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Home My WebLink AboutNC0072664_Regional Office Historical File Pre 2018 (156)"-,j Y-r, Michael F. Easley, Go more 1/ William G. Ross Jr., Secretary North Carolina Department of Environment and Natural Resources Alan W. Klimek, P. E. Director Division of Water Quality November 7, 2005 Mr. Mark Hawes, Director of Environment and Safety Shurtape Technologies, LLC PO Box 1530 Hickory, NC 28603 Subject: Compliance Evaluation Inspection Stony Point WWTP NPDES Permit No. NCO072664 Alexander County, NC Dear Mr. Hawes: Enclosed is a copy of the Compliance Evaluation Inspection report for the inspection conducted at the subject facility on November 3, 2004 by Ms. Donna Hood of this office. Please inform the facility's Operator -in -Responsible Charge 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 Ms. Hood or me at (704) 663-1699. Sincerely, D. Rex Gleason, P.E. Surface Water Protection Regional Supervisor Enclosure cc: Alexander County Health Department N. C. Division of Water Quality, Mooresville Regional Office, 610 East Center Avenue, Suite 301, Mooresville, NC 28115 (704) 663-1699 N DE F 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 !NI! 2 US3I NCO072664 I11 .12I 05/11/03 117 18ICI 19ISI 20 U - Remarks 211111IIIIIIII IIII IIII IIII IIII IIII IIII IIIIIIII III6 Inspection Work Days Facility Self -Monitoring Evaluation Rating 61 QA ------ --------------------- Reserved- --------------------- 67 I 1.5 169 70l a l 711 I 721 N I 73 ILLJ I 174 751 I I I I I I 180 tom— 1_ 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) Stony Point Tape Plant 10:05 AM 05/11/03 05/05/01 Exit Time/Date Permit Expiration Date 8510 NC Hwy 90 Stony Point NC 28678 01:15 PM 05/11/03 09/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Travis E Brannon/ORC/828-322-2706/ Name, Address of Responsible Official/Title/Phone and Fax Number Travis Brannon,PO Box 1530 Hickory NC 286031530//828-322-2700/ Contacted 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 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 Donna knod MRO WQ/// J(--V - Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date Richard M Bridgeman 704-663-1699 Ext.264/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Permit: NCO072664 Owner - Facility: Stony Point Tape Plant Inspection Date: 11/03/2005 Inspection Type: Compliance Evaluation Permit (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? 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: Stony Point's permit is effective from 8/1/2004-3/31/2009. A TRC limit has been added this permit cycle and becomes effective on 2/1/2006. The facility.is in the process of installing tablet dechlorination to meet this limit (A to C No. 072664A01). Yes No NA NE nn■n ■❑❑❑ ❑■nn ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■ ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ (� rl ❑ Judge, and other that are applicable? Comment: The plant appeared very well maintained and operated at the time of the inspection. New blowers are going to be installed at the same time as the dechlorination facilities. Bar Screens Yes No NA NE Type of bar screen a.Manual ■ b.Mechanical ' rl Are the bars adequately screening debris? ■ n n ❑ Is the screen free of excessive debris? ■ 0 ❑ ❑ Is disposal of screening in compliance? ■ o o n Is the unit in good condition? ■ ❑ 0 n Comment: 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? ❑ ❑ ■ ❑ Are weirs level? ■ ❑ 0 Cl Is the site free of weir blockage? ■ ❑-❑ Cl Is the site free of evidence of short-circuiting? ■ ❑ ❑ ❑ Is scum removal adequate? ■ ❑ ❑ n Is the site free of excessive floating sludge? ❑ n ❑ Is the drive unit operational? ❑ ❑ ■ ❑ Is the return rate acceptable (low turbulence)? ■ ❑ n ❑ Is the overflow clear of excessive solids/pin floc? ■ ❑ n Cl Is the sludge blanket level acceptable? (Approximately Y. of the sidewall depth) n n n ■ Comment: Secondary clarifier effluent was very clear at the time of the inspection. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? ■ ❑ ❑ ❑ Are surface aerators and mixers operational? ❑ ❑ ■ ❑ Are the diffusers operational? ■ ❑ n ❑ Is the foam the proper color for the treatment process? `n I_l ■ 0 Permit: NC0072664 Inspection Date: 11/03/2005 Owner - Facility: Stony Point Tape Plant Inspection Type: Compliance Evaluation A-r,+;- , ❑-;- Yes No NA NE Does the foam cover less than 25% of the basin's surface? ■ ❑ ❑ ❑ Is the DO level acceptable? ❑ ❑ ❑ ■ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑ ■ Comment: The aeration basin appeared well mixed and oxygenated at the time of the inspection. No foam was present at the time of the inspection. Process control includes MLSS, MLVSS, pH, and DO. Stony Point, usually keeps their MLSS concentration around 2800-3000 mg/L. Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? ■ ❑ ❑ ❑ Are the tablets the proper size and. type? ■ ❑ ❑ ❑ Number of tubes in use? 1 Is the level of chlorine residual acceptable? ❑ ❑ ❑ ■ Is the contact chamber free of growth, or sludge buildup? ■ ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? ❑ Cl ■ ❑ Comment: During the inspection it was noted that the facility was using chlorine tablets (CCH calcium hypochlorite) that did not have labeling on the bucket expressing its intended use for effluent disinfection. A document was found on the chemical suppler's (Arch Chemicals) web site that showed these tablets were intended for wastewater disinfection, not just pool as the bucket labeling displayed. Please use only disinfection tablets with proper labeling for wastewater usage. Approved tablets were on site and being installed in the tablet chlorinator after the inspection. 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? ■ ❑ ❑ n Is the facility using a contract lab? ■ ❑ ❑ ❑ Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? ■ ❑ ❑ ❑ Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ ■ ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ ■ ❑ Comment: Stony Point holds field lab certification #5087. Water Tech Labs (#50) is used for sample analyses. Flow Measurement - Effluent Yes No NA NE Is flow meter used for reporting? ❑ ❑ ■ ❑ Is flow meter calibrated annually? ❑ ❑ ■ ❑ Is the flow meter operational? ❑ ❑ ■ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑• ❑ ■ Cl Comment: Effluent flow is measured by the bucket and stop watch method. 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? ■ ❑ ❑ ❑ 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 ■ Permit: NC0072664 Inspection Date: 11/03/2005 Record Keeping Are DMRs complete: do they include all permit parameters? Owner - Facility: Stony Point Tape Plant Inspection Type: Compliance Evaluation 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? Facility has copy of previous year's Annual Report on file for review? Comment: It was noted during.the inspection on the Chain of Custody that the time relinquished from the Stony Point operator did not match the time received by Water Tech Labs. Mr. Ray Pope, back up ORC, explained that he recorded the time he left the Stony'Point Plant to deliver the samples and not the time he relinghished the samples to the lab. Please be aware that the time relinquished is the time the samples leave that person's possesion and not a physical location. The time relinquished by Mr. Pope and time received by the lab should be very close, if not the same time. DMRs of September 2004-August 2005 were reviewed for the inspection. It was noted that zeros were being recorded on the DMR for maximum/minimum values during months when all less than values were reported. Please record actual data values for maximum/minimum and not zeros. Monthly averages were being calculated correctly. Effluent Sampling Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? Is proper temperature set for, sample storage (kept at 1.0 to 4.4 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: Effluent sampling is being performed as required by the permit. Effluent Pipe Is right of way to the outfall properly maintained? Are the receiving water free of foam other than trace amounts and other debris? If effluent (diffuser pipes are required) are they operating properly? Comment: Third Creek of the Yadkin-PeeDee Basin looked very clear with no visible impacts. \/— KL. 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