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Home My WebLink AboutNC0000892_Compliance Evaluation Inspection_20210107ROY COOPER Governor MICHAEL S. REGAN Secretary S. DANIEL SMITH Director Mr. Brian Reddy Plant Manager Arclin USA, Inc. 790 Corinth Road Moncure, NC 27559 NORTH CAROLINA Environmental Quality January 7, 2021 Subject: Compliance Evaluation Inspection Arclin USA, Inc. — Moncure Plant Permit No. NC0000892 Chatham County Dear Mr. Reddy: On December 11, 2020, Cheng Zhang of the Raleigh Regional Office (RRO) conducted a compliance evaluation inspection of the subject facility. The assistance provided by Mr. Chris Lamm, the backup Operator in Responsible Charge (ORC), and Mr. Bowman Harvey, the HSE Coordinator, was appreciated as it facilitated the inspection process. The inspection report is attached. The following observations were made: Arclin USA, Inc. — Moncure Plant is permitted to discharge at a rate of 0.1 MGD and consists of: aerated equalization (EQ) basin with surface aerators, active sludge aeration basin with surface aerators, secondary clarifier, sludge drying beds, effluent flow meter and composite sampler. The plant discharges into the Haw River, a WS-IV waters in the Cape Fear River basin. Current permit expires on July 31, 2016. The facility submitted permit renewal application On March 28, 2016, which is in review by the Division of Water Resources. 2. The facility has seven sludge drying beds (four 20 ft x 50ft ones and three 25 ft x 50 ft ones). The facility does not have tertiary sand filters. At the time of inspection, all beds were in use. Wasted sludge is injected and mixed with polymer before being planced on the beds. Dried sludge was placed in a storage area 9 (about one third full) adjacent to the beds and ready to be hauled away for composting by McGill Composting. Drying beds and sludge storage area are covered by roof. 3. Domestic sewage is pumped to the EQ basin from the domestic pump station. Process water is also pumped to the EQ basin. EQ basin has three surface aerators. Aeration basin also have three surface aerators. These aerators are turned on or off based on the DO levels at the basins. At the time of inspection, DO at aeration basin was 6.95 mg/L, which was higher than needed. norDE Q�� North Carolina Department of Environmental Quality I Division of Water Resources r rnani wa Raleigh Regional Office 13800 Barrett Drive I Raleigh, North Carolina 27609 oep'm 't ie n��menni"i;� 919.791.4200 4. Mixed liquor from aeration basin is pumped to the secondary clarifier, polymers is fed to facilitate settling of solids. At the time of inspection, sludge blanket was normal (2 feet in the 8 feet deep clarifier). 5. The ORC maintains a daily logbook. Lab results, chain -of -custody forms, and Discharge Monitoring Reports (DMRs) were complete and current, kept in good order and ready for review. February 2020 DMR data were compared to lab bench sheets; no data transcription errors were noted during the inspection. 6. The right of way to the Outfall 001 was well maintained. The effluent was observed to be clear and free of solids. No visible impacts were noted immediately downstream the effluent pipe. Outfalls 002, 003, and 004 (stormwater discharge outfalls) was also maintained and accessible. 7. The Stormwater Pollution Prevention Plan was reviewed and found compliant with permit requirements. Qualitative and analytical monitoring results were also reviewed. The facility had multiple benchmark exceedances (TSS, BOD, formaldehyde) and took appropriate tier actions with these exceedances. 8. Field lab parameter (Certificate No. 5285) calibration and analysis records were reviewed during the inspection. If you have any questions regarding the attached reports or any of the findings, please contact Cheng Zhang at: (919) 791-4200 (or email: cheng zhang,@ncdenr.gov). Sincerely, IDocuSigned dby: UAAA),SSX f, haWAt,(, B2916E6AB32144F... Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources Attachments: EPA Water Compliance Inspection Report Cc: Central Files w/attachment (Laserfiche) Raleigh Regional Office w/attachment David Lorbacher, ORC (electronic copy only) 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 IN 1 2 u 3 I NCO000892 I11 121 20/12/11 I17 18I � I 19 I s I 201 I 211IIIII 111111III II III III1 I I IIIII IIIIIIIII II r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 I 72 I n, I 71 I 74 79 I I I I I I I80 701� I 711 L LJ L -1 I I 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 Dermit Number) 10:OOAM 20/12/11 13/07/01 Arclin USA, Inc 790 Corinth Rd Exit Time/Date Permit Expiration Date Moncure NC 27559 12:30PM 20/12/11 16/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Bowman Harvey/Coordinator HSE/919-545-5753 / David Wayne Lorbacher/ORC/919-542-2526/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Bowman Harvey,790 Corinth Rd Moncure NC 27559/HSE Manager/919-545-5753/ Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran 0 Sludge Handling Dispo: Facility Site Review Effluent/Receiving Wate Laboratory 0 Storm Water 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 cusignedby: DWR/RRO WQ/919-791-4200/ Cheng Zhang E,1,71508E1EC41F 1/7/2021 ... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date by: 1/7/2021 FDocusigned w'SS& f, DWR/WQROS-RRO/919-791-4232 PA 2916E6AB3 1k ) EPA �orm ;ibbU ;i (FZev 9-94 Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0000892 I11 12I 20/12/11 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Stormwater Discharge Outfalls (SDO) 002, 003, and 004 were observed during the inspection and found maintained and accessible. Stormwater pollution prevention plan was reviewed and found compliant with permit requirements. Qualitavie and analytical monitoring data were reviewed. The facility had multiple benchmark exceedances (TSS, BOD, formaldehyde) and took appropriate tier actions with these exceedances. Page# Permit: NC0000892 Owner - Facility: Arclin USA, Inc Inspection Date: 12/11/2020 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ❑ ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The facility analyzes mixed liquor suspended solids, temperature, DO, and sludge blanket for process control Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ MEI application? Is the facility as described in the permit? ❑ 0 ❑ ❑ # Are there any special conditions for the permit? ❑ ❑ 0 ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? ❑ ❑ ❑ ❑ Comment: Current permit expired on July 31, 2016. Renewal application was received by the Division on March 28, 2016. The facility has seven sludge drying beds; "the four sand filter beds" listed in treatment units is misleading and may cause confusion. The facility does not have tertiary filters. Pump Station - Influent Is the pump wet well free of bypass lines or structures? Is the wet well free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Is SCADA telemetry available and operational? Is audible and visual alarm available and operational? Yes No NA NE ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ Comment: A simplex pump station pumps domestic sewage into EQ basin. Process wastewater is pumped to EQ basin. There's an process water overflow line in case of pump failure. Equalization Basins Yes No NA NE Is the basin aerated? 0 ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the basin free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Page# 3 Permit: NC0000892 Inspection Date: 12/11/2020 Owner - Facility: Arclin USA, Inc Inspection Type: Compliance Evaluation Equalization Basins Yes No NA NE Are float controls operable? ❑ ❑ 0 ❑ Are audible and visual alarms operable? ❑ ❑ 0 ❑ # Is basin size/volume adequate? E ❑ ❑ ❑ Comment: Three surface aerators/mixers. Water is usually pumped into aeratio basin. There is an overflow line connectina EQ basin and aeration basin. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? 0 ❑ ❑ ❑ Are the diffusers operational? ❑ ❑ 0 ❑ Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? 0 ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/I) 0 ❑ ❑ ❑ Comment: Three surface aerators/mixers. DO at basin was 6.95 mg/L. Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: Sludge blanket was about two feet. Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑ Page# 4 Permit: NC0000892 Inspection Date: 12/11/2020 Chemical Feed Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Owner - Facility: Arclin USA, Inc Inspection Type: Compliance Evaluation Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: Polymer is fed to mixed liquor before entering clarifier. Polymer is infected into wasted sludge before being placed on drying beds. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: Flow meter was calibrated on January 12, 2020. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? M ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: Drying Beds Yes No NA NE Is there adequate drying bed space? 0 ❑ ❑ ❑ Is the sludge distribution on drying beds appropriate? 0 ❑ ❑ ❑ Are the drying beds free of vegetation? 0 ❑ ❑ ❑ # Is the site free of dry sludge remaining in beds? 0 ❑ ❑ ❑ Is the site free of stockpiled sludge? 0 ❑ ❑ ❑ Is the filtrate from sludge drying beds returned to the front of the plant? 0 ❑ ❑ ❑ # Is the sludge disposed of through county landfill? ❑ 0 ❑ ❑ # Is the sludge land applied? ❑ 0 ❑ ❑ (Vacuum filters) Is polymer mixing adequate? ❑ ❑ 0 ❑ Page# 5 Permit: NC0000892 Inspection Date: 12/11/2020 Drying Beds Owner - Facility: Arclin USA, Inc Inspection Type: Compliance Evaluation Yes No NA NE Comment: The facility has seven drying beds (three larger ones and four smaller ones, all under roof). Dried sludge was place at the storage area adjacent to the beds (also under roof). All seven beds were in use. Sludge storage area was about 1/3 full. Dried sludge is hauled away by McGill for composting. Laboratory Are field parameters performed by certified personnel or 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 less than or equal to 6.0 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: The facility holds Field Lab Certification # 5258. Effluent Pipe Is right of way to the outfall properly maintained? Are the receiving water free of foam other than trace amounts and other debris? If effluent (diffuser pipes are required) are they operating properly? Comment: Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Two pumps are used to return or waste slud aeration basin. Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Sludae can be retured to EQ basin or Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ Dates, times and location of sampling Page# 6 Permit: NC0000892 Inspection Date: 12/11/2020 Record Keeping Name of individual performing the sampling Results of analysis and calibration Dates of analysis Owner - Facility: Arclin USA, Inc Inspection Type: Compliance Evaluation 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? (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operatc on each shift? Is the ORC visitation log available and current? Is the ORC certified at grade equal to or higher than the facility classification? Is the backup operator certified at one grade less or greater than the facility classification' Is a copy of the current NPDES permit available on site? Facility has copy of previous year's Annual Report on file for review? Comment: Yes No NA NE ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Page# 7