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Home My WebLink AboutNC0004952_Compliance Sampling Inspection_20170214 ROY COOPER Governor 5 MICHAEL S. REGAN Secretary Water Resources ENVIRONMENTAL QUAL:TY -� - `-- - - - - - S. JAY ZIMMERMAN Director February 14, 2017attaD° RECO Ms. PEM Carter, Sr. Environmental Engineer FEBn1 CNA Holding, LLC 2525 Blacksburg Road water Grover, NC 28073 �� 9 Subject: Compliance Sampling Inspection Celanese—Shelby Plant NPDES Permit No. NC0004952 Cleveland County Dear Ms. Carter: 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. Sincerely, Ori Tuvia, Environmental Engineer Mooresville Regional Office Division of Water Resources, DEQ Cc: NPDES Unit MRO Files Mooresville Regional Office I......v......Gln CnnI n...,*...A.,n Qi 6Vn'/111 hAnnroo,ills hl!` 9A11F • United States Environmental Protection Agency Form Approved: EPA Washington,D.C.20460 OMB No.2040-0057 • Water Compliance Inspection Report_ ._ Approval expirest8-31-98. • Section A:National Data System Coding(i.e.,PCS) • Transaction Code•. • NPDES yr/mo/day Inspection Type Inspector Fac Type 1 1„ 12 15 S1 3 I NCDoo4952 111 12 I 17/02/08 117 18 I I 19 12 j 201 I • 211 1 1 1 1 II I I - I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I r6 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 • QA Reserved- 67 11.0 LJ 70 id I 71 IN I 72 1 rJ i_I 1 731 I 174 751 1 1 1 1 1 1 180 • Section B:Facility Data L 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) • 10:05AM 17/02/08 13/11/01 Celanese-Shelby,Facility NC Hwy 198 • Exit Time/Date Permit Expiration Date Shelby NC 28150 • 01:10PM 17/02/08 18/08/31 Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data • /// Michael D.Sparks/ORC/704-480-5793/ Name,Address of Responsible OfficiaUTitle/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) III Permit M Flow Measurement II Operations&Maintenance • Records/Reports . I. Self-Monitoring Program • Sludge Handling Disposal • Facility Site Review II Effluent/Receiving Waters III 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 TuviaMRO WQ//704-663-1699/ �_JYI • 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. f . rDR Page# 1 NPDES yr/mo/day Inspection Type 1 31 NC0004952 111 121 17/02/08 117 18 I c 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 Owner-Facility: Celanese-Shelby Facility • Inspection Date: 02/08/2017 • 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 U 0 application? • Is the facility as described in the permit? • '❑ 0 0 #Are there any special conditions for the permit? • 0 0 0 Is access to the plant site restricted tothe 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 ma/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 0 Are all records maintained for 3 years(lab. reg. required 5 years)? ' • 0 0 0 Are analytical results consistent with data reported on DMRs? • 0 0 0 Is the chain-of-custody complete? • 0 0 0 Dates,times and location of sampling • Name of individual performing the sampling • Results of analysis and'calibration U Dates of analysis • Name of person performing analyses • Transported COCs • Are DMRs complete:do'they include all permit parameters? • 0 . 0 ❑ Has the facility submitted its annual compliance report to users and DWQ? 0 0 • .❑ (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 0 0 Is the ORC certified at grade equal to or higher than the facility classification? • 0 0 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 Ions,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 "" - Yes—No-NA NE Are field parameters performed by certified personnel or laboratory? . • 0 0 0 Are all other parameters(excluding field parameters)performed by a certified lab? - • 0 0 ❑- #Is the facility using a contract lab? • 0 0 0 #Is proper temperature set for sample storage(kept at less than or equal to 6.0 degrees • 0 •❑ 0 Celsius)? Incubator(Fecal Coliform)set to 44.5 degrees Celsius+/-0.2 degrees? • 0 0 0 Incubator(BOD)set to 20.0 degrees Celsius+/-1.0 degrees? 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 Samplinq Yes No NA NE Is composite sampling flow proportional? U 0 0 0 Is sample collected below all treatment units? U 0 0 0 Is proper volume collected? IS 0 0 0 Is the tubing clean? • 0 0 0 #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 • • ❑' 0 0 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 Yes No 'NA NE Is the plant generally clean with acceptable housekeeping? • 0 0 0 Does the facility analyze process control parameters,for ex: MLSS,MCRT,Settleable • 0 0 0 Solids, pH,DO,Sludge-Judge,and other that are applicable? Comment: Thewastewater 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 Yes No NA NE Type of bar screen a.Manual • • b.Mechanical ❑ Page# 4 Permit: NC0004952 Owner-Facility: Celanese-Shelby Facility Inspection Date: 02/08/2017 Inspection Type: Compliance Sampling • Bar Screens Yes No NA NE Are the bars adequately screening debris? • 0 0 0 Is the screen free of excessive debris? • 0 0 0 Is disposal of screening in compliance? • • 0 0 0 Is the unit in good condition? • 0 0 0 Comment: Grit Removal Yes No NA NE Type of grit removal a.Manual • •b.Mechanical ❑ Is-the grit free of excessive organic matter? - • 0 0 0 Is the grit free of excessive odor? • 0 0 0 #Is disposal of grit in compliance? • 0 0 0 Comment: Equalization Basins Yes No NA NE Is the basin aerated? • 0 0 0 Is the basin free of bypass lines or structures to the natural environment? • 0 0 0 Is the basin free of excessive grease? • • 0 0 0 - Are all pumps present? 0 0 I 0 Are all pumps operable? 0 0 • 0 Are float controls operable? - 0 0 • 0 Are audible and visual alarms operable? . 0 ❑ • 0 #Is basin size/volume adequate? • 0 0 0 • Comment: The process wastewater flows through three equalization basins(in series) prior to combining with the domestic wastewater. Sodium hydroxide(pH adiustment)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. • Chemical Feed Yes No NA NE Is containment adequate? U 0 -❑ ❑ Is storage adequate? • 0 -❑ 0 Are backup pumps available? • 0 0 0 Is the site free of excessive leaking? • 0 0 0 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 0 • Are surface aerators and mixers operational? • 0 0 0 Are the diffusers operational? 0 0 NI 0 Is the foam the proper color for the treatment process? • 0 0 0 Does the foam cover less than 25%of the basin's surface? • 0 0 0 Is the DO level acceptable? • 0 0 0 Is the DO level acceptable?(1.0 to 3.0 mg/I) 0. 0 U ❑ 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? a 0 0 0 Are weirs level? • 0 0 0 • Is the site free of weir blockage? • ❑ 0 0 Is the site free of evidence of short-circuiting? • 0 0 0 • • Is scum removal adequate? IN ❑ 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 • Is the overflow clear of excessive solids/pin floc? • ❑ 0 0 Is the sludge blanket level acceptable?(Approximately 1/4 of the sidewall depth) • 0 0 0 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? • 0 0 ❑ Are there adequate spare parts and supplies on site? • • 0 ❑ 0 11 Page# 6 • Permit: NC0004952 Owner-Facility: Celanese-Shelby Facility Inspection Date: 02/08/2017 Inspection Type: Compliance Sampling Pumps-RAS-WAS Yes No NA NE Comment: Lagoons Yes No NA NE Type of lagoons? Aerated #Number of lagoonsin operation at time of visit? 3 Are lagoons operated in? Series #Is a re-circulation line present? 0' 0 • 0 Is lagoon free of excessive floating materials? • U 000 #Are baffles between ponds or effluent baffles adjustable? 001110 Are dike slopes clear of woody vegetation? • 000 • Are weeds controlled around the edge of the lagoon? • 0 0 0 Are dikes free of seepage? • 000 Are dikes free of erosion? • 000 Are dikes free of burrowing animals? • 0 0 0 #Has the sludge blanket in the lagoon(s)been measured periodically in multiple 0 0 II 0 locations? #If excessive algae is present, has barley straw been used to help control the growth? 00110 Is the lagoon surface free of weeds? I ❑ ❑ ❑ Is the lagoon free of short circuiting? • ❑ ❑ ❑ 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? 111000 Is the filter surface free of clogging? • 000 Is thefilter free of growth? 0 0 0 • Is the air scour operational? 00 • 0 Is the scouring acceptable? • ❑ ❑ ❑ Is the clear well free of excessive solids and filter media? 001110 Comment: All six tertiary filters were operational and in-service. . Flow Measurement- Effluent Yes No NA NE #Is flow meter used for reporting? • 000 Page# 7 Permit: NC0004952 Owner-Facility: Celanese-Shelby Facility Inspection Date: 02/08/2017 Inspection Type: Compliance Sampling Flow Measurement-Effluent Yes No NA NE Is flow meter calibrated annually? • ❑ 0 0 Is the flow meter operational? • 0 0 0 (If units are separated)Does the chart recorder match the flow meter? 0 0 • 0 • 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 Yes No NA NE • Is right of way to the.outfall properly maintained? 0 0 • ❑ Are the receiving water free of foam other than trace amounts and other debris? • 0 0 0 If effluent (diffuser pipes are required) are they operating properly? 0 0 • ❑ • Comment: The effluent appeared clear with no floatable solids or foam. Aerobic Diciester Yes No NA NE Is the capacity adequate? • ❑ 0 0 Is the mixing adequate? ' • ❑ ❑ 0 Is the site free of excessive foaming in the tank? • 0 0 ,❑ #Is the odor acceptable? 11 ❑ ❑ ❑ #Is tankage available for properly waste sludge? • 0 ❑ 0 Comment: The facility is authorized to land apply digested sludge under the authority of Permit W00011038. • • • • Page# 8