NC0072664_Regional Office Historical File Pre 2018 (178)

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NCDENR
North Carolina Department of Environment and Natural Resources
Pat McCrory John E. Skvarla, III
Governor Secretary
May 27, 2014
Mr. Mark Hawes
Shurtape Technologies, LLC
P.O. Box 1530
Hickory, North Carolina 28603-1530
Subject: Compliance Evaluation Inspection
Stony Point Tape Plant
NPDES Permit No. NCO072664
Alexander County
Dear Mr. Hawes:
Enclosed please find a copy of the Compliance Evaluation Inspection report for the inspection
conducted at the subject facility on May 20, 2014, by Ms. Marcia Allocco of this office. Thank you for
Your assistance and that of Messrs. Eplin and Mr. Brannon during the inspection and everyone's
efforts to comply with the requirements of your NPDES permit.
The inspection report should be self-explanatory; however, should you have any questions
concerning the report, please do not hesitate to contact me at [phone] or
[e-mail].
cc: Wastewater Branch
MSC 1617 — Central files basement
MA
Sincerely,
Marcia Allocco, MS; Environmental Senior Specialist
Water Quality Regional Operations Section
Division of Water Resources, NCDENR
Mooresville Regional Office
Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115
Phone: [phone] Fax: [phone] Customer Service:1-877-623-6748
Internet: hfp://portal.ncdenr.org/web/wq
An Equal Opportunity 1 Affirmative Action Employer— 30% Recycled/10% Post Consumer paper

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United States Environmental Protection Agency
Form Approved.
�� Washington, D.C. 20460
OMB No. 2040-0057
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�pp;crlxpi"ra --
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 INI 2 15 I 31 NC0072664 111 121 14/05/20 117 181 C I 19I S I 20I
Remarks
211111111111111111Jill IIIIIIIIIIIIIII1111111111116
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---- —-------- -------Reserved------------
67I 1.5 169 70141 71 I N I 721 N I 73 L U 74 751 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)
09/04/01
09:35 AM 14/05/20
Stony Point Plant
Exit Time/Date
Permit Expiration Date
8510 NO Hwy 90 E
Stony Point NC 28678
12:42 PM 14/05/20
14/03/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Douglas Ray Hal l/ORC/828-267-8919/
Travis Edwin Brannon/ORC/828-267-8919/
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mark E Hawes,PO Box 1530 Hickory NO 286031530/Director of Environment &
Safety/828-267-8428/8778599746 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 Find in/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
Marcia Allocco MRO WQ//704-663-1699 Ext.2204/
A L
Signature of Management Q A Reviewer Agency/Office/Phone and Fax.Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPIDES
yr/mo/day
Inspection Type
I
Page # 2

i;
Permit: NCO072664 Owner - Facility: Stony Point Plant
Inspection Date:. 05/20/2014 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? n ❑ ■
Is the facility as described in the permit?
# Are there any special conditions for the permit?
Is access to the plant site restricted to the general public?
Is the inspector granted access to all areas for inspection?
Comment: NCO072664 was recently reissued by the Division with an effective date of
June 1, 2014. The reissued permit contains a nutrient reopener for High Rock Lake, a.
requirement for eDMR submission by March 1, 2015, and an exemption from annual
performance reporting due to the size of the treatment plant. The previous compliance
evaluation inspection was conducted on August 10, 2010.
Operations & Maintenance
Is the plant generally clean with acceptable housekeeping?
Yes No NA NE
■ n n n
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ n n n
Judge, and other that are applicable?
Comment: The permittee conducts process control sampling of pH, dissolved oxygen,
MLSS, MLVSS, and settleability in the operation of the WWTP. The air washer and
cooling tower discharges were rerouted from the WWTP in 2012 and are now directly
discharged under NCG500323. Removal of this "clean water" has aided the permittee
in maintaining dissolved oxygen in the WWTP. The permittee conducts semi-annual
maintenance on the blowers, air,filters, header piping, and tablet
chlorination/dechlorination systems.
Bar Screens
Yes
No
NA
NE
'Type of bar screen
a.Manual
■
b.Mechanical
n
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
Is the unit in good condition? _
■
n
n
n
Comment: Screenings are disposed with the WWTP sludge by Miller's Septic Service
at the Taylorsville WWTP.
Aeration Basins
Yes
No
NA
NE
Mode of operation
Ext. Air
Page # 3

Permit: NCO072664 Owner - Facility: Stony Point Plant
ins pec1Ljc j !)ate• 0E,20 2014. _ _ �, ^rt rr; Tyjae: Compllanre EvaluatiWrr . -..
Aeration Basins
Yes No NA NE .
Type of aeration system Diffused
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
Does the foam cover less than 25% of the basin's surface? ■ ❑ ❑ ❑
Is the DO level acceptable? ■ n n n
Is the DO level acceptable?(1.0 to 3.0 mg/1) ■ n n n
Comment: Process control data indicates the DO in the basin ranges from—2.1-3.1
mg/L. There was no foam in the basin during the inspection.
Secondary Clarifier Yes No NA NE
Is the clarifier free of black and odorous wastewater? ■ n n n
Is the site free of excessive buildup of solids in center well of circular clarifier? ❑ ❑ ■ n
Are weirs level? 0110
Is the site free of weir blockage? ■ n n ❑
Is the site free of evidence of short-circuiting? ■ n n n
Is scum removal adequate? ■ ❑ n 171
Is the site free of excessive floating sludge? ■ ❑ n n
Is the drive unit operational? n n ■ ❑
Is the return rate acceptable (low turbulence)? ■ n n n
Is the overflow clear of excessive solids/pin floc? ■ n n 171
Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) ■ n n n
Comment: Settleability results are used to help determine the wasting rate from the
clarifiers.
Disinfection -Tablet
_ __Are_tab[etch lorinators_operational? __
■
n
n
n _
Are the tablets the proper size and type?
■
n
n
n
Number of tubes in use? 2
Is the level of chlorine residual acceptable? ■ n n n
Is the contact chamber free of growth, or sludge buildup? ■ n n n
Page # 4

Permit: NCO072664 Owner - Facility: Stony Point Plant
Inspection Date: 05/20/2014.. , . inspection Type: Compliance Evaluation
Disinfection -Tablet „ Yes No NA NE
Is there chlorine residual prior to de -chlorination?
Comment: Permittee using calcium hypochlorite disinfection tablets.
De -chlorination
Type of system ?
Is the feed ratio proportional to chlorine amount (1 to 1)?
Is storage appropriate for cylinders?
# Is de -chlorination substance stored away from chlorine containers?
Comment:
Are the tablets the proper size and type?
Are tablet de -chlorinators operational?
Number of tubes in use?
Comment: Permittee using sodium sulfite dechlorination tablets.
Aerobic Digester
Is the capacity adequate?
Is the mixing adequate?
Is the site free of excessive foaming in the tank?
# Is the odor acceptable?
# Is tankage available for properly waste sludge?
Comment: The permittee aerates the 2,000-gallon sludge holding tank within the
WWTP. The sludge is taken to the Taylorsville WWTP by Miller's Septic Service. Three
loads of sludge (6,000 gals.) have been transported to date (in 2014). Three loads were
transported in 2013 (6,000 gals.) and a total of 32,000 gals. were transported in 2012
(elevated volumes because of cooling water discharges to WWTP).
Flow Measurement - Effluent
■nnn
Yes No NA NE
Tablet
■nnn
■nnn
2
# Is flow meter used for reporting? ❑ ■ Cl
Is flow meter calibrated annually? ❑ ❑ ■
is-the-flow-meter-operational-.—n-■-_n
(If.units are separated) Does the chart recorder match the flow meter? ❑ fl ■ .fl
Comment: Permittee uses the bucket/stop watch method of determining effluent flow.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional?
Page # 5

Permit: NCO072664 Owner - Facility: Stony Point Plant
Irk r^ Uon Date: 05/20/2014,,. .;, "4'. , � Qns� n.t?;_.n TY,P�: Compliance Evaluation
Effluent Sampling Yes No NA NE
Is sample collected below all treatment units? ■ n n n
Is proper volume collected? ■ n n n
Is the tubing clean? n n ■ n
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ n n n
Is the facility sampling performed as required by the permit (frequency, sampling type_ representative)? ■ n n n
Comment: The permit requires grab samples for all required parameters. All effluent
samples are kept on ice in a cooler until transfer to the contracted analytical laboratory
is completed. Please note that the effluent should directly enter the sampling container
for fecal coliform analyses; an intermediary dipper pole should not be used to fill the
sample container.
Effluent Pipe
Yes No NA NE
Is right of way to the outfall properly maintained?
■ n 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 ■ n
Comment:
Upstream / Downstream Sampling
Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ■ n n n
Comment:
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 n
# Is proper temperature 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: On -site analyses (temperature, pH, dissolved oxygen and total residual
chlorine) are performed under field laboratory certification #5087. Water Tech Labs, Inc.
(Certification #50) performs all remaining permit -required effluent analyses as well as
the MLSS and MLVSS process control analyses. The field instrumentation used on site
appeared to be properly calibrated and documented. The meters are calibrated/verified
twice per year by Water Tech Labs, Inc. (12/13/13 and 2/22/13). The temperature
reported on the DMRs is taken from the pH meter.
Record Keeping
YPc Mn NO NF
C
Page # 6

Permit: NC0072004 Owner - Facility: Stony Point Plant
Inspection Date:. 05/20/2014_1...;.,,,,.,_.., ;. ,,,, , , ,,;,{- Inspection Type: Compliance Evaluation r
Record Keeping T _ ` _ Yes No NA NE
Are records kept and maintained as required by the permit?_._ _ ■ ❑ n ❑
Is all required information readily available, complete and current? ■ 0 ❑_
Are all records maintained for 3 years (lab. reg. required 5 years)?
■
n n n
Are analytical results consistent with data reported on DMRs?
■
n n n
Is the chain -of -custody complete?
■
n Cl fl
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?
■
n n n
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?
❑
Q ■
Is the ORC visitation log available and current?
■
n 00
Is the ORC certified at grade equal to or higher than the facility classification?
■
❑ n
Is the backup operator certified at one grade less or greater than the facility classification?
■
n n n
Is a copy of the current NPDES permit available on site?
■
n El 0
Facility has copy of previous year's Annual Report on file for review?
!
Q ■
Comment: The permittee's records and logbooks were very organized and well
maintained and records requested during the inspection were readily available. DMRs
were reviewed for.April 2013 through March 2014. No limit violations were reported
during the review period and all monitoring frequencies were correct.
Page # 7