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Home My WebLink AboutNC0034860_Regional Office Historical File Pre 2018 (41)Beverly Eaves Perdue Governor A7iA. FqCDENR North Carolina Department of Environment and Division of Water Quality Coleen H. Sullins Director December 17, 2009 Mr. Harry McPherson, Senior Vice President Schneider Mills, Inc. Post Office Box 519 Taylorsville, North Carolina 28681. Subject Dear Mr. McPherson: Natural Resources Compliance Evaluation Inspection Schneider Mills WWTP NPDES Permit No. NCO034860 Alexander County, NC Dee Freeman Secretary Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on December 8, 2009 by Mr. Wes Bell of this Office. Please advise the facility's Operator -in -Responsible Charge 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 (704) 663-1699. Sincerely, Robert B. Krebs - Surface Water Protection Regional Supervisor Enclosure: Inspection Report cc: - Alexander County Health Department WB Mooresville Regional Office Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115 Phone: (704) 663-16991 fax: (704) 663.60401 Customer Service:1-877.623-6748 One Internet: www.ncwaterqualit .org Norf tl1Carofiii`1 An Equal Opportunity 1 Affirmative Action Employer- 50% Recycledi10% Post Consumer paper ✓ /'�' atimall . United States Environmental Protection Agency Form Approved. EPA Washington, D.C. 20460 OMB No. 2040-0057 Water Compliance Ins ection Report Approval expires8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES " yr/mo/day Inspection Type Inspector Fac Type 1 I NI 2 15I 31 NCO034860 Ill 121 09/12/08 117 181 cl 191 SI 20I Remarks 211111111111111111111111111111 IIli iill III I I I I I I116 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA — --- -----Reserved---------------- 671 1.5 169 70141 711 NJ 72I N I 73 W 74 751 I I I I I I 180 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) Schneider Mills WWTP 09:47 AM 09/12/08 05/11/01 Exit Time/Date Permit Expiration Date 1170 NC Hwy 16 N Taylorsville NC 28681 01.10 PM 09/12/08 10/07/31 Name(s) of Onsite Representative(s)fTitles(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 Harry McPherson,PO Box 519 Taylorsville NC 28661/Vice Contacted President/828-632-8181/ 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 j Wesley N Bell "�) /, J(,�� MRO WQ//704-663-1699 Ext.2192/ 1 '7 ignature of Management Q A Reviqwer1 Agency/Office/Phone and Fax Numbers Date -' Mllaeci.qif Allocco MRO WQ//704-663-1699 Ext.2204/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type 3I NCO034860 I11 12I 09/12/08 I17 18ICI (cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) FACILITY SITE REVIEW: The previous inspection (performed on 10124/08) noted oil -stained soil adjacent to the oil storage tanks and the need for the facility to be covered under a Stormwater Permit. No oil -stained soil was observed adjacent to the oil storage tanks (during this inspection) and the Division issued a Stormwater Permit (Certificate of Coverage No. NCG170413) on 1123/09 following the receipt of the facility's application on 12/8/08. A No Exposure Certification has been submitted to the Division (received on 10/15/09)for the exlusion of a Stormwater Permit; however, no approval has been issued to date. Page # 2 Permit: NCO034860 Owner - Facility: Schneider Mills WVVTP Inspection Date: 12/08/2009 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 application? ■ n fl 171 Is the facility as described in the.permit? ■ n n n # Are there any special conditions for the permit? n n ■ n Is access to the plant site restricted to the general public? ■ n n n Is the inspector granted access to all areas for inspection? ■ n n n Comment: The subject permit expires on 7/31/10. Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? ■ n n ❑ Is all required information readily available, complete and current? ■ n n Are all records maintained for 3 years (lab. reg. required 5 years)? ■ n n n Are analytical results consistent with data reported on DMRs? ■ n n n Is the chain -of -custody complete? ■ n ❑ 171 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? ■ Has the facility submitted its annual compliance report to users and DWQ? ❑ n ■ ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? ❑ ❑ ■ n Is the ORC visitation log available and current? ■ n Is the ORC certified at grade equal to or higher than the facility classification? ■ ❑ n Is the backup operator certified at one grade less or greater than the facility classification? ❑ n n Is a copy of the current NPDES permit available on site? ■ n n Facility has copy of previous year's Annual Report on file for review? ❑ n ■ ❑ Page # 3 Permit: NCO034860 Owner - Facility: Schneider Mills wWTP Inspection Date: 12/08/2009 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 October 08 through September 09. No effluent limit violations were reported and all monitoring frequenices were correct. Flow was inadvertently transcribed onto the DMR on 2/31/09. An amended February 09 DMR will be resubmitted. The ORC must ensure all visitations (including Backup ORC) and times on -site are documented in the log book. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? ■ 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? n n ■ n Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? n ❑ ® n Comment: On -site field analyses (pH, total residual chlorine, temperature, dissolved oxygen) are performed under laboratory certification #5012. Water Tech Labs' (Certification #50) and R & A Laboratories, Inc. (Certification #34) have also been contracted to provide analytical support. The laboratory instrumentation used for the field analyses appeared to be properly calibrated (and documented). The ORC must ensure all pH check standard measurements are documented and the TRC meter is verified (annual curve verification) once every 12 months. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ ❑ ■ n Is sample collected below all treatment units? ■ ❑ ❑ ❑ Is proper volume collected? ■ ❑ n n Is the tubing clean? ■ n n F1 # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ n n n Is the facility sampling performed as required by the permit (frequency, sampling type representative)? ■ n n n Comment: The subject permit requires both composite and grab effluent samples. The facility was granted a variance by the MRO on 5/26/98 to collect time -based composite samples. The facility was collecting 130 ml. aliquots every 20 minutes. The ORC must ensure the composite sampling start time is documented during all sampling events. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ■ n n 0— Comment: Page # 4 Permit: NCO034860 Inspection Date: 12/08/2009 Owner - Facility: Schneider Mills VVWTP Inspection Type: Compliance Evaluation )perations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■ ❑ ❑ rl Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ ❑ ❑ fl Judge, and other that are applicable? Comment:. The facility appeared to be properly operated and well maintained. The ORC has incorporated a comprehensive process control program. In addition, the ORC adds microbial supplements and soda ash to maintain proper treatment levels at the wastewater facility. Bar Screens Yes No NA Nt Type of bar screen a.Manual ■ b.Mechanical n Are the bars adequately screening debris? ■ n n n Is the screen free of excessive debris? ■ n n n Is disposal of screening in compliance? ■ fl ❑ n Is the unit in good condition? ■ n n ❑ Comment: Flow Measurement- Influent Yes No NA NE # Is flow meter used for reporting? ■ n n n Is flow meter calibrated annually? ■ ❑ n f1 Is the flow meter operational? ■ n n n (If units are separated) Does the chart recorder match the flow meter? n fl ■ Comment: The flow meter is calibrated twice per year and was last calibrated on 8/3/09 by ISI Instrumentation Services, Inc. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? ■ n n n Are surface aerators and mixers operational? ■ n n fl Are the diffusers operational? n n ■ n 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 fl Page # 5 Permit: NCO034860 Owner - Facility: Schneider Mills VVWTP Inspection Date: 12/08/2009 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Is the DO level acceptable?(1.0 to 3.0 mg/1) ■ n n n Comment: Secondarj Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? ■ ❑ ❑ n Is the site free of excessive buildup of solids in center well of circular clarifier? ■ n n n Are weirs level? ■ n n n Is the site free of weir blockage? ■ n n n Is the site free of evidence of short-circuiting? ■ o n o Is scum removal adequate? ■ n n n Is the site free of excessive floating sludge? ■ o n n Is the drive unit operational? ■ n n n Is the return rate acceptable (low turbulence)? ■ ❑ 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 n Comment: Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? ■ n n ❑ Are the receiving water free of foam other than trace amounts and other debris? ■ n n o If effluent (diffuser pipes are required) are they operating properly? n n ■ n Comment: Outfall 001 effluent appeared slightly cloudy with trace suspended solids and no foam. Outfall 002 effluent appeared clear with no floatable solids or foam. The receiving stream did not appear to benegatively impacted. Aerobic Digester Yes No NA NE Is the capacity adequate? ■ n n n Is the mixing adequate? ■ n n n Is the site free of excessive foaming in the tank? ■ n n n # Is the odor acceptable? ■ n n # Is tankage available for properly waste sludge? ■ n n n Comment: The digester is equipped with both a mixer and diffused air system. Drying Beds Yes No NA NE Is there adequate drying bed space? ■ n n n Page # 6 Permit: NC0034860 Inspection Date: 12/08/2009 Drying Beds Is the sludge distribution on drying beds appropriate? Are the drying beds free of vegetation? Owner - Facility: Schneider Mills WWTP Inspection Type: Compliance Evaluation # 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: The dewatered sludge is transported (by facility staff) to the Alexander County.Landfill. The sludge is then transported to the Foothills Environmental Landfill in Lenoir, N.C. for final disposal. ■nnn ■nnn Page # 7