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Home My WebLink AboutNC0002305_Compliance Evaluation Inspection_20191231 (2)DocuSign Envelope ID: B155AF80-7FFD-4289-B909-CDOC8F42CBC5 ROY COOPER NORTH CAPOLINA Gove7no? Environmental Quality -W HAEL - RE AN Secretary L=- A CTJTPEPPER Interim Direcmr December 31, 2019 Mr. Keith Westbrook Lear Corporation WWTP 1754 NC Highway 903 North Kenansville, NC 28349 SUBJECT: Compliance Inspection Report Lear Corporation WWTP NPDES Permit No. NC0002305 Duplin County A compliance inspection of the Lear Corporation WWTP was conducted on November 22, 2019 to verify that the facility is operating in compliance with the conditions and limitations specified in Permit NC0002305. The DWR would like to thank you and your staff for your time and assistance provided during the inspection. The findings and comments noted during this inspection are provided in the enclosed copy of the "Compliance Inspection Report". If you have any questions concerning this report, you may contact the inspector at (910) 796-7215 or via email at chad.coburn@ncdenr.gov . Sincerely, Signed by: [ro- ,",',','1E73B6F3456—N44rin.�o& ... Tom Tharrington, Assistant Regional Supervisor Water Quality Regional Operations Section Wilmington Regional Office Division of Water Resources, NCDEQ Cc: Wilmington Regional Office Files Central Files, Water Quality Section WE� North Carolina Department of Environmental Quality I Division of Water Resources 127 Cardinal Drive Extension, Wilmington, North Carolina 28405 910-796-7215 DocuSign Envelope ID: B5A99F2C-AE90-4E10-847A-DD789DFDF592 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 1 2 15 I 3 I NC0002305 111 12 I 19/11/22 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 131 QA ---------------------- Reserved ------------------- 671 70 I I 71 I I 72 I r I 73 I I 174 751 I I I I I I I80 u ty 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) 10:50AM 19/11/22 18/10/01 Lear Corporation WWTP 1754 NC Hwy 903 N Exit Time/Date Permit Expiration Date Kenansville NC 28349 01:00PM 19/11/22 23/04/30 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Edward Keith Westbrook/ORC/910-296-5200/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Edward K Westbrook,1754 NC Hwy 903 N Kenansville NC 28349/Wastewater Manager/910-296-5201/ 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 Chad Coburn DocuSigned by: DWR/WIRO WQ/910-796-7379/ E� r,D�wlt 1/2/2020 8237FC6EDFCC4A3... Signature of Manageme�locCu g �e6yiewer Agency/Office/Phone and Fax Numbers Date '1o,Y) 12/31/2019[Tom Tharringtn 7FE EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# DocuSign Envelope ID: B5A99F2C-AE90-4E10-847A-DD789DFDF592 NPDES yr/mo/day Inspection Type NC0002305 I11 121 19/11/22 117 18 JCJ Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) The facility appeared to be compliant with the NPDES permit during the inspection. All records were organized and available. Page# DocuSign Envelope ID: B5A99F2C-AE90-4E10-847A-DD789DFDF592 Permit: NC0002305 Owner - Facility: Lear Corporation WWTP Inspection Date: 11/22/2019 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 current permit doesn't expire until 2023. 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: Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Page# 3 DocuSign Envelope ID: B5A99F2C-AE90-4E10-847A-DD789DFDF592 Permit: NC0002305 Owner - Facility: Lear Corporation WWTP Inspection Date: 11/22/2019 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: 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: Equalization Basins Yes No NA NE Is the basin aerated? 0 ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the basin free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? ❑ ❑ ❑ Are audible and visual alarms operable? ❑ ❑ ❑ # Is basin size/volume adequate? ❑ ❑ ❑ Comment: 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? ❑ ❑ ❑ Page# 4 DocuSign Envelope ID: B5A99F2C-AE90-4E10-847A-DD789DFDF592 Permit: NC0002305 Inspection Date: 11/22/2019 Aeration Basins Is the DO level acceptable?(1.0 to 3.0 mg/1) Comment: The DO during this time of warmer months. Owner - Facility: Lear Corporation WWTP Inspection Type: Compliance Evaluation Yes No NA NE ❑ ❑ ❑ ■ is around 4 averaae but is between 1.5 to 2.5 durina the 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) • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ Comment: The ORC uses a sludae iudae to base the rate of wastina. PumDS are set to maintain a 30 day sludge age approximately. Settleometer is used to get MLSS. 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: Anaerobic Digester Yes No NA NE Type of operation: Is the capacity adequate? ❑ ❑ ❑ # Is gas stored on site? ❑ ❑ ❑ Is the digester(s) free of tilting covers? ❑ ❑ ❑ Is the gas burner operational? ❑ ❑ ❑ Is the digester heated? ❑ ❑ ❑ Is the temperature maintained constantly? ❑ ❑ ❑ Is tankage available for properly waste sludge? ❑ ❑ ❑ Page# 5 DocuSign Envelope ID: B5A99F2C-AE90-4E10-847A-DD789DFDF592 Permit: NC0002305 Owner - Facility: Lear Corporation WWTP Inspection Date: 11/22/2019 Inspection Type: Compliance Evaluation Anaerobic Digester Yes No NA NE Comment: Drying Beds Yes No NA NE Is there adequate drying bed space? 0 ❑ ❑ ❑ Is the sludge distribution on drying beds appropriate? 0 ❑ ❑ ❑ Are the drying beds free of vegetation? 0 ❑ ❑ ❑ # Is the site free of dry sludge remaining in beds? 0 ❑ ❑ ❑ Is the site free of stockpiled sludge? 0 ❑ ❑ ❑ Is the filtrate from sludge drying beds returned to the front of the plant? 0 ❑ ❑ ❑ # Is the sludge disposed of through county landfill? ❑ 0 ❑ ❑ # Is the sludge land applied? 0 ❑ ❑ ❑ (Vacuum filters) Is polymer mixing adequate? ❑ ❑ 0 ❑ Comment: EMA currently takes the solids and land applies. 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: De -chlorination Yes No NA NE Type of system ? Liquid 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 ❑ ❑ ❑ Comment: Are the tablets the proper size and type? ❑ ❑ 0 ❑ Are tablet de -chlorinators operational? ❑ ❑ 0 ❑ Number of tubes in use? Page# 6 DocuSign Envelope ID: B5A99F2C-AE90-4E10-847A-DD789DFDF592 Permit: NC0002305 Owner - Facility: Lear Corporation WWTP Inspection Date: 11/22/2019 Inspection Type: Compliance Evaluation De -chlorination Comment: Yes No NA NE Page#