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HomeMy WebLinkAboutNC0004979_Inspection_20190404ROY COOPER Governor MICHAEL S. PEGAN Secretary LINDA CULPEPPER Director e-0* STAOT — Vz cm N0RTH CAROLINA £rtk+r mmenfaf Qrso8ty April 9, 2019 Mr. Paul Draovitch, Senior Vice President Environmental, Health and Safety Duke Energy Carolinas. LLC Mail Code EC13K P.O. Box 1006 Charlotte, NC 28201 Subject: Compliance Evaluation Inspection Duke Energy Allen Steam Station NPDES Permit No. NC0004979 Gaston County Dear Mr. Draovitch: Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on March 26, 2019, and April 4, 2019, by Ori Tuvia and Joanna Harbison. Michael Gantt'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 ori.tuvia@ncdenr.gov. Cc: NPDES Unit, MRO files (Laserfiche) Michael Gantt (E-copy) Sincerely, DocuSigned by: A14CC681 AF27425... W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources QEQ.3 lww State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations Mooresville Regional Office 1 610 East Center Avenue, Suite 3011 Mooresville, North Carolina 28115 704 663 1699 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 I 2 15 I 3 I NC0004979 111 12 I 19/04/04 I17 18 I S I 19 I G I 201 I 211111 1 1 I I I I II I I I I I I I I I I I I 1 I I I I I I I I I I II I I I I I f6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 2.0 70 71 [.. I 72 73 L_LJ74 751 I I I I I I I80 u u 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 oermit Number) 10:OOAM 19/04/04 18/08/01 Plant Allen Steam Station 253 Plant Allen Rd Exit Time/Date Permit Expiration Date Belmont NC 28012 04:OOPM 19/04/04 23/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Michael R Gantt/ORC/704-829-2587/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Allen Stowe,526 S Chruch St Charlotte NC 282011002//704-382-4309/7043829840 No 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 DocuSigned by: Ori A Tuvia MRO WQ//704-663-1699/ 4/10/2019 Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger Division of Water Quality//704-2; EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. DocuSigned by: 4/10/2019 AtaccsatAFvazs... Page# NPDES yr/mo/day Inspection Type (Cont.) NC0004979 I11 121 19/04/04 117 18 JCJ Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) New permit was issued since the past inspection (March 22, 2018). The new permit has the following new areas: In anticipation of decreased use, Outfall 002 (the ash pond) has two (2) separate effluent limitations pages; one under normal/decanting stage and one for dewatering. New outfall 006 — the new outfall will receive all the effluent from the active coal pond, the coal pile coal yard sump, powerhouse sumps, WFGD, and WWT effluent. The discharge prior to reaching the effluent pipe will pass through a splitter box that could divert flow to either/both primary basins, each with 1.5 MGAL capacity. The effluent from both primary retention basins will than combine in a secondary retention basin with a 12.3 Mgal capacity, and finally an effluent retention structure (where final pH adjustments can be made). New Outfall 007 — New outfall is the emergency spillway of the new retention basin (listed under outfall 006) Four new toe drain discharges — 103, 104, 108 and 108 B. Page# Permit: NC0004979 Owner -Facility: Plant Allen Steam Station Inspection Date: 04/04/2019 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? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ 0 ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: The subject permit will expire on 7/31/2023. See Summary 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)? 0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ 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 DMRs complete: do they include all permit parameters? ❑ ❑ ❑ 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? ❑ ❑ 0 ❑ Comment: DMRs, Chain of custody's (COC), ORC logs, and Calibration lops were reviewed for the period of January 2019 through Feburary 2019. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ Page# 3 Permit: NC0004979 Owner -Facility: Plant Allen Steam Station Inspection Date: 04/04/2019 Inspection Type: Compliance Evaluation Laboratory Yes No NA NE Are all other parameters(excluding field parameters) performed by a certified lab? 0 ❑ ❑ ❑ # Is the facility using a contract lab? 0 ❑ ❑ ❑ # 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: The facility is certified to perform on -site field analyses (pH and temperature) under laboratory certification #5134. The remaining permit -required effluent analyses are performed by Duke Energy's Environmental Services Laboratory (Certification #248) and the contracted services of Prism Labs (low level mercury, Shealy Labs, Pace Labs, and ETS, Inc. (toxicity) Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ ❑ 0 ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? ❑ ❑ 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 ❑ ❑ ❑ representative)? Comment: The subject permit requires effluent grab samples. 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 was not generating electricity at the time of the inspection. The FGD WWTS is connected to a computer monitoring system to assist the on -site staff in the operation of the treatment units/processes. Equalization Basins Yes No NA NE Is the basin aerated? ❑ ❑ 0 ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the basin free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Page# 4 Permit: NC0004979 Owner -Facility: Plant Allen Steam Station Inspection Date: 04/04/2019 Inspection Type: Compliance Evaluation Equalization Basins Yes No NA NE Are float controls operable? 0 ❑ ❑ ❑ Are audible and visual alarms operable? ❑ ❑ 0 ❑ # Is basin size/volume adequate? 0 ❑ ❑ ❑ Comment: Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? 0 ❑ ❑ ❑ Comment: Static mixers are used. 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? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: The FGD WWTS effluent is measured by an in -line flow meter. Page# 5 Permit: NC0004979 Owner -Facility: Inspection Date: 04/04/2019 Inspection Type: Plant Allen Steam Station Compliance Evaluation Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? ❑ ❑ 0 ❑ Is flow meter calibrated annually? ❑ ❑ 0 ❑ Is the flow meter operational? ❑ ❑ 0 ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: Flow measurements for Outfalls 001, 003, and 004 are based on pump curves/lops. Outfall 002 and 006 discharaes are measured by a staff auaae/ultrasonic level indicator and weir. Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Is the site free of sludge buildup on belts and/or rollers of filter press? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ■ ❑ ❑ ❑ Comment: The FGD WWTS is equipped with three operational filter presses.The gypsum material from the FGD system is stored. 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? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: The effluents from the Outfalls appered clear with no floatable solids or foam. Page# 6