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Home My WebLink AboutNC0004375_Inspection_20190327ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Director Mr. Ken Hausle Clariant Corporation 4000 Monroe Road. Charlotte, North Carolina 28205 Dear Mr. Hausle: NORTH CAROLINA Environmental Quality 27 March 2019 Subject: Compliance Bio-monitoring Inspection Clariant Corp./Mt. Holly East WWTP NPDES Permit No. NC0004375 Mecklenburg County Enclosed is a copy of the Compliance Bio-monitoring Inspection Report for the inspection conducted at the subject facility on March 19, 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 chronic toxicity effluent samples collected on March 19 and 21, 2019 will be forwarded under separate cover. 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.bell(cr�,ncdenr.gov. Sincerely, DocuSigned by: A14CC681 AF27425... W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Enclosure: Inspection Report eCopy: Rusty Rozzelle, MCWQP D Q � North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1 610 East Center Avenue, Suite 301 1 Mooresville, North Carolina 28115 NORTH CAROLINA Da"MoM a enWmn�bl mwnq 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 NC0004375 111 12 I 19/03/19 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 131 QA ---------------------- Reserved ------------------- 67 2.0 70 71 ty[ � 72 I �, I 73 �74 751 I I I I I I I80 u 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) 09:05AM 19/03/19 18/01/01 Mount Holly East Facility 11701 Mount Holly Rd Exit Time/Date Permit Expiration Date Charlotte NC 28214 12:15PM 19/03/19 22/12/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Dwayne R Wallace/ORC/704-307-3870/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Deepak Parikh,4000 Monroe Rd Charlotte NC 28205/CEO/704-331-7000/7043771063 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: Wes Bell D' � MRO WQ//704-663-1699 Ext.2192/ 3/27/2019 E:,,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: e� 3/27/2019 AtaccsatAi=vazs... Page# NPDES yr/mo/day Inspection Type NC0004375 I11 121 19/03/19 117 18 JBI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NC0004375 Owner - Facility: Mount Holly East Facility Inspection Date: 03/19/2019 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? 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 industrial site currently has eight tenants that mainly discharge domestic wastewater to the WWTP. One of these tenants discharges approximately 5,000 gallons per day of process wastewater (soap/tap water) resulting from the washing of concrete forms. The last compliance evaluation inspection was performed by DWR staff on 6/5/18. 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 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 ❑ ❑ ❑ 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: NC0004375 Inspection Date: 03/19/2019 Record Keeping Owner - Facility: Mount Holly East Facility Inspection Type: Bioassay Compliance Yes No NA NE Comment: The records reviewed durina the inspection were oraanized and well maintained. Discharae Monitoring Reports (eDMRs) were reviewed for the period April 2018 through January 2019. No effluent limit violations were reported and all monitoring frequencies were correct. Revised April and December 2018 eDMRs will be submitted to correct the total nitrogen monthly loading values and include an effluent low level mercury result (December 2018 only). The paper copies for the revised August 2018 eDMR will also be mailed in to the n:.,:_:_ 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 analvses (conductivity. dissolved oxvaen. DH. temperature) are Derformed under the Clariant's field laboratory certification #5603. Pace Analytical Services, Inc. (Certification #40) has also been contracted to provide analytical support for all effluent parameters except field, toxicity and downstream sampling. ETT Environmental (Certification #) has been contracted to perform chronic toxicity tests and Shealy Environmental Services (Certification #329) has been contracted to perform all downstream sampling/analyses and the TRC analyses as part of the PPA. The ORC and staff must ensure that the temperature inside the refrigerator (at guard house) is monitored and documented (less than or equal to six degrees Celsius) in the event samples are temporarily stored for pickup by the contracted laboratory. 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 ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: The subject permit requires composite and grab effluent samples. Sampler aliquot volumes are periodically monitored and documented throughout the month. Upstream / Downstream Sampling Yes No NA NE Page# 4 Permit: NC0004375 Owner - Facility: Mount Holly East Facility Inspection Date: 03/19/2019 Inspection Type: Bioassay Compliance 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: The treatment units currently in service appeared to be properly operated and well maintained. Process control measurements are being documented and maintained on -site. 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: The facility is equipped with multiple stormwater equalization basins (alkaline and non -alkaline drainage areas) that have to be manually pumped back into the influent waste stream. 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 ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ Comment: A bypass conveyance system (via gravity flow) is connected from the influent pump station to stormwater equalization basin Z03B if flows exceed the pump station's capacity. Page# 5 Permit: NC0004375 Inspection Date: 03/19/2019 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: Mount Holly East Facility Inspection Type: Bioassay Compliance Yes No NA NE Diffused ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The circular aeration basin (former secondary clarifier) was operational and in service. The ORC continues to maintain a low biomass due to the low organic influent loading. 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) Comment: The weirs were not significantly unlevel and no short-circuiting was observed. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Flow Measurement - Effluent # Is flow meter used for reporting? • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ Yes No NA NE ■ ❑ ❑ ❑ Page# 6 Permit: NC0004375 Owner - Facility: Mount Holly East Facility Inspection Date: 03/19/2019 Inspection Type: Bioassay Compliance Flow Measurement - Effluent Yes No NA NE 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 ORC verifies the flow meter's accuracv twice per month and calibrates the flow meter as -needed during the bi-monthly verifications. The ORC typically calibrates the flow meter when flow values vary by more than five percent. The flow meter was last calibrated on 3/15/19. 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: The effluent appeared slightly brown with no floatable solids or foam. DWR staff collected effluent chronic toxicity samples on 3/19/19 and 3/21/19. The sample results will be forwarded under separate cover. Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Is the site free of sludge buildup on belts and/or rollers of filter press? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ Comment: The facility is equipped with two belt presses and two storage tanks (with mixing). One of the belt presses was not operational. The facility was not dewatering sludge at the time of the inspection. No dewatered sludge has been disposed into the on -site landfill (Cell #3) since October 2016. The disposal of sludge into the on -site landfill is permitted under the authority of Permit No. WQ0000537. Page# 7