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Home My WebLink AboutNC0034860_Compliance Evaluation Inspection_20191206 (2)ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Director Mr. Chip Swinnie, Plant Manager Schneider Mills, Inc. P.O. Box 519 Taylorsville, NC 28681 Dear Mr. Swinnie: NORTH CAROLINA £rtkbroAWenrcr grsoltty December 6, 2019 Subject: Compliance Bioassay Inspection Notice of Deficiency NOD-2019-PC-0251 Schneider Mills WWTP NPDES Permit No. NCO034860 Alexander County Enclosed is a copy of the Compliance Inspection for the inspection conducted at the subject facility on December 3, 2019, by Ori Tuvia and Michael Meilinger. 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 main area of concern observed during the inspection, was that the clarifier needs maintenance. The clarifier baffle is deteriorating and parts of it are rusted out completely causing solids to short circuit the baffle. The clarifier weir appeared to be uneven and discharging from only one side, in addition short circuiting was observed in several locations as well as missing a "tooth." Due to the age of the clarifier and the fact that the facility does not have a backup clarifier, it is recommended for the facility to develop a plan in case the clarifier would have a critical failure (such as shaft failure) which will require the clarifier to be taken out of service for prolonged maintenance. In accordance with Part II, Section C.2 of the subject permit, proper Operation and Maintenance (O&M) of the WWTP is required. In addition, it was observed that the RAS-WAS pump wet well, high water alarms, were not working at the time of the inspection and must be repaired. 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 Picture 1. Weir "tooth" missing Picture 2. Weir short circuiting Based on the necessary maintenance items, this letter has been issued as a Notice of Deficiency. You are requested to respond to this Notice in writing within thirty (30) days indicating your Plan of Action to ensure future compliance. At the time of the inspection split samples for toxicity were taken. The results will be sent at a later date when they have been returned from the lab. 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(c�r�,ncdenr.gov. Sincerely, Docu Signed by: A41014 w H P44.f for F161FB69A2D84A3... W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources Cc: NPDES, MRO Files (Laserfiche) 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 IF I 3 I NCO034860 111 12 I 19/12/05 I17 18 i Q i 19 i G i 201 I 211111 I I I I I I II I I 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 I I f6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 2.0 70 71 I— „ I 72 I �, I I —I 73 �74 751 I I I I I I I80 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) 09:50AM 19/12/05 15/11/01 Schneider Mills WWTP 1170 NC Hwy 16 N Exit Time/Date Permit Expiration Date Taylorsville NC 28681 11:45AM 19/12/05 20/07/31 Name(s) of Onsite Representative(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 Taylorsville 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 -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 DWR/MRO WQ/704-663-1699/ Michael J Mellinger DWR/MRO WQ/910-796-7336/ 12/6/2019 cc Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers DocuSigned by: Date 0 . ii ;P44-t4 12.6.19 E4F1611`1369AMUAI.. Andrew Pitner DWR/MRO WQ/704-663-1699 Ext.2180/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NCO034860 I11 121 19/12/05 117 18 JBI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NCO034860 Owner - Facility: Schneider Mills WWTP Inspection Date: 12/05/2019 Inspection Type: Bioassay Compliance 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 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? 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 CM 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? ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ❑ 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 May 2019 through June 2019. ORC should indicate on the COC the beginning and end time of composite sampling. Page# 3 Permit: NCO034860 Owner - Facility: Schneider Mills WWTP Inspection Date: 12/05/2019 Inspection Type: Bioassay Compliance 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)? 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? ❑ 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 reauires both comDosite and arab effluent samDles. The Division approved a variance 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 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: clarifier is in need of maintenance (see clarifier section). The ORC incorporates a comprehensive process control program with all measurements being properly documented and maintained on -site. Page# 4 Permit: NCO034860 Inspection Date: 12/05/2019 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? Owner - Facility: Schneider Mills WWTP Inspection Type: Bioassay Compliance 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 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: The influent flow meter (Outfall 001) is calibrated twice per year and was last calibrated by ISI. 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? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? ❑ ❑ 0 ❑ 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? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ 0 ❑ Comment: Aaueous lime and soda ash are added to maintain aDDroDriate DH/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 Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? ❑ ❑ ❑ Page# 5 Permit: NC0034860 Inspection Date: 12/05/2019 Secondary Clarifier Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Owner - Facility: Schneider Mills WWTP Inspection Type: Bioassay Compliance Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately'/ of the sidewall depth) Yes No NA NE ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The clarifier baffle deteriorating and parts of it are rusted out completely causing solids to short circuit the baffle. The clarifier weir appeared to be uneven and discharging from only one side, in addition short circuiting was observed in several locations as well as missing a "tooth" Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? E ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ 0 ❑ Comment: It was observed during the inspection that the RAS-WAS DumD wet well. hiah water alarms were not working at the time of the inspection and should be repaired. 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. 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? 0 ❑ ❑ ❑ # Is tankage available for properly waste sludge? 0 ❑ ❑ ❑ Comment: Page# 6 Permit: NC0034860 Inspection Date: 12/05/2019 Owner - Facility: Schneider Mills WWTP Inspection Type: Bioassay Compliance Drying Beds Is there adequate drying bed space? Is the sludge distribution on drying beds appropriate? 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 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ 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