NC0006190_Compliance Evaluation Inspection_20200107

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 NC0006190 111 12 I 19/12/16 I17 18 I S 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 72 73 L_LJ74 751 I I I I I I I80
u u
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)
09:30AM 19/12/16
19/02/01
South Fork Industries - Maiden Plant
100 W Pine St
Exit Time/Date
Permit Expiration Date
Maiden NC 28650
01:50PM 19/12/16
23/05/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Donald A Burkey/ORC/704-736-8960/
James S. Rhyne//828-428-9920 /
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Everette J Owens,PO Box 742 Maiden INC 28650//828-428-9921/
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:
Wes Bell DWR/MRO WQ/704-663-1699 Ext.2192/ 1/7/2020
Be
E:,,,�961D90=43T
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
W. Corey Basinger DWR/Division of Water Quality/704-235-2194/
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
DocuSigned by:
A14CC681AF27425...
1/7/2020
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NPDES yr/mo/day Inspection Type (Cont.)
NC0006190 I11 12, 19/12/16 117 18 JCJ
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
BAR SCREENS SECTION cont'd:
The Permittee and staff should investigate the removal of the dumpster from receiving the side -stream
discharge from the fine lint screens. The dumpster maintains several inches of wastewater inside the
container and continues to create a potential unpermitted discharge of wastewater onto the concrete
driveway while being emptied by the contracted company. The dumpster should only receive
dewatered/dried lint from the screening process.
SECONDARY CONTAINMENT:
The secondary containment structure for the hydrogen peroxide and salt brine tanks continues to be in
need of repair. Significant cracks were observed throughout the concrete floor and the vertical joint
facing the driveway. In addition, air bubbles were observed in the standing water inside the
containment structure along one of these significant fractures in the concrete flooring. All cracks in the
containment structure's floors and wall must be repaired and properly maintained.
The drain valve for the containment structure was also left open; therefore, any spills would not be
contained in this structure. The drain valve must be kept closed and secured with only authorized
personnel being able to open the valve. Only clean water (without contamination) is allowed to be
discharged out of this containment structure and all discharge events have to be documented (date,
time, observation of the water, individual performing the discharge event, etc.). Please be advised that
if an unpermitted discharge from this containment structure enters surface waters, then the Permittee
may be assessed civil penalties up to twenty-five thousand dollars ($25,000.00) per day per violation.
In addition, the Permittee would also be responsible for any cleanup activities and/or damages to
surface waters.
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Permit: NC0006190
Inspection Date: 12/16/2019
Owner - Facility: South Fork Industries - Maiden Plant
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
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application?
Is the facility as described in the permit?
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# Are there any special conditions for the permit?
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Is access to the plant site restricted to the general public?
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Is the inspector granted access to all areas for inspection?
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Comment: The last compliance evaluation inspection by DWR staff was performed on 3/14/19.
Record Keeping
Yes No NA NE
Are records kept and maintained as required by the permit?
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Is all required information readily available, complete and current?
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Are all records maintained for 3 years (lab. reg. required 5 years)?
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Are analytical results consistent with data reported on DMRs?
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Is the chain -of -custody complete?
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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?
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Has the facility submitted its annual compliance report to users and DWQ?
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(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator
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on each shift?
Is the ORC visitation log available and current?
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Is the ORC certified at grade equal to or higher than the facility classification?
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Is the backup operator certified at one grade less or greater than the facility classification?
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Is a copy of the current NPDES permit available on site?
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Facility has copy of previous year's Annual Report on file for review?
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Permit: NC0006190
Inspection Date: 12/16/2019
Record Keeping
Owner - Facility: South Fork Industries - Maiden Plant
Inspection Type: Compliance Evaluation
Yes No NA NE
Comment: The records reviewed durina the inspection were oraanized and well maintained. Discharae
Monitoring Reports (eDMRs) were reviewed for the period January 2019 through October
2019. All monitoring frequencies were correct. The facility staff must ensure to document
on future eDMRs (Comments Section) whether or not a color plume was observed around
the effluent pipe during the weekly instream sampling events.
Monthly average effluent Chemical Oxygen Demand (COD) violations were reported in
February and March 2019. The Division has previously addressed these limit violations
through the issuances of Notice of Violations (NOVs).
The wastewater treatment plant staff have made commendable improvements to the record
keeping program.
Laboratory
Yes No NA NE
Are field parameters performed by certified personnel or laboratory?
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Are all other parameters(excluding field parameters) performed by a certified lab?
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# Is the facility using a contract lab?
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# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
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Celsius)?
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees?
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Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
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Comment: The on -site field analyses (dissolved oxygen, pH, temperature) are performed under South
Fork Industries' field laboratory certification #5302. R&A Laboratories (all permit -required
analyses except field) has also been contracted to provide analytical support.
Influent Sampling
Yes No NA NE
# Is composite sampling flow proportional?
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Is sample collected above side streams?
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Is proper volume collected?
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Is the tubing clean?
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# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
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Celsius)?
Is sampling performed according to the permit?
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Comment: The subiect Dermit requires influent comDosite samDlina for color. The facilitv staff must
ensure that the influent sample is representative
of both waste streams that are separately
conveyed into the screening area.
Effluent Sampling
Yes No NA NE
Is composite sampling flow proportional?
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Is sample collected below all treatment units?
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Is proper volume collected?
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Permit: NC0006190 Owner - Facility: South Fork Industries - Maiden Plant
Inspection Date: 12/16/2019 Inspection Type: Compliance Evaluation
Effluent Sampling
Yes No NA NE
Is the tubing clean?
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# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
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Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
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representative)?
Comment: The subject permit requires composite and grab effluent 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: The wastewater treatment facility appeared to be adequately treating wastewater at the time
of the inspection. Process control measurements were being documented and maintained
on -site.
Operation and maintenance issues were noted during the inspection and will be discussed
further in the Bar Screen, Aeration Basins, Secondary Clarifier and Lagoon Sections.
Bar Screens
Yes No NA NE
Type of bar screen
a.Manual
b.Mechanical
Are the bars adequately screening debris?
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Is the screen free of excessive debris?
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Is disposal of screening in compliance?
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Is the unit in good condition?
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Comment: The facilitv is eauiDDed with three fine lint screens (shakers) and a manual bar screen (prior
to aeration basins). Only one fine lint screen was in service and a second screen was not
operational. Screenings are disposed by a contracted company.
A concrete containment wall was constructed around the dumpster; however, the wall did
not appear to be containing all wastewater. The wall must be repaired to ensure all
wastewater is contained and conveyed to the wastewater treatment facility. See "Summary"
Section for additional comments.
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Permit: NC0006190
Inspection Date: 12/16/2019
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)
Owner - Facility: South Fork Industries - Maiden Plant
Inspection Type: Compliance Evaluation
Yes No NA NE
Ext. Air
Surface
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Comment: Both aeration basins were in service and are eauiDDed with surface aeration. Aeration basin
#2 only had one operational surface aerator. In addition, the third surface aerator for
aeration basin #2 has been on -site for several months but has not been installed. Both
aerators (aeration basin #2) must be repaired and/or re -installed as soon as possible.
Please be advised that the subject permit requires the Permittee to properly operate and
maintain all facilities of treatment and control at all times (Permit Condition Reference: Part
11, Section C(2) Proper Operation and Maintenancel.
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?
Is the site free of excessive floating sludge?
Is the drive unit operational?
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
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Comment: Both secondary clarifiers were oDerational and in service. The clarifier weirs were not
excessively uneven; however, the weirs, skimmer arm, scum box, etc. appeared to be
severely rusted and deteriorated. All severely rusted and deteriorated clarifier components
must be evaluated and rehabbed to prevent equipment failure. Please be advised that the
subject permit requires the Permittee to properly operate and maintain all facilities of
treatment and control at all times [Permit Condition Reference: Part 11, Section C(2) Proper
Operation and Maintenancel.
Page# 6

Permit: NC0006190
Inspection Date: 12/16/2019
Owner - Facility: South Fork Industries - Maiden Plant
Inspection Type: Compliance Evaluation
Pumps-RAS-WAS
Yes No NA NE
Are pumps in place?
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Are pumps operational?
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Are there adequate spare parts and supplies on site?
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Comment: Each secondary clarifier is equipped with multiple pumps (RAS/WAS). One of the RAS
pumps was not operating properly and will need to be repaired/replaced.
Flow Measurement - Effluent
Yes No NA NE
# Is flow meter used for reporting?
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Is flow meter calibrated annually?
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Is the flow meter operational?
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(If units are separated) Does the chart recorder match the flow meter?
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Comment: The flow meter is calibrated twice per year and was last calibrated on 8/27/2019 by
Clearwater, Inc.
Effluent Pipe
Yes No NA NE
Is right of way to the outfall properly maintained?
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Are the receiving water free of foam other than trace amounts and other debris?
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If effluent (diffuser pipes are required) are they operating properly?
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Comment: The effluent appeared a grayish color with trace suspended solids and foam.
Lagoons
Yes No NA NE
Type of lagoons?
# Number of lagoons in operation at time of visit?
1
Are lagoons operated in?
# Is a re -circulation line present?
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Is lagoon free of excessive floating materials?
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# Are baffles between ponds or effluent baffles adjustable?
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Are dike slopes clear of woody vegetation?
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Are weeds controlled around the edge of the lagoon?
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Are dikes free of seepage?
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Are dikes free of erosion?
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Are dikes free of burrowing animals?
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# Has the sludge blanket in the lagoon (s) been measured periodically in multiple
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locations?
# If excessive algae is present, has barley straw been used to help control the growth?
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Page# 7

Permit: NC0006190
Inspection Date: 12/16/2019
Lagoons
Is the lagoon surface free of weeds?
Is the lagoon free of short circuiting?
Owner - Facility: South Fork Industries - Maiden Plant
Inspection Type: Compliance Evaluation
Yes No NA NE
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Comment: Wastewater solids are removed and land aaalied by Svnaaro under the authoritv of Permit
No. WQ0006984.
Adequate freeboard was being maintained. The corrective actions to address the severe
erosion around the stormwater drain (adjacent to the lagoon) were incomplete. All holes
must be filled in properly and the ground surrounding the stormwater drain must be properly
graded. Note: The appropriate erosion control measures/grading must also be employed at
the upgradient stormwater drain if needed. Please be advised that the subject permit
requires the Permittee to properly operate and maintain all facilities of treatment and control
at all times [Permit Condition Reference: Part II, Section C(2) Proper Operation and
Maintenancel.
The erosion and holes observed along the northern lagoon bank will be addressed in the
Non -Discharge Inspection Report dated 12/18/2019.
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