NC0002305_Compliance Evaluation Inspection_20220525

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
ROY COOPER
Governor
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
Stephan Molino
Lear Corporation
1754 NC Highway 903
Kenansville, NC 28349
NORTH CAROLINA
Environmental Quality
June 02, 2022
SUBJECT: Compliance Inspection Report
Lear Corporation WWTP
NPDES WW Permit No. NC0002305
Duplin County
Dear Permittee:
The North Carolina Division of Water Resources conducted an inspection of the Lear Corporation WWTP
on 5/25/2022. This inspection was conducted to verify that the facility is operating in compliance with
the conditions and limitations specified in NPDES WW Permit No. NC0002305. 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 Helen Perez with the Water
Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215 or via email at
[e-mail].
ATTACHMENTS
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Sincerely,
DocuSigned by:
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E3ABA14AC7DC434...
Morella Sanchez -King, Regional Supervisor
Water Quality Regional Operations Section
Wilmington Regional Office
Division of Water Resources, NCDEQ
North Carolina Department of Environmental Quality I Division of Water Resources
Wilmington Regional Office 1127 Cardinal Drive Extension Wilmington. North Carolina 28405
910.796.7215

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
United States Environmental Protection Agency
E PA 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 NC0002305 111 121 22/05/25 117 18 I O I 19 I S I 201
Type
I
21IIIIII
IIIIIIIIIIIIIIIIII
I
IIIIII
IIIIIIIII1I
P6
Inspection
671
Work Days
Facility Self -Monitoring
I 7°
I3
Evaluation Rating
I 711D
B1
1
72
QA
I N
I 73I
I
I I
Reserved
74 71
1
1 1
1
1
1
180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES Dermit Number)
Lear Corporation WWTP
1754 NC Hwy 903 N
Kenansville NC 28349
Entry Time/Date
09:OOAM 22/05/25
Permit Effective Date
18/10/01
Exit Time/Date
10:35AM 22/05/25
Permit Expiration Date
23/04/30
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
George Yankay//910-296-5201 /
George R Yankay/ORC/910-540-0684/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
George Yankay, /ORC/910-296-5201/
Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenar Records/Reports
Self -Monitoring Progran Sludge Handling DispoFacility Site Review Compliance Schedules
Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s)
Helen I Perez
of Inspector(s) Agency/Office/Phone and Fax Numbers Date
,-IDocuSigned by:DWR/WIRO WQ/910-796-7387/ 6/2/2022
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'-1D645B4A39694BE...
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers
Morella Sanchez -King DWR/WIRO WQ/910-796-7218/
DocuSigned by: Date
Hotta.c $,r.r c41 ICZ2/2022
E3ARA14AC7DC434 .-_,-a
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page# 1

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
31
NPDES yr/mo/day
NC0002305 I11 121 22/05/25
17
Inspection Type
18LI
(Cont.)
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
A routine compliance inspection of the Lear Corporation WWTP was conducted on May 25, 2022.
The purpose of the evaluation was to verify that the facility is operating in compliance with the
conditions and limitations specified in NPDES Permit NC0002305. George Yankay, ORC, was present
during the inspection.
This facility is a 1.5 MG extended aeration treatment plant that treats approximately 94% industrial
wastewater from the finished synectic textile product plant. The remaining wastewater treated is from
the water softner backwash of the WTP and the domestic waste from the facility's restrooms.
Currently, flow is averaging between 0.6 to 0.8 MG and discharges from Outfall 001 to the Northeast
Cape Fear River, classified as C-Swamp waters.
The facility currently follows the effluent limits and monitoring requirements for production based on
limits of 51,774 Ibs of finished product per day (A(1.)). The Permittee can request authorization to
apply new production limits (A(2.)) if average production level in a calendar year exceeds 62,100 Ibs
per day of finished product.
The Permittee has made many improvements to the facility in the last year. The following upgrades to
the wastewater plant have been made or are in the process of being implemented: 6 new submersible
pumps in the sludge holding tank for better sludge consistency; a sludge line from the EQ basin to
the digester; a new Gorman Rupp sludge pump; 3 new submersible pumps with cutter heads,
mounted on rail systems in the clarifier scum pit; replacement of weirs and outer baffle for Clarifier #2;
new refrigerated composite sampler; new hand railings around the aeration basin, EQ, digester and
chlorine contact chamber for safety.
A file review for the permit cycle shows the following:
2019- 1 Oil & Grease day/month limit violation
2020- 1 Cyanide month limit violation
3 DO day limit violations
Multiple monitoring violations
Fecal day limit violation
2021- 2 Fecal day limit violations
1 TSS day limit violation
2022- 1 DO monthly limit violation
1 Fecal day limit violation
3 Toxicity fails
Chronic Toxicity tests failed in January, February and April 2022. A change in vendor and chemical
used in treatment could be the issue and staff is working on determining the exact cause.
Operators collect the upstream/downstream samples as required but showed interest in belonging to
a monitoring coalition because of the difficulty in sample collection. The Coalition Coordinator is Mark
Vander Borgh and can be reached at 919-743-8423 to discuss options.
The current permit expires on April 30, 2023. A renewal application submittal is required six months
prior to expiration. The facility is compliant with NPDES Permit NC0002305. Please review the
comment sections of the inspection report for more details.
Page# 2

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
Permit: NC0002305
Inspection Date: 05/25/2022
Owner - Facility: Lear Corporation WWTP
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 El 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? • El El El
Comment: Condition A (4.) allows the Permittee to request authorization of new production limits (A
(2.)) if the average production level in a calendar year exceeds 62,100 Ibs/day of
finished product. Currently, the production level is based on an average of 51,774
Ibs/day (A (1.)). Floating aerators have been added to the aeration basin and sludge
digester.
Compliance Schedules
Is there a compliance schedule for this facility?
Is the facility compliant with the permit and conditions for the review period?
Comment: No comment.
Yes No NA NE
❑ ❑ • ❑
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? • El El El
Is all required information readily available, complete and current? • El ❑ ❑
Are all records maintained for 3 years (lab. reg. required 5 years)? • El El El
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 El ❑ • ❑
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? • ❑ ❑ ❑
Page# 3

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
Permit: NC0002305
Inspection Date: 05/25/2022
Owner - Facility: Lear Corporation WWTP
Inspection Type: Compliance Evaluation
Record Keeping
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
• ❑ ❑ ❑
▪ El El El
❑ ❑ • ❑
Comment: Operation and maintenance activites are lopped on the computer daily. This log is very
detailed and complete. DMRs and lab results were reviewed and found to be consistent
with reporting.
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: All field lab parameters are analyzed under the Field Lab Certification # 244.
Calibration records and bench sheets reviewed were complete. Envirochem analyzes
all other parameters except toxicity. ETS is contracted to analyze quarterly toxicity
samples.
Flow Measurement - Effluent
# 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 effluent flow meter was calibrated on 4-11-2022.
Yes No NA NE
• ❑ ❑ ❑
• ❑ ❑ ❑
• ❑ ❑ ❑
❑ ❑ • ❑
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 DOME
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: Due to the nature of the wastewater, the operator relies on visual cues such as color,
foam and thickness of the wastewater in the aeration basin for process control.
Bar Screens
Type of bar screen
Yes No NA NE
Page# 4

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
Permit: NC0002305
Inspection Date: 05/25/2022
Owner - Facility: Lear Corporation WWTP
Inspection Type: Compliance Evaluation
Bar Screens Yes No NA NE
a.Manual ❑
b.Mechanical •
Are the bars adequately screening debris? ❑ ❑ El •
Is the screen free of excessive debris? • ❑ ❑ ❑
Is disposal of screening in compliance? • ❑ ❑ ❑
Is the unit in good condition? • ❑ ❑ ❑
Comment: No comment.
Equalization Basins
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?
Yes No NA NE
• ❑ ❑ ❑
• ❑ ❑ ❑
❑ ❑ • ❑
• ❑ ❑ ❑
Comment: The 2 MG EQ basin has 2 floating aerators and 1 mixer. A number system to monitor
the level of wastewater is stationed along the berm wall. Plans are in place to remove
solids that have accumulated on the bottom of the EQ. A new Gorman Rupp portable
sludge pump has recently been purchased to help with this project. In addition, a new
sludge line from the EQ basin directly to the digester is under construction.
Aeration Basins Yes No NA NE
Mode of operation Ext. Air
Type of aeration system Surface
Is the basin free of dead spots? El • ❑ ❑
Are surface aerators and mixers operational? • El El El
Are the diffusers operational? ❑ El • ❑
Is the foam the proper color for the treatment process? El El El •
Does the foam cover less than 25% of the basin's surface? El El ❑ •
Is the DO level acceptable? El El El •
Is the DO level acceptable?(1.0 to 3.0 mg/I) ❑ El ❑ •
Page# 5

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
Permit: NC0002305
Inspection Date: 05/25/2022
Owner - Facility: Lear Corporation WWTP
Inspection Type: Compliance Evaluation
Aeration Basins Yes No NA NE
Comment: Two VFD pumps move wastewater from the EQ to the 2 MG aeration basin. The basin
has 11 floating aerators, 5 were in operation causing some dead spots with caked
solids floating on surface. Polymer is added at the discharge of the aeration basin
before entering the 2 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: Flow from the aeration basin goes through the splitter box into 2 secondary clarifiers.
The weirs on Clarifier #2 are corroded and causing some short-circuiting. There are
plans in the budget to replace the weirs and outer baffle. Also budgeted are the
installation of 3 new scum pit pumps with cutter heads mounted on a rail system. Flow
from the secondary clarifiers goes to a tertiary clarifier which mixes with alum for further
clarification. Effluent from the teriary clarifier was observed to be clear of solids.
Pumps-RAS-WAS
Are pumps in place?
Are pumps operational?
Are there adequate spare parts and supplies on site?
Yes No NA NE
• ❑ ❑ ❑
• ❑ ❑ ❑
• ❑ ❑ •
Comment: WAS from the secondary clarifiers is pumped to the digester. WAS from the tertiary
clarifier goes to a gravity sludge thickener tank where filtrate goes back to the EQ and
sludge is pumped to the digester.
Disinfection -Liquid
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?
Yes No NA NE
• ❑ ❑ ❑
• ❑ ❑ ❑
Page# 6

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
Permit: NC0002305
Inspection Date: 05/25/2022
Owner - Facility: Lear Corporation WWTP
Inspection Type: Compliance Evaluation
Disinfection -Liquid
Is the contact chamber free of growth, or sludge buildup?
Is there chlorine residual prior to de -chlorination?
Yes No NA NE
• ❑ ❑ ❑
Comment: The chlorine contact chamber is a circular tank with baffle walls to slow the flow down to
allow enough contact time. Chemicals are stored in a building with adequate
containment and ventilation.
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? ❑ El • El
Comment: Liquid de -chlorination solution is added as flow leaves the chlorine contact tank.
Are tablet de -chlorinators operational?
Number of tubes in use?
Comment:
❑ ❑ • ❑
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? • El El El
Is sample collected below all treatment units? • El El El
Is proper volume collected? El El El •
Is the tubing clean? ❑ ❑ ❑ •
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 El El El •
degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type • El El El
representative)?
Comment: The composite sampler was not working and samples are being collected manually. A
new refrigerated composite sampler is in the budget for purchasing.
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, El El El
and sampling location)?
Comment: Operators collect the upstream/downstream samples as required but showed interest
in belonging to a monitoring coalition because of the difficulty in sample collection. The
Permitte can contact Mark Vander Borgh, Coalition Coordinator, at 919-743-8423 to
discuss options.
Page# 7

DocuSign Envelope ID: 538055D1-AA26-41CB-9A52-4A2C30FD34E8
Permit: NC0002305
Inspection Date: 05/25/2022
Owner - Facility: Lear Corporation WWTP
Inspection Type: Compliance Evaluation
Solids Handling Equipment
Is the equipment operational?
Is the chemical feed equipment operational?
Is storage adequate?
Is the site free of high level of solids in filtrate from filter presses or vacuum filters?
Is the site free of sludge buildup on belts and/or rollers of filter press?
Is the site free of excessive moisture in belt filter press sludge cake?
The facility has an approved sludge management plan?
Yes No NA NE
• ❑ ❑ ❑
• ❑ ❑ ❑
❑ ❑ ❑ •
Comment: The rotating sludge drum thickener on site was not in operation during the inspection.
Aerobic Digester
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?
Yes No NA NE
▪ El El El
• ❑ ❑ ❑
• ❑ ❑ ❑
• ❑ ❑ ❑
Comment: The 1 MG digester has 4 floating aerators and 1 mixer. Digester solids can be
processed through the drum thickener or pumped directly to the 500,000 gallon sludge
holding tank. Six new submersible pumps to improve the sludge consistency in the
sludge holding tank is in the process of being installed. The 12 sand sludge drying
beds listed in the permit are present but are not used. EMA is contracted to haul and
land apply solids under their land application permit.
Page# 8