NC0000639_Compliance Evaluation Inspection_20190114

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NORTH CAROLINA
ROY COOPER Environmental Quality
Governor
MICHAEL S. REGAN
Secretary
LINDA CULPEPPER
Director
January 14, 2019
Mr. Henry Needham
Sapona Manufacturing Company
P.O. Box 2464
Asheboro, NC 27204
SUBJECT: Compliance Evaluation Inspection
Sapona Manufacturing Company WWTP
NPDES Permit No. NC0000639
Randolph County
Dear Mr. Needham:
On January 10, 2019, Jenny Graznak and Kelli Park of this office, met with Arnold Allred, Operator in
Responsible Charge (ORC), and Joe Walsh, Back Up ORC, to perform a Compliance Evaluation
Inspection at the Sapona Manufacturing Company wastewater treatment plant. This type of inspection
consists of two basic parts: an in-office file review and an on-site inspection of the treatment facility.
The attached EPA inspection form details the areas that were evaluated during this inspection. Some
pertinent findings from the inspection are described in the inspection summary.
The inspection found the facility to be satisfactory. If you have any questions regarding the inspection •
or this report, please contact Jenny Graznak or me at(336) 776-9800.
Sincerely,
p-Sherri V. Knight, P.E.
Regional Supervisor
Water Quality Regional Operations
Division of Water Resources
Attachments: EPA Water Compliance Inspection Report
cc: Central Files
WSRO
L_NPDES Unit
D_EC
North Carolina Department of Environmental Quality I Division of Water Resources
Winston-Salem Regional Office 1450 W.Hanes Mill Road,Suite 300 I Winston-Salem,North Carolina 27105
336-776-9800

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 [ I 3 I NC0000639 111 121 19/01/10 117
18 I�. 19► G 20I
211 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 I I I I I I I I I I P6
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA Reserved
67 I I 70 I I 711 I 72 11....1 I 73I I 174
75IJ I I I I I I 180
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 permit Number) 11 30AM 19/01/10 17/01/01
Sapona Manufacturing Company
Exit Time/Date Permit Expiration Date
2478 Cedar Falls Rd
12 30PM 19/01/10 21/09/30
Cedar Falls NC 27230
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
///
Arnold Eugene Allred/ORC/336-824-6440/
Joseph Michael Walsh/ORC/336-736-7180/
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
Arnold Eugene Allred,3309 Walker Store Rd Franklinville NC
No
272488375/1336-672-0892/
Section C Areas Evaluated Dunng Inspection(Check only those areas evaluated)
Permit El Flow Measurement Operations&Maintenance Records/Reports
Self-Monitoring Program II Sludge Handling Disposal IN Facility Site Review Effluent/Receiving Waters
Section D Summary of Finding/Comments(Attach additional sheetsiof narrative and checklists as necessary)
(See attachment summary) '
Name(s)and Signature(s)of Inspector(s) Agency/Office/Phone and Fax Numbers Date Jennifer F Graznak szVc2sriWSRO WQ//336-771-5000/ i A 9!?'Ci 9
Signature of M gemen Reviewer Agency/Office/Phone and Fax Numbers Date
I(ICI('9
EPA Form 35 (Rev 9-94)Previous editions are obsolete
Page# 1

NPDES yr/mo/day Inspection Type 1
31 NC0000639 111 121 19/01/10 117 18 i i
Section D Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
The inspection found the facility to be satisfactory. Please note that the facility exceeded the daily
maximum limit for Total Suspended Solids in April 2018, and therefore received a Notice of Deficiency
from DEQ.All parameters appear to have been sampled according to the permit requirements.
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Permit: NC0000639 Owner-Facility: Sapona Manufacturing Company
Inspection Date: 01/10/2019 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 0 0 • 0
application'?
Is the facility as described in the permit'? 0 • ❑ ❑
#Are there any special conditions for the permit'? ❑ • ❑ ❑
• 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 permit cover sheet does not include the sludge holding tank or the equalization tank with
grinder pumps. These need to be added to the components list durinq the next permit
renewal process. Outfall 002 only discharges when the air conditioning is used durinq the
summer months.
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping'? • ❑ ❑ ❑
Does the facility analyze process control parameters,for ex MLSS, MCRT, Settleable • ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable'?
Comment: Sapona does all of their own maintenance on the system.After the influent pump station,the
entire system is gravity flow.
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit'? • ❑ ❑ ❑
Is all required information readily available, complete and current? • ❑ ❑ ❑
Are all records maintained for 3 years(lab. reg. required 5 years)' ❑ ❑ ❑
Are analytical results consistent with data reported on DMRs? • ❑ ❑ ❑
Is the chain-of-custody complete'? • ❑ ❑ ❑
Dates,times and location of sampling III
Name of individual performing the sampling •
Results of analysis and calibration U
Dates of analysis •
Name of person performing analyses •
Transported COCs •
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 ❑ ❑ I ❑
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'? • ❑ ❑ ❑
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Permit: NC0000639 Owner-Facility: Sapona Manufacturing Company
Inspection Date: 01/10/2019 Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
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? ❑ ❑ II ❑
Comment Mr.Allred performs pH, chlorine, and temperature using field parameter certification#5408.
Envirolink and Meritech analyze all other parameters for the facility.
Bar Screens Yes No NA NE
Type of bar screen
a Manual
b Mechanical ❑
Are the bars adequately screening debris'? • ❑ ❑ ❑
Is the screen free of excessive debris'? MI ❑ ❑ ❑
Is disposal of screening in compliance'? • ❑ ❑ ❑
Is the unit in good condition'? • ❑ ❑ ❑
Comment:
Flow Measurement-Effluent Yes No NA NE
#Is flow meter used for reporting'? ❑ IIII ❑ ❑
Is flow meter calibrated annually'? ❑ ❑ • ❑
Is the flow meter operational'? ❑ ELM ❑
(If units are separated) Does the chart recorder match the flow meter'? ❑ ❑ • ❑
Comment The permit requires an instantaneous weekly flow measurement. Influent flow is estimated
by the operators.There is an effluent flow meter, but it is not used for reporting purposes
because it is set up in the treatment set-up prior to the chllorine contact and is only used for
process control purposes
Aeration Basins Yes No NA NE
Mode of operation Ext.Air
Type of aeration system Diffused
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'? ❑ ❑ ❑
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AP
Permit: NC0000639 Owner-Facility: Sapona Manufacturing Company
Inspection Date: 01/10/2019 Inspection Type: Compliance Evaluation
Aeration Basins Yes No NA NE
Is the DO level acceptable?(1.0 to 3.0 mg/I) 0 0 0 •
Comment.
Secondary Clarifier Yes No NA NE '
Is the clarifier free of black and odorous wastewater? • 0 0 0
Is the site free of excessive buildup of solids in center well of circular clarifier? 0 0 • 0
Are weirs level? • 0 0 0
Is the site free of weir blockage? • 0 0 0
Is the site free of evidence of short-circuiting? • 0 0 0
Is scum removal adequate? • 0 0 0
Is the site free of excessive floating sludge? • 0 0 0
Is the drive unit operational? • 0 0 0
Is the return rate acceptable(low turbulence)? II 0 0 0
Is the overflow clear of excessive solids/pin floc? • 0 0 ❑
Is the sludge blanket level acceptable?(Approximately'/4 of the sidewall depth) ❑ 0 0 •
Comment:
Disinfection-Liquid Yes No NA NE
Is there adequate reserve supply of disinfectant? IN 0 0 0
(Sodium Hypochlorite) Is pump feed system operational? _ • 0 0 0
Is bulk storage tank containment area adequate?(free of leaks/open drains) • 0 0 0
Is the level of chlorine residual acceptable? 0 0 0 •
Is the contact chamber free of growth, or sludge buildup? • 0 0 0
Is there chlorine residual prior to de-chlorination? 0 0 0 IN
Comment. Liquid hypochlorite is now added immediately after the clarifier to allow for extra chlorine
contact time.The liquid is added via timer.
De-chlorination Yes No NA NE
Type of system? Liquid
Is the feed ratio proportional to chlorine amount(1 to 1)? 0 0 0 •
Is storage appropriate for cylinders? 0 0 III 0
#Is de-chlorination substance stored away from chlorine containers? IN 0 0 0
Are the tablets the proper size and type? 0 0 0
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Permit: NC0000639 Owner-Facility: Sapona Manufacturing Company
Inspection Date: 01/10/2019 Inspection Type: Compliance Evaluation
De-chlorination Yes No NA NE
Comment: Liquid calcium thiosulfate is added at the end of the chlorine contact chamber.
Are tablet de-chlorinators operational? ❑ ❑ ❑ II
Number of tubes in use'?
Comment: -
Aerobic Digester Yes No NA NE
Is the capacity adequate'? ❑ ❑ • ❑
Is the mixing adequate'? ❑ ❑ • ❑
Is the site free of excessive foaming in the tank'? MI ❑ ❑ ❑
#Is the odor acceptable'? • ❑ ❑ ❑
#Is tankage available for properly waste sludge'? • ❑ ❑ ❑
Comment* Sludge from the bottom of the clarifier is pumped into a sludge holding tank on a daily basis.
The solids are removed from the tank as necessary by Kivett and Sons Septic Tank Service
for disposal in•the Franklinville WWTP (this typically occurs once per month and is tracked
on the daily logs).
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? ❑ ❑ MI ❑
Is sample collected below all treatment units' ❑ ❑ ❑
Is proper volume collected'? • ❑ ❑ ❑
Is the tubing clean'? ❑ ❑ 11 ❑
#Is proper temperature set for sample storage(kept at less than or equal to 6 0 degrees ❑ ❑ ❑ •
Celsius)?
Is the facility sampling performed as required by the permit(frequency,sampling type IM ❑ ❑ ❑
representative)'
Comment: Grab samples are collected from the effluent trough.
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained'? ❑ ❑ • ❑
Are the receiving water free of foam other than trace amounts and other debris'? • ❑ ❑ ❑
If effluent (diffuser pipes are required) are they operating properly'? ❑ ❑ U ❑
Comment The effluent pipe is under water in the Deep River and cannot be seen.
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