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Home My WebLink AboutNC0043320_WWTP Inspection_20041209Michael F. Easley, Governor William G. Ross Jr., Secretary North Carolina Department of Environment and Natural Resources Alan W. Klimek, P.E. Director Division of Water Quality December 9, 2004 Mr. Paul Smart Burlington Industries LLC PO Box 250 Cordova NC 28330 SUBJECT: December 7, 2004 Compliance Evaluation Inspection Burlington Industries LLC 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 December 7, 2004. The Compliance Evaluation Inspection was conducted by Belinda S. Henson of the Fayetteville Regional Office. The facility was found to be in Compliance with permit NC0043320. The cooperation of Mr. Paul Smart, ORC and Ms. Dorothy Quick, Backup Operator were greatly appreciated. As a reminder preservationof the Waters of the State can only be acquired through consistent NPDES permit compliance. Please refer to the enclosed inspection report for additional observations, comments, and recommendations. If you or your staff have any questions, please canine at 910-486-1541. Sincerely, L1ocJ 41e Belinda S. Henson Environmental Chemist II /bsh cc: Central Files Fayetteville Files NCDENR Division of Water Quality 225 Green Street -Suite 714 Fayetteville, NC 28301-50431 (910)486-1541 Telephone (910)486-0707 Fax Customer Service 1 877 623-7748 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 INI 2 U 31 NC0043320 111 121 04/12/07 1 17 u Type Inspector Fac Type 20I 18ICI 19151 Li u u u Remarks 2111IIIIIII111III1IIIIIIIIIIIIl1IIIIIIIIIIII1III166 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 671 169 70 IJ 71 U 72 U 11 174 751 1 I I 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) Burlington Industries LLC - Richmond Plant 740 Old Cheraw Hwy Cordova NC 28330 Entry Time/Date 10:10 AM' 04/12/07 Permit Effective Date 04/09/01 Exit Time/Date 12:45 PM 04/12/07 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/ Dorothy Lorraine Quick/ORC/910-997-5001/ /// Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Paul Smart,740 Cheraw Hwy Cordova NC 28330/Plant Contacted No Engineer/910-997-5001/ 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 Belinda S Henson v4 ,/ IIEJYiaC-i0 FRO WQ//910-486-1541/910-486-0707 I — Cj — Q 4 Signature o „- . semen/• 7eviewer Agency/Office/Phone and Fax Numbers Date Paul E Rawls i 910-486-1541/910-486-0707 12 - r C)' O1 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. NPDES yNmo/day Inspection Type 31 NC0043320 111 121 04/12/07 117 18 I (cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) The facility has field parameter certification #5061 for the following parameters: pH, DO, Conductivity, Temperature and Residual Chlorine. Microbac analyzes the remaining NPDES permit parameters with the exception of Toxicity, which is completed by Pace. Laboratory records were reviewed for the months April, May and June 2004 and compared to Discharge Monitoring Reports (DMRs). All records reviewed appeared to be accurate. A compliance report for the period September 2003 through September 2004 revealed one weekly fecal coliform violation in November 2003. The facility received a Notice of Violation from our office. The following recommendations were noted during the inspection: 1. The return pumps appeared to have paint worn from the surfaces. These areas should be painted in the near future to eliminate major repairs in the future. 2. The 150 pound chlorine cylinders should be labeled empty or full. 3. The grass that was located on the surface of the digester liquid should be removed to assist with maintaining the units in the plant. 4. The generator should be tested more frequently and documented. DOOM ❑ ❑❑■ ❑ ❑❑■ ❑ ❑ ❑ ❑ ❑ ❑ II ❑ ❑ ❑ 11 D ❑ ❑ ■ O 001. O 0011 O 001 O 0011 ❑ ❑ ❑ • dN VN uN sal. O 001 ❑ ❑ ❑ • O 001 O 001 0 dN `dN uN sal. 0.00 0.00 0.00 ❑ • ❑ ❑ 0.00 ❑ ■❑❑ ❑ • ❑ ❑ O 1100 dN VN oN Sal. ❑ ❑ ❑ • ❑ ❑ ❑ • dN VN uN sa.l O 001 O 001 ❑ ■ ❑ ❑ O 001 ❑ ■ ❑ ❑ dN VN uN se.l 6 6uoiinq;o awl eoeJJns ay; sl Moog u!d/spllos an!ssaaxa;o reap MOI;.leno ay; si 6(eouaingJn; Mol) alge;daooe a;ei wn;ai ay; si Lalgeldaooe lane! lNuelq e6pnls ayl si 61euogeJedo;lun OAIJp ay; si 6e6pnIs 6ulleog enISseaxa;o owl Ns ay; s! Leienbepe lenowe; wnos sl 66uglnano-pots;o eouepina;o pail Ns ay; sl 6e6e3loolq J!em )o awl ells ay; s! 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Mog luengul :;uawwoo 6IeuogeJado pue a gellene wuepe lensin pue Nuns si Lleuol;eJedo pue algellene ti;awalal vayos sl 6olgeJedo spi;uoo;eoil a.y 6aigsjedo sdwnd tie 8Jy 6luesaad sdwnd Ile aJy LeseoJ6 enpsaaxa;o 004 IIeM;aM ay; sl 6alge;deoae 6uideo osnoq leJeua6 ay; si ,sawn;onils Jo soul! ssed/q;o awl Hem;em dwnd ay; s! luenllul - uoilels ownd 'Mahal Jo; aag;o mo of peXe; OJaM spJooei • Awe; pue aaueualuleo; •slaplo )IJ0M peleieue6lalndwoo g6noly; l;els /q pe eidwoo sI eoueualuleW :luawwoo 66uidoojesnoq alge;deooe yl!M ueep Alleieua6;ueld ay; s! 6sllem to 's;ld 'slue; JOAO SJOAOO to punole slum se tons amid ul salnpnlls Ala;es lelaue6 anal!weld ay; sao0 aoueualuieini g suugwadG :;uawwoo 6uo!loedsul Jo; Seale lie o; ssaaae pa;uel6 Joloadsui atl s! 6ollgnd lelaue6 ay; o; peloplsal a;is weld ay; o; ssaaae si awied ay; lo) suol;lpuoa lelaads Aue play; ply 6;Iwied ay; u! pequasep se Allilae; ay; si 6uol;ealldde Mau e pepiwgns eon wJed ay; seH •(ssej to sy;Uow g u! sal!dxa ;pied ;uaswd eq;;I) Hulled uoi;enien3 eoueiidwo3 uoi;3edsui weld puowyoN - 011 sep;snpui uol6u!IJn8 - m-11 sap;snpui uol6uiim9 :l(;iiioed - JauMO bO/LO/Z6 :e;ea uoi;oadsuii OZEEb000N :;iwied Permit: NC0043320 Owner - Facility: Burlington Industries LLC - Burlington Industries LLC - Richmond Plant Inspection Date: 12/07/04 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NF Comment: Sludge depths were approximately 1 foot. The effluent appeared to have a cloudy color. As per Ms. Quick, the cloudy (milky) color appears when the industry discharges vats of what they call Size which is an agent that assists in fixing dye into the cloth for the facility. During the inspection, I observed the cloudy (milky) color discharged in the influent. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Facility has three (3) return pumps. All return pumps are operational. A recommendation would be to paint the return pumps in the near future to eliminate major repairs in the future. Aeration Basins. Mode of operation Type of aeration system Is the basin free of dead spots? • ❑ ❑ O Are surface aerators and mixers operational? .000 Are the diffusers operational? ❑ ❑ E ❑ Is the foam the proper color for the treatment process? 1 ❑ ❑ ❑ Yes No NA NF ■ O ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • Yes No NA NF Does the foam cover less than 25% of the basin' s surface? 1 ❑ ❑ ❑ Is the DO level acceptable? 1 ❑ O ❑ Are settleometer results acceptable? • ❑ ❑ O Comment: The facility has two (2) aeration basins. Both aeration basins are operational. One aeration basin is utilized for treatment of wastewater while the other is basically a standby. Basin #1 contains two (2) aerators and one (1) mixer. The aerators are set on timers that allow the aerators to be switched every 10 minutes and operate 4 minutes. The most recent Mixed Liquor Suspended Solids (MLSS) results were 2200 mg/L. Disinfection Yes No NA NF Type of system ? Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is ventilation equipment operational? Is ventilation equipment properly located? Is SCBA equipment available on site? Is SCBA equipment operational? Is staff trained is operating SCBA equipment? Is staff trained in emergency procedures? Is an evacuation plan in place? Are tablet chlorinators operational? Are the tablets the proper size and type? Number of tubes in use? (Sodium Hypochlorite) Is pump feed system operational?. Is bulk storage tank containment area adequate? (free of leaks/open drains) Is the level of chlorine residual acceptable? Is there adequate detention time Is the contact chamber free of growth, or sludge buildup? Comment: Chlorine is added to the influent (domestic) to assist with disinfection. The addition of chlorine does not occur at the wastewater plant but a location at the back of the building which houses the industrial process which includes making cloth, sewing cloth and dyeing swatches (small pieces) of cloth. 111000 11000 ■ ❑ ❑ ❑ ■ ❑❑❑ • ❑ ❑ ❑ ❑ ❑•❑ O 010 O 010 11000 O 00111 ❑ ❑ E0 ❑ ❑ •❑ ❑ ❑ E0 O 010. O 00111 O 00111 DO 1110 Permit: NC0043320 Owner - Facility: Burlington Industries LLC - Burlington Industries LLC - Richmond Plant Inspection Date: 12/07/04 Inspection Type: Compliance Evaluation Pump Station - Fffluent Is the pump wet well free of bypass lines or structures? Is the general housekeeping acceptable? Is the wet well free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Is SCADA telemetry available and operational? Is audible and visual alarm available and operational? Comment: Effluent flows by gravity to the outfall. Yes Nn NA NF O ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ O 0.0 ❑ ❑■❑ O 0.0 O 0.0 ❑ ❑ ■ ❑ ,Standby Power Yes No NA NF Is automatically activated standby power available? 1 ❑ ❑ ❑ Is generator tested weekly by interrupting primary power source? 0.00 Is generator tested under load at least quarterly? 0.00 Was generator tested & operational during the inspection? ❑ ❑ ❑ 1 Do the generator(s) have adequate capacity to operate the entire wastewater site? • ❑ ❑ ❑ Does generator have adequate fuel? 0 0 0 • Is there an emergency agreement with a fuel vendor for extended run on back-up power? 0 0 0 • Comment: The generator is tested under load annually. A recommendation would be to test the generator weekly by interrupting the primary power source. ahoratory Yes No NA NF Are field parameters performed by certified personnel or laboratory? • ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? 1 ❑ ❑ ❑ Is the facility using a contract lab? 1 ❑ O ❑ Are analytical results consistent with data reported on DMRs? 1 ❑ ❑ ❑ Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? ❑ ❑ 1 ❑ Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ 1 ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? 00.0 Comment: Flow Measurement - Influent Yes Nn NA NF Is flow meter used for reporting? 00.0 Is flow meter calibrated annually? ❑ O E ❑ Is flow meter operating properly? 0 0 • 0 (If units are separated) Does the chart recorder match the flow meter? O ❑ E ❑ Comment: Flow Measurement- Effluent Yes Nn NA NF Is flow meter used for reporting? 1 ❑ ❑ ❑ Is flow meter calibrated annually? 1 ❑ ❑ ❑ Is flow meter operating properly? .000 (If units are separated) Does the chart recorder match the flow meter? 1 ❑ O ❑ Comment: The effluent flow meter was calibrated September 23, 2004 by facility instrumentation staff (Bill Thompson). Yes Nn NA NF Record Keeping Are records kept and maintained as required by the permit? Is all required information readily available, complete and current? ■ ❑ ❑ ❑ 11000 Permit: NC0043320 Owner - Facility: Burlington Industries LLC - Burlington Industries LLC - Richmond Plant Inspection Date: 12/07/04 Inspection Type: Compliance Evaluation Record Keeping Are all records maintained for 3 years (lab. reg. required 5 years)? Are analytical results consistent with data reported on DMRs? Are sampling and analysis data adequate and include: 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 Plant records are adequate, available and include O&M Manual As built Engineering drawings Schedules and dates of equipment maintenance and repairs Are DMRs complete: do they include all permit parameters? Has the facility submitted its annual compliance report to users? (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? Is the facility description verified as contained in the NPDES permit? Does the facility analyze process control parameters, for example: MLSS, MCRT, Settleable Solids, DO, Sludge Judge, pH, and others that are applicable? Facility has copy of previous year's Annual Report on file for review? Comment: Influent Samnling Is composite sampling flow proportional? Is sample collected above side streams? Is proper volume collected? Is the tubing clean? Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? Is sampling performed according to the permit? Comment: Fff uient 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 1.0 to 4.4 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: The effluent composite sampler temperature was 0 degrees Celsius. The acceptable temperature range of samples during storage and for stored sample extracts, is 1.0 to 4.4 degrees Celsius. Ref: Federal Register, July 1, 1995; 40 CFR 136; Table II. Aerobic Digester Yes No NA NF • 000 • 000 • 000 • • • • • • 1.000 • • • • 000 • ❑ ■ O • 000 • ❑ ❑ ❑ • 000 ▪ ❑ ❑ ❑ • 000 • 000 • 000 O 0.0 Yes No NA NF ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ O ONO Yes No NA NF • 000 • 000 • ❑ ❑ ❑ ■ ❑❑❑ • 000 • 000 Yes No NA NF Permit: NC0043320 Owner - Facility: Burlington Industries LLC - Burlington Industries LLC - Richmond Plant Inspection Date: 12/07/04 Inspection Type: Compliance Evaluation Aerobic Digester Yes No NA NF Is the capacity adequate? • ❑ 00 Is the mixing adequate? 0 • 0 ❑ Is the site free of excessive foaming in the tank? • ❑ ❑ ❑ Is the odor acceptable? U ❑ � Comment: The aerator in the digester has been repaired but has not been placed back into the digester. The facility plans to contract with a crane service in order to place the aerator in the digester. A recommendation is to remove the grass from the edge of the digestor to assist with maintaining the facility. Drying Beds Yes No NA NF Is there adequate drying bed space? 1 ❑ ❑ ❑ Is the sludge distribution on drying beds appropriate? 0 0 • 0 Are the drying beds free of vegetation? 1 ❑ Is the site free of dry sludge remaining in beds? 1 ❑ 0 Is the site free of stockpiled sludge? 1 000 Is the filtrate from sludge drying beds returned to the front of the plant? 0 0 E 0 Is the sludge disposed of through county landfill? 0 0 E 0 Is the sludge land applied? 00.0 (Vacuum filters) Is polymer mixing adequate? 0 0 E 0 Comment: Facility has never wasted any solids onto the drying beds as per Ms. Quick in the years she has been employed there. All solids from the clarifiers are returned to the aeration basin. Fffluent Pipe Yes No NA NF Is right of way to the outfall properly maintained? Are receiving water free of solids and floatable wastewater materials? 1 Are the receiving waters free of solids / debris? 1 Are the receiving waters free of foam other than a trace? 0 0 0 • Are the receiving waters free of sludge worms? 1 If effluent (diffuser pipes are required) are they operating properly? 00.0 Comment: Regional Field Inspectors Check List for Field Parameters Name of site to be Inspected: _ Field certification # (if. applicable): �n NPDES n _ Region: #: � Cr�n �� I. Circle the ararneter or arameters erformed at this site: Settleable Solids�pductivit emperatur esidual Chtonn � , II. Instrumentation: Does the facility have the equipment necessary to analyze field parameters as circled above? No A acC.trrnel p 1-1Er - - r►l r? Lip Inspector: /-/ rt, 1. A pH meter 2. A Residual Chlorine meter 3. . DO meter 4. A Cone for settleable solids Ye Yes 5. A thermometer or meter that measures temperature. *Yes Yes No No 6. Conductivity meter III. Calibration/Analysis; 1. Is the pH meter calibrated uer eaach day ofeuse? d checked with a third 2. For Total Residual Chlorine, is a check standard analyzed each day of use? 3. Is the air calibration of the D0 meter performed each day of use? 4. For Settleable Solids, is 1 liter of sample settled for 1 hour? 5. Is the temperature measuring device calibrated annually against a certified thermometer? 6. For Conductivity, is a calibration standard analyzed each day of use? Yes Yes Yes No Colt No No P4rrrtfr 55011 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. volurne and 1 hour time settling time documented? 8. For Temperature, is the annual calibration of the measuring device documented? . Comments: qes Yes No No .... 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 Re: GENERATOR AT WASTE WATER TREATMENT FACILI... Subject: Re: GENERATOR AT WASTE WATER EATMENT 'ACILLTY AT-B.PRIeHM'OND PLAN TTI'EyRIv1aIT NO:NC0043320 From: Belinda Henson <Belinda.Henson@ncmail.net> Date: Wed, 15 Dec 2004 14:13:58 -0500 To: "Smart.Paul" <smart.paul@burlington.com> Thank you Paul for the call yesterday. This will be noted in our files. Have a good day. Belinda Smart.Paul wrote: AS I NOTED TO YOU IN OUR TELEPHONE CONVERSATION WE DO NOT HAVE A BACK UP GENERATOR. IN THE PAST WHEN WE HAD POWER FAILURES OUR PROCESS WAS ALSO EFFECTED THEREFORE THE FLOW TO THE WASTE TREATMENT FACILITY WAS ALSO EFFECTED. IF WE EVERY HAD A FAILURE OF JUST THE POWER TO THE WASTE TREATMENT PLANT THEN WE WOULD MONITOR OUR DISCHARGE. WE WOULD ALSO TRY TO CONTAIN OUR INFLUENT AND REDUCE OUR PROCESS UNTIL REPAIRS WHERE MADE OR A TEMPORARY POWER SOURCE WAS PUT IN PLACE. 1 of 1 12/15/2004 2:14 PM