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Home My WebLink AboutNC0069311_Compliance Evaluation Inspection_20230515ROY COOPER Governor ELIZABETH S. BISER Secrefory RICHARD E. ROGERS, JR. Vireclur NORTH CAROLINA Environmental Quality May 15, 2023 Christopher Doherty, Director of Public Utilities Franklin County 1630 US Highway 1 Youngsville, NC 27596 Subject: Compliance Evaluation Inspection Franklin County WWTP NPDES Permit Number NCO069311 Franklin County Dear Mr. Doherty: On May 4, 2023, Mitch Hayes of the Raleigh Regional Office conducted the subject inspection with the assistance of Paul Langfield, Operator in Responsible Charge. Below is a list of findings developed from the inspection and review of the permit. 1. The subject permit was reissued March 31, 2021, became effective May 1, 2021, and will expire September 30, 2025. 2. The 3.0 MGD facility consists of the following units: mechanical bar screen; influent pump station; vortex grit removal system; influent splitter box; dual 1.5 MGD each aeration / anaerobic / anoxic basins; dual 70 feet wide , 14 foot deep secondary clarifiers; 16 disk cloth tertiary filters with continuous back wash; dual 2 feet wide by 4 foot long UV disinfection train; 12" Parshall flume with post aeration; one each 1700 gpm re -use pump station; one each 500,000 gallons aerobic digester; one each 129 gallon sludge thickener; one each 75,000 gallon sludge holding basin; 8 sludge drying beds; and one 550 KW on site generator for backup power. 3. At the time of inspection, one aeration / anaerobic / anoxic zone was being operated due to low inflow. The number 1 secondary clarifier was not in service due to broken gears. The color in the aeration zone was medium chocolate brown. All diffusers appeared to be operating. Foam covered less than 10% of the surface aera. Sludge blanket in the number 2 clarifier measured I 1 feet with a side wall depth of 14 feet. Mr. Langfield stated they will waste more in order to bring down the solids content. The digester was approximately three-quarters full. Activated sludge is digested for approximately sixty days and then gravity thickened, and land applied under contract with Granville Farms Inc. permit number WQ0000838. Effluent flowing off the weirs appeared clear with no blockage. Effluent in the clear well appeared clear with no solids. Effluent was mixing well with Cedar Creek with no negative impacts. North Carolina Departmenl of Enciromncitial Quality I Division of Water Resourecs Raleigh Regional Office 1 901) Barrett Drive I Raleigh North Carolina 27609 919191.4200 4. Discharge monitoring reports for the period March 2021 through March 2023 were reviewed for compliance with permit limits and monitoring requirements. Notice of Violation was issued for the following: weekly and monthly permit limit violation for total ammonia nitrogen for 02.2022. Frequency violations for the following: TSS for 04.03.2021; total ammonia nitrogen for 05.22.202 l ; total hardness for 09.30.2021; BOD for 05.22.2021; total cadmium for 05.31.2022; total copper for 05.31.2022; total nitrite plus nitrate for 12.03.2022; and TKN for 12.03.2022. 5. Commercial lab results, chain of custody records, and bench sheets were compared with data submitted on the discharge monitoring report for March 2023. No discrepancies were noted. Franklin County Laboratory, certified laboratory number 350, analyses the following: pH, DO, conductivity, fecal coliform, and TSS. Meritech Labs analyses all other parameters. 1 would like to thank Paul Langfeld for his time and cooperation with this inspection. If you have any questions about this letter or the inspection, please contact Mitch Hayes at 919.791.4261 or at mitch.hayes cr,deq.nc.0 . Sincerely, Vanessa E. Manuel, Assistant Regional Supervisor Raleigh Regional Office Water Quality Regional Operations Section NC- DEQ Laserfiche s North Carolina Deparanem of linviroumcnial Qualily I Division of Water Resources ® EIQ /) � 512 North Salisbury Street 1 1611 Mail Senice Center I Raleigh. North Carolina 27699-161 1 919.747.90M United States Environmental Protection Agency Form Approved. EPA Washington, D.C. 20460 OMB No. 2040-0057 Water Compliance Inspection Report Approval expires B-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yrlmolday Inspection Type inspector Fac Type 1 1ti l 2 15 1 3 1 NCO069311 111 121 23/05/04 117 181 r- I 19 I c I 201 I 211 1 1 1 1 1 1 1 1 1 11 1 1 1 1 1 1..,1 1 1 1 1 1 1.1.,1 1. 1 1 1 1 1 1 1 11 1 1 1 r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ------Reserved------ 1 71 I I 72 I ti I 73 � 74 71_ 1 1 1 I 1 1 J80 67 70 [z J u LLJ Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include Entry Time/Date Permit Effective Dale POTW name and NPDES Dermit Number) 10:OOAM 23/05/04 21/05/01 Franklin County WWTP 1099 Lane Store Rd Exit Time/Date Permit Expiration Date Franklinton NC 27525 11:45AM 23/05/04 25/09/30 Name(s) of Onsite Representative(s)ITitles(s)/Phone and Fax Number(s) Other Facility Data 111 Mark Lynn Prowell/ORC/919494-58501 Paul David Langfield/1919-239-00101 Paul David LangfieldlORC1919-239-00101 Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Bill Harvey,PO Box 685 Franklinton NC 27525068511919494-541519194942225 Q Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit E Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran E Sludge Handling Dispo: Facility Site Review EffluentlReceiving 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/OfficelPhone and Fax Numbers Dale Mitchell S Hayes DWRIRRO WOl919-79142001 1 ✓ 1 Signat re of Management Q A Reviewer AgencylOfficelPhone and Fax Numbers Date u — ft7-1Q1-,[2.T2 W4-71 rS, 2a7.3 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yrlmolday Inspection Type (Cont.) 31 NCO069311 I11 1 23/05/04 17 18 I C I Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) The subject permit was reissued March 31, 2021, became effective May 1, 2021, and will expire September 30, 2025. The 3.0 MGD facility consists of the following units: mechanical bar screen; influent pump station; vortex grit removal system; influent splitter box; dual 1.5 MGD each aeration 1 anaerobic / anoxic basins; dual 70 feet wide , 14 foot deep secondary clarifiers; 16 disk cloth tertiary filters with continuous back wash; dual 2 feet wide by 4 foot long UV disinfection train; 12" Parshall flume with post aeration; one each 1700 gpm re -use pump station; one each 500,000 gallons aerobic digester; one each 129 gallon sludge thickener; one each 75,000gallon sludge holding basin; 8 sludge drying beds; and one 550 KW on site generator for backup power. At the time of inspection, one aeration 1 anaerobic 1 anoxic zone was being operated due to low inflow. The number 1 secondary clarifier was not in service due to broken gears. The color in the aeration zone was medium chocolate brown. All diffusers appeared to be operating. Foam covered less than 10% of the surface sera. Sludge blanket in the number 2 clarifier measured 11 feet with a side wall depth of 14 feet. Mr. Langfield stated they will waste more in order to bring down the solids content. The digester was approximately three-quarters full. Activated sludge is digested for approximately sixty days and then gravity thickened, and land applied under contract with Granville Farms Inc. permit number WO0000838. Effluent flowing off the weirs appeared clear with no blockage. Effluent in the clear well appeared clear with no solids. Effluent was mixing well with Cedar Creek with no negative impacts. Discharge monitoring reports for the period March 2021 through March 2023 were reviewed for compliance with permit limits and monitoring requirements. Notice of Violation was issued for the following: weekly and monthly permit limit violation for total ammonia nitrogen for 02.2022. Frequency violations for the following: TSS for 04.03.2021; total ammonia nitrogen for 05.22.2021; total hardness for 09.30.2021; BOD for 05.22.2021; total cadmium for 05.31.2022; total copper for 05.31.2022; total nitrite plus nitrate for 12.03.2022; and TKN for 12.03.2022. Commercial lab results, chain of custody records, and bench sheets were compared with data submitted on the discharge monitoring report for March 2023. No discrepancies were noted. Franklin County Laboratory, certified laboratory number 350, analyses the following: pH, DO, conductivity, fecal coliform, and TSS. Meritech Labs analyses all other parameters. Page# Permit: NCO069311 Owner - Facility: Franklin County WWTP Inspection Date: 05/04/2023 Inspection Type: Compliance Evaluation 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 0 ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ 00 application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # 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? No ❑ ❑ Comment: 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)? ■ ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? M ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility 0 ❑ ❑ ❑ classification? Page# 3 Permit: NC0069311 Owner - Facility: Franklin County WWTP Inspection Date: 05/04/2023 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Is a copy of the current NPDES permit available on site? 0 ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? 0000 Comment: Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? N ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? 0000 If effluent (diffuser pipes are required) are they operating properly? 0000 Comment: Effluent appeared clear with no solids and foam. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0000 Is flow meter calibrated annually? 01100 Is the flow meter operational? 0000 (If units are separated) Does the chart recorder match the flow meter? 0000 Comment: Effluent used for reporting. Aerobic Digester Yes No NA NE Is the capacity adequate? ■ ❑ ❑ ❑ Is the mixing adequate? M ❑ ❑ ❑ Is the site free of excessive foaming in the tank? 0 ❑ ❑ ❑ # Is the odor acceptable? ■ ❑ ❑ ❑ # Is tankage available for properly waste sludge? ■ ❑ ❑ ❑ Comment: Digester was approximately three- uarters full. Drying Beds Yes No NA NE Is there adequate drying bed space? M ❑ ❑ ❑ Is the sludge distribution on drying beds appropriate? M ❑ ❑ ❑ Are the drying beds free of vegetation? M ❑ ❑ ❑ # Is the site free of dry sludge remaining in beds? M ❑ ❑ ❑ Is the site free of stockpiled sludge? ■ ❑ ❑ ❑ Is the filtrate from sludge drying beds returned to the front of the plant? ■ ❑ ❑ ❑ # Is the sludge disposed of through county landfill? ❑ M ❑ ❑ Page# 4 Permit: NC0069311 Owner - Facility: Franklin County WWTP Inspection Date: 05/04/2023 Inspection Type: Compliance Evaluation Drying Beds Yes No NA NE # Is the sludge land applied? 0 Cl ❑ ❑ (Vacuum filters) Is polymer mixing adequate? 0000 Comment: Granville Farms Inc. hauls sludge for the facility. Solids Handling Equipment Yes No NA NE Is the equipment operational? 0 ❑ ❑ ❑ Is the chemical feed equipment operational? 0 ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ 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? ■ ❑ ❑ ❑ Comment: Sludge eguipemnt was not in use. Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? M ❑ ❑ ❑ Is the wet well free of excessive grease? ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? 0 ❑ ❑ ❑ Comment: 4 pumps. Bar Screens Yes No NA NE Type of bar screen a.Manual ❑ b.Mechanical Are the bars adequately screening debris? ■ ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? ■ ❑ ❑ ❑ Is the unit in good condition? ■ ❑ ❑ ❑ Comment: Page# 5 Permit: NC0069311 Owner -Facility: Frank -in County WWTP Inspection Date: 05/04/2023 Inspection Type: Compliance Evaluation Bar Screens Yes No NA NE Grit Removal Yes No NA NE Type of grit removal a.Manual Cl b.Mechanical ■ Is the grit free of excessive organic matter? N ❑ ❑ ❑ Is the grit free of excessive odor? ■ ❑ ❑ ❑ # Is disposal of grit in compliance? ■ ❑ ❑ ❑ Comment: 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? S ❑ ❑ ❑ Is the site free of weir blockage? ■ ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? N ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? N ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? N ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) ❑ 0 ❑ ❑ Comment: Clarifier # 1 was out of service due to broken gears. The number #2 clarifier SB was 11 feet with a SD of 16 feet. Mr. Langfield stated that he would waste more to bring the solids content down. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? No ❑ ❑ Are surface aerators and mixers operational? ■ ❑ ❑ ❑ Are the diffusers operational? N ❑ ❑ ❑ Is the foam the proper color for the treatment process? S ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? N ❑ ❑ ❑ Page# 6 Permit: NCO069311 Owner -Facility: Franklin County WWTP Inspection Date: 05/04/2023 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mgll) 0 ❑ ❑ ❑ Comment: Nutrient Removal Yes No NA NE # Is total nitrogen removal required? 0 ❑ ❑ ❑ # Is total phosphorous removal required? N ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? 00 ❑ ❑ Is nutrient removal process operating properly? 00 ❑ ❑ Comment: Microseed is on site but currently not being used for nitrogen removal. Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Cross flow Is the filter media present? moo ❑ Is the filter surface free of clogging? 0 ❑ ❑ ❑ Is the filter free of growth? ■ ❑ ❑ ❑ Is the air scour operational? ❑ ❑ ■ ❑ Is the scouring acceptable? ❑ ❑ M ❑ Is the clear well free of excessive solids and filter media? 0 ❑ ❑ ❑ Comment: Filters are Aqua Rabic disc filters. Disinfection - UV Yes No NA NE Are extra UV bulbs available on site? 0 ❑ ❑ ❑ Are UV bulbs clean? 0 ❑ ❑ ❑ Is UV intensity adequate? 0 ❑ ❑ ❑ Is transmittance at or above designed level? 0 ❑ ❑ ❑ Is there a backup system on site? 0 ❑ ❑ ❑ Is effluent clear and free of solids? N ❑ ❑ ❑ Comment: Standby Power Yes No NA NE Is automatically activated standby power available? ❑ ❑ ❑ Page# 7 Permit: NCO069311 Owner - Facility: Franklin County WWTP Inspection Date: 05/04/2023 Inspection Type: Compliance Evaluation Standby Power Yes No NA NE Is the generator tested by interrupting primary power source? ❑ ■ ❑ ❑ Is the generator tested under load? 0 ❑ ❑ ❑ Was generator tested & operational during the inspection? ❑ 0 ❑ ❑ Do the generator(s) have adequate capacity to operate the entire wastewater site? M ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up M ❑ ❑ ❑ power? Is the generator fuel level monitored? N ❑ ❑ ❑ Comment: Generator is operated under load once a month. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0000 Are all other parameters(excluding field parameters) performed by a certified lab? M ❑ ❑ ❑ # Is the facility using a contract lab? M ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 0 ❑ ❑ ❑ degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ■ ❑ ❑ ❑ Incubator (BOD) set to 20.0 degrees Celsius +1- 1.0 degrees? ❑ ❑ N ❑ Comment: Influent Sampling Yes No NA NE # Is composite sampling flow proportional? ❑ ■ ❑ ❑ Is sample collected above side streams? ■ ❑ ❑ ❑ Is proper volume collected? ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 0 ❑ ❑ ❑ degrees Celsius)? Is sampling performed according to the permit? M ❑ ❑ ❑ Comment: Influent is time based Effluent Sampling Yes No NA NE Is composite sampling flow proportional? M ❑ ❑ ❑ is sample collected below all treatment units? ■ ❑ ❑ ❑ Is proper volume collected? No ❑ ❑ Is the tubing clean? No ❑ ❑ Paget 8 Permit: NCO069311 Owner - Facility: Frankl n County WWTP Inspection Date: 05/04/2023 Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE # 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 0000 representative)? Comment: Upstream 1 Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, ■ ❑ ❑ ❑ and sampling location)? Comment: Environment 1 collects UID samples. Page# 9