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Home My WebLink AboutNC0004685_Compliance Evaluation Inspection_20240507ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director NORTH CAROLINA Environmental Quality May 7, 2024 Kenneth Hale, Plant Manager Electric Glass Fiber America, LLC. 940 Washburn Switch Road Shelby, NC 28150 SUBJECT: Compliance Evaluation Inspection Electric Glass Fiber America, LLC. WWTP NPDES Permit No. NC0004685 Cleveland County Dear Mr. Hale: Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on April 25, 2024, 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. Should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bell(a,deq.nc. gov. Sincerely, DocuSigned by: Aw N Nuft F161 F669A2D84A3... Andrew Pitner, P.G. Regional Supervisor Water Quality Regional Operations Section Mooresville Regional Office Division of Water Resources, NCDEQ Enclosure: Inspection Report Cc: NPDES Program Files - Laserfiche f, �-DWE Q North Carolina Department of Environmentat Quality I Division of Water Resources Mooresville Regional Office 1 610 East Center Avenue. Suite 30I 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 NC0004685 111 121 24/04/25 I17 18 LC] 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) 10:10AM 24/04/25 21/07/01 Electric Glass Fiber America LLC 940 Washburn Switch Rd Exit Time/Date Permit Expiration Date Shelby NC 28150 01:25PM 24/04/25 26/06/30 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data John Charles Littlejohn/ORC/704-434-2261/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Kenneth Hale,940 Washburn Switch Rd Shelby NC 28150//704-434-2261/ 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 signed by: DWR/MRO WQ/704-235-2192/ 5/7/2024 Be& E�:',,','�96D90=437 ... Signature of Ma umut QhBpviewer Agency/Office/Phone and Fax Numbers Date Andrew Pitn rA*,4' H PZUMR/MRO WQ/704-663-1699 Ext.2180/ 5/7/2024 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0004685 I11 12I 24/04/25 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NC0004685 Owner -Facility: Electric Glass Fiber America LLC Inspection Date: 04/25/2024 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 ❑ ❑ ❑ 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 last compliance evaluation inspection at this facility was performed by DWR staff on 9/13/22. Record Keeping Are records kept and maintained as required by the permit? Is all required information readily available, complete and current? Are all records maintained for 3 years (lab. reg. required 5 years)? Are analytical results consistent with data reported on DMRs? Is the chain -of -custody complete? Dates, times and location of sampling Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Are DMRs complete: do they include all permit parameters? Has the facility submitted its annual compliance report to users and DWQ? (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? Is the ORC visitation log available and current? Is the ORC certified at grade equal to or higher than the facility classification? Is the backup operator certified at one grade less or greater than the facility classification? Is a copy of the current NPDES permit available on site? Facility has copy of previous year's Annual Report on file for review? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: The records reviewed durinq the inspection were orqanized and well maintained Discharge Monitoring Reports (eDMRs) were reviewed for the period March 2023 through February 2024. No limit and/or monitoring violations were reported. In-depth operation and maintenance records including process control measurements were being documented and maintained on -site. Page# 3 Permit: NC0004685 Inspection Date: 04/25/2024 Record Keeping Owner -Facility: Electric Glass Fiber America LLC Inspection Type: Compliance Evaluation Laboratory Are field parameters performed by certified personnel or laboratory? Are all other parameters(excluding field parameters) performed by a certified lab? # Is the facility using a contract lab? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? Yes No NA NE Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ Comment: On -site field analyses (dissolved oxygen, conductivity, pH, temperature) are performed under the Company's field laboratory certification #5489. Pace Analytical Services, ETT Environmental, Inc. (chronic toxicity) and Environmental Testing Solutions, Inc. (ETS) have also been contracted to provide analytical support. Effluent Sampling Is composite sampling flow proportional? Is sample collected below all treatment units? 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 the facility sampling performed as required by the permit (frequency, sampling type representative)? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The subject permit requires effluent composite and grab samples. The composite sampler is calibrated monthly (at a minimum) to ensure the programmed aliquot volume is beina collected. 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? Page# 4 Permit: NC0004685 Inspection Date: 04/25/2024 Owner -Facility: Electric Glass Fiber America LLC Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Comment: The wastewater treatment facility appeared to be properly operated and well maintained. The operations staff incorporate a comprehensive process control program. The facility is equipped with a computer monitoring system to assist the wastewater staff in alarm notifications and treatment oDerations. Bar Screens Type of bar screen a.Manual b.Mechanical Are the bars adequately screening debris? Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The domestic waste stream flows through a comminutor and the industrial waste stream flows through a manual bar screen prior to being combined in the influent wet well. Screenings are disposed in the County Landfill. 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 industrial waste stream can be diverted into an overflow storage basin (lined). The facility is also equipped with addition equalization/surge tanks. Pump Station - Influent Is the pump wet well free of bypass lines or structures? Is the wet well free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Is SCADA telemetry available and operational? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 5 Permit: NC0004685 Owner -Facility: Electric Glass Fiber America LLC Inspection Date: 04/25/2024 Inspection Type: Compliance Evaluation Pump Station - Influent Yes No NA NE Is audible and visual alarm available and operational? 0 ❑ ❑ ❑ Comment: 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? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? ■ ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: Both primaries were operational and in service. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? ■ ❑ ❑ ❑ Are surface aerators and mixers operational? 0 ❑ ❑ ❑ Are the diffusers operational? 0 ❑ ❑ ❑ Is the foam the proper color for the treatment process? ■ ❑ ❑ ❑ 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: The facility uses two aeration basins (circular tanks) operated in series. The first aeration basin is equipped with diffused aeration and 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? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ Page# 6 Permit: NC0004685 Inspection Date: 04/25/2024 Secondary Clarifier 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? Owner -Facility: Electric Glass Fiber America LLC Inspection Type: Compliance Evaluation 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) Comment: All three secondaries were operational and in service. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Aqueous lime is added in the influent wet well and aeration basins to maintain appropriate pH levels. Aluminum chloride is added in the equalization tank (prior to the primaries) to enhance metals precipitation. Ferric chloride and polymers are added at multiDle locations to enhance settlina. Filtration (High Rate Tertiary) Type of operation: Is the filter media present? Is the filter surface free of clogging? Is the filter free of growth? Is the air scour operational? Is the scouring acceptable? Is the clear well free of excessive solids and filter media? Yes No NA NE Down flow ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Page# 7 Permit: NC0004685 Owner -Facility: Inspection Date: 04/25/2024 Inspection Type: Electric Glass Fiber America LLC Compliance Evaluation Filtration (High Rate Tertiary) Yes No NA NE Comment: The facility is equipped with a traveling -bridge tertiary filter that was operational and in service. 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? ❑ ❑ 0 ❑ Comment: The flow meter is calibrated twice per year and was last calibrated on 12/11 /2023 b Clearwater, Inc. 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? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: The effluents from Outfalls 001 and 002 were clear with no floatable solids or foam. The receiving stream did not appear to be negatively impacted. 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: The sludge belt press was operational and in service. Sludge is disposed at the County Landfill by a contracted company. Daily paint filter tests are performed during the operation of the belt press and twice per year TCLP sampling/analyses are also performed on the dewatered sludge. Page# 8