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Home My WebLink AboutNC0034860_Regional Office Historical File Pre 2018 (45)`O�OF WATF9QG Michael F. Easley, Govemor�''"'�/1j William G. Ross Jr., Secretary r "r North Carolina Department of Environment and Natural Resources March 6, 2007 Mr. Harry McPherson, Vice President Schneider Mills, Inc. Post Office Box 519 Taylorsville, North Carolina 28681 Alan W. Klimek, P.E. Director Division of Water Quality Subject: Notice of Deficiency 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 February 28, 2007 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. It is requested that a written response be submitted to this Office by March 27, 2007' addressing the deficiencies noted in the Laboratory, Effluent Sampling, and Drying Beds Sections of the report. In responding, please address your comments to the attention of Ms. Marcia Allocco. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Mr. Bell or me at (704) 663-1699. Sincerely, � "i. John Lesley Acting Regional Supervisor Surface Water Protection Enclosure cc: Alexander County Health Department mm GA NCDENR NNorthCarolina aturally Mooresville Regional Office Division of Water Quality Phone 704-663-1699 Customer Service Internet: www.ncwaterquality.org 610 East Center Ave, Suite 301 Mooresville, NC 28115 Fax 704-663-6040 1-877-623-6748 An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper 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 I r,I 2 15I 31 NCO034860 Ill 121 07/02/28 117 181 CI 19I sI 20I I Remarks 21I1II IIIIIIIIIIIIIIIIIIII1IIIIIIIIIIIIIIIIIII1116 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA --------------------------- Reserved ---------------------- 67I 1.5 169 701 31 711 NJ 721 N I 731 i! 174 751 I I I I I I 180 LLJ 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 09:24 AM 07/02/28 05/11/01 Exit Time/Date Permit Expiration Date 1170 NC Hwy 16 N Taylorsville NC 28681 12:00 PM 07/02/28 10/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Darren David Webb/0R.C/828-632-8181/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Harry MCPherson,PO Box 519 Taylorsville NC 28681/// 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 Wesley N Bell 1) 1 n �' MR.O WQ//704-663-1699 Ext.231/ � /I "7 Sig �a ure of Management Q A Review r� 1 Agency/Office/Phone and Fax Numbers Da e , Marcia . locco MRO WQ//704-235-2204/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type (cont.) 1 3I N00034860 I11 12I 07/02/28 1 17 18H Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) RECORD KEEPING SECTION cont'd: DMRs were reviewed for the period January 06 through December 06. No limit violations were reported and all monitoring frequencies were correct. The ORC must ensure all permit limits and sampling types (ex. "G"-Grab or "C"-Composite) are properly documented on future DMRs. Any treatment plant visitations (including holidays and facility shutdown periods) by the ORC and/or Backup ORC should be documented in the visitation log book. The TRC values were being reported below the lowest detection level verified on the TRC meter (100 ug/1). In addition, the ORC must ensure all values are properly calculated to determine the monthly average values. The overall record keeping system was well maintained. Page # 2 C Permit: NCO034860 Inspection Date: 02/28/2007 Owner - Facility: Schneider Mills WWTP 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 n # Are there any special conditions for the permit? n ❑ ■ Cl 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: 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 rl Are analytical results consistent with data reported on DMRs? ■ n 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 ■ ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? Cl ❑ ■ Is the ORC visitation log available and current? ■ n 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 Comment: See "Summary" Section for additional comments. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? ■ n 00 Page # 3 Permit: NCO034860 Inspection Date: 02/28/2007 Owner - Facility: Schneider Mills WWTP Inspection Type: Compliance Evaluation Laboratory Are all other parameters(excluding field parameters) performed by a certified lab? # Is the facility using a contract lab? Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? Comment: On -site field analyses are performed under laboratory certification #5012. Water Tech Labs (Certification #50) and R & A Laboratories (Certification #34) have also been contracted to provide analytical support. The TRC meter utilized for the effluent field analyses had not been properly calibrated/verified during the period of January 06 through November 13, 2006. Effluent Sampling Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: The Division approved time -based composite sampling at this facility on 5/26/98; however, the sampler was collecting 390 mi. aliquots once per hour. Tirne-based composite samples are to be collected at intervals of no greater than 20 minutes apart (during any 24-hour period) and the aliquots must be no less than 100 mis. Yes No NA NE ■nnn ■nnn ■nnn nn■n nn■n Yes No NA NE n n ■ n ■nnn ■nnn ■nnn ■nnn n■nn 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 n Comment: Operations & Maintenance Is the plant generally clean with acceptable housekeeping? Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ n n n Judge, and other that are applicable? Comment: The treatment units appeared to be properly operated and well maintained. The ORC incorporates a comprehensive process control program. Bar Screens Type of bar screen a.Manual vow Kl , uA MF: ■ Page # 4 Permit: NCO034860 Owner - Facility: Schneider Mills WWrP Inspection Date: 02/28/2007 Inspection Type: Compliance Evaluation Bar Screens Yes No NA NE 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 ■ o Comment: The bubbler type flow meter is calibrated once per year (minimum). The flow meter was last calibrated by ISI Instrumentation Services, Inc. on 1/5/07. 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 n m o 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 Is the DO level acceptable?(1.0 to 3.0 mg/1) n n ■ o Comment: The facility utilizes two mechanical aerators in the aeration basin. 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 n n Is the site free of weir blockage? ■ n n n Is the site free of evidence of short-circuiting? ■ n n n Page # 5 Permit: NCO034860 Owner - Facility: Schneider Mills WWTP Inspection Date: 02/28/2007 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is scum removal adequate? ■ n n Is the site free of excessive floating sludge? ■ n n n 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 n Comment: The ORC must ensure all clarifier weir joints are properly connected and sealed. 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 n ■ n Comment: The effluent appeared clear with trace suspended solids and no foam. The receiving strearn did not appear to be negatively impacted. Aerobic Diciester 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 # Is tankage available for properly waste sludge? ■ n n n Comment: Pging Beds Yes No NA NE Is there adequate drying bed space? ■ n n n Is the sludge distribution on drying beds appropriate? ■ n n n Are the drying beds free of vegetation? ■ n n n # Is the site free of dry sludge remaining in beds? ■ n n n Is the site free of stockpiled sludge? n ■ n n Is the filtrate from sludge drying beds returned to the front of the plant? ■ n n n # Is the sludge disposed of through county landfill? ■ Cl n n # Is the sludge land applied? n n ■ n Page # 6 C Permit: NC0034860 Inspection Date: 02/28/2007 Drying Beds (Vacuum filters) Is polymer mixing adequate? Owner - Facility: Schneider Mills WVVfP Inspection Type: Compliance Evaluation Comment: The sludge is dewatered and stockpiled on -site. The sludge is transported to the Foothills Environmental Landfill in Lenoir, N.C. for final disposal. The facility staff did not initiate adequate measures to prevent stormwater and groundwater contamination at the sludge storage/stockpiled area. Yes No NA NE n n ■ n Page # 7