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Home My WebLink AboutNC0004952_Inspection_20170214NPDES DOCUMENT SCANNING COVER :MEET NC0004952 Celanese Shelby Facility NPDES Permit: Document Type: Permit Issuance Wasteload Allocation Authorization to Construct (AtC) Permit Modification Complete File - Historical Engineering Alternatives (EAA) Correspondence Owner Name Change Instream Assessment (67b) Speculative Limits Environmental Assessment (EA) Document Date: February 14, 2017 This document its printed on reuse paper - ignore any content on the reirerse wide ROY COOPER Governor Water Resources ENVIRONMENTAL QUALITY February 14, 2017 Ms. PEM Carter, Sr. Environmental Engineer CNA Holding, LLC 2525 Blacksburg Road Grover, NC 28073 Dear Ms. Carter: MICHAEL S. REGAN Secretary S. JAY ZIMMERMAN Director RECEIVEDOE O FEB 2 2 Z017 Water Quality on Penn►ttin9 Subject: Compliance Sampling Inspection Celanese — Shelby Plant NPDES Permit No. NC0004952 Cleveland County Enclosed is a copy of the Compliance Sampling Inspection for the inspection conducted at the subject facility on February 8, 2017, by Ori Tuvia. Michael Sparks, Michael Queen's, Randy Turner's and 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. Split samples were taken during the inspection. Results of the split sampling will be forwarded upon completion of analyses. 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 i ............. can A. Quill 9t11 nMnrnc,tiuc P otl11F United States Environmental Protection Agency EPA 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 yrlmo/day Inspection 3 I NC0004952 111 12 17/02/08 117 1 1�, 1 2 1.i Type 18 I I I I I I1111I Inspector Fac Type 19 1 2 I 20 i 1 211II1 I I I II [II I II 1I I I1 I II I I I I I I ILI I i66 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA 67110 1 701d I 71I„j 72 Lii Reserved 731 1 V 751 1 I I I 1 1 180 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Celanese -Shelby Facility NC Hwy 198 Shelby NC 28150 Entry Time/Date 10:05AM 17/02/08 Permit Effective Date 13/11/01 Exit Time/Date 01:10PM 17/02/08 Permit Expiration Date 18/08/31 Name(s) of Onsite Representative(s)/iles(s)/Phone and Fax Number(s) 1/1 • Michael D. Sparks/ORC/704-480-5793/ Other Facility Data Name, Address of Responsible OfficiaVTitle/Phone and Fax Number Contacted Rafael Gonzalez,2525 Blacksburg Rd Grover NC 28073/Site Director/704-480-5728/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Row 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 Ori A Tuvia MRO WQ//704-663-1699/ Date n / 114 03... 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. /4-/es 2i0,F Page# 1 31 NPDES NC0004952 r 1 121 yr/mo/day 17/02/08 17 Inspection Type 18[II 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On -Site Representatives: The following Company personnel were in attendance during the inspection: Ms. PEM Carter/Sr. Environmental Engineer; Mr. Michael Sparks/ORC; Mr. Randy Turner Lab Supervisor; and Mr. Michael Queen/Backup ORC Page# 2 Permit: NC0004952 Inspection Date: 02/08/2017 Owner - Facility: Celanese -Shelby Facility Inspection Type: Compliance Sampling Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new 0 0 • 0 application? Is the facility as described in the permit? 11 0 0 0 # Are there any special conditions for the permit? • 0 0 0 Is access to the plant site restricted to the general public? 0 0 0 Is the inspector granted access to all areas for inspection? • 0 0 0 Comment: The subject permit expires on 8/31/2018. The facilty permit limits are in pounds/day rather then mg/L. Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? • 0 0 0 Is all required information readily available, complete and current? • ❑ 0 0 Are all records maintained for 3 years (lab. reg. required 5 years)? • 0 0 ❑ Are analytical results consistent with data reported on DMRs? • 0 0 0 Is the chain -of -custody complete? 11 0 0 0 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 0 0 Has the facility submitted its annual compliance report to users and DWQ? 0 0 11.❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator 0 0 • 0 on each shift? Is the ORC visitation log available and current? 11 0 0 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 0 0 Is a copy of the current NPDES permit available on site? • 0 0 0 Facility has copy of previous year's Annual Report on file for review? • 0 0 0 Comment: The records reviewed during the inspection were organized and well maintained. DMRs, COCs. Bench sheets, Calibration logs and ORC visitation logs. were reviewed for the period January 2016 through September 2016. Laboratory Yes No NA NE Page# 3 Permit: NC0004952 Owner - Facility: Celanese -Shelby Facility Inspection Date: 02/08/2017 Inspection Type: Compliance Sampling 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 ■ ❑ 0 0 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑❑■❑ Comment: On -site effluent analyses (fecal coliform, pH, temperature, TSS) are performed under the Company's laboratory certification #221. Prism Laboratories. Inc. (BOD, oil & grease, total nitrogen, total phosphorus. pollutant scan) and ETT. Inc. (toxicity) have also been contracted to provide analytical support. The laboratory instrumentation used for field analyses appeared to be properly calibrated/verified and documented. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ■ ❑ ❑ ❑ Is sample collected below all treatment units? ■ ❑ ❑ ❑ Is proper volume collected? ■ ❑ ❑ ❑ Is the tubing clean? ■ 0 0 0 # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees ■ ❑ 110 Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type ■ ❑ ❑ ❑ representative)? Comment: The subject permit requires both composite and grab effluent samples. The ORC and staff must ensure to perform/document periodic aliquot verifications on the composite sampler. 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 ■ ❑ ❑ ❑ 110 ❑ ❑ Comment: The wastewater facility appeared to be properly operated and well maintained. The facility staff incorporate a comprehensive process control program with all measurements being properly documented and maintained on -site. Bar Screens Type of bar screen a.Manual b.Mechanical Yes No NA NE ■ 0 Page# 4 Permit: NC0004952 Owner - Facility: Celanese -Shelby Facility Inspection Date: 02/08/2017 Inspection Type: Compliance Sampling Bar Screens Are the bars adequately screening debris? Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? Comment: Grit Removal Type of grit removal a.Manual b.Mechanical Is the grit free of excessive organic matter? Is the grit free of excessive odor? # Is disposal of grit in compliance? Comment: 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? Yes No NA NE ■ ❑ ❑❑ IN ❑ ❑ ❑ • ❑ ❑ Cl ■ ❑❑❑ Yes No NA NE • 0 • ❑ Cl ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ▪ ❑ ❑ ❑ ❑ ❑ 1 ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ Comment: The process wastewater flows through three equalization basins (in series) prior to combining with the domestic wastewater. Sodium hydroxide (pH adjustment) is added to the first EQ Basin and phosphoric acid (nutrient supplement) is added on an as -needed basis at the third EQ Basin. A fourth equalization tank is also available for emergency situations. Ch em i cal Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Yes No NA NE • ❑ •❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ▪ ❑ ❑ ❑ Page# 5 Permit: NC0004952 Owner - Facility: Celanese -Shelby Facility Inspection Date: 02/08/2017 Inspection Type: Compliance Sampling Chemical Feed Yes No NA NE Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? • 0 ❑ 0 Are surface aerators and mixers operational? • 0 0 0 Are the diffusers operational? 0 ❑ • 0 Is the foam the proper color for the treatment process? 11 0 ❑ ❑ Does the foam cover Tess than 25% of the basin's surface? •❑ ❑ 0 Is the DO level acceptable? 11 0 0 0 Is the DO level acceptable?(1.0 to 3.0 mg/I) 0 ❑ • 0 Comment: Both aeration basin trains were operational and in service at the time of the inspection. Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? • 0 0 0 Is the site free of excessive buildup of solids in center well of circular clarifier? •❑ ❑ ❑ Are weirs level? • 0 0 ❑ Is the site free of weir blockage? 11 0 0 0 Is the site free of evidence of short-circuiting? • 0 0 0 Is scum removal adequate? 11 0 0 0 Is the site free of excessive floating sludge? • 0 0 0 Is the drive unit operational? • 0 0 0 Is the return rate acceptable (low turbulence)? • 0 0 0 Is the overflow clear of excessive solids/pin floc? ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/. of the sidewall depth) MEI ❑ ❑ Comment: One of the wto secondary clarifiers was operational and in service, the second was taken down for maintenance.. Pumps-RAS-WAS Yes No NA NE Are pumps in place? • 0 0 0 Are pumps operational? • ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ ❑ • Page# 6 Permit: NC0004852 Inspection Date: 02/08/2017 Owner - Facility: Celanese -Shelby Facility Inspection Type: Compliance Sampling Pumps-RAS-WAS Yes No NA NE Comment: Lagoons Type of lagoons? # Number of lagoons in operation at time of visit? Are lagoons operated in? # Is a re -circulation line present? Is lagoon free of excessive floating materials? # Are baffles between ponds or effluent baffles adjustable? Are dike slopes dear of woody vegetation? Are weeds controlled around the edge of the lagoon? Are dikes free of seepage? Are dikes free of erosion? Are dikes free of burrowing animals? • # Has the sludge blanket in the lagoon (s) been measured periodically in multiple locations? # If excessive algae is present, has barley straw been used to help control the growth? Is the lagoon surface free of weeds? Is the lagoon free of short circuiting? Yes No NA NE Aerated 3 Series ❑ ❑ • ❑ • ❑ ❑ ❑ ❑ ❑ II ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑❑ • ❑ ❑ ❑ 11 ❑ ❑ ❑ ❑ ❑ III ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The facility is equipped with three polishing ponds (operated in series) and two sludge holding ponds. Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Down flow Is the filter media present? 1 ❑ ❑ ❑ Is the filter surface free of clogging? II 0 0 0 Is the filter free of growth? 0 Cl 0 • Is the air scour operational? 0 0 • 0 Is the scouring acceptable? 1 ❑ 0 ❑ Is the clear well free of excessive solids and filter media? 0 0 11 0 Comment: All six tertiary filters were operational and in-service. Flow Measurement - Effluent # Is flow meter used for reporting? Yes No NA NE • ❑ ❑ ❑ Page# 7 Permit: NC0004952 Inspection Date: 02/08/2017 Owner - Facility: Celanese -Shelby Facility Inspection Type: Compliance Sampling Flow Measurement - Effluent 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 ■❑❑❑ 111 ❑ ❑ ❑ ❑ ❑ II ❑ Comment: The flow meter is calibrated/verified on a quarterly basis and was last calibrated/verified on 2/1/2017 by the Company's I & E personnel. 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: The effluent appeared clear with no floatable solids or foam. Yes No NA NE ❑ ❑■❑ 11000 O 0110 Aerobic Digester Yes No NA NE Is the capacity adequate? 110 ❑ ❑ Is the mixing adequate? •❑ ❑ ❑ Is the site free of excessive foaming in the tank? • ❑ ❑ ❑ # Is the odor acceptable? 111 0 ❑ ❑ # Is tankage available for properly waste sludge? 11 ❑ 0 ❑ Comment: The facility is authorized to land apply digested sludge under the authority of Permit WQ0011038. Page# 8