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Home My WebLink AboutNCG500618_Compliance Evaluation Inspection_20211012ROY COOPER Governor ELIZABETH S. BISER Secretary S. DANIEL SMITH NORTH CAROLINA Director Environmental Quality October 12, 2021 Frank Bumgarner Facilities Manager Mack Molding Company 149 Water Tank Road Statesville, North Carolina 28677 Subject: Compliance Evaluation Inspection Mack Molding Company NPDES Permit No. NCG500618 Iredell County Dear Mr. Bumgarner: Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on October 5, 2021, by Mr. Wes Bell of this Office. Should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192, or via email at wes.bell@ncdenr.gov. Enclosure: Inspection Report NORTH Dep®rlmont of Environmental Onolit Sincerely, by: EDocuSigned '""14z7l— A14CC681AF27425... W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ North Carolina Department of Environmental Quality 1 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 Code 1 IN I 2 IL 21 1 1 1 1 NPDES yr/mo/day Inspection I 3 I NCG500618 111 121 21/10/05 117 Type 1810I I I 1 1 1 Inspector Fac Type 191 S I 2011 1 1 1 1 1 11 1 1 1 I I I 1 1 1 1 1 1 I I I I I 1 11 1 1 1 I 1 P6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 67I1.0 I 70I4 I 71IN I 72 I N I 73I 1 74 751 I I 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 oermit Number) Mack Molding Company 149 Water Tank Rd Statesville NC 28677 Entry Time/Date 09:15AM 21/10/05 Permit Effective Date 21/01/04 Exit Time/Date 10:42AM 21/10/05 Permit Expiration Date 25/11/30 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Frankie Bumgarner/Facilities Manager/704-878-4433 /7048731966 Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Frankie Bumgarner,149 Water Tank Rd Statesville NC 28677//704-878-4433/7048731966 Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran 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/ 10/12/2021 L14)&,, 73a1 A61696D9OCC3437... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger DWR/Division of Water Quality/704-235-2194/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. DocuSigned by: 10/12/2021 "-A14CC681AF27425... Page# 1 NPDES yr/mo/day 31 NCG500618 111 121 21/10/05 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NCG500618 Inspection Date: 10/05/2021 Owner - Facility: Mack Molding Company Inspection Type: 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: The facility discharges non -contact cooling water (primary) and air compressor condensate. Note: The air compressor condensate does not enter surface waters (absorbs into the mulch). The last compliance evaluation inspection at this facility was performed by DWR staff on 12/21/17. 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? 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: The records reviewed during the inspection were organized and well maintained. Page# 3 Permit: NCG500618 Inspection Date: 10/05/2021 Owner - Facility: Mack Molding Company Inspection Type: Compliance Evaluation 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: The facility contracts Statesville Analytical Holdings, LLC to perform COD and oil & grease analyses. The chemical company (DuBois) that oversees the chemical composition in the non -contact cooling water system performs the calibrations to the in -line pH monitoring system. 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)? Comment: The subject permit requires effluent grab samples. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, ❑ ❑ • ❑ and sampling location)? Comment: The non -contact cooling water is discharged into a stormwater ditch; therefore, no instream monitoring is required (per Permit). 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 ❑ ❑ ME Solids, pH, DO, Sludge Judge, and other that are applicable? Page# 4 Permit: NCG500618 Inspection Date: 10/05/2021 Owner - Facility: Mack Molding Company Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Comment: The water supplied to the non -contact cooling water system is from an on -site well (not chlorinated). Dica 66 (corrosion inhibitor) continues to be added to the non -contact cooling water system. Microbial growth is controlled by an ozone treatment system. DuBois personnel perform monthly checks on the non -contact cooling water system. The air compressor condensate is treated by an oil/water separator and spent oil filters are disposed at the Iredell County Landfill. The facility is in the process of installing a new oil/water separator treatment system. 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 effluents from the non -contact cooling water and air compressor condensate discharges were clear with no suspended solids or oil sheens. Page# 5