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Home My WebLink AboutNC0072664_Regional Office Historical File Pre 2018 (179)WaterResources ENVIRONMENTAL QUALITY January 25, 2018 Mr. Mark Hawes Shurtape Technologies, LLC. P.0 Box 1530 Hickory, NC 28603 Subject: Compliance Inspection Stony Point Tape Plant NPDES Permit No. NCO072664 Alexander County Dear Mr. Hawes: 1 R'COOPER LL,O-y Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Interim Director Enclosed is a copy of the Compliance Inspection report for the inspection conducted at the subject facility on January 24, 2018, by Ori Tuvia. Your 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 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 1 2 15 I 3 I NCD072664 I11 121 17/01/24 I17 181,.1 19 i G i 201 I 211111 1=1 I I I I II I I LI I I I I I I I I I I I I I I .I I I I I II I I I 1 1 166 I Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 67 1.0 701a j 71 I„ I 72 ti 731 �74. 751 I I I I l80 I-J l-J I I I 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) 09:00AM 17/01/24 14/06/01 Stony Point Plant Exit Time/Date Permit Expiration Date 8510 NC Hwy 90 E 10:20AM 17/01/24 19/03/31 Stony Point NC 28678 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Douglas Ray HaIUORC/828-267-8919/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Mark E Hawes,PO Box 1530 Hickory NC 286031530/Director of Environment & No Safety/828-267-8428/8778599746 Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self -Monitoring Program �. Sludge Handling Disposal E.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 WQ//704-663-1699/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger MRO WQ//704-235-2194/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. n Page# NPDES yr/mo/day Inspection Type 1 31 NCo0726sa I11 121 17/01/24 117 18 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NCO072664 Inspection Date: 01/24/2017 Permit Owner - Facility: Stony Point Plant Inspection Type: Compliance Evaluation (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? Yes No NA NE ❑ ❑ M ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The subject permit expires on 3/31/2019. Air washer and cooling tower discharges were rerouted from the WWTP in 2012 and are now directly discharged under NCG500323 Record Keepinq 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)? E ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? E ❑ ❑ ❑ 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? M ❑ ❑ ❑ 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 ❑ ❑ 0 ❑ 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? 0 ❑ ❑ ❑ 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? M ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ M ❑ Comment: The permittee's records and logbooks were very organized and well maintained and records requested during the inspection were readily available. DMRs, COCs, Maintenance logs and calibration logs were reviewed for January 2017 through September 2017. Page# 3 Permit: NCO072664 Owner -Facility: Stony Point Plant Inspection Date: 01/24/2017 Inspection Type: Compliance Evaluation Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? M ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? M ❑ ❑ ❑ # Is the facility using a contract lab? ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees M ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ M ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ M ❑ Comment: On -site analvses (temperature. DH, dissolved oxvoen and total residual chlorine) are performed under field laboratory certification #5087. Water Tech Labs, Inc. (Certification #50) performs all remaining permit -required effluent analyses as well as the MLSS and MLVSS process control analyses. The field instrumentation used on site appeared to be properly calibrated and documented. The meters are calibrated/verified twice per year by Water Tech Labs, Inc. N/8/2018). The temperature reported on the DMRs is taken from the pH meter. Effluent Samplinq Yes No NA NE Is composite sampling flow proportional? ❑ ❑ ❑ Is sample collected below all treatment units? M ❑ ❑ ❑ 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 0 ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type M ❑ ❑ ❑ representative)? Comment: The permit requires orab samples for all reauired parameters. All effluent samDles are kept on ice in a cooler until transfer to the contracted analytical laboratory is completed. 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? M ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable - ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Page# 4 Permit: NCO072664 Inspection Date: 01/24/2017 Owner -Facility: Stony Point Plant Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Comment: The permittee conducts process control sampling of PH, dissolved oxygen, MLSS, MLVSS, and settleability in the operation of the VVVVTP. The air washer and cooling tower discharges were rerouted from the WVVTP in 2012 and are now directly discharged under NCG500323 Bar Screens Yes No NA NE Type of bar screen a.Manuat b.Mechanical ❑ Are the bars adequately screening debris? ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? N ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Screenings are disposed with the WWTP sludge by Miller's Septic Service. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? N ❑ ❑ ❑ 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? N ❑ ❑ ❑ Is the DO level acceptable? ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑ Comment: 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? ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? N ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? N ❑ ❑ ❑ Page# 5 Permit: NC0072664 Owner -Facility: Stony Point Plant Inspection Date: 01/24/2017 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is the drive unit operational? ❑ ❑ M ❑ Is the return rate acceptable (low. turbulence)? 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? M ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately '/< of the sidewall depth) E ❑ ❑ ❑ Comment: Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? ❑ ❑ ❑ Are the tablets the proper size and type? 0 ❑ ❑ ❑ Number of tubes in use? 2 Is the level of chlorine residual acceptable? 0 ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? 0 ❑ ❑ ❑ Comment: De -chlorination Yes No NA NE Type of system ? Tablet Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ .❑ ❑ Is storage appropriate for cylinders? ❑ ❑ ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ ❑ ❑ Comment: Are the tablets the proper size and type? M ❑ ❑ ❑ Are tablet de -chlorinators operational? M ❑ ❑ ❑ Number of tubes in use? 2 Comment: Aerobic Digester Yes No NA NE Is the capacity adequate? 0 ❑ ❑ ❑ Is the mixing adequate? 0 ❑ ❑ ❑ Is the site free of excessive foaming in the tank? M ❑ ❑ ❑ # Is the odor acceptable? M ❑ ❑ ❑ # Is tankage available for properly waste sludge? M ❑ ❑ ❑ Page# 6 Permit: NCO072664 Inspection Date: 01/24/2017 Aerobic Digester Owner - Facility: Stony Point Plant Inspection Type: Compliance Evaluation Yes No NA NE Comment: The permittee aerates the 2 000-gallon sludge holding tank within the WWTP. The sludge is taken to the Taylorsville WWTP by Miller's Septic Service Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? No ❑ ❑ 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: 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: Permittee uses the bucket/stop watch method of determining effluent flow. Page# 7