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Home My WebLink AboutNC0025135_Compliance Evaluation Inspection_20200810DocuSign Envelope ID: FODCOF6E-F7B8-4OB3-ACC5-7362FF388CBE . ROY COOPER MICHAEL S. REGAN Secr&a Secretary '��"`•'�' S. DANIEL SMITH NORTH CAROLINA Alrecror Environmental Quality August 10, 2020 Lee T Huffman Huffman Finishing Company Inc PO Box 170 Granite Falls, NC 28630-0170 SUBJECT: Compliance Inspection Report Huffman Finishing NPDES WW Permit No. NCO025135 Caldwell County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Huffman Finishing on 8/06/2020. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0025135. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". Please respond in writing to this office within 30 days of your receipt of this letter regarding your plans or measures to be taken to address the following issues: • The rake in the secondary clarifier is functioning but appears to have reached the end of its functional life and is nearing structural failure, this component should be evaluated for repair or replacement immediately. 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. ATTACHMENTS Ec: LF Sincerely, IrDocuSigned by: PAbf� t�60i 082B1105A3CA418... Tim Heim, P.E., Environmental Engineer Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ NortrDEro rsDepartmentofEnvironmental Quslrty I Division of Water Resources Ashswe Ragnna.Off:ce 1 2090 V.S. 70Hthw3y I Sw nanoa, North Caro:ina 23773 223296-4500 DocuSign Envelope ID: FODCOF6E-F7B8-4OB3-ACC5-7362FF388CBE 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 u 3 I NCO025135 I11 121 20/08/06 I17 18I � I 19 I s I 201 I 211IIIII 111111III II III III1 I I IIIII IIIIIIIII II r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 I 72 I n, I 71 I 74 79 I I I I I I I80 701 I 71 I LL -1 I I LJ 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 permit Number) 09:30AM 20/08/06 16/05/01 Huffman Finishing 4919 Hickory Blvd Exit Time/Date Permit Expiration Date Granite Falls NC 28630 11:30AM 20/08/06 20/01/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Jonathan David Gragg/ORC/828-396-4444/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Lee T Huffman,PO Box 170 Granite Falls NC 286300170/Manager/Owner/828-396-1741 / No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar 0 Facility Site Review Effluent/Receiving Wate 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 Timothy H Heim DWR/ARO WQ/828-296-4665/ 8/10/2020 DocuSigned by: Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date FDocuSi9ned by: 8/ 10 / 2 0 2 0 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# DocuSign Envelope ID: FODCOF6E-F7B8-40B3-ACC5-7362FF388CBE NPDES yr/mo/day Inspection Type (Cont.) NC0025135 I11 12I 20/08/06 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Tim Heim of the Asheville Regional Office performed a Compliance Evaluation Inspection on August 6, 2020. Jonathan Gragg (ORC) was present at the time of the inspection. Mr. Gragg took over as ORC approximately 2 months ago and reported that while the facility was well run, he is continuing small process adjustments to optimize the facility for both treatment and energy efficiency. The inspection included a file review of the Permit status, bench sheets and DMRs, as well as a facility inspection. The NPDES Outfall was not able to be access due to a downed tree blocking the road. Sample record keeping was thorough and well organized. The site was well maintained and appeared to be operating within compliance to permit NCO025135 and no violations of permit conditions were observed at the time of the inspection. The ORC demonstrated detailed knowledge of the facility, its history and its operation. The facility currently operates at approximately 40,000 gal/day, 4 days a week. Influent combines industrial and domestic wastewater from the mill. The following items were noted at the time of the inspection: The rake in the secondary clarifier is functioning but appears to have reached the end of its functional life and is nearing structural failure, this component should be evaluated for repair or replacement immediately. Secure the chlorine gas cylinders to prevent accidental tip over. Maintain the road to the Outfall to allow access. Page# DocuSign Envelope ID: FODCOF6E-F7B8-4OB3-ACC5-7362FF388CBE Permit: NCO025135 Owner -Facility: Huffman Finishing Inspection Date: 08/06/2020 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 ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Process controls include pH and MLSS. Influent quality is very consistent and the facility does not experience I&I. 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: 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? 0 ❑ ❑ ❑ Are audible and visual alarms operable? 0 ❑ ❑ ❑ # Is basin size/volume adequate? 0 ❑ ❑ ❑ Oxidation Ditches Yes No NA NE Are the aerators operational? 0 ❑ ❑ ❑ Are the aerators free of excessive solids build up? 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? ❑ ❑ ❑ Are settleometer results acceptable (> 30 minutes)? ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑ Page# 3 DocuSign Envelope ID: FODCOF6E-F7B8-4OB3-ACC5-7362FF388CBE Permit: NCO025135 Owner -Facility: Huffman Finishing Inspection Date: 08/06/2020 Inspection Type: Compliance Evaluation Oxidation Ditches Are settelometer results acceptable?(400 to 800 ml/I in 30 minutes) Comment: 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 ❑ ❑ ❑ ■ Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: Wastewater in the clarifier at this facility is typically black from the dye process. ORC report the sludge depth is maintained at approximately 2-3' out of a total depth of 15'. The rake arm appears to be at the end of its useful life and should be evaluated for replacement immediately. Disinfection -Gas Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de -chlorination? Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)? If yes, then is there a Risk Management Plan on site? If yes, then what is the EPA twelve digit ID Number? (1000- - ) If yes, then when was the RMP last updated? Yes No NA NE ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ Comment: Spare gas cylinders need to be secured to prevent them from accidentally falling over. Page# 4 DocuSign Envelope ID: FODCOF6E-F7B8-40B3-ACC5-7362FF388CBE Permit: NC0025135 Owner -Facility: Huffman Finishing Inspection Date: 08/06/2020 Inspection Type: Compliance Evaluation Standby Power Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Was generator tested & operational during the inspection? Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Is the generator fuel level monitored? Yes No NA NE ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The mill maintains the backup generator. Long term power loss would also result in termination of influent from the mill. Page# 5