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Home My WebLink AboutNC0072664_Compliance Evaluation Inspection_20161104Water Resources StiVIRONMEMAL OUAL1TY PAT MCCRORY . Governor DONALD R. VAN DER VAART secremry S. JAY ZIMMERMAN Din dor November 4, 2016 Mr. Mark Hawes Shurtape Technologies, LLC. . P.0 Box 1530 Hickory, NC 28603 Subject: Compliance Inspection Stony Paint Tape Plant NPDES Permit No. NCO072664 Alexander County Dear Mr. Hawes: Enclosed is a copy of the Compliance Inspection report for the inspection conducted at the subject facility on October 31, 2016, 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. . Sincerely, Ori Tuvia, Environmental Engineer Mooresville Regional Office Division of Water Resources, DEQ Cc:- NPDES Unit, MRO Files Mooresville Regional Office United States Environmental Protection Agency Form Approved. EPA Mshingtori,, D.C. 20460 OMB No. 2040-0057 , -. . Water Compliance Inspection ,Report Approval expires a-31-96 Section k National Data System Coding (Le., PCS) Transaction Code NPDES yarno/day. Inspection Type Inspector Fac Type 1 IN i 2 h 1 3 I riCo072664. I11 12 16110/3, 17 181 � 1 19 I c I 20� I 211111111111111111111111111111111 111111L•1II1If6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 67 1.0 .70'Id I 71 J I 72 i N i 731 I 174 75 80 LJ Section B: Facility !Data LJ 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 Dermit Number) 09:25AM 16/10/31 14/06/01 Stony Point Plant. Exit Time/Date 'permit Expiration Date. 8510 NC Hwy 90 E -12:30PM 16/10/31 19/03/31 Stony Point NC 28678 Name(s) of Onsite Representative(s)mties(s)/Phone and Fax Numbers) Other Facility Data Douglas Ray HaIVORC/828-267-8919/ Jeny Eplin//828-267-8212! 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/826-267-842818778599746 .Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Pemtit 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/1704-663-1699/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax.Numbers Date W. Corey Basinger.. MRO WQ//704-23572194/ i EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 Permit: NC0012664 Owner - Facility: Stony Point Plant Yes No NA NE Are records kept and,maintained as.requlred by the permit? A ❑ . Inspection Date: 10/31/2016 Inspection Type: Compliance Evaluation ❑ Is all required information readily available' complete and current? Is the ORC certified at grade equal to or higher than. the facility classification? M ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? ❑ Permit Yes No � NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ 0M ❑ 0 application? ' -M-E] ❑ ❑. Is the facility as,described in the permit? W IT ❑ ❑ # Are there any special conditions for the permit?. ❑ M . ❑ 0 - -Is Is access to the plant site restricted to the general public? 0 ❑ [3 ❑. Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: The subject permit expires on 3/31/2019. Air washer and cooling towerdischarges were, rerouted from the WV.VrP in 2012 and are now directly discharged under NCG500323: Are DMRs complete: do't.hey include all permit parameters?: N' ❑ Record Keepina . ,. Yes No NA NE Are records kept and,maintained as.requlred by the permit? A ❑ . ❑ ❑ Is all required information readily available' complete and current? Is the ORC certified at grade equal to or higher than. the facility classification? M ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? ❑ ❑. ❑ Are analytical -results consistent with data reported on DMRs? ❑ ❑ ❑ ❑ Q Is the chain -of -custody complete? -M-E] ❑ ❑. Dates, times and -location of sampling . calibration logs were reviewed for January 2016 through March 2016. Name of individual performing the sampling .: 3 Results of.analysis and calibration Dates of analysis Name of person performing analyses Transported CM Are DMRs complete: do't.hey include all permit parameters?: N' ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ 0 ❑ (if the facility is:= or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator „ ❑:-;.� ❑ 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? M ❑ ❑ ❑ 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? : ;'W- ❑ ❑ ' ❑ Facility has copy of previous year's Annual Report on file for review? ..❑ ❑ ::0- ❑ Comment:.. The aermittee's records and logbooks were very organized and well maintainedand records reguested dui in tq he�inspecti6h were readily available:°DMRs. GOCs,`Maintenance" loos and calibration logs were reviewed for January 2016 through March 2016. Page# 3 Permit: NCO072664 Owner - Facility: Stony Point Plant . is taken from the pH meter. Effluent Sampling Yes No NA NE Inspection Date: 10/31/2016 Inspection Type: Compliance Evaluation _ Is sample collected below all treatment units? ❑ ❑ ❑ Is proper volume collected? ❑ Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? ❑ ❑ ❑ Q 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 ❑ �E-1 ❑ ❑ Celsius)? �. Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ ❑ . ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- degrees? ❑ ❑ ❑ ❑ Comment: On-site analyses (temperature. PH, dissolved oxygen 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. (12/16/2015 and 6/13/2016). The temperature reported on the MRS is taken from the pH meter. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? IT- ❑ 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 0 ❑ 11+1 . ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type M ❑= 0 ❑ representative)? Comment:. The permit reouires arab samples for all required parameters: All effluent samples are kept - on 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 . N ❑ ❑ ❑ sampling location)? Comment: Operations &Maintenance . :Yes No NA NE Is the.plant generally clean with acceptable housekeeping? 0 ❑ 1113 Does the facility analyze. process control parameters,,for ex: MLSS, MCRT, Settleable M ❑ 110 Solids,. pH,"D0,'Sludge Judge,, and other that are. applicable?. Page# 4 Permit: NCO072664 Owner - Facility: Stony Point Plant Inspection Date: 10/31/2016 Inspection Type: Compliance Evaluation,.. Operations &'Maintenance .Yes No NA NE Comment: The Dermittee conducts. process control sampling of PH, dissolved oxygen, MLSS. MLVSS, and'settleability in the operation of the W.WrP. The air washer and cooling tower discharges were rerouted from the VWVfP in 2012 and are now. directy discharged under NCG500323. Bar Screens Yes No NA NE Type of bar screen a.Manual. �. b.Mechariical " ❑ Are the bars adequately screening debris? A ❑ ❑ ❑ Is the screen free of excessive debris? ❑ ❑ ❑ Is disposal of screening in compliance? ❑ ❑ ❑ Is the'unit in good condition? 0" ❑ ❑ ❑ Comment: 'Screenings are disposed with the VWVFP 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? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? ❑ ❑ N ❑ Are the diffusers operational? ❑ ❑ ❑ Is the foam the proper color for the treatment process? ❑ ` ❑ ❑ Does the foam cover less than 25% of the basin's surface? ❑ ❑ ❑ Is the DO level acceptable? , . E -❑ IT ❑ Is the DO level ac6eptable?(1.0 to 3.0 mg/I) 11 0 11 M Comment: Secondary Clarifier Yes No NA NE Is the. clarifier free of black and odorous wastewater? E. ❑ ` ❑ '. ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? ❑ ❑ N ❑ Are weirs level? :<. .E _.T1, ' ❑ El Is the site. free.ofweir blockage? V 1U '0 ❑ Is the sitefree of evidence of short-circuiting? ❑ ❑ ❑, Is scum removal adequate? M ❑ ❑ •❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Page# 5 Permit: NCO072664 Owner - Facility: Stony Point Plant Inspection Date: 10/31/2016 Inspection Type: Compliance Evaluation ❑ ❑ ❑ ❑ Secondary Clarifier Yes No NA NE Is the drive unit operational? . ❑`,- El 0 ❑ Is the return rate acceptable (low turbulence)? M ❑ ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? M ❑. ❑ ❑ Is the sludge blanket level acceptable? (Approximately. %4 of the sidewall depth) M ❑ 11. ❑ Comment: ❑ ❑ ❑ ❑ Disinfection -Tablet Are tablet chlorinators operational? Are the tablets the proper size and type? Number of tubes in use? Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge,buildup? Is there chlorine residual prior to de -chlorination? Comment:. De -chlorination Type of system? 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? Are.tablet de -chlorinators operational? Number of tubes in use? Comment: Aerobic Digester Is the capacityadequate? Is the mixing.adequate? Is the site free of excessive foaming in the tank? # Is the_ odor: acceptable? . # Is tankage' available for properly waste sludge? Yes No NA NE ❑ ❑ ❑ ❑ El 1:1 2 M ❑ ❑ ❑ M ❑ ❑ ❑ Yes No NA NE Tablet ■. p 0 . ❑.. ❑ ❑ ❑ ❑ ❑ ❑ M,-❑ ❑ ❑ M ❑ ❑ ❑ 2 Yes No NA NE ❑ ❑ ❑ M ❑ , ❑ • ..❑ ❑ ❑ .M ❑ ❑ ❑ ❑ ❑ ❑ Page# 6 0 Permit: NC0072664 Owner - Facility: Stony Point Plant Inspection Date: 10/31/2016 Inspection Type: Compliance Evaluation Aerobic Digester Yes No 'NA NE Comment:.' The permittee aerates the 2,000 -gallon sludge holding tank within the WVVTP. The sludge is taken to the Taylorsville WIMP by Miller's Septic Service. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? Q El . Is flow meter calibrated annually? ❑ ❑ ❑ Is the flow meter operational? ❑ ❑ ❑ If units are separated) Does the' chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: Permittee uses the buckettstop watch method of determining effluent flow. 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? E ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ ❑ Comment: