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Home My WebLink AboutNC0004626_Compliance Evaluation Inspection_20230120United States Environmental Protection Agency Form Approved. EPA Washington, D.C. 20460 OMB No. 2040-0057 Water Compliance Inspection Report Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 IN 1 2 u 3 I NC0004626 111 121 23/01/20 I17 18 LC] I 19 I s I 201 I 211IIIII 111111III II III III1 I I IIIII IIIIIIIII II r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 I 72 I ni I 71 I 74 79 I I I I I I I80 701 I 71 I LL -1 I I LJ Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include Entry Time/Date Permit Effective Date POTW name and NPDES Dermit Number) 09:OOAM 23/01/20 22/05/01 Lexington Manufacturing Facility 473 New Jersey Church Rd Exit Time/Date Permit Expiration Date Lexington NC 27292 12:OOPM 23/01/20 27/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Kimerly Brett Burkhart/ORC/336-239-5956/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Kurt Christian,473 New Jersey Chruch Rd Lexington NC 27292//336-357-8151/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran 0 Sludge Handling Dispo: 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) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Ron Boone Docusigned by: DWR/WSRO WQ/336-776-9690/ Seren Homer DWR/WSRO WQ/336-776-9698/ 2/8/2023 �P/1�3ri �a2r�ri1- Jesse Barnes DWR/WSRO WQ/336-776-9701/ 41797473D3194ED... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date Docusigned by: - T. 2/8/2023 FL 14bb4at22bUY4EA.. EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0004626 I11 12I 23/01 /20 117 18 i c i (Cont.) Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Jesse Barnes, of the North Carolina Division of Water Resources (DWR), Winston-Salem Regional Office (WSRO), conducted a compliance evaluation inspection of the Electric Glass Fiber America, LLC Lexington Manufacturing Facility on January 20, 2023. Kimerly Burkhart, Operator in Responsible Charge (ORC), was present for the inspection. The facility was found to be compliant with the subject permit. Inspection findings are detailed in the attached Water Compliance Inspection Report. The current permit, NC0004626, became effective April 15, 2022 and expires at midnight on March 31, 2027. The facility is as described in the permit and there are no special conditions. A fence encloses the entire facility and security staff monitor the entrance. Operating staff granted access to all areas of the facility for inspection. All permit -required records were available, complete, and well organized. DMR data for April 2021 and October 2022 were analyzed for reporting, record -keeping, and transcription accuracy with no errors found. All parameter analyses were verified to be performed by either a certified field laboratory or a certified contract laboratory. Laboratory refrigerator for field sample storage was within acceptable temperature range, verified with thermometer and daily monitoring log. Field sample storage appeared to be compliant with requirements. The laboratory area and outdoor areas were neat and clean. The facility analyzes sufficient process control parameters. Quarterly upstream hardness grab sampling has been performed as required by the permit (most recently in December 2022). The mechanical bar screen system appeared to be operating appropriately. The equalization basin appeared to not be used frequently, as it contained very little wastewater but some sludge and vegetation. One surface aerator was observed in the EQ basin, but the operator indicated that it is inoperable and out of service. With the aerator inoperable, the EQ basin has no other means of aeration. The primary clarifier appeared to be operating appropriately. The aeration basin was observed operating with diffused aeration, minimal foam, and sufficient mixing. Minimal algal growth was noted in the secondary clarifier. Weirs were free of blockages from algal growth. Some suspended solids/floc was observed in the weir overflow, but not excessive in nature and effluent TSS is compliant with permit limits. Significant corrosion was observed on the chlorine contact tank. The indoor chemical storage area currently houses many drums, minibulks, and other containers of various highly corrosive and/or reactive substances. No immediate containment issues were observed. Solids handling equipment is appropriately maintained and available for use as described in the permit. The whole -plant automatic backup generator is tested weekly. Weekly tests are neither conducted Page# Permit: NC0004626 Inspection Date: 01/20/2023 Owner - Facility: Lexington Manufacturing Facility Inspection Type: Compliance Evaluation under load, nor with the primary power source disconnected. The effluent pipe was observed to be underwater at the time of inspection. Operators indicated that this was due to the current high water level and the effluent pipe is normally not submerged. Upon request for additional information and clarification, the permittee submitted confirmation of flow -proportional composite sampling methods via email- see filed correspondence. The effluent flow meter signal is transmitted to the composite sampler and the sampler operates with variable timing, constant volume. The sampler is programmed to pulse (at 240 gallons of flow per pulse) 41 times between samples, and to take 130 mL aliquots. Page# Permit: NC0004626 Owner - Facility: Lexington Manufacturing Facility Inspection Date: 01/20/2023 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 ❑ ❑ 0 ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ 0 ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: The current permit, NC0004626, became effective April 15, 2022 and expires at midnight on March 31, 2027. The facility is as described in the permit and there are no special conditions. A fence encloses the entire facility and security staff monitor the entrance. Operating staff granted access to all areas of the facility for inspection. 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: All permit -required records were available, complete, and well organized. DMR data for April 2021 and October 2022 were analyzed for reporting, record -keeping, and transcription accuracy and no errors were found. Page# 4 Permit: NC0004626 Inspection Date: 01/20/2023 Record Keeping Owner - Facility: Lexington Manufacturing Facility 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 Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ Comment: All parameter analyses were verified to be performed by either a certified field laboratory or a certified contract laboratory. Laboratory refrigerator for field sample storage was within acceptable temperature range, verified with thermometer and daily monitoring log. Field sample storage appeared to be compliant with requirements. Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The laboratory area and outdoor areas were neat and clean. The facility analyzes sufficient process control parameters. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, ■ ❑ ❑ ❑ and sampling location)? Comment: Quarterly upstream hardness grab sampling has been performed as required by the permit (most recently in December 2022). Bar Screens Yes No NA NE Type of bar screen a.Manual ❑ b.Mechanical Are the bars adequately screening debris? 0 ❑ ❑ ❑ Is the screen free of excessive debris? ■ ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: The mechanical bar screen system appeared to be operating appropriately. Page# 5 Permit: NC0004626 Inspection Date: 01/20/2023 Owner - Facility: Lexington Manufacturing Facility Inspection Type: Compliance Evaluation 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 equalization basin appeared to not be used frequently, as it contained very little wastewater but some sludge and vegetation. One surface aerator was observed in the EQ basin, but the operator indicated that it is inoperable and out of service. With the aerator inoperable, the EQ basin has no other means of aeration. 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: The primary clarifier appeared to be operating appropriately. Aeration Basins Mode of operation Type of aeration system 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? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE Ext. Air Diffused ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Page# 6 Permit: NC0004626 Inspection Date: 01/20/2023 Owner - Facility: Lexington Manufacturing Facility Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Is the DO level acceptable? ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑ Comment: The aeration basin was observed operating with diffused aeration, minimal foam, and sufficient mixing. Secondary 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 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) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Minimal algal growth was noted in the secondary clarifier. Weirs were free of blockages from algal growth. Some suspended solids/floc was observed in the weir overflow, but not excessive in nature and effluent TSS is compliant with permit limits. 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? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de -chlorination? Comment: Significant corrosion was observed on the chlorine contact tank. De -chlorination Type of system ? Is the feed ratio proportional to chlorine amount (1 to 1)? Is storage appropriate for cylinders? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE Liquid ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ Page# 7 Permit: NC0004626 Inspection Date: 01/20/2023 De -chlorination Owner - Facility: Lexington Manufacturing Facility Inspection Type: Compliance Evaluation # Is de -chlorination substance stored away from chlorine containers? Are the tablets the proper size and type? Comment: None Are tablet de -chlorinators operational? Number of tubes in use? Comment: None Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Yes No NA NE ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ ■ ❑ ❑ ❑ Comment: The indoor chemical storage area currently houses many drums, minibulks, and other containers of various highly corrosive and/or reactive substances. No immediate containment issues were observed. 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: Solids handling equipment is appropriately maintained and available for use as described in the permit. Standby Power Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Was generator tested & operational during the inspection? Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Yes No NA NE ■ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 8 Permit: NC0004626 Inspection Date: 01/20/2023 Standby Power Is the generator fuel level monitored? Owner - Facility: Lexington Manufacturing Facility Inspection Type: Compliance Evaluation Yes No NA NE ■ ❑ ❑ ❑ Comment: The whole -plant automatic backup qenerator is tested weekly. Weekly tests are neither conducted under load, nor with the primary power source disconnected. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? M ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: The effluent pipe was observed to be underwater at the time of inspection. Operators indicated that this was due to the current high water level and the effluent pipe is normally not submerged. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ Comment: None Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 0 ❑ ❑ ❑ degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: Upon request for additional information and clarification, the permittee submitted confirmation of flow -proportional composite sampling methods via email- see filed correspondence. The effluent flow meter signal is transmitted to the composite sampler and the sampler operates with variable timing, constant volume. The sampler is programmed to pulse (at 240 gallons of flow per pulse) 41 times between samples, and to take 130 mL aliquots. Page# 9