NC0000353_NOV2018PC0073_20180228

DocuSign Envelope ID: 82D040DC-6650-4232-8D46-4B7B018Al2F1
Wer ter Resources
ENWROMME"TAL 4UALdTY
February 28, 2018
Gregory Taveras, Manager Operations
The Quartz Corp USA
8342 S. 226 Bypass
PO Box 309
Spruce Pine, NC 28777
SUBJECT: NOTICE OF VIOLATION
Tracking Number: NOV-2018-PC-0073
Permit No. NC0000353
Quartz Corp — Altapass WWTP
Mitchell County
Dear Permittee:
ROY COOPER
Goverwr
MICH-kEL S. FECAL
SE A=-�
LI -\TD A CUIL.PEPPEF,
lh,e 'on Direci
The North Carolina Division of Water Resources (DWR) conducted an inspection of the Quartz Corporation Altapass
facility on February 7, 2018. This inspection was conducted to verify that the facility is operating in compliance
with the conditions and limitations specified in NPDES WW Permit No. NC0000353. 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 Asheville
Regional Office. The following violation(s) were noted during the inspection:
Inspection Area Description of Violation
Record Keeping Effluent characteristics/pollutants are analyzed daily but not reported on DMRs.
Operations & Maintenance Significant rust and decay of structures, as well as excessive solids in the clarifier discharge
troughs were observed.
Clarifier/Thickeners Weirs observed are severely decayed.
Excessive solids were present in the perimeter discharge trough.
Units are covered restricting proper inspection.
State of North Carolina I Environmental Quality I Water Resources
2090 U.S. 70 Highway, Swannanoa, NC 28778
828-296-4500

DocuSign Envelope ID: 82D040DC-6650-4232-8D46-4B7B018Al2F1
In addition, the issues below must also be addressed:
Compliance Issue(s):
The wastewater treatment flow schematics submitted in the permit renewal are incorrect. These shall be updated
and submitted to DWR.
Effluent characteristics/pollutants are analyzed daily but not reported on DMRs. The results of all tests on the
characteristics of the effluent, including but not limited to NPDES Permit Monitoring Requirements, shall be
reported on DMRs. The August 2017 through January 2018 DMRs shall be resubmitted with all analyzed data.
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.
To prevent further action, please respond in writing to this office within 30 days of the date of this Notice
of Violation regarding your plans or measures to be taken to address the indicated violations and other identified
issues.
If you should have any questions, please do not hesitate to contact Linda Wiggs with the Water Quality
Regional Operations Section in the Asheville Regional Office at 828-296-4500.
ATTACHMENTS -Inspection Report
Ec: Teresa Morris (email)
WQS ARO Server
NPDES Laserfiche
Sincerely,
DocuSigned by:
7E617A38285848C...
G. Landon Davidson, P.G., Regional Supervisor
Water Quality Regional Operations Section
Asheville Regional Office
Division of Water Resources, NCDEQ
State of North Carolina I Environmental Quality I Water Resources
2090 U.S. 70 Highway, Swannanoa, NC 28778
828-296-4500

DocuSign Envelope ID: 82D040DC-6650-4232-8D46-4B7B018Al2F1
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 I 3 I NC0000353 111 12 I 18/02/07 I17 18 I S J 19 LG] 201 I
211111 1 1 1 1 1 111 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 111 1 1 1 1 1 166
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ----------------------Reserved-------------------
67 70 I I 71 I I 72 I r l 73 I I 174 751 I I I 1 1 1 I80
u ty I 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 oermit Number)
09:30AM 18/02/07
12/06/01
The Feldspar Corporation
530 Altapass Rd
Exit Time/Date
Permit Expiration Date
Spruce Pine NC 28777
05:OOPM 18/02/07
16/02/28
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Jim Garofalo,PO Box 99 Spruce Pine INC 28777//828-467-0788/8287662110
Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Operations & Maintenance Records/Reports Self -Monitoring Program
Facility Site Review Effluent/Receiving Waters Laboratory Storm Water
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
Linda S Wiggs DS ARO WQ//828-296-4500 Ext.4653/
E�'W
Signature of Manag ent°�ii���e Agency/Office/Phone and Fax Numbers Date
3/2/2018
7E617A38285848C...
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page#

DocuSign Envelope ID: 82D040DC-6650-4232-8D46-4B7B018Al2F1
NPDES yr/mo/day Inspection Type (Cont.)
NC0000353 111 121 18/02/07 1 17 18 ICI
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Linda Wiggs and Jason Smith with DWR met onsite at the Altapass facility with Glen Young, James
Garafola, Teresa Morris, Ryan Fredsall, Joe Pitman and Chris Gentry with Quartz Corp. Jason Smith
with DWR Laboratory Certification group performed a laboratory inspection. Linda Wiggs performed
an inspection of the Altapass facility and it's WWTP.
The wastewater treatment flow schematics submitted in the permit renewal are incorrect. These shall
be updated and submitted to DWR.
The clarifiers/thickeners are covered making inspection, operations and maintenance practically
impossible. Inspection of the clarifiers was performed with great difficulty by glancing at small sections
through the stair/walkway grates. The observations indicated significant rust and decay of structures,
as well as excessive solids in the discharge troughs. Two of the three thickeners were in operation at
the time of the inspection.
Effluent characteristics/pollutants are analyzed daily but not reported on DMRs. The results of all tests
on the characteristics of the effluent, including but not limited to NPDES Permit Monitoring
Requirements, shall be reported on DMRs.
The August 2017 through January 2018 DMRs shall be resubmitted with all analyzed data.
A temporary portable manually activated pump is in place as a contingency for the tailings pumps. Staff
stated sometime in June through a July 10th timeframe the plant will be shut down for maintenance
activities including replacement of the tailings pumphouse apparatus, including new trough, pumps,
tanks.
The Altapass processing facility is covered under Stormwater Permit NCG020818. Quartz Corp has
an updated site map for this facility; Shield Engineering, dated December 2017. This site map has
delineated the drainage areas; the map delineates 5 drainage areas. The map also indicates outfalls
and basin; 4 outfalls (1 WW/3 SW) and 5 basins are noted. Quartz Corp is working towards getting
most of the processing facility's stormwater flows directed to the WWTP; 1 drainage area is indicated
on the map draining to the WWTP, it is 14.2 acres. The four remaining drainage areas are associated
with outfalls covered under the stormwater permit NCG020818 as wastewater discharges. Three
outfalls and 5 basins are indicated on the map associated with the NCG020818. It had rained the day of
the inspection and 4 of the 5 basins had water in them. The basins on this site appear to be "Sediment
Basins with Rock Dams". They have been observed not functioning properly. The most notable
improper function observed was piping along the bottom of the rock dam. These types of structures
are not conducive to wastewater effluent sampling which is required at all the outfalls at the processing
plant. Quartz Corp has attempted to put a pipe near the top of the rock dam for sampling, with limited
success. This is most likely due to the piping. Three of the basins side slopes are not stabilized,
allowing additional solids into the basins.
During the facility shut down this summer an evaluation of the structural integrity and operational status
of the thickeners and components needs to take place.
Page#

DocuSign Envelope ID: 82D040DC-6650-4232-8D46-4B7B018Al2F1
Permit: NC0000353 Owner - Facility: The Feldspar Corporation
Inspection Date: 02/07/2018 Inspection Type: Compliance Evaluation
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?
Comment: The clarifier/thickener structures are covered. It does not appear Operations and
Maintenance can be performed. Significant rust and decay of structures, as well as
excessive solids in the perimeter discharge troughs were observed.
Quartz Corp staff monitor Fluoride, Turbidity and pH daily at the effluent for process
controls, these results are to be reported. See summary.
Permit
(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?
Is access to the plant site restricted to the general public?
Is the inspector granted access to all areas for inspection?
Comment: The wastewater treatment flow schematics submitted in the
See summary.
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?
Is audible and visual alarm available and operational?
Yes No NA NE
■ ❑ ❑ ❑
❑ ■ ❑ ❑
• ❑ ❑ ❑
• ❑ ❑ ❑
• ❑ ❑ ❑
renewal are incorrect.
❑ ■ ❑ ❑
❑ ❑ ■ ❑
• ❑ ❑ ❑
• ❑ ❑ ❑
❑ ❑ ■ ❑
❑ ❑ ■ ❑
❑ ❑ ■ ❑
Comment: A temporary portable manually activated pump is in place as a contingency
for the tailings
pumps.
Repairs are scheduled this summer.
Laboratory
Yes No NA NE
Are field parameters performed by certified personnel or laboratory?
0
❑
❑
❑
Are all other parameters(excluding field parameters) performed by a certified lab?
0
❑
❑
❑
# Is the facility using a contract lab?
0
❑
❑
❑
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
0
❑
❑
❑
Celsius)?
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DocuSign Envelope ID: 82D040DC-6650-4232-8D46-4B7B018Al2F1
Permit: NC0000353 Owner - Facility: The Feldspar Corporation
Inspection Date: 02/07/2018 Inspection Type: Compliance Evaluation
Laboratory Yes No NA NE
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: See summary.
Secondary 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?
❑
0
❑
❑
Is the drive unit operational?
❑
❑
❑
0
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: Weirs observed are severely decaved.
Excessive solids were present in the perimeter discharge trough.
The clarifier/thickeners are covered restricting proper inspection. Regardless,
what was
observed indicated possible issues as checked above.
See summary.
Effluent Sampling
Yes No NA NE
Is composite sampling flow proportional?
0
❑
❑
❑
Is sample collected below all treatment units?
0
❑
❑
❑
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
0
❑
❑
❑
Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
0
❑
❑
❑
representative)?
Comment: See summary.
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and 0 ❑ ❑ ❑
sampling location)?
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DocuSign Envelope ID: 82D040DC-6650-4232-8D46-4B7B018Al2F1
Permit: NC0000353 Owner - Facility: The Feldspar Corporation
Inspection Date: 02/07/2018 Inspection Type: Compliance Evaluation
Upstream / Downstream Sampling
Yes No NA NE
Comment: Any additional upstream/downstream sampling is required to also be reported on the DMRs.
See summary.
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:
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
❑
NPDES Permit Monitoring Requirements, shall be reported on DMRs.
Name of individual performing the sampling
❑
See above and summary.
Results of analysis and calibration
❑
Dates of analysis
❑
Name of person performing analyses
❑
Transported CM
❑
Are DMRs complete: do they include all permit parameters?
0
❑
❑
❑
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?
❑
❑
❑
0
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?
❑
❑
0
❑
Comment: The results of all tests on the characteristics of the effluent, including
but not limited to
NPDES Permit Monitoring Requirements, shall be reported on DMRs.
See above and summary.
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