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Home My WebLink AboutNC0003425_Compliance Evaluation Inspection_20121212Aja NC®ENR North Carolina Department of Environment and Natural Resources Beverly Eaves Perdue Governor December 12, 2012 Mr. Mike Mosley Plant Manager Roxboro Steam Electric Power Plant 1700 Dunnaway Rd Semora, NC 27343 Dear Mr. Mosley. Division of Water Quality Charles Wakild, P.E. Director JAN 10 2013 CENTRAL FILES DWQIB®G 1 Dee Freeman Secretary Subject: NPDES Compliance Inspection Report Roxboro Steam Electric Power Plant NPDES Wastewater Discharge Permit No. NC0003425 Person County The North Carolina Division of Water Quality conducted an inspection of the Roxboro Steam Electric Power Plant on 11/13/2012. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES Wastewater Permit No. NC0003425 A summary of the findings and comments noted during this inspection is provided in the attached complete inspection report titled "Water Compliance Inspection Report". If you have any questions concerning this report, please contact me at 919-791-4255 in the Raleigh Regional Office. Sincerely, Autumn Romanski Environmental Program Consultant Attachment Cc. Mr. Shannon Langley 410 S Wilmington St. PEB 4 Raleigh, NC 27601 Raleigh Regional Office — File DWQ/Raleigh — Central Files and Stormwater Permitting Unit NPDES Complex Permitting Unit Roxboro Electric Steam Plant Inspection 2012 1. Permit: Your permit became effective May 1, 2007 and expired March 31, 2012. However the facility should continue to operate under the expired permit until the new permit is issued. The facility is not currently under a Special Order by Consent. The permittee is reminded to read, understand and comply with all of the terms and conditions contained in the permit. If you have questions concerning your responsibilities, call the Raleigh Regional Office to speak to a Division of Water Quality Surface Water staff member. The facihty currently has no stormwater requirements in the current permit, nor does the facility have a separate individual stormwater permit Steam Electric Power Plants with process stormwater are required to obtain stormwater coveraZe as applicable The application for renewal of the permit was received in September 2011 and includes the addition of stormwater outfall(s). 2. Compliance Schedules: The permit does not have any outstanding compliance schedules for this facility. 3. Facility Site Review: The overall condition of the plant site was satisfactory. The appearance of the facility was in acceptable condition indicating that the current housekeeping practices are very good. 4. Self -Monitoring Program: You are reminded that your monitoring samples must be collected, preserved, and analyzed by appropriate procedures and methods. You should maintain records of the sampler temperature, and a certified laboratory must calibrate the sample thermometers annually. Your operator is reminded that he/she must keep a logbook of all operation/maintenance activities undertaken at the facility. The logbook should include all daily process control activities including any field measurements conducted for process control. A visitation log for the facility must also be maintained. The facility is currently in compliance with these requirements 5 Records/Reports: a) A review of the daily monitoring data submitted during the previous 12 -month period and a review of the permit conditions indicates the facility was in compliance with the permit requirements and/or limitations. Roxboro Electric Steam Plant Inspection 2012 The facility was issued no penalty assessments and no notices of violation for the 12 -month period from September 2011 to September 2012 b) The facility must designate a certified Operator -in -Responsible -Charge (ORC) having a certification level equal to or greater than the facility classification. A Back-up ORC must also be designated with a minimum certification level at least one level less than the facility classification. The ,facility is currently in compliance with these requirements This facility is classified as a Physical Chemical I and the Operator in Responsible Charge (ORC) is Amber Ramey, she meets the Grade H Biological and Physical Chemical I certification requirements Several back-up ORC's are available at the plant that hold a Grade II Biological and Physical Chemical I The ORC and the operators of this facility do an excellent job The facility is current) in n compliance with these requirements 6 Laboratory: For all analytical data submitted for compliance monitoring purposes, a certified laboratory must be utilized for all laboratory analysis. Additionally, if field parameter testing is conducted, an operator certified to perform the specified field parameter analysis is also required. The operator needs to be sure to calibrate all meters/instrumentation before each use and retain all calibration records. The facility is currently in compliance with these requirements and utilizes the Roxboro Plant field lab parameter certification # 5080 The facility has used ENCO Laboratory, Inc and Pace Analytical Labs both labs meet the NC certified commercial laboratory requirement 7 Flow Measurement: If the permit requires a flow measurement device for determining the effluent flow, the flow measurement device must be calibrated annually This facility is required to monitor and report influent flow continuously (by pump logs at plant intake) for the "final outfall 003 " (referred to in the permit as heated water discharge) and the facility is in compliance with this requirement It was explained that intake water meter calibrations are done annually as required 8 Solids Handling/Disposal- The andlin /g Disposal• The facility must dispose of solids by an acceptable method such as a landfill or utilize the services of an approved solids hauling and disposal contractor, which requires the facility to be included under the contractor's non -discharge permit (i.e. Roxboro Electric Steam Plant Inspection 2012 land application). The facility is reminded to maintain adequate records (i e. shipment dates, quantities, etc.) of any solids hauling and/or disposal activities. The facility utilizes the Roxboro Steam Electric Plant Industrial Waste Landfill permitted by NC Division of Waste Management, SWP9 73-02 9. Compliance Sampling: Compliance sampling was not conducted during this inspection. 10. Operations & Maintenance: The followiniz items were noted duringtspection, please forward a response a Please provide an update on status of repairs and permit monitoring at Outfall 002 upon the completion of the maintenance at Outfall 002. b. The facility is in compliance with permit operations and maintenance requirements as of the date of this inspection Compliance Status: ® Compliant Name and Signature of Inspector: Autu Romanski Surface Water Protection Section Raleigh Regional Office ❑ Non-compliant ❑ Neither _15ate United States Environmental Protection Agency Form Approved EPA Washington, D C 20460 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 Type Inspector Fac Type 1 I N 2 I G I 31 NC0003425 111 121 12/11/13 117 18 C 19I C I 201 L! U J L! Remarks 2111111111 11111111 1111 1111 11111111 1111111111111116 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA -------------------------Reserved---------------------- 671 1 69 70U 71 I I 72 UN 73 LJJ 74 751 1 1 1 1 1 1 1 80 t_! Section B: Facility Data 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) Roxboro Steam Electric Power Plant 09 00 AM 12/11/13 09/07/01 Exit Time/Date Permit Expiration Date Person County Rd 1377 Roxboro NC 27573 12 00 PM 12/11/13 12/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data /// Amber Michelle Ramey/ORC/336-597-6139/ Name, Address of Responsible Official/Title/Phone and Fax Number Mike Mosley,1700 Dunnaway Rd Semora NC 27343/// ContactedNo Section C Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenance Records/Reports Self -Monitoring Program Sludge Handling Disposal Facility Site Review Compliance Schedules 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 Autumn H Romanski /� G�C�C.^ RRO WQ//919-791-4247/ e! I5ignat re of Manage ent Q R rgency/O ice/Phone and Fax Numbers em�- � Date ` V V."- — / - - — L/ EPA Form 350-3 (Rev 9-94) Previous editions are obsolete Page # 1 , NPDES yr/mo/day Inspection Type (cont ) 1 3INC0003425 __j 11 12I 12/11/13 17 18I ' Section D Summary of Finding/Comments (Attach additional) sheets of narrative and checklists as necessary) The facility was compliant with the permit requirements the day of the Inspection. Inspection items completed, not covered In the standard BIMs checklist: 1) Follow up on Outfall 002 repairs and discuss schedule/detail of proposed repairs - The flow at Outfall 002 will be pumped around to allow for the repairs. The facility reported that the flow and monitoring at Outfall 002 will be Interrupted as a result of the repair work due to logistical and safety concerns The interruption in monitoring will occur coincident to maintenance and therefore would not be considered a monitoring violation during maintenance duration end of November -December 2012. Also, Outfall 002 Is an Internal outfall, permit monitoring for the NPDES Final Outfall 003 will continue as normal.The repairs are expected to be completed by December 31, 2012. 2) Follow up on bioreactor operations & maintenance/bioreactor performance/emergency plan - Discussed the Bioreactor Condition of the permit The facility reported having an operation and maintenance plan (tied closely with General Electric Service/Manufacturers recommendations. Monitoring Included: pH, ORP, COD and Molasses feed. An emergency response plan in event of an upset Is required to be maintained and available for inspection. 3)Follow up on chemical trails: Coal trials/bioreactor performance and gypsum effects/KleeNScrub- The trial dealing with re -emission has not yet taken place No notable changes to wastewater or gypsum byproduct were reported as a result of the chemical trials to date. 4) Reviewed the Intake screen backwash. There Is no monitoring required at this location by the current permit. This backwash appears to be mechanical, so you would expect the discharge water quality to be consistent with the intake lake water Page # 2 Permit: NC0003425 Inspection Date: 11/13/2012 Permit Owner - Facility. Roxboro Steam Electric Power Plant Inspection Type: Compliance Evaluation (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. DWQ received permittee's permit renewal application on September 28, 2011 as required and the RRO has forwarded a Staff Report for permit renewal dated May 23, 2012. The permit expired March 31, 2012 and has not yet been re- issued. This inspection was conducted based on compliance with the expired permit. The facility currently has no stormwater requirements in this permit, nor does the facility have a separate Individual Stormwater Permit. The facility did include stormwater outfalls in the September 2011 Permit Application. The facility also has stormwater outfalls from impervious surfaces/parking areas that drain to the Heated Water Discharge Canal. Compliance Schedules Is there a compliance schedule for this facility? Yes No NA NE Yes No NA NE 0000 Is the facility compliant with the permit and conditions for the review period? ❑ ❑ ■ ❑ Comment. Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? N ❑ ❑ ❑ Does the facility analyze process control parameters, for ex MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ ❑ ❑ ❑ Judge, and other that are applicable? Page # 3 Permit: NC0003425 Owner - Facility: Roxboro Steam Electric Power Plant Inspection Date: 11/13/2012 Inspection Type: Compliance Evaluation Operations & Maintenance Comment: Discussed the repair schedule and repair details for Outfall 002. The flow at Outfall 002 will be pumped around to allow for the repairs. The facility reported that the flow and monitoring at Outfall 002 will be Interrupted during the time period of the repairs. Outfall 002 is an Internal outfall, permit monitoring for the NPDES Final Outfall will continue as normal. Discussed the Operations and Maintenance of the Bioreactor/Bioreactor Condition of the permit. The facility reported having an operation and maintenance plan (tied closely with General Electric Service/manufacturers recommendations). An emergency repsonse plan in event of an upset is required to be maintained and available for inspection. 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 CDCs Are DMRs complete do they include all permit parame_ers? 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 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? 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 Page # 4 Permit: NC0003425 Inspection Date: 11/13/2012 Owner - Facility. Roxboro Steam Electric Power Plant Inspection Type: Compliance Evaluation Record Keeping Comment: The facility was in compliance with record keeping requirements and does an excellent job with required DMR records and Monitoring Data documentation. 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: All NPDES wastewater outfalls at this facility have been inspected annually by RRO and there were no changes to note the day of this inspection. Field inspection time (during a rainy day) was spent to view stormwater outfalls to determine applicability for inclusion in the new permit, to confirm outfall locations, and to review the stormwater information provided in the permit renewal application The drainage maps and labeling of the storm drainage system was observed. Discussed plans in event of spills to the stormwater drainage system and observed outfalls to the heated water discharge canal. Yes No NA NE Yes No NA NE OOOM ❑❑❑■ ❑❑■❑ Page # 5