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Home My WebLink AboutNC0001384_Compliance Evaluation Inspection_20170605Water Resources ENVIRONMENTAL QUALITY June 05, 2017 Mr. Michael Durham, CEO Burlington Technologies, Inc. 5928 NC Highway 87 North Gibsonville, NC 27249 SUBJECT: Compliance Evaluation Inspection Burlington Technologies - WWTP NPDES Permit No. NC0001384 Caswell County Dear Mr. Durham: ROY COOPER Governor MICHAEL S. REGAN Secretary S. JAY ZIMM ERMAN Director RECEIVED/NCDEWWR JUN 12 2017 Water Quality Permitting Section On June 05, 2017, Min Xiao and Paul DiMatteo of this office met with Earl Wrenn from Burlington Manufacturing Services and Mark Nault and David Merritt from Meritech to perform a Compliance Evaluation Inspection on the Burlington Manufacturing Plant wastewater treatment system. The inspection findings are detailed below and an inspection checklist is attached. I. Permit The current permit became effective October 1, 2016, and will expire at midnight on May 31, 2021. A current copy of permit was kept onsite. H. Self -Monitoring Program The DMRs were reviewed for the period January 2016 through December 2016. The facility was found to have limit violation of Fecal Coliform in January and December. In addition, Williamsburg Plant has a renewed permit which increases the monitoring frequency of temperature (from monthly to daily), flow and pH (from monthly to weekly) for Outfall 2 and Outfall 3. The new permit was effective in October 2016, but the changes were not noticed, and the sampling frequency remained the same as the old permit in October and November, 2016. These violations have all been addressed previously. M. Flow Measurement The NPDES permit requires weekly instantaneous flow reporting. No meter was used for flow measuring. The ORC uses a graduated cylinder to estimate the instantaneous flow, and transfer the results to million gallons per day. Flow measurement data is kept inside a field log book. IV. Sludge Handling and Disposal Sludge is removed from the digester by Jenkins, Co. twice per year The last sludge removal date was May 22, 2017. Sludge disposal dates were documented in the field notebook onsite. V. Operations and Maintenance The WWTP was clean and organized, and it appeared to be no issues with the facility operations and maintenance at the time of inspection. The only deficiency was that the cover of the dechlorination well was broken. State of North Carolina I Environmental Quality I Water Resources 450 West Hanes MITI Road, Suite 300, Winston-Salem, NC 27105 Phone 336-776-98001Internet www ncdenrgov VI. Facility Site Review The facility is permitted to discharge wastewater from Outfalls 001, 002, and 003. Treated restroom wastewater was discharged through Outfall 001. The package plant consists of a manual bar screen, aeration basin, clarifier, tablet chlorination, contact chamber, tablet dechlorination, and sludge digester. Because the facility is underfed, dog food is used to feed the microbes in aeration basin. Water discharges from Outfall 002 is basically stormwater from the roof. The air washer was out of service 12 years ago. Stormwater is collected by building storm sewer and treated with liquid or tablet dechlorination before discharging through 002. Cooling waters associated coolmg tower blowdown is discharged via Outfall 003. Tablet dechlorination is used before discharging. VII. Records/Reports A comparison of the February 2017 monitoring report with the operator's records and the corresponding laboratory data sheets from Meritech showed that all results were transcribed correctly onto the DMR. Flow, temperature, total residual chlorine, pH, and dissolved oxygen are measured onsite, and the other parameters are measured by Meritech lab VIII. Effluent/Receiving Waters Effluent from Outfall 1 and 2 discharges into an unnamed tributary to Laughin Creek, and the effluent from Outfall 3 flows into an unnamed tributary to Grays Branch. The discharge of all the three outfalls was observed to be clear on the day of inspection. Should you have any questions concerning this report, please contact Min Xiao or me at (336) 776-9800 Sincerely, XSherri V Knight, PE Regional Supervisor Water Quality Regional Operations Section Division of Water Resources cc: Earl Wrenn (Earl.Wrenn@bmspioneer com) David Merritt (david.merritt@meritechlabs.com) Marc Nault (marcwnault@yahoo.con) Central Files NPDES Unit WSRO 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 2 15 I 3 I NC0001384 I11 12 17/06/05 17 18 I S I 19 1 G I 201 I 21111111 1111111 11 11 1 11 1111 1 1 11111 1111111 11 1 1 f6 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA Reserved 67 70 I I 71 � 72 I N 73 74 75 80 I_J LJ LJJ 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) 09 45AM 17/06/05 16/10/01 Williamsburg Plant 5928 Hwy 87 N Exit Time/Date Permit Expiration Date Gibsonville NC 27249 11 06AM 17/06/05 21/05/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data /// Marc W NauIUORC/336-342-4748/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Robert Fanole,PO Box 691 Burlington NC 272150691/Plant Engineer/336-584-1166/ No Section C Areas Evaluated During Inspection (Check only those areas evaluated) Permit N Flow Measurement Operations & Maintenance Records/Reports Self-Monitonng Program N Sludge Handling Disposal 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 Min Xiao WSRO WQ//336769800/ XN ��ne�,7 i Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date /Z 40/7 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete Page# NPDES yr/mo/day Inspection Type 31 NC0001384 I11 12 17/06/05 17 18 ICI Section D Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# i Permit. NC0001384 Owner -Facility: Williamsburg Plant Inspection Date: 06/05/2017 Inspection Type: Compliance Evaluation Yes No NA NE Are records kept and maintained as required by the permit? 0 Permit Yes No NA NE (If the present permit expires In 6 months or less) Has the permittee submitted a new 0 ❑ ❑ ❑ application? Are all records maintained for 3 years (lab reg required 5 years)? 0 ❑ ❑ Is the facility as described In the permit? M ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ 0 ❑ ❑ Is access to the plant site restricted to the general public? M ❑ ❑ ❑ Is the Inspector granted access to all areas for Inspection? 0 ❑ ❑ ❑ Comment The current permit became effective October 1 2016 and will expire at midnight on May 31, 2021 A current copy of permit was kept onsite Dates of analysis Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required Information readily available, complete and current? M ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ 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 CDCs Are DMRs complete do they Include all permit parameters? 0 ❑ ❑ ❑ 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 2417 with a certified operator ❑ ❑ M ❑ 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? 0 ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? N ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? 0 ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ 0 ❑ Comment Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Page# 3 Permit NC0001384 Owner -Facility Williamsburg Plant Inspection Date- 06/05/2017 Inspection Type- Compliance Evaluation Operations & Maintenance Yes No NA NE Does the facility analyze process control parameters, for ex MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment Bar Screens Yes No NA NE Type of bar screen Ext Air ❑ ❑ Type of aeration system a Manual 0 ❑ Is the basin free of dead spots? N ❑ b Mechanical ❑ Are surface aerators and mixers operational? ❑ ❑ 0 Are the bars adequately screening debris? N ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment Aeration Basins Yes No NA NE Mode of operation Ext Air ❑ ❑ Type of aeration system Diffused 0 ❑ Is the basin free of dead spots? N ❑ ❑ ❑ Are surface aerators and mixers operational? ❑ ❑ 0 ❑ Are the diffusers operational? 0 ❑ ❑ ❑ Is the foam the proper color for the treatment process? N ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? E ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1 0 to 3 0 mg/1) ❑ N ❑ ❑ Comment The DO level was around 5 mq/I The facility usually has higher DO level Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? N ❑ ❑ ❑ Is the site free of excessive buildup of solids In censer well of circular clarifier? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? N ❑ ❑ ❑ Page# 4 r Permit. NC0001384 Owner - Facility: Williamsburg Plant Yes No NA NE Are tablet chlorinators operational? 0 ❑ Inspection Date 06/05/2017 Inspection Type, Compliance Evaluation ❑ Are the tablets the proper size and type? 0 ❑ Secondary Clarifier Yes No NA NE Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? M ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? M ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) ❑ ❑ ❑ 0 Comment - Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? 0 ❑ ❑ ❑ Are the tablets the proper size and type? 0 ❑ ❑ ❑ Number of tubes In use? 3 ❑ ❑ # Is de -chlorination substance stored away from chlorine containers? Is the level of chlorine residual acceptable? ❑ ❑ ❑ 0 Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? 0 ❑ ❑ ❑ Comment De -chlorination Yes No NA NE Type of system ? Tablet 0 ❑ Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ ❑ 0 Is storage appropriate for cylinders? M ❑ ❑ ❑ # Is de -chlorination substance stored away from chlorine containers? M ❑ ❑ ❑ Are the tablets the proper size and type? 0 ❑ ❑ ❑ Comment. Two declonnation tubes In use Are tablet de-chlonnators operational? ❑ ❑ ❑ Number of tubes in use? 2 Comment Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? ❑ 0 ❑ ❑ Is flow meter calibrated annually? ❑ ❑ M ❑ Is the flow meter operational? ❑ ❑ M ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ M ❑ Comment No meter was used for flow measuring The ORC uses a graduated cylinder to estimate the Instantaneous flow, and transfer the results to million gallons per day Page# 5 N Permit: NC0001384 Owner - Facility: Williamsburg Plant Inspection Date. 06/05/2017 Inspection Type: Compliance Evaluation Flow Measurement - Effluent Yes No NA NE Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? M ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment Effluent from Outfall 1 and 2 discharges Into an unnamed tributary to Laughin Creek, and the effluent from Outfall 3 flows Into an unnamed tributary to Grays Branch The discharge of all the three outfalls was observed to be clear on the day of Inspection Page# 6