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HomeMy WebLinkAboutNC0006190_Inspection_20190327ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Director CERTIFIED MAIL #: 7016 1370 0000 2591 1940 RETURN RECEIPT REQUESTED Mr. Everette Owens South Fork Industries, Inc. Post Office Box 742 Maiden, North Carolina 28650 Dear Mr. Owens: NORTH CAROLINA Environmental Quality 27 March 2019 Subject: Notice of Violation Compliance Bio-monitoring Inspection South Fork Industries/Maiden WWTP NPDES Permit No. NC0006190 Catawba County Tracking #: NOV-2019-PC-0212 Enclosed is a copy of the Compliance Bio-monitoring Inspection Report for the inspection conducted at the subject facility on March 14, 2019, by Mr. Wes Bell of this Office. Please inform the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding a copy of the enclosed report. The results of the effluent chronic toxicity samples collected on March 12 and 14, 2019 will be forwarded under separate cover. This report is being issued as a Notice of Violation (NOV) due to the following: 1) Unpermitted discharge of wastewater (from the lint dumpster) onto the ground and stormwater drainage system that occurred in February 2019; 2) Failure to report the unpermitted discharge of wastewater/bypass that occurred in February 2019; 3) Failure to collect 24-hr. influent composite color samples; 4) Failure to properly report effluent data on the Discharge Monitoring Reports (eDMRs); 5) Failure to maintain proper lagoon freeboard and erosion controls. These are violations of the subject NPDES Permit and North Carolina General Statute (G.S.) 143-215 as detailed in the Bar Screens/Summary, Record Keeping/Summary and Influent Sampling Sections of the attached report. Pursuant to G.S. 143- 215.6A, a civil penalty of not more than twenty-five thousand dollars ($25,000.00) per violation, per day may be assessed against any person who violates or fails to act in accordance with the terms, conditions, or requirements of any permit issued pursuant to G.S. 143-215.1. Penalties may also be assessed for any damage to surface waters of the State that may result from the violations. It is requested that a written response be submitted to this Office by April 16, 2019, detailing the actions taken to address all above -noted violations. In responding, please address your comments to the attention of Mr. Wes Bell. North Carolina Department of Environmental Quality I Division of Water Resources D_ E� Mooresville Regional Office 1610 East Center Avenue, Suite 301 1 Mooresville, North Carolina 28115 NORTH CAROLINA Da"MoM a enWmn�bl mwnq 704,663.1699 Mr. Everette Owens Page Two 27 March 2019 The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bellkncdenr.gov. Sincerely, DocuSigned by: A14CC681 AF27425... W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Enclosure: Inspection Report 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 NC0006190 111 12 I 19/03/14 I17 18 I Q I 19 I G I 201 I 211111 1 1 I I I I II I I I I I I I I I I I I 1 I I I I I I I I I I II I I I I I f6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 2.0 70 71 ty[ �, � 72 I �, I 73 � 74 751 I I I I I I I80 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) 08:55AM 19/03/14 19/02/01 South Fork Industries - Maiden Plant 100 W Pine St Exit Time/Date Permit Expiration Date Maiden NC 28650 01:30PM 19/03/14 23/05/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Donald A Burkey/ORC/704-736-8960/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Everette J Owens,PO Box 742 Maiden INC 28650/Owner/828-428-9921/ 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 Doc uSigned by: Wes Bell D"� MRO WQ//704-663-1699 Ext.2192/ 3/2 5/2019 E A:6)96D90CC343T 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: eyj � 3/27/2019 AtaccsatAFz�azs... Page# NPDES yr/mo/day Inspection Type (Cont.) NC0006190 I11 12, 19/03/14 117 18 JBI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On -site Representatives: The following South Fork Industries' personnel were in attendance during the inspection: Donald Burkey, Jamie Rhyne, and Todd Burgin. BAR SCREENS SECTION cont'd: An abundant amount of lint was observed on the ground and adjacent to multiple storm drains during the inspection. A company employee indicated to DWR staff and the ORC that the lint dumpster had overflowed onto the ground approximately three to four weeks earlier due to a drain blockage. The Division was never notified of this unpermitted discharge of wastewater. Please be advised that the discharge of wastewater without a permit is a violation of N.C. General Statute (G.S.) 143-215.1 and the failure to notify the Division within 24-hrs of first knowledge of a bypass, non-compliance, spill, etc. is also a violation of G.S. 143-215.1 and the requirements of the subject NPDES Permit. The lint inside the dumpster is removed and disposed (at County Landfill) by a contracted company. The Permittee must ensure that no discharges of wastewater onto the ground and/or stormwater drainage system occurs during this removal process by the contracted company. RECORD KEEPING SECTION cont'd: The records reviewed during the inspection were organized and readily accessible; however, there were numerous transcription errors noted on the January 2018 — March 2018 eDMRs. These errors include the following: a zero was reported as a result for several parameters (on several days) that were not sampled for throughout the January 2018 — March 2018 period; no influent color values reported for last two weeks in February 2018; no effluent and upstream hardness values reported during first quarter of 2018. All eDMRs will have to been revised and resubmitted. The ORC and staff must ensure that all effluent values are reported down to the appropriate detection level and all monitoring reports (eDMRs) are accurate and complete prior to submittal. SECONDARY CONTAINMENT: The previously repaired crack in the secondary containment structure for the peroxide and salt storage tanks is in need of repair again. The crack should be immediately repaired and an inspection program should be implemented to ensure the integrity of the containment structural is periodically monitored and repaired (if needed). In addition, there were several areas that posed a significant exposure to stormwater runoff (oil stained concrete, open buckets with oil, lint/debris on the ground, etc.). The Permittee must ensure that the requirements of the facility's Stormwater Permit (NCG170414) are being properly implemented. Page# Permit: NC0006190 Inspection Date: 03/14/2019 Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Bioassay Compliance 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? E ❑ ❑ ❑ 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 last compliance evaluation inspection was performed by DWR staff on 2/22/18. 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? ❑ ❑ ❑ Page# 3 Permit: NC0006190 Inspection Date: 03/14/2019 Record Keeping Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Bioassay Compliance Yes No NA NE Comment: Discharae Monitorina Reports (eDMRs) were reviewed for the period January 2018 throuah December 2018. Effluent BOD violations (5 - daily maximum and a monthly average) and COD violations (1 — daily maximum) were reported in January 2018. An effluent chronic toxicity failure was reported in March 2018. The facility failed to monitor effluent total nitrogen and total phosphorus in November 2018 and failed to monitor effluent chromium, color COD, phenols and sulfide during the week of 12/23/18 — 12/29/18. The Division has separately addressed these violations through the issuances of NOVs. See "Summary" Section for additional comments. 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 ❑ ❑ ❑ 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 analvses (dissolved oxvaen. DH and temperature) are performed under the South Fork Industries' field laboratory certification #5302. R&A Laboratories (all effluent parameters except field) has also been contracted to provide analytical support. The previous ORC is currently listed as the laboratory contact. Mr. Jason Smith, Division's Laboratory Certification Unit, should be contacted to update the contact information. Mr. Smith can be contacted by phone at 828-296-4679 or via email at iason.m.smith(a-.ncdenr.gov. Influent Sampling Yes No NA NE # Is composite sampling flow proportional? ❑ ❑ 0 ❑ Is sample collected above side streams? 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 sampling performed according to the permit? ❑ 0 ❑ ❑ Comment: The facilitv was not collectina 24-hr. comDosite samples (color) as reauired by the Permit (Part II, Section A. Definitions/Composite Sample). A review of the sampler's program revealed the sampler had only collected samples for approximately twelve (12) hrs. In addition, facility staff must ensure that the influent composite sample is representative of both waste streams that are separately conveyed into the screening area. Effluent Sampling V-- 61- NIA NIC Page# 4 Permit: NC0006190 Owner - Facility: South Fork Industries - Maiden Plant Inspection Date: 03/14/2019 Inspection Type: Bioassay Compliance 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? N ❑ ❑ ❑ # 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 subiect Dermit reauires composite and arab effluent samples. Monthlv aliauot checks are performed. 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? Comment: A new ORC was designated by the Permittee on 3/18/19. The wastewater treatment facility appeared to be adequately treating wastewater at the time of the inspection. Process control measurements were beina documented and maintained on -site. 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? 0 ❑ ❑ ❑ Comment: Two of the three fine lint screens (shakers) were operational and in service. Process wastewater is used to convey the screened lint into a dumpster. The process wastewater discharges back into the influent waste stream via drain hole in the bottom of the dumpster. See "Summarv" Section for additional comments. Page# 5 Permit: NC0006190 Inspection Date: 03/14/2019 Aeration Basins Mode of operation Type of aeration system 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? Is the DO level acceptable?(1.0 to 3.0 mg/1) Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Bioassay Compliance Yes No NA NE Ext. Air Surface ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: Both aeration basins were operational and in service. All aerators (3 - Basin #1 and 2 - Basin #2) were also operational and in service. No negative impacts were observed in the secondaries due to the foam coverage. Microbial supplements are added on a daily basis. 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? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: A DOlvmer and flocculant are added to the clarifier influent to enhance settlina and color removal. Clarifier weirs are not excessilvely uneven. The secondary clarifier effluent flows through a post aeration tank prior to flow measurement and discharae. Both surface aerators were oDerational and in service. Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ ❑ Page# 6 Permit: NC0006190 Inspection Date: 03/14/2019 Pumps-RAS-WAS Comment: Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Bioassay Compliance 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: The flow meter is calibrated twice per year and was last calibrated on 2/22/19 by Clearwater, Inc. Effluent Pipe 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? Yes No NA NE Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ Yes No NA NE ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ Comment: The effluent appeared slightly red with trace suspended solids and no foam. DWR staff collected effluent samples for chronic toxicity on 3/12/19 and 3/14/19. The results of these effluent samples will be forwarded under separate cover. 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 1 ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 7 Permit: NC0006190 Inspection Date: 03/14/2019 Lagoons Owner - Facility: South Fork Industries - Maiden Plant Inspection Type: Bioassay Compliance Yes No NA NE Comment: The freeboard along the berm adjacent to the creek appeared to be less than two feet in several areas. The facility staff should keep a minimum of two feet of freeboard (at a minimum) in the laaoon. In addition. severe erosion was observed around the stormwater drain adjacent to the lagoon (near the perimeter fence of adjoining property/park) Immediate repairs should be implemented to prevent continued erorsion and potential impacts to the lagoon berm. Please be advised that the subject permit requires the permittee to properly operate and maintain all facilities and systems of treatment and control at all times [Permit Condition Reference: Part II, Section C(2) Proper Operation and Maintenancel. Page#