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Home My WebLink AboutNCG500214_CEI_NOV2018PC0125_20180412Water Resources ENVIRONMENTAL QUALITY April 12, 2018 CERTIFIED MAIL # 70161370 0000 2596 0238 RETURN RECEIPT REQUESTED Mr. George Altice, Director of Corporate Engineering Pharr Yarns, LLC P.O. Box 1939 McAdenville, NC 28101 ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Interim Director Subject: Notice of Continuing Violation and Recommendation for Enforcement Compliance Evaluation Inspection NOV-2018-PC-0125 Pharr Yarns, Inc. NPDES Permit No. NCG500214 Gaston County Dear Mr. Altice: 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 previous inspection conducted on February 22, 2017 resulted in a Notice of Deficiency (NOD -2017 -PC -0027) due to the failure to report exceedances of permit limits within 24 hours from the time the Operator in Responsible Charge (ORC) became aware of the circumstances. Additional violations for failure to report exceedances of permit limits were discovered during the recent inspection on April 11, 2018. At the time of the inspection it was discovered that sampling conducted on March 1, 2017 resulted in an oil and grease violation (35 mg/L) for daily maximum and monthly average permit limits at outfall 003. Sampling conducted on September 1, 2017 also resulted in an oil and grease violation (16 mg/L) for monthly average permit limits at Outfall 001. The oil and grease permit daily maximum limit is 20 mg/L and the monthly average permit limit is 15 mg/L. Neither of these exceedances of the permit limit were reported to the Division within 24 hours from the time the ORC become aware of the circumstances. A Notice of Violation and Notice of Recommendation for Enforcement, pursuant to G.S. 143-215.6A, may result in a civil penalty of not more than twenty-five thousand dollars ($25,000.00) per day, per violation and may be assessed against any person who violates or fails 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 to act in accordance with the terms, conditions, or requirements of any permit issued pursuant to G. S. 143-215.1. 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. 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. 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 NCG500214 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 g I 71 72n, 73I i74 751 1 1 1 1 80 u Int 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 15/11/04 Pharr 1-85 Plant 300 Dickson Rd Exit Time/Date Permit Expiration Date Mc Adenville NC 28101 11:30AM 18/04/11 20/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted George Altice,PO Box 1939 Mc Adenville NC 281011939/Director of Corporate Engineering/704-823-2397/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenance Records/Reports Self -Monitoring Program 0 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 —Ic MRO WQ//704-663-1699/ 4/12/2018 ERRnc;7A?r)p:nl7AQR 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 NCG500214 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: NCG500214 Owner - Facility: Pharr 1-85 Plant Yes No NA NE Are records kept and maintained as required by the permit? ❑ 0 Inspection Date: 04/11/2018 Inspection Type: Compliance Evaluation ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 0 ❑ Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ 0 ❑ application? 0 ❑ ❑ ❑ 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 7/31/2020. The previous inspection was conducted on 2/17/2017 and resulted in a NOD for faliure to report exceedances to permit limits within 24 hours from the time the permittee becomes Are DMRs complete: do they include all permit parameters? aware of the circumstances. ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? 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? 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 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? ❑ ❑ 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? ❑ ❑ 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? ❑ ❑ ❑ Page# 3 Permit: NCG500214 Inspection Date: 04/11/2018 Record Keeping Owner - Facility: Pharr 1-85 Plant Inspection Type: Compliance Evaluation Comment: The 2017 - 2018 (1st half) semiannual DMRs were reviewed durina the inspection Yes No NA NE Sampling done on March 1, 2017 had an oil and -grease violation for daily maximum and monthly average at outfall 3 (35 mq/L) . Sampling done on Septmber 1, 2017 had an oil and grease violation for monthly average at outfall 1 (16 mq/L). The permit daily limit is 20 mg/L and monthly average is 15 mg/L . ORC must contact MRO staff in case of a violation within 24 hours from the time he becomes aware of the violation. 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? M ❑ ❑ ❑ # 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)? 0 ❑ ❑ ❑ 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: Shealy Environmental Services, Inc. (Certification #329) has been contracted to perform all effluent analyses. 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: Effluent arab samplina for Outfalls 001. 002 (when active) and 003 is Derformed accordin to the permit's requirements 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 ❑ ❑ ❑ Page# 4 Permit: NCG500214 Owner - Facility: Pharr 1-85 Plant Inspection Date: 04/11/2018 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: The site arounds were well maintained. The facilitv has desianated three outfalls that consist of the following: Outfall 001 - boiler blowdown, Outfall 002 inactive for the past 4 years - noncontact cooling water (autoclaves), and Outfall 003 - noncontact cooling water (air washers). Outfalls 002 (when active) and 003 discharge directly to drainage ditches. The effluent from Outfall 001 is discharged into a stormwater pond (equipped with a fountain) prior to the receiving stream (second pond/unnamed tributary to South Fork Catawba River) 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: Oufall 002 was not discharging at the time of the inspection. The effluent was clear with no foam from Outfall 001 and 003 Page# 5