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Home My WebLink AboutNC0037371_NOV2017PC0445_20170717Water Resources ENVIRQNMtiNTAL QUAUTiY CERTIFIED MAIL # 70151520 0002 6880 2580 RETURN RECEIPT REQUESTED July 7, 2017 Mr. Walter Rhyne Belmont Textile Machinery Company P.O. Box 568 Mount Holly, NC 28120 Subject Dear Mr. Rhyne: ROY COOPER Govemor MICHAEL S REGAN Secretary S JAY ZIMMERMAN Director RECEIVEDINCDEU®\NR JUL 12 M7 Water 0 S coon Permitting Notice of Violation Compliance Evaluation Inspection NOV-2017-PC-0445 Belmont Textile Machinery Company WWTP NPDES Permit No. NCO037371 Gaston County Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on July 5, 2017 by Ori Tuvia. Joseph Cote's 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 main area of concern observed during the inspection was that at the time of the inspection both blower/motor units were not operational and the plant was running on undersized backup blower. Due to the undersized blower, the settablelty of solids at the time of the inspection was very low about 72% after 15 minutes. As per your permit, the facility must have 2 operational, properly sized blowers/motors. Additional areas of concern observed during the inspection were: 1) There are safety concerns about the lack of adequate grating and railing installed at the chlorine contact/dechlorination areas. No railings were observed at the specified area at the time of the inspection. 2) The laboratory instrumentation used for residual chlorine field analyses had failed the 10 ug/L parameter of the past chlorine curve. The instrument chlorine curve should be redone. Mooresville Regional Office Location 610 East Center Ave, Suite 301 Mooresville, NC 28115 nom___ r-rnn nnn nnnn i -- 1-1 n -- 11en You are requested to respond in writing within 10 days of receipt of this Notice detailing a plan of action as to how the facility will return two properly sized blowers/motors to immediate service. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Ori Tuvia at (704) 235-2190, or at ori.tuvia@ncdenr.gov. Sincerely, W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources Cc. NPDES Unit MRO Files 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 15 1 3 I NCO023540 I11 12 17/07/05 17 181,.1 191 G I 201 I Lfi 21111111 1111111 11 11 1 11 1111 1 1 11111 111111111 1_1 �6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA — Reserved - 74 751 I I I [ I80 67 10 70 [, j 71 1 N J 1 72 I N I 731 I 1 A lJ L_J I I I 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) 09 15AM 17/07/05 15/05/01 Belmont Textile Machinery WWTP 1212 W Catawba Ave Exit Time/Date Permit Expiration Date Mount Holly NC 28120 11 20A 17/07/05 20/02/29 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data /// Joseph R Cote/ORCr/04-827-5836/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Walter P Rhyne,PO Box 568 Mount Holly NC 281200168//704-827-5836[7048278551 No Section C Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & MamtenancE Records/Reports Self -Monitoring Program E 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/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W Corey Basinger MRO WQ//704-235-2194/ EPA For 3560-3 (Rev 9-94) Previous editions are obsolete -�V4 *t,7 - Page# NPDES yr/mo/day Inspect on Type 31 NCO023540 I11 12 17/07/05 17 18 ICI Section D Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit NCO023540 Owner -Facility Belmont Textile Machinery WWfP Inspection Date 07/05/2017 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 El ElEl ❑ ❑ application? E ❑ ❑ ❑ 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 subject permit expires on 2/29/2020. 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? E ❑ ❑ ❑ 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 CDCs Are DMRs complete do they Include all permit parameters? 0 ❑ ❑ ❑ 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 24/7 with a certified operator ❑ ❑ N ❑ 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? N ❑ ❑ ❑ 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? ❑ ❑ E ❑ Comment The records reviewed during the inspection were organized and well maintained DMRs, CDCs, calibration logs and ORC logs were reviewed for the period March 2016 through April 2017 Operations & Maintenance Yes No NA NE Page# 3 Permit NCO023540 Owner - Facility Belmont Textile Machinery WWTP Inspection Date 07/05/2017 Inspection Type Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ❑ N ❑ ❑ Does the facility analyze process control parameters, for ex MLSS, MCRT, Settleable ❑ ❑ E ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment The facility appeared to be adequately treating the wastewater at the time of the Inspection however, at the time of the inspection both blower/motor units were not operational and the plant was running on undersized backup blower Due to the undersized blower, the settablelty of solids at the time of the inspection was very low about 72% after 15 minutes Wastewater solids are removed once per year by Ray's Septic Service Solids were last removed on 6/13/2017 additionally, there are safety concerns due to the lack of adequate railing/grating at the chlorine contact/dechlorination areas The permittee should ensure that adequate prating and railing are Installed at the chlorine contact/dechlonnation areas 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 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ E ❑ ❑ ❑ Comment On-site field analyses (PH, total residual chlorine, temperature) are performed under the facility's field laboratory ,certification # 5479 K&W Labs (Certification #559) has also been contracted to provide analytical support The laboratory instrumentation used for residual chlorine field analyses, had failed the 10 uq/L parameter of the past chlorine curve ■❑ 0 E Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ ❑ 0 ❑ Is sample collected below all treatment units? E ❑ ❑ ❑ 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 N ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment The subject permit requires effluent grab samples Bar Screens Yes No NA NE Page# 4 E Permit NCO023540 Inspection Date 07/05/2017 Bar Screens Type of bar screen Owner -Facility Belmont Textile Machinery wwTP Inspection Type Compliance Evaluation Yes No NA NE a Manual 0 No NA NE Mode of operation Ext Air b Mechanical ❑ Type of aeration system Diffused Are the bars adequately screening debris? ❑ 0 ❑ ❑ Is the screen free of excessive debns? 0 ❑ ❑ ❑ - Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? ❑ ❑ E ❑ Comment The Influent passes through a communitor and a coarse bar screen prior to the aeration N ❑ ❑ basin Is the DO level acceptable? ❑ ❑ ❑ Aeration Basins Yes No NA NE Mode of operation Ext Air Type of aeration system Diffused 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? N ❑ ❑ ❑ Is the DO level acceptable? ❑ ❑ ❑ 0 Is the DO level acceptable?(1 0 to 3 0 mg/1) ❑ ❑ ❑ 0 Comment Doa food Is added as a food supplement five days per week at a minimum) due to the low Influent flows/loading The facility is equipped with two blower/motor units, however, at the time of the inspection both blower/motor units were not operational and the plant was running on undersized backup blower Due to the undersized blower, the settablelty of solids at the time of the inspection was very low about 72% after 15 minutes 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? 1'lM►r•7i!U1UU= N ❑ ❑ ❑ ❑ ❑ ■ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ E ❑ Page# 5 Permit NCO023540 Owner - Facility Inspection Date 07/05/2017 Inspection Type Belmont Textile Machinery WwrP Compliance Evaluation Are tablet chlorinators operational? M Secondary Clarifier Yes No NA NE 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) 0 ❑ ❑ ❑ Comment Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? M ❑ ❑ ❑ Are the tablets the proper size and type? M ❑ ❑ ❑ Number of tubes in use? 1 M ❑ # Is de -chlorination substance stored away from chlorine containers? Is the level of chlorine residual acceptable? M ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? M ❑ ❑ ❑ Comment. De -chlorination Yes No NA NE Type of system ? Tablet Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ 0 ❑ Is storage appropriate for cylinders? ❑ ❑ M ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ 0 ❑ ❑ Are the tablets the proper size and type? 0 ❑ ❑ ❑ Comment The chlorination and dechlorination tablets are stored inside the industrial facility Are tablet de -chlorinators operational? M ❑ ❑ ❑ Number of tubes in use? 1 Comment The chlorinated wastewater is pumped through the dechlor tablet unit prior to the effluent pumping area Flow Measurement - Effluent # 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 flows are measured by a dose counter (150 gallons per dose) Yes No NA NE ❑ ❑ M ❑ ❑ M ❑ ❑ ❑ ❑ M ❑ ❑ ❑ M ❑ Page# 6 W Permit NC0023540 Owner -Facility Belmont Textile Machinery WWTP Inspection Date 07/05/2017 Inspection Type Compliance Evaluation 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 Page# 7