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Home My WebLink AboutNC0004979_Compliance Evaluation Inspection_20210216ROY COOPER Ccwerrrar MICHAEL 5. REGAN $. DAF4IEL SMITH D r cror Rick Roper, General Manager III Duke Energy Carolinas, LLC Allen Steam Station 253 Plant Allen Road Belmont, NC 28012 Dear Mr. Roper: NORTH CAROLINA En fr nmerttoi Qualify February 16, 2021 Subj ect: Compliance Evaluation Inspection Duke Energy Allen Steam Station NPDES Permit No. NC0004979 Gaston County Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on February 8, 2021, by Ori Tuvia. Michael Gantt's cooperation during the site visit was much appreciated. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed repot. 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. Sincerely, —DocuSigned by: —A14CC681AF27425... W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources Attachment: CEI report Cc: MRO Files (Laserfiche) , Michael Gantt (E-copy) State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations Mooresville Regional Office 1610 East Center Avenue, Suite 301 I Mooresville, North Carolina 28115 704 663 1699 United States Environmental Protection Agency E PA Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection 1 u 2 1s 1 3 I NC0004979 111 121 21/02/08 117 Type 18 [ i I I I I I Inspector Fac Type 19 i G I 201 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 II I I I I I 166 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 6711.0 I 7° I4 I 71 IN I 72 I N I 73I I 174 L� 1 751 180 1 11111 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Plant Allen Steam Station 253 Plant Allen Rd Belmont NC 28012 Entry Time/Date 09:OOAM 21/02/08 Permit Effective Date 20/03/01 Exit Time/Date 10:35AM 21/02/08 Permit Expiration Date 23/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Michael R Gantt/ORC/704-829-2587/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Allen Stowe,526 S Chruch St Charlotte NC 282011002//704-382-4309/7043829840 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran Sludge Handling Dispos Facility Site Review Effluent/Receiving Wate Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Ori A Tuvia Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date 2/16/2021 ,-DocuSigned by: DWR/MRO WQ/704-663-1699/ RRO 7A7rlF(1174QP Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger DWR/Division of Water Quality/704-235-2194/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. ,—DocuSigned by: 2/16/2021 `—A14CC681AF27425... Page# 1 31 NPDES yr/mo/day NC0004979 111 121 21/02/08 117 Inspection Type 18 [j (Cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) The new permit has the following new areas: In anticipation of decreased use, Outfall 002 (the ash pond) has two (2) separate effluent limitations pages; one under normal/decanting stage and one for dewatering. New outfall 006 — the new outfall will receive all the effluent from the active coal pond, the coal pile coal yard sump, powerhouse sumps, WFGD, and WWT effluent. The discharge prior to reaching the effluent pipe will pass through a splitter box that could divert flow to either/both primary basins, each with 1.5 MGAL capacity. The effluent from both primary retention basins will than combine in a secondary retention basin with a 12.3 Mgal capacity, and finally an effluent retention structure (where final pH adjustments can be made). New Outfall 007 — New outfall is the emergency spillway of the new retention basin (listed under outfall 006) Four new toe drain discharges — 103, 104, 108 and 108 B Submerged Flight Conveyor (SFC) system was put into service to handle the station's bottom ash in a dry manner. The system was necessary due to the fact that all station inputs to the ash basin will no longer be decanting/dewatering operations. Prior to the SFC system being put into service, bottom ash was sluiced to the ash basin via a system of pumps and piping. The SFC system is an ash handling system. The water in the system is reused and recirculated in a closed loop system. pH is monitored and adjusted using soda ash to maintain the system water pH to minimize corrosion to the piping and components. The bottom ash is collected at the ash hopper of the boiler and transported via piping and pumps to the SFC. Once the bottom ash and water reaches the SFC, the bottom ash collects in the lower portion of the tank and the conveyor removes the bottom ash and deposits it to the storage area. Once the bottom ash is in the storage are, it can then be loaded into trucks and transported to the station landfill. Page# 2 Permit: NC0004979 Inspection Date: 02/08/2021 Owner - Facility: Plant Allen Steam Station 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: The subject permit will expire on 7/31/2023. See Summary 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 operatc 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? Yes No NA NE ❑ ❑ • ❑ • ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ ❑ ❑ • • • ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • Comment: Inspection conducted durinq Covid-19 restrictions. A full file review was not conducted. Requested lab results and COCs for the month of October 2020. These were sent via email in a timely manner and were complete. Laboratory Yes No NA NE Page# 3 Permit: NC0004979 Inspection Date: 02/08/2021 Owner - Facility: Plant Allen Steam Station Inspection Type: Compliance Evaluation Laboratory Are field parameters performed by certified personnel or laboratory? Are all other parameters(excluding field parameters) performed by a certified lab? # Is the facility using a contract lab? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ Comment: The facility is certified to perform on -site field analyses (pH and temperature) under laboratory certification #5134. The remaining permit -required effluent analyses are performed by Duke Energy's Environmental Services Laboratory (Certification #248) and the contracted services of Prism Labs (low level mercury), Shealy Labs, Pace Labs, and ETS, Inc. (toxicity) 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 less than or equal to 6.0 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: The subject permit requires effluent grab samples. Upstream / Downstream Sampling Is the facility sampling performed as required by the permit (frequency, sampling type, anc sampling location)? Comment: Operations & Maintenance Is the plant generally clean with acceptable housekeeping? Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge, and other that are applicable? Yes No NA NE ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ ❑ ❑ • ❑ Page# 4 Permit: NC0004979 Inspection Date: 02/08/2021 Owner - Facility: Plant Allen Steam Station Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Comment: The facility was not generating electricity at the time of the inspection. The FGD WWTS is connected to a computer monitoring system to assist the on -site staff in the operation of the treatment units/processes. since the previous inspection a Submerged Flight Conveyor (SFC) system was put into service and handles the station's bottom ash in a dry manner. The system will replace the decanting/dewatering operations from the ash basin. (see summary for more details) Equalization Basins Is the basin aerated? Is the basin free of bypass lines or structures to the natural environment? Is the basin free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? Comment: Secondary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Comment: Chemical Feed Is containment adequate? Is storage adequate? Yes No NA NE ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 5 Permit: NC0004979 Inspection Date: 02/08/2021 Owner - Facility: Plant Allen Steam Station Inspection Type: Compliance Evaluation Chemical Feed Are backup pumps available? Is the site free of excessive leaking? Comment: Static mixers are used. Flow Measurement - Influent # 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? Comment: The FGD WWTS effluent is measured by an in -line flow meter Flow Measurement - Effluent # 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ Yes No NA NE ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ Comment: Flow measurements for Outfalls 001, 003, and 004 are based on pump curves/logs. Outfall 002 and 006 discharges are measured by a staff guage/ultrasonic level indicator and weir. Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ Comment: The FGD WWTS is equipped with three operational filter presses.The gypsum material from the FGD system is stored. Bottom ash from the SFC collects in the lower portion of the tank and the conveyor removes the bottom ash and deposits it to the storage area. Once the bottom ash is in the storage are, it can then be loaded into trucks and transported to the station landfill. Effluent Pipe Is right of way to the outfall properly maintained? • Yes No NA NE ❑ ❑ ❑ Page# 6 Permit: NC0004979 Inspection Date: 02/08/2021 Owner - Facility: Plant Allen Steam Station Inspection Type: Compliance Evaluation Effluent Pipe Are the receiving water free of foam other than trace amounts and other debris? If effluent (diffuser pipes are required) are they operating properly? Yes No NA NE • ❑ ❑ ❑ ❑ ❑ • ❑ Comment: The effluent from Outfall 006 appered clear with no floatable solids or foam. Page# 7