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Home My WebLink AboutNC0000272_Inspection_20180829 DocuSign Envelope ID:6B8E5A60-3B98-4B32-99F9-627F1 BBFECAF F,0Y COOPER NOR H CAsL� LiNA Goi6yr r £nvlrortmemrai Qua firy -N1TCI-LAEL S. REG_A—'<I ;i—:f— L=---k C-ULPEPPER : :—f.x D: f— September 18, 2018 John Frazier Blue Ridge Paper Products Inc PO Box 4000 Canton, NC 28716 SUBJECT: Compliance Inspection Report Canton Mill NPDES WW Permit No. NC0000272 Haywood County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Canton Mill on 8/29/2018. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0000272. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the inspection and therefore, a response to this inspection report is not required. If you should have any questions, please do not hesitate to contact me with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4500 or via email at tim.heim@ncdenr.gov. Sincerely, DocuSigned by: fi�bf{� l�uw� I 2H81ft,"KE., Environmental Engineer Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENT Cc: WQS-ARO Server LF 08292018_NC0000272_CEILtr.Docx North Carolina Department of Environmental Quality I Division of Water Resources 2090 U.S.70 Highway,Swannanoa,NC 28778 828-296-4500 DocuSign Envelope ID:6B8E5A60-3B98-4B32-99F9-627F1 BBFECAF 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 NCO000272 I11 12 I 18/08/29 I17 18 L d 19 L G j 201 211 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I r6 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- 671 70IJ 71 I I 72 LJ I n, I 73I I I74 751 I I I I I I I80 Section B: Facility Data I—I— Name and Location of Facility Inspected(For Industrial Users discharging to POTW,also include Entry Time/Date Permit Effective Date POTW name and NPDES permit Numbed 09:OOAM 18/08/29 10/07/01 Canton Mill 175 Main St Exit Time/Date Permit Expiration Date Canton NC 28716 03:OOPM 18/08/29 15/06/30 Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data John J Pryately/ORC/828-707-7976/ Name,Address of Responsible Official/Title/Phone and Fax Number Contacted Derric Brown,PO Box 4000 Canton NC 28716//828-646-2318/ Yes Section C:Areas Evaluated During Inspection(Check only those areas evaluated) Permit E Flow Measurement Operations&Maintenance E Self-Monitoring Program Sludge Handling Disposal E Facility Site Review Effluent/Receiving Waters 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 ° s "Y 9/18/2018 Timothy H Heim fim�j R6M ARO WQ//828-296-4665/ Mika] Willmer DO-1gsA 418 ARO WQ//828-296-4686/ //°/o/o�/s�g�d by: 9/18/2018 [ aEcza Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date s °° 9/18/2018 EPA Form 3560-3(Rev 9-94)Previous editions are obsolete. Page# 1 DocuSign Envelope ID:6B8E5A60-3B98-4B32-99F9-627F1 BBFECAF NPDES yr/mo/day Inspection Type (Cont.) 1 31 NC0000272 I11 121 18/08/29 117 18 I c Section D:Summary of Finding/Comments(Attach additional sheetsof narrative and checklists as necessary) Tim Heim and Mikal Willmer of the Asheville Regional Office performed a Compliance Evaluation Inspection, based on a complaint follow-up, on August 29, 2018. Jacob Trantham (Lab Supervisor), John Pryately, (ORC), John Frazier(Water and Water Manager), and Tracy Willis (BORC and WW Operations Supervisor) of Evergreen Paper were present at the time of the inspection. Mill personnel were helpful and knowledgeable during the inspection, and all areas were fully accessible to the inspectors. An update on the ongoing situation with the town's domestic influent and potential connection to fecal exceedances was also provided at the time of the inspection. Another sanitary feed line from the mill has been located and repaired (however this was unlikely to reduce the exceedances). Powdered granular chlorine is being added to the chip piles as a preventative measure, and additional sampling of the mill's domestic sewer for fecal coliform sources is being performed. The mill also continues to work with Fiss Consultants and Canton. The Town of Canton continues to add industrial users and there is concern that they do not have full control or understanding of what these sources might be contributing to the sewer. The inspection included a file review of the Permit status, as well as a facility inspection and evaluation of the NPDES Outfall. Sample record keeping was thorough and well organized. The site was well maintained and appeared to be operating within compliance to permit NC0000272 and no violations of permit conditions were observed at the time of the inspection. The ORC and plant staff demonstrated detailed knowledge of the facility, its history and its operation. All areas of concern noted from the complaint were investigated during the inspection, and the following items were noted (all information provided by knowledgeable plant staff and vetted during the field inspection): 1.Patches on the secondary sludge return line: These patches were temporarily secured with ratchet straps while the bonding agent set and now appear structurally competent, the line now appears fully sealed and the straps will be removed. It should be noted that this line is under negative pressure and a hole would not likely result in a release of material. If a leak were to occur, Mr. Pyratley reports, spilled sludge would drain to the headworks. This line is scheduled to be replaced in its entirety in Spring 2020. Additionally, this line is critical to production and failure would result in production showdown of the mill. 2.Primary clarifier redundancy: #1 clarifier is not currently in use, but can be utilized to accommodate excess flow if#2 or#3 primary were to fail. The mill WWTP could still run at full capacity (barring a concurrent major storm event)should this occur. 3.Secondary clarifier redundancy: #4 &#5 clarifiers are operational. If#4 or#5 were to fail, either single secondary clarifier could handle full production (barely)and #6 clarifier and#1 clarifier could be used to buffer flow while repairs were being made. The rotating assembling in #2 is functional but in need of repair, which is scheduled to occur in 2018. 4.The plant maintains the ability to pump between all 6 clarifiers to manage flows and provide options during an emergency repair situation. 5.The mill will experience a planned major"cold outage" in the Spring of 2020 and many additional significant repairs are planned to occur at this time. Page# 2 DocuSign Envelope ID:6B8E5A60-3B98-4B32-99F9-627F1 BBFECAF Permit: NC0000272 Owner-Facility: Canton Mill Inspection Date: 08/29/2018 Inspection Type: Compliance Evaluation 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 E ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Facility collects and analyzes numerous process control samples throughout the day for both the WWTP and to track efficiency in the production process. 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? E ❑ ❑ ❑ #Are there any special conditions for the permit? E ❑ ❑ ❑ Is access to the plant site restricted to the general public? E ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? E ❑ ❑ ❑ Comment: Permit includes special condition for color variance. This is subject to discussion for next permit renewal. Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑ Is the wet well free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? 0 ❑ ❑ ❑ Comment: Telemetry and alarms are connected to the control room which is staffed 24 hours a day, 7 days a week. Primary 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? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? E ❑ ❑ ❑ Is the site free of evidence of short-circuiting? E ❑ ❑ ❑ Is scum removal adequate? ❑ ❑ ❑ Is the site free of excessive floating sludge? ❑ ❑ ❑ Page# 3 DocuSign Envelope ID:6B8E5A60-3B98-4B32-99F9-627F1 BBFECAF Permit: NC0000272 Owner-Facility: Canton Mill Inspection Date: 08/29/2018 Inspection Type: Compliance Evaluation Primary Clarifier Yes No NA NE Is the drive unit operational? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: #1 clarifier is not currently in use, but can be utilized to accommodate excess flow if#2 or #3 primary were to fail. The mill WWTP could still run at full capacity (barring a concurrent major storm event)should this occur. Pumps-RAS-WAS Yes No NA NE Are pumps in place? E ❑ ❑ ❑ Are pumps operational? E ❑ ❑ ❑ Are there adequate spare parts and supplies on site? E ❑ ❑ ❑ Comment: The secondary WAS return line is functional, but is scheduled to be replaced during the 2020 Cold Outage according to facility staff. 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? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ 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'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: #4 &#5 secondary clarifiers are operational. If#4 or#5 were to fail, either single secondary clarifier could handle full production (barely) and#6 clarifier and #1 clarifier could be used to buffer flow while repairs were being made. The rotating assembly in #2 is functional but in need of repair, which is scheduled to occur in 2018. Aeration Basins Yes No NA NE Mode of operation Ext.Air Type of aeration system Surface Is the basin free of dead spots? E ❑ ❑ ❑ Are surface aerators and mixers operational? E ❑ ❑ ❑ Page# 4 DocuSign Envelope ID:6B8E5A60-3B98-4B32-99F9-627F1 BBFECAF Permit: NC0000272 Owner-Facility: Canton Mill Inspection Date: 08/29/2018 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Are the diffusers operational? E ❑ ❑ ❑ Is the foam the proper color for the treatment process? E ❑ ❑ ❑ Does the foam cover less than 25%of the basin's surface? E ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) 0 ❑ ❑ ❑ Comment: Surface aerators are run at maximum capacity to contribute to cooling of effluent in addition to adding DO to adequate levels. 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: Diffusers appeared to be operating normally. Solids Handling Equipment Yes No NA NE Is the equipment operational? S ❑ ❑ ❑ Is the chemical feed equipment operational? E ❑ ❑ ❑ Is storage adequate? E ❑ ❑ ❑ Is the site free of high level of solids in filtrate from filter presses or vacuum filters? E ❑ ❑ ❑ Is the site free of sludge buildup on belts and/or rollers of filter press? E ❑ ❑ ❑ Is the site free of excessive moisture in belt filter press sludge cake? 0 ❑ ❑ ❑ The facility has an approved sludge management plan? 0 ❑ ❑ ❑ Comment: #4 Filter press is currently operating at approximately 60% capacity according to the ORC and will be rebuilt in 2019. The facility typically only needs to operate 1 of the 4 presses at a time. Page# 5