NC0035211_Compliance Evaluation Inspection_20170125

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 NCO035211 111 12 I 17/01/25 I17 18 I S J 19 L G ] 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-------------------
671 70 I I 71 I I 72 I r I 73 I I 174 751 I I I I I I I80
u Section B: Facility Data I� I I i
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) 10:30AM 17/01/25 15/06/01
Dudley Shoals Plant
5100 Burns Rd Exit Time/Date Permit Expiration Date
Granite Falls NC 28630 11:30AM 17/01/25 20/03/31
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mark E Hawes,PO Box 1530 Hickory NC 286031530//828-322-2700/8283255387
Yes
Section C:Areas Evaluated During Inspection(Check only those areas evaluated)
Permit Operations&Maintenance 0 Records/Reports Self-Monitoring Program
Facility Site Review Effluent/Receiving Waters
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
Linda S Wiggs ARO WQ//828-296-4500 Ext.4653/
Daniel J Boss ARO WQ//828-296-4658/
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.
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NPDES yr/mo/day Inspection Type (Cont.) 1
31 NCO035211 I11 121 17/01/25 117 18 ICI
Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
Present for inspection were Cecil Cline, Tony Setzer, Keith Johnson and Mike Bradshaw with Shuford
Yarns, Jerry Younce with Water Tech (ORC/Lab)and Dan Boss with DWR.
An inspection of the Non-Contact Cooling Water(NCG500321)was also performed. As noted in that
inspection report Shuford staff indicated that the Air Compressor Cooling Tower water discharges to
the Wastewater Septic/Sand filter system and not directly to the creek. This needs to be verified and
quantified.
Flows are estimated by water usage (City Water). The quantity of water being discharged through the
Cooling Water discharge pipe and the Wastewater discharge pipes is unclear. An estimate needs to
be obtained during sampling events at each discharge pipe.
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Permit: NCO035211 Owner-Facility: Dudley Shoals Plant
Inspection Date: 01/25/2017 Inspection Type: Compliance Evaluation
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:
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? 0 ❑ ❑ ❑
#Are there any special conditions for the permit? ❑ ❑ 0 ❑
Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑
Comment:
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑
Is all required information readily available, complete and current? 0 ❑ ❑ ❑
Are all records maintained for 3 years(lab. reg. required 5 years)? 0 ❑ ❑ ❑
Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑
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? 0 ❑ ❑ ❑
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? ❑ ❑ ❑
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Permit: NCO035211 Owner-Facility: Dudley Shoals Plant
Inspection Date: 01/25/2017 Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Facility has copy of previous year's Annual Report on file for review? ❑ ❑ 0 ❑
Comment:
Septic Tank Yes No NA NE
(If pumps are used) Is an audible and visual alarm operational? ❑ ❑ 0 ❑
Is septic tank pumped on a schedule? 0 ❑ ❑ ❑
Are pumps or syphons operating properly? ❑ ❑ 0 ❑
Are high and low water alarms operating properly? ❑ ❑ MEI
Comment: Bumqarner Septic Hauler pumps the septic tank 2/yr. The last pumping was in September
of 2016.
Sand Filters (Low rate) Yes No NA NE
(If pumps are used) Is an audible and visible alarm Present and operational? ❑ ❑ 0 ❑
Is the distribution box level and watertight? ❑ ❑ ❑
Is sand filter free of ponding? 0 ❑ ❑ ❑
Is the sand filter effluent re-circulated at a valid ratio? ❑ ❑ 0 ❑
#Is the sand filter surface free of algae or excessive vegetation? 0 ❑ ❑ ❑
#Is the sand filter effluent re-circulated at a valid ratio? (Approximately 3 to 1) ❑ ❑ 0 ❑
Comment: The sand filter wall has been improved to avoid run on of stormwater.
The Dosing Bells were replaced in 2013.
The distribution lines are cleaned 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:
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