NC0004944_NOV2016PC0398_20160816

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Certified Mail # 7015 1520 0002 8386 7748
Return Receipt Requested
August 11, 2016 `� �i`i nmwe��f��`t
AUC, � � 2016
Donald Peterson, Owner
Durafiber Technologies Inc. tiNat�r secs en
7401 Statesville Blvd. Permitting
Salisbury, NC 28145
SUBJECT: NOTICE OF VIOLATION & INTENT TO ASSESS CIVIL PENALTY
Tracking Number: NOV-2016-PC-0398
Permit No. NC0004944
DuraFiber Technologies Inc.
Rowan County
Dear Mr. Peterson:
The ,North Carolina ,Division of Water Resources conducted an inspection ,of the DuraFiber Technologies Inc. on
August 4, 2016. This -inspection was.conducted to verify that the facility is operating in compliance with the
conditions and limitations specified in NPDES WW Permit No. NC0004944. A summary of the findings and
comments noted during the inspection are provided in the enclosed copy of the inspection report.,
The Compliance Evaluation inspection was conducted by Division of Water Resources staff from the Mooresville
Regional Office. The following violation(s) were noted during the inspection:
Inspection Area
r
Description of Violation
Operations, & Maintenance
Effluent trough on secondary clarifier is filled with sludge and growing vegetation, vegetation
also noted growing on weirs.
Flow Measurement - Effluent
Facility did not have annual calibration records for flow meter.
Record Keeping
Facility did not have sludge processing or disposal records.
Laboratory
Facility is performingBOD, Fecal Coliform and field parameters. During inspection it was noted
that thermometers for storage refrigerator, BOD incubator, Fecal Coliform incubator, and DO
meter have not been -checked against. NIST traceable thermometer. Last temperature check
was dated 2013.
State of North Carolina I Environmental Quality I Water Resources
610 East Center Avenue, Suite 301, Mooresville, NC 28115
704-663-1699

I
Inspection Area Description of Violation �l
Secondary Clarifier RAS pump not operating at time of inspection. Secondary clarifier we denitrifying with solids
flowing over weir. Accumulation of sludge in effluent trough with vegetation (grass) growing
in effluent trough.
In addition, the issues below must also be addressed:
Compliance Issue(s):. RAS pumps not in operation, accumulation of sludge and vegetation in effluent
trough on secondary clarifier -
Please be advised that in accordance with your NPDES Permit No. 0004944, Part II, Section C., 2. Proper Operation
and Maintenance, The Permittee shall at all times provide the operation and maintenance resources necessary to
operate the existing facilities at optimum efficiency.
Flow meter did not have annual calibration records '-
In accordance with NPDES Permit No. 0004944, Part II, Section D., 3. Flow Measurements, Flow measurements
devices shall be accurately calibrated at a minimum of once per year and maintained to ensure that the accuracy of
the measurements is consistent with the accepted capability of that type of device.
Facility did not have sludge processing or sludge disposal records —
In accordance with NPDES Permit No. 0004944, Part II, Section C., 6. Removed Substances; The Permittee shall
comply with all existing Federal regulations governing the disposal of sewage sludge (40 CFR Part 503). The
Permittee shall notify the Permit Issuing Authority of any significant change in its sludge, use or disposal practices.
In accordance with 40 CFR Part 503 Standards for the Use and Disposal of Sewage Sludge records shall be kept and
maintained for a period of 5 years.
Thermometers'' in Laboratory have not'been checked against NIST traceable therniometer.'Laboratory
is certified under Laboratory Certification:flumber 200
In accordance with 40 CFR Part 136r(SeeNC WW/GW Laboratory Certification web site) Temperature measuring
devices must be' calibrated against a ,National Institute of Standards & Technology (NIST) traceable -thermometer
every 12 `months and any corrections must be documented. Agreement between the thermometers must be within
0.5° C.
A Notice of Violation/Intent to Issue Civil Penalty is being issued for the noted violation of North Carolina General
Statute (G.S.) 143-215.,1 and the facility's NPDES Permit. Pursuant to G.S. 143-215.6A, a-civilpenalty of not
more than twenty-five thousand dollars ($25,000.00) may be assessed 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.
If you wish to provide -additional information regarding the noted violation, request technical assistance, or
discuss overall compliance please respond,in writing within ten (10) business days after receipt of this Notice. A
review of your response will be considered along -with: any information provided on the submitted Discharge
Monitoring Report(s): You will•then be notified of any civil -penalties that may be assessed regarding the
violations. If no response is received in this Office within the 10 -day period, a civil penalty
assessment may be prepared.

r.`
v
Remedial actions should have already been taken to correct this problem and prevent further occurrences in the
future. The Division of Water Resources may pursue enforcement action for this and any additional violations of
State law. If the violations are of a continuing nature, not related to operation and/or maintenance problems,
and you anticipate remedial construction activities, then you may wish to consider applying for_ a Special Order by
Consent.
Reminder: Pursuant to Permit Condition 6 in Section E. the Permittee is required to verbally notify the Regional
Office as soon as possible, not to exceed 24 hours, from first knowledge of any non-compliance at
the facility including limit violations, bypasses of, or failure of a treatment.unit. A written report may
be required within 5 days if directed by Division staff. Prior notice should be given for anticipated or
potential problems due to planned maintenance activities, taking units off-line, etc.
Additionally and if you have not already done so, you may wish to consider registering to use the Division's new
e -DMR system for the completion and electronic submittal of monthly Discharge Monitoring Reports (DMRs).
For more information, please visit the eDMR Website at the following address:
http://portal.ncdenr.org/web/wq/admin/bog/ipu/edmr.
If you should have any questions, please do not hesitate to contact Roberto Scheller with the Water Quality
Regional- Operations Section in the Mooresville Regional Office at 704-663-1699.
Sincerely,
W. Corey Basinger, Regional Supervisor
Water Quality. Regional Operations Section
Mooresville Regional Office
Division of Water Resources, NCDEQ
ATTACHMENTS
Cc: Beth Swanson, Laboratory Certification Branch, Email: [e-mail]
WQS Mooresville Regional Office - Enforcement File
NPDES Compliance/Enforcement Unit - Enforcement File
State of North Carolina I Environmental Quality I Water Resources
610 East Center Avenue, Suite 301, Mooresville, NC 28115
704-663-1699

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 2 15 3 I NC0004944 111 1,2 1 16/08/04 17 18 i ,, i 19 Li I 201 I
2111 1 1 1 1 1 1 1 1 1 1 1. I I I I I I I I I I I I I I I I I I I I 'I I I I I I I I I I -166
I
Reserved
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA --Reserved-
I I 72 I N 73 I I 174 751 1 1 1 I I I 180
67 70 71 J
671
I_I l� I I 1
Section B: FacilityData.
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:OOAM 16/08/04
10/10/01
Dural Technologies Inc.
7401 Statesville Blvd
Exit Time/Date
permit Expiration Date
Salisbury NC 28147
11:56AM 16/08/04
14/03/31
Name(s) of Onsite Representative(s)rritles(s)/Phone and Fax Number(s)
Other Facility Data ;
William Keith McDonald/ORC/336-472-2023/
Name, Address of Responsible OfriciaUritie/Phone and Fax Number
Contacted
_
Donald Peterson,7401 Statesville Blvd Salisbury NC 28147/Plant
No
Manager/704-636-6000/
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenance Records/Reports
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 Signatures) of Inspectors) Agency/Office/Phone and Fax Numbers Date
Roberto Scheller MRO WQ//252-946-6481/ ' 1
Signature of Management Q A Reviewer Agen ifiice/Phone and Fax Numbers Date
W. Corey Basinger MRO WQ//704-235-2194/
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Ifill I111111111IOI�,pC-aQ . avJt2 •ice
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Page#

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Permit NC0004944 Owner -Facility:, DuraFiberTechnologies Inc.
Inspection Date: 08/04/2016 Inspection Type: Compliance Evaluation
Operations & Maintenance - Yes No NA'NE
Does the facility analyze process control parameters, for ex: MLSS,-MCRT, Settleable N' ❑ ❑ ❑
Solids, pH, DO; Sludge Judge, and other that are applicable?
Comment: Effluent trough on secondary clarifier was filled with sludge and growing vegetation.
Vegetation also noted growing on weirs.
RAS pump not operating resulting in clarifier denitrifying.
Bar Screens
Yes No NA NE
Type of bar screen
. ❑
a.Manual
❑
b.Mechanical
a.Manual
Is the grit free of excessive organic matter?
❑ , ❑ ❑
Is the grit free of excessive odor?
❑ ❑ ❑
b.Mechanical
❑
❑
❑
❑
Are the bars adequately screening debris?
❑ .
❑
❑
Is the screen free of excessive debris?
❑
. ❑
❑
Is disposal of screening in compliance?
M
❑
- ❑
❑
Is the unit in good condition?
M.
El
1-1 ❑
❑
Comment:
Grit Removal
Yes No NA NE
Type of grit removal
. ❑
a.Manual
❑
b.Mechanical
Is the'basin free of bypass lines or structures to the natural environment?
Is the grit free of excessive organic matter?
❑ , ❑ ❑
Is the grit free of excessive odor?
❑ ❑ ❑
# Is disposal of grit in compliance?
❑ ❑ ❑
Comment:
Equalization Basins
Yes No NA NE'
Is the'basin aerated?
. ❑
❑
, M
❑
Is the'basin free of bypass lines or structures to the natural environment?
0
'❑
'.❑
❑
Is the basin free of excessive grease?
M
❑
❑
❑
Are all pumps present?
[1-11
❑
Are all pumps operable?
❑
❑
, ❑
Are float controls operable?
❑
❑
M
❑
Are audible and visual alarms operable?
11
'❑
-❑
❑
# Is basin size/volume adequate?
0
❑
❑
❑
Page# 4

Permit NC0004944
Inspection Date: 08/04/2016
Equalization Basins
Owner - Facility Durafter Technologies Inc.
Inspection Type: Compliance Evaluation
Comment: EQ basin consist of 2 covered above ground tanks.
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 mg/I)
Yes No NA NE_
Yes No NA NE
Ext. Air
Is the clarifier free of black and odorous wastewater?
❑
Surface
❑
❑
■
❑-
❑
❑
10
❑
❑
❑
❑
❑
■
❑
X
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
■
❑
❑
❑
.N
Comment: MLSS thin with color of slightly turbid water. RAS pump on secondary clarifier not
operational resulting in treatment unit having no acculamation of bio -mass.
Secondary Clarifier
Yes No NA NE
Is the clarifier free of black and odorous wastewater?
❑
E
❑
❑
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?
❑
N
❑
❑
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?
❑
❑
❑
11.
Is the return rate acceptable (low turbulence)?
❑"
0
❑
❑
Is the overflow clear of excessive solids/pin floc?
❑
0
❑
❑
Is the sludge blanket'level acceptable? (Approximately % of the sidewall depth)
❑
N
❑
❑
Comment: RAS pump not operating at time of inspection. Secondary clarifier was denitrifying with
solids flowing over weir. Accumulation of sludge -in effluent trough with y6getation'&bgs)
growing in effluent trough.
Pumps-RASMAS
Yes No. NA NE
Are pumps in place?
❑
❑"
❑
Are pumps operational?
❑ I N
❑
❑
Are there adequate spare parts and supplies on site?
❑ E
❑
❑
Page# 5

1
Permit N00004944 _ Owner -Facility: DuraFiberTechnologies Inc.
Inspection Date: 08/04/2016 Inspection Type: Compliance Evaluation
Pumps -RAS -WAS Yes No NA NE
Comment: RAS pumps not operational.
Aerobic Digester
Is the capacity adequate?
Is the mixing adequate?
Is the site free of excessive foaming in the tank?
# Is the odor acceptable?
# Is tankage available for properly waste sludge?
Comment: One of the two areation basins is being used as aerobic digester.
Lagoons
Type of lagoons?
# Number of lagoons in operation at time of visit?
Are lagoons operated in?
# Is a re -circulation line present?
Is lagoon free of excessive floating materials?
# Are baffles between ponds or effluent baffles adjustable? �
Are dike slopes clear of woody vegetation?
Are weeds controlled around the edge of the lagoon?
Are dikes free of seepage?
Are dikes free of erosion?
Are dikes free of burrowing animals?
# 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?
Is the lagoon surface free of weeds?
Is the lagoon free of short circuiting?
Comment: Lagoons follow treatment units and are used as polishing ponds. '
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?
Yes No NA NE
Yes No NA NE
❑
❑
❑
3
❑
❑
M
❑
❑
❑
M
❑
❑
❑
'M
❑
❑
• ❑
Yes No NA NE
Aerated
1
3
❑
❑
Series
M
❑
❑
❑
■
❑
❑
❑
❑
❑
❑
M
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
M
❑
❑
❑
❑
❑
❑
■
❑
.❑
❑
❑
❑
■
❑
M
❑
❑
❑
■
❑
❑
❑
Yes No NA NE
❑
❑
❑
M
❑
❑
❑
Page# 6

Permit: NC0004944 Owner -Facility: Durafter Technologies Inc.
Inspection Date: 08/04/2016 Inspection Type: Compliance Evaluation
Yes No NA NE
# Is flow meter used for reporting?
0
Laboratory
Yes No NA NE
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
❑
0
❑
❑
Celsius)?
Is the flow meter operational?
0
❑
❑
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: Facility is performing BOD, Fecal Coliform and field prameters. During inspection it was
noted that thermometers for storage refrigerator, BOD incubator, Fecal Coliform incubator,
and DO meter have not been checked aginst NIST traceable thermometer. Last
temperature check was dated 2013.
Flow Measurement - Influent
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: Facility did not have annual calibration records for flow meter.
Page# . 7