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Home My WebLink AboutNC0034860_Regional Office Historical File Pre 2018 (42)Michael F. Easley, Governor William G. Ross Jr., Secretary North Carolina Department of Environment and Natural Resources Coleen H. Sullins. Director Division of Water Quality November 14, 2008 Mr. Harry McPherson, Vice President Schneider Mills, Inc. Post Office Box 519 Taylorsville, North Carolina 28681 Subject: Compliance Evaluation Inspection Schneider Mills WWTP NPDES Permit No. NCO034860 Alexander County, NC Dear Mr. McPherson: Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on October 24, 2008 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. . During the inspection, it was determined that the facility would be required to apply for a Stormwater Permit due to the type of industrial activity (textile) and the presence of stormwater outfalls. Stormwater Permits are required under the authority of G.S. 143-215.1 and the application form (Notice of Intent) can be obtained from the Division's website address (Stormwater Section): http://h2o.ehnr.state.nc.us/su/Forms Documents.htm. The Notice of Intent (NOI) with the supporting documentation and fee should be submitted to the Division (address listed on the NOI) by December 15, 2008. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Mrs. Allocco, Mr. Bell or me at (704) 663-1699. Sincerely, Robert B. Krebs Surface Water Protection Regional Supervisor Enclosure cc: Alexander County Health Department MW M NC®ENR N it arolma Naturally Mooresville Regional Office Division of Water Quality Phone 704-663-1699 Internet: www.newaterquality.orr 610 East Center Ave, Suite 301 Mooresville, NC 28115 Fax 704-663-6040 An EQual OpportunitvlAffirmative Action Employer — 50% Recycled110% Post Consumer Paper Customer Service 1-877-623-6748 United States Environmental Protection Agency Form Approved. Washington, D.C. 20460 EPA 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 I NI 2 15I 31 NCO034860 111 121 08/10/24 117 18I CI 19I sI 201 II Remarks 211IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII6 `Inspection Work Days Facility Self -Monitoring Evaluation Rating 131 QA - ---------------------------Reserved---------------------- 67I 1.5 169 70I 4 I 711 N I 72I.N I 73 LU 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) 09:40 AM 08/10/24 05/11/01 Schneider Mills WWTP Exit Time/Date Permit Expiration Date 1170 NC Hwy 16 N Taylorsville NC 28681 01:00 PM 08/10/24 10/07/31 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 Harry McPherson,PO Box 519 Taylorsville NC 28681/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)&;J/f Agency/Office/Phone and Fax Numbers Date / Wesley N Bell r, � MRO WQ//704-663-1699 Ext.2192/ Si nature of Management Q A R ie r Agency/Office/Phone and Fax Numbers ate Marcia Allocco MRO WQ//704-663-1699 Ext.2204/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. 11 Page # 1 NPDES yr/mo/day Inspection Type 3I NCO034860 I11 12I 08/10/24 l 17 18I i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) FACILITY SITE REVIEW: During the inspection, oil had been discharged onto the ground adjacent to the pumping system for the oil storage tank (manufacturing area). The oil contaminated soil must be remmoved and properly disposed, with all affected areas being restored (as close as possible) back to the condition existing prior to the discharge. The failure to cleanup oil discharges can subject the facility to civil penalties up to $5,000.00. Page # 2 Permit: NCO034860 Owner - Facility: Schneider Mills VOh7P Inspection Date: 10/2412008 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 n n Is the facility as described in the permit? ■ n ❑ n # Are there any special conditions for the permit? n n ■ Cl Is access to the plant site restricted to the general public? ■ n n Is the inspector granted access to all areas' for inspection? ■ n n n Comment: Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? ■ n n n Is all required information readily available, complete and current? ■ n 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 Is the chain -of -custody complete? ■ n n n 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? ■ n n n Has the facility submitted its annual compliance report to users and DWQ? n n ■ n (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? n n ■ n Is the ORC visitation log available and current? ■ n n Is the ORC certified at grade equal to or higher than the facility classification? ■ n n n Is the backup operator. certified at one grade less or greater than the facility classification? ■ n n n Is a copy of the current NPDES permit available on site? ■ n n n Facility has copy of previous year's Annual Report on file for review? n n ■ n Page # 3 Permit: NCO034860 Owner - Facility: Schneider Mills WWrP Inspection Date: 10/24/2008 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: DMRs were reviewed for the period August 07 through July 08. No limit violations were reported for Outfalls 001 and 002. Only one effluent total suspended solids value (Outfall 002) was reported in May 08. The Division separately addressed this monitoring violaiton by the issuance of an NOV. All monitoring frequencies were correct for Outfall 001. The facility staff must ensure that the correct permit limits and all ORC/Backup ORC visitations are properly documented on future DMRs. In addition, the facility staff must ensure that copies of the sludge records are kept at the WWTP. Overall, the facility's records were organized and well maintained. 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? ■ D D n # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? n ■ n Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? n ❑ ■ n Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? n n ■ n Comment: On -site field analyses are performed under laboratory certification #5012 (Schneider Mills). Water Tech Labs (Certification #50) and R & A Laboratories (Certification #34) have also been contracted to provide analytical support. The laboratory instrumentation utilized for field analyses appeared to be properly calibrated. The facility staff must ensure that the effluent total residual chlorine values (Outfall 002) are not reported below the lowest standard (100 ug/1) verified on the chlorine meter. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? n n ■ n Is sample collected below all treatment units? ■ ❑ n n Is proper volume collected?' ■ fl ❑ n Is the tubing clean? ■ Cl n rl # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ ❑ Cl n Is the facility sampling performed as required by the permit (frequency, sampling type representative)? ■ Cl n n Comment: The Division approved time -based composite sampling on 5/26/98. The facility is collecting 130 ml. aliquots every 20 minutes. 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 Comment: Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■ n n ❑ Page # 4 Permit: NCO034860 Inspection Date: 10/24/2008 Owner - Facility: Schneider Mills WWfP Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, D0, Sludge ■ 0 n n Judge, and other that are applicable? Comment: The facility appeared to be properly operated and well maintained at the time of the inspection. The facility staff incorporate a comprehensive process control program. Bar Screens Yes No NA NE 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? ■ n n n Is the unit in good condition? ■ n 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 n n Is the flow meter operational? ■ n n n (If units are separated) Does the chart recorder match the flow meter? n n ■ n Comment: The flow meter is calibrated twice per year and was last calibrated on 7/30/08 by IS[ 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 n Are the diffusers operational? ❑ n ■ Cl 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 Page # 5 Permit: NC0034860 Owner - Facility: Schneider Mills WWTP Inspection Date: 10/24/2008 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Comment: Microbial supplements and soda ash are added to the aeration basin on an as needed basis. 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? ■ D ❑ D Are weirs level? ■ D n D Is the site free of weir blockage? ■ n n n Is the site free of evidence of short-circuiting? ■ n n D Is scum removal adequate? ■ D D D Is the site free of excessive floating sludge? ■ n D D 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? ■ D n D Is the sludge blanket level acceptable? (Approximately '/< of the sidewall depth) ■ D D n Comment: A cationic polymer is added in the clarifier influent to aid in settling. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? ■ D n D Are the receiving water free of foam other than trace amounts and other debris? ■ D D D If effluent (diffuser pipes are required) are they operating properly? In n ■ ❑ Comment: The effluent appeared slightly turbid with no foam. The receiving stream did not appear to be negatively impacted. Aerobic Digester Yes No NA NE Is the capacity adequate? D D n ■ Is the mixing adequate? ■ D D D Is the site free of excessive foaming in the tank? ■ n Cl n # Is the odor acceptable? ■ D D D # Is tankage available for properly waste sludge? ■ D n D Comment: Drying Beds Yes No NA NE Is there adequate drying bed space? ■ n n D Is the sludge distribution on drying beds appropriate? ■ D ❑ Page # 6 Permit: NC0034860 Inspection Date: 10/24/2008 Drying Beds Are the drying beds free of vegetation? # Is the site free of dry sludge remaining in beds? Owner - Facility: Schneider Mills WWTP Inspection Type: Compliance Evaluation 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: All sludge has been removed and properly disposed from the sludge stockpile/storage area. The facility staff currently transport the dewatered sludge to the county landfill. The sludge is then transported from the county landfill to the Foothills Environmental Landfill in Lenoir, N.C. for final disposal. ■nnn ■nnn ■nnn ■ n n n ■nnn n n ■ n n n ■ ❑ Page # 7