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Home My WebLink AboutNC0004812_Inspection_20181029 qr ROY COOPER r% Gam _ MICHAEL S.REGAN 1 ecmldry " ate,, ' LINDA CULPEPPER InIC&M a'rffw NORTH AROLINA Emir Oean Men tat Quality October 29, 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 Subject: Notice of Deficiency Compliance Evaluation Inspection NOD-2018-PC-0306 Pharr Yarns WWTP NPDES Permit No. NC0004812 Gaston County Dear Mr. Altice: Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on October 9, 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) No application has been sent for the subject NPDES permit that is due to expire on January 31, 2019. The facility is expecting to rescind its permit in the next couple of months,but the expected time for the permit recession will be after the permit expiration date. The facility must submit a permit renewal application to the NPDES Permitting Unit. 2) The flow meter is past due for calibration. The flow meter was due for calibration on December 14, 2017. If the contracted company is unable to calibrate the flow meter, please ask them to provide written documentation to you(email or a letter) indicating such. State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations Mooresville Regional Office 1 610 East Center Avenue,Suite 3011 Mooresville,North Carolina 28115 704 663 1699 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(ancdenr.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 2 15 1 3 I NC0004812 111 12 I 18/10/09 I17 18 I S i 19 i G i 201 I 21I111II IIIIIIIIIII III IIII I IIIIII IIIIIIIII1 f6 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- 67 1.0 70 71 [„ I 72 n 73 L_LJ74 751 I I I I I I I80 Section B: Facility Data u 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 18/10/09 14/08/01 Pharr Yarns Industrial WWTP 147 Willow Dr Exit Time/Date Permit Expiration Date Mc Adenville NC 28101 11:05AM 18/10/09 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 2 81 01 1 93 9//704-8 2 3-2 39 7/ 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 MRO WQ//704-663-1699/ 10/29/2018 Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger Division of Water Quality//704-2, EPA Form 3560-3(Rev 9-94)Previous editions are obsolete. DocuSigned by: e� 10/29/2018 AtaccsatAFvazs... Page# 1 NPDES yr/mo/day Inspection Type 1 31 NC0004812 I11 121 18/10/09 117 18 JCJ Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0004812 Owner-Facility: Pharr Yarns Industrial WWTP Inspection Date: 10/09/2018 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 ❑ 0 ❑ ❑ application? 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 is expecting to rescind its permit in the next couple of months, but the expected time will be after the permit expiration date. The facility will send application to the permitting unit. 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? ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ 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? ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ❑ Comment: During previous inspection (April 11, 2018) it was noted ORC logs fail to include maintenance work done. During the inspection ORC logs were much better and included maintenance work, 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: 10/09/2018 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE 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 ❑ ❑ ❑ 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. 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? Comment: At the time of the inspection the facility looked much better than previous inspection, with less foam and secondary clarifier in much better condition. 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? N ❑ ❑ ❑ 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? ❑ 0 ❑ ❑ Is the DO level acceptable? ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/I) ❑ ❑ ❑ Page# 4 Permit: NC0004812 Owner-Facility: Pharr Yarns Industrial WWTP Inspection Date: 10/09/2018 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Comment: The aeration basin is equipped with three aerators and a mixer. Excessive amount of foam was observed. Bar Screens Yes No NA NE Type of bar screen a.Manual b.Mechanical ❑ Are the bars adequately screening debris? 0 ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? M ❑ ❑ ❑ 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? M ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ 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 facility is equipped with two secondary clarifiers (one operational). At the time of the inspection the secondary clarifier appeared to be in much better condition than the last inspection. 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? ❑ ❑ ❑ Page# 5 Permit: NC0004812 Owner-Facility: Pharr Yarns Industrial WWTP Inspection Date: 10/09/2018 Inspection Type: Compliance Evaluation Filtration (High Rate Tertiary) Yes No NA NE Is the scouring acceptable? 0 ❑ ❑ ❑ Is the clear well free of excessive solids and filter media? M ❑ ❑ ❑ Comment: All three tertiary filters were operational and in service. The filter backwash is returned to the head of the plant (aeration basin). 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? ❑ ❑ ❑ (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. If lab can not calibrate the flow meter please ask them write a letter that indicates that. 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)? ❑ ❑ ❑ 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 Page# 6 Permit: NC0004812 Owner-Facility: Pharr Yarns Industrial WWTP Inspection Date: 10/09/2018 Inspection Type: Compliance Evaluation De-chlorination Yes No NA NE Comment: Tablets are put in above surface tube. Chlorinated discharge is circulated into the tube. 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? ❑ ❑ ❑ Comment: Page# 7