NC0026042_Inspection_20220304

United States Environmental Protection Agency
E PA Washington, D.C. 20460
Water Compliance Inspection Report
Form Approved.
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
1 IN I 2 IL I 3 I NC0026042 111 121 22/02/08 117
Type
181 R I
I I I I I
Inspector Fac Type
191 S I 201 I
211 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 1 I P6
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved
671 I 7° I3 I 711D 1 72 I N I 731 I 74 71
I I
1 1 1 1 1 1 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Robersonville WWTP
1149 Rogerson Rd
Robersonville NC 27871
Entry Time/Date
08:OOAM 22/02/08
Permit Effective Date
17/05/01
Exit Time/Date
10:30AM 22/02/08
Permit Expiration Date
21/11/30
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
James Earl Pittman/ORC/252-235-4900/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Elizabeth Jenkins,PO Box 487 Robersonville NC 278710487//252-508-0311/
No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenar Records/Reports
Self -Monitoring Progran Sludge Handling DispoFacility Site Review Effluent/Receiving Wate
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
Robert E Bullock DWR/WARO WQ/252-948-3843/ 3/4/2022
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page# 1

3I
NPDES yr/mo/day
NC0026042 111 121 22/02/08
I17
Inspection Type
18 LB]
(Cont.)
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
The review period for this inspection was September 2018 through December 2021.Two Notice of
Deficiencies, Four Notice of Violations and Two Civil Penalty assessments were issued over the
review period.
A split toxicity sample was taken on February 8th and February 10th. The split samples were sent to
Meritech and Aquatic Toxicity lab in Raleigh for analysis.. Both of these sample results were pass.
The annual report provided during the inspection was not accurate. The annual report did not list all
the months that the facility was Non -Compliant. The annual report listed months that the facility was
Compliant when the facility was actually Non -Compliant with the NPDES permit.
The current permit was set to expire on November 30, 2021. A renewal application has been
submitted and the existing permit will remain effective until a new permit is issued.
Grease in the wastewater is mixing with the grit which is causing the grit to bond together. The ORC
stated that they have to keep breaking up the grit to help remove it from the system.
The "equalization basin" is a anerobic and anoxic zone. On the day of inspection the mixers were off
and there was an excessive amount of solids and vegetation on the top of the basin. The ORC stated
that the mixers were off because with all the solids and vegetation the mixers will plug. With the mixers
not running the basin is acting as a settling basin and this is not the intent of this basin. The ORC
stated that the basin will be cleaned out in March 2022
The digester is almost full. The ORC stated that the sludge will be land applied in March 2022.
On the day of inspection the #5 Clarifier and #6 Clarifiers needed repairs. The #5 Clarifier arm was
not working and the clarifier was online. ORC stated that a shear pin had broken and they are
working to have this repaired. The #6 Clarifier was down and was not operational. James stated that
the gear box for the clarifier arm was damaged and that the gear box had to be rebuilt. The estimate
for replacing the gear box was approximately $70,000 and they are going to bring this to the Town
Council for approval.
The facility is judged to be Non -Complaint with NPDES permit NC0026042.
Page# 2

Permit: NC0026042
Inspection Date: 02/08/2022
Owner - Facility: Robersonville WWTP
Inspection Type: Bioassay Compliance
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? • ❑ ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable II ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment:
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 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?
Yes No NA NE
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Comment: The annual report provided during the inspection was not accurate. The annual report
did not list all the months that the facility was Non -Compliant. The annual report listed
months that the facility was Compliant when the facility was actually Non -Compliant with
the NPDES permit.
James Pittman is the ORC with Tony Lucas and Phillip Bone as the backup ORC.
Permit Yes No NA NE
Page# 3

Permit: NC0026042
Inspection Date: 02/08/2022
Owner - Facility: Robersonville WWTP
Inspection Type: Bioassay Compliance
Permit
(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?
Yes No NA NE
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Comment: The current permit was set to expire on November 30, 2021. A renewal applic
been submitted and the current permit will remain effective until a new permit
Laboratory
Are field parameters performed by certified personnel or laboratory?
Are all other parameters(excluding field parameters) performed by a certified lab?
# Is the facility using a contract lab?
# 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?
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
ation has
is issued.
Yes No NA NE
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Comment: Envirolink is field parameter certified with all other samples sent to a contract lab
Bar Screens
Type of bar screen
a.Manual
b.Mechanical
Are the bars adequately screening debris?
Is the screen free of excessive debris?
Is disposal of screening in compliance?
Is the unit in good condition?
Comment: Grit is disposed of in the landfill
Pump Station - Influent
Is the pump wet well free of bypass lines or structures?
Is the wet well free of excessive grease?
Are all pumps present?
Are all pumps operable?
Yes No NA NE
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Yes No NA NE
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Page# 4

Permit: NC0026042
Inspection Date: 02/08/2022
Owner - Facility: Robersonville WWTP
Inspection Type: Bioassay Compliance
Pump Station - Influent
Are float controls operable?
Is SCADA telemetry available and operational?
Is audible and visual alarm available and operational?
Comment: On the day of inspection a small amount of grease was in the lift station.
Grit Removal
Type of grit removal
a.Manual
b.Mechanical
Is the grit free of excessive organic matter?
Is the grit free of excessive odor?
# Is disposal of grit in compliance?
Yes No NA NE
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Yes No NA NE
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Comment: Grease in the wastewater is mixing with the grit which is causing the grit to bond
together. The ORC stated that they have to keep breaking up grit on the bottom to
help remove it from the system.
Influent Sampling
# Is composite sampling flow proportional?
Is sample collected above side streams?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0
degrees Celsius)?
Is sampling performed according to the permit?
Yes No NA NE
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Comment: Influent sampler is on constant time and constant volume with a sample taken every 8
minutes. The sampler temperature was 4 degrees on the day of inspection.
Equalization Basins
Is the basin aerated?
Is the basin free of bypass lines or structures to the natural environment?
Is the basin free of excessive grease?
Are all pumps present?
Are all pumps operable?
Are float controls operable?
Are audible and visual alarms operable?
Yes No NA NE
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Page# 5

Permit: NC0026042
Inspection Date: 02/08/2022
Owner - Facility: Robersonville WWTP
Inspection Type: Bioassay Compliance
Equalization Basins Yes No NA NE
# Is basin size/volume adequate?
• ❑ ❑ ❑
Comment: The "equalization basin" is a anerobic and anoxic zone. On the day of inspection the
mixers were off and there was an excessive amount of solids and vegetation on the top
of the basin. The ORC stated that the mixers were off because with all the solids and
vegetation the mixers will plug. With the mixers not running the basin is acting as a
settling basin and this is not the intent of this basin. The ORC stated that the basin will
be cleaned out in March 2022
Oxidation Ditches
Are the aerators operational?
Are the aerators free of excessive solids build up?
# Is the foam the proper color for the treatment process?
Does the foam cover less than 25% of the basin's surface?
Is the DO level acceptable?
Are settleometer results acceptable (> 30 minutes)?
Is the DO level acceptable?(1.0 to 3.0 mg/I)
Are settelometer results acceptable?(400 to 800 ml/I in 30 minutes)
Comment:
Pumps-RAS-WAS
Are pumps in place?
Are pumps operational?
Are there adequate spare parts and supplies on site?
Comment:
Aerobic Digester
Is the capacity adequate?
Is the mixing adequate?
Is the site free of excessive foaming in the tank?
# Is the odor acceptable?
# Is tankage available for properly waste sludge?
Yes No NA NE
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Yes No NA NE
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Yes No NA NE
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Comment: On the day of inspection the digester was almost full. The ORC stated that the sludge
will be land applied in March 2022.
Secondary Clarifier Yes No NA NE
Page# 6

Permit: NC0026042
Inspection Date: 02/08/2022
Owner - Facility: Robersonville WWTP
Inspection Type: Bioassay Compliance
Secondary Clarifier
Is the clarifier free of black and odorous wastewater?
Is the site free of excessive buildup of solids in center well of circular clarifier?
Are weirs level?
Is the site free of weir blockage?
Is the site free of evidence of short-circuiting?
Is scum removal adequate?
Is the site free of excessive floating sludge?
Is the drive unit operational?
Is the return rate acceptable (low turbulence)?
Is the overflow clear of excessive solids/pin floc?
Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth)
Yes No NA NE
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Comment: On the day of inspection the #5 Clarifier and #6 Clarifiers needed repairs. The #5
Clarifier arm was not working and the clarifier was online. ORC stated that a shear pin
had broken and they are working to have this repaired. The #6 Clarifier was down and
was not operational. James stated that the gear box for the clarifier arm was damaged
and that the gear box had to be rebuilt. The estimate for replacing the gear box was
approximately $70,000 and they are going to bring this to the Town Council for
approval.
Filtration (High Rate Tertiary)
Type of operation:
Is the filter media present?
Is the filter surface free of clogging?
Is the filter free of growth?
Is the air scour operational?
Is the scouring acceptable?
Is the clear well free of excessive solids and filter media?
Comment: The facility uses a Disc Filter for Tertiary treatment
Yes No NA NE
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▪ El El El
Chemical Feed Yes No NA NE
Is containment adequate? • ❑ ❑ El
Is storage adequate? ■ El El El
Are backup pumps available? ■ El ❑ ❑
Is the site free of excessive leaking? • El El El
Comment:
Page# 7

Permit: NC0026042
Inspection Date: 02/08/2022
Owner - Facility: Robersonville WWTP
Inspection Type: Bioassay Compliance
Disinfection -Gas
Are cylinders secured adequately?
Are cylinders protected from direct sunlight?
Is there adequate reserve supply of disinfectant?
Is the level of chlorine residual acceptable?
Is the contact chamber free of growth, or sludge buildup?
Is there chlorine residual prior to de -chlorination?
Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No.
7782-50-5)?
If yes, then is there a Risk Management Plan on site?
If yes, then what is the EPA twelve digit ID Number? (1000- - )
If yes, then when was the RMP last updated?
Comment:
De -chlorination
Type of system ?
Is the feed ratio proportional to chlorine amount (1 to 1)?
Is storage appropriate for cylinders?
# Is de -chlorination substance stored away from chlorine containers?
Are the tablets the proper size and type?
Comment: Sodium Sulfite is used for dechlor
Are tablet de -chlorinators operational?
Number of tubes in use?
Comment:
Flow Measurement - Effluent
# Is flow meter used for reporting?
Is flow meter calibrated annually?
Is the flow meter operational?
(If units are separated) Does the chart recorder match the flow meter?
Yes No NA NE
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Yes No NA NE
Liquid
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Yes No NA NE
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▪ El El El
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Comment: Effluent flow meter was calibrated on March 9, 2021 by Carolina Technical Services
Effluent Sampling
Is composite sampling flow proportional?
Yes No NA NE
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Page# 8

Permit: NC0026042
Inspection Date: 02/08/2022
Owner - Facility: Robersonville WWTP
Inspection Type: Bioassay Compliance
Effluent Sampling Yes No NA NE
Is sample collected below all treatment units? • ❑ ❑ ❑
Is proper volume collected? ■ ❑ ❑ ❑
Is the tubing clean? • ❑ ❑ ❑
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 • ❑ ❑ ❑
degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type • ❑ ❑ ❑
representative)?
Comment: Effluent sampler is on constant time and constant volume with a sample taken every 7
minutes. The sampler temperature on the day of inspection was 3 degrees.
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:
Upstream / Downstream Sampling
Is the facility sampling performed as required by the permit (frequency, sampling type,
and sampling location)?
Comment:
Yes No NA NE
▪ El 1=1 El
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Yes No NA NE
Page# 9