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Home My WebLink AboutNC0004243_Compliance Evaluation Inspection_20210524 SENT VIA ELECTRONIC MAIL ONLY: NO HARD COPY WILL BE MAILED May 24, 2021 John Moss Coats American Inc. Email: john.moss@coats.com SUBJECT: Compliance Inspection Report Sevier Plant NPDES WW Permit No. NC0004243 McDowell County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Sevier Plant on 5/19/2021. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0004243. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the inspection and therefore, a response to this inspection report is not required. If you should have any questions, please do not hesitate to contact Lauren Armeni with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4667 or via email at lauren.armeni@ncdenr.gov. Sincerely, Daniel Boss, Assistant Regional Supervisor Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS: Inspection Report Ec: LF Sara Hudgins, ORC DocuSign Envelope ID: 49930609-CF9E-4117-8BB4-F6B41F044ED8 EPA United States Environmental Protection Agency 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 Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 N 52 NC0004243 21/05/19 C S31112171819 20 21 66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- N67707172 73 74 75 80 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Sevier Plant 630 American Thread Rd Marion NC 28752 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 10:00AM 21/05/19 17/12/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Other Facility Data 12:30PM 21/05/19 21/11/30 Name, Address of Responsible Official/Title/Phone and Fax Number Bruce Duncan,PO Box 368 Marion NC 28752//828-837-5171/8288375767 Contacted No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self-Monitoring Program 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 Inspector(s)Agency/Office/Phone and Fax Numbers Date Lauren E Armeni DWR/ARO WQ/828-296-4500/ Timothy H Heim DWR/ARO WQ/828-296-4665/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page#1 DocuSign Envelope ID: 49930609-CF9E-4117-8BB4-F6B41F044ED8 5/24/2021 DocuSign Envelope ID: DA092A99-F8F1-4A86-BD07-6F159C929C1D 5/24/2021 5/24/2021 NPDES yr/mo/day 21/05/19 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Lauren Armeni and Tim Heim, with the Asheville Regional Office, conducted a Compliance Evaluation Inspection of Coats American Inc. - Sevier Finishing Plant WWTP on May 19, 2021. This inspection was conducted to determine whether the facility is being operated and maintained in compliance with NPDES Permit No. NC0004243. Sara Hudgins (ORC) and John Moss (Facilities Engineering Manager) were present and assisted in the inspection. Overall, the plant is well-maintained and operated. The color of the wastewater was pale green, which was confirmed to be a pigment from the industrial processes at the plant, as the plant utilizes various dyes for the thread they produce. No deficiencies were noted during the inspection. On previous inspection reports, small holes were noted in the inner ring of Secondary Clarifier #1, but a stainless steel ring was installed which has corrected the issue. Secondary Clarifier #2 is offline and has been for years. The sludge depth was checked in secondary clarifier #1, and it was determined that there was no sludge. Continue to maintain site conditions near the weir to prevent vegetation from interfering with flow measurement, and continue to maintain facility conditions around the containment berms to prevent the intrusion of large tree roots or burrowing animals. NC0004243 17 (Cont.) Page#2 DocuSign Envelope ID: 49930609-CF9E-4117-8BB4-F6B41F044ED8DocuSign Envelope ID: DA092A99-F8F1-4A86-BD07-6F159C929C1D Permit:NC0004243 Inspection Date:05/19/2021 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Permit Yes No NA NE (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? Comment: 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? Process controls include pH, temperature and COD, which are all measured with in-line meters. DO is measured periodically in the aeration basin. Comment: Record Keeping Yes No NA NE 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 operator 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? Page#3 DocuSign Envelope ID: 49930609-CF9E-4117-8BB4-F6B41F044ED8DocuSign Envelope ID: DA092A99-F8F1-4A86-BD07-6F159C929C1D Permit:NC0004243 Inspection Date:05/19/2021 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Record Keeping Yes No NA NE 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: Equalization Basins Yes No NA NE 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: The equalization basin acts as extra capacity and detention time for the facility. 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/l) The aeration basin is basin is being operated as an aerated lagoon rather than an activated sludge process because of the large settling area. The DO is periodically measured. Comment: 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? Page#4 DocuSign Envelope ID: 49930609-CF9E-4117-8BB4-F6B41F044ED8DocuSign Envelope ID: DA092A99-F8F1-4A86-BD07-6F159C929C1D Permit:NC0004243 Inspection Date:05/19/2021 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Secondary Clarifier Yes No NA NE 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 ¼ of the sidewall depth) The small holes in the inner plate of Secondary Clarifier #1 have been fixed by installing a stainless steel ring. Secondary Clarifier #2 is offline and has been for years. See summary for details. Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Disinfection-Liquid Yes No NA NE Is there adequate reserve supply of disinfectant? (Sodium Hypochlorite) Is pump feed system operational? Is bulk storage tank containment area adequate? (free of leaks/open drains) Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de-chlorination? The drain in the chlorine storage room goes to the headworks of the plant. There is still no secondary containment around the tank in the event of a spill. Comment: De-chlorination Yes No NA NE Type of system ?Liquid Is the feed ratio proportional to chlorine amount (1 to 1)? Is storage appropriate for cylinders? # Is de-chlorination substance stored away from chlorine containers? Are the tablets the proper size and type? Ozone is used in conunction with the liquid de-chlorination.Comment: Page#5 DocuSign Envelope ID: 49930609-CF9E-4117-8BB4-F6B41F044ED8DocuSign Envelope ID: DA092A99-F8F1-4A86-BD07-6F159C929C1D Permit:NC0004243 Inspection Date:05/19/2021 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation De-chlorination Yes No NA NE Are tablet de-chlorinators operational? Number of tubes in use? Comment: Effluent Sampling Yes No NA NE 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)? Ms. Hudgins indicated the sampler is set to collect 200-mL aliquots.Comment: 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? The flow meter is calibrated weekly.Comment: Effluent Pipe Yes No NA NE 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: Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? Mr. Moss verified that upstream and downstream sampling locations are correct and have not changed. 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'$.,.t* '` .^�y ,ww b ,�_ - - - 9 s. FF IF, - FitII I'XV s IF At c' {pop, —. : -a I All. IF _ .. .; - +�111 In `y .- '� ., .fib•+ �: P � 12/8/2020 12/9/2020 BOD <2.0 TSS <2.5 NH3 <0.2 Fecal Coliform 15 c uli ��v BOD <2.0 TSS <2.5 COD <20 12/10/2020 BOD <2.0 TSS <2.5 COD <20 12/15/2020 BOD <2.0 TSS <2.5 NH3 <0.2 Fecal Coliform <1 12/16/2020 BOD <2.0 TSS <2.5 COD <20 12/17/2020 BOD <2.0 TSS <2.5 COD <20 12/21/2020 BOD <2.0 TSS <2.5 NH3 <0.2 Fecal Coliform <1 �aIrjra- 12/23/2020 BOD <2.0 TSS <2.5 COD <20 COD <20 (2/29/2020 BOD <2.0 TSS <2.5 NH3 <0.2 Fecal Colifonn <1 2/30/2020 BOD <2.0 TSS <2.5 COD <20 12/31/2020 BOD <2.0 TSS <2.5 COD <20 COD <20 COD <20 S PERMIT NO.: NC0004243 400 FACILITY NAME: Sevier Plant OWNER NAME: Coats Amencan Inc GRADE: WW-3 eDMR PERIOD: 12-2020 (December 2020) ►.•* ,yo Reporting Reason: ENhKua>✓ - ,.v , .,n-•.-.W_..---• A moww/u / OAS Inr PERMIT VERSION: 4.0 CLASS: WW-3. ORC: Sara Lynn Hudgins ORC HAS CHANGED: No VERSION: 2_0 PERMIT STATUS: Active COUNTY: McDowell ORC CERT NUMBER: 1009429 STATUS: Submitted - __,-.__ r�.r. sT� _ nn� wtn TiC!`LIA72(-:F'k• 1v�i Discharge Monitoring Report -Copy Of Record (C(?R_NCQOQ4243 Ver Z.0_12 2020.pdt�