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Home My WebLink AboutNC0004243_Compliance Evaluation Inspection_20240621 SENT VIA ELECTRONIC MAIL ONLY: NO HARDCOPY WILL BE MAILED June 21, 2024 John J Moss Coats American Inc Email: john.moss@coats.com SUBJECT: Compliance Inspection Report Sevier Plant NPDES WW Permit No. NC0004243 McDowell County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Sevier Plant on 6/12/2024. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0004243. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the inspection and therefore, a response to this inspection report is not required. If you should have any questions, please do not hesitate to contact Mikal Willmer with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4686 or via email at mikal.willmer@deq.nc.gov. Sincerely, Daniel Boss, Assistant Regional Supervisor Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS: Inspection Report Ec: Sara Hudgins, ORC LF DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688 EPA United States Environmental Protection Agency Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 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 N 52 NC0004243 24/06/12 C S31112171819 20 21 66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- N67707172 73 74 75 80 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Sevier Plant 630 American Thread Rd Marion NC 28752 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 10:00AM 24/06/12 17/12/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Sara Lynn Hudgins/ORC/828-756-4111/ Other Facility Data 12:00PM 24/06/12 21/11/30 Name, Address of Responsible Official/Title/Phone and Fax Number John J Moss,630 American Thread Rd Marion NC 287528534/Facilities Engineering Manager/828-756-4111/8287567108 Contacted No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self-Monitoring Program Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters 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 Melanie Kemp DWR/ARO WQ/ - - / Mikal Willmer DWR/ARO WQ/828-296-4686/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page#1 DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688 6/21/2024 6/21/2024 6/21/2024 NPDES yr/mo/day 24/06/12 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Mikal Willmer and Melanie Kemp, with the Asheville Regional Office, conducted a Compliance Evaluation Inspection on June 12, 2024. This inspection was conducted to determine whether the facility is being operated and maintained in compliance with NPDES Permit #NC0004243. Sara Hudgins, ORC, and John Moss, Facilities Engineering Manager, with Coats were present and assisted in the inspection. Overall, the facility was operated well and maintained in compliance with permit requirements. The following items were noted during the inspection: Standby Power: No standby power is available for the WWTP. ORC reports they do not experience power outages frequently and if power is out, the factory is not discharging. There is also adequate capacity within the WWTP at current flows. Record Keeping/Permit: All records were available for review and maintained within the ORC’s office. The permit is in renewal. Please continue to operate under the currently expired permit until a final permit has been issued. Aeration Basin: This is an earthen-lined basin operated as an aerated lagoon due to detention time. Two surface aerators and four Roots blowers typically run 24 hours a day. Basin Berms: All berms appeared to be well maintained and free of woody vegetation that may impact the treatment system. No major issues with groundhogs or other burrowing animals that might compromise the integrity of the basins. Secondary Clarifier: only one secondary clarifier is in use, due to current flows. The weirs were replaced when the drive was repaired. No solids build up within the clarifier. ORC reports they do not need to waste from the clarifier because of the settling that occurs in the EQ and aeration basin. Solids: No reported issues or build up of solids. Please continue to monitor solids within the EQ and aeration basin to ensure there isn’t a reduction in treatment capacity. Upstream/Downstream Sampling Locations: Coats has been notified of upcoming bridge work at downstream location D1. Please contact the Division once a construction date has been provided to discuss potential impacts to sampling. The facility may wish to revisit the need for upstream location U1 during the current permit renewal. NC0004243 17 (Cont.) Page#2 DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688 Permit:NC0004243 Inspection Date:06/12/2024 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Record Keeping Yes No NA NE 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? Comment: Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge, and other that are applicable? check pH, temp and DO on ocassion and clarifier TSS is measured periodically for process control. Comment: 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? # Are there any special conditions for the permit? Page#3 DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688 Permit:NC0004243 Inspection Date:06/12/2024 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Permit Yes No NA NE Is access to the plant site restricted to the general public? Is the inspector granted access to all areas for inspection? Permit is in renewal. See summary for details.Comment: Standby Power Yes No NA NE Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Was generator tested & operational during the inspection? Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Is the generator fuel level monitored? ORC reports there is not a generator onsite. See summary for details.Comment: Equalization Basins Yes No NA NE 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? EQ basin gravity feeds into the aeration basin/aerated lagoon.Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface 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? Page#4 DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688 Permit:NC0004243 Inspection Date:06/12/2024 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Aeration Basins Yes No NA NE 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 mg/l) operated as an aerated lagoon.Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? ORC reports no issues obtaining parts as needed.Comment: Secondary Clarifier Yes No NA NE 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 ¼ of the sidewall depth) Facility only utilizes one secondary clarifier due to flows. See summary for details.Comment: Disinfection-Liquid Yes No NA NE Is there adequate reserve supply of disinfectant? (Sodium Hypochlorite) Is pump feed system operational? Is bulk storage tank containment area adequate? (free of leaks/open drains) Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de-chlorination? Page#5 DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688 Permit:NC0004243 Inspection Date:06/12/2024 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Disinfection-Liquid Yes No NA NE Chlorine is fed flow-paced at the head of the chlorine contact chamber and ozone is fed along the entire length of the chamber. Recommend staff maintain a spill control kit at the WWTP. Comment: De-chlorination Yes No NA NE Type of system ?Liquid Is the feed ratio proportional to chlorine amount (1 to 1)? Is storage appropriate for cylinders? # Is de-chlorination substance stored away from chlorine containers? Comment: Are the tablets the proper size and type? Are tablet de-chlorinators operational? Number of tubes in use? Comment: Disinfection - Ozone Yes No NA NE Are all production units operational Is mixing and detention time adequate # Is injection at multiple points used continuously in conjunction with chlorine.Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? Chart recorder has digital read out and totalizer. Flow meter is calibrated weekly and recorded by the ORC. Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? Page#6 DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688 Permit:NC0004243 Inspection Date:06/12/2024 Owner - Facility: Inspection Type: Sevier Plant Compliance Evaluation Effluent Sampling Yes No NA NE # 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)? Sampler was at 3 degrees at the time of the inspection. ORC reports the sample volume is set to 200 mL and is verified periodically. Comment: Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? Are the receiving water free of foam other than trace amounts and other debris? If effluent (diffuser pipes are required) are they operating properly? Comment: Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? See summary for details.Comment: Page#7 DocuSign Envelope ID: 74FA7DDA-189A-4C3C-907A-72970B96F688