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Home My WebLink AboutNC0043320_WWTP Inspection_20120305NCDENR North Carolina Department of Environment and Natural Resources Division of Water Quality Beverly Eaves Perdue Charles Wakild, P. E. Dee Freeman Governor Director Secretary March 5, 2012 Paul Smart Burlington Industries LLC 740 Cheraw Hwy Cordova, NC 28330 SUBJECT: February 29, 2012 Compliance Evaluation Inspection Burlington Industries LLC Richmond Plant Permit No: NC0043320 Richmond County Dear Mr. Smart : Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted on February 29, 2012. The Compliance Evaluation Inspection was conducted by Mark Brantley, Environmental Senior Specialist, of the Fayetteville Regional Office. The cooperation of Mr. H T Davidson, facility's back-up ORC was greatly appreciated. The facility was found to be in Compliance with permit NC0043320. As a reminder, preservation of the Waters of the State can only be achieved through consistent NPDES Permit compliance. Comments • Facility was clean and neat in appearance at the time of the inspection. • Laboratory records were compared to the monthly discharge report for the month. of November 2011. No transcription errors were found under this review. • Maintenance records and the ORC logbooks were up to date and well kept. • The Division of Water Quality now has an electronic method for facilities to submit their monthly discharge monitoring reports. This method allows improvements in data quality, data availability, and it has built in validation rules to reduce reporting errors. For more information please visit our website at http://portal.ncdenr.org/web/wq/admin/bog/ipu/edmr. If you have any questions or wish to begin using this program please call me at 910-433-3327. Location: 225 Green Street, Suite 714, Fayetteville, NC 28301 Phone (910) 433-3300\FAX: 910-486-0707\Customer Service: 1-877-623-6748 Internet: www.ncwaterquality.org NorthCarolina Naturally An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper Mr. Smart Page 2 March 5, 2012 Please refer to the enclosed inspection report for additional observations and comments. If you or your staff have any questions, please call me at 910-433-3327. Sincerely, Mark Brantley Environmental Senior Specialist Surface Water Protection Section Fayetteville Regional Office cc: Hiram Terry Davidson,.ORC Central Files 'bttttikkrile7' United States Environmental Protection Agency EPA Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approvafexpires831-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection 1 2 151 31 NC0043320 111 121 12/02/29 117 Type Inspector Fac Type . 181 r I 191 c I 201 I 1- -! III,IIIIIIII66 Remarks 2111.IIIIII IIIIIIII IIIIII.IIIIII IIIII.1II Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 671 169 701 31 71 I N 1 721 N 1 73 I I 174 751 I. I I. I I I 180 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Richmond Plant 740 Old Cheraw Hwy . - Cordova NC 28330 • Entry Time/Date 10:30 AM . 12/02/29 Permit Effective Date 10/05/01 Exit Time/Date 01:15 PM 12/02/29 Permit Expiration Date ' 14/02/28 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) //1 Hiram Terry Davidson/ORC/910-997-5001/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number , Contacted Paul Smart,740 Cheraw Hwy Cordova NC 28330/Plant Engineer/910-997-5001/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement • Operations & Maintenance Records/Reports Self -Monitoring Program Facility Site Review • Effluent/Receiving Waters 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 Mark Brantley - FRO WQ//910-433-3300 Ext.727/ 0 .7 - 5 1;2 Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date i Belinda S Henson �j (44014000DYD FRO WQ//910-433-3300 Ext.726/ 3 - -7— I a EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type 31 NC0043320 1 11 121 12/02/29 117 181CI (cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Comments Facility was clean and neat in appearance at the time of the inspection. Laboratory records were compared to the monthly discharge report for the month of November 2011. No transcription errors were found under this review. Maintenance records and the ORC logbooks were up to date and well kept. The Division of Water Quality now has an electronic method for facilities to submit their monthly discharge monitoring reports. This method allows improvements in data quality, data availability, and it has built in validation rules to reduce reporting errors. For more information please visit our website at http://portal.ncdenr.org/web/wq/admin/bog/ipu/edmr. If you have any questions or wish to begin using this program please call me at 910-433-3327. Page # 2 Permit: NC0043320 Owner - Facility: Richmond Plant Inspection Date: 02/29/2012 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■ n n ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge .■ n n n Judge, and other that are applicable? Comment: Permit (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: Record Keeping 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? Yes No NA NE n nan ■ nnn n n■n ■ nnn ■ nnn Yes No NA NE ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn ■ ■ ■ ■ ■ ■ ■ nnn n n■n 00•0 ■ ❑nn ■ nnn ■ nnn ■ nnn Page # 3 Permit: NC0043320 Owner - Facility: Richmond Plant Inspection Date: 02/29/2012 Inspection Type: Compliance Evaluation Record Keeping Facility has copy of previous year's Annual Report on file for review? Comment: 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? Comment: Flow Measurement - Effluent # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? . Comment: Bar Screens Type of bar screen a.Manual b.Mechanical Are the bars adequately screening debris? Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? Comment: 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? Yes No NA NE n n■n Yes No NA NE ■ nnn. ■ nnn n n■n Yes No NA NE ■ nnn ■ nnn ■ nnn n n■n Yes No NA NE ■ n ■ nnn ■ nnn ■ nnn ■ nnn Yes No NA NE ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn Page # 4 Permit: NC0043320 Owner - Facility: Richmond Plant Inspection Date: 02/29/2012 Inspection Type: Compliance Evaluation , Secondary Clarifier 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 1/4 of the sidewall depth) Comment: Aeration Basins Mode of operation Type of aeration system Is the basin free of dead spots? Are surface aerators and mixers operational? Are the diffusers operational? Is the foam the proper color for the treatment process? 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/I) Comment: Disinfection -Gas Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup?. Is there chlorine residual prior to de -chlorination? Does the Stationary Source have more than 2500 lbs of Chlorine (CAS No. 7782-50-5)? If yes, then is there a Risk Management Plan on site? If yes, then what is the EPA twelve digit ID Number? (1000- If yes, then when was the RMP last updated? Comment: Pumps-RAS-WAS Are pumps in place? Yes No NA NE ■ nnn ■ nnn ■ nnn ■ nnn Yes No NA NE Ext. Air Surface ■ nnn ■ nnn nn■n ■ nnn ■ nnn ■ nnn ■nnn Yes No NA NE ■ nnn ■ nnn ■ nnn ■ nnn ■ ❑ ❑ ❑ ■ nnn ❑n.❑ nn■n Yes No NA NE ■ nnn Page # 5 Permit: NC0043320 Owner - Facility: . Richmond Plant Inspection Date: 02/29/2012 Inspection Type: Compliance Evaluation Pumps-RAS-WAS Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Effluent Sampling Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: Upstream / Downstream Sampling Yes No NA NE ■ nnn ■ nnn Yes No NA NE nn■n ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? • n n n Comment: Page # 6