NC0034860_Regional Office Historical File Pre 2018 (31)

FILE
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Pat McCrory Thomas A. Reeder John E. Skvarla, III
Governor Acting Director Secretary
July 2, 2013
Mr. Chip Swinnie, Plant Manager
Schneider Mills, Inc.
Post Office Box 519
Taylorsville, North Carolina 28681
Subject: Compliance Evaluation Inspection
Schneider Mills WWTP
NPDES Permit No. NCO034860
Alexander County
Dear Mr. Swinnie:
Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the
subject facility on June 26, 2013 by Mr. Wes Bell of this Office. Please inform the facility's Operator -in -
Responsible (ORC) of our findings by forwarding a copy of the enclosed report.
The report should be self-explanatory; however, should you have any questions concerning this report, please ;'
do not hesitate to contact Mr. Bell at [phone] or at wes.bell@,ncdenr.gov. {
Sincerely,
Michael L. Parker
Regional Supervisor
Surface Water Protection Section
Enclosure:
Inspection Report
cc: Alexander County Health Department
1VIN:?
Mooresville Regional Office
Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115
Phone: [phone] Fax: [phone] Customer Service:1-877-623-6748
Internet www.ncwaterquality.org
Nort�Caxolina
Fatrr�ll�
An Equal Opportunity 1 Affirmative Action Employer— 30% Recycled/10%q Post Consumer paper, ,

United States Environmental Protection Agency Form Approved.
Washington, D.C. 20460 OMB No. 2040-0057 EPA
Approval expires 8-31-98 .
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES YY r/mo/da Inspection Type Inspector Fac Type
1 I N I 2 1 5 I 3 I NC0034860 111 12I 13/06/26 117 18I C I 19I S I 20I I
Remarks
21IIIIIIIIIIIIIIII ������II I I I I IIIIIIII IIII11111116
—
Inspection Work Days Facility Self -Monitoring Evaluation Rating 61 CIA -Reserved
A
671 1.5 169 70 14 I 71LNJ 72 I N I 73 LU 74 751 I I I I I I I 80
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) 11/01/01
09:20 AM 13/06/26
Schneider Mills WWTP
Exit Time/Date Permit Expiration Date
1170NCHwy 16N
11:50 AM 13/06/26 15/07/31
Taylorsville NC 28681
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 28681/Plant Manager/828-632-8181/ No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
. Permit Flow Measurement N Operations & Maintenance 0 Records/Reports
. Self -Monitoring Program Sludge Handling Disposal E Facility Site Review N Effluent/Receiving Waters
Laboratory
A
(See attachment summary)
Name(s) and Signature(s) oInspector(s)
Wes Bell
of Management Q A
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
eets
-Agency/Office/Phone and Fax Numbers Date
MRO WQ//704-663-1699 Ext.2192/
Agency/Office/Phone and Fax Numbers _ D to
MRO WQ//704-663-1699 Ext.2204/
Page # 1

NPDES yr/mo/day Inspection Type 1
31` NC0034860 I11 12, 13/06/26 111 18, _,
ls
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Page # 2

Permit: NCO034860 owner - Facility: Schneider Mills WWTP
Inspection Date: 06/26/2013 Inspection Type: Compliance Evaluation
Yes No NA NE
Permit
(If the present permit expires in 6 months or less). Has the permittee submitted a new application? o o ■
0
Is the facility as described in the permit? o
# Are there any special conditions for the permit? o o ■ o
■
Is access to the plant site restricted to the general public? 000
Is the inspector granted access to all areas for inspection? ■ o Cl .
Comment: The subject permit expires on 7/31/2015.
The last inspection (Biomonitoring) was performed on 5/17/2011.
Yes No NA NE
Record Keeping
Are records kept and maintained as required by the permit?
■o00
Is all required information readily available, complete and current?
■000
■non
Are all records maintained for 3 years (lab. reg. required 5 years)?
Are analytical results consistent with data reported on DMRs?
■000
Is the chain -of -custody complete? ■ o
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 COCs
Are DMRs complete: do they include all permit parameters?
■noo
Has the facility submitted its annual compliance report to users and DWQ? o 0013
(If the facility is = or > 5 MGD permitted flow) Do they operate 2417 with a certified operator on each shift? El ■ o
■o❑n_
Is the ORC visitation log available and current?
Is the ORC certified at grade equal to or higher than the facility classification?
■nnn
Is the backup operator certified at one grade less or greater than the facility classification? ■ o
0
Is a copy of the current NPDES permit available on site? ■ o 0 0
oo■o
Facility has copy of previous year's Annual Report on file for review?
Page # 3

Permit: NCO034860
Inspection Date: 06/26/2013
Owner - Facility: Schneider Mills WWTP
Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Comment: The records reviewed during the inspection were organized and well
maintained. Discharge Monitoring Reports (DMRs) were reviewed for the period May
2012 through April 2013. No effluent limit violations were reported and all monitoring
frequencies were correct.
The ORC and staff must ensure that a minumum of ten days is between the twice per
month total suspended solids effluent samples for Outfall 002 (September 2012 DMR).
Laboratory
Yes
No
NA
NE
Are field parameters performed by certified personnel or laboratory?
■
n
n
n
Are all other parameters(excluding field parameters) performed by a certified lab?
■
n
n
n
# Is the facility using a contract lab?
■
n
n
n
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
■
n
n
n
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees?
00
■
n
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
n
n
■
Cl
Comment: On -site field analyses (pH, total residual chlorine, dissolved oxygen,
temperature) are performed under the facility's field laboratory certification #5012.
Water Tech Labs, Inc. (BOD, TSS, ammonia, nutrients) and R & A Labs (chronic
toxicity, metals) have also been contracted to provide analytical support.
The laboratory instrumentation used for field analyses appeared to be properly
calibrated and documented. The ORC and staff must ensure that the effluent TRC
values (Outfall 002) are not reported below the lowest standard verified on the TRC
meter (annual curve verification). In addition, the 10 pH buffer had expired and should
be replaced prior to the next sampling event.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? ❑ ❑ ■ 11
Is sample collected below all treatment units? ■ n ❑ n
Is proper volume collected? ■ ❑ n n
Is the tubing clean? ■ n n n
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ ❑ n
Is the facility sampling performed as required by the permit (frequency, sampling type representative)? ■ n n n
Comment: The Division approved a variance to collect time -based composite samples
on 5/26/2009. The sampler was programmed to collect 300 mi. aliquots every twenty
minutes. The ORC and staff should continue to periodically calibrate (and document)
the. aliquot volume (100 mi. aliquots at a minimum). The aliquot volume was verified at
approximately 325 mis. during the inspection.
Upstream / Downstream Sampling Yes No NA NE
Page # 4

Permit: NCO034860 Owner - Facility: Schneider Mills WWTP
Inspection Date: 06/26/2013 Inspection Type: Compliance Evaluation_. ... .
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency; sampling type, and sampling location)? ■ fl ❑ 0
Comment:
Yes No NA NE
Operations & Maintenance
■rElnn
Is the plant generally clean with acceptable housekeeping?
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ ❑ Q
Judge, and other that are applicable?
Comment: The facility appeared to be properly operated and well maintained. The
ORC incorporates a comprehensive process control program with all measurements
being properly documented and maintained on -site.
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?
Comment:
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?
Comment: The flow meter is calibrated/verified twice per year and was last
calibrated/verified on 1/31/2013 by IS[ Instrumentation Services, Inc. .
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?
Yes No NA NE
■
El
Yes No NA NE
Ext. Air
Surface
■nnn
■n,nn
■❑■0
Page # 5

C
Permit: NCO034860 Owner - Facility: Schneider Mills WWTP
Inspection Date: 06/26/2013 Inspection Type:•,. Compliance Evaluation
Aeration Basins Yes No. NA NE
Is the foam the proper color for the treatment process? n n ■ n
Does the foam cover less than 25% of the basin's surface? ■ n n n
Is the DO level acceptable? ■ n n n
Is the DO level acceptable?(1.0 to 3.0 mg/1) ■ n n n
Comment: Aqueous lime and soda ash are added to maintain appropriate
alkalinity/pH levels. The ORC also adds an accelerator (microrganism food) and
additional microrganisms to maintain the biological treatment process.
Secondary Clarifier
Yes
No NA NE
Is the clarifier free of black and odorous wastewater?
■
n n n
Is the site free of excessive buildup of solids in center well of circular clarifier?
n
n ■ n
Are weirs level?
■
n
Is the site free of weir blockage?
■
n n n
Is the site free of evidence of short-circuiting?
■
n Cl n
Is scum removal'adequate?
■
❑ n ❑
Is the site free of excessive floating sludge?
■
❑ ❑ 11
Is the drive unit operational?
■
n n n
Is the return rate acceptable (low turbulence)?
■
n n n
Is the overflow clear of excessive solids/pin floc?
■
n n n
Is the sludge blanket level acceptable? (Approximately'/< of the sidewall depth) ,
■
❑ n n
Comment: A polymer is added in the clarifier influent to enhance settling. The sludge
blanket was measured at approximately three feet during the inspection.
Pumps-RAS-WAS Yes No NA NE
Are pumps in place? ■ n n n
Are pumps operational? ■ n n n
Are there adequate spare parts and supplies on site? n ❑ n ■
Comment:
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained? ■ n n n
Are the receiving water free of foam other than trace amounts and other debris? ■ n n n
If effluent (diffuser pipes are required) are they operating properly? n ❑ ■ ❑
Page # 6

Permit: N00034860 Owner -Facility: Schneider Mills WWTP
Inspection Date: 06/26/2013 Inspection Type: Compliance Evaluation
Effluent Pipe Yes No NA NE
Comment: Outfall 001 effluent appeared clear with trace suspended solids and no
foam. Outfall 002 effluent appeared clear with no floatable solids or foam.
Aerobic Digester
Is the capacity adequate?
Is the mixing adequate?
Is the site free of excessive foaming in the tank?
# Is the odor acceptable?
# Is tankage available for properly waste sludge?
Comment: The facility is equipped with two blower/motor units; however, one of the
motors was in the process of being repaired.
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?
Comment: Dewatered sludge is transported (by company staff) to the Alexander
County Landfill.
Yes No NA NE
Yes No NA NE