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Home My WebLink AboutNC0035211_Compliance Evaluation Inspection_20211122DocuSign Envelope ID: 311 E83D7-A904-4DD0-8B38-B11 F8DEA5601 ROY COOPER Governor ELIZABETH S. BISER Secretary S. DANIEL SMITH DirectOr NORTH CAROLENA Environmental Qualify SENT VIA ELECTRONIC MAIL ONLY: NO HARD COPY WILL BE MAILED. November 22, 2021 Beth Anderson, Director of Environmental Health & Safety Shuford Yarns, LLC - Dudley Shoals Plant E-mail: BAnderson@shufordyarns.com SUBJECT: Compliance Inspection Report Dudley Shoals Plant NPDES WW Permit No. NC0035211 Caldwell County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Dudley Shoals Plant on 11/17/2021. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0035211. 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 Timothy Heim with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4500 or via email at tim.heim@ncdenr.gov. ATTACHMENTS Ec: LF Josh Greene, ORC Sincerely, p—DocuSigned by: J 4-2 '—E397192DABFB4FF... Daniel Boss, Asst. Regional Supervisor Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ North Carolina Department of Environmental Quelfy I olvtslon of Water Resources Asheville Regional Office 12090 O.S. Highway 70 I Swannanoa, Noah Carolina 28778 828.290 4500 DocuSign Envelope ID: 311 E83D7-A904-4DD0-8B38-B11 F8DEA5601 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 NPDES yr/mo/day Inspection 1 IN I 2 IL I 3 I NC0035211 111 121 21/11/17 117 Type 1810I IIIIIIIIIII Inspector Fac Type 19I S I 2011 21IIIIII IIIIIIIIIII IIIIIII I IIIIII P6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 671 I 70I I 711 172 I N I 73I 1 74 71 I I I I I I I I 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) Dudley Shoals Plant 5100 Burns Rd Granite Falls NC 28630 Entry Time/Date 09:30AM 21/11/17 Permit Effective Date 20/09/01 Exit Time/Date 11:OOAM 21/11/17 Permit Expiration Date 25/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Joshua Steven Greene/ORC/828-396-4444/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Beth Anderson,2815 1st Ave S W Hickory NC 28602//828-324-5393/8283223802 Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Operations & Maintenar Records/Reports Self -Monitoring Progran 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) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Timothy H Heim DWR/ARO WQ/828-296-4665/ Doc S,gneabY: 11/22/2021 Tim him �A>a„so,ro,n Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date D se eabY: 11/22/2021 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 DocuSign Envelope ID: 311 E83D7-A904-4DD0-8B38-B11 F8DEA5601 31 NPDES yr/mo/day NC0035211 I11 121 21 /11 /17 17 Inspection Type 18LI (Cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Tim Heim of the Asheville Regional Office performed a Compliance Inspection of the Facility on November 17, 2021. Josh Greene (ORC), Beth Anderson (Shuford Yards EH&S Director) and Mike Bradshaw (Plant Manager) assisted with the inspection. This inspection was performed concurrent with the CEI for the Non -Contact Cooling Water General Permit (NCG500321). The facility appeared well maintained and operated at the time of the inspection, and in compliance with Permit NC0035211. No deleterious impact to the receiving stream was observed. The following items were noted at the time of the inspection: Re -grout the distribution box in the sand filter bed as necessary to prevent leakage and ensure even distribution of wastewater to the filter media. Verify that the septic tank upstream of the sand filter is periodically checked and solids are removed as necessary to protect the filter bed. Page# 2 DocuSign Envelope ID: 311 E83D7-A904-4DD0-8B38-B11 F8DEA5601 Permit: NC0035211 Inspection Date: 11/17/2021 Owner - Facility: Dudley Shoals Plant Inspection Type: Compliance Evaluation 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 El El El Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new El ❑ ❑ application? Is the facility as described in the permit? • El El El # Are there any special conditions for the permit? El El • El Is access to the plant site restricted to the general public? • ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? • ❑ ❑ ❑ Comment: Septic Tank (If pumps are used) Is an audible and visual alarm operational? Is septic tank pumped on a schedule? Are pumps or syphons operating properly? Are high and low water alarms operating properly? Comment: Sand Filters (Low rate) (If pumps are used) Is an audible and visible alarm Present and operational? Is the distribution box level and watertight? Is sand filter free of ponding? Is the sand filter effluent re -circulated at a valid ratio? # Is the sand filter surface free of algae or excessive vegetation? # Is the sand filter effluent re -circulated at a valid ratio? (Approximately 3 to 1) Yes No NA NE ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ Yes No NA NE ❑ ❑ • ❑ ❑ • ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Re -grout the distribution box in the sand filter bed as necessary to prevent leakage and ensure even distribution of wastewater to the filter media. 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 3 DocuSign Envelope ID: 311 E83D7-A904-4DD0-8B38-B11 F8DEA5601 Permit: NC0035211 Inspection Date: 11/17/2021 Owner - Facility: Dudley Shoals Plant Inspection Type: Compliance Evaluation Effluent Pipe If effluent (diffuser pipes are required) are they operating properly? Comment: Yes No NA NE ❑ ❑ • ❑ Page# 4