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NC0000752_Historical_2017-2022
ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Interim Director Mr. Wilbur G. Kessinger Jr. Kapstone Kraft Paper Corporation 100 Gaston Rd. Roanoke Rapids, North Carolina 27870 Dear Mr. Kessinger: NORTH CAROLINA Environmental Quality August 10, 2018 Subject: Issuance of NPDES Permit Permit NC0000752 Roanoke Rapids Mill WWTP Halifax County Facility Class IV The Division of Water Resources is forwarding herewith the Final NPDES Permit for Roanoke Rapids Mill WWTP. This permit is issued pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina and the U.S. Environmental Protection Agency dated October 15, 2007 (or as subsequently amended). This Final Permit contains no significant changes from the Draft Permit. The Division is unable to grant your request to reduce the instream sampling since it would make the permit less stringent and it is not allowed by the rules after the Public Notice. Please submit this request during the next renewal. If any parts, measurement frequencies, or sampling requirements contained in this permit are unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty (30) days following receipt of this letter. This request must be in the form of a written petition, conforming to Chapter 150B of the North Carolina General Statutes, and filed with the office of Administrative Hearings, 6714 Mail Service Center, Raleigh, North Carolina 27699-6714. Unless such a demand is made, this permit shall be final and binding. Please note that this permit is not transferable except after notice to the Division. The Division may require modification or revocation and reissuance of the permit. This permit does not affect �9Q�1� North Carolina Department of Environmental Quality I Division of Water Resources 512 North Salisbury Street 11611 Mall Service Center I Raleigh. North Carolina 27699-1611 919.707.9000 the legal requirements to obtain other permits which may be required by the Division of Water Resources or any other Federal, State, or Local governmental permits that may be required. If you have any questions on this permit, please contact Sergei Chernikov at 919-807-6386. Sincerely, rda Culp,etefim Director vision of Water Resources Hardcopy: Central Files, NPDES Files Raleigh Regional Office, Water Quality E-copy: US EPA, Region IV WSS/Aquatic Toxicology Branch PERCS North Carolina Department of Environmental Quality I Division of Water Resources 512 North Salisbwy Street 116U Mail Service center I Raleigh North Carolina 27699-1611 919.707.9000 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENTAL QUALITY DIVISION OF WATER RESOURCES PERMIT TO DISCHARGE WASTEWATER UNDER THE NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM In compliance with the provisions of North Carolina General Statute 143-2IS. 1, other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Federal Water Pollution Control Act, as amended, KapStone Kraft Paper Corporation is hereby authorized to discharge wastewater from a facility located at the KapStone Kraft Paper Corporation WWTP 100 Gaston Road Roanoke Rapids Halifax County to receiving waters designated as the Roanoke River in the Roanoke River Basin in accordance with effluent limitations, monitoring requirements, and other applicable conditions set forth in Parts I, II, III and IV hereof. This permit shall become effective September 1, 2018. This permit and authorization to discharge shall expire at midnight on March 31, 2022. Signed this day August 10, 2018. LyiFfdallCulpepper, n irector "ion of Water Resources By Authority of the Environmental Management Commission Page 1 of 8 Permit NC0000752 SUPPLEMENT TO PERMIT COVER SHEET All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked. As of this permit issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the permit conditions, requirements, terms, and provisions included herein. KapStone Kraft Paper Corporation is hereby authorized to: 1. Continue to operate an existing 28.0 MGD wastewater treatment facility (outfall 001) consisting of the following: ♦ Mechanical bar screen ♦ Primary clarifier ♦ Emergency holding pond ♦ Sludge lagoon ♦ Aeration basin ♦ Three stabilization ponds 2. Continue to discharge non -contact cooling water from the B & C evaporator (outfall 002), and 3. Discharge from said treatment works, located at the KapStone Kraft Paper Wastewater Treatment Plant, North Roanoke Avenue, Roanoke Rapids, Halifax County, at the locations specified on the attached map into the Roanoke River which is classified C waters in the Roanoke River Basin. Page 2 of 8 Permit NC0000752 Part I A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS 115A NCAC 02B .0400 et seq., 02B .0500 et seq.] During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall serial number 001 - process water and stormwater. Such discharges shall be limited and monitored6 by the Permittee as specified below: EFFLUENT CHARACTERISTICS LIMITS MONITORING REQUIREMENTS Monthly Avera a Daily Maximum Measurement Frequency Sample a Sample Location' Flow 28.0 MGD Continuous Recorder I or E BOD, 5 day, 20'C 8,680.0 lbs da 17,361.0 lbs da Daily5 Composite E Total Suspended Solids 18,601.0 lbs da 37,202.0 lbs da Dailys Composite E Dissolved Oxygen, m L Dail s Grab E, U, D Temperature, OC Dail s Grab E, U, D Conductivity, pnihocm Dail 5 Grab E, U, D NH3 as N, m L Monthly Composite E Total Nitrogen NO2+NO3+TKN,m L Monthly Composite E Total Phosphorus, m L Monthly Composite E Chronic ToXiCity2,3 Quarterly Composite E Total Co era 211.25 µ L 227.36 µ L Quarterly Composite E H 6.0 — 9.0 standard units Dail 5 Grab E Pentachloro henol4 1.80lbs/day Weekly Grab E Trichloro henol4 1.64 lbs/day Weekly Grab E Total Hardness, m L Monthly Composite E, U Footnotes: 1. Sample locations: E - Effluent, I - Influent, U - Upstream at NC Highway 48 Bridge, D - Downstream at NC Highway 158. All upstream and downstream samples shall be collected as grab samples. Stream sampling shall be conducted 3/week during June, July, August and September and weekly during the remainder of the year. 2. Chronic Toxicity (Ceriodaphnia) P/F at 3.7%; March, June, September and December; see A. (3.), Chronic Toxicity Pass/Fail Permit Limit. 3. Monitoring for metals and the whole effluent toxicity test shall be conducted at the same time. 4. Monitoring for pentachlorophenol and trichlorophenol is not required unless chlorophenolic containing biocides are used at the facility. If chlorophenolic-containing biocides are used at the facility, monitoring for pentachlorophenol and trichlorophenol shall commence immediately for the duration of the use of the biocides and for a period of not less than two months after discontinuing use of the biocides. 5. Daily shall mean everyday except Saturdays, Sundays, and legal holidays. 6. The permittee shall submit Discharge Monitoring Reports electronically using NC DWR's eDMR application system. Please See Special Condition A. (6.). There shall be no discharge of floating solids or visible foam in other than trace amounts. Page 3 of 8 Permit NC0000752 A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [15A NCAC 02B .0400 et seq., 02B .0500 et seq.] During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall(s) serial number 002 - non -contact cooling water. Such discharges shall be limited and monitored4 by the Permittee as specified below: EFFLUENT LIMITS MONITORING REQUIREMENTS CHARACTERISTICS Monthly Daily Measurement Sample Sample Average Maximum Frequency a Location Flow Semi- Estimate Effluent annuall Temperature'C See note 1 See note 1 Semi- Grab Effluent annually Semi- Effluent, pH 6.0 - 9.0 standard units2 Grab Upstream, annually Downstream3 Footnotes: 1. The temperature of the effluent will be regulated so that the temperature of the receiving stream does not increase more than 2.8'C (5.05°F) above the natural water temperature and does not exceed a maximum of 29°C (84.2°F). 2. The pH shall not be less than 6.0 standard units nor more than 9.0 standard units. In the event that effluent pH shall be recorded outside this range, any value that falls within the range of pH measured at the upstream and downstream points shall be considered compliant. Effluent pH shall be sampled on the same days that stream samples for pH are taken. See Condition A. (5.), pH Re -opener. 3. Upstream at NC Highway 48 Bridge, Downstream at NC Highway 158. 4. The permittee shall submit Discharge Monitoring Reports electronically using NC DWR's eDMR application system. Please See Special Condition A. (6.). There shall be no chromium, zinc or copper added to the treatment system except as pre - approved additives to biocidal compounds. The permittee shall obtain authorization from the Division prior to any use of biocide in the cooling water (See A. (4), Biocide Condition). There shall be no discharge of floating solids or visible foam in other than trace amounts. Page 4 of 8 Permit NC0000752 A. (3.) CHRONIC TOXICITY PERMIT LIMIT (QRTRLY) [15A NCAC 02B .0200 et seq.] The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia dubfa at an effluent concentration of 3.7%. The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be performed during the months of March, June, September, and December. Effluent sampling for this testing shall be performed at the NPDES permitted final effluent discharge below all treatment processes. If the quarterly test procedure results in a failure or ChV below the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -December 2010) or subsequent versions. All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the parameter code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWR Form AT-3 (original) is to be sent to the following address: Attention: North Carolina Division of Water Resources Water Sciences Section/Aquatic Toxicology Branch 1621 Mail Service Center Raleigh, North Carolina 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Water Sciences Section no later than 30 days after the end of the reporting period for which the report is made. Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream. Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the Water Sciences Section at the address cited above. Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required during the following month. Assessment of toxicity compliance is based on the toxicity testing month. Should any test data from this monitoring requirement or tests performed by the North Carolina Division -of Water Resources indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring requirements or limits. NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival, minimum control organism reproduction, and appropriate environmental controls, shall constitute an invalid test and will require immediate follow-up testing to be completed no later than the last day of the month following the month of the initial monitoring. Page 5 of 8 Permit NC0000752 A. (4.) BIOCIDE CONDITION [G.S. 143-215.1(b)] The permitted shall not use any biocides except those approved in conjunction with the permit application. The permitted shall notify the Director in writing at least ninety (90) days prior to instituting use of any additional biocide in the treatment system, which may be toxic to aquatic life (other than biocides previously reported to the Division). Such notification shall include completion of Biocide Worksheet Form 101 and a map indicating the discharge point and receiving stream. A. (5.) PH REOPEAER [G.S. 143-215.1(b)] The Division may re -open this permit to remove pH limitation footnotes at Outfall 002, should new information indicate water quality problems due to declining pH in this portion of the river. A. (6.) ELECTRONIC REPORTING OF DISCHARGE MONITORING REPORTS [G.S. 143-215.1(b)] Federal regulations require electronic submittal of all discharge monitoring reports (DMRs) and program reports. The final NPDES Electronic Reporting Rule was adopted and became effective on December 21, 2015. NOTE: This special condition supplements or supersedes the following sections within Part II of this permit (Standard Conditions for NPDES Permits): • Section B. (11.) Signatory Requirements • Section D. (2.) Reporting • Section D. (6.) Records Retention • Section E. (5.) Monitoring Reports 1. Reporting Requirements [Supersedes Section D. 12.1 and Section E. 15.1 lall The permittee shall report discharge monitoring data electronically using the NC DWR's Electronic Discharge Monitoring Report (eDMR) internet application. Monitoring results obtained during the previous month(s) shall be summarized for each month and submitted electronically using eDMR. The eDMR system allows permitted facilities to enter monitoring data and submit DMRs electronically using the internet. Until such time that the state's eDMR application is compliant with EPA's Cross -Media Electronic Reporting Regulation (CROMERR), permittees will be required to submit all discharge monitoring data to the state electronically using eDMR and will be required to complete the eDMR submission by printing, signing, and submitting one signed original and a copy of the computer printed eDMR to the following address: NC DEQ / Division of Water Resources / Water Quality Permitting Section ATTENTION: Central Files 1617 Mail Service Center Raleigh, North Carolina 27699-1617 If a permittee is unable to use the eDMR system due to a demonstrated hardship or due to the facility being physically located in an area where less than 10 percent of the households have broadband access, then a temporary waiver from the NPDES electronic reporting requirements may be granted and discharge monitoring data may be submitted on paper DMR forms (MR 1, 1. 1, 2, 3) or alternative forms approved by the Director. Duplicate signed copies shall be submitted to the mailing address above. See "How to Request a Waiver from Electronic Reporting" section below. Page 6 of 8 PermitNC0000752 Regardless of the submission method, the first DMR is due on the last day of the month following the issuance of the permit or in the case of a new facility, on the last day of the month following the commencement of discharge. Starting on December 21, 2020, the permittee must electronically report the following compliance monitoring data and reports, when applicable: • Sewer Overflow/Bypass Event Reports; • Pretreatment Program Annual Reports; and • Clean Water Act (CWA) Section 316(b) Annual Reports. The permittee may seek an electronic reporting waiver from the Division (see "How to Request a Waiver from Electronic Reporting" section below). 2. Electronic Submissions In accordance with 40 CFR 122.41(1)(9), the permittee must identify the initial recipient at the time of each electronic submission. The permittee should use the EPA's website resources to identify the initial recipient for the electronic submission. Initial recipient of electronic NPDES information from NPDES-regulated facilities means the entity (EPA or the state authorized by EPA to implement the NPDES program) that is the designated entity for receiving electronic NPDES data [see 40 CFR 127.2(b)]. EPA plans to establish a website that will also link to the appropriate electronic reporting tool for each type of electronic submission and for each state. Instructions on how to access and use the appropriate electronic reporting tool will be available as well. Information on EPA's NPDES Electronic Reporting Rule is found at: httt)s: / /www.federalregister. gov / documents / 2015 / 10 / 22 / 2015-24954 / national -pollutant - discharge -elimination -system -nodes -electronic -reporting -rule Electronic submissions must start by the dates listed in the "Reporting Requirements" section above. 3. How to Request a Waiver from Electronic Reporting The permittee may seek a temporary electronic reporting waiver from the Division. To obtain an electronic reporting waiver, a permittee must first submit an electronic reporting waiver request to the Division. Requests for temporary electronic reporting waivers must be submitted in writing to the Division for written approval at least sixty (60) days prior to the date the facility would be required under this permit to begin submitting monitoring data and reports. The duration of a temporary waiver shall not exceed 5 years and shall thereupon expire. At such time, monitoring data and reports shall be submitted electronically to the Division unless the permittee re -applies for and is granted a new temporary electronic reporting waiver by the Division. Approved electronic reporting waivers are not transferrable. Only permittees with an approved reporting waiver request may submit monitoring data and reports on paper to the Division for the period that the approved reporting waiver request is effective. Information on eDMR and the application for a temporary electronic reporting waiver are found on the following web page: http: / /deo.nc.gov/about/divisions/water-resources/edmr Page 7 of 8 Permit NC0000752 4. Signatory Requirements [Supplements Section B 111.1 Ibl and Supersedes Section B (11.) LIl All eDMRs submitted to the permit issuing authority shall be signed by a person described in Part II, Section B. (I I.)(a) or by a duly authorized representative of that person as described in Part II, Section B. (11.)(b). A person, and not a position, must be delegated signatory authority for eDMR reporting purposes. For eDMR submissions, the person signing and submitting the DMR must obtain an eDMR user account and login credentials to access the eDMR system. For more information on North Carolina's eDMR system, registering for eDMR and obtaining an eDMR user account, please visit the following web page: http: / /dea.nc.eov/ about/ divisions /water-resources/edmr Certification. Any person submitting an electronic DMR using the state's eDMR system shall make the following certification [40 CFR 122.22]. NO OTHER STATEMENTS OF CERTIFICATION WILL BE ACCEPTED: certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are sigmficantpenalties for submitting false information, including the possibility offines and imprisonment for knowing violations." 5. Records Retention [Supplements Section D. 16.11 The permittee shall retain records of all Discharge Monitoring Reports, including eDMR submissions. These records or copies shall be maintained for a period of at least 3 years from the date of the report. This period may be extended by request of the Director at any time [40 CFR 122.41]. Page 8 of 8 d to Vis �6"�1 irJi 4�) N R Outfall001 G Outfall002 1( , 1 1 i M 71011 '106L tom: - .! •' �`�" i:� �' i 1F ��/„ % l � � Jstliai 29t f.� ♦ �� �� I A A To t � Tower J J ..�CHT r + Kapstone Kraft Paper Corp.- NC0000752 Facility 0 USGS Quad Number: 628NW Lat.: 36°28'19" Location Receiving Stream: Roanoke River Long.: 77038'14" Stream class: C SCALE 1:24 000 Subbasin: Roanoke, 03-02-08 North } DowSign Envelope ID: 39B4BC91-6F5B-4OE5-6B75-F437CBB29AF6 Notice of Deficiency Roanoke Rapids Mill WWTP Page 2 of 2 If you should need any assistance or would like to discuss this non-compliance situation, please contact Alys Hannum of the Raleigh Regional Office at alys.hannum(a)ncdenr.00v, or by phone at 919-791-4255. Sincerely, CDo uftned by: UaIn t SSA f. kAO At,I. 82916E8AB321"F.. Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources, NCDEQ cc: WQS Raleigh Regional Office - Enforcement File Laserfiche DocuSign Envelope ID: 39B4BC91-8F5B-40E5-8B75-F437CBB29AF6 ROY COOPER .r.v, r ;l �I ELIZABETH S. BISER S. DANIEL SMITH �'oRn� c„aoune. �,...,., rnroannrenra Quanry Certified Mail # 7020 3160 0000 4115 3470 Return Receipt Requested January 26, 2022 Benjamin P White, General Manager Westrock Kraft Paper LLC PO Box 458 Roanoke Rapids, NC 27870-0458 SUBJECT: NOTICE OF DEFICIENCY Tracking Number: NOD-2022-PC-0012 Permit No. NC0000752 Roanoke Rapids Mill WWTP Halifax County Dear Permittee: A review of the December 2020 Discharge Monitoring Report (DMR) for the subject facility revealed the deficiency(s) indicated below: Sample Location Parameter Date Type of Deficiency 1/31/2021 Outfall 002 Missing Please be aware that non-compliance with your permit could result in enforcement action by the Division of Water Resources for these and any additional violations of State law. The Raleigh Regional Office encourages you to take all necessary actions to bring your facility into compliance. DowSign Envelope ID: 60093DD5-94CE-46F2-9A38-D84803075245 Notice of Deficiency Roanoke Rapids Mill WWTP Page 2 of 2 If you should need any assistance or would like to discuss this non-compliance situation, please contact Alys Hannum of the Raleigh Regional Office at alvs.hannum@ncdenr.gov, or by phone at 919-791-4255. Sincerely, COocuSipnetl by: VAV t,SS#. f, e2916RAS321441` Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources, NCDEQ cc: WQS Raleigh Regional Office - Enforcement File Laserfiche DEQ' DowSign Envelope ID: 60093DD5-94CE-46F2-9A3B-D84803075245 R_OYCOOPER� ED2A8ETH S. BfSER k:rn S. DANIEL SMITH - - m...,,- 1 ,. 1-1.- .. , Certified Mail # 7020 3160 0000 4115 3494 Return Receipt Requested January 26, 2022 Benjamin P White, General Manager Westrock Kraft Paper LLC PO Box 458 Roanoke Rapids, NC 27870-0458 SUBJECT: NOTICE OF DEFICIENCY Tracking Number: NOD-2022-PC-0013 Permit No. NC0000752 Roanoke Rapids Mill WWTP Halifax County Dear Permittee: A review of the August 2020 Discharge Monitoring Report (DMR) for the subject facility revealed the deficiency(s) indicated below: Sample Location Parameter Date Type of Deficiency 10/1/2020 Outfall 002 Missing Please be aware that non-compliance with your permit could result in enforcement action by the Division of Water Resources for these and any additional violations of State law. The Raleigh Regional Office encourages you to take all necessary actions to bring your facility into compliance. 0 WestRock November 10, 2020 Federal Express Tracking Number: 7720 3715 5921 Jason Robinson, P.E. Water Quality Regional Operations Raleigh Regional Office NCDEQ 3800 Barrett Drive, Suite 101 Raleigh, NC 27609 Subject: Sanitary Sewer Incident September 18, 2020 W61(,SD0704 100 Gaston Rd. Roanoke Rapids, NC 27870 NC Dept of Environmental Quality NOV 1120 Raleigh Regional Office This letter/email is in reference to a sanitary sewer backup that occurred on September 18, 2020 at the WestRock Kraft Paper, LLC. mill in Roanoke Rapids, Halifax County, North Carolina. A Notice of Violation (NOV) was issued by the Department of Water Quality (DWQ) on October 22, 2020 and received from the Roanoke Rapids Post Office on November 3, 2020 for this event. Through a series of subsequent telephone calls and emails, the Department emphasized that, before any action from DWQ to rescind the NOV could be considered, a written request must be submitted by WestRock. This written correspondence is being submitted in support of our request to rescind the NOV. The following discussions provide an overview of the sewer layout at the mill, a description of the September 18 incident and the mill's response, a summary of the subsequent contact with DEQ, and WestRock's position on the matter. Waste water collection and treatment activities for the City of Roanoke Rapids are contracted out to the Roanoke Rapids Sanitary District (RRSD). The RRSD main sanitary sewer line runs through the south edge of the mill property on its way to a lift pump station and the RRSD waste water treatment plant in Weldon. One of the Mill's sanitary sewer lines ties into the RRSD sanitary sewer at the SW corner of the mill property. A Google Earth overhead and a more detailed sewer sketch is included with this letter. Scanned pdf files are attached to the email. Both drawings identify the mill sanitary sewer manhole that overflowed on September 18, the RRSD sewer and the tie in point where the mill sewer meets the RRSD sewer. The mill storm water ditch is also identified. Heavy rains periodically cause the RRSD sanitary sewer to exceed capacity creating backups on the customer lines throughout the City. Mill sanitary sewer manholes are subject to these backup situations. One location in particular that overflowed on September 18. is a manhole located within our property boundaries near our main truck access gate. That manhole is positioned right in the middle of truck traffic coming in and going out of our Security Gate 1. A storm water ditch beginning in this area and running around the south and east boundaries of the mill then discharging directly into the Roanoke River is in close proximity to the manhole. Approximately 70% of the City's rain water runoff also discharges into that stormwater ditch. A RRSD sanitary sewer back up is precisely what happened on September 18. The day/night before the event brought a 4+ inch rain event to the Roanoke Rapids area. Between 8:00 and 8:30 AM on the morning of September 18, 2020, water was observed to be upwelling from the aforementioned manhole on the Mill's sanitary sewer. Mill maintenance and the Environmental Department responded and sandbagged the manhole directing the majority of the sanitary sewer water to nearby Mill process sewers. It was immediately estimated that up to 3,500 gallons of water came out of the manhole of which an estimated 500 gallons made its way to the nearby storm water ditch. Other backups likewise occurred throughout the City as a result of the influx of stormwater to the collection system. 16 In the past, on such occurrerr he RRSD, recognizing that they were the cause, took responsibility for making the proper notifications to the agency. Through discussions with RRSD, it is our understanding that a change in their policy regarding such notifications occurred the first of the year, and they are no longer making notifications for events that occur on WestRock property to the agency. To prevent the event from going undetected by the agency, WestRock has voluntarily provided the notification for this event even though the release was caused solely by issues with the RRSD sewer system. In their defense, when these events have occurred in the past, RRSD has responded quickly following our notifications to them and assisted with cleanup and investigation into the cause. On September 18, an immediate (within 24-hrs) notice was made by WestRock to Mr. Cheng Zhang of the Raleigh Regional office reporting 3500 gallons of spillage. A follow up report of the incident was completed on Agency forms and submitted to Mr. Zhang on September 23 via email. In the follow up report, after further investigations with more accurate information, the total amount of spillage was reported at 3,000 gallons with 500 gallons to surface waters (the storm water ditch). On November 3, we received notice that we had a certified letter at the post office. That correspondence was the NOV. There have been several subsequent phone calls and emails relative to the NOV this week, including the 1OAM November 5 call. The root cause of the release that occurred on September 18 was the lack of RRSD sewer capacity to manage significant storm events. The mill has evaluated the following potential options for containing sewer overflows when they occur, keeping in mind that WestRock cannot do anything to eliminate the root cause of the event, which was the sanitary sewer upset. 1. Raise the manhole covers We would have to raise manhole covers closest to the RRSD sewer three-four feet in elevation in order to be adequately above the RRSD sanitary sewer and prevent back flows in that area. Not only would this not prevent the backup moving to other areas in the mill, raising those manholes would impede log truck and other traffic into and exiting the mill. 2. Sealable manholes also could be installed. This likewise, would not prevent backups from moving to other locations in the mill. 3. We have had discussions with RRSD about the situation during which, they assured us that they have hired a consultant to look into the matter, notjust only at WestRock, but throughout the City. As stated, the root cause of the sanitary sewer overflow and the release to the waterway is the lack of sufficient capacity in the RRSD sewer system and its inability to handle heavy rains. Our sanitary sewer flow has to have a discharge path. That path is the RRSD sewer. As such, it is hereby requested that the NOV be rescinded. Maintaining compliance with all environmental regulations is in the core values of WestRock Company. We are very proud of the near spotless environmental record of the Roanoke Rapids mill. Notices of Violations are of utmost importance to us and justly deserve immediate attention and action. Please keep us informed of the progress in the handling of the subject NOV. Thank you for your attention and reaction to this unfortunate incident. If you have any questions please don't hesitate to call. We look forward to your response. Sincerely, Benjamin General Manager Enclosures Ket Nina Butler, WestRock Chief Environmental Officer and Associate General Council Brad Justus, WestRock Environmental Services Manager Mike Knudson, WestRock Environmental Manager Chris Williams, WestRock waste treatment ORC Dan Brown, Roanoke Rapids Sanitary District D%^ -5ali .A W eeF Rk Roaneiu c F411�.O�s M►�\ / \ �\\ 063.4' 0 I� 11 4'CI 1 11 III 1�:11 8•\ IA II1 I�LLIIN 62.21' 11J�� ` `. PVC 1 1 1 1 IW 62.21' INV 62.7' W 64.5' CONTRACTOR PARKING FZRso sr�..r ROY COOPER Governor MICHAEL S. REGAN Secretary S. DANIEL SMITH Direnor Mr. Benjamin White, General Manager WestRock Kraft Paper P.O. Box 458 Roanoke Rapids, NC 27870 NORTH CAROLINA Environmental Quality March 25, 2020 Subject: Compliance Evaluation Inspection Roanoke Rapids Mill WWTP Permit No. NC0000752 Northampton County Dear Mr. White: �m. On March 11, 2020, Jason Robinson of the Raleigh Regional Office (RRO) conducted a compliance evaluation inspection of the subject facility. The assistance provided by Mr. Christopher Williams, the operator in responsible charge (ORC), Mr. Matthew Upton, the backup ORC, Mr. Michael Knudson, Environmental Manager and Mr. Paul Kinnin, Environmental Technician (laboratory staff) was appreciated as it facilitated the inspection process. The inspection report is attached. The following observations were made: This facility, known as Roanoke Rapids Mill WWTP and owned by Westrock Kraft Paper LLC (formerly owned by Kapstone Kraft Paper Corporation) is permitted to discharge at a rate of 28.0 MGD and consist of. mechanical bar screen, primary clarifier, emergency holding pond, sludge lagoon, aeration pond, and three stabilization ponds. The sludge lagoon, aeration pond and stabilization ponds and Outfall 001 (and on -site landfill) are located on the opposite side of the river from the Mill. Outfall 002 discharges non -contact cooling water on the Mill -side of the river. Both outfalls discharge directly to the Roanoke River, a Class C water in the Roanoke River basin. The facility also has sludge -handling facility and onsite landfill that is covered by permit WQ0000436 (Surface Disposal of Residual Solids (503 exempt). 2. The most recent permit for the new owner was just issued and effective on March 18, 2020. The permit will expire on April 30, 2021. A renewal application should be submitted at least 180 days prior to expiration. 3. This treatment facility is classified as a WW-4. Mr. Christopher Williams (ORC) is a certified W W-4 operator, and Mr. Matthew Upton (bORC) is a certified W W-3 operator. 4. The ORCs maintain a detailed daily logbook. Lab results, chain -of -custody forms, and electronic D E Q North Carolina Department of Environmental Quality I Division of Water Resources Raleigh Regional Office 13800 Barrett Drive I Raleigh, North Carolina 27609 s env 'e� 919.791.4200 Roanoke Rapid W WTP — Wesuock Kraft Pape Permit No. NC0000752 Discharge Monitoring Reports (eDMRs) were complete and current, kept in good order and ready for review. August and October 2019 eDMR data was compared to lab bench sheets; no data transcription errors were noted during the inspection. Parameter analyses are performed by Meritech (Certificate # 165). Toxicity analysis is done by Environmental Testing Solutions (Certification #37). 5. Field lab parameter calibration and analysis records were reviewed during the inspection. The facility analyzes BOD, TSS, pH, conductivity, DO, Suspended Residue and temperature (Certificate #183). The laboratory was inspected in a cursory manner. 6. The influent bar screens are mechanically cleaned every 8 hours. Untreated wastewater can be routed to the emergency holding pond prior to the bar screens. All three influent pumps into the primary clarifier were in operation. The primary clarifier was in good condition. Sludge from the primary clarifier is pumped via two sludge pumps into a blending tank and is then dewatered at the sludge handling facility beside the clarifier. Two trains of belt presses, screw presses, and chemical feed systems are present. Typically train operations are alternated between the two. Dewatered sludge is disposed at the onsite land fill across the river via truck. Leachate from the land fill and the old sludge pond flows by gravity into the aeration pond and is treated along with the effluent from the primary clarifier (WQ0000436). 8. Effluent from the clarifier is transported across the river via gravity and is further treated at the aeration pond across the river. There are thirty-one 2,135 hp aerators. One was down for maintenance during the inspection. The number of aerators on-line is controlled by the DO level in the pond. 9. Effluent from the aeration pond is further treated in the three in -series stabilization ponds before being discharged to the river. Samples are taken at the discharge point of the final stabilization pond. A composite sampler was present, and temperature was just below 4 degrees. Flow is measured and reported just prior to the discharge. The flow meter was last calibrated on July 15, 2019. 10. Outfall 001 was observed. The right of way was maintained. The effluent was observed to be clear and free of solids. No visible impacts were noted immediately downstream the effluent pipe. Outfall 002 was observed from across the river (from Outall 001). (see next page) 2of3 Roanoke Rapid WWTP— Westro A Paper Permit No. NC0000752 The overall condition of the facility is compliant with Division standards. If you have any questions regarding the attached reports or any of the findings, please contact Jason Robinson at jason.t.robinson@ncdenr.gov Sincerely, J Scott Vinson D Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources, NCDEQ Attachments Compliance Inspection Report Cc: DWR Laserfiche -31-) as Raleigh Regional Office w/attachment Chris Williams, ORC: chris.m.williamsAwestrock.com 3 of 3 United States Environmental Protection Agency Form Approved. EPA Washington. D C 20460 OMB No. 204MO57 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 IF I 3 I NC0000752 I11 12 20/03/11 17 18LC] 191 � I 201 I 21111111111111111 11111111111111 IIIIIIUI II r6 Inspection Work Days Facility Self-Monitonng Evaluation Rating B1 CA -Reserved 67 [ ....... . J70 U 71 U 72 L1J u I 731 I 174 7 I I I I I I I I80 I I I 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 permit Number) 01:OOPM 20103111 18I09I01 Roanoke Rapids MITI WWTP 100 Gaston Rd Exit Time/Date Permit Expiration Date Roanoke Rapids NC 27870 03.o0PM 20103/11 22/03/31 Names) of Onsite Representative(s)/Ttles(s)/Phone and Fax Number(s) Other Facility Data Christopher Michael WilliamslORC/252-533-6237/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Benjamin P White,PO Box 458 Ronok Rpd Afs NC 27870/General Manager/252-533-6335/ Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar N Records/Reports Sludge Handling Dispo; E 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 Jason T Robinson, DWR/RRO WO/919-791-0200/ Signature of ManageCmeentt 0 AAReviewer Agency/Office/Phoneand Fax Numbers Date q�.ze�.t � •`'!�/ 9�9 T %� ill �� /'�/2r l-� 1 ��ZJ EPA Form 3560.3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type (Cont.) NC0000752 I1 1 20/03/11 17 18 1 C 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On March 11, 2020, Jason Robinson of the Raleigh Regional Office (RRO) conducted a compliance evaluation inspection of the subject facility. The assistance provided by Mr. Christopher Williams, the operator in responsible charge (ORC), Mr. Matthew Upton, the backup ORC, Mr. Michael Knudson, Environmental Manager and Mr. Paul Kinnin, Environmental Technician (laboratory staff) was appreciated as it facilitated the inspection process. The inspection report is attached. The following observations were made: 1. This facility, known as Roanoke Rapids Mill WWTP and owned by Westrock Kraft Paper LLC (formerly owned by Kapstone Kraft Paper Corporation) is permitted to discharge at a rate of 28.0 MGD and consist of: mechanical bar screen, primary clarifier, emergency holding pond, sludge lagoon, aeration pond, and three stabilization ponds. The sludge lagoon, aeration pond and stabilization ponds and Outfall 001 (and on -site landfill) are located on the opposite side of the river from the Mill. Outfall 002 discharges non -contact cooling water on the Mill -side of the river. Both outfalls discharge directly tc the Roanoke River, a Class C water in the Roanoke River basin. The facility also has sludge -handling facility and onsite landfill that is covered by permit WQ0000436 (Surface Disposal of Residual Solids (503 exempt). 2. The most recent permit for the new owner was just issued and effective on March 18, 2020. The permit will expire on April 30, 2021. A renewal application should be submitted at least 180 days prior tc expiration. 3. This treatment facility is classified as a WW-4. Mr. Christopher Williams (ORC) is a certified WW-4 operator, and Mr. Matthew Upton (bORC) is a certified WW-3 operator. 4. The ORCs maintain a detailed daily logbook. Lab results, chain -of -custody forms, and electronic Discharge Monitoring Reports (eDMRs) were complete and current, kept in good order and ready for review. August and October 2019 eDMR data was compared to lab bench sheets: no data transcriptior errors were noted during the inspection. Parameter analyses are performed by Meritech (Certificate # 165). Toxicity analysis is done by Environmental Testing Solutions (Certification #37). 5. Field lab parameter calibration and analysis records were reviewed during the inspection. The facility analyzes BOD, TSS, pH, conductivity, DO, Suspended Residue and temperature (Certificate #183). The laboratory was inspected in a cursory manner. 6. The influent bar screens are mechanically cleaned every 8 hours. Untreated wastewater can be routed to the emergency holding pond prior to the bar screens. All three influent pumps into the primary clarifier were in operation. The primary clarifier was in good condition. 7. Sludge from the primary clarifier is pumped via two sludge pumps into a blending tank and is then dewatered at the sludge handling facility beside the clarifier. Two trains of belt presses, screw presses, and chemical feed systems are present. Typically train operations are alternated between the two. Dewatered sludge is disposed at the onsite land fill across the river via truck. Leachate from the land fill and the old sludge pond flows by gravity into the aeration pond and is treated along with the effluent from the primary clarifier (WQ0000436). 8. Effluent from the clarifier is transported across the river via gravity and is further treated at the aeration pond across the river. There are thirty-one 2,135 hp aerators. One was down for maintenance during the inspection. The number of aerators on-line is controlled by the DO level in the pond. Page# Permit: NC0000752 Inspection Date: 03/11/2020 Owner • Facility: Roanoke Rapids MITI WWiP Inspection Type: Compliance Evaluation 9. Effluent from the aeration pond is further treated in the three in -series stabilization ponds before being discharged to the river. Samples are taken at the discharge point of the final stabilization pond. f composite sampler was present, and temperature was just below 4 degrees. Flow is measured and reported just prior to the discharge. The flow meter was last calibrated on July 15, 2019. 10. Outfall 001 was observed. The right of way was maintained. The effluent was observed to be clear and free of solids. No visible impacts were noted immediately downstream the effluent pipe. Outfall 002 was observed from across the river (from Outall 001). Page# Permit: NC0000752 Owner -Facility: Roanoke Rapids MITI WWTP Inspection Date: 0311112020 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 ❑ ❑ E ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ E ❑ ❑ Is access to the plant site restricted to the general public? N ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? E ❑ ❑ ❑ Comment Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? E ❑ ❑ ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ 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 24t7 with a certified operatc E ❑ ❑ ❑ on each shift? Is the ORC visitation log available and current? N ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? 0 ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification' 0 ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? 0 ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ❑ Comment: Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? E ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? 0 ❑ ❑ ❑ Page# 4 Permit: NC0000752 Owner - Facility: Roanoke Rapids MITI WWTP Inspection Date: 03/11/2020 Inspection Type: Compliance Evaluation Laboratory Yes No NA NE # Is the facility using a contract lab? E ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees N ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/_ 0.2 degrees? ❑ ❑ N ❑ Incubator (BOD) set to 20.0 degrees Celsius +/_ 1.0 degrees? IN ❑ ❑ ❑ Comment: 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 N ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Bar Screens Yes No NA NE Type of bar screen a.Manual ❑ b.Mechanical Are the bars adequately screening debris? ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Equalization Basins Yes No NA NE Is the basin aerated? ❑ ❑ ❑ N Is the basin free of bypass lines or structures to the natural environment? ❑ ❑ ❑ N Is the basin free of excessive grease? ❑ ❑ ❑ Are all pumps present? ❑ ❑ ❑ 0 Are all pumps operable? ❑ ❑ ❑ 0 Are float controls operable? ❑ ❑ ❑ Are audible and visual alarms operable? ❑ ❑ ❑ # Is basin size/volume adequate? ❑ ❑ ❑ Comment: Flow can be diverted to the Emergency Holding Pond prior to the bar screen. Page# 5 Permit: NC0000752 Owner -Facility: Roanoke Rapids MIIIWWTP Inspection Date: 03/11/2020 Inspection Type: Compliance Evaluation Primary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? 0 ❑ ❑ ❑ Are weirs level? N ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? E ❑ ❑ ❑ Is the drive unit operational? E ❑ ❑ ❑ Is the sludge blanket level acceptable? ❑ ❑ ❑ E Is the sludge blanket level acceptable? (Approximately '/. of the sidewall depth) ❑ ❑ ❑ 0 Comment Solids Handling Equipment Yes No NA NE Is the equipment operational? E ❑ ❑ ❑ Is the chemical feed equipment operational? E ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Is the site free of high level of solids in filtrate from filter presses or vacuum filters? N ❑ ❑ ❑ Is the site free of sludge buildup on belts and/or rollers of filter press? E ❑ ❑ ❑ Is the site free of excessive moisture in belt filter press sludge cake? 0 ❑ ❑ ❑ The facility has an approved sludge management plan? 0 ❑ ❑ ❑ Comment: Sludge handling equipment and on -site landfill covered by permit WQ0000436 (Surface Disposal of Residual Solids (503 exempt)) Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? 0 ❑ ❑ ❑ Are the diffusers operational? N ❑ ❑ ❑ Is the foam the proper color for the treatment process? N ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? E ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) 0 ❑ ❑ ❑ Page# 6 Permit: NC0000752 Owner - Facility: Roanoke Rapids MITI 1MNTP Inspection Date: 03111t2020 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Comment: Lagoons Yes No NA NE Type of lagoons? Facultative # Number of lagoons in operation at time of visit? 3 Are lagoons operated in? Series # Is a re -circulation line present? ❑ M ❑ ❑ Is lagoon free of excessive floating materials? 0 ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? 0 ❑ ❑ ❑ Are dike slopes clear of woody vegetation? 0 ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? 0 ❑ ❑ ❑ Are dikes free of seepage? 0 ❑ ❑ ❑ Are dikes free of erosion? 0 ❑ ❑ ❑ Are dikes free of burrowing animals? M ❑ ❑ ❑ # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ M ❑ Is the lagoon surface free of weeds? 0 ❑ ❑ ❑ Is the lagoon free of short circuiting? 0 ❑ ❑ ❑ Comment: 3 stabilzation ponds in series are located after the aeration basin, and prior to discharge. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? M ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: 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? ❑ ❑ M ❑ Comment: Page# 7 WaterResources ENVIRONMENTAL QUALITY April 11, 2018 Mr. Benjamin White Vice President of Mill Operation Kapstone — Kraft Paper Corporation 100 Gaston Road Roanoke Rapids, NC 27870 Subject: Compliance Evaluation Inspection Kapstone — Kraft Paper Corporation - Roanoke Rapids Paper Mill Permit No. NC0000752 Northampton County Dear Mr. White: ROY COOPER cnven,ur MICHAEL S. REGAN . Secretary LINDA CULPEPPER Interim Director On November 16, 2016, Cheng Zhang of the Raleigh Regional Office (RRO) conducted a compliance evaluation inspection of the subject facility. The assistance provided by Mr. Neal Davis, the operator in responsible charge (ORC), Mr. Chris Williams, the backup ORC, and Mr. Paul Kinnin, was appreciated as it facilitated the inspection process. The inspection report is attached. The following observations were made: Kapstcme — Kraft Paper Corporation - Roanoke Rapid Paper Mill W WTP is permitted to discharge at a rate of 28.0 MGD and consist of: mechanical bar screen, primary clarifier, emergency holding pond, sludge lagoon, aeration pond, and three stabilization ponds. The plant discharges to Roanoke River, a Class C water in the Roanoke River basin. 1. Current permit expired on March 31, 2017. The facility submitted permit renewal application On September 23, 2016. A draft permit was sent to the facility for comments. 2. All three influent pumps were in operation. The primary clarifier was in good condition. 3. Sludge from the primary clarifier was dewatered at the sludge handling facility, two trains of belt presses, screw presses, and chemical feed system were available. One train was in use at the time of inspection, the other was off line for repair and maintenance. Dewatered sludge was disposed at the onsite land fill. Leachate from the land fill and the old sludge pond flows by gravity into the aeration pond and is treated along with the effluent from the primary clarifier. 4. Effluent from the clarifier was further treated at the aeration pond. All 31 aerators were in operational condition. Numbers of aerators on line was controlled by the DO level in the basin. Division of Water Resources, Raleigh Regional Office, Water Quality Operations Section http://portal.ncdenr.org/web/wq/aps 1628 Mail Service Center, Raleigh, NC 27699-1628 Phone: (919) 791-4200 Location: 3800 Barrett Drive, Raleigh, NC 27609 Fax: (919) 788-7159 Kapstone— Kraft Paper Corporation woke Rapids Paper Mill Permit No. NC0000752 5. Effluent from the aeration pond was further treated in the three stabilization ponds before being discharged to the river. 6. The ORC maintains a daily logbook. Lab results, chain -of -custody forms, and Discharge Monitoring Reports (DMRs) were complete and current, kept in good order and ready for review. November 2017 DMR data were compared to lab bench sheets; no data transcription errors were noted during the inspection. 7. The right of way to Outfall 001 was well maintained. The effluent was observed to be clear and free of solids. No visible impacts were noted immediately downstream the effluent pipe. Outfall 002 was also maintained and accessible. 8. Field lab parameter (Certificate No. 183) calibration and analysis records were reviewed during the inspection. The overall condition of the facility is compliant with Division standards. If you have any questions regarding the attached reports or any of the findings, please contact Cheng Zhang at: (919) 791-4200 (or email: chenQ.zhang_Ancdenr.gov). Sinceely, Danny S ith Water Quality Regional Supervisor Raleigh Regional Office Attachments Compliance Inspection Report Cc: Central Files w/attachment Raleigh Regional Office w/attachment Neal Davis — ORC w/attachment United states Environmental Protection Agency Form Approved. EPA Washington. D L 20,160 OMB No. 2040-0057 Water Compliance Inspection Report Approval expires B-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type � IN 1 2 Ib 3 I NC0000752 I11 12 18/03/12 17 18 Li 19 1 g I 20I I 21111111 1111111 11 l l l ll 1111 l l 11111 111111111 11166 I Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 CA Reservetl 67 70 L._.J 71 u 72 I IN I 73 f I I74 75I I I I80 I I 1 I I Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW also include Entry Time/Date Permit Effective Date POTVV name and NPDES oermit Number) 10:OOAM 18/03/12 12/06/01 Kapstone Kraft Paper Corporation WVVrP Exit Time/Date Permit Expiration Date 100 Gaston Rd Roanoke Rapid INC 27870 12.30PM 18/03/12 17/03131 Names) of Onsite Representabve(s)/Thles(syPhone and Fax Numbers) Other Facility Data 1/1 Neal R Davis/ORC/252-533-6295/ Name, Address of Responsible OfficiaVTida/Phone and Fax Number Contacted Benjamin P White.PO Box 458 Roanoke Rapids INC 278700458//252-533-6335/2525336465 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit E Flow Measurement Operations 8 Maintenanc6 Records/Reports Self -Monitoring Program E Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) %ame(s) and Signature(s) of Inspector(s) Agency/OfficelPhone and Fax Numbers Date Chang Zhang PRO WO//919-791-02001 /g- vyp^r''�• ��-Gt-c• �L �� t r I y0 t $ignatu of Management A 4IR.e,,e/ Agency/Office/Phone and Fax Numb�rsf Date EPA Form 60-3 (Rev 9.94) Previous editions are obsolete. Page# Permit: NC0000752. Owner • Facility: Kopstone Kraft Paper Corporation VNNrP Inspection Date: 03/1212018 Inspection Type: Compliance Evaluabon Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? E ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: DO. TSS. pH. and conductitivity, Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ M ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ ❑ E ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: Draft permit in review Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? M ❑ ❑ ❑ Is all required information readily available, complete and current? M ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? M ❑ ❑ ❑ Is the chain -of -custody complete? E ❑ ❑ ❑ 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? M ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ 0 ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 2417 with a certified operator ❑ ❑ ❑ on each shift? Is the ORC visitation log available and current? 0 ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? E ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? M ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? E ❑ ❑ ❑ Page# 3 Permit: NC0000752 Owner -Facility: Kopstooe Kraft Paper Corporation VAVTP Inspection Date: 03112i2010 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Facility has copy of previous year's Annual Report on file for review? ❑ ❑ 0 ❑ Comment: Effluent Pipe Yes No NA NE Is right of way to the ouffall properly maintained? N ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: Right of way to both Outfall 001 and 002 was maintained properly. Flow Measurement - Influent Yes No NA NE # Is Flow meter used for reporting? 0 ❑ ❑ ❑ Is Flow meter calibrated annually? N ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: Meter was calibrated on August 17 2017 Solids Handling Equipment Yes No NA NE Is the equipment operational? 0 ❑ ❑ ❑ Is the chemical feed equipment operational? E ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Is the site free of high level of solids in filtrate from filter presses or vacuum filters? 0 ❑ ❑ ❑ Is the site free of sludge buildup on belts and/or rollers of filter press? 0 ❑ ❑ ❑ Is the site free of excessive moisture in belt filter press sludge cake? 0 ❑ ❑ ❑ The facility has an approved sludge management plan? 0 ❑ ❑ ❑ Comment: Two rotary screen thickeners and two screw presses. One of each was off line for maintenance. Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑ Is storage adequate? E ❑ ❑ ❑ Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? E ❑ ❑ ❑ Comment: Defoamer fed to effluent and aeration basin Surfaric acid (pHl hydrogen peroxide (hydrogen sulfide control) and polymer fed to primary clarifier sludge Page# 4 Permit: H00000L2 Owner -Facility: Kapstone Kraft Paper Corporation NMfrP Inspection Date: 03,12�2018 Inspection Type: Compliance Evaluation Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? M ❑ ❑ ❑ Is the wet well free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? M ❑ ❑ ❑ Are Float controls operable? M ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? M ❑ ❑ ❑ Comment: Three pumps controled by SCADA Overflow channel to emergency pond 20.4 acre emergency pond holds 28 million gallons of waste water under emergency situations such as Power failure mechanical problems or high strength waste Bar Screens Yes No NA NE Type of bar screen a.Manual ❑ b.Mechanical Are the bars adequately screening debris? ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? M ❑ ❑ ❑ Is the unit in good condition? M ❑ ❑ ❑ Comment: Screen runs on timer Primary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier?. 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? M ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? M ❑ ❑ ❑ Is the sludge blanket level acceptable? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately '/4 of the sidewall depth) M ❑ ❑ ❑ Comment Page# 5 Permit: NC0000752 Inspection Dale: 03/12/2018 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? Is the DO level acceptable? Is the DO level acceptable?(1.0 to 3.0 ni owner - Facility: Kapstone Waft Paper Corporation VJwrP Inspection Type: Compliance Evaluation Yes No NA NE Ext. Air Surface ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ E ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ Comment: All 31 surface aerators were functional Number of aerators online is controlled by the DO sensor in the basin DO level at the channel to first stabilization pond ranges from 0.5 to 4 mq/I. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? E ❑ ❑ ❑ # Is the facility using a contract lab? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees N ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ 0 ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? 0 ❑ ❑ ❑ Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ 0 ❑ ❑ Is sample collected below all treatment units? N ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? E ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees N ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type N ❑ ❑ ❑ representative)? Comment: Fixed time fixed volume composite samplin Influent Sampling Yes No NA NE Page# 6 Permit: nM0000752 Owner -Facility: Kapstone Kraft Paper Corporation WvViP Inspection Date: 03, 122018 Inspection Type: Compliance Evaluation Influent Sampling Yes No NA NE # Is composite sampling flow proportional? ❑ 0 ❑ ❑ Is sample collected above side streams? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? M ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Is sampling performed according to the permit? M ❑ ❑ ❑ Comment: Fixed time fixed volume composite sampling no influent flow meter. Lagoons Yes No NA NE Type of lagoons? Facultative # Number of lagoons in operation at time of visit? 3 Are lagoons operated in? Series # Is a re -circulation line present? ❑ ❑ 0 ❑ Is lagoon free of excessive floating materials? 0 ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? ❑ ❑ 0 ❑ Are dike slopes clear of woody vegetation? 0 ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? M ❑ ❑ ❑ Are dikes free of seepage? 0 ❑ ❑ ❑ Are dikes free of erosion? 0 ❑ ❑ ❑ Are dikes free of burrowing animals? 0 ❑ ❑ ❑ # Has the sludge blanket in the lagoon (s) been measured periodically in multiple M ❑ ❑ ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ 0 ❑ Is the lagoon surface free of weeds? 0 ❑ ❑ ❑ Is the lagoon free of short circuiting? M ❑ ❑ ❑ Comment: 1/5 of the first stabilization pond is dredged every Year Page# 7 Region;....ispectors' Checklist for Fif __ Parameters t-acun Name: e_ r 2r // Regional Plant Inspector: Gtid� -ail NPDES #: c Do0p7 —'2_ Regional Inspector Contact #: q if —7 fr — *is-� Field Lab Certification #: / Region: �7 ¢ =S. L, Lab Contact: &j / k,'n ; n Date: 3 / ( Z / J-o IT I. Check the parameter(s) performed at this site for reporting purposes. ❑ Total Residual Chlorine (TRC) ® Temperature (TEMP) ® Specific Conductivity (SC) ® pH m Dissolved Oxygen (DO) ❑ Settleable Residue (SETT) II. General Laboratory Innta anv nreantinne in enrfinn Yn Are instruments, meters, probes, photometric cells, etc. maintained in good condition? Are standards, reagents and consumables used within manufacturer expiration dates? RC gel standard is exem t. I El Yes ❑ No ® Yes ❑ No Are the following items documented where a licable Item TRC plFL TEMP DO SC SETT Date of sample collection* X JC Time of sample collection* X pC X x Sample collector's initials or signature X Y_ �c Date of sample analysis* Time of sample analysis* )L Analyst initials or signature �( X Sam le location yc y� X .... .— I-- `^ .... aI lu of laiysis may Ve me same Tor in siru or on -site measurements. III. Total Residual Chlorine Total Residual Chlorine meter make and model: Is a check standard analyzed each day of use? Circle one: gel or liquid standard ❑ Yes ❑ No What is the assigned/observed value of the daily check standard? Is a 5-point calibration verificationperformed? Note date of last verification: ❑ Yes ❑ No Alternatively, does the lab construct a linear regression, using 5 standards, to calculate results? Note date of last calibration curve constructed: ❑ Yes ❑ No True values: ❑ Ng/L ❑ mg/L Obtained values: ❑ pg/L ❑ mg/L What program are samples analyzed on? Are results reported in proper units? Check one: /L ❑ m /L ❑ Yes ❑ No Are results reported between the facility's permit limit and the compliance limit of 50 pg/L? If value is less than the low standard, report as "<x", where x=low standard conc. ❑ Yes ❑ No Are samples analyzed within 15 minutes of collection? ❑ Yes ❑ No IV. pH pH meter make and model: OR/ON —STAR H eQ 2-8 /d ) Is the pH meter calibrated with at least 2 buffers per mfg's instructions each day of use? Note buffers used: q_ 7 , 1 D M Yes ❑ No Is the pH meter calibration checked with an additional buffer each day of use? Note check buffer used: 7 Yes ❑ No Does the check buffer read within t0.1 S.U. of the known value? Yes ❑ No Are the following items documented: Meter calibration? Yes ❑ No Check buffer reading? ® Yes ❑ No Are samples anal ed within 15 minutes of collection? ® Yes ❑ No Are sample results reported to 0.1 pH units? FA Yes ❑ No V. Temperature What instrument(s) is used to measure temperature? Check all that apply: ❑ pH meter ❑ DO meter ❑ Conductivity meter ® Digital thermometer ❑ Glass thermometer Is the instrument/thermometer calibration checked at least annually against a NIST traceable or NIST certified thermometer? f ural,,6,rcc A04,V /►,a_{a,�a,. -7.4 ill Yes ❑ No Are temperature, corrections even if zeroposted on the instrument/thermometer? ® Yes ❑ No Are samples measured in situ or on -site? [REQUIRED - there is no holding time for temperature] M Yes ❑ No Are sample results reported in degrees C? 91 Yes ❑ No VI. Dissolved Oxygen DO meter make and model: V. S :' — r -o -Is theair-calibration of -the -DO meter rformed-each day -of use? -- -- — ® Yes ❑ No Are the following items documented: Meter calibration? ® Yes ❑ No Are samples analyzed within 15 minutes of collection? Yes ❑ No Are results reported in m /L? © Yes ❑ No VII. Conductivity Conductivity meter make and model: OA1,OV I STAR, /3 2 5 Is the meter calibrated daily according to the manufa urer's instructions? Note standard used this is generallya one -point calibration): o o /brt'rn o,C s /C,„ Yes ❑ No Is a daily check standard analyzed? Note value: ,_-O J ^»I s / c M ® Yes ❑ No Are the following items documented: Meter calibration? ® Yes ❑ No Are samples anal zed within 28 days of collection? ❑X Yes ❑ No Are results reported in mhos/cm some meters display equivalent S/cm units)? Yes ❑ No Vill. Settleable Residue Does the laboratory have an Imhoff Cone in good condition? ❑ Yes ❑ No Is the sample settled for 1 hour? ❑ Yes ❑ No Is the sample aitated after 45 minutes? ❑ Yes ❑ No Are the following items documented: Volume of sample analyzed? Note volume analyzed: ❑ Yes ❑ No Date and time of sample analysis(settling start time)? ❑ Yes ❑ No Time of agitation after 45 minutes of settling? ❑ Yes ❑ No Sample analysis completion(settling end time)? ❑ Yes ❑ No Are samples analyzed within 48 hours of collection? ❑ Yes ❑ No Are results reported in ml/L? ❑ Yes ❑ No IX. Was a paper trail (comparing contract lab and on -site data to DMR) _ performed? If so, list months reviewed: 11 / so i ® Yes ❑ No X. Is follow-up by the Laboratory Certification program recommended? ❑ Yes No XI. Additional comments: l3r, laah a- pa-c-e,-'z/ z3 i -,—o I Please submit a copy of this completed form to the Laboratory Certification program at: DWQ Lab Certification, Chemistry Lab, Courier # 52-01-01 Electronic copies may be emailed to Iinda.chavis(c�ncdenr.gov. Revision 04/20/2012 WarerResources ENVIRONMENTAL QUALITY January 23, 2018 Mr. Neal Davis Kapstone Kraft Paper Corp 100 Gaston Road Roanoke Rapids, NC 27870 Subject: Bioassay Compliance Evaluation Inspection Whole Effluent Toxicity Test Kapstone Kraft Paper Corporation WWTP NPDES Permit No: NC0000752/001 1laiifax County N PIAA^tvj�r10 Dear Mr. Davis: kuii ��vrca Governor MICHAEL S. REGAN secretary LINDA CULPEPPER Intenm Dmdw Whole Effluent samples were collected from Kapstone Kraft Paper Corporation W WTP on December 5 and December 7, 2017 by Cheng Zhang of Division of Water Resource (DWR), Raleigh Regional Office. These samples were for use in a chronic Cer•iodaphnia dubia pass -fail toxicity test, which was performed by the staff at DWR Aquatic Toxicity Branch. This test passed for the toxicity inspection. Toxicity test information follows. Test Type 3-Brood Ceriodaphnia dubia chronic pass fail Test Concentration 3.7% Test Result Pass (for Toxicity Inspection) If you have any questions regarding the attached report or any of the findings, please contact Cheng Zhang at: (919) 791-4200 (or email: chene zhangQncdenr.gov). h Water Quality Regional Supervisor Raleigh Regional Office Attachments: Compliance Inspection Report Cc: Central Files w/attachment Raleigh Regional Office w/attachment Division of Water Resources, Raleigh Regional Office, Water Quality Operations Section http://poilal.nedenr.orwweb!wq/aps 1628 Mail Service Center, Raleigh, NC 27699-1628 Phone: (919) 7914200 Location: 3800 Barrett Drive, Raleigh, NC 27609 Fax: (919) 788-7159 Urmed States Enwonmental Protection Agency Approved. EPA wasmngton D.0 20e60 No. 204MO57 F'i-PM-PB'-val Water Compliance Inspection Report expires 8-31-98 Section A. National Data System Coding (i.e., PCs) Transaction Code NPDES ynmo/day inspection Type Inspector Fee Type 1 U 2 15 I 3 I NC0000752 I11 12 171l2/05 17 16 I o I 19 I q J 20I I 211 11 IIIIIII1III I II IIII I II(III IIIIIlUl l l f6 Inspection Work Days Facility Self -Monitoring Evaluation Rating Bt CA Reserved 67L I 70 L71 n 72LtiJ 731 I 174 75 I I I I SO Section 9: Facility Data Name and Location of Facility Inspected (For Industnal Users discharging to POTW, also include Entry Time(Date Permit Effective Dale POTW name and NPDES oennd Number) 10 30AM 17/12/05 12IG6101 Kapstone Kraft Paper Corporation WWfP 100 Gaston Rd Exit Time)Date Permit Expiration Dale Roanoke Rapid NC 27870 11.00AM 17/12105 17/03/31 Names) of Onsite Representative(syTitles(s)/Phone and Fax Number(s) Other Facility Data Neal R Davts/ORC/252-533-6295/ Name, Address of Responsible Official/Titte/Phone and Fax Number Contacted Benjamin P White,PO Box 458 Roanoke Rapids NC 278700458//252-533-6335/2525336465 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Other Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(a) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Chang Zhang RRO WOI/919-7914200/ Si nalu of Management Reviewer Ag cy/Office/Phone and Fax N tubers Date r Z�� G✓� EPA Form 3 -3 (Rev 9-94) Previous editions are ob.olete. Page# a NPDES ynmo/day Inspection Type 31 NCO000762 I11 12 17112/05 17 18 U Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Two 24-hour composite effluent samples were collected on December 5, and December 7, 2017,respectively. Ceriodaphnia dubia chronic pass/fail test was performed at Division of Water Resources' Aquatic Toxicity Branch, the result of the test was PASS. Page#