc. on 04/16/2021. Effluent Pipe Is right of way to the outfall properly maintained? Are the receiving water free of foam other than trace amounts and other debris? If effluent (diffuser pipes are required) are they operating properly? Yes No NA NE ❑ ❑ ■ ❑ Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: Final effluent flows by gravity down a cascade, stair step for post aeration into the receiving stream, Panther Branch. Page# 8