NC0004685_Inspection_20190111

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ROY COOPER
Governor
MICHAEL S.REGAN
Secretary
LINDA CULPEPPER µ ++ '
Director NORTH CAROLINA
Enivii anmertfal Qrso111y
14 January 2019
Mr.Todd Douthit, Manufacturing Manager
Nippon Electric Glass
940 Washburn Switch Road
Shelby, NC 28150
Subject: Compliance Sampling Inspection
NEG Industries/Shelby Facility
NPDES Permit No. NC0004685
Cleveland County
Dear Mr. Douthit:
Enclosed is a copy of the Compliance Sampling Inspection for the inspection conducted at the
subject facility on January 9, 2019 by Ori Tuvia and Tony Parker. Richard Young's, Guy O'Connor's
and John Littlejohn'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.
At the time of the inspection split samples for Oil and Grease,TSS, Metals (Zinc, Copper and
Lead) were taken. The results will be forwarded to you via separate correspondence.
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 [e-mail]
Sincerely,
DocuSigned by:
A14CC681 AF27425...
W. Corey Basinger
Regional Supervisor
Mooresville Regional Office
Division of Water Resources
cc: NPDES, MRO files (Laserfiche)
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State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations
Mooresville Regional Office 1 610 East Center Avenue,Suite 3011 Mooresville,North Carolina 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 IN I 2 15 I 3 I NC0004685 111 12 I 19/01/09 I17 18 LC]I 19 I G I 20I
211 1 I 1 I I I I I I I I I I I 1 1 I 1 1 I I I I I I I I I I I I I I I I I I I I 1 f6
Inspection Work Days Facility Self-Monitoring Evaluation Rating 131 QA ----------------------Reserved-------------------
67 1.0 70 71 [„ I 72 n 73 L_LJ74 751
I I I I I I I80
u Section B: Facility Data u
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) 08:05AM 19/01/09 14/05/01
Electric Glass Fiber America LLC
940 Washburn Switch Rd Exit Time/Date Permit Expiration Date
Shelby NC 28150 10:20AM 19/01/09 18/08/31
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
Guy Peter O'Connor/ORC/704-434-2261/
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
Richard M Young,940 Washburn Switch Rd Shelby NC
28150//704-434-2261/7044340792 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
DocuSigned by:
Ori A Tuvia --ci MRO WQ//704-663-1699/ 1/14/2019
cc
FMM0r7A')nr-Q17AQQ
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
W. Corey Basinger Division of Water Quality//704-2;
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.
DocuSigned by:
eyl 1/14/2019
AtaccsatAFz�azs... Page# 1

NPDES yr/mo/day Inspection Type 1
31 NC0004685 I11 121 19/01/09 11 7 18 I S
Section D:Summary of Finding/Comments(Attach additional sheetsof narrative and checklists as necessary)
Complaince Sampling Inspection. Split samples for Oil and Grease, TSS, Metals (Zinc, Copper and
Lead)
Page# 2

Permit: NC0004685 Owner-Facility: Electric Glass Fiber America LLC
Inspection Date: 01/09/2019 Inspection Type: Compliance Sampling
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? 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 expired on 8/31/2018, a permit renewal application was sent.
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 CM
Are DMRs complete: do they include all permit parameters? ❑ ❑ ❑
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? ❑ ❑ ❑
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 records reviewed during the inspection were organized and well maintained. DMR's,
COC's ORC logs, calibration logs and Process control logs were received for the period of
July 2018-Sept 2018.
Laboratory Yes No NA NE
Page# 3

Permit: NC0004685 Owner-Facility: Electric Glass Fiber America LLC
Inspection Date: 01/09/2019 Inspection Type: Compliance Sampling
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)?
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: On-site field analyses (conductivity, DO, pH and temperature) are performed under NEG's
laboratory certification#5489. Pace Analytical Services, Inc. (BOD. TSS, fluoride, ammonia,
nutrients, Oil &grease, metals)and R&A Laboratories, Inc. (Toxicity) have also been
contracted to provide analytical support. The laboratory instrumentation used for field
analysis appeared to be properly calibrated and well documented.
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: The subject permit requires effluent composite and grab samples.
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit(frequency, sampling type, and 0 ❑ ❑ ❑
sampling location)?
Comment:
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?
Page# 4

Permit: NC0004685 Owner-Facility: Electric Glass Fiber America LLC
Inspection Date: 01/09/2019 Inspection Type: Compliance Sampling
Operations & Maintenance Yes No NA NE
Comment: The facility appeared to be properly and well maintained. The operations staff incorporate
comprehensive process control program with all measurements being properly documented
and maintained on-site. The facility is equipped with computer/alarm notification system to
assist the wastewater staff in the operation of the treatment units/processes.
The surge retention pond at the influent of the plant appeared to have accesses vegetation
growth and need to be cleared.
Bar Screens Yes No NA NE
Type of bar screen
a.Manual
b.Mechanical ❑
Are the bars adequately screening debris? 0 ❑ ❑ ❑
Is the screen free of excessive debris? 0 ❑ ❑ ❑
Is disposal of screening in compliance? 0 ❑ ❑ ❑
Is the unit in good condition? ❑ ❑ ❑
Comment:
Equalization Basins Yes No NA NE
Is the basin aerated? ❑ ❑ 0 ❑
Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑
Is the basin free of excessive grease? 0 ❑ ❑ ❑
Are all pumps present? 0 ❑ ❑ ❑
Are all pumps operable? 0 ❑ ❑ ❑
Are float controls operable? 0 ❑ ❑ ❑
Are audible and visual alarms operable? 0 ❑ ❑ ❑
#Is basin size/volume adequate? 0 ❑ ❑ ❑
Comment:
Primary 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 ❑ ❑ ❑
Page# 5

Permit: NC0004685 Owner-Facility: Electric Glass Fiber America LLC
Inspection Date: 01/09/2019 Inspection Type: Compliance Sampling
Primary Clarifier Yes No NA NE
Is the site free of excessive floating sludge? 0 ❑ ❑ ❑
Is the drive unit operational? 0 ❑ ❑ ❑
Is the sludge blanket level acceptable? 0 ❑ ❑ ❑
Is the sludge blanket level acceptable? (Approximately'/of the sidewall depth) 0 ❑ ❑ ❑
Comment: Both primaries were operational and in service.
Chemical Feed Yes No NA NE
Is containment adequate? 0 ❑ ❑ ❑
Is storage adequate? 0 ❑ ❑ ❑
Are backup pumps available? E ❑ ❑ ❑
Is the site free of excessive leaking? 0 ❑ ❑ ❑
Comment: Chemical additions to selected treatment processes include the following: plymers,
bentonite/clay mixture, ferric chloride, aluminum, lime and defoamer.
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? 0 ❑ ❑ ❑
Is the DO level acceptable? 0 ❑ ❑ ❑
Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ 0 ❑
Comment: The facility uses two aeration basins operated in series. The first aeration tank is equipped
with diffused and mechanical aeration and the second aeration tank is equipped with
diffused aeration.
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 ❑ ❑ ❑
Page# 6

Permit: NC0004685 Owner-Facility: Electric Glass Fiber America LLC
Inspection Date: 01/09/2019 Inspection Type: Compliance Sampling
Secondary Clarifier Yes No NA NE
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'/4 of the sidewall depth) 0 ❑ ❑ ❑
Comment: Two out of the three secondary clarifiers were operational and in service at the time of the
inspection. The third clarifier was not used due to low flow.
Pumps-RAS-WAS Yes No NA NE
Are pumps in place? N ❑ ❑ ❑
Are pumps operational? 0 ❑ ❑ ❑
Are there adequate spare parts and supplies on site? 0 ❑ ❑ ❑
Comment:
Filtration (High Rate Tertiary) Yes No NA NE
Type of operation:
Is the filter media present? 0 ❑ ❑ ❑
Is the filter surface free of clogging? ❑ ❑ ❑
Is the filter free of growth? ❑ ❑ ❑
Is the air scour operational? ❑ ❑ 0 ❑
Is the scouring acceptable? ❑ ❑ ❑
Is the clear well free of excessive solids and filter media? ❑ ❑ 0 ❑
Comment: The facility is equipped with a traveling bridge tertiary filter. The filter backwash is returned to
the head of the wastewater plant.
Flow Measurement- Effluent Yes No NA NE
#Is flow meter used for reporting? 0 ❑ ❑ ❑
Is flow meter calibrated annually? 0 ❑ ❑ ❑
Is the flow meter operational? 0 ❑ ❑ ❑
(If units are separated) Does the chart recorder match the flow meter? 0 ❑ ❑ ❑
Comment: The flow meter is calibrated/verified regularly. Last calibrated on 8/20/2018 by Clear Water
Inc.
Effluent Pipe Yes No NA NE
Page# 7

Permit: NC0004685 Owner-Facility: Electric Glass Fiber America LLC
Inspection Date: 01/09/2019 Inspection Type: Compliance Sampling
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: At the time of the inspection effluent from outfalls 001 and 002 appeared clear with no
discoloring.
Solids Handling Equipment Yes No NA NE
Is the equipment operational? 0 ❑ ❑ ❑
Is the chemical feed equipment operational? 0 ❑ ❑ ❑
Is storage adequate? 0 ❑ ❑ ❑
Is the site free of high level of solids in filtrate from filter presses or vacuum filters? 0 ❑ ❑ ❑
Is the site free of sludge buildup on belts and/or rollers of filter press? 0 ❑ ❑ ❑
Is the site free of excessive moisture in belt filter press sludge cake? ❑ ❑ ❑
The facility has an approved sludge management plan? ❑ ❑ 0 ❑
Comment: Thickened sludge is dewatered on a belt press. Dewatered solids are transported to the
county landfill for final disposal by waste pros.
Page# 8

ROY COOPER
Governor
MICHAEL S. REGAN
Secretary
LINDA CULPEPPER
Director
Mr. Todd Douthit, Manufacturing Manager
Nippon Electric Glass
940 Washburn Switch Road
Shelby, NC 28150
Dear Mr. Douthit:
NORTH CAROL INA
Enrtronmerrfal griorrly
February 22, 2019
Subject: Compliance Sampling Inspection
NEG Industries/Shelby Facility
NPDES Permit No. NC0004685
Cleveland County
Enclosed is a copy of the laboratory results for the effluent samples collected during the
Compliance Sampling Inspection performed at the subject facility on January 9, 2019 by Ori Tuvia. 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 ori.tuvia&ncdenr.gov.
cc: NPDES, MRO files (Laserfiche)
Sincerely,
DocuSigned by:
BB057A2DE017498...
Ori Tuvia, Environmental Engineer
Mooresville Regional Office
Division of Water Resources, DEQ
D� E
State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations
Mooresville Regional Office 1 610 East Center Avenue, Suite 3011 Mooresville, North Carolina 28115
704 663 1699

AC58583 Nol-th Carolina Dhision of Water Resources Water Sciences Sectioti Laboratory Results
Lac. Deacr.:
MC0O04655
County
Cleveland
Collector:
OTUVIA
MsitlD
Region:
Mooresville
Report To
MRO
Location ID:
MRO NLC
River Basin
Collect Date:
0VOW2019
Priority
RDUTINE
Emergency
Collect T ime:
08:24
Sample Matrix:
5U R FAC E WATER
COC Yea1No
Yea
Sample Depth
Loc. Type:
Other
Final Report
tf this report is labeled preliminary report, the results have nor beery validated. Do not use for Regulatory purposes.
Resultl
Method
Analysis
Units
CAS # AnalVte Name
PQL Qualifier
Reference
Date
Validated by
LAB
Sample temperature at receipt by lab
2.2
C
1110119
MSWIFT
WET
Residue —Suspended in liquid
6.2 6.2 U
mgiL
SM 2540 D-1997
1115M9
CGREEN
MET
Cu by ICPMS
2.0 2.4
ugrL
EPA 200.8Rev5.4
215119
ESTAFFORD1
Pb by ICPMS
2.0 2.0 U
ug4-
EPA 200.3Rev5.4
2i5119
ESTAFFORD1
Zn by ICPMS
10 10 U
ugrL
EPA 200.8Rev5.4
215119
ESTAFFORD1
AC58584 Noith Carolina Division of Water Resources Water Sciences Section LaboratW Results
Loc. Descr.:
NCO004685
County:
Cleveland
Collector:
O TUVIA
Visi[ID
Region:
Mooresville
Report To
MRO
Location ID:
MRO NLC
River Basin
Collect Date:
0110912019
Priority
ROUTINE
Emergency
Collect Time:
08_24
Sample Matrix:
SURFACEWATER
COC YeslNo
Yes
Sample Depth
Lac. Type:
Other
Final Report
If this report is labeled preliminary report; the results have not been validated. Do not cis for Regulatory purposes.
Result! Units Method Analysis
CAS t Analyte Name PQL qualifier Reference Date Validated by
LAB
Sample temperature at receipt by lab 2.2 1110119 MSWIFT
WET
Grease and ail in liquid 10 10 U mglL EPA 1664 B 1125/19 CGREEN