NC0000272_Compliance Evaluation Inspection_20160701

PAT MCCRORY
FI L DONALD R. VAN DER VAART
Secretary
S. JAY ZIMMERMAN
Water Resources Director
ENVIRONMENTAL OUALITV
July 1, 2016
Mr. Brian Satterfield, Manager, EHS&S Business Unit
Blue Ridge Paper Products Inc.
P.O. Box 4000
Canton NC 28716
SUBJECT: Compliance Evaluation Inspection
Blue Ridge Paper Products Inc. Canton Mill
Permit No.: NC0000272
Haywood County
Dear Mr. Satterfield:
On June 23, 2016, Mika] Willmer, and I conducted a Compliance Evaluation Inspection of the NPDES
Discharge Permit that serves the Blue Ridge Paper Products Inc. Canton Mill WWTP. Based on
records reviewed, on-site evaluation and interviews with staff, the system was determined to be in
compliance with permit NC0000272. An inspection report is attached for your records with findings
summarized. The system and its components appear to be well maintained and operated.
Two items of significance were ongoing at the time of the inspection.
1. The facility has reported repeated exceedances of permit limits for Fecal Coliform during the past
month, despite excess chlorine residual mixing with the domestic influent. Plant staff have been
diligent in communicating the issue to DEQ Regional staff, and in working to address the problem.
Similar and/or related problems have occurred in the past. The facility is encouraged to investigate both
short term (return to compliance with discharge limits) and long term (engineering solutions to address
and eliminate potential reoccurrence) solutions(e.g. a chlorine contact basin).
2. In a letter dated 23 June 2016, the mill has requested to perform a maintenance outage in early
August to minimize environmental impact due to ongoing low flow conditions in the Pidgeon River.
This approach was utilized in 2008. DEQ has no exceptions to this approach.
Stain of North Carolina I Ei vhonmental Quality I Water Resources
2090 U.S.Highway 70 Swammr0e,NC 28778
928 296 4500

The assistance of Nick McCracken, ORC and Wanda Webb, BORC during the inspection was greatly
appreciated, as Mr. McCracken is highly knowledgeable about the WWTP and its components. If there
are questions or additional information is needed regarding system operation, maintenance, or permit
questions, please feel free to contact me at 828-296-4500. Please refer to the enclosed inspection report
for additional observations and comments.
Sincerely, `
Tim Heim, P.E.
Environmental Engineer
Enc.
cc: Nick McCracken, ORC
MSC 1617-Central Files-Basement
Asheville Files
\\Wp3dnfpO6.eads.neads.net\data\WR\WQ\Haywood\Wastewater\Industrial\Blue Ridge Paper 00272\CEI letter 07-01-2016.doe

PP
United States Environmental Protection Agency Form Approved.
EPA Washington,D.C.20460 OMB No.204MO57
Water Compliance Inspection Report Approval expiresB-31-98
Section A:National Data System Coding(i.e.,PCS)
Transaction Code NPDES yr/molday Inspection Type Inspector Fac Type
1 IN 1 2 IS I 3 I N00000272 I11 12 16/06/23 17 18 L, j 19 1 c I 201L I
211 1 1 1 I I I I I I 11 I I I I I I I I I I I I 1 I I I I I I I I I I 11 I I I 1- EI r6
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 CA Reserved
67I I 701 1 71 I L
1 72 1 uJ I I I 1 731 I 174 75I I I I I I I I80
L� LJ it 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) 01:00pm 16/06/23 10/07/01
Canton Min
175 Main St Fait Time/Date Pemtit Expiration Date
Canton NC 28716 04:30PM 16/06/23 15/06/30
Name(s)of Onsne Representative(s)MUes(s)/Phone and Fax Number(s) Other Facility Data
/ll
Nicholas Morgan McCmcken/ORC/828-646-2874/
Wanda Kay Webb BradweNORC/828-646-2104/
Name,Address of Responsible OfficiaVTitle/Phone and Fax Number
Contacted
Demo Brown,PO Box 4000 Canton NC 28716/1828-646-23181
Yes
Section b:Areas Evaluated During Inspection(Check only those areas evaluated)
Permit Flow Measurement Operations&Maintenance E Self-Monitoring Program
Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters
Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s)and Signature(s)of Inspectors) Agenry/OKce/Phone and Fax Numbers Dale
Timothy H Heim r%4— ARO WQ//828-2964665/
Mika] Willmar ARO WQ//8 28-29 6 46861
Signature of Manage A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.
Page# 1

NPDES yr/molday Inspection Type (Cont.) 1
31 NC0000272 I11 12 ia/oa/23 17 18 [, j
Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
Tim Heim and Mika[Willmer of the Asheville Regional Office performed a Compliance Evaluation
Inspection on June 23th, 2016. Nick McCracken (ORC) and Wanda Webb (BORC) of Evergreen
Packaging were present during the inspection.
The WWTP was well maintained and appeared to be in compliance at the time of the inspection,with
the excpetion of the ongoing issue described below.
Two items of significance were ongoing at the time of the inspection.
1.The facility has reported repeated exceedances of permit limits for Fecal Coliform during the past
month, despite excess chlorine residual mixing with the domestic influent. Plant staff have been diligent
in communicating the issue to DEQ Regional staff, and in working to address the problem. Similar
and/or related problems have occurred in the past.The facility is encouraged to investigate both short
term (return to compliance with discharge limits)and long term (engineering solutions to address and
eliminate potential reoccurrence) solutions.
2. In a letter dated 23 June 2016, the mill has requested to perform a maintenance outage in early
August to minimize environmental impact due to ongoing low flow conditions in the Pidgeon River.This
approach was utilized in 2008. DEQ has no exceptions to this approach.
Page# 2

PPP
Permit: NCO000272 Owner-Facility: Canton M01
Inspection Date: 06/23/2016 Inspection Typo: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑
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 includes an on-site lab and analyses for PH. Settleable Solids, and other
applicable parameters for process control. The plant aims to keep%Total Solids above
35%. ORC stated the plant was looking to increase solids.
Permit Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new 9 ❑ ❑ ❑
application?.
Is the facility as described in the permit? M ❑ ❑ ❑
#Are there any special conditions for the permit? 0 ❑ ❑ ❑
Is access to the plant site restricted to the general public? M ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? M ❑ ❑ ❑
Comment: Special permit conditions related to color reduction. See file for details.
Bar Screens Yes No NA NE
Type of bar screen
a.Manual ❑
b.Mechanical
Are the bars adequately screening debris? M ❑ ❑ ❑
Is the screen free of excessive debris? 0 ❑ ❑ ❑
Is disposal of screening in compliance? E ❑ ❑ ❑
Is the unit in good condition? ❑ 110
Comment: Bar screens are cleaned twice a day.
Grit Removal Yes No NA NE
Type of grit removal
a.Manual ❑
b.Mechanical E
Is the grit free of excessive organic matter? E ❑ ❑ ❑
Is the grit free of excessive odor? E ❑ ❑ ❑
#Is disposal of grit in compliance? E ❑ ❑ ❑
Comment: Grit removal system cleaned twice a day.
Page# 3

Permit NC0000272 Owner-Facility: Canton Mill
Inspection Date: 06/23/2016 Inspection Type: Compriance Evaluation
Primary 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? N ❑ ❑ ❑
Are weirs level? E ❑ ❑ ❑
Is the site free of weir blockage? ❑ ❑ ❑
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 sludge blanket level acceptable? 0 ❑ ❑ ❑
Is the sludge blanket level acceptable?(Approximately Y4 of the sidewall depth) 0 ❑ ❑ ❑
Comment: Use torque alarms as a means to monitor sludge blanket levels Light sheen present in
clarifier, but is being adequately removed.
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? ❑ ❑ E ❑
Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑
Does the foam cover less than 25%of the basin's surface? N ❑ ❑ ❑
Is the DO level acceptable? ❑ ❑ ❑
Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑
Comment: ORC stated DO levels generally run 3-5 mg/L. The DO is continuously monitored using an
LDO probe.
Secondary Clarifier Yes No NA NE
Is the clarifier free of black and odorous wastewater? E ❑ ❑ ❑
Is the site free of excessive buildup of solids in center well of circular clarifier? E ❑ ❑ ❑
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 ❑ ❑ ❑
Page# 4

PPPP
Permit: NC0000272 Owner-Facility: Canton Mill
Inspection Date: 06/23/2016 Inspection Type: compliance Evaluation
Secondary Clarifier Yes No NA NE
Is the drive unit operational? N ❑ ❑ ❑
Is the return rate acceptable(low turbulence)? 0 ❑ ❑ ❑
Is the overflow clear of excessive solids/pin floc? M ❑ ❑ ❑
Is the sludge blanket level acceptable?(Approximately%of the sidewall depth) M ❑ ❑ ❑
Comment: No polymers are used natural settling. The plant utilizes a sludge fudge to measure sludge
blanket levels.
Pure OXVQen Yes No NA NE
Type of pure oxygen system Bulk storage
Is there a back-up source for the system? 0 ❑ ❑ ❑
Are mixers operational? 0 ❑ ❑ ❑
Are samples port/points easily accessible? ❑ ❑ ❑
Comment: There are currently two bulk oxygen tanks on site. Currently only one is in use. Nick
McCracken stated the tanks were set for replacement.
Effluent Pipe Yes No NA NE '
Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑
Are the receiving water free of foam other than trace amounts and other debris? N ❑ ❑ ❑
If effluent (diffuser pipes are required) are they operating properly? N ❑ ❑ ❑
Comment: Three diffuser pipes in use. Outfall encased in concrete, only confined space access.
Page# 5