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Home My WebLink AboutNC0004685_Compliance Evaluation Inspection_20220914ROY COOPER Governor ELIZABETH 5. BISER Secretory RICHARD E. ROGERS, JR. Director NORTH CAROLINA Enihron mental quality September 14, 2022 Mr. Alan Toney, Manufacturing Manager Nippon Electric Glass 940 Washburn Switch Road Shelby, NC 28150 Subject: Compliance Evaluation Inspection NEG Industries/Shelby Facility NPDES Permit No. NC0004685 Cleveland County Dear Mr. Toney: Enclosed is a copy of the Compliance Sampling Inspection for the inspection conducted at the subject facility on September 13, 2022, by Ori Tuvia. John Littlejohn, Mark Lockridge and Richard Young's cooperation during the site visit was much appreciated. The facility continues to do excellent job doing preventive repairs and maintenance. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed report. If you any questions, please contact Ori Tuvia at (704) 235-2190, or via email at ori.tuvia@ncdenr.gov. Sincerely, 4t1 [/ DocuSignedNut,. by: '24.44t F161FB69A2D84A3... Andrew H. Pitner P.G., Assistant Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Cc: NPDES Unit, MRO Files (Laserfiche) State of North Carolina 1 Environmental Quality 1 Water Resources 1 Water Quality Regional Operations Mooresville Regional Office 1 610 East Center Avenue, Suite 301 1 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 21IIIIII NPDES yr/mo/day Inspection L 3 I NC0004685 111 121 22/09/13 117 Type 1810I IIIIIIIIIII Inspector Fac Type 191S I 2011 IIIIIIIIIIIIIIIIII I IIIIII P6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 67I1.0 I 70I4 I 71IN I 72 I N I 731 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 permit Number) Electric Glass Fiber America LLC 940 Washburn Switch Rd Shelby NC 28150 Entry Time/Date 09:55AM 22/09/13 Permit Effective Date 21/07/01 Exit Time/Date 12:30PM 22/09/13 Permit Expiration Date 26/06/30 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// John Charles Littlejohn/ORC/704-434-2261/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Richard M Young,940 Washburn Switch Rd Shelby NC 28150//704-434-2261/7044340792 No 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 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 Ori A Tuvia Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date ,-DocuSigned by: DWR/Division of Water Quality/704-663-1699/ 9/14/2022 BB057A2DE017498... Signature of Man Andrew Pitn RePttsa4R viewer Agency/Office/Phone and Fax Numbers Date r A44 ' H P' /R/MRO WQ/704-663-1699 Ext.2180/ 9/14/2022 F161 FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 NPDES yr/mo/day 31 NC0004685 111 121 22/09/13 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0004685 Inspection Date: 09/13/2022 Owner - Facility: Electric Glass Fiber America LLC 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: The subject permit expires on 6/30/2026 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 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ▪ ❑ ❑ ❑ Comment: The records reviewed during the inspection were organized and well maintained. DMR's, COC's ORC logs, calibration logs and Process control logs for the period of February 2022 - July 2022 were reviewed. Page# 3 Permit: NC0004685 Inspection Date: 09/13/2022 Owner - Facility: Electric Glass Fiber America LLC 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? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ Effluent Sampling Yes No NA NE Is composite sampling flow proportional? • ❑ ❑ ❑ Is sample collected below all treatment units? • ❑ ❑ ❑ Is proper volume collected? • ❑ El El Is the tubing clean? • El El El # Is proper temperature set for sample storage (kept at less than or equal to 6.0 ■ El ❑ ❑ degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type • El El El representative)? Comment: The subject permit requires effluent composite and grab samples. 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: 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 facility appeared to be properly and well maintained. The operations staff incorporate comprehensive process control program with all measurements being properly documented and maintained on -site. The facility is equipped with computer/alarm notification system to assist the wastewater staff in the operation of the treatment units/processes. The facility continues to do excellent job doing preventive repairs and maintenance. Bar Screens Yes No NA NE Page# 4 Permit: NC0004685 Inspection Date: 09/13/2022 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Compliance Evaluation 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? 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? Comment: Primary Clarifier 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 sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Comment: Both primaries were operational and in service. Yes No NA NE • El • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 5 Permit: NC0004685 Inspection Date: 09/13/2022 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Compliance Evaluation Chemical Feed Yes No NA NE Is containment adequate? • ❑ ❑ ❑ Is storage adequate? • ❑ ❑ ❑ Are backup pumps available? ■ ❑ ❑ ❑ Is the site free of excessive leaking? • ❑ ❑ ❑ Comment: Chemical additions to selected treatment processes include the following: plymers, bentonite/clay mixture, ferric chloride, aluminum, lime and defoamer. 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/I) ❑ ❑ • ❑ Comment: The facility uses two aeration basins operated in series. The first aeration tank is equipped with diffused and mechanical aeration and the second aeration tank is equipped with diffused aeration. 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? • ❑ El El Is the site free of weir blockage? • El El El Is the site free of evidence of short-circuiting? • El ❑ ❑ Is scum removal adequate? • El El El Is the site free of excessive floating sludge? • El El El Is the drive unit operational? • El El El Is the return rate acceptable (low turbulence)? • El ❑ ❑ Is the overflow clear of excessive solids/pin floc? • El El El Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) • El El ❑ Comment: All three secondary clarifiers were operational and in service at the time of the inspection. Page# 6 Permit: NC0004685 Inspection Date: 09/13/2022 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Compliance Evaluation Secondary Clarifier Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Yes No NA NE Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Is the filter media present? • El ❑ ❑ Is the filter surface free of clogging? • ❑ ❑ ❑ Is the filter free of growth? ■ ❑ El ❑ Is the air scour operational? El El • El Is the scouring acceptable? ❑ El ❑ • Is the clear well free of excessive solids and filter media? El El • El Comment: The facility is equipped with a traveling bridge tertiary filter. The filter backwash is returned to the head of the wastewater plant. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? • ❑ ❑ ❑ Is flow meter calibrated annually? • El El El Is the flow meter operational? • ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? El El El • Comment: The flow meter is calibrated/verified twice a year by Clear Water Inc. Was last calibrated on 6/29/2022. 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? Comment: Solids Handling Equipment Is the equipment operational? Yes No NA NE • ❑ ❑ ❑ Yes No NA NE Page# 7 Permit: NC0004685 Inspection Date: 09/13/2022 Owner - Facility: Electric Glass Fiber America LLC Inspection Type: Compliance Evaluation Solids Handling Equipment 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: Thickened sludge is dewatered on a belt press. Dewatered solids are transported to the county landfill for final disposal by waste pros. Page# 8