NC0004979_Inspection_20190404

ROY COOPER
Governor
MICHAEL S. PEGAN
Secretary
LINDA CULPEPPER
Director
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N0RTH CAROLINA
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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 [phone], or at
[e-mail].
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
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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
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0
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application?
Is the facility as described in the permit?
0
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# Are there any special conditions for the permit?
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0
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Is access to the plant site restricted to the general public?
0
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Is the inspector granted access to all areas for inspection?
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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?
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Is all required information readily available, complete and current?
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Are all records maintained for 3 years (lab. reg. required 5 years)?
0
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Are analytical results consistent with data reported on DMRs?
0
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Is the chain -of -custody complete?
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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?
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Has the facility submitted its annual compliance report to users and DWQ?
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(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator
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on each shift?
Is the ORC visitation log available and current?
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Is the ORC certified at grade equal to or higher than the facility classification?
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Is the backup operator certified at one grade less or greater than the facility classification?
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Is a copy of the current NPDES permit available on site?
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Facility has copy of previous year's Annual Report on file for review?
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0
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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?
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0
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Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
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0
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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?
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0
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Is sample collected below all treatment units?
0
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Is proper volume collected?
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Is the tubing clean?
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0
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# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
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0
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Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
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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?
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0
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Is the basin free of bypass lines or structures to the natural environment?
0
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Is the basin free of excessive grease?
0
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Are all pumps present?
0
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Are all pumps operable?
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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
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Are audible and visual alarms operable?
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0
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# Is basin size/volume adequate?
0
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Comment:
Chemical Feed
Yes No NA NE
Is containment adequate?
0
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Is storage adequate?
0
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Are backup pumps available?
0
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Is the site free of excessive leaking?
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Comment: Static mixers are used.
Secondary Clarifier
Yes No NA NE
Is the clarifier free of black and odorous wastewater?
0
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Is the site free of excessive buildup of solids in center well of circular clarifier?
0
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Are weirs level?
0
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Is the site free of weir blockage?
0
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Is the site free of evidence of short-circuiting?
0
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Is scum removal adequate?
0
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Is the site free of excessive floating sludge?
0
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Is the drive unit operational?
0
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Is the return rate acceptable (low turbulence)?
0
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Is the overflow clear of excessive solids/pin floc?
0
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Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth)
0
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Comment:
Flow Measurement - Influent
Yes No NA NE
# Is flow meter used for reporting?
0
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Is flow meter calibrated annually?
0
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Is the flow meter operational?
0
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(If units are separated) Does the chart recorder match the flow meter?
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0
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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?
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0
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Is flow meter calibrated annually?
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0
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Is the flow meter operational?
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0
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(If units are separated) Does the chart recorder match the flow meter?
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0
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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
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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
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Are the receiving water free of foam other than trace amounts and other debris?
0
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If effluent (diffuser pipes are required) are they operating properly?
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Comment: The effluents from the Outfalls appered clear with no floatable solids or foam.
Page# 6