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Home My WebLink AboutNC0004812_CEI_NOV2018PC0124_20180412;na Water R esources ENVIRONMENTAL QUALITY ROY COOPER coverrwr MICHAEL S. REGAN Secretary LINDA CULPEPPER Interim Director April 12, 2018 CERTIFIED MAIL # 7016 1370 0000 2596 0238 RETURN RECEIPT REQUESTED Mr. George Altice, Director of Corporate Engineering Pharr Yarns, LLC P.O. Box 1939 McAdenville, NC 28101 Dear Mr. Altice: Subject: Notice of Violation Compliance Evaluation Inspection NOV-2018-PC-0124 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 April 11, 2018 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 December 14, 2017. 2) ORC staff must indicate maintenance work done in the facility, including the date equipment was taken offline and date the equipment was repaired and returned to service. 3) At the time of the inspection, the secondary clarifier currently in use was in need of maintenance. Short- circuiting was evident. Additionally, the clarifier trough was full of debris (see pictures 1 and 2 below). 4) At the time of the inspection, excessive amount of foam was observed in the treatment units, including the effluent sampling location (see picture 3 below). 5) The effluent sampler tubing was dirty and in need to replacement (see picture 3 below). 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 Internet: www.ncwaterquality.org Picture 1 Picture 2 Picture 3 Please be advised that this correspondence is a Notice of Violation. You are requested to respond to this Notice in writing within fifteen (15) days of receipt indicating your plan of action to ensure future compliance. Failure to respond and/or failure to resolve the violations could subject you to further action by the Division of Water Resources. 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.tuviakncdenr.gov. Sincerely, DocuSigned by: A14CC681 AF27425... W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources cc: NPDES, MRO files (Laserfiche) Jaime Davis (E -Copy) 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 1 IN I 2 15 I 3 I NC0004812 111 12 I 18/04/11 I17 18 I S i 19 LG] i 201 I 211111 1 1 1 1 1 111 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 111 1 1 1 1 1 166 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- 67 1.0 70 I z I 71 I I 72 I r, I 73 I I I74 751 1 1 1 1 1 1 180 I—I 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 oermit Number) 09:55AM 18/04/11 14/08/01 Pharr Yarns Industrial WWTP 147 Willow Dr Exit Time/Date Permit Expiration Date Mc Adenville NC 28101 11:30AM 18/04/11 19/01/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data James Lester Davis/ORC/704-813-9342/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted George Altice,PO Box 1939 Mc Adenville NC 281011939//704-823-2397/ 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 Inspector(s) Agency/Office/Phone and Fax Numbers Date DocuSigned by: Ori A Tuvia� MRO WQ//704-663-1699/ 4/12/2018 EBB057A2DE017498... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger MRO WQ//704-235-2194/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. DocuSigned by: 4/12/2018 Page# EA14CC681AF27425... NPDES yr/mo/day Inspection Type NC0004812 111 121 18/04/11 1 17 18 JCJ Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NC0004812 Owner - Facility: Pharr Yarns Industrial WWTP Inspection Date: 04/11/2018 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)? ❑ ❑ ❑ Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ 0 ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: The subject permit expires on 1/31/2019. The facility has rescinded its land application permit. 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? ❑ 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? ❑ ❑ ❑ ❑ 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? ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ ❑ (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? ❑ 0 ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ❑ Comment: Records reviewed during the inspection were organized and well maintained. DMRs, COCs, ORC logs and calibration logs were reviewed for October 2017 through March 2018. ORC logs must be more detailed and include maintenance work done, including the date equipment was taken offline and date the equipment was repaired and returned to service. Page# 3 Permit: NC0004812 Owner - Facility: Pharr Yarns Industrial WWTP Inspection Date: 04/11/2018 Inspection Type: Compliance Evaluation Yes No NA NE Is composite sampling flow proportional? 0 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? 0 ❑ ❑ ❑ # 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 0 ❑ ❑ ❑ Celsius)? 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 analvses (dissolved oxvaen and temDerature) are performed under the facilitv's laboratory certification #5278. Shealy Environmental Services, Inc. (BOD, TSS, ammonia, fecal coliform, COD, phenols, chromium, conductivity, nutrients, pH, total residual chlorine), R&A Laboratories (sulfide), ETT, Inc. (toxicity), and City of Gastonia/Crowders Creek Laboratory (color) have also been contracted to provide analytical support. At the time of the inspection the thermometer was past due for verification, having expired on January 9, 2017. The dissolved oxygen meter appeared to be properly calibrated and documented Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? ❑ 0 ❑ ❑ # 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 0 ❑ ❑ ❑ representative)? Comment: The subiect Dermit requires effluent composite and arab samples. At the time of the inspection the sampler tubing appeared to be dirty. The ORC and staff must ensure to perform and document periodic aliquot verifications (100 mL minimum) on the composite sampler. Aliquot taken at the time of the inspection was 175 mL. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and 0 ❑ ❑ ❑ sampling location)? Comment: Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ❑ 0 ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Page# 4 Permit: NC0004812 Inspection Date: 04/11/2018 Operations & Maintenance Owner - Facility: Pharr Yarns Industrial WWTP Inspection Type: Compliance Evaluation Yes No NA NE Comment: At the time of the inspection an excessive amount of foam was observed in the treatment units including at the sampling location. Secondary clarifier used at the time of the inspection was in need of maintenance (See Secondary clarifier section). Process control measurements were being documented and maintained on-site. Aeration Basins Mode of operation Type of aeration system Is the basin free of dead spots? Are surface aerators and mixers operational? Are the diffusers operational? Is the foam the proper color for the treatment process? 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/1) Ext. Air Surface ■ ❑ ❑ ❑ E ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ Comment: The aeration basin is equipped with three aerators and a mixer. Excessive amount of foam was observed. 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: The aeration basin effluent is screened (coarse screen) prior to the clarifier. 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? Yes No NA NE 0 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ Page# 5 Permit: NC0004812 Owner - Facility: Inspection Date: 04/11/2018 Inspection Type: Pharr Yarns Industrial WWTP Compliance Evaluation # Is flow meter used for reporting? 0 Pumps -RAS -WAS Secondary Clarifier Yes No NA NE Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ 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: The facilitv is eauiDDed with two secondary clarifiers (one operational). At the time of the inspection short-circuiting was evident. Additionally, the clarifier trough was full of debris. # Is flow meter used for reporting? 0 Pumps -RAS -WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ ❑ 0 Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? ❑ 0 ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? 0 ❑ ❑ ❑ Comment: The flow meter is past due for calibration. The flow meter was due for calibration on December 14, 2017. Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Down flow Is the filter media present? ❑ ❑ ❑ Is the filter surface free of clogging? ❑ ❑ ❑ Is the filter free of growth? ❑ ❑ ❑ Is the air scour operational? ❑ ❑ ❑ 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 -Liquid Yes No NA NE Page# 6 Permit: NC0004812 Owner - Facility: Pharr Yarns Industrial WWTP Yes No NA NE Type of system ? Tablet Inspection Date: 04/11/2018 Inspection Type: Compliance Evaluation ❑ Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ Disinfection -Liquid Yes No NA NE Is there adequate reserve supply of disinfectant? 0 ❑ ❑ ❑ (Sodium Hypochlorite) Is pump feed system operational? 0 ❑ ❑ ❑ Is bulk storage tank containment area adequate? (free of leaks/open drains) 0 ❑ ❑ ❑ 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: 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 ? Tablet ❑ ❑ 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? ❑ ❑ 0 ❑ Are the tablets the proper size and type? 0 ❑ ❑ ❑ Comment: Dechlor tablets are used. Are tablet de -chlorinators operational? 0 ❑ ❑ ❑ Number of tubes in use? 1 Comment: Tablets are put in above surface tube. Chlorinated discharge is circulated into the tube. 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? 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: The effluent appeared slightly turbid (tea colored) with foam. Page# 7 Permit: NC0004812 Inspection Date: 04/11/2018 Owner - Facility: Pharr Yarns Industrial WWTP Inspection Type: Compliance Evaluation Aerobic Digester Yes No NA NE Is the capacity adequate? 0 ❑ ❑ ❑ Is the mixing adequate? ❑ ❑ ❑ 0 Is the site free of excessive foaming in the tank? 0 ❑ ❑ ❑ # Is the odor acceptable? M ❑ ❑ ❑ # Is tankage available for properly waste sludge? 0 ❑ ❑ ❑ Comment: The facility is equipped with a 2 MG aerobic digester. The facility has rescinded its land application permit. Page# 8