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Home My WebLink AboutNC0072664_Regional Office Historical File Pre 2018 (51)CDE North Carolina Department of Environment and Natural Resources Beverly Eaves Perdue Governor Mr. Mark Hawes - Shurtape Technologies, LLC P.O. Box 1530 Hickory, NC 28603-1530 Dear Mr. Hawes: Division of Water Quality Coleen H. Sullins Director August 10, .2010 Subject: Compliance Evaluation Inspection Stony Point Tape Plant NPDES Permit NC0072664 Alexander County, North Carolina Dee Freeman Secretary Enclosed please find a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on August 10, 2010-by Ms. Donna Hood of this Office. Please inform the facility's Operator -in - Responsible Charge of the findings by forwarding a copy of the enclosed report. The company should be lauded for their exceptionally operated and maintained wastewater treatment plant, attention to record keeping detail and desire protect the environment. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Ms. Hood or me at (704) 663-1699. . Sincerely, Q Robert B. Krebs Surface Water Protection Regional Supervisor Enclosure cc: Central Files DH Mooresville Regional Office Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115 Phone: (704) 663-16991 Fax: (704) 663-60401 Customer Service: 1-877-623-6748 Internet http://portal.ncdenr.org/webiwq An Equal Opportunity 1 Affirmative Action Employer — 50% Recycled110% Post Consumer paper Nne orthCarolina Nati` ally 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 I NI 2 15I 31 N00072664 Ill 121 10/08/10 117 18I CI 19I SI 20I II Remarks 211 6 Inspection Work Days Facility Self -Monitoring Evaluation Rating 131 QA — -- -- -- - -- Reserved------- -- 67 I 169 70151 711 I 72 I N I 73 L1J 74 75I 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) 12:45 PM 10/08/10 09/04/01 Stony Point Plant Exit Time/Date Permit Expiration Date 8510 NC Hwy 90 E Stony Point NC 28678 03:00 PM 10/08/10 14/03/31 Name(s) of Onsite Rep resentative(s)fTitles(s)/Phone and Fax Number(s) Other Facility Data Mark Hawes//828-322-2700 ext 5428/ Travis Edwin Brannon/ORC/704-585-6511/ Name, Address of Responsible Official/Title/Phone and Fax Number Mark E Hawes,PO Box 1530 Hickory NC 286031530/Director of Environmentacted & Safety/828-322-2700/8283255387 Yes 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 b: Summary of Finding/Comments Attach additional sheets of.narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Age ncy/Office/Phone'and Fax Numbers Date Donna Ho MRO WQ//704-663-1699 Ext:2193/ ill Si t re f Management Q A er Agency/Office/Phone and Fax Numbers Date Marcia Allocco WQ//709-663-1699 Ext.2209/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type .3I NC0072664 I11 12, 10/08/10 I1.7 18ICI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page # 2 Permit: NCO072664 Owner - Facility: Stony Point Plant Inspection Date: 08/10/2010 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 application? ❑ ❑ ■ Is the facility as described in the permit? ■ ❑ ❑ Q # Are there any special conditions for the permit? ❑ ■ ❑ ❑ Is access to the plant site restricted to the general public? fl ■ n n Is the inspector granted access to all areas for inspection? ■ n n n Comment: Dechlorination has been added to the facility description.. Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■ n ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ ❑ ❑ fl Judge, and other that are applicable? Comment: The facility incorporates an extensive process control program to help ensure proper treatment of the facility's wastewater. 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? ■ n fl n Are all records maintained for 3 years (lab. reg. required 5 years)? ®❑ rl n Are analytical results consistent with data reported on DMRs? ® n n n Is the chain -of -custody complete? ■ fl n n 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 IN Are DMRs complete: do they include all permit parameters? ■ n n n Has the facility submitted its annual compliance report to users and DWQ? n n ■ n (If the facility is = or > 5 MGD permitted Flow) Do they operate 24/7 with a certified operator on each shift? n n ■ n Is the ORC visitation log available and current? ®❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? �nnn Is the backup operator certified at one grade less or greater than the facility classification? ®n n n Page # 3 Permit: NCO072664 Owner - Facility: Stony Point Plant Inspection Date: 08/10/2010 Inspection Type: Compliance Evaluation �. Record Keeping Yes No NA NE Is a copy of the current NPDES permit available on site? ■ n n n Facility has copy of previous year's Annual Report on file for review? n n ■ n Comment: DMRs for April 2009-March 2010 were reviewed for the inspection. Data for April 30, 2009 was omitted from the DMR. Please submit an amended DMR showing the excluded data. No violations were noted for the review period. All records were exceptionally organized and easily accessible. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? ■ n n n Are all other parameters(excluding field parameters) performed by a certified lab? ■ n n n # Is the facility using a contract lab? ■ n ❑ n # Is proper tern perature.set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ n n n Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? n n ® n Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? n n ■ n Comment: A laboratory inspection was performed concurrent to the NPDES inspection. Please refer to the inspection report by Mr. Chet Whiting, of this Office, for any laboratory recommendations. Aerobic Digester Yes No NA NE Is the capacity adequate? ■ . n n n Is the mixing adequate? ■ ❑ n n Is the site free of excessive foaming in the tank? ®n n n # Is the odor acceptable? ■ n n n # Is tankage available for properly waste sludge? n n n Comment: Millers Septic hauls sludge from the facility. Final sludge disposal occurs at the Town of Taylorsville WIMP. The facility disposed of approximately 16,000 gallons of sludge from the facility for the calendar year 2009. Bar Screens Yes No NA NE Type of bar screen a. Manual b. Mechanical Are the bars adequately screening debris? ■ n n n Is the screen free of excessive debris? ® n n n Is disposal of screening in compliance? ■ n n n Page # 4 Permit: NCO072664 owner - Facility: Stony Point Plant Inspection Date: 08/10/2010 Inspection Type: Compliance Evaluation i Bar Screens Yes No NA NE Is the unit in good condition? ■ ❑ Cl n Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Is the basin free of dead spots? ■ n n n Are surface aerators and mixers operational? ❑ n ■ n Are the diffusers operational? ■ n n n Is the foam the proper color for the,treatment process? ■ n n n Does the foam cover less than 25% of the basin's surface? ®❑ ❑ n Is the DO level acceptable? ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) n n o ■ Comment: The aeration basin appeared well mixed and adequately oxygenated with no foam at the time of the inspection. Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? ■ n ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? n n ■ n ■ ❑ ❑ n Are weirs level? Is the site free of weir blockage? ®❑ n Is the site free of evidence of short-circuiting? ■ Cl n n Is scum removal adequate? ■ n n n Is the site free of excessive floating sludge? ®❑ ❑ ❑ ❑ n ■ ❑ . 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%.of the sidewall depth) ❑ n ❑ ■ Comment: Secondary clarifier effluent was clear on the day of the inspection. De -chlorination Yes No NA NE Tablet Type of system ? Is the feed ratio proportional to chlorine amount (1 to 1)? ■ n n .n Page # 5 Permit: NCO072664 Owner - Facility: Stony Point Plant Inspection Date: 08/10/2010 Inspection Type: Compliance Evaluation De -chlorination Yes No NA NE Is storage appropriate for cylinders? n ■ # Is de -chlorination substance stored away from chlorine containers? ■ n n n Comment: Are the tablets the.proper size and type? ■ ❑ n n Are tablet de -chlorinators operational? ■ n n n Number of tubes in use? 2 Comment: Norweco sodium bisulfite tablets are used for dechlorination. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? n n ■ n Is flow meter calibrated annually? n n ■ n Is the flow meter operational? n n ■ n (If units are separated) Does the chart recorder match the flow meter? n n ® ❑ Comment: Flow is measured by the bucket and stopwatch method.. Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? ®❑ n ❑ Are the tablets the proper size and type? ®n ❑ fl Number of tubes in use? 1 Is the level of chlorine residual acceptable? n n n ■ Is the contact chamber free of growth, or sludge buildup? ® n n n Is there chlorine residual prior to de -chlorination? ❑ .❑ ❑ ■ Comment: Aquaward calcium hypochlorite is used for disinfection. There was approximately 7 inches of sludge in the chlorine contact chamber. Effluent Sampling Yes No NA NE Is'composite sampling flow proportional? n n ■ ❑ Is sample collected below all treatment units? ■ ❑ ❑ ❑ Is proper volume collected? ®n ❑ n Is the tubing clean? n # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ❑ n n ■ Is the facility sampling performed as required by the permit (frequency, sampling type representative)? ®❑ ❑ n Comment: Page # 6 Permit: NC0072664 Owner - Facility: Stony Point Plant Inspection Date: 08/10/2010 inspection Type: Compliance Evaluation Effluent Pipe Is right of way to the outfall properly maintained? ❑ n n Are,the receiving water free of foam other than trace amounts and other debris? n n n If effluent (diffuser pipes are required) are they operating properly? n n ❑ Comment: The receiving stream appeared unaffected by the discharge on the day of the inspection. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ■ ❑ ❑ 0— Comment: Page # 7