NC0085839_Inspection_20180501

WaterResou ces
EHWROMMEWAl QUALITY
May 2, 2018
Rick Singleton
Unimin Corporation
PO Box 100
Bakersville, NC 28705
SUBJECT: Compliance Inspection Report
Red Hill Quartz Processing Plant
NPDES WW Permit No. NCO085839
Mitchell County
Dear Mr. Singleton:
ROY COOPER
Gorerna,
MICHAEL S. R[E.GAN
SBGlB1CQti
LT -NDA CFULPEPPER
lhJ err m Direclar
The North Carolina Division of Water Resources conducted an inspection of the Red Hill Quartz
Processing Plant on 4/03/2018. This inspection was conducted to verify that the facility is
operating in compliance with the conditions and limitations specified in NPDES WW Permit No.
NC0085839.
The enclosed inspection report has action items we discussed during the inspection that require
your attention.
If you should have any questions, please do not hesitate to contact me at 828-296-4500 or
via email at [e-mail].
Sincerely,
E-4
DocuSigned by:
tiwol,� wl, l y
6C38CDE295CF449...
Linda Wiggs
Water Quality Regional Operations Section
Asheville Regional Office
Division of Water Resources, NCDEQ
ATTACHMENTS -Inspection Report
Cc: WQS ARO Server
Laserfiche
G:\WR\WQ\Mitchell\Wastewater\Industrial\Unimin Red Hill 85839\4-3-2018 visit\20180501_NC0085839_CEI.rtf
State of North Carolina I Environmental Quality I Water Resources
2090 U.S. 70 Highway, Swannanoa, NC 28778
828-296-4500

DocuSign Envelope ID: 2DD4996B-DEDB-4262-BEBA-54D3152BB57A
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 I 2 15 I 3 I NCO085839 111 12 I 18/04/03 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 I� 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 18/04/03
12/06/01
Red Hill Quartz Processing Plant
Unimin Quartz Processing
Exit Time/Date
Permit Expiration Date
Spruce Pine NC 28777
03:30PM 18/04/03
16/02/29
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
Steve Westmoreland,PO Box 588 Spruce Pine NC 287770588//828-765-0912/
Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Operations & Maintenance Records/Reports Self -Monitoring Program 0 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
Linda S Wiggs EW ARO WQ//828-296-4500 Ext.4653/ 5/2/2018
Sigr Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
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DocuSign Envelope ID: 2DD4996B-DEDB-4262-BEBA-54D3152BB57A
NPDES yr/mo/day Inspection Type (Cont.)
NCO085839 111 121 18/04/03 1 17 18 ICI
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Inspector, Linda Wiggs, met onsite with several Unimin staff to follow up on a complaint received by
EPA and to perform a laboratory inspection with Jason Smith from the DEQ Laboratory Section.
Unimin staff present during the inspections were, Andy Greene, Rick Singleton, Steve Wilson and
Dennis Johnson.
Sampling below the raw water dam shall take place weekly for pH, TSS and Fluoride. The analysis
results, date, time and precipitation within 24 hours shall be recorded in the operator log. This
information shall also be sent to Linda Wiggs via email monthly until further notice.
Photo documentation has been requested of E Pond #2 once it has been cleaned.
Maintenance activities, such as the cleaning of the E Pond, weir and troughs should be recorded in the
operator log.
Process water pH is monitored in several locations. Location of the probes were discussed for more
representative monitoring. Also discussed as a contingency, the trigger pH values be reconsidered,
i.e. the set 9.7 pH 5 -minute trigger be altered to 9.0 pH.
The diverter valve for #1 did not activate during the inspection. Maintenance staff took immediate repair
actions which were documented the following day to the inspector. The diverter valves are an integral
component of the wastewater system to avoid non-compliant effluent discharged to the river.
Increased inspection/exercising of these valves may be warranted.
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DocuSign Envelope ID: 2DD4996B-DEDB-4262-BEBA-54D3152BB57A
Permit: NCO085839 Owner - Facility: Red Hill Quartz Processing Plant
Inspection Date: 04/03/2018 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: See summary.
Record Keeping
Yes No NA NE
Are records kept and maintained as required by the permit?
0
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Is all required information readily available, complete and current?
0
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Are all records maintained for 3 years (lab. reg. required 5 years)?
0
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Are analytical results consistent with data reported on DMRs?
0
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Is the chain -of -custody complete?
0
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Dates, times and location of sampling
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Name of individual performing the sampling
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Results of analysis and calibration
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Dates of analysis
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Name of person performing analyses
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Transported CDCs
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Are DMRs complete: do they include all permit parameters?
0
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Has the facility submitted its annual compliance report to users and DWQ?
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0
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(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator
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on each shift?
Is the ORC visitation log available and current?
Yes No NA NE
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Is the ORC certified at grade equal to or higher than the facility classification?
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Is the backup operator certified at one grade less or greater than the facility classification?
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Is a copy of the current NPDES permit available on site?
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Facility has copy of previous year's Annual Report on file for review?
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0
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Comment:
Secondary Clarifier
Yes No NA NE
Is the clarifier free of black and odorous wastewater?
0
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Is the site free of excessive buildup of solids in center well of circular clarifier?
0
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Are weirs level?
0
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Is the site free of weir blockage?
0
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Is the site free of evidence of short-circuiting?
0
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DocuSign Envelope ID: 2DD4996B-DEDB-4262-BEBA-54D3152BB57A
Permit: NCO085839 Owner - Facility:
Red Hill Quartz Processing Plant
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Inspection Date: 04/03/2018 Inspection Type:
Compliance Evaluation
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Secondary Clarifier
Yes No NA NE
Is scum removal adequate?
0
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Is the site free of excessive floating sludge?
0
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Is the drive unit operational?
0
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Is the return rate acceptable (low turbulence)?
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0
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Is the overflow clear of excessive solids/pin floc?
0
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Is the sludge blanket level acceptable? (Approximately '/, of the sidewall depth)
M
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Comment: 50' thickener #1, back online —30 days.
70' thickener #2, weir and trough need cleaning. Record in operator log. See summary.
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?
Yes No NA NE
N
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Comment: E Donds and raw water ponds were evaluated. SamDlina below the dam of the raw water
ponds shall take place. See summary.
Equipment was onsite to clean E Pond #2.
Effluent Pipe
Yes No NA NE
Is right of way to the outfall properly maintained?
0
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Are the receiving water free of foam other than trace amounts and other debris?
0
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If effluent (diffuser pipes are required) are they operating properly?
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0
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DocuSign Envelope ID: 2DD4996B-DEDB-4262-BEBA-54D3152BB57A
Permit: NCO085839
Inspection Date: 04/03/2018
Effluent Pipe
Comment:
Owner - Facility: Red Hill Quartz Processing Plant
Inspection Type: Compliance Evaluation
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?
Comment: Jason Smith will send the laboratory inspection report under separate cover.
Yes No NA NE
Yes No NA NE
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