NC0034860_Regional Office Historical File Pre 2018 (53)

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IMPORTAN

M• Darren Webb
IIIs I'�1C\��`'* PSchneider .O. Box 51911s Inc.
.i Taylorsville, NC 28681
July21, 2003
Mr. Richard Bridgeman
NCDENR
Mooresville Regional Office
919 North Main St
Mooresville, NC 28115
Notice of violation
Schneider Mills Inc. WWTP
NPUES Permit# N00034860
Alexander County, NC
Dear Mr. Bridgeman:
This letter is to address the self -monitoring section of the compliance evaluation inspection
regarding the NOV's for December 2002 and March 2003. There was also a daily maximum effluent
sulfide violation on 20 March 2003. 1 have been researching this sulfide problem. Our new permit
started November 2002. Prior to this time sulfide was not on our permit After I received high readings
for sulfide from the lab in December 2002, 1 started reading books and consulting colleagues to find out
more about sulfide and its possible sources. I have spoken with Joe Corporon, John Lesley(NCDENR),
and Tony Gregg(Water Tech Labs) about the issue. In addition, I have had samples of `size' (a
chemical treatment used on yam which is common in all textile facilities) analyzed, and found the
results to have high sulfide levels. In response to this information, I have sent letters to the size
manufacturers to see what they can do to help us resolve the problem. On 23 May 2003, 1 started
adding MB-17 to our waste treatment system. This is a special blend of bacteria that is designed to
help reduce sulfide concentration. This approach seems to be working, however any additional advice
or support would be welcome. Please feel free to contact Darren Webb or Gary Elder at (828) 632-
8181 with any questions or comments. Thank you for your time.
Sincerely,
Darren Webb
Water Plant Manager
RES
JUL 2 2 200
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�oF W ArE9
Michael F. Ea I Governor V
William G. Ross, Jr.,Secretary
North Carolina Department of Environment and Natural Resources
> Alan W. Klimek, P.E., Director
O `C Division of Water Quality
Coleen Sullins, Deputy Director
Division of Water Quality
July 15, 2003
CERTIFIED MAIL 70012510 0004 8286 7041
RETURN RECEIPT REQUESTED
Mr. Harry McPherson, Vice President
,Schneider Mills Inc.
Post Office Box 519
Taylorsville, North Carolina 28681
Subject: Notice of Violation
Compliance Evaluation Inspection
Schneider Mills WWTP
NPDES Permit No. NCO034860
Alexander County, N.C.
Dear Mr. McPherson:
Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection -
conducted at the subject facility on July 10, 2003 by Mr. Wes Bell of this Office. Please advise the
faFijjty's Operator -in -Responsible Charge of our findings by forwarding a copy of the enclosed report
to him.
This report is being issued as a Notice of Violation (NOV) due to the limit violations of the
subject NPDES Permit and North Carolina General Statute (G.S.) 143-215.1 as detailed -in the Self -
Monitoring Section of the attached report. Pursuant to G.S. 143-215.6A, a civil penalty of not
more than twenty-five thousand dollars ($25,000.00) per violation, per day may be assessed against
any person who violates or fails to act in accordance with the terms, conditions, or requirements of
any permit issued pursuant to G.S. 143-215.1.
. It is requested that a written response be submitted to this Office by August 8, 2003,
addressing the limit violations noted in the Self -Monitoring Section of the report. In responding,
please address your comments to the attention of Mr. Richard Bridgeman.
NCDENR
Customer Service Mooresville Regional Office, 919 North Main Street, Mooresville, NC 28115 PHONE [phone]
1 877-623-6748 FAX [phone]

Mr. Harry McPherson
Notice of Violation
Page Two
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 [phone].
Sincerely,
VL
\ ,c� D. Rex Gleason, P.E.
Water Quality Regional Supervisor
Enclosure
cc: Alexander County Health Department

d
United States Environmental Protection Agency
. Washington, D.C. 20460
F
Form Approved.
P A"t
OMB No. 2040-0057
Water Compliance Inspection Report
Approval expires B-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 I N I 2 1 5 1 3 I NCO034860 111 121 03/07/2.0 I.17 18 I -, t 19 I C I 20 Li
Ll L J LJ LJ
Remarks
21111, 111, 11111 111111111111111111111111111 111111166
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved
671 1.5 1 69 70 L,J 71 it„ 72 L„ 73 I 74
751 I I I I I I 180
Section B: FacilityData
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)
11:13 AM 03/07/10
02/11/01
Schneider Mills Incorporated
Exit Time/Date
Permit Expiration Date
1170 NC Hwy 16 North
Taylorsville NC 28681
01:15 PM 03/07/10
05/07/31
Name(s) of Onsite Representative(s)/fitles(s)/Phone and Fax Number(s)
Other Facility Data
Darren David Webb/ORC/828-632-0876/
Name, Address of Responsible Officialfritle/Phone and Fax Number
Contacted
Gary D E1der,P O Box 5i9 Taylorsville NC 28681//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)
PERMIT:
The permit adequately describes the facility. The Division issued a permit correction on 12/9/02
regarding changes in the sample frequency and type (Outfall 002) for flow, TSR, and iron.
RECORDS AND REPORTS:
DMRs, chain of custody forms, laboratory analyses, calibration data, Operator -in -Responsible Charge
(ORC)visitation/daily operation and maintenance log, process control data, flow charts, and sludge
(coot.)
records were reviewed. The records were in-depth and well maintained.
FACILITY
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Wesley N Bell MRO WQ//704-663-1699/704-663-6040
7 A6 to
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.

I
NPDES
yr/mo/day
31 NC0034860 111 121 03/07/10 1
17
Inspection Type
18 i�c,L_J
(cont.) 1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
SITE REVIEW/OPERATIONS & MAINTENANCE:
The treatment facility appeared to be operating properly and the surrounding grounds were well
maintained_ The mixed liquor suspended solids were adequately mixed and well oxygenated. Soda ash and
bacterial enzymes are added to the aeration basin to enhance treatment. Polymers are also utilized as a
settling aid. Bar screenings are properly disposed. The facility is appropriately staffed with
certified operators. The ORC was very knowledgeable of the treatment processes and equipment used at the
facility_
The process control program includes DO, pH, MLSS, settleability tests, microscopic examinations, and
sludge blanket measurements. Sludge wasting'is based on the MLSS measurements.
Although the facility provides restricted access to the WWTP, the aeration basin and clarifier did not
have appropriate railing. Please be advised that Subpart D, 1910.23(c), of 29 CFR Part 1910, which
contains the Occupational Safety and Health Standards for General Industry, specifies that "Every
open -sided floor or platform 4 feet or more above adjacent floor or ground level shall be guarded by
standard railing.._." The facility must insure that adequate grating and railing is installed for the
safety of the operators and inspectors.
LABORATORY:
Water Tech Laboratories, Inc. (Certification # 50) in Granite Falls, N.C. and R & A Laboratories
(Certification #34) in Kernersville, N.C. have been contracted to provide analytical support_ All
on -site field analyses are performed under laboratory certification # 5012. Please refer to Mr. Chet
Whiting's (Division's Laboratory Certification Unit) inspection report for the field laboratory
certification inspection performed on 7/10/03.
1
EFFLUENT/RECEIVING STREAM:
The effluents from Outfall 001 and 002 were clear with no suspended solids or foam. The receiving stream
did not appear to be negatively impacted.
SELF -MONITORING PROGRAM:
Self -monitoring reports (for Outfalls 001 and 002) were reviewed for the period April 2002 through March
2003, inclusive. Daily maximum effluent sulfide violation was reported on 3/20/03. Monthly average
effluent sulfide violations were reported for December 2002 and March 2003. All monitoring frequencies
and locations appeared correct. All samples appeared to be properly preserved and meet the required
holding times. The facility was granted a variance by the Division to collect time -based composite
samples, provided that the flow from the facility does not vary by more than 30$.
FLOW MEASUREMENT:
The influent is continuously measured by a parshall flume and an ISCO bubbler type flow meter with
totalizer and chart recording_ The flow meter is calibrated 2/yr by ISI Instrumentation Services, Inc.
The flow meter was last calibrated on 1/29/03.
SLUDGE DISPOSAL:
Dewatered sludge is taken to the Foothills Landfill in Lenoir, N.C. by Republic Services, Inc. for final
disposal.

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Article Addressed to:
6 HARRY McPHERSON, VICE PRES.
SCHNEIDER MILLS INC.
TO BOX 519
!TAYLORSVILLE NC 28681
'wghvb 7/16/03
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