Surname completely incorrect in new pport?

If you can trust the pport office to operate efficiently, send the pport back via secure speed post with a covering letter and the doents, state the degree and reasons for urgency (if she is about to travel) in a letter, and a money order for any additional fee (inquire ahead of time by phone or on the Internet). If you don't trust their efficiency, you will have to take the pport and doents and wait in line. Take food and water.