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Home My WebLink AboutNC0034860_Compliance Evaluation Inspection_20171115Water Resources ENVIRONMENTAL QUALITY ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Interim Director November 15, 2017 Mr. Chip Swinnie, Plant Manager Schneider Mills, Inc. P.O. Box 519 Taylorsville, NC 28681 RECERIE DIN CD� 0XIII IR Subject: Compliance Inspection Schneider Mills WWTP NPDES Permit No. NCO034860 Alexander County Dear Mr. Swinnie: NOV 21 2011 Water Qualay Permitting Section Enclosed is a copy of the Compliance Inspection for the inspection conducted at the subject facility on November 3, 2016, by Ori Tuvia. Darren Webb's cooperation 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) ORC Must Record the beginning and end time of composite sampling. 2) At the time of the inspection the flow meter values did not match the calculated value, ORC will need to farther investigate. 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.tuvia@ncdenr.gov. Cc: NPDES Unit MRO Files Sincerely, Ori Tuvia, Environmental Engineer Mooresville Regional Office Division of Water Resources, -DEQ Mooresville Regional Office Location. 610 East Center Ave., Suite 301 Mooresville, NC 28115 Phone (704) 663-16991 Fax; (704) 663-60401 Customer Service 1-877-623-6748 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 a, PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 u 2 15 1 3 I NCO034860 I11 12 17/11/14 17 181,•1 19I c I 20I 1166 2111.11 1 1 1 1 1 1 II 11 I I I I I I I I I I I I I I I I I I I I I II I I I 1 I Reserved------ Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA-Reserved- 67 1 a 70 �d � 71 J� 72 1 ti � 731 I 174 75III j_U80 67110 LJ L_I I I I 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 30AM 17/11/14 15/11/01 Schneider Mills WWTP 1170 NC Hwy 16 N Exit Time/Date Permit Expiration Date Taylorsville NC 28681 11 30AM 17/11/14 20/07/31 Name(s) of Onsite Representabve(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data /// Darren David Webb/ORC/828-632-8181/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Chip Swinnie,PO Box 519 Taylorsviile NC 286810519/Plant Manager/828-632-8181/ No Section C Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self-Monitonng 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 On A Tuwa .-• - � MRO W0/f704-663-1699/ Signature of Managem t Q v wer Agency/Office/Phone and Fax Numbers Date Andrew Pltner , O WQ//704-663-1699 Ext 21 1 IS 1 , r EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete Page# NPDES yr/mo/day Inspection Type 31 NCO034860 I11 12 17/11/14 17 18 ICI Section D Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# . _f Permit NCO034860 Owner -Facility Schneider MillsWWTP Inspection Date 11/14/2017 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? N ❑ ❑ ❑ 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? N ❑ ❑ ❑ Comment: The subject permit expires on 7/31/2020 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? N ❑ ❑ ❑ 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 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? E ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ 0 ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator ❑ ❑ E ❑ on each shift? Is the ORC visitation log available and current? 0 ❑ ❑ ❑ 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? ❑ ❑ ❑ 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. The records reviewed during the inspection were organized and well maintained DMRs. COCs. Calibration logs and ORC visitation logs were reviewed for the period November 2016 through September 2017. ORC must indicate the beginning and end time of composite sampling: Page# 3 Incubator (Fecal Coliform) set to 44 5 degrees Celsius+/- 0 2 degrees? ❑ ❑ 0 ❑ Incubator (BOD) set to 20 0 degrees Celsius +/-1 0 degrees? ❑ ❑ 0 ❑ Comment: On-site field analyses (dissolved oxygen PH, temperature, total residual chlorine) are performed under the Company's field laboratory certification #5012 Water Tech Labs (BOD TSS ammonia nutrients) and R & A Laboratories, Inc (toxicity and metals) have also been contracted to provide analytical support Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ Permit N00034860 Owner -Facility Schneider Mills WWTP ❑ Is sample collected below all treatment units? ❑ Inspection Date 11/14/2017 Inspection Type Compliance Evaluation ❑ Is proper volume collected? 0 ❑ Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? E ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? E ❑ ❑ ❑ # Is the facility using a contract lab? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6 0 degrees N ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44 5 degrees Celsius+/- 0 2 degrees? ❑ ❑ 0 ❑ Incubator (BOD) set to 20 0 degrees Celsius +/-1 0 degrees? ❑ ❑ 0 ❑ Comment: On-site field analyses (dissolved oxygen PH, temperature, total residual chlorine) are performed under the Company's field laboratory certification #5012 Water Tech Labs (BOD TSS ammonia nutrients) and R & A Laboratories, Inc (toxicity and metals) have also been contracted to provide analytical support Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ ❑ ❑ Is sample collected below all treatment units? ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? N ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6 0 degrees 0 ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type ❑ ❑ ❑ representative)? Comment The subject permit requires both composite and grab effluent samples The Division improved a vanance'to collect time -based composite samples on 5/26/1998 provided that the flows do not vary by more than 30% The sampler was collecting 300 ml aliquot every twenty minutes with an internal temperature of less than four degrees celsius Upstream / Downstream Samplina Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and ❑ ❑ ❑ sampling location)? Comment Operations & Maintenance Yes No NA NE ` Is the plant generally clean with acceptable housekeeping? N ❑ ❑ ❑ Does the facility analyze process control parameters, for ex MLSS, MCRT, Settleable E ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment The wastewater facility appeared to be properly operated and well maintained. The ORC incorporates a comprehensive process control program with all measurements being properly documented and maintained on-site Page# 4 14 m Permit NCO034860 Inspection Date 11/14/2017 Owner -Facility Schneider Mills WWTP Inspection Type Compliance Evaluation 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- Bar screenings are disposed at the Alexander County Landfill Flow Measurement - Influent # 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? Yes No NA NE E ❑ ❑ ❑ * ❑ ❑ ❑ * ❑ ❑ ❑ * ❑ ❑ ❑ Yes No NA NE E ❑ ❑ ❑ N ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment- The influent flow meter (Outfall 001) is calibrated twice per vear and was last calibrated b ISI At the time of the Inspection the flow meter values did not match the calculated value. ORC will need to investigate The flows for Outfall 002 are based on the calculated backwash volume (3.150 -gallons) and the number of backwash events per day 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 ❑ Are the diffusers operational? ❑ ❑ N ❑ Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? 0 ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1 0 to 3 0 mg/1) ❑ ❑ E ❑ Comment- Agueous lime and soda ash are added to maintain appropriate pH/alkalinity levels The ORC also adds food (BOD)/nutrient (nitrogen and phosphorus) supplements and selective microrganisms to maintain the biological treatment process. Secondary Clarifier Yes No NA NE Page# 5 Permit NC0034860 Owner -Facility Schneider Mills WWTP Is right of way to the outfall properly maintained? 0 ❑ Inspection Date 11/14/2017 Inspection Type Compliance Evaluation Are the receiving water free of foam other than trace amounts and other debris? 0 ❑ Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? E ❑ ❑ ❑ Is the site free of excessive buildup of solids In center well of circular clarifier? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? N ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? ❑ ❑ 0 ❑ Is the site free of excessive floating sludge? E ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence) 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) 0 ❑ ❑ ❑ Comment. Polymer Is added to the clarifier influent to enhance settling Pumps -RAS -WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ ❑ 0 Comment 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? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ ❑ 0 Comment At the time of the inspection the effluent appeared to be clear E ❑ ❑ ❑ Aerobic Digester Yes No NA NE Is the capacity adequate? ❑ ❑ ❑ Is the mixing adequate? ❑ ❑ ❑ Is the site free of excessive foaming in the tank? N ❑ ❑ ❑ # Is the odor acceptable? E ❑ ❑ ❑ # Is tankage available for properly waste sludge? E ❑ ❑ ❑ Comment Page# 6 R d Permit NC0034860 Inspection Date 11/14/2017 Dryrna Beds Is there adequate drying bed space? Is the sludge distribution on drying beds appropriate? Owner -Facility Schneider Mills WWTP Inspection Type Compliance Evaluation Are the drying beds free of vegetation? # Is the site free of dry sludge remaining in beds? Is the site free of stockpiled sludge? Is the filtrate from sludge drying beds returned to the front of the plant? # Is the sludge disposed of through county landfill? # Is the sludge land applied? (Vacuum filters) Is polymer mixing adequate? Yes No NA NE E ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ N ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ N ❑ ❑ ❑ N ❑ Comment. The dewatered sludges from the wastewater treatment system (drying beds) and water treatment system are transported to the Alexander County Landfill for disposal Page# 7