NC0077615_Compliance Evaluation Inspection_20160331

PAT MCCRORY
DONALD R. VAN DER VAART
WaterResvurcesw S. JAY ZIMMERMAN
CN V IRONMLN FAL QUALITY
March 31, 2016
Mr. Brian Foor, Plant Manager
RECEIVED/NCDE6l/DWR
Origin Food Group, LLC APR 0 7 1016
P.O. Box 7621
Statesville, NC 28687 W permitter ting Seeccttiion
Subject: Compliance Evaluation Inspection
Origin Food Group, LLC WWTP
NPDES Permit No. NCO077615
Iredell County
Dear Mr. Foor:
Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted
at the subject facility on March 30, 2016 by Ori Tuvia. Roy Moose, Dena Myers and Jerry
Rodgers cooperation during the site visit was much appreciated. Please advise the staff
involved with this NPDES Permit by forwarding a copy of the enclosed report.
The report should be self-explanatory; however, should you have any questions
concerning this report, please do not hesitate to contact Ori Tuvia at [phone], or at
[e-mail].
Sincerely,
Ori Tuvia, Environmental Engineer
Mooresville Regional Office
Division of Water Resources, DEQ
Cc' NPDES Unit
Iredell County Health Department
MRO Files
Mooresville Regional Office
Location:610 East Center Ave.,Suite 301 Mooresville,NC 28115
Phone:[phone]\Fax:[phone]\Customer Service:1-877-623-6748

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United States Environmental Protection Agency Form Approved.
EPA Washington,DC 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 15 1 3 I N00077615 111 12 16/03/30 17 18191 G i 20I
1,.1
21111111 111111111111111111 1 111111 11111111111 r6
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA -------Reserved----------
67 10 70 Id I 71 IN I 72 I N] 731 I 174 751 1 1 1 1 1_.U80 180
L-1 Section B:FacilityDataDI ata LJ 1 I I
Name and Location of Facility Inspected(For Industrial Users discharging to POTW,also include Entry Time/Date Permit Effective Date
POTW name and NPAES permit Number) 10:30AM 16/03/30 14/04/01
Origin Food Group,LLC
Exit Time/Date Permit Expiration Date
306 Stamey Farm Rd
11:15AM 16/03/30 19/03/31
Statesville NC 28677
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
Dena C Myers//704-872-4697/
Jerry L Rogers/ORCl704-872-4697/
Roy Moose///
Name,Address of Responsible OfficiaUTitle/Phone and Fax Number
Contacted
Brian Foor,PO Box 7621 Statesville NC 28687//704-768-9000/
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
® 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
On A Tuvia MRO WQ//704-663-1699/
3/3 v16
Signature of Managem t Q - eviewer Agency/Office/Phone and Fax Numbers Date
Andrew PitnerM W//704-663-1699 Ext.2150 wllt
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete
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1
NPDES yr/mo/day Inspection Type 1
31 NCO077615 I11 12 16/03/30 17 18 ICI
L Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
Page# 2

Permit: NCO077615 Owner-Facility. Origin Food Group,LLC
Inspection Date: 03/30/2016 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? ❑ ❑ ❑
#Are there any special conditions for the permit? ❑ •0 ❑ ❑
Is access to the plant site restricted to the general public? ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑
Comment: The subject permit expires on 3/31/2019 The facility had no effluent discharge since the last
inspection on 01/26/2012.
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑
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? ❑ ❑ 0 ❑
(If the facility is=or>5 MGD permitted flow)Do they operate 2417 with a certified operator ❑ ❑ 0 ❑
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? 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? ❑ ❑ 0 ❑
Comment: The records were reviewed during the inspection were organized and well maintained.
DMR's and ORC logs were reviewed for the period of June 2013- December 2015. Due to
the facility not having any effluent discharge since the last inspection on 01/26/2012,there
was no sampling done.
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Permit: NCO077615 Owner-Facility: Origin Food Group,LLC
Inspection Date: 03/30/2016 Inspection Type- Compliance Evaluation
Laboratory Yes No NA NE
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? ❑ ❑ ® ❑
Comment: No sampling Statesville Analytical has been contracted to perform required effluent
sampling.
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? ® ❑ ❑ ❑
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? ❑ ❑ ■ ❑
Is disposal of screening in compliance? ❑ ❑ ® ❑
Is the unit in good condition? ® ❑ ❑ ❑
Comment:
Aeration Basins Yes No NA NE
Mode of operation Ext.Air
Type of aeration system Diffused
Page# 4

Permit. NCO077615 Owner-Facility: Origin Food Group,LLC
Inspection Date: 03/30/2016 Inspection Type: Compliance Evaluation
Aeration Basins Yes No NA NE
Is the basin free of dead spots? ® ❑ ❑ ❑
Are surface aerators and mixers operational? ❑ ❑ M ❑
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? ❑ ❑ M ❑
Is the DO level acceptable? ❑ ❑ ■ ❑ t
Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ® ❑
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 Y.of the sidewall depth) ❑ ❑ ® ❑
Comment:
Disinfection-Tablet Yes No NA NE
Are tablet chlorinators operational? ® ❑ ❑ ❑
Are the tablets the proper size and type? ® ❑ ❑ ❑
Number of tubes in use? 2
Is the level of chlorine residual acceptable? ❑ ❑ ® ❑
Is the contact chamber free of growth,or sludge buildup? ❑ ❑ ® ❑
Is there chlorine residual prior to de-chlorination? ❑ ❑ ® ❑
Comment:
De-chlorination Yes No NA NE
Page# 5

Permit- NCO077615 Owner-Facility: Origin Food Group,LLC
Inspection Date 03/30/2016 Inspection Type. Compliance Evaluation
De-chlorination Yes No NA NE
Type of system-? Tablet
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? ® ❑ ❑ El
Comment:
Are the tablets the proper size and type? ® ❑ ❑ ❑
Are tablet de-chlorinators operational? ® ❑ ❑ ❑
Number of tubes in use? 1
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? ❑ ❑ ® ❑
#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 permit requires effluent grab samples. No discharge have been rep orte `f
inspection on 1/20/2012.
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? ❑ ❑ ® ❑
Comment: Instantaneous flow would be measured by the bucket and stopwatch method.
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?
Comment:
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