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Home My WebLink AboutNC0006190_Compliance Evaluation Inspection_20231204ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director CERTIFIED MAIL #: 7020 3160 0000 3283 0908 RETURN RECEIPT REQUESTED: Everette Owens, Plant Manager South Fork Industries, Inc. P.O. Box 742 Maiden, NC 28650 SUBJECT: Notice of Violation Compliance Evaluation Inspection South Fork Industries WWTP NPDES Permit No. NC0006190 Catawba County Tracking #: NOV-2023-PC-0596 Dear Mr. Owens: NORTH CAROLINA Environmental Quality December 4, 2023 Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on November 29, 2023, by Mr. Wes Bell of this Office. This Office would like to thank all WWTP staff for their cooperation and assistance that was provided throughout this inspection. Please advise the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding the enclosed report. This report is being issued as a Notice of Violation (NOV) due to the late submittal of the November 2022 monitoring report and the failures to provide proper operation and maintenance, which are violations of the subject NPDES Permit and North Carolina General Statute (G.S.) 143-215.1. Please note that G.S. 143-215.6A provides for a civil penalty of not more than twenty-five thousand dollars ($25,000.00), or twenty-five thousand dollars ($25,000.00) per day when the violation is of a continuing nature, against any person who violates or fails to act in accordance with the terms, conditions, or requirements of any permit issued pursuant to G.S. 143-215.1. Penalties may also be assessed for any damage to surface waters of the State that may result from the violation. North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1 610 East Center Avenue, Suite 301 1 Mooresville, North Carolina 28115 704.6631699 Your response to the previous inspection report indicated that steps would be taken to do upgrades at the wastewater treatment plant including rehabbing the clarifiers, installing diffused aeration, etc.; however, no progress has been made to achieve these upgrades to date. It is requested that a written response be submitted to this Office by December 25, 2023, detailing the actions taken to address all violations and maintenance issues discussed in this report. The response should also include an estimated timeline when these maintenance issues will be addressed. In responding, please address your comments to the attention of Mr. Wes Bell. Should you have any questions concerning this Notice, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bellkdeq.nc. gov. Enclosure: Inspection Report Cc: NPDES Program Files - Laserfiche Sincerely, Docu Signed by: a�s.4tW H P44,ft F161 FG69A2D84A3... Andrew H. Pitner, P.G., Regional Supervisor Water Quality Regional Operations Section Mooresville Regional Office Division of Water Resources, NCDEQ North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1 610 East Center Avenue, Suite 301 1 Mooresville, North Carolina 28115 704.6631699 United 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 NC0006190 I11 121 23/11/29 I17 18I � I 19 I s I 20L] 21111I I I I I I I II I I I I I I I I I I I I I I I I I I I I I I I II I I I I I r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 2.0 701d I 71 I„ I 72 I r., I 71 I 74 79 I I I I I I I80 L—I ty L-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 POTW name and NPDES permit Number) 09:20AM 23/11/29 19/02/01 South Fork Industries - Maiden Plant 100 W Pine St Exit Time/Date Permit Expiration Date Maiden NC 28650 01:25PM 23/11/29 23/05/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Donald A Burkey/ORC/704-736-8960/ James S. Rhyne//828-428-9920 / Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Everette J Owens,PO Box 742 Maiden NC 286500742//704-732-6946/7047322352 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 Wes Bell Docusignedby: DWR/MROWQ/704-235-2192/ 12/4/2023 A61696D90=437... Signature of Man gerR@r"nA`4Fl?6viewer Agency/Office/Phone and Fax Numbers Date Andrew PitnLrs-4H P4416WR/MRO WQ/704-663-1699 Ext.2180/ 12/4/2023 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0006190 I11 12I 23/11/29 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NC0006190 Owner -Facility: South Fork Industries- Maiden Plant Inspection Date: 11/29/2023 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? 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: The Division received the permit renewal application and supporting documentation on 1 /26/2023. The last compliance evaluation inspection at this facility was performed by DWR staff on 4/12/2022. 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 • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Page# 3 Permit: NC0006190 Inspection Date: 11/29/2023 Owner -Facility: South Fork Industries- Maiden Plant Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: The records reviewed durinq the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed for the period October 2022 through September 2023. Daily maximum effluent limit violations were reported in November 2022 (TSS), December 2022 (BOD) and January 2023 (BOD, COD, TSS). Monthly average effluent limit violations were reported in January 2023 (BOD, COD, TSS) and February 2023 (BOD). The Division has previously addressed the limit violations through the issuances of civil penalty assessments. The facility failed to submit the November 2022 eDMR by the end of the following month as required by the subject permit. The Division received the November 2022 eDMR on 1/13/2023. 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? 0 ❑ ❑ ❑ # 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 Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ ■ ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ ■ ❑ Comment: On -site field parameters (pH and temperature) are performed under South Fork Industries' field laboratory certification #5302. Statesville Analytical and ETS, Inc. (toxicity) have also been contracted to provide analytical support. The internal chain of custody form for the instream sampling events should indicate that the conductivity samples are placed on ice within 15 minutes of sample collection. Influent Sampling # Is composite sampling flow proportional? Is sample collected above side streams? Is proper volume collected? Is the tubing clean? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Is sampling performed according to the permit? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The subject permit requires influent color composite samples. The facility has previously obtained approval to collect time -based composite samples. Sampler aliquots are verified monthly (at a minimum). Effluent Sampling Yes No NA NE Is composite sampling flow proportional? E ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Page# 4 Permit: NC0006190 Owner -Facility: South Fork Industries- Maiden Plant Inspection Date: 11/29/2023 Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE 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 ■ ❑ ❑ ❑ degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type ❑ ❑ ❑ representative)? Comment: The subject permit requires composite and grab effluent samples. Sampler aliquots are verified monthly (at a minimum). Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, 0 ❑ ❑ ❑ and sampling location)? 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 ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Operation & maintenance records and process control measurements are bein maintained on -site. The facility appeared to be adequately treating wastewater; however, there were several operation and maintenance concerns noted during this inspection as discussed in more detail in the Bar Screen and Secondary Clarifier Sections. 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? 0 ❑ ❑ ❑ Is disposal of screening in compliance? ■ ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Page# 5 Permit: NC0006190 Inspection Date: 11/29/2023 Owner -Facility: South Fork Industries- Maiden Plant Inspection Type: Compliance Evaluation Bar Screens Yes No NA NE Comment: Two of three shakers (fine lint screening) and manual bar screen (prior to aeration basins) were operational and in service. The secondary containment berm for the lint dumpster was leaking and needs to be repaired. The platform housing the shakers was severely rusted with several holes, potentially creating a safety hazard. The permittee must ensure that all treatment units/processes are safely accessible for maintenance, inspection, etc. In addition, the subject permit requires the permittee to Properly operate and maintain all facilities and systems of treatment at all times [Permit Condition Reference: Part II, Section C(2) Proper Operation & Maintenancel. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? ❑ 0 ❑ ❑ Are surface aerators and mixers operational? 0 ❑ ❑ ❑ Are the diffusers operational? ❑ ❑ 0 ❑ Is the foam the proper color for the treatment process? ❑ ❑ 0 ❑ Does the foam cover less than 25% of the basin's surface? ❑ 0 ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ 0 ❑ Comment: Both aeration basins and the mechanical aerators (two per basin) were operational and in service. Both basins were completely covered in foam: however, no foam carryover was observed in the secondaries. Supplements (microbial, nutrient, etc.) are periodically added to enhance treatment. 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 • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 6 Permit: NC0006190 Inspection Date: 11/29/2023 Owner -Facility: South Fork Industries- Maiden Plant Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Comment: Both clarifiers have continued to exhibit significant rust and corrosion on the metal walkways, weirs, scum baffle, scum box, and skimmer arm. Note: Although the weirs were not level, no short-circuiting was observed. The clarifiers need to be rehabbed to prevent potential catastrophic failures of the treatment units and ensure operator safety (metal walkways). Please be advised that the subject permit requires the permittee to properly operated and maintain all facilities and systems of treatment at all times [Permit Condition Reference: Part ll, Section C(2) Proper Operation & Maintenancel. Pumps-RAS-WAS Yes No NA NE Are pumps in place? ■ ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ ❑ Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ Comment: The flow meter is calibrated twice per year and was last calibrated on 8/23/2023. 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? ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: The effluent appeared light purple with trace suspended solids and no foam. Lagoons Yes No NA NE Type of lagoons? # Number of lagoons in operation at time of visit? 1 Are lagoons operated in? # 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? ❑ ❑ ■ ❑ Page# 7 Permit: NC0006190 Owner -Facility: South Fork Industries- Maiden Plant Inspection Date: 11/29/2023 Inspection Type: Compliance Evaluation Lagoons Yes No NA NE 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? 0 ❑ ❑ ❑ # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ 0 ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ 0 ❑ Is the lagoon surface free of weeds? ■ ❑ ❑ ❑ Is the lagoon free of short circuiting? ❑ ❑ ❑ Comment: The facility's sludge lagoon is equipped with a surface aerator. Synagro has been contracted to remove and dispose of the sludge via land application (under Synagro's Land Application Permit). Sludge is usually removed/disposed once every two years. The Iaaoon had several feet of freeboard. Page# 8