NC0004685_Compliance Evaluation Inspection_20160724

PAT MCCRORY
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DONALD R. VAN DER VAART
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WaterResuurees S. JAY ZIMMERMAN
eNVIRONMENTAL QUALITY L!lYCCtoY
June 24, 2016 RECEIVEDINCQE0 JJ1fVFt
Mr.Todd Douthit, Manufacturing Manager 'JUL 0 7 2015
PPG Industries Fiber Glass Products, Inc. Water Cluality
940 Washburn Switch Road Permitting Section
Shelby, NC 28150
Subject: Compliance Evaluation Inspection
PPG Industries/Shelby Facility
NPDES Permit No. NC0004685
Cleveland County
Dear Mr. Douthit:
Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at
the subject facility on June 23, 2016 by Ori Tuvia. Richard Young's, Guy O'Connor's,John Little's and
Linda Bridge'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 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
[e-mail].
Sincerely,
s �
Ori Tuvia, Environmental Engineer
Mooresville Regional Office
Division of Water Resources, DEQ
Cc: NPDES Unit
MRO Files
Mooresville Regional Office
Location:610 East Center Ave.,Suite 301 Mooresville,NC 28115
Phone:[phone] Fax:[phone] Customer Service:1-877-623-6748

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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 1 3 I NC0004685 I11 121 16/06/23 I17 18 LC 1 19 1 s I 20I
211 1 1 1 1 1 1 1 •1 1 11 1 1 . 1 1 I I I I I- I I 1 I I I I I I I I I I 11 -I l i 1 1 _P6
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA Reserved
67 1.0 70 id 1 71 iN i 72 1 ti J 731 I 174 75III I_U80
LJ Section B:Facility Data LI I I
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) 09:30AM 16/06/23 14/05/01
PPG-Shelby facility
940 Washburn Switch Rd Exit.Time/Date Permit Expiration Date
Shelby NC 28150 12:25PM 16/06/23 18/08/31
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
Guy Peter O'Connor/ORCf704-434-2261/
John Charles Littlejohn/ORC/704434-2261/
Richard M Young/Associate Engineer Environmental Sr/704A34-2261 ext 359/7044340792
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
Richard M Young,940 Washburn Switch Rd Shelby NC
No
28150004-434-2261/7044340792
1 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
Ori A Tuvia MRO WQ//704-663-1699/
61 q1)
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.
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NPDES yr/mo/day Inspection Type 1
31 NC0004685 111 121 16/08/23 1 17 18 I C I
Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
Page# 2

Permit: NC0004665 Owner-Facility: PPG-Shelby facility
Inspection Date: 06/23/2016 Inspection Type: Compliance Evaluation
Permit - Yes No NA' NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ 0 ❑
application?,
Is the facility as described in the permit? M ❑ ❑ ❑
#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? 'M ❑ ❑ ❑
Comment: The subject permit will expire at 8/31/2018.
Record Keeping 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)? M ❑ .❑ .❑
Are analytical results consistent with data reported on DMRs? M ❑ 11, ❑
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 MRS complete:do they include all permit parameters? A ❑ ❑ ❑
Has the facility submitted its annual compliance report to users and DWQ? ❑. ❑ E ❑
(if the facility is=or>5 MGD permitted flow)Do they operate 24/7 with a certified operator ❑ -❑ M ❑
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? ❑ ❑ ❑
Is the backup operator certified at one grade less or greater than the facility classification? _-M ❑ _❑ ❑
Is a,copy of the current NPDES permit available on site? A ❑ ❑ ❑
Facility has copy of previous year's Annual Report on,file for review? M ❑ ❑ ❑
Comment: The records reviewed during the inspection were'organized and well maintained. DMRs,
COCs ORC visitation logs. Calibration logs and process control logs were reviewed for the
77
period November 2015,thrdUgh April 2016.
Laboratory Yes. No NA NE.
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Permit: NC0004685 Owner-Facility:. PPG-Shelby facility
Inspection Date: 06/23/2016 Inspection Type: Compliance Evaluation ,
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑
Are all other parameters(excluding field parameters)performed by a certified lab? 0 ❑ ❑ ❑
#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? ❑ ❑ 0 ❑
Incubator(BOD)set to 20.0 degrees Celsius+/-1.0 degrees? ❑ ❑ 0 ❑
Comment: On-site field analyses(conductivity,dissolved oxygen, PH',temperature)are performed
under the PPG's laboratory certification#5489. Pace Analytical Services, Inc. (BOD,TSS,
flouride, ammonia, nutrients. oil&grease, metals)and R&A Laboratories, Inc. (toxicity)have
also'been contracted to provide analytical support.The laboratory instrumentation used for
field analyses appeared to be properly calibrated and well documented
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? M ❑ ❑ ❑
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 composite and grab samples.
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? 0 ❑ ❑ ❑
Does the facility analyze process control parameters,for ex: MLSS,MCRT,Settleable ❑ ❑ ❑
Solids,pH, DO,Sludge Judge,and other that are applicable?
Comment: -The facility appeared to be properly operated'and well maintained. The operations staff
incorporate a comprehensive process control program with all measurements being
properly documented and maintained on-site.
The-facility is equipped with a computer/alarm notification system to assist the wastewater
staff in the operation of the treatment units/processes_
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• Permit: NC0004685 Owner-Facility: PPG-Shelby facility
Inspection Date: 06/23/2016 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE _
Bar Screens Yes No NA NE
Type of bar screen
a.Manual
b.Mechanical ❑
Are the bars adequately screening debris? M. ❑ ❑ ❑
Is the screen free of excessive debris? 0 ❑ ❑ ❑
Is disposal of screening in compliance? M ❑ ❑ ❑
Is the unit in good condition? N ❑ ❑ ❑
Comment:
Equalization Basins Yes No NA NE
Is the basin aerated? ❑ ❑ ❑ "
Is the basin free of bypass lines or structures to the natural environment? M ❑ ❑ ❑
Is the basin free of excessive grease? 0 ❑ ❑ ❑
Are all pumps present? ❑ ❑ ❑
Are all pumps operable? ❑ ❑ ❑
Are float controls operable? 0 ❑ ❑ ❑
Are audible and visual alarms operable? E ❑ ❑ ❑
#Is basin size/volume adequate? .0 ❑ ❑ ❑
Comment:
Primary Clarifier Yes No NA NE
Is the clarifier'free of black and odorous wastewater? ❑ ' ❑ ❑
Is the site free of excessive buildup of solids in center well of circular clarifier? M ❑ ❑ ❑
Are weirs level? 0 ❑ .❑ ❑
Is the site free of weir blockage? ❑ ❑ ❑
Is the site free of evidence of.short-circuiting? ❑ ❑ ❑
Is scum removal adequate? E ❑ ❑ ❑
Is the site free of excessive floating sludge? ❑ ❑ ❑
Is the drive unit operational? 'M ❑ ❑ ❑
Is the sludge blanket level acceptable?-
Is
cceptable?Is the sludge blanket level acceptable?(Approximately%of the sidewall,depth) M ❑' ❑ ❑
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y
Permit: NC0004685 Owner-Facilit : PPG-Shelby facility
Inspection Date: 06/23/2016 Inspection Type: Compliance Evaluation
Primary Clarifier Yes-No NA NE
-Comment: Both primaries were operational and in service.
Chemical Feed Yes No NA,NE
Is containment adequate? rE ❑ ❑ ❑
Is storage adequate? E ❑ ❑ .❑
Are backup pumps available? ❑ ❑ ❑
Is the site free of excessive leaking? ❑ ❑ ❑
Comment:, Chemical additions to selected treatment processes include the following: polymers,
bentonite/clay-mixture,ferric chloride, aluminum chloride, lime,and defoamer.
Aeration Basins Yes No NA NE
Mode of operation
Type of aeration system Diffused
Is the basin free of dead spots? E ❑ ❑ ❑
Are surface aerators and mixers operational? ❑ ❑ ❑
Are the diffusers operational? E ❑ ❑ ❑
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? 0 ❑ ❑ ❑
Is the DO level acceptable?(1.O.to 3.0 mg/1)' ❑ ❑ 0 ❑
Comment: The facility uses two aeration basins operated in series. The first aeration tank is equipped
with diffused and mechanical aeration and the second aeration tank is equipped with
diffused aeration.
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? N ❑ ❑ ❑
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? ❑ ❑ ❑
Is the drive unit operational? 0 ❑ ❑ ❑
Is the return rate acceptable(low turbulence)? 0 ❑ ❑ ❑
Is the overflow clear of excessive solids/pin floc? ❑ ❑ ❑
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Permit: NC0004685 Owner-Facility: PPG-Shelby facility
Inspection Date: 06/23/2016 Inspection Type: Compliance Evaluation
Secondary Clarifier Yes No.NA NE
Is the sludge blanket level acceptable?(Approximately%of the sidewall depth) 0 ❑ ❑ ❑
Comment`: Two out of the three secondary clarifiers were operational and in service at the time of the
inspection.The third clarifier was not used due to low flow.
Pumps-RAS-WAS Yes No NA NE
Are pumps in place? ❑ ❑ ❑
Are pumps operational? N ❑ ❑ ❑
Are there adequate spare parts and supplies on site? ❑ ❑ ❑
Comment:.
Filtration (High Rate Tertiary) Yes No NA NE
Type of operation: Down flow
Is the filter media present? N ❑ ❑ ❑
Is the filter surface free of clogging? N ❑ ❑ ❑
Is the filter free of growth? M ❑ ❑ ❑
Is the air scour operational? ❑ ❑ 0 ❑
Is the scouring acceptable? ❑ ❑ ❑ 0
Is the clear well free of excessive solids and filter media? ❑ ❑ 0 ❑
Comment: " The facility is equipped with a traveling bridge teritary filter. The filter backwash is returned
to the head of the wastewater plant.
Flow Measurement- Effluent Yes No NA NE
#Is flow meter used for reporting? A ❑ ❑ ❑
Is flow meter calibrated annually? M ❑ ❑ ❑
Is the flow meter operational? N ❑ ❑ ❑
(If units are separated)Does the chart recorder match the flow meter? ❑ ❑ ❑
Comment: The flow meter is calibrated/verified regulary. Last calibrated on 4/152016 by Clear Water,
Inc.
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑
Are the receiving water free of foam other than trace amounts and other debris? N ❑ ❑ ❑
If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑
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Permit: NC0004685 Owner-Facility PPG-Shelby facili ty
Inspection Date: 06/23/2016 Inspection Type: Compliance Evaluation
Effluent Pipe, Yes No NA NE
Comment: At the time of the inspection the effluent(Outfall 001)appeared clear with no discoloring,
floateble solids or foam. The receiving stream did not appear to be negatively impacted.
Solids Handling Equipment Yes No NA NE
Is the equipment operational? 0 ❑ ❑ ❑
Is the chemical feed equipment operational? 0 ❑ ❑ ❑
Is storage adequate? 0 ❑ ❑ ❑
Is the site free of high level of solids in filtrate from filter presses or vacuum filters? 0 ❑ ❑ ❑
Is the site free of sludge buildup on belts and/or rollers of filter press? 0 ❑ ❑ ❑
Is the site free of excessive moisture in belt filter press sludge cake? 0 ❑ .❑ ❑
The facility has an approved sludge management plan? ❑ ❑ ❑ N
Comment: Thickened sludge is deWatered on a belt press. Dewatered solids are transported to the
County Landfill for final disposal by waste pros. Last transported on 4/13/2016.
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