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Home My WebLink AboutNC0043320_WWTP Inspection_20091207• ATA, NCDEHR North Carolina Department of Environment and Natural Resources Division of Water Quality Beverly Eaves Perdue Coleen H. Sullins Governor Director December 7, 2009 Paul Smart Operator in Responsible Charge (ORC) P.O. Box 250 Cordova, NC 28330-0250 Subject: COMPLIANCE EVALUATION INSPECTION Burlington Industries, Inc. Burlington Industries -Richmond Plant NPDES Permit No. NC0043320 Richmond County Dear -Mr. Smart: Enclosed you will find a copy of the Compliance Evaluation Inspection report for the inspection that was conducted on November 9, 2009. On the day of this inspection the facility appeared to be in compliance with the conditions of Burlington's NPDES permit NC0043320. At the time of this inspection, the plant outfall composite sampler appeared to be adjusted to collect samples at a rate of one sample per hour. With this CEI report, Burlington is allowed to sample the Plant Effluent 001 24-hour composite by the Constant time/constant volume method — a series of grab samples of equal volume collected over a 24-hour period at a constant time interval. The grab samples shall be taken at intervals of no greater than 20 minutes apart during any 24-hour period and must be of equal size and of no less than 100 milliliters. Please adjust your effluent composite sampler accordingly. The 24-hour sample storage refrigerator, located in the laboratory building, also contained refreshments. For sanitary- and safety reasons, please do not store drinks (or food) for human consumption in the same refrigerator as WWTP samples. The thermometer was not found in a liquid in the refrigerator. Please keep the sample refrigerator thermometer in a container of waterinside of the sample refrigerator as this will improve the accuracy of reading the temperature within the refrigerator. 225 Green St., Suite 714, Fayetteville, NC 28301-5043 Phone: 910-433-33001 FAX: 910-486-07071 Customer Service: 1-877-623-6748 Internet: www.ncwaterquelity.org • An Equal Opportunity i Affirmative Action Employer Dee Freeman Secretary NorthCarolina N titmlly Mr. Smart December 7, 2009 Page 2 If you have any questions or comments concerning this report, please feel free to contact me at (910) 433-3312. Sincerel N CDa We Lopez Environmental Specialist Idl Enclosures: EPA Water Compliance Inspection Report Regional Field Inspectors Check List for Field Parameters cc: tin-D=1110J United States Environmental Protection Agency EPA Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98. Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection 1 I NI 2 15I 3I NC0043320 111 121 09/11/09 117 Type Inspector Fac Type 18I CI 191 SI 201 I IIIIIIII.III66 Remarks 21LjIIIIIIIIIIIIII IIIIIIII IIIIIIIIIIII Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 671 2.0 169 70I Li 711 I 72I NI 731 1 I.74 751 I I 1 I 1 1 180 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 12:01 PM 09/11/09 Permit Effective Date 04/09/01 Exit Time/Date 02:00 PM 09/11/09 Permit Expiration Date 09/02/28 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Paul Robert Smart/ORC/910-417-2207/ 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 Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) a -8ignature(s) of Inspector(s) Agency/Office/Phone and Fax Dale Lopez FRO wQ//910-433-3300 Ext.712/ Numbers Date �j t9 7 • Signature of Management Q A eviewer Agency/Office/Phone and Fax Numbers Datei a/ 5/07 4. 1./.1140. EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type 31 NC0043320 111 121 09/11/09 117 18ICI (cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On the day of this inspection the facility appeared to be in compliance with the conditions of Burlington's NPDES permit NC0043320. At the time of this inspection, the plant outfall composite sampler appeared to be adjusted to collect samples at a rate of one sample per hour. With this CEI report, Burlington is given permission to sample the Plant Effluent 001 24-hour composite by the Constant time/constant volume method — a series of grab samples of equal volume collected over a 24-hour period at a constant time interval. The grab samples shall be taken at intervals of no greater than 20 minutes apart during any 24-hour period and must be of equal size and of no less than 100 milliliters. Please adjust your effluent composite sampler accordingly. The 24-hour sample storage refrigerator, located in the laboratory building, also contained refreshments. For sanitary and safety reasons, please do not store drinks (or food) for human consumption in the same refrigerator as WWTP samples. The thermometer was not observed in a liquid in the refrigerator. Please keep the sample refrigerator thermometer in a container of water inside of the sample refrigerator as this will improve the accuracy of reading the temperature within the refrigerator. Page # 2 Permit: NC0043320 Owner - Facility: Richmond Plant Inspection Date: 11/09/2009 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■ n 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 Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new application? • n n n Is the facility as described in the permit? ■ n n n # Are there any special conditions for the permit? ■ n n n Is access to the plant site restricted to the general public? •000 Is the inspector granted access to all areas for inspection? • fl n n Comment: The permit application and the staff report were submitted on time. Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? • n n n Is all required information readily available, complete and current? • n n n Are all records maintained for 3 years (lab. reg. required 5 years)? ■ n ❑ n Are analytical results consistent with data reported on DMRs? ■ ❑ ❑ n Is the chain -of -custody complete? • n n n 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? ■ n n n Has the facility submitted its annual compliance report to users and DWQ? n n 0 • (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? n n ■ n Is the ORC visitation log available and current? ■ n n n Is the ORC certified at grade equal to or higher than the facility classification? ■ n n n Is the backup operator certified at one grade less or greater than the facility classification? ■ n n n Is a copy of the current NPDES permit available on site? ■ n n n Page # 3 Permit: NC0043320 Owner - Facility: Richmond Plant Inspection Date: 11/09/2009 Inspection Type: Compliance Evaluation Record Keeping Facility has copy of previous year's Annual Report on file for review? 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? 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 'A of the sidewall depth) Comment: Yes No NA NE nnn■ Yes No NA NE ■ nnn ■ nnn ■ nnn nnn■ Yes No NA NE ■ n ■ nnn ■ nnn ■ nnn ■ nnn Yes No NA NE ■ nnn ■ nnn ■ nnn ■ n n n ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn anon ■ nnn Page # 4 • Permit: NC0043320 Owner - Facility: Richmond Plant Inspection Date: 11/09/2009 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? ■ ❑ ❑ n Are surface aerators and mixers operational? ■ n n n Are the diffusers operational? n 0 • 0 Is the foam the proper color for the treatment process? • n El Does the foam cover less than 25% of the basin's surface? • El El 11 Is the DO level acceptable? ■ ❑ n n Is the DO level acceptable?(1.0 to 3.0 mg/I) ■ n n n Comment: Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? • n n Are all other parameters(excluding field parameters) performed by a certified lab? ' ■ ❑ n ❑ # 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)? ■ n n Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? n n ■ n Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? n ❑ • El Comment: The 24-hour sample storage refrigerator, located in the laboratory building, also contained refreshments. For sanitary and safety reasons, please do not store drinks (or food) for human consumption in the same refrigerator as WWTP samples. The thermometer was not found in a liquid in the refrigerator. Please keep the sample refrigerator thermometer in a container of water inside of the sample refrigerator as this will improve the accuracy of reading the temperature within the refrigerator. 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)? Yes No NA NE n ■nn ■ nnn • nnn • 000 inn❑ ■ ❑nn Page # 5 e Permit: NC0043320 Owner - Facility: Richmond Plant Inspection Date: 11/09/2009 Inspection Type: Compliance Evaluation Effluent Sampling Comment: The permittee is hereby given permission to perform set time/set volume type 24-hour composite sample at the 001 Plant Outfall. Please review the definition of composite sample requirements in NPDES permit and set up the sampler accordingly. Yes No NA NE Page # 6 Regional Field Inspectors Check List for Field Parameters Name of site to be Inspected;. Burlington Date: 11/09/2009 Field certification # (if applicable): . 5061 Inspector: Dale Lopez NPDES #: NC0043320 Region: FRO I. Circle the parameter or parameters performed at this site. Residual. Chlorine Settleable Solids, II. Instrumentation: pH DO Conductivity Temperature A. Does the facility have the equipment necessary to analyze field parameters as circled above? 1. A pH.meter Fisher Accumet pH Meter 900 2. A Residual Chlorine meter 3. DO meter YSI 550A1 4. A Cone for settleable solids 5. A thermometer or meter that measures temperature. 6. Conductivity meter III. Calibration/Analysis: 1. Is the pH .meter calibrated with 2 buffers and checked with a third buffer each day of use? 2. For Total Residual Chlorine, is a check standard analyzed each day of use? 3. Is the air calibration of the DO meter performed each:day of use? fres fres Yes Yes Yes Yes Yes N'es Yes . 4. For Settleable Solids, is 1 liter of sample settled for 1 hour? Yes 5. Is the temperature measuring devicecalibrated annually against a certified thermometer? 6. For Conductivity, is a calibration standard analyzed each day of use? fres Yes No No No IV. Documentation: 1. Is the date and time that the sample was collected documented? 2. Is the sample site documented? 3. Is the sample collector documented? 4. Is the analysis date and time documented? 5. Did the analyst sign the documentation? 6. Is record of calibration documented? 7. For Settleable Solids, is sample volume and 1 hour time settling time documented? 8. For Temperature, is the annual calibration of the measuring device documented? Comments: 1Yes IYes iYes 'Yes iYes !Yes No No Yes No hYes No Please submit a copy of this completed form to the Laboratory Certification Program. DWQ Lab Certification Chemistry Lab Courier # 52-01-01 FIELD INSPECTOR CHECKLIST REV. 04/23/2002