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Home My WebLink Aboutnc0004685_Compliance Evaluation Inspection_20210121ROY COOPER Cvveme- MI HAEL 5. REGAN s:(rc.r r S. DANIEL SMITH f]rrrrex' NORTH CAROL INA Err wtronmeitr i Quality January 21, 2021 Mr. Todd Douthit, Manufacturing Manager Nippon Electric Glass 940 Washburn Switch Road Shelby, NC 28150 Subject: Compliance Bioassay Inspection NEG Industries/Shelby Facility NPDES Permit No. NC0004685 Cleveland County Dear Mr. Douthit: Enclosed is a copy of the Compliance Sampling Inspection for the inspection conducted at the subject facility on January 19, 2021, by Ori Tuvia. John Littlejohn and Richard Young's cooperation during the site visit was much appreciated. The facility continues to do excellent job doing preventive repairs and maintenance. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed report. At the time of the inspection split samples for Toxicity were taken, the results will be forwarded to you via separate correspondence. If you any questions, please contact Ori Tuvia at (704) 235-2190, or via email at ori.tuvia@ncdenr.gov. Sincerely, ,-DocuSigned by: A44444# H P444.4 '-F161FB69A2D84A3... for W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources Cc: NPDES Unit, MRO Files (Laserfiche) State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations Mooresville Regional Office 1610 East Center Avenue, Suite 301 I Mooresville, North Carolina 28115 704 663 1699 United States Environmental Protection Agency E PA Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction 1 IN Code 2 �-I5 NPDES yr/mo/day Inspection Type Inspector Fac I 3 I NC0004685 111 121 21/01/19 117 18 i =3 i 19 Li i 201 Type 211 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I I 1 1 1 1 1 1 1 1 1 I 1 I 1 111 1 1 1 1 1 1 1 I 1 166 Inspection 67I2.0 Work Days Facility Self -Monitoring I 70I4 Evaluation Rating I 71 B1 ID I 72 QA I N I 73I Reserved I 174 L� 1 751 1 1 1 1 1 1 180 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Electric Glass Fiber America LLC 940 Washburn Switch Rd Shelby NC 28150 Entry Time/Date 08:45AM 21/01/19 Permit Effective Date 14/05/01 Exit Time/Date 11:OOAM 21/01/19 Permit Expiration Date 18/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// John Charles Littlejohn/ORC/704-434-2261/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Richard M Young,940 Washburn Switch Rd Shelby NC 28150//704-434-2261/7044340792 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran Sludge Handling Dispos Facility Site Review Effluent/Receiving Wate Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) Ori ATuvia of Inspector(s) DocuSigned Agency/Office/Phone and Fax Numbers Date by: DWR/MRO WQ/7o4-663-1699/ BB057A2DE017498... ' 1/21/2021 Signature of Man Andrew Pitn -•neatdsQQr1Rgviewer Agency/Office/Phone and Fax Numbers Date r p444444/ H P'/R/MRO WQ/704-663-1699 Ext.2180/ 1.21.21 F161FB69A2D84A3,._ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 NPDES yr/mo/day 31 NC0004685 111 121 21/01/19 I17 Inspection Type 18 EH! 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0004685 Inspection Date: 01/19/2021 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Bioassay Compliance Permit (If the present permit expires in 6 months or less). Has the permittee submitted a new application? Is the facility as described in the permit? # Are there any special conditions for the permit? Is access to the plant site restricted to the general public? Is the inspector granted access to all areas for inspection? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The subject permit expired on 8/31/2018, a permit renewal application was sent. Complaince Bioassy Inspection. Split samples for toxcity. Record Keeping Are records kept and maintained as required by the permit? Is all required information readily available, complete and current? Are all records maintained for 3 years (lab. reg. required 5 years)? Are analytical results consistent with data reported on DMRs? Is the chain -of -custody complete? 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? (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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • • • • • • ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ Comment: The records reviewed during the inspection were organized and well maintained. DMR's, COC's ORC logs, calibration logs and Process control logs for october 2020 were reviewed. Laboratory Yes No NA NE Page# 3 Permit: NC0004685 Inspection Date: 01/19/2021 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Bioassay Compliance 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: Inspected during Covid-19 no labratory review 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 less than or equal to 6.0 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: The subject permit requires effluent composite and grab samples. Upstream / Downstream Sampling Is the facility sampling performed as required by the permit (frequency, sampling type, anc sampling location)? 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 Judge, and other that are applicable? Yes No NA NE ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The facility appeared to be properly and well maintained. The operations staff incorporate comprehensive process control program with all measurements being properly documented and maintained on -site. The facility is equipped with computer/alarm notification system to assist the wastewater staff in the operation of the treatment units/processes. The facility continues to do excellent job doing preventive repairs and maintenance. Bar Screens Type of bar screen Yes No NA NE Page# 4 Permit: NC0004685 Inspection Date: 01/19/2021 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Bioassay Compliance Bar Screens a.Manual b.Mechanical Are the bars adequately screening debris? Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? Comment: Equalization Basins Is the basin aerated? Is the basin free of bypass lines or structures to the natural environment? Is the basin free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? Comment: Primary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Both primaries were operational and in service. Chemical Feed Yes No NA NE Page# 5 Permit: NC0004685 Inspection Date: 01/19/2021 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Bioassay Compliance Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Chemical additions to selected treatment processes include the following: plymers, bentonite/clay mixture, ferric chloride, aluminum, lime and defoamer. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? • ❑ ❑ ❑ Are surface aerators and mixers operational? • ❑ ❑ ❑ Are the diffusers operational? • ❑ ❑ ❑ Is the foam the proper color for the treatment process? • ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? • ❑ ❑ ❑ Is the DO level acceptable? • ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/I) ❑ ❑ • ❑ Comment: The facility uses two aeration basins operated in series. The first aeration tank is equipped with diffused and mechanical aeration and the second aeration tank is equipped with diffused aeration. Secondary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: All three secondary clarifiers were operational and in service at the time of the inspection. Page# 6 Permit: NC0004685 Inspection Date: 01/19/2021 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Bioassay Compliance Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Filtration (High Rate Tertiary) Type of operation: Is the filter media present? Is the filter surface free of clogging? Is the filter free of growth? Is the air scour operational? Is the scouring acceptable? Is the clear well free of excessive solids and filter media? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ Comment: The facility is equipped with a traveling bridge tertiary filter. The filter backwash is returned tc the head of the wastewater plant. Flow Measurement - Effluent # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? Comment: The flow meter is calibrated/verified twice a year by Clear Water Inc. 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: Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Yes No NA NE ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 7 Permit: NC0004685 Inspection Date: 01/19/2021 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Bioassay Compliance Solids Handling Equipment Yes No NA NE Is the site free of sludge buildup on belts and/or rollers of filter press? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? ■ ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ Comment: Thickened sludge is dewatered on a belt press. Dewatered solids are transported to the county landfill for final disposal by waste pros. Page# 8