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Home My WebLink AboutNC0004987_Compliance Evaluation Inspection_20191127 (2)ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Director Mr. Rick Roper, Station Manager Duke Energy Carolinas, LLC 8320 E NC 150 Hwy. Terrell, North Carolina 28682 Dear Mr. Roper: NORTH CAROLINA Environmental Quality November 27, 2019 Subject: Compliance Evaluation Inspection Duke Energy Carolinas/Marshall Steam Station NPDES Permit No. NC0004987 Catawba County Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on November 21, 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 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@ncdenr.gov. Sincerely, Docu Signed by: t�z.cititgU H P,.z�.�. F161FB69A2D84A3... for W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Enclosure: Compliance Inspection Report 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 IF I 3 I NC0004987 111 12 I 19/11/21 I17 18 I S i 19 i G i 201 I 211111 I I I I I I II I I I I I I I I I I I I I 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 B1 QA ---------------------- Reserved ------------------- 67 2.0 70 Id I 71 [.. I 72 73 L_LJ74 751 I I I I I I I80 I —I 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) 09:30AM 19/11/21 18/05/01 Marshall Steam Station NC Hwy 150 Exit Time/Date Permit Expiration Date Terrell NC 28682 02:OOPM 19/11/21 21/09/30 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Joseph Scott La Sala/EHS Professional Sr/828-478-7820 /8284787776 Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Rick Roper,8320 E NC 150 Hwy Terrell NC 28682/Station Manager/828-478-7600/ 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 19E�Docu` Wes Bell signedd by: DWR/MRO WQ/704-663-1699 Ext.2192/ 11/27/2019 2 re 1696D90CC343T Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers�uw H P:zH�. Docusigned by: Date E4F1611`1369AMUAI.. Andrew Pitner DWR/MRO WQ/704-663-1699 Ext.2180/ 11.27.19 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0004987 I11 121 19/11/21 117 18 JCJ Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NC0004987 Owner - Facility: Marshall Steam Station Inspection Date: 11/21/2019 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 ❑ ❑ 0 ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? E ❑ ❑ ❑ 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 Division issued a minor Dermit modification on 11/12/19 to remove Internal Outfall 004 No chlorine is added to any of the discharges. The construction activities associated with the lined retention basin (Outfall 005), yard sump (Internal Outfall 001/001A), FGD wet scrubber wastewater treatment facility (internal Outfall 006) and holding basins (Internal Outfall 010) have been completed. The ash basin was taken out of service in March 2019 and decanting was initiated in July 2019. The construction of the decant water treatment system was completed in September 2019. The last compliance evaluation inspection by DWR staff was performed on 9/27/18. Record Keeping Are records kept and maintained as required by the permit? 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 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? W-TozFs►1c111111111111111►1:� ■ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ Page# 3 Permit: NC0004987 Inspection Date: 11/21/2019 Record Keeping Facility has copy of previous year's Annual Report on file for review? Owner - Facility: Marshall Steam Station Inspection Type: Compliance Evaluation Yes No NA NE ❑ ❑ ■ ❑ Comment: The records reviewed during the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed for the period October 2018 through September 2019. No effluent limit violations were reported and all monitoring frequencies were correct. 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: The facility is certified to perform on -site field analyses (pH and temperature) under field laboratory certification #5155. Duke Energy's Analytical Laboratory (Certification #248) and the contracted services of Pace Analytical Services and ETS, Inc. also provide laboratory support for all permit -required analyses. Influent Sampling Yes No NA NE # Is composite sampling flow proportional? ❑ ❑ 0 ❑ Is sample collected above side streams? ❑ ❑ 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 ❑ ❑ 0 ❑ Celsius)? Is sampling performed according to the permit? 0 ❑ ❑ ❑ Comment: The subject permit requires grab samples at Internal Outfalls 003, 006 and 010. 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 ❑ ❑ 0 ❑ Celsius)? Page# 4 Permit: NC0004987 Owner - Facility: Marshall Steam Station Inspection Date: 11/21/2019 Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: The subject permit requires effluent grab samples. 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 NPDES wastewater treatment facilities aDDeared to be DroDerly oDerated and well maintained. The FGD wet scrubber wastewater treatment system (WTS) is staffed twenty-four hours per day/seven days per week. A computer monitoring system has been connected to the treatment components for Outfalls 002, 005 and 006 (Internal) and yard sumps (high water level) to assist the on -site staff in the operation of the treatment equipment/processes including alarm conditions, flow, PH, TSS, etc. 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: Both eaualization basins (FGD wet scrubber WTS) are eauiDDed with mixers (all oDerational and in service). Chemical Feed Yes No NA NE Is containment adequate? N ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Page# 5 Permit: NC0004987 Owner - Facility: Marshall Steam Station Inspection Date: 11/21/2019 Inspection Type: Compliance Evaluation Chemical Feed Yes No NA NE Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? E ❑ ❑ ❑ Comment: Outfalls 002, 005, 006, and 010 are equipped chemical feed equipment/facilities. Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? ❑ ❑ 0 ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: Both clarifiers (FGD wet scrubber WTS) were operational. Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Is the filter media present? ❑ ❑ ❑ Is the filter surface free of clogging? ❑ ❑ ❑ Is the filter free of growth? ❑ ❑ ❑ Is the air scour operational? ❑ ❑ ❑ Is the scouring acceptable? ❑ ❑ ❑ Is the clear well free of excessive solids and filter media? ❑ ❑ ❑ Comment: The FGD wet scrubber WTS is equipped with both sand filtration and ultrafiltration systems (all operational). Solids Handling Equipment Yes No NA NE Is the equipment operational? 0 ❑ ❑ ❑ Is the chemical feed equipment operational? 0 ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Is the site free of high level of solids in filtrate from filter presses or vacuum filters? ❑ ❑ ❑ Page# 6 Permit: NC0004987 Inspection Date: 11/21/2019 Solids Handling Equipment Owner - Facility: Marshall Steam Station Inspection Type: Compliance Evaluation Yes No NA NE 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? 0 ❑ ❑ ❑ Comment: The FGD wet scrubber WTS is equipped with multiple filter presses (all operational). Dewatered sludge, off -spec gypsum, bottom ash and fly ash are disposed into the permitted on -site landfill. The gypsum material from the FGD wet scrubber system is reused by an outside company (National Gypsum) in the dry wall market. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ 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: Outfall 001 flows are measured by DumD curves/loas. Outfalls 002. 005. 006. and 010 are equipped with magnetic flow meters. The flows for Outfall 003 are based on pipe diameter/water level measurements and the supporting flow calculations. The magnetic flow meters will be calibrated/verified annually. 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 discharges from Outfalls 001, 002 and 005 appeared clear with no floatable solids or foam. The receiving stream did not appear to be negatively impacted. Page# 7