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HomeMy WebLinkAboutNC0072664_Regional Office Historical File Pre 2018 (167)4 murape 26 January 2010— Certified Mail Return Receipt Requested FEB - 4 2010 2 :0 Annual System Performance Report North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, North Carolina 276994617 Subject: Annual System Performance Report — CY2009- . NPDES Permit No fN 007�66y4-- Shurtape Technologies — Stony Point Plant Alexander County Q D FEB 2 2010 DENR-WATER QUALM POINT SOURCE BRANCH Attached please find the annual performance report for the subject facility owned by Shurtape Technologies. Please be advised that this report has been prepared in accordance with the format suggested in Kerr T. Stevens' 19 October 1999 letter. I. General Information a. Name of Regulated Entity: Shurtape Technologies b. Contact: Mark E. Hawes, P.E. PO Box 1530 Hickory, NC 28603-1530 Phone: 828-322-2700, extension 4428 e-mail: mhawes@shurtape.com C. Permit: NCO072664 d. Description of treatment process: Shurtape Technologies operates a 10,000 gpd extended aeration type WWTP to treat domestic wastewater generated by Shurtape's Stony Point Tape Plant. The extended aeration plant consists of an inlet. bar screen, aeration basin, hopper -type clarifier with a v-notch type weir, tablet -type chlorination, tablet de -chlorination, and an aerated sludge holding tank. Discharge of the treated wastewater is into Third Creek in the Yadkin -Pee Dee River Basin. To optimize the operation of the WWTP, Shurtape conducts process testing of MLSS, MLVSS,and settleability in.the aeration basin. H. Performance a. Description of overall 12-month performance: The previous twelve months performance was reviewed with the ORC, Mr.. Travis Brannon, Certificate No. 990808. Review of the system performance consisted of reviewing the operator's logbook, process control equipment calibration logbooks, sludge removal records, and DMR's from January 2009 through December 2009. During this time period, no effluent violations occurred. During this time period, all process Shurtape Technologies, LLC 8510 NC Hwy 90 E Stony Point, NC 28678 www.shurtape.com Nwual System Performance Report 26 January 2010 Page 2-of 4 control monitoring equipment was found to have met calibration checks unless further described herein. Buffer solutions used for pH meter calibrations were valid; and all sampling results have attached chain of custody forms. The operator logbooks verified that the system had been attended as required with maintenance activities performed., During 2009, there were no events noted in the logbook that would cause the facility to operate in a non -compliant manner. The facility operated in compliance. b. During the time period of January 2009 through December 2009 no effluent violations occurred. Upon review of the November 2009 DMR, it was found that one pH reading was errantly reported as 9.09, which is above the allowable 6 — 9 pH range. However, the log book indicated that the correct reading was 7.09. An amended DMR was subsequently submitted. Likewise, on September 14, 2009, low-level chlorine was not reported on the DMR. Also on this same DMR, the number of hours that the ORC was on -site were not reported. A corrected DMR has been submitted. Additionally, the following were identified during the annual review: On February 16, 2009, the vendor invoice indicates that 2,000 gallons of sludge were pumped and disposed. The ORC appears to have errantly written this sludge pumping event down as happening on February 17, 2009. • During the period of April 13 - 15, 2009, discrepancies were noted between the log book, daily check sheets, and the DMR for low-level chlorine. o The April 1 P DMR reported a low-level chlorine of 21 ug/L, which agreed with the log book, but disagreed with the daily check sheet. The daily check sheet indicated 31 ug/L. o The April 14`h DMR reported <20 ug/L as the low-level chlorine, which agreed with the daily check sheet, but disagreed with the log book. The log book indicated 31 ug/L on this day. o On April 15f, the DMR did not report a low-level chlorine. Likewise, there was no calibration of the low-level meter on this day, and the daily check' sheet does not indicate a low-level chlorine sample for this date. However, the log book indicates <20 ug/L for low-level chlorine. These discrepancies were reported to NCDENR, and NCDENR and Shurtape, both agreed that an amended DMR was not necessary. Regardless of the discrepancies, all results were below the 50 ug/L compliance limit. • On May 6, 2009, Dissolved Oxygen (DO) concentrations were reported on the DMR; however, verification of the calibration of the DO meter was not- documented. Calibration records indicate that the DO meter calibration was verified on May 7, 2009. The DO meter was calibrated on April 28, 2009 by Water Tech Labs, and the May 7, 2009 calibration verification indicated that the meter was working properly. An amended DMR was not submitted. iinual System Performance Report 26 January 2010 Paae 3 of 4 On August 12, 2009, calibration of the low-level chlorine meter was not documented. All previous and post calibrations of the low-level meter indicate that the meter was performing properly. An amended DMR was not submitted. C. Description of any known environmental impacts of violations: N/A — No known violations of effluent limitations. d. Description of corrective actions taken to address violations or deficiencies: No known violations existed for the reporting period. Section (b) above describes several events where no action was necessary, and two events where DMRs were amended: • The September DMR was amended to address not reporting the ORC hours on one day and a low-level chlorine that was not reported. The November DMR was amended to address the pH, which was errantly reported as 9.09 on November 24`h, when the correct pH was 7.09. Shurtape has met the requirements to conduct analysis of field parameters on site through Lab Certification Procedures. Lab Certification No. 5087; EPA Lab ID No. NC01311 Proficiency testing was completed during August and September 2009. The initial submittal for. low-level chlorine was not within the allowable range. A second submittal later in September resulted in acceptable results. The approval report issued 30 September 2009. g. Notification: Shurtape's WWTP serves the manufacturing facility at Stony Point. There are no other users connected to the system. Therefore, Shurtape is the only user of the system. A copy of this report is sent to the Vice President of Manufacturing and the Executive Vice President. III. Certification I certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true; accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fines and imprisonment for knowing violations. David Neff Date Plant Manager nual System Performance Report 26 January 2010 Page 4 of 4 Upon review of this report, should any questions arise, please contact Mark Hawes at (828) 325-5428 or via e-mail at mhawes@shurtape.com. Respectfully Submitted, Jerry Eplin, P.E. Environmental & Process Engineer cc: Wayne Helton. Stephen Shuford David Neff Mark Hawes Matt Moore Doug Hall Travis Brannon 1 Check List for Annual WWTP Certification for DWQ.xis 2664 Shurtape Technologies, LLC Stony Point - Plant # 31 Date: 26-Jan-10 Reviewed by: Certified by: ORC: DMR Review: January OK February OK March OK April See below May See below June OK name - • - I. , signature Environmental Plant Manager Travis Brannon Sample Results Reviewed for each Week and the Attached Chain of Custody Forms July OK January OK July OK August See below February OK August OK September See below March OK September OK October OK April OK October OK November see below I May OK November OK December OK June OK December OK Sludge Records Reviewed: 21 Jan 2009 - 2000 gal; 16 Feb 2009 - 2000 gal; 09 April 2009 - 2000 gal; 29 April 2009 - 4000 gal; 25 Jun 2009 - 2000 gal; 15 Sep 2009 - 2000 gal; 20 Nov 2009 - 2000 gal; 10 Dec 2009 - 2000 gal - . i pH Buffers Checked: 4 Exp Date: Oct-13 pH / Temp. Meter External Meter 220875:1 01/05/2009; 08/10/09; Calibration Dates: Meter 226683: 01/05/2009; DO / Temp. Meter External Meter 08A100904: 01/05/09; 05/23/09; 7 Exp Date: Sep-11 Calibration Date: 08/10/09 Meter 0913100202: 04/28/09 Spectrophotometer External Low Level:'01/05/2009; 08/10/09" Calibration Date: 12/28/09 10 Exp Date: Apr-10 High Level: 01/05/2009; 12/28/09 NIST Traceable 02/21/09; 08/10/09 pH, Residual CIz, y _ a ML55, MLV55 Parameters samples for Dissolved Oxygen o o E pH, & DO On -Site: Temperature o a. 30 Minute Settleability Frequency of Calibration Corning 313 5/N 226683 - pH d Temperature Corning 313 S/N 220875 - pH & Temperature rn 0 Meters YSI 550A 5/N 08A100904 - DO 4 Temperature c Minimum of annual external calibrations, Used On YSI 550A S/N 09D1o0202 - DO di Temperature 5 Yes - all meters calibrated. see above for dates. Site: HACH 2400 5/N 05000007985 Spectrophotometer cd m 2 HACH Pocket Colorimeter II 5/N 040200010597 U ERTCO NIST Traceable Thermometer 5/N 3037 Summary of ORC Log Book Review: -ogbook is up to date with appropriate notations of actions by ORC and back-up ORC. Logbook appears to contain all operational information required to iemonstrate compliance. Dates and times appear to be noted correctly. Information in logbook corresponds to that recorded on the DMRs submitted :hroughout CY2009, with the exception of the following: - On February 16, 2009, vendor records/invoice indicates 2,000 gallons of sludge were pumped and disposed; however, the log book indicates that this )ccurred on February 17th, 2009. It is suspected that the ORC wrote the entry down on the wrong line of the log book. - On April 13 - 15, 2009, low level chlorine readings recorded in the log book, on daily check lists, and on the DMR did not all agree. None of the readings mere above the 50 ug/L compliance level. - On May 6, 2009, DO calibration was not documented. - On August 12, 2009, calibration of the low level chlorine meter was not documented. - On September 14, 2009, low level chlorine was not reported on the DMR. A corrected DMR has since been submitted. - On September 15, 2009, the submitted DMR did not document the numbers of hours that the ORC was on -site. A corrected DMR has since been - On November 24, 2009, the DMR incorrectly reported a pH as 9.09, when the correct reading was 7.09. A corrected DMR has since been submitted. NOTE that for low level chlorine readings and the DO readings reported above, all prior and post QC checks were satisfactory, and the equipment was within calibration dates, so the readings should be accurate. 1 Check List for Annual WWTP Certification for DWQ.xls Shurtape Technologies, LLC 72664 Stony Point - Plant # 31 Summary of Review: Annual Performance Test for Field Parameters: pH: Method 4500 H+B & TRC: Method 4500 CIG Corning pH & YSI DO meters both have correction factors noted'on meters (current factor is 110"). Modified DMRs were submitted to address the issues described above for September and November. On April 13-15, 2009, discrepancies existed between the low level chlorine records as recorded in the log book, in daily check sheets - and on the DMR. The April 13th DMR reported low level chlorine of 21 ug/L, which agreed with the log book. However, both of these disagreed with the daily check sheet, where 31 ug/L was recorded. On April 14th, the DMR reported <20 ug/L as the low level chlorine concentration, which agreed with the daily check sheet. However, the log book indicated 31 ug/L on this day. Lastly, the log book indicated <20 ug/L low level chlorine concentration on April:15th, however, the DMR, daily check sheet, and calibration records indicate that no reading was obtained on April 15th. Since none of the possible readings were greater than the 50 ug/L compliance level, Shurtape and DENR both agreed that a modified DMR was not required. On February 16th; vendor records/invoice indicates that 2000 gallons of sludge were pumped and disposed. However, the log book records this as happening on the 17th; instead of the 16th. It is suspected that the ORC wrote the event down on the wrong line. Initial review was performed on January 8 and 9, 2010. Final review was completed on January 26, 2010 after submittal of the amended Wks. Field Parameters Lab Certification No.: 5087 EPA Lab Code: NCO1311 Annual Performance Audit Completed: 8, 9, and 26 Jan 2010