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HomeMy WebLinkAboutWQ0003396_Compliance Report_20221123DocuSign Envelope ID: 85F18269-1122-4D72-92BC-96AEFE5A6D65 ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Henry Scheller, Plant Mananger Arauco North America 955 Corinth Road Mocure, NC 27559 Subject: NORTH CAROLINA Environmental Quality November 30, 2022 Compliance Evaluation Inspection Permit # WQ0003396 Facility: Arauco - Monocure WWTF/WW Irrigation system Chatham County Ms. Scheller, On November 14, 2022, Jim Westcott and Tyler Clark from the Raleigh Regional Office visited your wastewater treatment and irrigation system and met with Savannah Carroll to evaluate compliance with the subject permit. Ms. Carrols' comprehensive tour of your facility was informative and greatly appreciated. The facility is permitted for the operation .03952 (MGD) wastewater treatment and irrigation facility consisting of a 33.85-acre spray irrigation area and all associated piping, valves, controls, and appurtenances with no discharge of wastes to surface waters. The permit, which was issued August 6, 2021, is current and effective through July 31, 2025. At the time of inspection, required maintenance, discharge, flow and meter calibration records, spill prevention plan, residuals management plan, annual standard soil fertility analysis, ORC documentation, GW-59 records and NDMR, NDAR were available for review. The facility currently is transferring all its internal process waters to the city of Sanford's Big Buffalo WWTF and totals a monthly average of 110,00 GPD under an administrative waiver for non -discharge since November 6, 2020 and continues to operate under Industrial User Permit (IUP 000042). The facility is permitted to discharge up to 150,000 GPD. The facility is permitted to operate a closed loop recycle and conjunctive reclaimed North Carolina Department of Environmental Quality 1 Division of Water Resources Raleigh Regional Office I 3800 Barren Drive I Raleigh, North Caro1ma 27609 919 791 4200 DocuSign Envelope ID: 85F18269-1122-4D72-92BC-9BAEFE5A6D65 water system which is currently not in use. All the 9 active spray fields have been offline since June 2020. The treatment system has been secured since November 2020. Residuals management plan records indicate the remaining material collected from the W/W system was removed July 9, 2021 and transferred to pond C for residuals storage. The Wastewater Treatment system has been secured since November 2020. Enco lab draws the facility samples prior to discharge to the collection system once per six months (O&G 4x/six months), the city of Sanford draws 4x/six months. Sherill environmental draws monitoring well samples for GW-59 analysis and process discharge waters including samples from a surface water sampling station located at a downstream point of Shattock creek. The permit does not have limits for any parameter other than monthly flow average, frequency, and sample type. Record of certification for the facility ORC and backup ORC were on file and available for review. Facility NDMR and NDAR forms were submitted as required and reviewed. The effluent flow meter(s) were last calibrated April 28, 2022 and are calibrated every six months by Kewtech for both domestic and industrial water. Soils analysis was not conducted during 2020. Analysis was conducted and records available for 2021 and 2022. GW-59 reports for 2020-2021 were reviewed and corresponding lab results were reviewed against the documents for accuracy from Pace Analytical. No discrepancies in the data were noted and the facility is drawing the required samples as required by the permit. Numerous wells at the facility have reported permit exceedances during the latest sampling event (7/22/2022). Neary every monitoring well, excluding MW-20 at the facility had reporting exceedances for the following parameters: • MW-3: pH • MW-4: TDS, Chloride • MW-5: TDS, Chloride • MW-8: TDS, Chloride, Fecal coliform • MW-9: TDS, Fecal coliform • MW-18R: pH • MW-19: TDS, Chloride, Fecal coliform • MW-20: no exceedances • MW-21: TDS, Fecal coliform Well MW-3 is within the review boundary. Wells MW-4, MW-5, MW-8, and MW-9 are located between the review boundary and compliance boundary. Wells MW-18R, MW-19, North Carolina Deossinicnt of Environmental Quality I Division of Water Resources 512 North Salisbury Street 11611 Mail Service Center 1 Raleigh, North Carolina 27699.1611 919.707.9000 DocuSign Envelope ID: 85F18269-1122-4D72-92BC-96AEFE5A6D85 MW-20 and MW-21 are all located outside of the permit compliance boundary. TDS and chloride exceedances are historical and have been above permitted limits since 2005. A visible inspection was attempted for all nine monitoring well on the property. All but one well (MW-9) was inspected for locks and any potential damage. All wells were found to be in satisfactory condition except for MW-5 which had a cracked concrete well pad possibly damaged by mowing equipment. Wells MW-19, MW-20 and MW-21 are all located in the floodplain of nearby Shaddox Creek to the east and could be subject to inundation during an extreme flooding event. Lagoons 5C and 5D were evaluated. The earthen dam separating the two lagoons has been temporarily replaced by a large water filled coffer dam securing lagoon 5D while residual materials were being removed and transferred to 5C. Additionally, the berm(s) are under construction to build up the freeboard level(s) 2 feet or greater to meet the protection requirements of the 100-year flood plain requirements of lagoon 5D. The spray fields currently not in use are being evaluated for potential planting of certain species of trees in conjunction with NC state as a potential research site to evaluate nutrient uptake and removal efficiencies in remediated sites. If you have questions or comments about this inspection or the requirements to take corrective action (if applicable), then please contact Jim Westcott at james.westcottOncdenr.gov or 919-791-4247. Sincerely, Decualened by: EINALssa . M auA.ut,t, B291eEMAB32141F... Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources, NCDEQ Cc: Laserfiche North Carolina L7k,pmtne¢t of Environmental Quality I Division of Water Resources 512 North Salisbury Street 1 1611 Mail Service Center I Raleigh, North Carolina 27699-1611 919 707.9000 DocuSign Envelope ID: 85F18289-1122-4D72-92BC-96AEFE5A6D65 iak915 North Carolina Department of Envunnmental Quality I Division of Water Resources 512 North Salisbury Street 1 16 k I Mail Service Center I Raleigh, North Carolina 27699-161 L 919.707.9000 Permit: WQ0003396 SOC: County: Chatham Region: Raleigh Compliance Inspection Report Effective: 08/06/21 Effective: Expiration: 07/31/25 Owner : Arauco North America Inc Expiration: Facility: Arauco - Moncure WWTF 985 Corinth Rd Contact Person: Yvonne Couts Title: ORC Directions to Facility: South US1, exit onto Old US Hwy 1, Left on Corinth Rd, facility on left. System Classifications: SI, WW2, Primary ORC: Patrick Mays Secondary ORC(s): Patrick Mays Rawindraraj Mylvaganam On -Site Representative(s): Related Permits: Inspection Date: 11/14/2022 Entry Time 01:OOPM Primary Inspector: James Westcott Secondary Inspector(s): Timothy Clark Reason for Inspection: Routine Permit Inspection Type: Wastewater Irrigation Facility Status: II Compliant 0 Not Compliant Question Areas: ▪ Treatment Flow Measurement -Effluent ▪ Treatment Flow Measurement -Water Use Records • Record Keeping ▪ End Use -Irrigation • Treatment Disinfection III Storage • Wells (See attachment summary) Certification: 1010112 1009460 1007617 Moncure NC 27559 Exit Time: 03:30PM Phone: 919-545-5848 Phone: 919-642-6600 919-642-6600 919-542-2128 Phone: 919-791-4247 Inspection Type: Compliance Evaluation ▪ Treatment Flow Measurement -Influent ▪ Treatment ▪ Treatment Lagoons • Treatment Influent Pump Station IMI End Use -Infiltration ▪ End Use -Reuse • • • • • Miscellaneous Questions Treatment Barscreen Treatment Sludge Storage/Treatment Treatment Clarifiers Treatment Flow Measurement Standby Power Page 1 of 9 Permit: WQ0003396 Owner - Facility:Arauco North America Inc Inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Inspection Summary: At the time of inspection, required maintenance, discharge, flow and meter calibration records, spill prevention plan, residuals management plan, annual standard soil fertility analysis and NDMR, NDAR and GW-59 records were available for review. The facility currently is transferring all its internal process waters to the city of Sanford's Big Buffalo WWTF and totals a monthly average of 110,00 GPD under an administrative waiver for non -discharge since November 6, 2020 and continues to operate under Industrial User Permit (IUP 000042). The facility is permitted to discharge up to 150,000 GPD. The facility is permitted to operate a closed loop recycle and conjunctive reclaimed water system which is currently not in use. All the 9 active spray fields have been offline since June 2020. The treatment system has been secured since November 2020. Residuals management plan records indicate the remaining material collected from the W/W system was removed July 9, 2021 and transferred to pond C for residuals storage. The Wastewater Treatment system has been secured since November 2020. Enco lab draws the facility samples prior to discharge to the collection system once per six months (O&G 4x/six months), the city of Sanford draws 4x/six months. Sherill environmental draws monitoring well samples for GW-59 analysis and process discharge waters including samples from a surface water sampling station located at a downstream point of Shattock creek. The permit does not have limits for any parameter other than monthly flow average, frequency, and sample type. Record of certification for the facility ORC and backup ORC were on file and available for review. Facility NDMR and NDAR forms were submitted as required and reviewed. The effluent flow meter(s) were last calibrated April 28, 2022 and are calibrated every six months by Kewtech for both domestic and industrial water. Soils analysis was not conducted during 2020. Analysis was conducted and records available for 2021 and 2022. GW-59 reports for 2020-2021 were reviewed and corresponding lab results were reviewed against the documents for accuracy from Pace Analytical. No discrepancies in the data were noted and the facility is drawing the required samples as required by the permit. Numerous wells at the facility have reported permit exceedances during the latest sampling event (7/22/2022). Neary every monitoring well, excluding MW-20 at the facility had reporting exceedances for the following parameters: • MW-3: pH • MW-4: TDS, Chloride • MW-5: TDS, Chloride • MW-8: TDS, Chloride, Fecal coliform • MW-9: TDS, Fecal coliform • MW-18R: pH • MW-19: TDS, Chloride, Fecal coliform • MW-20: no exceedances • MW-21: TDS, Fecal coliform Well MW-3 is within the review boundary. Wells MW-4, MW-5, MW-8, and MW-9 are located between the review boundary and compliance boundary. Wells MW-18R, MW-19, MW-20 and MW-21 are all located outside of the permit compliance boundary. TDS and chloride exceedances are historical and have been above permitted limits since 2005. A visible inspection was attempted for all nine monitoring well on the property. All but one well (MW-9) was inspected for locks and any potential damage. All wells were found to be in satisfactory condition except for MW-5 which had a cracked Page 2of9 Permit: W00003396 Owner - Facillty:Arauco North America Inc Inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine concrete well pad possibly damaged by mowing equipment. Wells MW-19, MW-20 and MW-21 are all located in the floodplain of nearby Shaddox Creek to the east and could be subject to inundation during an extreme flooding event. Lagoons 5C and 5D were evaluated. The earthen dam separating the two lagoons has been temporarily replaced by a large water filled coffer dam securing lagoon 5D while residual materials were being removed and transferred to 5C. Additionally, the berm(s) are under construction to build up the freeboard level(s) 2 feet or greater to meet the protection requirements of the 100-year flood plain requirements of lagoon 5D. The spray fields currently not in use are being evaluated for potential planting of certain species of trees in conjunction with NC state as a potential research site to evaluate nutrient uptake and removal efficiencies in remediated sites Page 3 of 9 Permit: WQ0003396 Owner - Facility: Arauco North America Inc Inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine TVDe Single Family Spray, LR Activated Sludge Spray, LR Activated Sludge Drip, LR Single Family Drip Reuse (Quality) Lagoon Spray, LR Infiltration System Activated Sludge Spray, HR RecyclelReuse Treatment Yes No NA NE O o o o • • • • Yes No NA NE Are Treatment facilities consistent with those outlined in the current permit? 0 ❑ 0 . Do all treatment units appear to be operational? (if no, note below.) DOOM Comment: The W/W treatment system has been off line beginning November 2020 and all line power secured / tied to the lift station for transfer of facility process water to the city of Sanford. Treatment Influent Pump Station Is the pump station free of bypass lines or structures? Is the general housekeeping acceptable? Are all pumps present? Are all pumps operable? Are floats/controls operable? Are audio and visual alarms available? Are audio and visual alarms operational? # Are SCADA/Telemetry alarms required? Are SCAPA/Telemetry available? Are SCADA/Telemetry operational? Comment: Treatment Flow Measurement -Influent Is flowmeter calibrated annually? Is flowmeter operating properly? Does flowmeter monitor continuously? Does flowmeter record flow? Does flowmeter appear to monitor accurately? Yes No NA NE ❑❑11❑ • ❑❑❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑❑❑ • ❑❑❑ ■ ❑❑❑ ■ ❑❑❑ ■ ❑❑❑ ▪ ❑❑❑ Yes No NA NE • ❑❑❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑❑❑ ■ ❑❑❑ Comment: Q meter is calibrated by Kewtech every six months and the date of last calibration was 4/28/22. Page 4 of 9 Permit: WQ0003396 Owner - Facility: Arauco North America Inc Inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Treatment Flow Measurement -Water Use Records Is water use metered? Are the daily average values properly calculated? Yes No NA NE • ❑❑❑ ▪ ❑❑❑ Comment: Daily Q is measured and the city of Sanford uses an average to determine billing for each month. Treatment Flow Measurement -Effluent Is flowmeter calibrated annually? Is flowmeter operating properly? Does flowmeter monitor continuously? Does flowmeter record flow? Does flowmeter appear to monitor accurately? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑❑❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Q meter calibrated every six months. Facility averages approx. 110.000 GPD. Running average approx. 50.000 of internal process water. Standby Power Yes No NA NE, Is automatically activated standby power available? •❑ ❑ ❑ Is generator tested weekly by interrupting primary power source? •❑ ❑ ❑ Is generator operable? •❑ ❑ ❑ Does generator have adequate fuel? •❑ ❑ ❑ Comment: Treatment Barscreen Yes No NA NE Is it free of excessive debris? DOOM Is disposal of screenings in compliance? ❑ ❑ ❑ Are the bars spaced properly? ❑ ❑ ❑ Is the unit in good condition? DOOM Comment. Treatment system has been secured since November 2020. Treatment Clarifiers Yes No NA NE Are the weirs level? ❑ ❑ ❑ Are the weirs free of solids and algae? ❑ ❑ ❑ Is the scum removal system operational? DOOM Is the scum removal system accessible? DOOM Is the sludge blanket at an acceptable level? DOOM Is the effluent from the clarifier free of excessive solids? DOOM Comment: Treatment system has been secured since November 2020. Treatment Sludge Storage/Treatment Yes No NA NE Is the aeration operational? ❑ ❑ ❑ M Is the aeration pattem even? ❑ ❑ ❑ Page 5of9 permit: WQ0003396 Owner - Facility: Arauco North America Inc Inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine If required, are Sanitary "Ts" present in tankage? ❑ ❑ ❑ • Comment: Treatment system has been secured since November 2020. Residuals manacement plan records indicate the remaninu material collected from the W/W system was removed July 9. 2021 and transferred to pond C for residuals stoaraae. Treatment Disinfection as No NA NE Is the system working? ❑ ❑ ❑ Do the fecal coliform results indicate proper disinfection? ❑ ❑ ❑ • Is there adequate detention time (>=30 minutes)? ❑ ❑ ❑ • Is the system properly maintained? ❑ ❑ ❑ ■ If gas, does the cylinder storage appear safe? ❑ ❑ ❑ Is the fan in the chlorine feed room and storage area operable? ❑ ❑ ❑ Is the chlorinator accessible? ❑ ❑ ❑ If tablets, are tablets present? ❑ ❑ ❑• Are the tablets the proper size and type? ❑ ❑ ❑ • Is contact chamber free of sludge, solids, and growth? ❑ ❑ ❑ If UV, are extra UV bulbs available? DOOM If UV, is the UV intensity adequate? ❑ ❑ ❑ # Is it a dual feed system? ❑ 0 0 • Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)? ❑ ❑ ❑ If yes, then is there a Risk Management Plan on site? ❑ ❑ ❑• If yes, then what is the EPA twelve digit ID Number? (1000- ) If yes, then when was the RMP last updated? Comment: Treatment system has been secured since November 2020. Enco lab draws the facility samples prior to discharge to the collection system once per six months (O&G 4x/six months), the city of Sanford draws 4x/six months. Records for ORC and backup ORC are on file and were available for review. Record Keeping Yes No NA NE Is a copy of current permit available? • ❑ ❑ ❑ Are monitoring reports present: NDMR? M000 NDAR? •❑ ❑ ❑ Are flow rates less than of permitted flow? ❑ • ❑ ❑ Are flow rates less than of permitted flow? ❑•❑ ❑ Are application rates adhered to? ❑ ❑ 0 • Is GW monitoring being conducted, if required (GW-59s submitted)? • 0 ❑ ❑ Are all samples analyzed for all required parameters? •❑ ❑ ❑ Are there any 2L GW quality violations? •❑ ❑ ❑ Is GW-59A certification form completed for facility? •❑ ❑ ❑ Is effluent sampled for same parameters as GW? •❑ ❑ ❑ Page 6 of 9 Permit: W00003396 Owner - Facillty:Arauco North America Inc Inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Do effluent concentrations exceed GW standards? Are annual soil reports available? # Are PAN records required? # Did last soil report indicate a need for lime? If so, has it been applied? Are operational logs present? Are lab sheets available for review? Do lab sheets support data reported on NDMR? Do lab sheets support data reported on GW-59s? Are Operational and Maintenance records present? Were Operational and Maintenance records complete? Has permittee been free of public complaints in last 12 months? Is a copy of the SOC readily available? No treatment units bypassed since last inspection? • ❑ ❑❑ • ❑ ❑❑ ❑ ❑ •❑ ❑ ❑ N❑ ❑ ❑ •❑ • ❑ ❑❑ • ❑ ❑ ❑ • ❑ ❑❑ • ❑ ❑❑ • ❑ ❑ ❑ ❑ ❑ ❑ O 0110 ❑ ❑ M❑ • ❑ ❑ ❑ Comment: 9 on site spray fields are inactive and have been decomitioned since June 2020. Sherill environmental draws monitoring well samples for both W/W and GW-59 analysis / reports including samples from a surface water sampling staion located at a downstream point of Shattock creek. End Use -Irrigation Yes No NA NE Are buffers adequate? •❑ ❑ ❑ Is the cover crop type specified in permit? • 0 ❑ ❑ Is the crop cover acceptable? •❑ ❑ ❑ Is the site condition adequate? MIDE1121 Is the site free of runoff / ponding? M ❑ ❑ ❑ Is the acreage specified in the permit being utilized? •❑ ❑ ❑ Is the application equipment present? •❑ ❑ ❑ Is the application equipment operational? 0.00 Is the disposal field free of limiting slopes? •❑ ❑ ❑ Is access restricted and/or signs posted during active site use? ❑ ❑ ❑ ■ Are any supply wells within the CB? DOOM Are any supply wells within 250' of the CB? ❑ ❑ ❑ How close is the closest water supply well? ❑ ❑ ❑ Is municipal water available in the area? DOOM # Info only: Does the permit call for monitoring wells? •❑ ❑ ❑ Are GW monitoring wells located properly w/ respect to RB and CB? MOOD Are GW monitoring wells properly constructed, including screened interval? MOOD Are monitoring wells damaged? 00110 Page 7 of 9 Permit: WQ0003396 Owner - Facility: Arauco North America Inc inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Comment: The 9 on site spray fields are inactive and have been secured since June of 2020. End Use -Infiltration # Is the application High Rate or Low Rate? Are buffers maintained? Are any supply wells within the CB? Are any supply wells within 250' of the CB? Is municipal water available in the area? Are GW monitoring wells required? Are GW monitoring wells located properly w/ respect to RB and CB? Are GW monitoring wells properly constructed, including screened interval? Is a usable green area maintained? Is the disposal site acceptable? is the distribution equipment acceptable? Is the disposal site free of ponding? Is the disposal site free of breakout? Are the disposal sites free of solids, algae, etc.? Do the records show that the fields are properly maintained? Are the disposal sites free of vegetation? Do any surface water features appear to be adversely Impacted by GW discharge? No chemicals or rototiller used to eliminate vegetation, solids, algae, etc.? Yes No NA NE • ❑❑❑ • ❑ ❑❑ • ❑❑❑ ▪ ❑❑❑ • ❑❑❑ • ❑❑❑ • ❑❑❑ • ❑❑❑ ❑ ❑❑■ ❑ ❑❑■ ❑ ❑❑■ ❑ ❑ ❑• ❑ ❑❑■ ■ ❑❑❑ • ❑❑❑ ❑ ❑M❑ ❑ ❑❑111 Comment' Several of the monitoring wells have exceedances of TSS and Chlorides within the compliance boundrv. End Use -Reuse Is the acreage in the permit being utilized? Does the acreage specified in the permit correspond to the measured acreage at the site? Are all essential units provided in duplicate? Is an automatically activated standby power source available? Is the equalization capacity adequate? Is aerated flow equalization present? Has the turbidity meter been calibrated in the last 12 months? Does the turbidity meter have recording capabilities? Is all flow diverted at the appropriate times? Is all upset wastewater diverted from reuse storage unit? Is all upset wastewater treated, retreated, or disposed of acceptably? Is upset wastewater treated prior to discharge to irrigation storage? is public access restricted from irrigation area during active site use? Yes No NA NE ❑ ❑❑■ 111000 ❑ ❑ ❑• • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑❑❑ ❑ ❑❑• ❑ ❑❑■ ❑ ❑❑• ❑ ❑ ❑• ❑ ❑ ❑• ❑ ❑ ❑• ❑ ❑❑■ Page 8 of 9 permit: WQ0003396 Owner - Facility: Arauco North America Inc Inspection Date: 11/14/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine if golf course, is a sign posted in plain sight on the club house? Is the cover crop acceptable? Are buffers adequate? Is the site free of pondinglrunoff? Is the acreage in the permit being utilized? Is the application equipment acceptable? Is the application area free of limiting slopes? How close is the closest water supply well? Are any supply wells within the CB? Are any supply wells within 250' of the CB? Is municipal water available in the area? Are GW monitoring wells required? Are GW monitoring wells located properly w/ respect to RB and CB? Are GW monitoring wells properly constructed, including screened interval? ❑ ❑❑■ • ❑ ❑❑ • ❑ ❑❑ • 000 ❑ ❑❑■ • 000 • 000 • 00111 ❑ ❑❑■ ❑ ❑❑■ • ❑❑❑ • 000 •❑❑❑ • 000 Comment: The spray irrigation fileds have been out of service since June 2020 and a permit waiver is active for the transfer of Q directly to the city of Sanford Big Buffalo WWTF via a direct tie in to the city collection system. Soils analysis was not conducted during 2020. Analysis was conducted and records availalble for 2021 and 2022. Page 9 of 9 1 • 4 • 1 • • 4 '• . • • • I Est Jim ■