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Home My WebLink AboutNC0004685_Compliance Evaluation Inspection_20170525yD. WaterRssvurces t' NVIRONMtENT'.AL flUAUTY May 25, 2017 Mr. Todd Douthit, Manufacturing Manager PPG Industries Fiber Glass Products, Inc. 940 Washburn Switch Road Shelby, NC 28150 ROY COOPER Governor MICHAEL S. REGAN Secretary S. JAY ZIMMERMAN Director Subject: Compliance Evaluation Inspection PPG Industries/Shelby Facility NPDES Permit No. NC0004685 Cleveland County Dear Mr. Douthit: Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on May 23, 2017, by Ori Tuvia. Richard Young's, Guy O'Connor's, John Littlejohn's and Linda Bridge's cooperation during the site visit was much appreciated. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed report. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Ori Tuvia at (704) 235-2190, or at ori.tuvia@ncdenr.gov. Cc: NPDES Unit MRO Files Sincerely, Ori Tuvia, Environmental Engineer Mooresville Regional Office Division of Water Resources, DEQ 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 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 [L] i 2 15 I 3 1 N00004685 Ill 12 17/05/23 17 18 IC I 19 I c I 20 Ll 211 I I I I I 111111111 11 III 11 I I I I I I I I I I I I I 11 1 1 I. I I 166 I Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA — Reserved 67 1.0 70 71 itIti I 72 I N 7311 I 174 75Ill 80 LJ LJ I I Section B: FacilityData 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) 01:20PM 17/05/23 14/05/01 PPG - Shelby facility 940 Washburn Switch Rd Exit Time/Date Permit Expiration Date Shelby NC 28150 03:45PM 17/05/23 18/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data /// Guy Peter O'Connor/ORC/704434-2261/ Name, Address of Responsible OfficiaUTitle/Phone and Fax Number Contacted Richard M Young,940 Washburn Switch Rd Shelby NC 28150//704-434-2261!7044340792 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 Ori A Tuvia MRO WQW04-663-16991 Signature of Management Reviewer Agency/Office/Phone and Fax Numbers Date Andrew Pitner- MRO WQ//704-663-1699 Ext.21 5•�S i7 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type 31 Nc0004885 �11 12 17/05/23 17 18 ICI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NC0004685 Inspection Date: 05/23/2017 Owner - Facility: PPG -Shelby facility 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? M ❑ ❑ ❑ # Are there any special conditions for the permit? ■ ❑ ❑ ❑ 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 subject permit will expire at 8/31/2018. Record Kee in Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required information readily available, complete and current? ■ ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? ■ ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? ❑ ❑ ❑ ❑ Is the chain -of -custody complete? ❑ ❑ ❑ ❑ Dates, times and location of sampling COCs,_ORC visitation logs. Calibration logs and process control logs were reviewed for the period July 2016 through April 2017. 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? ❑ ❑ M ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 2417 with a certified operator ❑ ❑ M ❑ on each shift? Is the ORC visitation log available and current? 0 ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? M ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? 0 ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? r ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? 0 ❑ ❑ ❑ Comment: The records reviewed during the inspection were organized and well maintained. DMRs. COCs,_ORC visitation logs. Calibration logs and process control logs were reviewed for the period July 2016 through April 2017. Laboratory Yes No NA NE Page# 3 Permit: NC0004685 Owner -Facility: PPG -Shelby facility Inspection Date: 05/23/2017 Inspection Type: Compliance Evaluation Yes No NA NE Is composite sampling flow proportional? 0 ❑ Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? ■ ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? M ❑ ❑ ❑ # Is the facility using a contract lab? S ❑ ❑ ❑ # 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? ❑ ❑ ■ ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ 0 ❑ Comment: On-site field analyses (conductivity, dissolved oxygen PH, temperature) are performed under the PPG's laboratory certification #5489. Pace Analytical Services Inc. BOD TSS flouride, ammonia, nutrients. oil & grease, metals) and R&A Laboratories, Inc. (toxicity) have also been contracted to provide analytical supl2ort. The laborato instrumentation used for field analyses appeared to be properly calibrated and well documented. Effluent Sampling - Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? N ❑ ❑ ❑ Is proper volume collected? M ❑ ❑ ❑ Is the tubing clean? M ❑ ❑ ❑ # 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 effluent composite and grab samples. Upstream / Downstream Samplinq 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? M ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable M ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The facility appeared to be properly operated and well maintained. The operations staff incorporate a comprehensive process control pro -gram with all measurements beim - properly erl documented and maintained on-site. The facility is @guipped with a computer/alarm notification system to assist the wastewater staff in the operation of the treatment units/ processes. Page# 4 Permit: NC0004685 Owner -Facility: PPG -Shelby facility Inspection Date: 05/23/2017. Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE 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? ■ ❑ ❑ ❑ Is the unit in good condition? ■ ❑ ❑ ❑ Comment: Equalization Basins Yes No NA NE Is the basin aerated? ❑ ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? ■ ❑ ❑ ❑ Is the basin free of excessive grease? N ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? ■ ❑ ❑ ❑ Are audible and visual alarms operable? M ❑ ❑ ❑ # Is basin size/volume adequate? M ❑. ❑ ❑ Comment: Primary 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? ■ ❑ ❑ ❑ Are weirs level? N ❑ ❑ ❑ Is the site free of weir blockage? ■ ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? M ❑ ❑ ❑ Is the site free of excessive floating sludge? ❑ ❑ ❑ Is the drive unit operational? ❑ ❑ ❑ Is the sludge blanket level acceptable? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) M . ❑. ❑ ❑ Page# 5 Permit: NC0004685 Inspection Date: 05/23/2017 Primary Clarifier Comment: Both primaries were operational and in service. Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps.available? Is the site free of excessive leaking? Owner -Facility: PPG -Shelby facility Inspection Type: Compliance Evaluation Yes No NA NE Yes No NA NE ❑ ❑ ❑ ■ ❑ ❑ ❑ N ❑ ❑ ❑ Comment: Chemical additions to selected treatment processes include the following: polymers, bentonite/clay mixture, ferric chloride, aluminum chloride, lime, and defoamer. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the clarifier free of black and odorous wastewater? N Is the basin free of dead spots? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? E ❑ ❑ ❑ Are the diffusers operational? 0 ❑ ❑ ❑ Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? 0 ❑ ❑ ❑ Is the DO level acceptable? ■ ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ 0 N ❑ Comment: The facility uses two aeration basins operated in series. The first aeration tank is equipped ❑ ❑ Is the return rate acceptable (low turbulence)? with diffused and mechanical aeration and the second aeration tank is equipped with ❑ ❑ Is the overflow clear of excessive solids/pin floc? diffused aeration. ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? N ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? ■ ❑ ❑ ❑ Is the site free of excessive floating sludge? E ❑ ❑ ❑ Is the drive unit operational? E ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Page# 6 Permit: NC0004685 Owner - Facility: PPG -Shelby facility. Inspection Date: 05/23/2017 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) M ❑ ❑ ❑ Comment: Two out of the three secondary clarifiers were operational and in service at the time of the inspection. The third clarifier was not used due to low flow Yes No NA NE Type of operation: Pumps -RAS -WAS Yes No NA NE Are pumps in place? ■ ❑ ❑ ❑ Are pumps operational? ■ ❑ ❑ ❑ Are, there adequate spare parts, and supplies on site? M ❑ ❑ ❑ Comment: Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Flow Measurement- Effluent Yes No NA NE Is the filter media present? M ❑ ❑ ❑ Is the filter surface free of clogging? M ❑ ❑ ❑ Is the filter free of growth? M ❑ ❑ ❑ Is the air scour operational? ❑ ❑ 0 ❑ Is the scouring acceptable? ❑ ❑ ❑ 0 Is the clear well free of excessive solids and filter media? ❑ ❑ M ❑ Comment: The facilitv is eouipoed with a traveling bridoe teritary filter. The filter backwash is returned to the head of the wastewaterIp ant• Flow Measurement- Effluent Yes No NA NE # Is flow meter used for reporting? M ❑ ❑ ❑ Is flow meter calibrated annually? M ❑ ❑ ❑ Is the flow meter operational? ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ■ ❑ ❑ ❑ Comment: The flow meter is calibrated/verified reraularv. Last calibrated on 2/17/2017 by Clear Water Inc. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? r ❑ . ❑ ❑ 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 ❑ Page# 7 Permit: NC0004685 Owner - Facility: PPG -Shelby facility Inspection Date: 05/23/2017 Inspection Type: Compliance Evaluation Effluent Pipe Yes No NA NE Comment: At the time of the inspection the effluent (Outfall 001) appeared clear with no discoloring. floatable solids or foam. The receiving stream did not appear to be negatively impacted. Solids Handlina Equipment Yes No NA NE Is the equipment operational? ■ ❑ ❑ ❑ Is the chemical feed equipment operational? ■ ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Is the site free of excessive moisture in belt filter press sludge cake? N ❑ ❑ ❑ The facility has an approved sludge management plan? ❑ ❑ ■ ❑ Comment: Thickened sludge is dewatered on a belt press Dewatered solids aretransported to the County Landfill for final disposal by_waste_p_ros. Page# 8