The URL can be used to link to this page

Home My WebLink AboutNC0006190_Compliance Evaluation Inspection_20210429ROY COOPER Governor DIONNE DELLI-GATTI Secretary S. DANIEL SMITH Director Everette Owens, Plant Manager South Fork Industries, Inc. P.O. Box 742 Maiden, NC 28650 Dear Mr. Owens: NORTH CAROLINA Environmental Quality April 29, 2021 SUBJECT: Compliance Evaluation Inspection South Fork Industries WWTP NPDES Permit No. NC0006190 Catawba County Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on April 15, 2021, by Mr. Wes Bell of this Office. Please inform the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding a copy of the enclosed report. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bell@ncdenr.gov. Enclosure: Inspection Report DNORTH CPPOLINA _E Sincerely, DocuSigned by: A.•144w H P,44 F161 FB69A2D84A3... fo r W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Mooresville Regional Office Division of Water Resources, NCDEQ North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1610 East Center Avenue. Suite 301 I Mooresville. North Carolina 28115 704.663.1699 United States Environmental Protection Agency EPA 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 I 2 IL NPDES yr/mo/day Inspection Type Inspector Fac I 3 I NC0006190 111 121 21/04/15 I17 1810I 19I S I 2011 Type 21IIIIII IIIIIIIIIIIIIIIIII I IIIIII IIIIIIIIIII P6 Inspection 67I2.0 Work Days Facility Self -Monitoring I 70I4 Evaluation Rating I 71IN B1 I 72 QA I N I 73I 1 I I Reserved 74 751 1 I I I I I I 180 l Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) South Fork Industries - Maiden Plant 100 W Pine St Maiden NC 28650 Entry Time/Date 08:53AM 21/04/15 Permit Effective Date 19/02/01 Exit Time/Date 01:15PM 21/04/15 Permit Expiration Date 23/05/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Donald A Burkey/ORC/704-736-8960/ James S. Rhyne//828-428-9920 / Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Everette J Owens,PO Box 742 Maiden NC 286500742/Plant Manager/704-732-6946/7047322352 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran Sludge Handling Dispo: Facility Site Review Effluent/Receiving Wate Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) Wes Bell of Inspector(s) Agency/Office/Phone and Fax Numbers Date —Docusigned by: DWR/MRO WQ/704-663-1699 Ext.2192/ 4/28/2021 '-A61696D90CC3437... Signature of Man Andrew Pitn fants(dnikdReviewer Agency/Office/Phone and Fax Numbers Date r 4014 4' H P'xstocNR/MRO WQ/704-663-1699 Ext.2180/ 4.29.21 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 sI NPDES yr/mo/day NC0006190 111 121 21/04/15 117 Inspection Type 18 [j (Cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) BAR SCREENS SECTION cont'd: This Office still has concerns with the potential discharge of wastewater onto the concrete driveway (near storm drains) and potentially state roads (leakage from garbage truck) during the unloading of the lint dumpster by the contracted company. The permittee and staff should supervise the unloading of the lint dumpster into the garbage truck to determine if any of these conditions occur. If these conditions do occur then the permittee must incorporate the appropriate corrective actions to prevent these unpermitted wastewater discharges. STORMWATER/SECONDARY CONTAINMENT: Repairs had been made to the secondary containment structure for the salt brine and hydrogen peroxide storage tanks. The drain valve was left open as has been noted in previous inspections. The drain valve must be kept closed in a locked position where only authorized personnel can open the valve. There is a stormwater drain located adjacent to the loading dock and tote bin that collects oil from the air pollution control system. Oil sheens were observed on the asphalt directly beside the stormwater grate (opposite side of straw bales). Additional measures need to be incorporated to prevent any petroleum, contaminated runoff, etc. from entering the stormwater drainage system. Please be advised that the permittee can be assessed civil penalties up to $25,000.00 per day per violation for any unpermitted discharges to surface waters. In addition, the permittee would be responsible for any damages to surface waters caused by the discharge. Page# 2 Permit: NC0006190 Inspection Date: 04/15/2021 Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Compliance Evaluation 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 last compliance evaluation inspection at this facility was performed by DWR staff on 12/16/2019. 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • • • • • ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ Page# 3 Permit: NC0006190 Inspection Date: 04/15/2021 Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: The records reviewed during the inspection were organized and well maintained. Discharge monitoring reports (eDMRs) were reviewed for the period January 2020 through February 2021. COD effluent monthly average violations were reported in January, March and December 2020 and January and February 2021. BOD effluent monthly average violations were reported in December 2020 and January and February 2021. A TSS effluent monthly average violation was reported in January 2021. COD and BOD effluent daily maximum violations were reported in December 2020 and January and February 2021 (BOD only). TSS effluent daily maximum violations were also reported in December 2020. Chronic toxicity failures were reported in December 2020 and January and February 2021. An effluent COD was not analyzed within the required holding time in June 2020. The Division has separately addressed all of the above -noted violations through the issuances of either Notice of Violations (NOVs) or NOV/civil penalty assessments. 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ Comment: On -site field analyses (dissolved oxygen, pH, temperature) are performed under South Fork Industries' laboratory certification #5302. Statesville Analytical, LLC. has been currently contracted to perform all remaining permit -required analyses except chronic toxicity. Meritech has been contracted to perform the chronic toxicity tests. Influent Sampling # Is composite sampling flow proportional? Is sample collected above side streams? 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 sampling performed according to the permit? Yes No NA NE ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The subject permit requires time -based influent color samples. The facility was not sampling during the inspection; however, the sampler collected less than one hundred mis. during the on -site test. Staff had recently changed the tubing and the sampler was immediately adjusted to collect the appropriate aliquot volume. Staff must ensure that the sampler is appropriately adjusted during any sampler maintenance activities. Page# 4 Permit: NC0006190 Inspection Date: 04/15/2021 Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Compliance Evaluation 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)? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The subject permit requires composite and grab effluent samples. The effluent sampler temperature was approximately 3.5 degrees Celsius and collecting 200 mis. per aliquot. Facility staff should continue to check and document the periodic (monthly at a minimum) aliquot checks on the influent and effluent samplers. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, an( • ❑ ❑ ❑ 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 • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The wastewater treatment facility appeared to be adequately treating wastewater at the time of the inspection. Process control measurements and operation/maintenance activities were being documented and maintained on -site. Bar Screens Type of bar screen 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? Yes No NA NE • • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The facility is equipped with two lint screens (shakers) and a manual bar screen. All were operational and in service. The containment wall for the lint dumpster had been repaired following previous inspection. See "Summary" Section for additional comments. Page# 5 Permit: NC0006190 Inspection Date: 04/15/2021 Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? • ❑ ❑ ❑ Are surface aerators and mixers operational? • El ❑ ❑ Are the diffusers operational? ❑ El • ❑ 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? • El El El Is the DO level acceptable?(1.0 to 3.0 mg/I) • El ❑ ❑ Comment: Both aeration basins were in service. All surface aerators were operational and in service. Microbial supplements (bacteria, food supplements, etc.) are added to the aeration basins. No foam carry-over was observed in the secondary clarifiers. Secondary Clarifier Yes No NA NE 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) • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Both clarifiers were operational and in service. The weirs were not excessively uneven. The permittee should continue to plan and implement the rehabilitation of the severely rust& and deteriorated clarifier components (weirs, scum railing, scum beach, etc.). Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Yes No NA NE Page# 6 Permit: NC0006190 Inspection Date: 04/15/2021 Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Compliance Evaluation Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Comment: Yes No NA NE • ❑ ❑ ❑ Flow Measurement - Effluent Yes No NA NE # 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 twice per year and was last calibrated on 2/9/2021 by Clearwater, 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? Yes No NA NE ❑ ❑ • ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ Comment: The effluent appeared light purple with trace suspended solids and no foam. Aerobic Digester Yes No NA NE Is the capacity adequate? • ❑ ❑ ❑ Is the mixing adequate? ❑ ❑ • ❑ Is the site free of excessive foaming in the tank? • ❑ ❑ ❑ # Is the odor acceptable? • ❑ ❑ ❑ # Is tankage available for properly waste sludge? • ❑ ❑ ❑ Comment: The sludge lagoon had two aerators in service. Adequate freeboard was being maintained and the previously noted erosion issues had been addressed. A contracted company (Synagro) land applies sludge under the authority of Permit No. WQ0006984. Page# 7