Name Of Industry:   	  Slugem Hosiery Mills, Inc. – Plant #2	   IUP #    0010	
Address Of Industry:   	100 Industry Drive				       IUP Expiration Date:
		      	Typicalville, NC  27666				       	12/31/2006	
Industry Representatives:						Title
	Billy-Bob Slugem						President		
	Josephine Spill							Maint. Sup.		
POTW Representatives:						Title
	Jane D. Wastewater						Dir. Public Works	
	Bob Operations							WWTP ORC		
Date Of Inspection:   	8/15/2006			   Time Of Inspection:   	10 am	  am/pm
Purpose of Inspection:  Annual   	X	   Other (Describe)   	IUP Renewal			
POTW to which IU discharges   	Town of Typicalville WWTP	NPDES #    	NC0012345	
Is SIU currently in SNC?   	No	   If yes, for what?   					

PART I - INITIAL INTERVIEW
Has anything changed since the last inspection or IUP application in the following:
						COMMENTS
Product				NO   	panty hose					
Raw materials used		YES   	new waste minimization work – substituting out some of our more toxic 						chemicals.  POTW was involved.
Manufacturing processes		NO   							
       Categorical, if applicable	NA 							
Production rate			YES   	may have increase in future, discussed IUP requirement for PRIOR notification	
Number of employees		NO   							
Number of shifts			NO   							

Comments:  Great job on waste minimization efforts, and especially letting us know details as you went along

PART II - PLANT TOUR - Visit all areas where wastewater is generated or where there are drains to the POTW.
Plant Tour Section A - PRODUCTION AND STORAGE AREAS

1.  Are there floor drains in the production area?    YES / NO    Where do they go?     To pretreatment.  Discussed potential for spills from chemicals stored in production area.									
2.  Are production areas diked, contained, or otherwise constructed in such a way as to prevent harm to the WWTP, especially from spills or slugs?    YES / NO   Comments:   	A few barrels don’t have required spill containment trays.  Update Emergency Plan to describe better storage of bagged chemicals so don’t get wet, and also do dry cleanup of powder type spills before wash down area.											
3.  Are there floor drains in the storage area?    YES / NO    Where do they go?   	  Spill containment pits.	
4.  Are storage tanks and areas diked, contained, or otherwise constructed in such a way as to prevent harm to the WWTP, especially from spills or slugs?    YES / NO    Comments:   	Spill containment pits are self-contained (have no outlets).  SIU’s Slug/Spill Plan outlines procedures how SIU will address removal and disposal of any spills				
5.  Are process and storage tanks and pipes labeled?    YES / NO 
6.  How are off-spec raw materials, and products disposed of?   	Off-spec or unused raw materials and process chemicals sent back to vendor.  Off-spec product is landfilled.								
7.  When is the production area cleaned?   Clean screens and wash down dye area at end of every shift.	Weekly cleaning of dry process areas.  Dry process area clean up does not produce any wastewater					
8.  Is the wastewater from cleaning the production area discharged to the POTW?    YES / NO 
9.  What non-process wastewaters are discharged to POTW?   		Boiler blowdown, cooling/HVAC blowdown, domestic, cafeteria – all are in sample point.						           

Comments:

PART II - Plant Tour Section B - PRETREATMENT SYSTEM
Ask the operator to describe pretreatment system.  Don’t have pretreatment per se.  Have screens in dyeing production area.  NOTE Comminuter and EQ aeration basin NOT in use								 
1.  Does operator seem knowledgable about the system?  YES  Comments: shift managers responsible for screen cleaning 	
2.  Are all units operational?    YES
3.  How often does operator/maintenance person check system?   	shift managers responsible for screen cleaning 	
4.  Is there an operator for each shift?    YES  shift managers responsible for screen cleaning
5.  How and when is sludge disposed of?   	Each shift.  Into regular trash.						
6.  Is there a schedule for preventative maintenance?    YES 	Shift managers inspect screens at each cleaning
Comments:

PART II - Plant Tour Section C - SAMPLING POINT(S) AND FLOW MEASUREMENT
(Collect a sample if desired.)
1.  Does an outside lab complete sampling?    YES    If yes, name of lab.   	ABC Labs			
2.  If industry completes sampling, ask the industry representative to describe sampling procedures.    Comments:   	             I reminded Billy-Bob that they are responsible for sample collection quality, etc. even though they have an outside lab collect the samples.  We all watched lab staff set up and collect samples last year, and reviewed their written procedures last year (after lab snafu).  Now Billy-Bob or Josephine are present when lab staff are on-site.			            
3.  Is flow measurement equipment operational?    YES     Comments:   Went over equipment cleaning question in application.  Called contractor to discuss - he faxed pages that recommend at least weekly visual observation of flume and equipment, with removal of debris, solids, algae, etc.  Since Josephine reads meter daily, she will add column on her flow sheet where she will record her visual observations, etc.							
4.  Is there a calibration log for the flow meter?    YES / NO    Comments:   	Josephine had to call the contractor to obtain a copy of the last calibration.  Told Billy-Bob that his new IUP will require him to submit the documentation with his regular monthly report.											            
Comments:

PART III - EXIT INTERVIEW
Review monitoring records and other SIU records required by IUP.
1.  Are files well organized?  YES / NO  Comments:   	Much improved from last year.  Thanks!	
2.  Are sample collection / chain-of-custody forms filled out properly?    YES / NO    Comments:    see sampling question	
3.  Do results in files agree with reports sent to POTW?  YES / NO  Comments:   					
4.  Who has authority to shut down production should a spill or slug discharge occur?   	Bob, Josephine, and all line and	 shift supervisors.  See Emergency Plan										
5.  How does SIU inform employees of whom to call at POTW in case of spill/slug?   	Notices posted all over factory.  Nextel numbers for Bob and Josephine.  Line and shift supervisors are readily available.  POTW numbers also listed, so any employee can call if others not available.										
If slug/spill plan is already required by POTW, review procedures.
6.  Is SIU implementing slug/spill plan?  YES / NO  Comments:   	Slugem’s slug and spill prevention measures to protect the POTW are incorporated into their overall plant Emergency Plan.  
Comments:

INSPECTION RESULTS
Slug/Spill Control Plan Needed?    Have one, but it needs updates to address potential for spills from chemicals stored in production area, storage of bagged chemicals, dry cleanup of powder type spills and employee training.
Comments, Required or Recommended Actions:   		submit updated plan by 10/15/2006			

Signature of Inspector(s)   		Jane Wastewater		  Date: 	8/15/06	
					Bob Operations			  Date: 	8/15/06