The URL can be used to link to this page

Home My WebLink AboutNC0004812_Compliance Evaluation Inspection_20161212Water Resources ENVIRONMENTAL QUALITY December 12, 2016 Mr. George Altice, Director of Corporate Engineering Pharr Yarns, LLC P.O. Box 1939 McAdenville, NC 28101 Dear Mr. Altice: PAT MCCRORY Govemor DONALD R. VAN DER VAART secretary 8. JAY ZIMMERMAN Director RECEIVEDINCDEQIMR . DEC 28 2016 Water Quality Permitting Section Subject: Compliance Evaluation Inspection - Pharr Yarns WWTP NPDES Permit No. NC0004812 Gaston County Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on December 8, 2016, by,Ori Tuvia. The cooperation of James Davis during the site visit was much appreciated,. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed report. The following areas of concern were observed during the inspection: 1) The flow meter is past due for calibration. The flow meter was due for calibration on September 2016. 2) ORC staff must indicate maintenance work done in the facility. 3) At the time of 'the inspection, excessive amount of foam was observed in the treatment units. 4) Facility is missing Chain of Custodies for color sampling -done by the City of Gastonia. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Ori Tuvia at (704) 235-2190, or at ori.tuviana,ncdenr.gov. Sincerely; Ori Tuvia, Environmental Engineer Mooresville Regional Office - Division of Water Resources, DEQ cc: NPDES (Unit), MRO files, Gaston County Health Department Mooresville Regional Office Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115 - . Phone: (704) 663-1699 Vax: (704) 663.60401 Customer Service:1.877-623-6748 Internet: www n6v aierquality.org u United States Environmental Protection Agency FOrrrl Approved. EPA Washington, D.C. 20,460 OMB No. 2040-0057' Water C0I pliaf1C@ Inspection Report- ._ ..: Approval expires 8-31-98 Section A: National Data System Coding (Le.,'PCS) . Transaction Code NPDES yr/mo/day Inspection Type Inspector • Fac Type 1 'u 2 u 3 I NC0004812 Ill 12 16/12/08 17 18I 19 I c I 20 Lj I 211,11111 I II III ICI II I II I II I I I.I I I I I II II1111 11�6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 OA Reserved 67 1.0 701d I 71 Iti I 72 I �L I 731 I 174 75 LJ t I I 80 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 permit Number) 10:15AM 16/12/08 14/08/01 Pharr Yams Industrial WWTP 147 Willow Dr Exit Time/Date Permit Expiration Date Mc-Adenville NC 28101 12:15PM 16/12108. 19/01/31 Narre(s) of Onsite Representative(s)fritles(s)/Phone and Fax Number(s) Other Facility Data /// James Lester Davis/0RC/704-813-93421 Name, Address of Responsible OfficiaVritle/Phone and Fax Number Contacted George Altice,PO Box 1939 McAdenville NC 281011939/f704-823-2397/ No 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 Inspectors) Agency/Office/Phone and Fax Numbers Date Or! A Tuvia MRO WO//704-663-1699f Signature of Manage m nt P A Re ' er Agency/Office/Phone and Fax Numbers Date Andrew Pitnera�0 WQ0704-663-1699 Ext.21 _ 1_ t NPDES yr/mo/day Inspection Type 1 31 N00004812 �11 12 16/12/08 17 18 ICI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) -Page# :2 ' Permit: NC0004812 Owner - Facility: Pharr Yams Industrial WWrP Inspection Date: 12/08/2016 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 ❑ ❑ E ❑ 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? 0 ❑ .❑ ❑ Is the inspector granted access to all areas for inspection? E ❑ ❑ ❑ Comment: Overall, the facility is properly described in the permit; however, dechlorination was not included as a treatment process. The subject permit expires on 1/31/2019. Record Keeping " - Yes No NA NE Are records kept and maintained as required by the permit? -E -.❑ ❑ ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? -0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain'' -of -custody complete? 'M ❑ ❑ 13 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? M ❑ ❑ ❑ Has the facility submitted its annual' compliance report to users and DWQ? ; ❑ ❑ M ❑ (If the facility is '= or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator ❑ ❑0 ❑ on each shift? Is the ORC visitation log available.and current? M ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? 11 ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? 0 ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? ❑ ❑ ❑ Facility has copy of previous year's Annual Report -on file for review? ❑ ❑ ❑ :Comment: Records reviewed during the inspection were organized and well maintainedAhe ORC must ensure that all records are accessible and maintained as reguired-by the permit. 2015 . DMRs. COCs. ORC logs and calibration logs were reviewed for December :.September 2016. COC for color testing done f?y the'.city of Gastonia'was ORC.Inns must he more detailed and include maintenance work bone_• through missing.' "'' Page# 3 Permit: NC0004812 Owner -Facility: Pharr Yarns Industrial WWrP Inspection Date: 12/08/2016 ' Inspection Type: compliance Evaluation VecordKe-epina'_ _ _ _ .___ _. - _ _ _ .� ___..___ Yes No NA NE Laboratory. -- Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0- ❑ ❑ ❑ Are all other parameters (excluding field parameters) performed by a certified lab? ❑ ❑ ❑ # Is the facility using a contract lab? E ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees, 70 ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ N ❑ T Incubator (BOD) set to 20.0 degrees Celsius +/-1.0 degrees? ❑ ❑ N ❑ Comment: On -site field analyses (dissolved oxygen and temperature) are performed under the facility's laboratory certification #5278. Shealy Environmental Services, Inc. (BOD, TSS, ammonia, Laboratory (color) have also, been contracted to provide analytical support. The dissolved oxygen meter appeared to be properly calibrated and documented Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? M ❑ ❑ ❑ is the tubing clean? ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees _N ❑ ❑ ❑ Celsius)?. Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: The subject permit requires effluent composite and grab samples. The- ORC and staff must ensure to perform and document periodic aliquot verifications 000 mis.• minimum) on the composite sampler. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and A ❑ ❑ ❑ sampling location)? Comment: Operations & Maintenance Yes No NA NE Is the plant generally clean with' acceptable. housekeeping? . ❑ ❑ ❑ Does the facility analyze process control -parameters, for ex: ,MLSS, MCRT,.Settleable ❑ ❑ Solid pH, DO,.Sludge�Judge; and otfierfhatareapplicable? Page# 4. Permit: NC0004812 Inspection Date: 12/08/2016 Owner - Facility: Pharr Yams IndustrialWWTP Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Comment:. At the time of the inspection an excessive amount of foam was observed in the treatment -. units. Process control measurements were being documented and maintained on -site. 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? [I'M ❑ El - Are the diffusers operational? ❑ ❑ 0 ❑ 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/l) ❑ ❑ M❑ Comment: The aeration basin is equipped with three aerators and a mixer. At the time of the inspection one of the aerators was operational and work was being done on it. Other,aerators were not . in operation to allow work on the aerator. Bar Screens Yes No''NA NE Type of bar screen a.Manual b.Mechanical ❑ Are the bars adequately screening debris? ❑ ❑ ❑ Is the screen free of excessive debris? M ❑ ❑ ❑ Is disposal of screening in compliance? El - ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: - The aeration basin effluent is screened (coarse screen) prior to the clarifier. Secondary Clarifier Yes No NA NE 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? 0 • ❑ ❑ ❑ Is the site free of weir blockage? : _ : A ❑ ❑ ❑ Is the site free of evidence of short-circuiting? .❑ ❑ ❑ Is scum removal adequate? • ❑ ❑ 0 Permit: NC0004812 Owner -Facility: Pharr Yams IndustrialWWTP Inspection Date: 12%08/2018 Inspection Type: Compliance Evaluation Secondary Clarifier` - °.: Yes No" NA NE" 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? 0. ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately %4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: The facility is eguipoed with two secondary clarifiers (one operational). A Pumps-RAS-WAS Yes No NA NE Are pumps in place? N ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ ❑ Comment: Flow Measurement _ Effluent Yes No NA NE # Is flow meter used for reporting? - ❑ ❑ ❑ Is flow meter calibrated annually? ❑ 0 ❑ ❑ Is the flow meter, operational? "❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? N ❑ ❑ .❑ Comment: The flow meter is past due for calibration. The flow meter was due for calibration on September 2016. Filtration (High Rate Tertiary) Yes No' NA NE Type' of operation: Down flow Is the filter media present? il ❑ ❑ I❑ Is the filter surface free of clogging? E ❑ ❑ ❑ Is the filter free of growth? ❑ ❑ ❑ Is the air scour operational? ❑ ❑ 0 ❑ Is the scouring acceptable? ❑ ❑ ❑ Is the clear well free of excessive solids and filter media? 0 ❑ ❑ ❑ ' Comment: . -All -three tertiary filters were operational and in service. The filter backwash is returned to the head of the plant (aeration basin). . Foam was evident downstream of the filters. Disinfection-Liouid .Yes No NA NE 'Is there adequate reserve supply of disinfectant? ❑ ❑ ❑ :. = Page# 6 S • r Permit:, NC0004812 Owner - Facility: Pharr Yarns Industrial WWrP -Inspection Date: 12/08/2016 ' Inspection Type: Compliance Evaluation 'Disinfection-Liguid Yes No NA Nt" (Sodium Hypochlorite) Is pump feed system operational? ® -0 ❑ ' ❑ ❑ Is bulk storage tank containment area adequate? (free of leaks/open drains) ❑ ❑ ❑ Is the level of chlorine residual acceptable? 0 ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? El 1111 Comment: Chlorine levels (total and free) are periodically monitored (process control) in the chlorine contact chamber. Only one train of the chlorine contact chamber was being used due to low influent flows. De -chlorination Yes No NA NE Type of system ? Liquid Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ 0 ❑ Is storage appropriate for cylinders? ❑ ❑ - 0 ❑ # Is de -chlorination substance stored away from chlorine containers? O ❑ ❑ ❑ .Comment: Are the tablets the proper size and type? Are tablet de -chlorinators operational? Number of tubes in use? • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Dechlor tablets are also used (as needed basis) as a supplement to the ascorbic acid. Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑' Is storage adequate? 0 ❑ ❑ ❑ Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? 0 ❑ ❑ ❑ Comment: Effluent Pipe Yes No NA NE 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: The effluent appeared slightly turbid (tea colored) with foam. The receiving stream did not appear to be negatively impacted. Small amount of foam was observed in the receiving stream belowAhe effluent discharge. r ,. Page# .7 0 Permit: NC0004812 Owner - Facility: Pharr Yarns Industrial wWTP - Inspection Date: 12108/2016 Inspection Type: Compliance Evaluation Effluent Pipe :Yes `No NA" NE " Aerobic Digester - Yes No NA NE Is the capacity adequate? 0 ❑ ❑ ❑ Is the mixing adequate? ❑ ❑ ❑ t Is the site free of excessive foaming in the tank? M. ❑ ❑ ❑ # Is the odor acceptable? ❑ ❑ ❑ # Is tankage available for properly.waste sludge?0 ❑ ❑ ❑ Comment: The facility is equipped with a 2 MG aerobic digester. The facility has not removed any wastewater solids in approximately four years.