NC0024201_Historical information roanoke rapids 2013_20131231

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December 16, 2013
RE: November 2013 DMR for NC0024201
This is to notify you of situations that pertain to data reported on the enclosed DMR.
If you have any questions, please contact me at [phone].
Sincerely,
CC: Gregg Camp, ORC
Dan Brown, CEO
November 25, 26 - The CBOD Glucose/Glutamic Acid standard was outside of the acceptable range of
164+/- 30.7 mg/1.
Waste Water Treatment Plant
135 Aqueduct Rd. Weldon, NC 27890 [phone] Fax [phone]
Attn: Central Files
DENR/DWQ
1617 Mail Service Center
Raleigh, NC 27699-1617
Greta Glover
Laboratory Supervisor
wirrJfy
Waste Water Treatment Plant
135 Aqueduct Rd.Weldon, NC 27890 [phone] Fax [phone]
The Roanoke Rapids Sanitary District Wastewater Plant (WWTP) has a monthly Total Suspended
Solids (TSS) limit of 30 milligrams per liter (mg/l) and an 85 % removal requirement. The WWTP
was noncompliant for November 2013 with a 34.7 TSS and an 82.2 % removal.
The WWTP is experiencing bulking sludge. Microscopic examination reveals no filamentous
organisms. The sludge is finely dispersed and will not settle and therefore easily washes out
with effluent flow. Laboratory comparison of data from this year to last at the same time
shows nearly a 50% increase in food to microorganism (F/M) ratio. Literature states a 10%
increase in F/M ratio can cause bulking sludge.
The WWTP has two Trickling Filters that buffers flow from the Primary Clarifiers before reaching
the Activated Sludge System. With the lower plant flows of recent one Filter with recirculation
will accomplish the buffering needed. The Filters had both Rotary Distributors replaced in the
mid to late nineties. Unlike the Distributors of the past these Distributors were built with
bottom load bearings rather than top load bearings. The WWTP has experienced much trouble
with this style of Distributor. In 2012 funding was budgeted to have both Distributors rebuilt in
2013 and retrofitted with top load bearings. The first Distributor was in the process of being
machined for retrofitting when the bearing of the Distributor still in service failed. The lack of
no buffering led to the organic over load and the resulting bulking sludge.
The bulking sludge caused three extremely high TSS results that led to the noncompliance. The
numbers were 176.0,142.0 and 186.1 mg/l. Without these anomalies the monthly average
would be 14.7 and the percent removal 93.4. The first high number was due to a pump failure
which was feeding polymer to aid in solids settling. The other two high numbers was a result of
high flow wash out due to 2.4 inches of rain in two days.
To control the loss effluent solids the WWTP did the following. Approximately $77,500 was
spent to rebuild the first distributor. It is back on line but will take some time before zoogleal
mass can be established and buffering begins. Around $5500.00 was spent on polymer to aid
settling. Over $1000.00 of spare pump parts were on hand to be able to repair the polymer
pump as quickly as possible. Extra maintenance was done to the on line Distributor to keep it in
operation. The wasting was halted to bring the F/M ratio back in balance. Extra sampling and
V5'
Waste Water Treatment Plant
135 Aqueduct Rd.Weldon, NC 27890 [phone] Fax [phone]
testing was done to improve the TSS weekly and monthly averages. And during high flow day's
equalization tanks were used to store flow to minimize solids wash out.
The WWTP spent approximately $84,000.00 and put in a great deal of effort to obtain
compliance.
i snr
th's+n&t
Level of Treatment:
/J, 70?
Surface Water Name: > i/gf
Yes No
Were samples taken during event?
r
Describe the Repairs Made or Actions Taken:
am
Was WWTP compliant with permit requirements? Yes No
Yes No
Incident Started:
Incident Ended:
(must be given even if it is a rough estimate)
1/Yes__No
Iff
Permit Number:
County: y
^Secondary Treatment Chlorination/Disinfection Only
WWTP Upset, Spill, or Bypass 5-Day Reporting Form
(Please Print or Type Use Attachments if Needed)
Cause or Reason for the Upset/Spill/Bypass:
^/ou> Cover !(,
If yes, please list the following:
Volume Reaching Surface Waters: 7 0 2
Did the Spill/Bypass result in a Fish Kill?
None Primary Treatment
Estimated Volume of Spill/Bypass: / ,
Did the Spill/Bypass reach the Surface Waters?
Source of the Upset/Spill/Bypass (Location or TreatmentJJnit):
> c f1 aj P>') ter- $ ia / f orx
Permittee:
Facility Name:di ft/urr
North Carolina Department of Environment and Natural Resources
Division of Water Quality
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n J?
Date: /J - 2 ?- / 3 Time: V/ /c>
Date: /3 - a ? - 13 - Time: 3o
JJ
24~Hour Report Made To:Division of Water Quality Emergency Management
Date: ^-30- /3
Other Agencies Notified (Health Dept, etc):
Phone Number:
Did DWQ Request an Additional Written Report?Yes
If Yes, What Additional Information is Needed:
Spill/Bypass Reporting Form (August 1997)
WWTP Upset, Spill, or Bypass 5-Day Reporting Form
Page 2
Action TakenJo Contain Spill, Clean Up and Remediate the Site_(rf applicable):
NA
Action Taken or Proposed to be Taken to Prevent Occurrences:
Lf 1 f a A /Z? r aj
Additional Comments About the Event;
NA
Time: 3'Contact Name:l(i
Person Reporting Event:
ra,‘A
Describe the Repairs Made or Actions Taken:
MP
Time: 3» P
Time:
Surface Water Name:
__Yes___No /V /I
Date: 73^7’7 3 ..
Date:
Permittee: /foono/fe -ft f
Facility Name:
Cause or Reason for the Upset/Spjn/Bypass:
C^er K
nAAn-p Upset ■ Spill, or Bypass 5-Day Reporting .Form
1■ (Please Print or Type Use Attachments if Needed)
Permit Number: Q I -
County: ------------
North Carolina Department of Environment and Natural Resources
Division of Water Quality
fDtlDJ
source of the Upset/Spill/Bypass (Location or Treatment UnitL.
/>/ C /differ
Incident Started:
Incident Ended:
Level of Treatment;
__None j/Pri^ry Treatment —Secondary Treatment Chlorination/Osinfection Only
Estimated Volume of Spill^S) H <Zf ‘L&--------------^be 9iven even if it * 3 r°U9h
Did the Spill/Bypass reach the Surface Waters? „—Yes jXNo
If yes, please list the following:
Volume Reaching Surface Waters:------
Did the Spill/Bypass result in a Fish Kill?
Was WWTP compliant with permit requirements? ------Yes------No
Were samples taken during event? ------Yes uZ^N°
Additional Comments About the.Event:
Emergency Management _Division of Water Quality
Date: 1" 3 -Jj.
Other Agencies Notified (Health Dept, etc):
Phone Number: Person Reporting Event:

Spiil/Bypass Reporting Form (August 1997)
Did DWQ Request an Additional Written Report?
If Yes, What Additional Information is Needed;
WWTP Upset, Spill, or Bypass 5-Day Reporting Form
Page 2
Time: ; ; 0 o
Yes J^Tlo
24-Hour Report Made To;
Contact
Action Taken to Contain Spill. Clean Up and Remediate the Site (if applicable^
fWf’ 7^ 61
Action Taken or Proposed to be Taken to Prevent Occurrences:
$ sjerr ^e'
f /k tP 0 5 Q/eGf\e^ f
February 18, 2013
Subject:NOTICE OF DEFICIENCY
Dear Mr. Brown:
Parameter Date
Flow 1/30/2013
11/20/2013 54.81 mg/L 45 mg/L Weekly
11/30/2013 34.7 mg/L 30 mg/L
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper
North Carolina Division of Water Resources
Internet: vvww.ncwaterquality.org
Total
Suspended
Solids
Total
Suspended
Solids
A review of the November 2013 Discharge Monitoring Report (DMR) revealed a monitoring and
limit violation of the following parameter(s) at Outfall 001:
Pat McCrory
Governor
1628 Mail Service Center, Raleigh, NC 27699-1628
Location: 3800 Barrett Drive, Raleigh, NC 27609
Monthly Average
Exceeded
Phone[phone]
Fax [phone]
John E. Skvarla, III
Secretary
Mr. R. Danieley Brown
Roanoke Rapid Sanitary District
135 Aqueduct Rd.
Weldon, NC 27890
NOD-2014-LM-0001
Roanoke Rapids Sanitary District WWTP
Permit No.NC0024201
Halifax County
Reported
Value
None
Limit
Value
n/a
Reporting
Requirement
Continuous
Failure to monitor and meet permit limits for parameters as per permit requirements. DM Rs
reviewed November 2013 confirm lack of flow monitoring and exceedance of limits. DWR
received remedial actions taken to correct the cause(s) of this violation with the November 2013
DMR. If certifiable data for Flow monitoring violation described above is available an amended
DMR should be provided to rectify the noncompliance, please submit amended DMR (as
applicable) to the Division of Water Quality by March 18, 2014.
Customer Service
1-877-623-6748
NorthCarolina Naturally
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Resources
Thomas A. Reeder
Director
Page 2 of 2 NOD-2014-LM-0001
Send copies of the amended report to:
AND
ncen
Unresolved violations may lead to the issuance of a Notice of Violation and/or assessments of
civil penalties. Violations are subject to a civil penalty assessment of up to $25,000.00 per day
for each violation. Any efforts undertaken to bring the facility back into compliance are not an
admission and will be considered in any future actions undertaken.
If you have any questions or require any additional information, please contact Autumn
Romanski at [phone] ([e-mail]) or myself at [phone].
Jsi
Danny Smith/
Raleigh Regional Operations Supervisor
Division of Water Resources-Raleigh Regional Office
1628 Mail Service Center
Raleigh, NC 27699-1628
Division of Water Resources-Central Files
1617 Mail Service Center
Raleigh, NC 27699-1617
1
Roanoke Rapids Sanitary District
WASTEWATER SPILL IN HALIFAX COUNTY
C:\L’scrsUnluycs\AppDala\Loc.irvMicrosoft’Wiiidous\Tcnipor.in Imemci Filcs\Conicnl.OutlookW3QKLCU5\l50l07 WWTP Spill Press Release (2l.doc
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The North Carolina Department of Environment and Natural Resources, Division of
Waler Resources was notified of the event on January 7th, 2015 and is reviewing the
matter.
In accordance with the regulation, the following news release has been prepared and issued to
media in the affected county (ies):
P.O. Box 308
1000 Jackson Street
Roanoke Rapids, NC
27870
[phone]
Fax: [phone]
www.rrsd.org
Press Release
1/9/15, 5:48 PM
Contact: Dan Brown, CEO
Via FAX: [phone]
On January 7th, 2015 Roanoke Rapids Sanitary District (RRSD), operating under NPDES
Permit Number NC0024201, had a total wastewater spill of an estimated 44,900 gallons
from the Roanoke River Wastewater Treatment Plant located at 135 Aqueduct Rd,
Weldon, NC. The spill began at 5:55 p.m. and ended at 6:15 p.m. Untreated wastewater
spilled into the waters of the state tributary to the Roanoke River in the Roanoke River
Basin when loss of power due to equipment failure occurred at the plant. The standby
generator was turned on per the District's Curtailable Service Agreement Schedule 6C
with Dominion North Carolina Power. The generator lost total power and the transfer
switch failed to switch back to utility. To minimize the bypass, 74,000 gallons was
diverted to flow equalization basins with the District’s 12” diesel pump. Preparation is
being made for all known repairs necessary to reduce the likelihood of occurrence and
return the system to service to minimize further discharge.
House Bill 1160, which the General Assembly enacted in July 1999, (Revised per S729, NC General
Statue 143.215.1C) requires municipalities, animal operations, industries, and others who operate
waste handling systems to issue news releases when a waste spill of 1,000 gallons or more
reaches surface waters of the state.
by oi><59<Z6is ©
'ITOKVA -/gA fi). I2. 2015
Roanoke Rapids Sanitary District
February 27, 2013
2013MAH
Re:
Dear Sir:
Very truly yours,
Enclosures
Cc:
o 4 W
c 'doauncnts and scltings'rdb'my documciits'jipdcs permit' 12_s>s performance aim report Hrdoc
North Carolina Division of Water Quality
NPDES Section
1617 Mail Service Center
Raleigh, N.C. 27699-1617
Gregg Camp
Gregg Wilson
File
2012 System Performance Annual Report
NPDES #NC0024201
NPDES #WQC00027
NCG110000
Page.
1/1
Enclosed please find three (3) copies of the District’s System Performance Annual Report.
This report is submitted to meet the requirements of the NCDENR/DWQ policy to promote
public oversight of system performance for reduction and elimination of sanitary sewer
overflows (SSO's) from wastewater treatment works and sewer collection systems.
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
If these documents should be provided to additional DWQ personnel; or if additional
information is required, please contact me.
P.O. Box 308
1000 Jackson Street
Roanoke Rapids, NC 27870
[phone]
Fax: [phone]
www.rrsd.org
R. Danieley Brdwn, P.E.
Chief Executi\/e Officer
Wf)
-
-A 20^3ANNUAL PERFORMANCE REPORT 2012
ROANOKE RAPIDS SANITARY DISTRICT
1.GENERAL INFORMATION
B.Responsible entity: Roanoke Rapids Sanitary District, Dan Brown, CEO
C.Person in charge/contact
1.
2.
D. Applicable Permit(s)
1.
2.
E. Description of C.S.:
The Chockoyotte Creek Interceptor handles the south side of Roanoke Rapids and three sub­
divisions, Lake View Park, Greenbriar and Lincoln Fleights, outside the Roanoke Rapids city
limits. The interceptor begins east of Zoo Road. There is one primary basin pump station
along the route. Pipe size ranges from 12’' to 30”.
C.S.: North Carolina Environmental Management Commission System-wide
Wastewater Collection System Permit No. WQCS00027
The Roanoke River Interceptor collects wastewater from basins located on the north side of
Roanoke Rapids. The Gaston and Northampton basins are included in this service area. The
Interceptor begins just west of NC 48 in Roanoke Rapids. There are 3 primary basin pump
stations and 2 secondary pump stations along the route. Pipe sizes for the Interceptor ranges
from 18” to 30”.
C.S.: Gregg Wilson, Supervisor
Melvin Douglas Moore, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, Distribution & Collection
PO Box 308
Roanoke Rapids, NC 27870
Phone: [phone]
WWTP: Gregg Camp, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, WWTP
135 Aqueduct Road
Weldon, NC 27890
Phone: [phone]
WWTP: NPDESNC0024201
Land Application (L.A.): WQ000I989
Stormwater (General): NCG110000
The system has six sewer lift stations. Three stations are located in the Gaston, NC system.
One of these serves a Northampton County School, one serves the Chowan Housing Projects
and the other station pumps all flows from Northampton County across the NC 48 Bridge
crossing the Roanoke River to the Roanoke River Interceptor. The remaining three pump
stations are located within the Roanoke Rapids system. Two of the stations, Belmont and
A. Regulated entity: Roanoke Rapids Sanitary District, Collection Systems (C.S.) and
Wastewater Treatment Plant (WWTP)
The collection system consists of approximately 130 miles of sewer lines. The sewer lines
within Roanoke Rapids, Gaston and all sub-divisions, which connect to the two main
Interceptors, range in size from 8” to 12”. There are two main Interceptors transporting
wastewater to the WWTP.
I
I
F. Description of WWTP:
II.PERFORMANCE
1.
The performance of the system in 2012 was good.
-2-
The wastewater treatment plant is rated at 8.34 million gallons per day (MGD). Peak flow is
rated at 12.5 MGD.
Treatment processes at the wastewater plant include grit and rag removal. This is followed by
primary clarification, trickling filter biological secondary treatment, activated solids
treatment, secondary clarification, final effluent chlorination/dechlorination processes, and
final pH adjustment.
Poplar Springs, discharge to the Roanoke River Interceptor while the Greenbriar Pump
Station discharges to the Chockyotte Creek Outfall.
C.S.:
The Roanoke Rapids Sanitary District’s collection system received its inaugural pennit in
2001 under the North Carolina Environmental Management Commission Department of
Environment and Natural Resources system wide wastewater collection system-
permitting program.
The Fat, Oil and Grease (FOG) program initiated in 1995 has been a good tool in
preventing Sanitary Sewer Overflows (SSO’s). We also have a fulltime employee for the
FOG Program who specifies type and capacity of grease traps on an individual basis for
all developments, maintains all records and inspects all grease traps. He also educates all
restaurants and high density residential housing about grease and how it affects our sewer
lines. The use of local newspaper for FOG program educational ads and the distribution
of brochures to restaurants and fast food businesses have also been effective.
Maintenance of records and inspection of grease traps is an ongoing measure to prevent
SSO’s.
During these processes solids are removed from two locations. Primary clarification removes
settleable solids from incoming wastewater to an anaerobic digestion unit. Here the solids, in
the absence of oxygen, receive pH adjustment, mixing, and heating to produce a stabilized
material. Once the solids are stable, excess water is decanted and returned to the plant for
further treatment. The stabilized, thickened solids are treated with lime for odor control then
removed to a holding tank to await land application.
There are two pumping stations in the wastewater plant distributing wastewater into and
through the plant. Of these two pump stations, one has the capacity to pump 20 MGD and the
other 27 MGD respectively. Also, to aid these two pump stations; a storm water pump station
has been installed. This station intercepts rainwater, an unnecessary load to the treatment
plant, and removes it before entry to the plant. It has the capacity to pump 11.5 MGD. In
conjunction to these two pump stations there is one pump station with capacity of 21 MGD to
remove treated flows from the plant in the event of high river levels preventing normal gravity
flow discharge. Various others pumps and mixers are located throughout the plant for process
control.
Secondary clarification removes solids from the activated solids process. Here, solids in the
presence of oxygen, ph control, and mixing, accumulate in excess. They are removed,
chemically stabilized, and added to a holding facility. All stabilized solids are analyzed and
land applied according to their nutrient value, ceiling and accumulative requirements.
Preventive Maintenance of at least four hours a week cleaning sewer mains has also been
an effective tool in reducing sewer backups and overflows. In 2012, District forces
A. Description of overall 12 month performance, noting highlights and deficiencies:
2.
-3 -
WWTP:
Overall performance for 2012 was good. There were no NPDES permit limits violations.
(See below) There were no monitoring or reporting violations.
Current plant capacity is 8.34 million gallons per day (MOD) with a peak flow of 12.5
MGD. For 2012 the yearly average low flow was 2.6MGD with minimum of 1.8 MGD.
The yearly average high flow was 6.7 MGD with a maximum of 14.7 MGD. The yearly
average total flow was 3.5 MGD or 42% of the plant capacity. This is an increase of only
100,000 gallons or nearly a negligible rise in flow. Rain can affect flows by inflow and
infiltration. In 2012, 58.0" of rain was recorded at the wastewater plant. The previous
year 46.8“ was recorded. This is an increase of 11.2” from the previous year and a 16.0”
increase over 2010. The increase in rain may have contributed to the negligible increase
of 100,000 gallons in 2012. However, with this significant increase in rain the last two
years, it is further evidence the District’s efforts to minimize inflow and infiltration is
working.
In response the District has maintained staff, critical parts inventory, equipment
inventory, made plans to better address extreme conditions, upgraded critical equipment,
planned back up or alternative operations, and requested better responsiveness from sub­
contractors. Responses are continuous and increasing.
The permit also contains daily maximum residual chlorine of 50 ug/1 (micrograms per
liter or parts per billion). Also permitted is pH. It must be maintained between 6 and 9
units. These two samples are grab or instantaneously collected.
There were nine reportable spills in 2012 of the collection system. The worst of these
was on August 25 when Roanoke Rapids had 1 1.5 inches of rain in a short period of time.
There were several streets washed out due to storm water and numerous sewer lines
washed out. District employees were very diligent in getting these lines repaired and
back in operation. There were also overflows from numerous manholes during this
event.
Linder the current permit, the District has a weekly effluent total suspended solids (TSS)
limit of 45 mg/1 (milligrams per liter or parts per million) and a monthly limit of 30 mg/1.
Also a weekly carbonaceous biochemical oxygen demand (CBOD) limit of 37.5 mg/1 and
a monthly limit of 25 mg/1. These two samples are composite collected. They are
collected over a twenty four hour period and on a flow proportional basis. The higher the
flow, the more sample collected and conversely, the lower the flow, less sample is
collected. The yearly average for TSS was 16.3 mg/1 and CBOD was 6.3 mg/1. Using
yearly average influent values for the same parameters this calculates to a 93.8% and 97.0
% removal rate respectively. The permit requirement is 85%.
The SCADA system that monitors all lift station 24 hours a day, 365 days a year has
prevented lift station overflows. In addition, each lift station is equipped with emergency
generators on site to prevent overflows from power outages, except Poplar lift station. In
the event we have rain or outages predicted, a portable generator is placed at the lift
station in case it is needed.
The District is keenly aware of and has been very responsive to increasing environmental
awareness. House Bill 1160, Clean Water Act of 1999, ratified by the North Carolina
General Assembly on July 20lh and signed into law July 21s’ by the governor, has
heightened this awareness. This bill codified as Chapter 329 session laws became
effective October 1999.
continued proactively cleaning the mains of high density residential housing prior to
major holidays to prevent any grease related spills. The use of degreasers in pump
stations on a regular schedule has proven to be very effective in preventing lift station
down time. Also all pumping stations are checked and cleaned a minimum of once
weekly.
Some of the repairs and upgrades in 2012 include the following.
-4-
In 2012, the District continued to be very active in maintenance issues and concerns. The
WWTP spent in excess of $641,000 on maintenance and repairs to equipment, supplies
and materials necessary to operate equipment and capitalized monies to replace and
upgrade equipment.
Influent pump station. The influent pump station transfers all incoming flow into the
plant. The station is equipped with four pumps. Their pumping capacities are 2, 4, 7, and
7 million gallons per day (MGD). The 2 and 4 MGD pumps are the “work horses” of this
pump station. They handle the majority of the work on normal flow days. This spares
Influent diversion box. The influent diversion box is the first area of the wastewater
process. The open air collection pit is where the two main interceptors bring all the
wastewater in the District's system to the wastewater plant. A 30” line, Roanoke River,
and a 36” line, Chockyotte, meet and blend at this location. From this point they are
piped to the first treatment process or preliminary station consisting of rag and grit
removal. The diversion has two slide gate valves. The influent gate when open allows
all flow from the Chockyotte and Roanoke River lines into the treatment processes of the
plant. Occasionally it must be closed to stop flow into the plant for downstream
equipment repairs. At this time all the flow is pumped to storage and returned to the
plant after repairs. The influent gate is an original gate from 1963 and is failing. A new
gate has been purchased to replace the original.
There were two rain events within one week of each other in August causing flows to
increase significantly which flushed lots of hard granular material into the Rotomat.
During these events, the comb was damaged. The comb acts to dislodge captured
undesirable materials into a conveyor that removes this material. The comb, made of
hardened stainless steel was bent and the holding bolts broken. This was causing the unit
to run in a bind and trip out. The comb was straightened out and reattached, returning the
unit to use. The Rotomat is the primary debris removal equipment which works
automatically. There is a manual back up which can be used in the event the Rotomat is
in need of service or repair. There are gates that are used to direct flow to whichever unit
needs to be used. The gate frames are original equipment from the 1960*s and made of
carbon steel. The gate frames had deteriorated and were replaced with stainless steel
frames.
Rotomat. The Rotomat is the first piece of equipment in the wastewater process. It
removes rags, plastics, paper, or other non-organic material before they can enter other
downstream processes. This is important to keep this material from clogging pipes,
binding pumps and mixers, and causing damage to other equipment. Flow enters a basket
area. As materials build up in the basket area, a sweeper arm comes on to remove the
built up items. The sweeper passes through a comb which causes the material to be
dropped into a screw auger for removal from the wastewater flow.
Grit Collector. The grit collector removes grit from the influent flow. Grit is removed at
this location to prevent excessive wear on downstream equipment. There are two grit
collectors. One is the primary collector and the other is a back-up. The primary unit,
installed in the mid 90's, uses a vortex motion to settle grit out of incoming wastewater.
A pump removes the settled grit from a hopper to a screw conveyor for removal to a
dumpster. The back-up collector, original equipment installed in the early 60's, uses
gravity to settle grit to a sump pump which pumps to a screw conveyor for removal to a
dumpster. Although this equipment is much older and less efficient than the newer
vortex technology, the gravity system is maintained for use during times when the vortex
unit may be down for repairs. There are gates that are used to direct flow to whichever
unit needs to be used. The gate frames are original equipment from the 1960's and made
of carbon steel. The frames had deteriorated and were replaced with stainless steel
frames.
-5-
wear and tear on the larger 7 MGD pumps which are needed in cases of higher flows.
They alternate based on run time hours until flows increase to a level where both are
needed together. This station is equipped with an emergency flow release valve in the
event flows from extreme weather conditions come in faster that the pumps can remove.
Without this valve catastrophic failure of the station would occur causing a long down
time for repairs. The valve is original equipment from the 1963. It is old technology
metal flap to metal seal and does not seal well allowing environmental waters to enter the
pump station placing extra unnecessary flow on the station. This valve was replaced with
an elastomer style valve that completely seals.
Filter Effluent Pump Station. The filter Effluent Pump Station (PEPS) collects all
incoming flow that has traveled through the primary clarifiers and trickling filters. It then
transfers this water on to the secondary system for further treatment. This station is
equipped with four pumps. Their pumping capacities are 2.1, 7.9, 7.9, and 9.2 million
gallons per day (MGD). Here as with the influent pump station, the smaller pump is the
“workhorse”. At this station the two 7.9 MGD pumps alternate after equal run times to
aid the 2.1 MGD pump during normal flows. The 9.2 MGD pump is the high flow pump
at this station. One of the 7.9 MGD pumps developed a vibration. To minimize damage,
Primary Clarifier. Primary clarifier (primary) is a circular tank with a cone shaped
bottom. Without the cone, the tank is 12’ deep. There are two primaries. At the bottom
of the cone is a hopper attached to pipe work that leads to a pump station called the
Primary Solids Pump Station. Wastewater which contains organic solids enters the
primary. A baffle slows the velocity of the wastewater entering the primary allowing the
solids to settle to the bottom of the tank. A motorized sweeper located on the tank
bottom sweeps the settled solids into the hopper. Using the pumps in the Primary Solids
Pump Station, solids are removed from the primary at regular scheduled intervals. The
solids are transferred to another process where they are treated and stabilized. There are
two horizontal centrifugal chopping pumps located in this pump station to make this
transfer. They are used on average three times a day for approximately an hour each
time. They transfer solids which by nature are abrasive. During the course of the year
both pumps started showing signs of inefficiency. On separate occasions they were
removed for repair. A spare is available to use in the absence of a pump under repair.
These pumps are also equipped with sight glasses for observing the thickness of the
solids being transferred. Only the thickest should be transferred. One of these sight
glasses began to leak and had to be repaired. The surface of the primary is skimmed by
a motorized skimmer. Its purpose is to remove floatables, mainly grease, from incoming
flow. These floatables are deposited in a trough connected to a collection box. Each
primary has one. The floatables are transferred to the same treatment and stabilization
process as the settled solids. There are two submersible vertical centrifugal chopper
pumps that are used for this application. One of these pumps also began having problems
transferring the collected floatables. It was removed and repaired. A spare is available to
use in the absence of a pump under repair. Due to some equipment installation in the
pump station which involved the roof and due to the age of the roof covering, the roof
covering had to be replaced.
Rotary Distribution (Trickling Filter). Biological wastewater treatment begins at this
phase of the wastewater treatment process. There are two rotary distributors.
Wastewater from the primary clarifier enters the center column of the circular rotary
distributor. The center column splits the water equally to four distribution arms. The
arms have holes (orifices) in the top which the water passes through then down the front
of the arm. This causes the distributor to rotate. Underneath the arms is a 5’ this bed of
rock. Microorganisms grow on the rock surface and as the wastewater trickles through
(trickling filter) the bed of rock, the microorganisms start cleaning up the wastewater.
The four arms supported by 1” vertical diameter stainless steel support truss rods
connected to the center column. There are 5 per arm for a total of 20 on the distributor.
In addition, there are two half inch horizontal cables between the four amis for a total of
eight. These cables help stabilize the arms. One of these cables broke and had to be
replaced.
-6-
Secondary System. The Secondary System is a biological treatment system consisting of
three aeration basins and two secondary clarifiers. The system is operated by the use of
various valves and piping, control panels, traveling siphon bridges with valves and
skimmer arms, gear boxes, motors, pumps, and blowers. Various repairs and upgrades
were done.
Each aeration basin is equipped with a mixing pump. They are piped into the basin so
that they blend basin content with blower air causing a mixing action. Each mixing pump
is controlled with a variable frequency drive (VFD). The VFD can speed up or slow
down the motor affecting the dissolved oxygen concentration in the basins. The displays
on the mix pumps that control the speed faded out and had to be replaced.
Removing and installing motors is difficult. The work area around them is small and the
power and motor leads are connected in a manner that disconnecting & reconnecting is
awkward because of a small electrical box. To make this easier, larger connection boxes
were installed on all four blowers and power/motor leads were fitted with quick
disconnects.
The electrical control system of the syphon bridges has had numerous repairs over the
years. The connection system was in a state of disrepair. The connection system was
replaced to make future repairs easier and safer.
Each pump has an automatic oiler to keep the internals lubricated and in working order.
In 2012 these oilers began to fail and had to be replaced. In addition, each pump has an
electrical control cabinet. These cabinets build up heat and if not removed will cause the
pump to trip out. To keep this from occurring, each cabinet is equipped with a cooling
fan. These fans began to fail and had to be replaced.
The mix pump system is accomplished with piping where air and solids are blended and
injected. The piping is connected with flanges. In 2012 some of the flanges failed & had
to be replaced. Both secondary clarifiers have a traveling syphon bridge driven by a
motor and gearbox with chain and sprocket and a pulley cable system. The traveling
syphon bridges had previously been retrofitted with temporary priming valves. These
valves were subject to leaking causing prime loss of the bridges. These valves were
removed and the prime of the bridges improved significantly. The traveling bridges are
equipped with a clutch system. In the event of any binding of the system, the clutch
releases to protect the system. The clutch on #2 failed and was replaced.
Disinfection. The final phase of the water treatment process is disinfection (pathogen
kill) and disinfection removal. Sodium Hypochlorite (bleach) is added to the wastewater
flow in sufficient amount to destroy potentially dangerous virus and bacteria. After this
process, sodium bisulfite is added to remove any remaining hypochlorite. This is
necessary because hypochlorite is hazardous to the aquatic life of the receiving stream.
This system is nearly two years old now and issues with it are beginning. The chemical
feed and transport lines and valves are PVC. Several locations along the PVC lines and
some valves had to be repaired. Cracks developed in lines and valves necessitating
replacement. Also, gaskets in several valves deteriorated which caused leaks. These
gaskets were replaced. The pumps that move the chemicals in this system are diaphragm
the pump was promptly removed from service and repairs made. Afterwards the pump
was returned to service.
There are four blowers, two 75 horsepower (#1 & #3 and two 100 horsepower (#2 & #4).
Blower #3 had multiple repairs in 2012. Each blower has an inlet and outlet bearing. On
#3 the inlet bearing had to be replaced. Also, the motor on the #3 blower went bad. The
motor was repaired and replaced. Finally, the internals of the blower failed. The motor
and bearings repairs were done in-house. However, the internals repair is an intricate job
so it was returned to the manufacturer. The repair was completed and the blower was
returned to service. In its absence, a spare was utilized.
-7 -
All functions of the heat exchanger are controlled by one piece of equipment called the
“fire eye’'. It is a safety component. If it senses improper operation of any electrical part,
it will not let the heat exchanger fire. If the eye itself fails, the heat exchanger will not
start either. Heat exchanger number 2 had this type of failure and had to have a new “fire
eye” installed. Also, on number I heat exchanger, the gas regulation valve failed. This
pail opens up as demand for gas, either methane or natural, increases or closes down as
demand decreases. This is all dependent on temperature settings. The gas regulator had
to be replaced to restore temperature control. The water bath of the heat exchangers is re­
circulated with a water pump to keep the warmest water in contact with re-circulated
solids. Without recirculation, proper solids heating will not occur. Heat exchanger
number I water pump failed and had to be replaced.
The water that is re-circulated through the heater is a closed loop system. It is reused
over and over. With some time water may be lost because of evaporation or possibly a
slight leak. To compensate for this each heater is equipped with a replenishing water
storage tank. One tank was installed in 1963 and the other in 1983. They both were
deteriorating beyond repair. Without storage water the heater will not run. A safety
device will recognize no water and shut the heater down. To prevent this storage tanks
on both heaters was replaced. Excess heat from the heaters has to be exhausted just as in
an automobile. The heaters are forced air vented through exhaust piping with the use of a
blower. It is important to exhaust properly to prevent noxious fumes, for example carbon
monoxide, from building up in the digester building. Heater #1 had some problems with
its exhaust system. First, the motor went bad and had to be replaced. Second, the
exhaust piping deteriorated and had to be replaced. To monitor proper temperature
settings, the digesters are equipped with chart recorders. The number one chart recorder
failed and was replaced. Each heater is equipped with a solids horizontal centrifugal
recirculation pump. The pump pulls solids out of the digester and loops them through the
heater and then returns them back to the digester. This looping can be intermittent or
continuous depending on temperatures and temperature settings. The pump for number 1
digester underwent a couple of repairs. First, the pump motor failed and had to be
Digesters and Stabilization. Digesters receive solids removed from primary clarifiers.
With heat and mixing and occasional chemical addition for pH control, solids are
stabilized. There are two digestions tanks. Each is heated with its own heat exchanger.
Each heat exchanger is a two chamber piece of equipment. One side is a heat
compartment and the other a water bath. Solids are re-circulated between the two
chambers where the heat is transferred or exchanged. A byproduct of the stabilization
process is methane. It is captured and used for fuel to heat the exchanger. The heat
exchangers are also equipped to run off natural gas as well at times when methane
production may be low or temperatures are colder requiring the use of supplemental fuel.
For this operation gas valves are required for both types of fuels.
style. There are two for the hypochlorite and two for the bisulfite. On average after a
year of service, these pumps have to be rebuilt. In 2012 these pumps were started being
rebuilt with the kits supplied by the manufacturer. The tanks which house the chemicals
are under warranty. To maintain this warranty, they must be inspected annually. In
2012, their first inspection was done. The electrical control system for the chemical feed
system must be protected from electrical surges which could result from lightning. The
piece of equipment used for this protection is a transient voltage surge suppressor
(TVSS). During a lightning storm, the TVSS stopped a surge and protected all
downstream electrical equipment as it is designed to do. However, when this occurred
the TVSS was damaged. The TVSS had to be replaced to continue to protect the
electrical equipment. A separate electrical issue arose in 2012. Voltage to the
disinfection building became erratic and low. Equipment in the building could not
operate correctly. After a search it was discovered that the electrical wires from the
motor control center feeding power to the disinfection building was not a continuous run.
Wires had splices in it located in an electrical access junction manhole. The splices had
corroded causing the electrical issues. The splices were repaired using a better style
splice kit hopefully to avoid this occurrence again in the future.
-8-
replaced. Second, the seal went bad causing a leak. The seal had to be replaced to stop
the leak. The tops of the digesters are unique. They are metal and float on the solids
being treated. They move up and down depending on the amount of solids in the
digester. However the lops are restricted to the “working zone” of the digester. If the top
gets too low it could crush. To high and it could fall off. To monitor this, the tops are
equipped with a level indicator with alarms. The alarm on #1 digester failed. It had to be
replaced to restore this safety feature. Because these tops are metal and exposed to the
atmosphere, they require painting to prevent deterioration. All tops were painted in 2012.
The pump at this station became inefficient. The pump impeller or the part that actually
forces flow wears over time. If it is not completely worn out it can be adjusted to return
efficiency. However, when completely worn out it must be replaced to return efficiency.
The pump was removed and inspected. The impeller only needed adjustment to return
efficiency. From this pump station the solids are pumped to one of two gravity settling
tanks. Flow out of these tanks is by gravity. Over the years flow from tank number 2
became restricted. On several occasions the tank had been inspected for debris causing
the restriction. The drain piping was also dismantled in this search as well. Trash and
debris was found on a couple of occasions but when put to use it still would not flow­
well. Tank number 2 was rotated off line again this year to cycle the tanks for equal
wear. Number 2 was also scheduled to be painted inside and out. To help accomplish
this the drain piping had to be dismantled. Another opportunity was taken to search for
the restriction. However, this time a TV camera was inserted into the lines. At this time
a plastic cap and a rubber float control cover were discovered. Previous cleaning of the
line had not removed this debris. This debris was removed and after the tank received its
paint job it was returned to service. Flow from this tank now has returned to normal.
During the year this same tank required other repairs as well. There is a motor and
gearbox attached to a mixing paddle. The paddle mixes the solids and polymer to make
good contact and aid the settling process. Both motor and gearbox wore out and had to
be replaced. Solids flowing out of the gravity tank are sent to the drum concentrator.
The concentrator runs on a series of pillar block bearings. These bearings stabilize the
drum. Without this stabilization the solids thickening belt tracks off the concentrator.
One of these bearings wore out and had to be replaced. Before polymer can be used for
the gravity tank or concentrator systems it must be maintained. Polymer is received in
concentrated form. It must be maintained through mixing. This is accomplished with the
use of progressive cavity pump. During the year a few repairs became necessary. First,
the pump motor failed and had to be replaced. Later the pump lost efficiency. The pump
was removed and taken apart. There are two parts working together to create the
pumping. The rotor and stator are these two parts. The stator was found worn and was
replaced. This returned the pump to normal efficiency.
Lime Stabilization. Waste activated thickened solids are stabilized through the use of
lime. Time and pH’s dictate the stabilization requirement. Lime is received in dry form
and transferred to a storage/feed silo. The dry lime is then fed to a preparation tank
where water is added creating slurry which is then added to a mixing tank containing
Biosolids Thickening. Excess solids from the secondary treatment process are thickened
by gravity settling tank and a drum concentrator with the use of polymers. Polymers
when mixed with solids create a reaction which causes solids to concentrate (floc) and
water separate. The purpose is to minimize the solids removed from the treatment plant
because removal charges are based on the amount of gallons removed. Excessive solids
from the secondary system enter a pump station by gravity flow. From here the solids are
pumped to a gravity settling tank to begin the thickening process. There are two gravity
settling tanks and one drum concentrator. Current flows necessitate the use of only one
gravity settling tank. This provides back up for the tank on line. The gravity settling
tank and drum concentrator can be used separately or in series. Wastewater operations
dictate which is used but normally the series option is used with the solids first entering
the tank. The gravity setting tanks are switched regularly to ensure proper operation and
even wear and tear on equipment. The pump station is used to send solids to the gravity
settling tank.
-9-
Generator. The plant generator is used to supply the entire plant with power in the event
utility power is interrupted. The generator is on a quarterly preventative maintenance
program with a contractor to maintain the engine. However, if the transfer switch which
transfers power from utility to generator does not function properly the generator cannot
Even though the MGT is mixed constantly, lime still precipitates out. Over time it builds
up on the tank bottom. This reduces the effectiveness of the mixers. Approximately
once a year, the tank is emptied and cleaned to remove the built up lime. This time also
allows for the mixers to be inspected for wear and tear and an opportunity for the oil
levels to be checked. Also, the integrity of the MGT can be inspected. However, the
inspection in 2012 was due to an emergency. One of the riser pipes for solids transfer
built up pressure and blew apart at the mechanical joint near ground level. The brackets
that hold the riser pipe to the tank were lifted causing damage to the brackets and to the
tank panels. The company that constructed the tank and does regular preventative
maintenance was called in to do an inspection and repairs. The tank was thoroughly
inspected and only minor damages found. The tank repairs were done by this contractor.
The mechanical joint of the riser pipe was repaired in house.
Million Gallons Stabilization Solids Storage Tank (MGT). The MGT holds all stabilized
solids from the digester stabilization process and the lime stabilization process. It
contains five mixers that are used to keep the two different stabilized solids blended, to
help keep lime in suspension with the stabilized solids, and for odor control. One of
these mixers had to be removed for repair. A spare was used in its absence. Once
repaired, the mixer was reinstalled. Stabilized solids are removed from the bottom of the
tank through four valves located in different areas of the tank. Over the years some of the
valves had broken and others were difficult to use. This made emptying the tank slow
and difficult. To remedy this situation all four valves were replaced. When solids are
removed for land application process a pump is used by the truck drivers with the use of a
remote switch located at their loading stand. The switch went bad bringing the
application process to a halt. The switch was promptly replaced restoring the process.
Solids are removed at a cost per gallon. During the storage water will still separate from
the solids. Also the tank size, one million gallons, is like a large rain gauge. This excess
w'ater is removed with a decent system saving thousands of dollars each year. During the
year part of the decant line and a valve burst. It w'as repaired so this process could
continue.
solids to be treated. The preparation tank when in use must be mixed constantly to
prevent lime from precipitating out and caking up creating a clogged discharge from the
tank. The mixing is accomplished with a paddle wheel run by a gearbox/motor combined
unit. This unit went bad and was replaced. Once the lime slurry is added to the solids
mixing tank and the proper level is reached, the treated tank is ready for transfer to a
downstream process. The levels can be monitored remotely with the use of a level
indicator called a pressure transducer. Having these indicators can allow an operator to
follow the tank levels. If a tank gets too low the mixers could cavitate causing damage to
the mixers. Also, if a tank gets to high it can overflow. The transducers failed and had to
be replaced. One of the lime/solids mixers failed and had to be rebuilt. A spare was used
in its absence. There are two wet well transfer stations associated with this process. The
first transfers stabilized solids to the holding tanks. The second transfers stabilized solids
from the holding tanks to final storage. The first wet well transfer control panel was
rebuilt in 2011. In 2012, an alarm “High” level light and horn was added. Also, in 2012
the second well transfer control panel was rebuilt. Now both stations are in good
electrical working condition. The holding tank stores lime stabilized solids until time and
pH measurements are achieved. To aid this process mixers are used. They are controlled
with a float style leveler. This was not a good application. It caused the mixers to turn
on and off repeatedly. This allowed lime to precipitate and undue wear and tear on the
mixers. To remedy this situation a different style of leveler called a multitrode was
installed. The operation now is constant. In 2012, to protect the metal integrity of the
lime silo, it was painted.
- 10-
be used. The transfer switch is now also on a regular scheduled maintenance program
with an outside contractor.
12" pump installation. The 12 inch pump installed at the head-works of the plant in 2000
remains a valuable tool in preventing spills. In the event of high flows or maintenance
repairs, water can be removed to two abandoned secondary clarifiers. These clarifiers
were taken off-line in the early eighties after plant upgrades. They were originally used
for stabilized biosolids storage. The capacity was increased by extending a wall up from
where the weir overflows were when used as secondary clarifiers. This increased the
storage capacity of the two tanks to 750,000 gallons. After a dedicated biosolids tank
was constructed, the two abandoned tanks were dedicated to spill containment. Once
stored, wastewater can be returned to the plant with an existing pump station. Some pipe
work has been added to this station and depending on conditions, water could be returned
as the tanks are filled. This further increases holding capacity or downtime, during high
flows or maintenance and repairs. In 2012, 4,355,788 gallons of wastewater were stored.
Since setup in 2000, 49,732,667 gallons of wastewater have been prevented from spilling.
At the average flow of 3.5 MGD in 2012, this would be 14.2 days of flow.
The diesel tank level indicator is mechanical and prone to sticking giving a false reading
of available diesel fuel gallons. To improve this reading an electronic device was
installed in the tank with an associated LED display. The gallons indicated are now more
accurate. A federal law enacted required certain diesel powered equipment to do some
air emissions cleanup. The emergency generator fell under this umbrella. In 2012, the
generator was equipped with an exhaust filter system to help control these emissions.
The emergency generator is also used to curtail. The District is under contract with
Dominion Power. From May 16'1' through September 30"' (summer curtailment) and
from December Is' through March 31st (winter curtailment), Dominion can request the
Another means of spill control is with a backup generator. The wastewater plant must
continue to run in the event of power interruptions from the power-supply company.
Power interruption can occur from equipment failure, road accidents, and weather events,
such as ice storms, electrical storms, tornadoes, and hurricanes. A 750 kilo-watt
generator is on site for events and can supply enough generated power to run the entire
plant. In 2012, there were five power interruptions resulting in the use of the back up
generator for power supply. This first occurred on February 1st and was due to failed line
transformer. The generator was used for 3 hours and 30 minutes and prevented 145,833
gallons from spilling. The second was on July 1st and was due to a storm blowing trees
down on service lines. The generator was used for 52 minutes to prevent 110,136 gallons
from spilling. The next three occurred on August 3rd, two separate events, and on August
6lh. The generator was employed for all three events preventing 188.015 gallons (Ihour
35 minutes), 187,500 gallons (Ihour 15minutes) and 194,600 gallons (Ihour 10 minutes)
respectively. The last three events were due to blown service line fuses. In all 826,084
gallons were prevented from spilling by using the backup generator for the five events
covering approximately eight and one half hours without normal power supply.
SCADA (Supervisor Control and Data Acquisition). SC AD A is a computer-based
program. It brings site information into the central operations center. SCADA is a useful
tool by providing monitoring information to be used for more efficient plant operation. It
also brings remote site alarms into the operations center, which provides better control
over plant problems. Additional SCADA work was done in the thickening/stabilization
area of the plant. Some additional pumps and mixers were added to the computer alarm
and trend identification and tracking system. There were also some motion detection
sensors added too pieces of equipment. Also receiving some additional SCADA work
was the digester building. The pearths, manometers, and exhaust fans were added and
the heater alarm signals were expanded. Due to the size and complexity, and some parts
of the SCADA system beginning to age, several repairs were necessary throughout the
year. Also, to keep the SCADA computer working reliably and efficiently, the data from
2011 was unloaded on to an external hard drive.
- II -
Since purchasing the land, investment improvements continued in 2012. Improvements
have been going on for nearly eight years. In 2012, the District over seeded the Bermuda
with annual rye. Because Bermuda goes dormant in cold weather months the rye over
seed makes the Bermuda acreage available for nutrient uptake if application to this site
becomes necessary. The District has strived to develop a model site. In 2012, in excess
of $1,500.00 was spent to maintain and enhance the application site. In 2012, the
District’s site was used for land application. This was the first time since 2008, just a few
months short of four years since previous use. In September, 471,200 gallons of
biosolids were applied over a four day period for an average 117,800 gallons per day.
Biosolids land application program. This program permitted by the Environmental
Protection Agency (EPA) ran well in 2012. In the required annual report to North
Carolina division of Water Quality (NCDWQ) and the (EPA), there were no deficiencies
or spills. In 2012 there were 208 lime stabilization events at 11,250 gallons per event for
a total of 2,477,250 gallons. This is 60 % of the days in a year. The anaerobic digestion
process produced an additional 932,400 gallons of stabilized solids. Although these
solids have met all requirements for stabilization, they are also limed. This is done solely
for the purpose of odor control. The wastewater plant has entered into agreement with
area farmers for the use of their land for biosolids application. The farmers in turn
receive the nutrient value, moisture content, soil remediation, and lime, which is a by­
product of ph control in the treatment process of the biosolids. If necessary, additional
lime can be applied. There are 3100 acres, consisting of 128 fields, available in Halifax,
Northampton, and Warren Counties. AH acreage was inspected, approved, and permitted
by the State of North Carolina. Using EPA approved treatment processes, 3,379,000
gallons of stabilized biosolids were safely applied to area lands, consisting of 1 I fields
and 308.4 acres, for beneficial reuse. Cost of this application process was approximately
$112,000. Cost of treatment to stabilize solids is separate. Land that grew fescue,
Bermuda, soybeans, wheat, and cotton was applied to. The amount applied in 2012 is
down 21 % from the previous year. Charges for application are based on gallons. In an
attempt to save application costs, biosolids are thickened as much as can possibly be
handled. The removed water is returned to the treatment plant. Also, once biosolids are
placed in storage for land application, water is further separated. This water along with
environmental water (rain, snow, etc) is decanted and returned to the treatment plant. In
2012, 325,384 gallons was decanted, at savings of $10,965. Although 3100 acres of land
is permitted and storage of 1,000,000 gallons is available, at times application is difficult
due to weather conditions, crop status, and crop rotation. Owning land would provide an
outlet for these times. In 2004, the District purchased a suitable land application site. It
is located in Northampton County where the District already has farmer owned land
permitted. The land has been developed for livestock (cow) operation. The area has
been split into two fields. One contains 41.8 acres of fescue and the other contains 67.2
acres of bermuda.
wastewater plant to supply its own power for parts of the day during peak demand.
These requests usually come on the hottest days of summer and the coldest days of
winter. Dominion can then send power that the District would normally use to other
places of need. Winter requests are usually from 6am to 11am (5 hours) but can be 5pm
to 10pm also possibly on the same day. However, each requests counts as one run.
Summer requests are from 2pm to 9pm (7 hours). The contract is limited. In the winter
requests to curtail are limited to 13 or 65 hours and summer 19 or 133 hours. In 2012 the
wastewater plant was called to run 17 times during the summer curtailment. There was 1
winter call. The District does incur the cost of diesel fuel. However, the rate structure
the wastewater plant has because of the contract off sets this cost and provides electrical
energy savings. An added benefit of this program is that it provides a means to exercise
the generator. This keeps the generator in better running condition and exposes any
potential problem. It would be better to find out a problem during a curtailment than an
actual power outage. Dominion does provide one waiver per curtailment season each
year for such cases where a mechanical issue should arise. By having the generator under
a contracted quarterly preventive maintenance program hopefully mechanical problems
will be minimized or eliminated.
- 12-
The biosolids were applied to the Bermuda side of the site only. In contrast for 2008, a
total of 1,053,000 gallons was applied of which 253,500 gallons were applied to the
Bermuda side and 799,500 gallons were applied to the Fescue side for a total of
1,053,000 gallons. This application event was over an eight day period for an average of
131,625 gallons per day.
All industrial pretreatment permits expired in 2012. Pennits were renewed with an
effective date of May 1,2012 and an expiration date of 5/31/2017.
The laboratory' submitted all required evaluation studies and received an acceptable rating
on all in-house study parameters. The laboratory received e-mail notification March 20,
2012 that it had satisfied its performance evaluation requirement for 2012.
The District’s Emergency Response Plan (ERP) was revised in and submitted to the state
October 9, 2012. The PERCS Unit approved the ERP revisions October 15, 2012. Each
industry was sent a revised edition.
In 2012, the pretreatment program began its five year Industrial Waste Survey as required
by state and federal pretreatment regulations. Submittal of the survey is required by
February 1,2013.
The pretreatment annual report (PAR) was submitted to the state pretreatment unit on
February 15, 2012. A letter, dated June 7, 2012, was received stating review of the PAR
indicates the report in good order and satisfied the requirements of the North Carolina
Pretreatment Program (PERCS Unit).
Monitoring Laboratory. The District wastewater plant has an on-site monitoring
laboratory. Analysis for NPDES reporting to the Division of Water Quality must be
performed by a certified laboratory. The laboratory is certified by the North Carolina
Division of Water Quality Laboratory Certification Section. In order to become certified
the laboratory facility must meet space and equipment specifications as well as analysis
performance evaluation. The laboratory- is currently certified for twelve inorganic
parameters and four Vector Attraction Reduction options for the treatment of biosolids.
The laboratory receives samples from approximately 39 sampling points that include
plant monitoring, industrial monitoring, performance evaluation studies, septage hauling,
and collection system samples.
The laboratory has two full-time and one part-time technician, a laboratory supervisor,
and laboratory manager. After the laboratory obtains certification, it must complete an
annual performance evaluation study and submit the results to the state certification
section. This performance evaluation must be in the form of a “blind” study. Study
samples are ordered from a state approved vendor. The study sample values are
unknown to the laboratory. The samples are analyzed and the results are submitted back
to the supplier fro grading. If the laboratory fails to achieve an acceptable rating on a
parameter for three consecutive samples, the laboratory could loose certification for that
parameter. If certification is lost, the laboratory must go through a recertification process
as if they had never achieved certification.
Industrial pretreatment program. In 2012 the industrial pretreatment program had
oversight of three significant industrial users. One user has a categorical discharge pipe.
Five non-significant industrial users are permitted to send flow to the wastewater plant.
Significant and non-significant status is determined in part by the volume of flow
discharged and the pollutants in the discharge. The pollutants, carried by certain
industrial wastes, determine the categorical status of an industry. Each industry whether
classified as a significant or non-significant user is issued a permit with limits and
monitoring requirements. In 2012 there were no significant industrial users in significant
non-compliance; a status based on the number and types of violations of a permit. There
were six notices of violation sent for permit violations.
- 13 -
In 2012, there were 52 restaurants in the District database. There was one restaurant to
close during 2012. Inspections of the restaurants and updates to the database continued
in 2012.
FOG public education is a requirement of the wastewater collections system permit
WQCS00027. Ongoing efforts from 2011 continued in 2012 with the revision of a FOG
slide that airs on local television Channel 15 and the addition of a FOG pamphlet
enclosure with one billing cycle. The administrative staff continues to distribute a FOG
ordinance package to all new Food Preparation Facilities when opening a new account.
The administrative staff also gives out industrial waste surveys to each person who
opened a commercial account that asks questions regarding food preparation and grease
traps.
A requirement of the wastewater plant through its NPDES permit is quarterly chronic
toxicity testing. The test involves using a predetermined amount of effluent along with a
There were no Notice of Violations or Notices to Correct sent out to any restaurant in
2012.
Fats, Oils, and Grease (FOG) Ordinance. The Roanoke Rapids Sanitary District adopted
its first Fats, Oils and Grease (FOG) Ordinance in 2005. Since then operational issues
under the ordinance arose. In 2008, the District addressed those in a revision and
subsequent adoption of new ordinance language.
Additional requirements of the program include state inspections, quarterly in-house
blind studies, maintaining a quality control program and a chemical hygiene plan, a
chemical inventory plan, equipment calibration and certifications, and certification fee.
The laboratory also works in association with the pretreatment program and biosolids
program in that analysis of samples taken by pretreatment technicians and plant operators
are brought to the laboratory for analysis. A laboratory' technician is also responsible for
entry of the resulting data into a spreadsheet that is used by the Pretreatment program for
its Long Term Monitoring Plan. Laboratory technicians are also responsible for data
entry into the plant operations spreadsheet used for NPDES permit compliance
monitoring and plant process control.
National Pollutant Discharge Elimination System (NPDES) permit. The wastewater
treatment plant has an NPDES permit. It is issued by the North Carolina Division of
Water Quality (NCDWQ) after final approval is granted by the Environmental Protection
Agency (EPA). The pennit authorizes discharge of treated wastewater to the
Roanoke River. The current permit is valid through March 2012. However, 180 days
(6months) prior to the current permit expiration an application for renewal must be
submitted. The renewal application was submitted September 2011. A draft permit was
received on December 27, 2012. This draft is provided to the public thirty days for
review and comment. Likewise, the District has thirty days for review and comment.
Some additional requests may be made. This process has begun.
The laboratory works in coordination with the state certification branch to certify field
testing equipment for the surrounding communities with small treatment facilities who
work on limited funds. At this time, the laboratory assists six small facilities with
equipment certification.
There were no sanitary sewer overflows or blockages reported in 2012 that were
attributed to FOG, a continuance from 2011 which also had no overflows or blockages.
The District continues a more frequent cleaning schedule of collection system lines that
service high density housing areas in an effort to further prevent sanitary sewer
overflows. The District also continues to clean lines that service high FOG volume areas,
such as restaurants, before seasonal high flows.
- 14-
Another testing requirement of the NPDES permit is the annual priority pollutant analysis
(APPA). As indicated, it is an annual test that checks the effluent for conventional and
non-conventional compounds, total recoverable metals, volatile organic compounds,
acid-extractable compounds, and base-neutral compounds. These substances, if found in
sufficient quantity, could be harmful to the wastewater plant, receiving stream, and the
public. To date, no substances have been found in significant quantity to cause harm.
The test is done seasonally over the term of a five year NPDES permit.
macroscopic organism. The wastewater treatment plant contracts this test with a private
independent laboratory. They collect sample and run the test. Ceriodaphnia are placed in
the effluent and must survive and reproduce for a specific length of time. Results of the
test are either pass or fail. A pass indicates the absence of substances in the effluent
which may be harmful or threaten aquatic life. The wastewater plant has been required to
test for chronic toxicity since April of 1993 or nineteen and one half years. To date only
one test has received a fail result. This occurred in July 2001. This test was collected
and tested by North Carolina Division of Water Quality (DWQ). DWQ has run this test
again with all passing. The latest was conducted in March 2011.
NCDWQ also requires an Annual Performance Report (APR). The report must contain at
a minimum, general information, performance, deficiencies, violations, spills and
bypasses, any known environmental impacts, and corrective measures to address
deficiencies or violations. Also, from the APR a condensed Consumer Confidence
Report (CCR) must be distributed to the customers of the District with information on
where to obtain the APR.
The wastewater plant now has a general storm water permit. It was received through an
application process as required by the NCDWQ. A requirement of this permit is a written
storm water management plan. The plan is used to evaluate potential pollution sources
and to select and implement appropriate methods to prevent or control the discharge of
pollutants to stormwater runoff. As a part of the plan, semiannual preventative
maintenance evaluations and semiannual inspections of site runoff areas are required.
Safety program. The safety program within the District is very active and assertive in its
approach to the protection of the employees and surrounding citizens. The program
consists of a safety officer, safety committee, incident/accident committee and appeals
committee. The safety officer sets up the monthly safety meetings, coordinates the
activities of the safety committee, keeps up with safety regulations, and many other
various safety activities. The safety committee prepares safety policy programs and
updates current ones. They also do site inspections and produce potential hazard punch
lists. The safety committee and safety officer also keeps up with and prepares for
updating regulations and integrating new regulations of OSHA. The incident/accident
committee reviews all potential accidents and accidents. The appeal committee follows
up the safety committee recommendation at the request of an employee. The attempt is to
minimize the seriousness of an accident and ultimately prevent accidents. As a result of
the awareness and training from the safety program, there were no loss work days in 2012
at the wastewater treatment plant. This makes the 7th straight year the wastewater plant
The Division of Water Quality (DWQ) conducted several inspections in 2012. The first
was on June 4Ih and was a wastewater permit inspection. Areas evaluated included
permit, self-monitoring, laboratory, flow measurement, solids handling disposal,
operations and maintenance, facility site review, records/reports and effluent receiving
waters. The second was on December 4th and was a solids generation and land
application permit inspection. Areas evaluated included miscellaneous questions,
pathogen and vector attraction, recordkeeping, treatment and sampling. The third was on
December 17,h and was a dual inspection. It was a wastewater permit inspection that
evaluated the same areas as the June 4'11 inspection. In addition, a storm water pennit
inspection was conducted. Additional areas evaluated were storm water and pollution
prevention. All four inspections indicated the wastewater plant was well maintained and
deemed compliant.
Permit limit violation
1.C.S.: None
2.WWTP: None
Monitoring and Reporting Violations
2012 Sanitary' Sewers Overflows (SSO)
1.
2. WWTP: N/A
Bypass of Treatment Facility
- 15 -
B. By month, list of the number and type of any violations of permit conditions,
environmental regulations, or environmental laws, including (but not limited to):
C.S.: None
WWTP: None
1.
2.
C.S.: There were 9 reportable SSO in 2012.
1. 5/9/2012 - Belmont pump station. -5100 gallons
2. 7/21/2012 - Manhole 46 at 3rd and Stark Dr.-1800 gallons
3. 8/19/2012 - Belmont pump sta.-6000 gallons
4. 8/19/2012 - River Rd. G-54-75000 gallons
5. 8/19/2012 - Manhole 46 at 3rd and Stark Dr. -6000 gallons
6. 8/25/2012 - Numerous Manhole during flood - 15001 gallons
7. 9/18/2012 - Manhole 46 at 3rd and Stark Dr. -7200 gallons
8. 9/18/2012-4th and Laurel -8400 gallons
9. 10/12/2012 - Hwy 48-Manhole A-l 80 - 2800 gallons
achieved this accomplishment. The Sanitary District was previously involved with the
Department of Labor (DOL) OSHA SHARP Program. DOL works with and inspects
companies by company’s request. After DOL requirements are met, companies are
awarded SHARP recognition. Participating in this program exempts companies from
unannounced inspections with possible fines. The District remained in this program for
several years before DOL restructured the program and removed the District from this
program. The correct program now is the STAR Program. The District began in 201 1
plans for admission into the STAR Program.
In 2012 efforts were continues to be admitted into this program. One of the requirements
is to be evaluated and instructed by a mentor. This would be a facility or organization
that has been through the STAR process and gained admittance. In February, Cabarrus
County sent two representatives to do a site evaluation. A pre-plant walk through was
done. The STAR program was explained in general. Items such as what to get prepared
for, what to expect, how to conduct and OSHA expectations plus others were discussed.
Then a site walk through produced a punch of concerns and deficiencies. Afterward a
post walk through evaluation was explained and the punch list was addressed. Much
time was used in 2012 to address all the items on the list. The most consuming was
general housekeeping. During the STAR preparation, a committee of 14 employees was
developed to implement the STAR program. This represents around 34% of District
employees. STAR program mandates employee participation strongly. Also during
2012, the star committee was given a list of eighteen points ranging from PRE, employee
participation, emergency programs/drills, self-inspections and others. Each member was
assigned one of the points and was responsible for making a presentation to be given to
OSHA at a later date. The committee met on several occasions during the year to
practice and develop a PowerPoint presentation. The presentation followed by a walk
through site preliminary evaluation early next year will determine if the District will be
allowed to continue to the next steps of STAR admittance.
C. Description of any known environmental impact of violations.
D.Description of corrective measures taken to address violations or deficiencies.
1.C.S.:
- 16-
RRSD performed preventative maintenance by cleaning with Jet-Vac and a root cutter
which is attached to the Jet-Vac hose for cutting roots, following with a CCTV camera to
inspect the lines after cleaning. The District also procured a new jetter which cleans the
line more effectively and proves to be more reliable than the old unit. Along with in­
house work, the District contracted services from KRG Utility Inc for further line
cleaning and CCTV.
C.S.: None
WWTP: None
MJ Price Construction cut and cleaned 16 miles of Chokyotte outfall and District
employees cut and cleaned 4.5 miles of outfall and cross country lines. KRG Utility Ic.
Cleaned and CCTV 16186.9 feet of line and District employees cleaned 70127 feet of
line fora total of 16.35 miles of line cleaned.
RRSD secured a planning grant from The Rural Center in 2012 to further evaluate the
Belmont area. The District employed W. K. Dickson to conduct a study including more
smoke testing, manhole evaluations and storm water dye testing to locate sources of l&l,
which has been the root cause of many reportable spills over the past few years.
1.
2.
1.
2.
C.S.: N/A
WWTP: Three
The first occurred on August 19Ih. Nearly two and one half inches of rain had fell
just prior to this date. Then an additional three and one half inches fell on this date.
Much higher than normal flows tried to pass through the plant. Approximately
63,000 gallons was bypassed that received grit and rag removal with primary
clarification and first step secondary treatment. On August 25th two bypasses
occurred on the same day when Roanoke Rapids received nearly twelve inches of
rain in approximately five hours. Flows into the plant, rated at 8.34 million gallons
per day (MGD), exceeded 20 MGD. The plant was overwhelmed with flow it could
not handle. The first location bypassed approximately 1,095,000 gallons which
received grit and rag removal treatment only. This lasted for about sixteen hours.
The second location bypassed approximately 1,363,000 gallons which received grit
and rag removal, primary clarification, and first step secondary treatment. This
lasted for about nineteen hours.
In October of 2012, RRSD contracted with KRG Utility and Ralph Hodge Construction
to pipe burst 372 ft. of 18” clay pipe to 21” polyethylene pipe to eliminate l&l from
several points in that line. The District replaced Manhole 180 in Hwy 48 with a new
manhole just off Hwy 48 in the right-of-way. At this time, the District also rerouted the
force main from 48 Lift Station to the new manhole. We had to bypass pump this section
of line while replacing for a period of approximately 2 weeks. We also had to pump and
haul from Hwy 48 Lift Station during this time.
During 2012 District employees performed 5 point repairs on sewer lines.
1. 8" and Rapids - 8’ section of 8” sewer line
2. 817 Rapids St. -replaced 14’ of 8” sewer line
3. East 7th St. - replaced 7’ of 8” sewer line
4. Premier Blvd. - replaced 6’ of 10” sewer line
5. 628 Marshall St. - replaced 20' of 12” sewer line
6. Installed new manhole on dead end line at 400 block of Carolina St.
r
2.
- 17-
WWTP:
The WWTP is very aggressive in reacting to violations and identifying potential
deficiencies. Once identified, plans are made to upgrade or replace potential deficiencies,
which may result in violation. Modifying operations, training operators, laboratory
training, improved equipment, maintenance inventory parts and equipment and raising
awareness is also an on-going and continuous process.
Some of the work done to prevent problems is the identification of potential spill areas.
Once identified, arrangements are made to stop or minimize and contain.
Primary clarifier influent lines have grease collection pits located on them. As the pits
collect grease and fill, the flow through the influent lines can be restricted, back up, and
cause spills. To prevent this from occurring, a contracted vacuum truck company is
scheduled regularly to remove the excess grease and keep he lines unrestricted.
Secondary clarifiers can have solids washed out during periods of high flows.
Operational strategies have been put into place to minimize this.
Low influent suspended solids can occur after rains making the 85% removal difficult.
Polymer can be fed into the secondary clarifiers aiding settlement of solids and help with
the 85% removal rate.
Training and directives have been put in place to prevent icing problems and equipment
failure that can result from the scum control spray system on the secondary clarifiers.
The hypochlorite bulk storage tanks, which came on line in 2001, are now on an annual
inspection program. The hope is to catch a problem, preventing a catastrophic spill
During high flows or some maintenance repairs, influent flow can be diverted to
equalization storage tanks. Once flows lower or repairs are complete, the stored water is
returned to the plant for treatment. Flow is diverted to these tanks with the use of a 12
inch (5 MGD) pump. Proper maintenance of the pump is critical. It has been rebuilt
once and is on an annual preventative maintenance contract to ensure reliability. The
pump is started monthly and quarterly pumping is done.
During the construction of the disinfection/disinfection removal process, a truck
unloading containment structure was installed. The structure is piped to a pumping
station equipped with pH alarms that are tied to the SCADA system. This provides
acknowledgement and control over a spill situation that may occur during chemical
delivery. The spill containment grating is open air. Normal rain can fill the containment
system. This would prevent collection in this system and a spill could occur. Level
indicators were installed on the containment system with SCADA. Now rain water, as it
accumulates, can be removed. Also, before each chemical delivery the system is pumped
down. The system is also pumped down regularly by assignment. To further control this
area, the discharge valve is kept in the closed position and the pump turned off.
The Emergency Flood Pump Station is critical for the removal of wastewater from the
plant when river levels are high. This station is backed up with a diesel pump capable of
removing the wastewater flow in the event of pump station failure or electrical failure.
Two things were done to ensure the diesel pump preparedness. The first was an engine
heater was added to ready the diesel for immediate use. Second, an automatic starter was
added to start and run the pump weekly for a specific amount of time. This keeps the
pump ready for use also.
- 18-
A valve exercise program is now employed. It keeps valves in good working order. In
the event of routine maintenance, equipment problems, or emergencies, valves used to
address these issues are in a state of readiness. As valves are repaired or replaced, they
are added to the exercise list. There are hundreds of valves located inside and outside of
various areas. Each operator has a list of valves to exercise.
Temporary pumps and hoses are used frequently. Hoses easily spring leaks. To prevent
hose leaks while pumping wastewater or biosolids, lay flat hose was replaced with
reinforced canoline hose.
There are various pump station alarms throughout the plant. Some are equipped with
local visual lights and audible horns or sirens, and some are even equipped with remote
SCADA alarms. In an attempt to keep functioning alarms, they are tested on a monthly
basis. As more alarms are installed, they are added to the testing list.
The gravity tank wet well pump station has been a site of previous spills. The station
now has a local high level alarm horn and light. This signal has also been added to the
SCADA system to give this alarm remotely to the operations building.
The plant storm water drains are blocked and gated to help control spills that might
otherwise be released from the plant site. Although painted bright yellow, they were
struck and broken on occasion. A new design keeps the containment from being easily
struck. Also, flags on poles have been added, further increasing visibility.
The SCADA alarm system is an extremely valuable tool for preventing spills and other
problems. As problems arise or equipment fails, prompt attention is given to repairs so
the alarms are returned to service.
The plant generator is capable of powering the entire plant in the event of power loss.
Without it, spills would occur. It is on a contracted quarterly preventative maintenance
program. Also, the transfer switch transfers incoming power to generator power is under
a preventative maintenance contract. Annually it is taken off line, disassembled,
inspected, and cleaned. Without a properly operating transfer switch, generator use is not
possible. It is also exercised monthly by the staff. And, curtailment program with the
main power supply company assures further testing and exercise of the generator.
Identifying and eliminating inflow and infiltration (l&I) is an on-going and difficult task.
It is important to control I&l to take excess flows off of the treatment plant. However, it
is also important to address because excess l&l “dilutes” incoming waste. With diluted
wastewater it is more difficult to meet the percent removal requirements (85%) of the
plant’s permit, l&l also hydraulically over loads treatment processes making it harder to
meet permit limits. In addition to hydraulic overloads during these events, debris such as
sand and rock, which has built in the collection system, gets flushed to treatment plant.
On two occasions in 2012 this was a significant problem. On August 19,h approximately
three and one half inches of rain fell in a relatively short period of time. Flows for the
day spiked up to 18.6 million gallons and the total for the day was 9.2 million gallons
(total plant capacity is 8.34 million gallons per day). Then on August 25tl' (less than one
week later) Roanoke Rapids received an additional eleven and one half inches of rain in a
very short period of time. Flows for the day spiked over 20 million gallons and the total
for the day was 14.7 million gallons. On August 19’1' the high flow flushed
approximately three pickup truck loads of sand and rock into the Rotomat/Grit collector
channel, basically shutting down these treatment processes. A vacuum truck has to be
brought in to vacuum all the debris out. Then less than one week later on August 25th an
additional two pickup truck loads of sand were flushed into the same area of the plant.
Again a vacuum truck was used to remove the debris. Average flow for 2012 was 3.5
million gallons per day. The month of August alone was 5.2 million gallons per day.
In 2012, more areas were identified and addressed to help resolve these problems. (See
II.D.I, above)
r
- 19-
The wastewater plant has a protective bank next to the Roanoke River, to the north,
Chockyotte Creek, to the east, and an unnamed creek, to the west. The entire length is
several thousand feet in length and over fifty feet in height in some locations. The slope
is very extreme. Several years ago the river began eroding the bank away. The District
began stabilizing the slope with a cloth bag filled with grout. The bags start at the top of
the slope and extended down into the river by several feet. The entire length was done in
sections. The next step was to stabilize the toe of the bags at the bottom of the river.
This was done with stacked storm cloth bags to secure the slope bags. After several
years, the last of the storm bags was completed in 2012.
The Stormwater Pollution Prevention Plan (SPPP) is a valuable tool in identifying
deficiencies. It incorporates annual awareness and training to all plant personnel. It also
requires semi-annual inspections of all plant equipment and facilities, containment, and
tanks and chemical storage. The plan also addresses chemical suppliers and contractors
through training. The plan allows for scheduled identification of deficiencies before they
become problems.
Each year during the budget process, close scrutiny is paid to the potential of deficiencies
which could lead to violations. Any identification of potential problems is addressed
during this process so that they are remedied before problems arise.
The Fat, Oil, and Grease (FOG) program continues to be a useful tool for the prevention
of spills. A pretreatment technician oversees and implements the program. The
technician inspects restaurants to ensure grease trap maintenance. Best Management
Practices for the control of grease entrance into the collection system is also conveyed.
Part of the FOG program is public education. The technician is required to incorporate
all users of the collection system. This is accomplished through door hangers, bill
inserts, poster distribution, advertisements, public service announcement and public
displays.
III.NOTIFICATION
IV.CERTIFICATION
-20-
Reduce
Recycle
Satisfy
Develop
A. I certify under penalty of law that this report is complete and accurate to the best of my
knowledge. I further certify that this report has been made available to the users of the
named system and that those users have been notified of its availability.
A. A condensed, summarized version of this report will accompany the annual water report
which will be distributed to the users and customers of the Roanoke Rapids Sanitary
District via mail. The full report will be available at the main office upon request.
R. Danieley Brown, PE/
Chief Executive Offic/r
Date
ANNUAL PERFORMANCE REPORT 2012
ROANOKE RAPIDS SANITARY DISTRICT
I.GENERAL INFORMATION
B.Responsible entity: Roanoke Rapids Sanitary District, Dan Brown, CEO
C. Person in charge/contact
1.
2.
D. Applicable Permit(s)
1.
2.
E. Description of C.S.:
The Chockoyotte Creek Interceptor handles the south side of Roanoke Rapids and three sub­
divisions, Lake View Park, Greenbriar and Lincoln Heights, outside the Roanoke Rapids city
limits. The Interceptor begins east of Zoo Road. There is one primary basin pump station
along the route. Pipe size ranges from 12” to 30”.
The system has six sewer lift stations. Three stations are located in the Gaston, NC system.
One of these serves a Northampton County School, one serves the Chowan Housing Projects
and the other station pumps all flows from Northampton County across the NC 48 Bridge
crossing the Roanoke River to the Roanoke River Interceptor. The remaining three pump
stations are located within the Roanoke Rapids system. Two of the stations, Belmont and
C.S.: North Carolina Environmental Management Commission System-wide
Wastewater Collection System Permit No. WQCS00027
The collection system consists of approximately 130 miles of sewer lines. The sewer lines
within Roanoke Rapids, Gaston and all sub-divisions, which connect to the two main
Interceptors, range in size from 8” to 12”. There are two main Interceptors transporting
waste water to the WWTP.
WWTP: Gregg Camp, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, WWTP
135 Aqueduct Road
Weldon, NC 27890
Phone: [phone]
The Roanoke River Interceptor collects wastewater from basins located on the north side of
Roanoke Rapids. The Gaston and Northampton basins are included in this service area. The
Interceptor begins just west ofNC 48 in Roanoke Rapids. There are 3 primary basin pump
stations and 2 secondary pump stations along the route. Pipe sizes for the Interceptor ranges
from 18” to 30”.
WWTP: NPDESNC0024201
Land Application (L.A.): WQ0001989
Stormwater (General): NCG110000
C.S.: Gregg Wilson, Supervisor
Melvin Douglas Moore, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, Distribution & Collection
PO Box 308
Roanoke Rapids, NC 27870
Phone: [phone]
A. Regulated entity: Roanoke Rapids Sanitary District, Collection Systems (C.S.) and
Wastewater Treatment Plant (WWTP)
II.PERFORMANCE
A. Description of overall 12 month performance, noting highlights and deficiencies:
The performance of the system in 2012 was good.
-2-
The wastewater treatment plant is rated at 8.34 million gallons per day (MOD). Peak flow is
rated at 12.5 MOD.
Poplar Springs, discharge to the Roanoke River Interceptor while the Greenbriar Pump
Station discharges to the Chockyotte Creek Outfall.
Treatment processes at the wastewater plant include grit and rag removal. This is followed by
primary clarification, trickling filter biological secondary treatment, activated solids
treatment, secondary clarification, final effluent chlorination/dechlorination processes, and
final pH adjustment.
The Fat, Oil and Grease (FOG) program initiated in 1995 has been a good tool in
preventing Sanitary Sewer Overflows (SSO’s). We also have a fulltime employee for the
FOG Program who specifies type and capacity of grease traps on an individual basis for
all developments, maintains all records and inspects all grease traps. He also educates all
restaurants and high density residential housing about grease and how it affects our sewer
lines. The use of local newspaper for FOG program educational ads and the distribution
of brochures to restaurants and fast food businesses have also been effective.
Maintenance of records and inspection of grease traps is an ongoing measure to prevent
SSO’s.
There are two pumping stations in the wastewater plant distributing wastewater into and
through the plant. Of these two pump stations, one has the capacity to pump 20 MGD and the
other 27 MGD respectively. Also, to aid these two pump stations; a storm water pump station
has been installed. This station intercepts rainwater, an unnecessary load to the treatment
plant, and removes it before entry to the plant. It has the capacity to pump 11.5 MGD. hi
conjunction to these two pump stations there is one pump station with capacity of 21 MGD to
remove treated flows from the plant in the event of high river levels preventing normal gravity
flow discharge. Various others pumps and mixers are located throughout the plant for process
control.
Preventive Maintenance of at least four hours a week cleaning sewer mains has also been
an effective tool in reducing sewer backups and overflows. In 2012, District forces
During these processes solids are removed from two locations. Primary clarification removes
settleable solids from incoming wastewater to an anaerobic digestion unit. Here the solids, in
the absence of oxygen, receive pH adjustment, mixing, and heating to produce a stabilized
material. Once the solids are stable, excess water is decanted and returned to the plant for
further treatment. The stabilized, thickened solids are treated with lime for odor control then
removed to a holding tank to await land application.
Secondary clarification removes solids from the activated solids process. Here, solids in the
presence of oxygen, ph control, and mixing, accumulate in excess. They are removed,
chemically stabilized, and added to a holding facility. All stabilized solids are analyzed and
land applied according to their nutrient value, ceiling and accumulative requirements.
F. Description of WWTP:
1. C.S.:
The Roanoke Rapids Sanitary District’s collection system received its inaugural pennit in
2001 under the North Carolina Environmental Management Commission Department of
Environment and Natural Resources system wide wastewater collection system-
pennitting program.
-3-
In response the District has maintained staff, critical parts inventory, equipment
inventory, made plans to better address extreme conditions, upgraded critical equipment,
planned back up or alternative operations, and requested better responsiveness from sub­
contractors. Responses are continuous and increasing.
Cun-ent plant capacity is 8.34 million gallons per day (MOD) with a peak flow of 12.5
MGD. For 2012 the yearly average low flow was 2.6MGD with minimum of 1.8 MGD.
The yearly average high flow was 6.7 MGD with a maximum of 14.7 MGD. The yearly
average total flow was 3.5 MGD or 42% of the plant capacity. This is an increase of only
100,000 gallons or nearly a negligible rise in flow. Rain can affect flows by inflow and
infiltration. In 2012, 58.0” of rain was recorded at the wastewater plant. The previous
year 46.8” was recorded. This is an increase of 11.2” from the previous year and a 16.0”
increase over 2010. The increase in rain may have contributed to the negligible increase
of 100,000 gallons in 2012. However, with this significant increase in rain the last two
years, it is further evidence the District’s efforts to minimize inflow and infiltration is
working.
continued proactively cleaning the mains of high density residential housing prior to
major holidays to prevent any grease related spills. The use of degreasers in pump
stations on a regular schedule has proven to be very effective in preventing lift station
down time. Also all pumping stations are checked and cleaned a minimum of once
weekly.
The permit also contains daily maximum residual chlorine of 50 ug/1 (micrograms per
liter or parts per billion). Also permitted is pH. It must be maintained between 6 and 9
units. These two samples are grab or instantaneously collected.
There were nine reportable spills in 2012 of the collection system. The worst of these
was on August 25 when Roanoke Rapids had 11.5 inches of rain in a short period of time.
There were several streets washed out due to storm water and numerous sewer lines
washed out. District employees were very diligent in getting these lines repaired and
back in operation. There were also overflows from numerous manholes during this
event.
The SCADA system that monitors all lift station 24 hours a day, 365 days a year has
prevented lift station overflows. In addition, each lift station is equipped with emergency
generators on site to prevent overflows from power outages, except Poplar lift station. In
the event we have rain or outages predicted, a portable generator is placed at the lift
station in case it is needed.
Under the current permit, the District has a weekly effluent total suspended solids (TSS)
limit of 45 mg/1 (milligrams per liter or parts per million) and a monthly limit of 30 mg/1.
Also a weekly carbonaceous biochemical oxygen demand (CBOD) limit of 37.5 mg/1 and
a monthly limit of 25 mg/1. These two samples are composite collected. They are
collected over a twenty four hour period and on a flow proportional basis. The higher the
flow, the more sample collected and conversely, the lower the flow, less sample is
collected. The yearly average for TSS was 16.3 mg/1 and CBOD was 6.3 mg/1. Using
yearly average influent values for the same parameters this calculates to a 93.8% and 97.0
% removal rate respectively. The permit requirement is 85%.
The District is keenly aware of and has been very responsive to increasing environmental
awareness. House Bill 1160, Clean Water Act of 1999, ratified by the North Carolina
General Assembly on July 20th and signed into law July 21st by the governor, has
heightened this awareness. This bill codified as Chapter 329 session laws became
effective October 1999.
2. WWTP:
Overall performance for 2012 was good. There were no NPDES permit limits violations.
(See below) There were no monitoring or reporting violations.
Some of the repairs and upgrades in 2012 include the following.
-4-
In 2012, the District continued to be very active in maintenance issues and concerns. The
WWTP spent in excess of $641,000 on maintenance and repairs to equipment, supplies
and materials necessary to operate equipment and capitalized monies to replace and
upgrade equipment.
Influent diversion box. The influent diversion box is the first area of the wastewater
process. The open air collection pit is where the two main interceptors bring all the
wastewater in the District’s system to the wastewater plant. A 30” line, Roanoke River,
and a 36” line, Chockyotte, meet and blend at this location. From this point they are
piped to the first treatment process or preliminary station consisting of rag and grit
removal. The diversion has two slide gate valves. The influent gate when open allows
all flow from the Chockyotte and Roanoke River lines into the treatment processes of the
plant. Occasionally it must be closed to stop flow into the plant for downstream
equipment repairs. At this time all the flow is pumped to storage and returned to the
plant after repairs. The influent gate is an original gate from 1963 and is failing. A new
gate has been purchased to replace the original.
There were two rain events within one week of each other in August causing flows to
increase significantly which flushed lots of hard granular material into the Rotomat.
During these events, the comb was damaged. The comb acts to dislodge captured
undesirable materials into a conveyor that removes this material. The comb, made of
hardened stainless steel was bent and the holding bolts broken. This was causing the unit
to run in a bind and trip out. The comb was straightened out and reattached, returning the
unit to use. The Rotomat is the primary debris removal equipment which works
automatically. There is a manual back up which can be used in the event the Rotomat is
in need of service or repair. There are gates that are used to direct flow to whichever unit
needs to be used. The gate frames are original equipment from the 1960’s and made of
carbon steel. The gate frames had deteriorated and were replaced with stainless steel
frames.
Rotomat. The Rotomat is the first piece of equipment in the wastewater process. It
removes rags, plastics, paper, or other non-organic material before they can enter other
downstream processes. This is important to keep this material from clogging pipes,
binding pumps and mixers, and causing damage to other equipment. Flow enters a basket
area. As materials build up in the basket area, a sweeper arm comes on to remove the
built up items. The sweeper passes through a comb which causes the material to be
dropped into a screw auger for removal from the wastewater flow.
Influent pump station. The influent pump station transfers all incoming flow into the
plant. The station is equipped with four pumps. Their pumping capacities are 2, 4, 7, and
7 million gallons per day (MGD). The 2 and 4 MGD pumps are the “work horses” of this
pump station. They handle the majority of the work on normal flow days. This spares
Grit Collector. The grit collector removes grit from the influent flow. Grit is removed at
this location to prevent excessive wear on downstream equipment. There are two grit
collectors. One is the primary collector and the other is a back-up. The primary unit,
installed in the mid 90’s, uses a vortex motion to settle grit out of incoming wastewater.
A pump removes the settled grit from a hopper to a screw conveyor for removal to a
dumpster. The back-up collector, original equipment installed in the early 60’s, uses
gravity to settle grit to a sump pump which pumps to a screw conveyor for removal to a
dumpster. Although this equipment is much older and less efficient than the newer
vortex technology, the gravity system is maintained for use during times when the vortex
unit may be down for repairs. There are gates that are used to direct flow to whichever
unit needs to be used. The gate frames are original equipment from the 1960’s and made
of carbon steel. The frames had deteriorated and were replaced with stainless steel
frames.
Filter Effluent Pump Station. The filter Effluent Pump Station (PEPS) collects all
incoming flow that has traveled through the primary clarifiers and trickling filters. It then
transfers this water on to the secondary system for further treatment. This station is
equipped with four pumps. Their pumping capacities are 2.1, 7.9, 7.9, and 9.2 million
gallons per day (MGD). Here as with the influent pump station, the smaller pump is the
“workhorse”. At this station the two 7.9 MGD pumps alternate after equal run times to
aid the 2.1 MGD pump during normal flows. The 9.2 MGD pump is the high flow pump
at this station. One of the 7.9 MGD pumps developed a vibration. To minimize damage,
-5-
wear and tear on the larger 7 MGD pumps which are needed in cases of higher flows.
They alternate based on run time hours until flows increase to a level where both are
needed together. This station is equipped with an emergency flow release valve in the
event flows from extreme weather conditions come in faster that the pumps can remove.
Without this valve catastrophic failure of the station would occur causing a long down
time for repairs. The valve is original equipment from the 1963. It is old technology
metal flap to metal seal and does not seal well allowing environmental waters to enter the
pump station placing extra unnecessary flow on the station. This valve was replaced with
an elastomer style valve that completely seals.
Rotary Distribution (Trickling Filter). Biological waste water treatment begins at this
phase of the wastewater treatment process. There are two rotary disfributors.
Wastewater from the primary clarifier enters the center column of the circular rotary
distributor. The center column splits the water equally to four distribution arms. The
arms have holes (orifices) in the top which the water passes through then down the front
of the arm. This causes the distributor to rotate. Underneath the arms is a 5’ this bed of
rock. Microorganisms grow on the rock surface and as the wastewater trickles through
(trickling filter) the bed of rock, the microorganisms start cleaning up the wastewater.
The four arms supported by 1” vertical diameter stainless steel support truss rods
connected to the center column. There are 5 per arm for a total of 20 on the distributor.
In addition, there are two half inch horizontal cables between the four arms for a total of
eight. These cables help stabilize the arms. One of these cables broke and had to be
replaced.
Primary Clarifier. Primary clarifier (primary) is a circular tank with a cone shaped
bottom. Without the cone, the tank is 12’ deep. There are two primaries. At the bottom
of the cone is a hopper attached to pipe work that leads to a pump station called the
Primary Solids Pump Station. Wastewater which contains organic solids enters the
primary. A baffle slows the velocity of the wastewater entering the primary allowing the
solids to settle to the bottom of the tank. A motorized sweeper located on the tank
bottom sweeps the settled solids into the hopper. Using the pumps in the Primary Solids
Pump Station, solids are removed from the primary at regular scheduled intervals. The
solids are transferred to another process where they are treated and stabilized. There are
two horizontal centrifugal chopping pumps located in this pump station to make this
transfer. 1 hey are used on average three times a day for approximately an hour each
time. They transfer solids which by nature are abrasive. During the course of the year
both pumps started showing signs of inefficiency. On separate occasions they were
removed for repair. A spare is available to use in the absence of a pump under repair.
These pumps are also equipped with sight glasses for observing the thickness of the
solids being transferred. Only the thickest should be transferred. One of these sight
glasses began to leak and had to be repaired. The surface of the primary is skimmed by
a motorized skimmer. Its purpose is to remove floatables, mainly grease, from incoming
flow. These floatables are deposited in a trough connected to a collection box. Each
primary has one. The floatables are transferred to the same treatment and stabilization
process as the settled solids. There are two submersible vertical centrifugal chopper
pumps that are used for this application. One of these pumps also began having problems
transferring the collected floatables. It was removed and repaired. A spare is available to
use in the absence of a pump under repair. Due to some equipment installation in the
pump station which involved the roof and due to the age of the roof covering, the roof
covering had to be replaced.
There are four blowers, two 75 horsepower (#1 & #3 and two 100 horsepower (#2 & #4).
Blower #3 had multiple repairs in 2012. Each blower has an inlet and outlet bearing. On
#3 the inlet bearing had to be replaced. Also, the motor on the #3 blower went bad. The
motor was repaired and replaced. Finally, the internals of the blower failed. The motor
and bearings repairs were done in-house. However, the internals repair is an intricate job
so it was returned to the manufacturer. The repair was completed and the blower was
returned to service. In its absence, a spare was utilized.
Removing and installing motors is difficult. The work area around them is small and the
power and motor leads are connected in a manner that disconnecting & reconnecting is
awkward because of a small electrical box. To make this easier, larger connection boxes
were installed on all four blowers and power/motor leads were fitted with quick
disconnects.
Secondary System. The Secondary System is a biological treatment system consisting of
three aeration basins and two secondary clarifiers. The system is operated by the use of
various valves and piping, control panels, traveling siphon bridges with valves and
skimmer arms, gear boxes, motors, pumps, and blowers. Various repairs and upgrades
were done.
the pump was promptly removed from service and repairs made. Afterwards the pump
was returned to service.
Each aeration basin is equipped with a mixing pump. They are piped into the basin so
that they blend basin content with blower air causing a mixing action. Each mixing pump
is controlled with a variable frequency drive (VFD). The VFD can speed up or slow
down the motor affecting the dissolved oxygen concentration in the basins. The displays
on the mix pumps that control the speed faded out and had to be replaced.
Each pump has an automatic oiler to keep the internals lubricated and in working order.
In 2012 these oilers began to fail and had to be replaced. In addition, each pump has an
electrical control cabinet. These cabinets build up heat and if not removed will cause the
pump to trip out. To keep this from occurring, each cabinet is equipped with a cooling
fan. These fans began to fail and had to be replaced.
Disinfection. The final phase of the water treatment process is disinfection (pathogen
kill) and disinfection removal. Sodium Hypochlorite (bleach) is added to the wastewater
flow in sufficient amount to destroy potentially dangerous virus and bacteria. After this
process, sodium bisulfite is added to remove any remaining hypochlorite. This is
necessary because hypochlorite is hazardous to the aquatic life of the receiving stream.
This system is nearly two years old now and issues with it are beginning. The chemical
feed and transport lines and valves are PVC. Several locations along the PVC lines and
some valves had to be repaired. Cracks developed in lines and valves necessitating
replacement. Also, gaskets in several valves deteriorated which caused leaks. These
gaskets were replaced. The pumps that move the chemicals in this system are diaphragm
-6-
The electrical control system of the syphon bridges has had numerous repairs over the
years. The connection system was in a state of disrepair. The connection system was
replaced to make future repairs easier and safer.
The mix pump system is accomplished with piping where air and solids are blended and
injected. The piping is connected with flanges. In 2012 some of the flanges failed & had
to be replaced. Both secondary clarifiers have a traveling syphon bridge driven by a
motor and gearbox with chain and sprocket and a pulley cable system. The traveling
syphon bridges had previously been retrofitted with temporary priming valves. These
valves were subject to leaking causing prime loss of the bridges. These valves were
removed and the prime of the bridges improved significantly. The traveling bridges arc
equipped with a clutch system. In the event of any binding of the system, the clutch
releases to protect the system. The clutch on #2 failed and was replaced.
-7-
All functions of the heat exchanger are controlled by one piece of equipment called the
■‘fire eye”. It is a safety component. If it senses improper operation of any electrical part,
it will not let the heat exchanger fire. If the eye itself fails, the heat exchanger will not
start either. Heat exchanger number 2 had this type of failure and had to have a new “fire
eye” installed. Also, on number 1 heat exchanger, the gas regulation valve failed. This
part opens up as demand for gas, either methane or natural, increases or closes down as
demand decreases. This is all dependent on temperature settings. The gas regulator had
to be replaced to restore temperature control. The water bath of the heat exchangers is re­
circulated with a water pump to keep the warmest water in contact with re-circulated
solids. Without recirculation, proper solids heating will not occur. Heat exchanger
number 1 water pump failed and had to be replaced.
Digesters and Stabilization. Digesters receive solids removed from primary clarifiers.
With heat and mixing and occasional chemical addition for pH control, solids are
stabilized. There are two digestions tanks. Each is heated with its own heat exchanger.
Each heat exchanger is a two chamber piece of equipment. One side is a heat
compailment and the other a water bath. Solids are re-circulated between the two
chambers where the heat is transferred or exchanged. A byproduct of the stabilization
process is methane. It is captured and used for fuel to heat the exchanger. The heat
exchangers are also equipped to run off natural gas as well at times when methane
production may be low or temperatures are colder requiring the use of supplemental fuel.
For this operation gas valves are required for both types of fuels.
The water that is re-circulated through the heater is a closed loop system. It is reused
over and over. With some time water may be lost because of evaporation or possibly a
slight leak. To compensate for this each heater is equipped with a replenishing water
storage tank. One tank was installed in 1963 and the other in 1983. They both were
deteriorating beyond repair. Without storage water the heater will not run. A safety
device will recognize no water and shut the heater down. To prevent this storage tanks
on both heaters was replaced. Excess heat from the heaters has to be exhausted just as in
an automobile. The heaters are forced air vented through exhaust piping with the use of a
blower. It is important to exhaust properly to prevent noxious fumes, for example carbon
monoxide, from building up in the digester building. Heater #1 had some problems with
its exhaust system. First, the motor went bad and had to be replaced. Second, the
exhaust piping deteriorated and had to be replaced. To monitor proper temperature
settings, the digesters are equipped with chart recorders. The number one chart recorder
failed and was replaced. Each heater is equipped with a solids horizontal centrifugal
recirculation pump. The pump pulls solids out of the digester and loops them through the
heater and then returns them back to the digester. This looping can be intermittent or
continuous depending on temperatures and temperature settings. The pump for number 1
digester underwent a couple of repairs. First, the pump motor failed and had to be
style. There are two for the hypochlorite and two for the bisulfite. On average after a
year of service, these pumps have to be rebuilt. In 2012 these pumps were started being
rebuilt with the kits supplied by the manufacturer. The tanks which house the chemicals
are under warranty. To maintain this warranty, they must be inspected annually. In
2012, their first inspection was done. The electrical control system for the chemical feed
system must be protected from electrical surges which could result from lightning. The
piece of equipment used for this protection is a transient voltage surge suppressor
(TVSS). During a lightning storm, the TVSS stopped a surge and protected all
downstream electrical equipment as it is designed to do. However, when this occurred
the TVSS was damaged. The TVSS had to be replaced to continue to protect the
electrical equipment. A separate electrical issue arose in 2012. Voltage to the
disinfection building became erratic and low. Equipment in the building could not
operate correctly. After a search it was discovered that the electrical wires from the
motor control center feeding power to the disinfection building was not a continuous run.
Wires had splices in it located in an electrical access junction manhole. The splices had
corroded causing the electrical issues. The splices were repaired using a better style
splice kit hopefully to avoid this occurrence again in the future.
replaced. Second, the seal went bad causing a leak. The seal had to be replaced to stop
the leak. The tops of the digesters are unique. They are metal and float on the solids
being treated. They move up and down depending on the amount of solids in the
digester. However the tops are restricted to the “working zone” of the digester. If the top
gets too low it could crush. To high and it could fall off. To monitor this, the tops are
equipped with a level indicator with alarms. The alarm on #1 digester failed. It had to be
replaced to restore this safety feature. Because these tops are metal and exposed to the
atmosphere, they require painting to prevent deterioration. All tops were painted in 2012.
The pump at this station became inefficient. The pump impeller or the part that actually
forces flow wears over time. If it is not completely worn out it can be adjusted to return
efficiency. However, when completely worn out it must be replaced to return efficiency.
The pump was removed and inspected. The impeller only needed adjustment to return
efficiency. From this pump station the solids are pumped to one of two gravity settling
tanks. Flow out of these tanks is by gravity. Over the years flow from tank number 2
became restricted. On several occasions the tank had been inspected for debris causing
the restriction. The drain piping was also dismantled in this search as well. Trash and
debris was found on a couple of occasions but when put to use it still would not flow
well. Tank number 2 was rotated off line again this year to cycle the tanks for equal
wear. Number 2 was also scheduled to be painted inside and out. To help accomplish
this the drain piping had to be dismantled. Another opportunity was taken to search for
the restriction. However, this time a TV camera was inserted into the lines. At this time
a plastic cap and a rubber float control cover were discovered. Previous cleaning of the
line had not removed this debris. This debris was removed and after the tank received its
paint job it was returned to service. Flow from this tank now has returned to normal.
During the year this same tank required other repairs as well. There is a motor and
gearbox attached to a mixing paddle. The paddle mixes the solids and polymer to make
good contact and aid the settling process. Both motor and gearbox wore out and had to
be replaced. Solids flowing out of the gravity tank are sent to the drum concentrator.
The concentrator runs on a series of pillar block bearings. These bearings stabilize the
drum. Without this stabilization the solids thickening belt tracks off the concentrator.
One of these bearings wore out and had to be replaced. Before polymer can be used for
the gravity tank or concentrator systems it must be maintained. Polymer is received in
concentrated form. It must be maintained through mixing. This is accomplished with the
use of progressive cavity pump. During the year a few repairs became necessary. First,
the pump motor failed and had to be replaced. Later the pump lost efficiency. The pump
was removed and taken apart. There are two parts working together to create the
pumping. The rotor and stator are these two parts. The stator was found worn and was
replaced. This returned the pump to normal efficiency.
Biosolids Thickening. Excess solids from the secondary treatment process are thickened
by gravity settling tank and a drum concentrator with the use of polymers. Polymers
when mixed with solids create a reaction which causes solids to concentrate (floc) and
water separate. The purpose is to minimize the solids removed from the treatment plant
because removal charges are based on the amount of gallons removed. Excessive solids
from the secondary system enter a pump station by gravity flow. From here the solids are
pumped to a gravity settling tank to begin the thickening process. There are two gravity
settling tanks and one drum concentrator. Current flows necessitate the use of only one
gravity settling tank. This provides back up for the tank on line. The gravity settling
tank and drum concentrator can be used separately or in series. Wastewater operations
dictate which is used but normally the series option is used with the solids first entering
the tank. The gravity setting tanks are switched regularly to ensure proper operation and
even wear and tear on equipment. The pump station is used to send solids to the gravity
settling tank.
Lime Stabilization. Waste activated thickened solids are stabilized through the use of
lime. Time and pH’s dictate the stabilization requirement. Lime is received in dry form
and transferred to a storage/feed silo. The dry lime is then fed to a preparation tank
where water is added creating slurry which is then added to a mixing tank containing
-8-
-9-
Generator. The plant generator is used to supply the entire plant with power in the event
utility power is interrupted. The generator is on a quarterly preventative maintenance
program with a contractor to maintain the engine. However, if the transfer switch which
transfers power from utility to generator does not function properly the generator cannot
Even though the MGT is mixed constantly, lime still precipitates out. Over time it builds
up on the tank bottom. This reduces the effectiveness of the mixers. Approximately
once a year, the tank is emptied and cleaned to remove the built up lime. This time also
allows for the mixers to be inspected for wear and tear and an opportunity for the oil
levels to be checked. Also, the integrity of the MGT can be inspected. However, the
inspection in 2012 was due to an emergency. One of the riser pipes for solids transfer
built up pressure and blew apart at the mechanical joint near ground level. The brackets
that hold the riser pipe to the tank were lifted causing damage to the brackets and to the
tank panels. The company that constructed the tank and does regular preventative
maintenance was called in to do an inspection and repairs. The tank was thoroughly
inspected and only minor damages found. The tank repairs were done by this contractor.
The mechanical joint of the riser pipe was repaired in house.
Million Gallons Stabilization Solids Storage Tank (MGT). The MGT holds all stabilized
solids from the digester stabilization process and the lime stabilization process. It
contains five mixers that are used to keep the two different stabilized solids blended, to
help keep lime in suspension with the stabilized solids, and for odor control. One of
these mixers had to be removed for repair. A spare was used in its absence. Once
repaired, the mixer was reinstalled. Stabilized solids are removed from the bottom of the
tank through four valves located in different areas of the tank. Over the years some of the
valves had broken and others were difficult to use. This made emptying the tank slow
and difficult. To remedy this situation all four valves were replaced. When solids are
removed for land application process a pump is used by the truck drivers with the use of a
remote switch located at their loading stand. The switch went bad bringing the
application process to a halt. The switch was promptly replaced restoring the process.
Solids are removed at a cost per gallon. During the storage water will still separate from
the solids. Also the tank size, one million gallons, is like a large rain gauge. This excess
water is removed with a decent system saving thousands of dollars each year. During the
year part of the decant line and a valve burst. It was repaired so this process could
continue.
solids to be treated. The preparation tank when in use must be mixed constantly to
prevent lime from precipitating out and caking up creating a clogged discharge from the
tank. The mixing is accomplished with a paddle wheel run by a gearbox/motor combined
unit. This unit went bad and was replaced. Once the lime slurry is added to the solids
mixing tank and the proper level is reached, the treated tank is ready for transfer to a
downstream process. The levels can be monitored remotely with the use of a level
indicator called a pressure transducer. Having these indicators can allow an operator to
follow the tank levels. If a tank gets too low the mixers could cavitate causing damage to
the mixers. Also, if a tank gets to high it can overflow. The transducers failed and had to
be replaced. One of the lime/solids mixers failed and had to be rebuilt. A spare was used
in its absence. There are two wet well transfer stations associated with this process. The
first transfers stabilized solids to the holding tanks. The second transfers stabilized solids
from the holding tanks to final storage. The first wet well transfer control panel was
rebuilt in 2011. In 2012, an alarm “High” level light and horn was added. Also, in 2012
the second well transfer control panel was rebuilt. Now both stations are in good
electrical working condition. The holding tank stores lime stabilized solids until time and
pH measurements are achieved. To aid this process mixers are used. They are controlled
with a float style leveler. This was not a good application. It caused the mixers to turn
on and off repeatedly. This allowed lime to precipitate and undue wear and tear on the
mixers. To remedy this situation a different style of leveler called a multitrode was
installed. The operation now is constant. In 2012, to protect the metal integrity of the
lime silo, it was painted.
be used. The transfer switch is now also on a regular scheduled maintenance program
with an outside contractor.
The diesel tank level indicator is mechanical and prone to sticking giving a false reading
of available diesel fuel gallons. To improve this reading an electronic device was
installed in the tank with an associated LED display. The gallons indicated are now more
accurate. A federal law enacted required certain diesel powered equipment to do some
air emissions cleanup. The emergency generator fell under this umbrella. In 2012, the
generator was equipped with an exhaust filter system to help control these emissions.
SCADA (Supervisor Control and Data Acquisition). SCADA is a computer-based
program. It brings site information into the central operations center. SCADA is a useful
tool by providing monitoring information to be used for more efficient plant operation. It
also brings remote site alarms into the operations center, which provides better control
over plant problems. Additional SCADA work was done in the thickening/stabilization
area of the plant. Some additional pumps and mixers were added to the computer alarm
and trend identification and tracking system. There were also some motion detection
sensors added too pieces of equipment. Also receiving some additional SCADA work
was the digester building. The pearths, manometers, and exhaust fans were added and
the heater alarm signals were expanded. Due to the size and complexity, and some parts
of the SCADA system beginning to age, several repairs were necessary throughout the
year. Also, to keep the SCADA computer working reliably and efficiently, the data from
2011 was unloaded on to an external hard drive.
The emergency generator is also used to curtail. The District is under contract with
Dominion Power. From May 16th through September 30th (summer curtailment) and
from December 1st through March 311,1 (winter curtailment), Dominion can request the
- 10-
12” pump installation. The 12 inch pump installed at the head-works of the plant in 2000
remains a valuable tool in preventing spills. In the event of high flows or maintenance
repairs, water can be removed to two abandoned secondary clarifiers. These clarifiers
were taken off-line in the early eighties after plant upgrades. They were originally used
for stabilized biosolids storage. The capacity was increased by extending a wall up from
where the weir overflows were when used as secondary clarifiers. This increased the
storage capacity of the two tanks to 750,000 gallons. After a dedicated biosolids tank
was constructed, the two abandoned tanks were dedicated to spill containment. Once
stored, wastewater can be returned to the plant with an existing pump station. Some pipe
work has been added to this station and depending on conditions, water could be returned
as the tanks are filled. This further increases holding capacity or downtime, during high
flows or maintenance and repairs. In 2012, 4,355,788 gallons of wastewater were stored.
Since setup in 2000, 49,732,667 gallons of wastewater have been prevented from spilling.
At the average flow of 3.5 MGD in 2012, this would be 14.2 days of flow.
Another means of spill control is with a backup generator. The wastewater plant must
continue to run in the event of power interruptions from the power-supply company.
Power interruption can occur from equipment failure, road accidents, and weather events,
such as ice storms, electrical storms, tornadoes, and hurricanes. A 750 kilo-watt
generator is on site for events and can supply enough generated power to run the entire
plant. In 2012, there were five power interruptions resulting in the use of the back up
generator for power supply. This first occurred on February 1st and was due to failed line
transformer. The generator was used for 3 hours and 30 minutes and prevented 145,833
gallons from spilling. The second was on July 1st and was due to a storm blowing trees
down on service lines. The generator was used for 52 minutes to prevent 110,136 gallons
from spilling. The next three occurred on August 3rd, two separate events, and on August
6 . The generator was employed for all three events preventing 188,015 gallons (Ihour
35 minutes), 187,500 gallons (Ihour 15minutes) and 194,600 gallons (Ihour 10 minutes)
respectively. The last three events were due to blown service line fuses. In all 826,084
gallons were prevented from spilling by using the backup generator for the five events
covering approximately eight and one half hours without normal power supply.
biosolids were applied
Since purchasing the land, investment improvements continued in 2012. Improvements
have been going on for nearly eight years. In 2012, the District over seeded the Bermuda
with annual rye. Because Bermuda goes dormant in cold weather months the rye over
seed makes the Bermuda acreage available for nutrient uptake if application to this site
becomes necessary. The District has strived to develop a model site. In 2012, in excess
of $1,500.00 was spent to maintain and enhance the application site. In 2012, the
District’s site was used for land application. This was the first time since 2008, just a few
months short of four years since previous use. In September, 471,200 gallons of
over a four day period for an average 117,800 gallons per day.
- 11 -
Biosolids land application program. This program permitted by the Environmental
Protection Agency (EPA) ran well in 2012. In the required annual report to North
Carolina division of Water Quality (NCDWQ) and the (EPA), there were no deficiencies
or spills. In 2012 there were 208 lime stabilization events at 11,250 gallons per event for
a total of 2,477,250 gallons. This is 60 % of the days in a year. The anaerobic digestion
process produced an additional 932,400 gallons of stabilized solids. Although these
solids have met all requirements for stabilization, they are also limed. This is done solely
for the purpose of odor control. The wastewater plant has entered into agreement with
area farmers for the use of their land for biosolids application. The farmers in turn
receive the nutrient value, moisture content, soil remediation, and lime, which is a by­
product of ph control in the treatment process of the biosolids. If necessary, additional
lime can be applied. There are 3100 acres, consisting of 128 fields, available in Halifax,
Northampton, and Warren Counties. All acreage was inspected, approved, and permitted
by the State of North Carolina. Using EPA approved treatment processes, 3,379,000
gallons of stabilized biosolids were safely applied to area lands, consisting of 11 fields
and 308.4 acres, for beneficial reuse. Cost of this application process was approximately
$112,000. Cost of treatment to stabilize solids is separate. Land that grew fescue,
Bermuda, soybeans, wheat, and cotton was applied to. The amount applied in 2012 is
down 21 % from the previous year. Charges for application are based on gallons. In an
attempt to save application costs, biosolids are thickened as much as can possibly be
handled. The removed water is returned to the treatment plant. Also, once biosolids are
placed in storage for land application, water is further separated. This water along with
environmental water (rain, snow, etc) is decanted and returned to the treatment plant. In
2012, 325,384 gallons was decanted, at savings of $10,965. Although 3100 acres of land
is permitted and storage of 1,000,000 gallons is available, at times application is difficult
due to weather conditions, crop status, and crop rotation. Owning land would provide an
outlet for these times. In 2004, the District purchased a suitable land application site. It
is located in Northampton County where the District already has farmer owned land
permitted. The land has been developed for livestock (cow) operation. The area has
been split into two fields. One contains 41.8 acres of fescue and the other contains 67.2
acres of bermuda.
wastewater plant to supply its own power for parts of the day during peak demand.
These requests usually come on the hottest days of summer and the coldest days of
winter. Dominion can then send power that the District would normally use to other
places of need. Winter requests are usually from 6am to 1 lam (5 hours) but can be 5pm
to 10pm also possibly on the same day. However, each requests counts as one run.
Summer requests are from 2pm to 9pm (7 hours). The contract is limited. In the winter
requests to curtail are limited to 13 or 65 hours and summer 19 or 133 hours. In 2012 the
wastewater plant was called to run 17 times during the summer curtailment. There was 1
winter call. The District does incur the cost of diesel fuel. However, the rate structure
the wastewater plant has because of the contract off sets this cost and provides electrical
energy savings. An added benefit of this program is that it provides a means to exercise
the generator. This keeps the generator in better running condition and exposes any
potential problem. It would be better to find out a problem during a curtailment than an
actual power outage. Dominion does provide one waiver per curtailment season each
year for such cases where a mechanical issue should arise. By having the generator under
a contracted quarterly preventive maintenance program hopefully mechanical problems
will be minimized or eliminated.
on-site monitoring
The District’s Emergency Response Plan (ERP) was revised in and submitted to the state
October 9, 2012. The PERCS Unit approved the ERP revisions October 15, 2012. Each
industry was sent a revised edition.
The pretreatment annual report (PAR) was submitted to the state pretreatment unit on
February 15, 2012. A letter, dated June 7, 2012, was received stating review of the PAR
indicates the report in good order and satisfied the requirements of the North Carolina
Pretreatment Program (PERCS Unit).
Industrial pretreatment program. In 2012 the industrial pretreatment program had
oversight of three significant industrial users. One user has a categorical discharge pipe.
Five non-significant industrial users are permitted to send flow to the wastewater plant.
Significant and non-significant status is determined in part by the volume of flow
discharged and the pollutants in the discharge. The pollutants, carried by certain
industrial wastes, determine the categorical status of an industry. Each industry whether
classified as a significant or non-significant user is issued a permit with limits and
monitoring requirements. In 2012 there were no significant industrial users in significant
non-compliance; a status based on the number and types of violations of a permit. There
were six notices of violation sent for permit violations.
The biosolids were applied to the Bermuda side of the site only. In contrast for 2008, a
total of 1,053,000 gallons was applied of which 253,500 gallons were applied to the
Bermuda side and 799,500 gallons were applied to the Fescue side for a total of
1,053,000 gallons. This application event was over an eight day period for an average of
131,625 gallons per day.
The laboratory has two full-time and one part-time technician, a laboratory supervisor,
and laboratory manager. After the laboratory obtains certification, it must complete an
annual performance evaluation study and submit the results to the state certification
section. This performance evaluation must be in the form of a “blind” study. Study
samples are ordered from a state approved vendor. The study sample values are
unknown to the laboratory. The samples are analyzed and the results are submitted back
to the supplier fro grading. If the laboratory fails to achieve an acceptable rating on a
parameter for three consecutive samples, the laboratory could loose certification for that
parameter. If certification is lost, the laboratory must go through a recertification process
as if they had never achieved certification.
Monitoring Laboratory. The District wastewater plant has an ( ' ’
laboratory. Analysis for NPDES reporting to the Division of Water Quality must be
performed by a certified laboratory. The laboratory is certified by the North Carolina
Division of Water Quality Laboratory Certification Section. In order to become certified
the laboratory facility must meet space and equipment specifications as well as analysis
performance evaluation. The laboratory is currently certified for twelve inorganic
parameters and four Vector Attraction Reduction options for the treatment of biosolids.
The laboratory receives samples from approximately 39 sampling points that include
plant monitoring, industrial monitoring, performance evaluation studies, septage hauling,
and collection system samples.
In 2012, the pretreatment program began its five year Industrial Waste Survey as required
by state and federal pretreatment regulations. Submittal of the survey is required by
February 1, 2013.
All industrial pretreatment permits expired in 2012. Permits were renewed with an
effective date of May 1,2012 and an expiration date of 5/31/2017.
The laboratory submitted all required evaluation studies and received an acceptable rating
on all in-house study parameters. The laboratory received e-mail notification March 20,
2012 that it had satisfied its performance evaluation requirement for 2012.
- 12-
Additional requirements of the program include state inspections, quarterly in-house
blind studies, maintaining a quality control program and a chemical hygiene plan, a
chemical inventory plan, equipment calibration and certifications, and certification fee.
The laboratory also works in association with the pretreatment program and biosolids
program in that analysis of samples taken by pretreatment technicians and plant operators
are brought to the laboratory for analysis. A laboratory technician is also responsible for
entry of the resulting data into a spreadsheet that is used by the Pretreatment program for
its Long Term Monitoring Plan. Laboratory technicians are also responsible for data
entry into the plant operations spreadsheet used for NPDES permit compliance
monitoring and plant process control.
There were no Notice of Violations
2012.
In 2012, there were 52 restaurants in the District database. There was one restaurant to
close during 2012. Inspections of the restaurants and updates to the database continued
in 2012.
A requirement of the wastewater plant through its NPDES permit is quarterly chronic
toxicity testing. The test involves using a predetennined amount of effluent along with a
- 13-
or Notices to Correct sent out to any restaurant in
There were no sanitary sewer overflows or blockages reported in 2012 that were
attributed to FOG, a continuance from 2011 which also had no overflows or blockages.
The District continues a more frequent cleaning schedule of collection system lines that
service high density housing areas in an effort to further prevent sanitary sewer
overflows. The District also continues to clean lines that service high FOG volume areas,
such as restaurants, before seasonal high flows.
Fats, Oils, and Grease (FOG) Ordinance. The Roanoke Rapids Sanitary District adopted
its first Fats, Oils and Grease (FOG) Ordinance in 2005. Since then operational issues
under the ordinance arose. In 2008, the District addressed those in a revision and
subsequent adoption of new ordinance language.
FOG public education is a requirement of the wastewater collections system permit
WQCS00027. Ongoing efforts from 2011 continued in 2012 with the revision of a FOG
slide that airs on local television Channel 15 and the addition of a FOG pamphlet
enclosure with one billing cycle. The administrative staff continues to distribute a FOG
ordinance package to all new Food Preparation Facilities when opening a new account.
The administrative staff also gives out industrial waste surveys to each person who
opened a commercial account that asks questions regarding food preparation and grease
traps.
National Pollutant Discharge Elimination System (NPDES) permit. The wastewater
treatment plant has an NPDES permit. It is issued by the North Carolina Division of
Water Quality (NCDWQ) after final approval is granted by the Environmental Protection
Agency (EPA). The permit authorizes discharge of treated wastewater to the
Roanoke River. The current pennit is valid through March 2012. However, 180 days
(bmonths) prior to the current permit expiration an application for renewal must be
submitted. The renewal application was submitted September 2011. A draft permit was
received on December 27, 2012. This draft is provided to the public thirty days for
review and comment. Likewise, the District has thirty days for review and comment.
Some additional requests may be made. This process has begun.
The laboratory works in coordination with the state certification branch to certify field
testing equipment for the surrounding communities with small treatment facilities who
work on limited funds. At this time, the laboratory assists six small facilities with
equipment certification.
macroscopic organism. The wastewater treatment plant contracts this test with a private
independent laboratory. They collect sample and run the test. Ceriodaphnia are placed in
the effluent and must survive and reproduce for a specific length of time. Results of the
test are either pass or fail. A pass indicates the absence of substances in the effluent
which may be harmful or threaten aquatic life. The wastewater plant has been required to
test for chronic toxicity since April of 1993 or nineteen and one half years. To date only
one test has received a fail result. This occurred in July 2001. This test was collected
and tested by North Carolina Division of Water Quality (DWQ). DWQ has run this test
again with all passing. The latest was conducted in March 2011.
Another testing requirement of the NPDES permit is the annual priority pollutant analysis
(APPA). As indicated, it is an annual test that checks the effluent for conventional and
non-conventional compounds, total recoverable metals, volatile organic compounds,
acid-extractable compounds, and base-neutral compounds. These substances, if found in
sufficient quantity, could be harmful to the wastewater plant, receiving stream, and the
public. To date, no substances have been found in significant quantity to cause harm.
The test is done seasonally over the term of a five year NPDES pennit.
NCDWQ also requires an Annual Perfonnance Report (APR). The report must contain at
a minimum, general information, perfonnance, deficiencies, violations, spills and
bypasses, any known environmental impacts, and corrective measures to address
deficiencies or violations. Also, from the APR a condensed Consumer Confidence
Report (CCR) must be distributed to the customers of the District with information on
where to obtain the APR.
The wastewater plant now has a general storm water permit. It was received through an
application process as required by the NCDWQ. A requirement of this permit is a written
storm water management plan. The plan is used to evaluate potential pollution sources
and to select and implement appropriate methods to prevent or control the discharge of
pollutants to stormwater runoff. As a part of the plan, semiannual preventative
maintenance evaluations and semiannual inspections of site runoff areas are required.
The Division of Water Quality (DWQ) conducted several inspections in 2012. The first
was on June 4lh and was a wastewater permit inspection. Areas evaluated included
permit, self-monitoring, laboratory, flow measurement, solids handling disposal,
operations and maintenance, facility site review, records/reports and effluent receiving
waters. The second was on December 4,h and was a solids generation and land
application permit inspection. Areas evaluated included miscellaneous questions,
pathogen and vector attraction, recordkeeping, treatment and sampling. The third was on
December 17th and was a dual inspection. It was a wastewater permit inspection that
evaluated the same areas as the June 4Ih inspection. In addition, a storm water permit
inspection was conducted. Additional areas evaluated were storm water and pollution
prevention. All four inspections indicated the wastewater plant was well maintained and
deemed compliant.
Safety program. The safety program within the District is very active and assertive in its
approach to the protection of the employees and surrounding citizens. The program
consists of a safety officer, safety committee, incident/accident committee and appeals
committee. The safety officer sets up the monthly safety meetings, coordinates the
activities of the safety committee, keeps up with safety regulations, and many other
various safety activities. The safety committee prepares safety policy programs and
updates current ones. They also do site inspections and produce potential hazard punch
lists. The safety committee and safety officer also keeps up with and prepares for
updating regulations and integrating new regulations of OSHA. The incident/accident
committee reviews all potential accidents and accidents. The appeal committee follows
up the safety committee recommendation at the request of an employee. The attempt is to
minimize the seriousness of an accident and ultimately prevent accidents. As a result of
the awareness and training from the safety program, there were no loss work days in 2012
at the wastewater treatment plant. This makes the 7th straight year the wastewater plant
- 14-
Permit limit violation
2.WWTP: None
Monitoring and Reporting Violations
2012 Sanitary Sewers Overflows (SSO)
2. WWTP: N/A
Bypass of Treatment Facility
- 15-
B. By month, list of the number and type of any violations of permit conditions,
environmental regulations, or environmental laws, including (but not limited to):
achieved this accomplishment. The Sanitary District was previously involved with the
Department of Labor (DOL) OSHA SHARP Program. DOL works with and inspects
companies by company’s request. After DOL requirements are met, companies are
awarded SHARP recognition. Participating in this program exempts companies from
unannounced inspections with possible fines. The District remained in this program for
several years before DOL restructured the program and removed the District from this
program. The correct program now is the STAR Program. The District began in 2011
plans for admission into the STAR Program.
In 2012 efforts were continues to be admitted into this program. One of the requirements
is to be evaluated and instructed by a mentor. This would be a facility or organization
that has been through the STAR process and gained admittance. In February, Cabarrus
County sent two representatives to do a site evaluation. A pre-plant walk through was
done. The STAR program was explained in general. Items such as what to get prepared
for, what to expect, how to conduct and OSHA expectations plus others were discussed.
Then a site walk through produced a punch of concerns and deficiencies. Afterward a
post walk through evaluation was explained and the punch list was addressed. Much
time was used in 2012 to address all the items on the list. The most consuming was
general housekeeping. During the STAR preparation, a committee of 14 employees was
developed to implement the STAR program. This represents around 34% of District
employees. STAR program mandates employee participation strongly. Also during
2012, the star committee was given a list of eighteen points ranging from PRE, employee
participation, emergency programs/drills, self-inspections and others. Each member was
assigned one of the points and was responsible for making a presentation to be given to
OSHA at a later date. The committee met on several occasions during the year to
practice and develop a PowerPoint presentation. The presentation followed by a walk
through site preliminary evaluation early next year will determine if the District will be
allowed to continue to the next steps of STAR admittance.
1. C.S.: None
1. C.S.: None
2. WWTP: None
1. C.S.: There were 9 reportable SSO in 2012.
1. 5/9/2012 - Belmont pump station. -5100 gallons
2. 7/21/2012 - Manhole 46 at 3rd and Stark Dr.-1800 gallons
3. 8/19/2012 - Belmont pump sta.-6000 gallons
4. 8/19/2012 - River Rd. G-54-75000 gallons
5. 8/19/2012 - Manhole 46 at 3rd and Stark Dr. -6000 gallons
6. 8/25/2012 - Numerous Manhole during flood - 15001 gallons
7. 9/18/2012 - Manhole 46 at 3rd and Stark Dr. -7200 gallons
8. 9/18/2012 -4th and Laurel -8400 gallons
9. 10/12/2012 - Hwy 48-Manhole A-180-2800 gallons
C. Description of any known environmental impact of violations.
D.Description of corrective measures taken to address violations or deficiencies.
- 16-
1.
2.
C.S.: N/A
WWTP: Three
The first occurred on August 19Ih. Nearly two and one half inches of rain had fell
just prior to this date. Then an additional three and one half inches fell on this date.
Much higher than normal flows tried to pass through the plant. Approximately
63,000 gallons was bypassed that received grit and rag removal with primary
clarification and first step secondary treatment. On August 25th two bypasses
occurred on the same day when Roanoke Rapids received nearly twelve inches of
rain in approximately five hours. Flows into the plant, rated at 8.34 million gallons
per day (MGD), exceeded 20 MGD. The plant was overwhelmed with flow it could
not handle. The first location bypassed approximately 1,095,000 gallons which
received grit and rag removal treatment only. This lasted for about sixteen hours.
The second location bypassed approximately 1,363,000 gallons which received grit
and rag removal, primary clarification, and first step secondary treatment. This
lasted for about nineteen hours.
RRSD performed preventative maintenance by cleaning with Jet-Vac and a root cutter
which is attached to the Jet-Vac hose for cutting roots, following with a CCTV camera to
inspect the lines after cleaning. The District also procured a new jetter which cleans the
line more effectively and proves to be more reliable than the old unit. Along with in­
house work, the District contracted services from KRG Utility Inc for further line
cleaning and CCTV.
RRSD secured a planning grant from The Rural Center in 2012 to further evaluate the
Belmont area. The District employed W. K. Dickson to conduct a study including more
smoke testing, manhole evaluations and storm water dye testing to locate sources of I&I,
which has been the root cause of many reportable spills over the past few years.
In October of 2012, RRSD confracted with KRG Utility and Ralph Hodge Construction
to pipe burst 372 ft. of 18” clay pipe to 21” polyethylene pipe to eliminate I&I from
several points in that line. The District replaced Manhole 180 in Hwy 48 with a new
manhole just off Hwy 48 in the right-of-way. At this time, the District also rerouted the
force main from 48 Lift Station to the new manhole. We had to bypass pump this section
of line while replacing for a period of approximately 2 weeks. We also had to pump and
haul from Hwy 48 Lift Station during this time.
MJ Price Construction cut and cleaned 16 miles of Chokyotte outfall and District
employees cut and cleaned 4.5 miles of outfall and cross country lines. KRG Utility Ic.
Cleaned and CCTV 16186.9 feet of line and District employees cleaned 70127 feet of
line for a total of 16.35 miles of line cleaned.
During 2012 District employees performed 5 point repairs on sewer lines.
1. 811' and Rapids - 8’ section of 8” sewer line
2. 817 Rapids St. -replaced 14’ of 8” sewer line
3. East 7th St. - replaced 7’ of 8” sewer line
4. Premier Blvd. - replaced 6’ of 10” sewer line
5. 628 Marshall St. - replaced 20’ of 12” sewer line
6. Installed new manhole on dead end line at 400 block of Carolina St.
I. C.S.:
1. C.S.: None
2. WWTP: None
- 17-
Traming and directives have been put in place to prevent icing problems and equipment
failure that can result from the scum control spray system on the secondary clarifiers.
During high flows or some maintenance repairs, influent flow can be diverted to
equalization storage tanks. Once flows lower or repairs are complete, the stored water is
returned to the plant for treatment. Flow is diverted to these tanks with the use of a 12
inch (5 MOD) pump. Proper maintenance of the pump is critical. It has been rebuilt
once and is on an annual preventative maintenance contract to ensure reliability. The
pump is started monthly and quarterly pumping is done.
During the construction of the disinfection/disinfection removal process, a truck
unloading containment structure was installed. The structure is piped to a pumping
station equipped with pH alarms that are tied to the SCADA system. This provides
acknowledgement and control over a spill situation that may occur during chemical
delivery. The spill containment grating is open air. Normal rain can fill the containment
system. This would prevent collection in this system and a spill could occur. Level
indicators were installed on the containment system with SCADA. Now rain water, as it
accumulates, can be removed. Also, before each chemical delivery the system is pumped
down. The system is also pumped down regularly by assignment. To further control this
area, the discharge valve is kept in the closed position and the pump turned off.
The hypochlorite bulk storage tanks, which came on line in 2001, are now on an annual
inspection program. The hope is to catch a problem, preventing a catastrophic spill
Secondary clarifiers can have solids washed out during periods of high flows.
Operational strategies have been put into place to minimize this.
Some of the work done to prevent problems is the identification of potential spill areas.
Once identified, arrangements are made to stop or minimize and contain.
Primary clarifier influent lines have grease collection pits located on them. As the pits
collect grease and fill, the flow through the influent lines can be restricted, back up, and
cause spills. To prevent this from occurring, a contracted vacuum truck company is
scheduled regularly to remove the excess grease and keep he lines unrestricted.
The Emergency Flood Pump Station is critical for the removal of wastewater from the
plant when river levels are high. This station is backed up with a diesel pump capable of
removing the wastewater flow in the event of pump station failure or electrical failure.
Two things were done to ensure the diesel pump preparedness. The first was an engine
heater was added to ready the diesel for immediate use. Second, an automatic starter was
added to start and run the pump weekly for a specific amount of time. This keeps the
pump ready for use also.
Low influent suspended solids can occur after rains making the 85% removal difficult.
Polymer can be fed into the secondary clarifiers aiding settlement of solids and help with
the 85% removal rate.
2. WWTP:
The WWTP is very aggressive in reacting to violations and identifying potential
deficiencies. Once identified, plans are made to upgrade or replace potential deficiencies,
which may result in violation. Modifying operations, training operators, laboratory
training, improved equipment, maintenance inventory parts and equipment and raising
awareness is also an on-going and continuous process.
- 18-
The plant storm water drains are blocked and gated to help control spills that might
otherwise be released from the plant site. Although painted bright yellow, they were
struck and broken on occasion. A new design keeps the containment from being easily
struck. Also, flags on poles have been added, further increasing visibility.
A valve exercise program is now employed. It keeps valves in good working order. In
the event of routine maintenance, equipment problems, or emergencies, valves used to
address these issues are in a state of readiness. As valves are repaired or replaced, they
are added to the exercise list. There are hundreds of valves located inside and outside of
various areas. Each operator has a list of valves to exercise.
There are various pump station alarms throughout the plant. Some are equipped with
local visual lights and audible horns or sirens, and some are even equipped with remote
SCADA alarms. In an attempt to keep functioning alarms, they are tested on a monthly
basis. As more alarms are installed, they are added to the testing list.
The gravity tank wet well pump station has been a site of previous spills. The station
now has a local high level alarm horn and light. This signal has also been added to the
SCADA system to give this alarm remotely to the operations building.
Identifying and eliminating inflow and infiltration (I&l) is an on-going and difficult task.
It is important to control I&I to take excess flows off of the treatment plant. However, it
is also important to address because excess I&I “dilutes” incoming waste. With diluted
wastewater it is more difficult to meet the percent removal requirements (85%) of the
plant s permit. I&I also hydraulically over loads treatment processes making it harder to
meet pennit limits. In addition to hydraulic overloads during these events, debris such as
sand and rock, which has built in the collection system, gets flushed to treatment plant.
On two occasions in 2012 this was a significant problem. On August 19th approximately
three and one half inches of rain fell in a relatively short period of time. Flows for the
day spiked up to 18.6 million gallons and the total for the day was 9.2 million gallons
(total plant capacity is 8.34 million gallons per day). Then on August 25th (less than one
week later) Roanoke Rapids received an additional eleven and one half inches of rain in a
very short period of time. Flows for the day spiked over 20 million gallons and the total
for the day was 14.7 million gallons. On August 19th the high flow flushed
approximately three pickup b uck loads of sand and rock into the Rotomat/Grit collector
channel, basically shutting down these treatment processes. A vacuum truck has to be
brought in to vacuum all the debris out. Then less than one week later on August 25th an
additional two pickup truck loads of sand were flushed into the same area of the plant.
Again a vacuum truck was used to remove the debris. Average flow for 2012 was 3.5
million gallons per day. The month of August alone was 5.2 million gallons per day.
In 2012, more areas were identified and addressed to help resolve these problems. (See
II.D.l, above)
The plant generator is capable of powering the entire plant in the event of power loss.
Without it, spills would occur. It is on a contracted quarterly preventative maintenance
program. Also, the transfer switch transfers incoming power to generator power is under
a preventative maintenance contract. Annually it is taken off line, disassembled,
inspected, and cleaned. Without a properly operating transfer switch, generator use is not
possible. It is also exercised monthly by the staff. And, curtailment program with the
main power supply company assures further testing and exercise of the generator.
I he SCADA alarm system is an extremely valuable tool for preventing spills and other
problems. As problems arise or equipment fails, prompt attention is given to repairs so
the alarms are returned to service.
Temporary pumps and hoses are used frequently. Hoses easily spring leaks. To prevent
hose leaks while pumping wastewater or biosolids, lay flat hose was replaced with
reinforced canoline hose.
- 19-
The Stormwater Pollution Prevention Plan (SPPP) is a valuable tool in identifying
deficiencies. It incorporates annual awareness and training to all plant personnel. It also
requires semi-annual inspections of all plant equipment and facilities, containment, and
tanks and chemical storage. The plan also addresses chemical suppliers and contractors
through training. The plan allows for scheduled identification of deficiencies before they
become problems.
The wastewater plant has a protective bank next to the Roanoke River, to the north,
Chockyotte Creek, to the east, and an unnamed creek, to the west. The entire length is
several thousand feet in length and over fifty feet in height in some locations. The slope
is very extreme. Several years ago the river began eroding the bank away. The District
began stabilizing the slope with a cloth bag filled with grout. The bags start at the top of
the slope and extended down into the river by several feet. The entire length was done in
sections. The next step was to stabilize the toe of the bags at the bottom of the river.
This was done with stacked storm cloth bags to secure the slope bags. After several
years, the last of the storm bags was completed in 2012.
Each year during the budget process, close scrutiny is paid to the potential of deficiencies
which could lead to violations. Any identification of potential problems is addressed
during this process so that they are remedied before problems arise.
The Fat, Oil, and Grease (FOG) program continues to be a useful tool for the prevention
of spills. A pretreatment technician oversees and implements the program. The
technician inspects restaurants to ensure grease trap maintenance. Best Management
Practices for the control of grease entrance into the collection system is also conveyed.
Part of the FOG program is public education. The technician is required to incorporate
all users of the collection system. This is accomplished through door hangers, bill
inserts, poster distribution, advertisements, public service announcement and public
displays.
III.NOTIFICATION
IV.CERTIFICATION
-20-
Reduce
Recycle
Satisfy
Develop
R. Danieley Brown, PE/
Chief Executive Offic/r
Date
A. A condensed, summarized version of this report will accompany the annual water report
which will be distributed to the users and customers of the Roanoke Rapids Sanitary
District via mail. The full report will be available at the main office upon request.
A. I certify under penalty of law that this report is complete and accurate to the best of my
knowledge. I further certify that this report has been made available to the users of the
named system and that those users have been notified of its availability.
ANNUAL PERFORMANCE REPORT 2012
ROANOKE RAPIDS SANITARY DISTRICT
I.GENERAL INFORMATION
B. Responsible entity: Roanoke Rapids Sanitary District, Dan Brown, CEO
C. Person in charge/contact
1.
2.
D. Applicable Permit(s)
1.
2.
E. Description of C.S.:
The collection system consists of approximately 130 miles of sewer lines. The sewer lines
within Roanoke Rapids, Gaston and all sub-divisions, which connect to the two main
Interceptors, range in size from 8” to 12”. There are two main Interceptors transporting
wastewater to the WWTP.
The Chockoyotte Creek Interceptor handles the south side of Roanoke Rapids and three sub­
divisions, Lake View Park, Greenbriar and Lincoln Heights, outside the Roanoke Rapids city
limits. The Interceptor begins east of Zoo Road. There is one primary basin pump station
along the route. Pipe size ranges from 12” to 30”.
The system has six sewer lift stations. Three stations are located in the Gaston, NC system.
One of these serves a Northampton County School, one serves the Chowan Housing Projects
and the other station pumps all flows from Northampton County across the NC 48 Bridge
crossing the Roanoke River to the Roanoke River Interceptor. The remaining three pump
stations are located within the Roanoke Rapids system. Two of the stations, Belmont and
C.S.: North Carolina Environmental Management Commission System-wide
Wastewater Collection System Permit No. WQCS00027
The Roanoke River Interceptor collects wastewater from basins located on the north side of
Roanoke Rapids. The Gaston and Northampton basins are included in this service area. The
Interceptor begins just west ofNC 48 in Roanoke Rapids. There are 3 primary basin pump
stations and 2 secondary pump stations along the route. Pipe sizes for the Interceptor ranges
from 18” to 30”.
WWTP: NPDESNC0024201
Land Application (L.A.): WQ0001989
Stormwater (General): NCG110000
WWTP: Gregg Camp, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, WWTP
135 Aqueduct Road
Weldon, NC 27890
Phone: [phone]
C.S.: Gregg Wilson, Supervisor
Melvin Douglas Moore, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, Distribution & Collection
PO Box 308
Roanoke Rapids, NC 27870
Phone: [phone]
A. Regulated entity: Roanoke Rapids Sanitary District, Collection Systems (C.S.) and
Wastewater Treatment Plant (WWTP)
II.PERFORMANCE
The performance of the system in 2012 was good.
-2-
Treatment processes at the wastewater plant include grit and rag removal. This is followed by
primary clarification, trickling filter biological secondary treatment, activated solids
treatment, secondary clarification, final effluent chlorination/dechlorination processes, and
final pH adjustment.
The wastewater treatment plant is rated at 8.34 million gallons per day (MOD). Peak flow is
rated at 12.5 MGD.
Poplar Springs, discharge to the Roanoke River Interceptor while the Greenbriar Pump
Station discharges to the Chockyotte Creek Outfall.
Preventive Maintenance of at least four hours a week cleaning sewer mains has also been
an effective tool in reducing sewer backups and overflows. In 2012, District forces
There are two pumping stations in the wastewater plant distributing wastewater into and
through the plant. Of these two pump stations, one has the capacity to pump 20 MGD and the
other 27 MGD respectively. Also, to aid these two pump stations; a storm water pump station
has been installed. This station intercepts rainwater, an unnecessary load to the treatment
plant, and removes it before entry to the plant. It has the capacity to pump 11.5 MGD. In
conjunction to these two pump stations there is one pump station with capacity of 21 MGD to
remove treated flows from the plant in the event of high river levels preventing normal gravity
flow discharge. Various others pumps and mixers are located throughout the plant for process
control.
The Fat, Oil and Grease (FOG) program initiated in 1995 has been a good tool in
preventing Sanitary Sewer Overflows (SSO’s). We also have a fulltime employee for the
FOG Program who specifies type and capacity of grease traps on an individual basis for
all developments, maintains all records and inspects all grease traps. He also educates all
restaurants and high density residential housing about grease and how it affects our sewer
lines. The use of local newspaper for FOG program educational ads and the distribution
of brochures to restaurants and fast food businesses have also been effective.
Maintenance of records and inspection of grease traps is an ongoing measure to prevent
SSO’s.
During these processes solids are removed from two locations. Primary clarification removes
settleable solids from incoming wastewater to an anaerobic digestion unit. Here the solids, in
the absence of oxygen, receive pH adjustment, mixing, and heating to produce a stabilized
material. Once the solids are stable, excess water is decanted and returned to the plant for
further treatment. The stabilized, thickened solids are treated with lime for odor control then
removed to a holding tank to await land application.
Secondary clarification removes solids from the activated solids process. Here, solids in the
presence of oxygen, ph control, and mixing, accumulate in excess. They are removed,
chemically stabilized, and added to a holding facility. All stabilized solids are analyzed and
land applied according to their nutrient value, ceiling and accumulative requirements.
A. Description of overall 12 month performance, noting highlights and deficiencies:
F. Description of WWTP:
1. C.S.:
The Roanoke Rapids Sanitary District’s collection system received its inaugural permit in
2001 under the North Carolina Environmental Management Commission Department of
Environment and Natural Resources system wide wastewater collection system­
permitting program.
-3 -
In response the District has maintained staff, critical parts inventory, equipment
inventory, made plans to better address extreme conditions, upgraded critical equipment,
planned back up or alternative operations, and requested better responsiveness from sub­
contractors. Responses are continuous and increasing.
The permit also contains daily maximum residual chlorine of 50 ug/1 (micrograms per
liter or parts per billion). Also permitted is pH. It must be maintained between 6 and 9
units. These two samples are grab or instantaneously collected.
The SC ADA system that monitors all lift station 24 hours a day, 365 days a year has
prevented lift station overflows. In addition, each lift station is equipped with emergency
generators on site to prevent overflows from power outages, except Poplar lift station. In
the event we have rain or outages predicted, a portable generator is placed at the lift
station in case it is needed.
Current plant capacity is 8.34 million gallons per day (MGD) with a peak flow of 12.5
MGD. For 2012 the yearly average low flow was 2.6MGD with minimum of 1.8 MGD.
The yearly average high flow was 6.7 MGD with a maximum of 14.7 MGD. The yearly
average total flow was 3.5 MGD or 42% of the plant capacity. This is an increase of only
100,000 gallons or nearly a negligible rise in flow. Rain can affect flows by inflow and
infiltration. In 2012, 58.0” of rain was recorded at the wastewater plant. The previous
year 46.8” was recorded. This is an increase of 11.2” from the previous year and a 16.0”
increase over 2010. The increase in rain may have contributed to the negligible increase
of 100,000 gallons in 2012. However, with this significant increase in rain the last two
years, it is further evidence the District’s efforts to minimize inflow and infiltration is
working.
Under the current permit, the District has a weekly effluent total suspended solids (TSS)
limit of 45 mg/1 (milligrams per liter or parts per million) and a monthly limit of 30 mg/1.
Also a weekly carbonaceous biochemical oxygen demand (CBOD) limit of 37.5 mg/1 and
a monthly limit of 25 mg/1. These two samples are composite collected. They are
collected over a twenty four hour period and on a flow proportional basis. The higher the
flow, the more sample collected and conversely, the lower the flow, less sample is
collected. The yearly average for TSS was 16.3 mg/1 and CBOD was 6.3 mg/1. Using
yearly average influent values for the same parameters this calculates to a 93.8% and 97.0
% removal rate respectively. The permit requirement is 85%.
There were nine reportable spills in 2012 of the collection system. The worst of these
was on August 25 when Roanoke Rapids had 11.5 inches of rain in a short period of time.
There were several streets washed out due to storm water and numerous sewer lines
washed out. District employees were very diligent in getting these lines repaired and
back in operation. There were also overflows from numerous manholes during this
event.
The District is keenly aware of and has been very responsive to increasing environmental
awareness. House Bill 1160, Clean Water Act of 1999, ratified by the North Carolina
General Assembly on July 20th and signed into law July 21st by the governor, has
heightened this awareness. This bill codified as Chapter 329 session laws became
effective October 1999.
continued proactively cleaning the mains of high density residential housing prior to
major holidays to prevent any grease related spills. The use of degreasers in pump
stations on a regular schedule has proven to be very effective in preventing lift station
down time. Also all pumping stations are checked and cleaned a minimum of once
weekly.
2. WWTP:
Overall performance for 2012 was good. There were no NPDES permit limits violations.
(See below) There were no monitoring or reporting violations.
Some of the repairs and upgrades in 2012 include the following.
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In 2012, the District continued to be very active in maintenance issues and concerns. The
WWTP spent in excess of $641,000 on maintenance and repairs to equipment, supplies
and materials necessary to operate equipment and capitalized monies to replace and
upgrade equipment.
There were two rain events within one week of each other in August causing flows to
increase significantly which flushed lots of hard granular material into the Rotomat.
During these events, the comb was damaged. The comb acts to dislodge captured
undesirable materials into a conveyor that removes this material. The comb, made of
hardened stainless steel was bent and the holding bolts broken. This was causing the unit
to run in a bind and trip out. The comb was straightened out and reattached, returning the
unit to use. The Rotomat is the primary debris removal equipment which works
automatically. There is a manual back up which can be used in the event the Rotomat is
in need of service or repair. There are gates that are used to direct flow to whichever unit
needs to be used. The gate frames are original equipment from the 1960’s and made of
carbon steel. The gate frames had deteriorated and were replaced with stainless steel
frames.
Rotomat. The Rotomat is the first piece of equipment in the wastewater process. It
removes rags, plastics, paper, or other non-organic material before they can enter other
downstream processes. This is important to keep this material from clogging pipes,
binding pumps and mixers, and causing damage to other equipment. Flow enters a basket
area. As materials build up in the basket area, a sweeper ami comes on to remove the
built up items. The sweeper passes through a comb which causes the material to be
dropped into a screw auger for removal from the wastewater flow.
Influent diversion box. The influent diversion box is the first area of the wastewater
process. The open air collection pit is where the two mam interceptors bring all the
wastewater in the District’s system to the wastewater plant. A 30” line, Roanoke River,
and a 36” line, Chockyotte, meet and blend at this location. From this point they are
piped to the first treatment process or preliminary station consisting of rag and grit
removal. The diversion has two slide gate valves. The influent gate when open allows
all flow from the Chockyotte and Roanoke River lines into the treatment processes of the
plant. Occasionally it must be closed to stop flow into the plant for downstream
equipment repairs. At this time all the flow is pumped to storage and returned to the
plant after repairs. The influent gate is an original gate from 1963 and is failing. A new
gate has been purchased to replace the original.
Influent pump station. The influent pump station transfers all incoming flow into the
plant. The station is equipped with four pumps. Their pumping capacities are 2, 4, 7, and
7 million gallons per day (MOD). The 2 and 4 MOD pumps are the “work horses” of this
pump station. They handle the majority of the work on normal flow days. This spares
Grit Collector. The grit collector removes grit from the influent flow. Grit is removed at
this location to prevent excessive wear on downstream equipment. There are two grit
collectors. One is the primary collector and the other is a back-up. The prunary unit,
installed in the mid 90’s, uses a vortex motion to settle grit out of incoming wastewater.
A pump removes the settled grit from a hopper to a screw conveyor for removal to a
dumpster. The back-up collector, original equipment installed in the early 60’s, uses
gravity to settle grit to a sump pump which pumps to a screw conveyor for removal to a
dumpster. Although this equipment is much older and less efficient than the newer
vortex technology, the gravity system is maintained for use during times when the vortex
unit may be down for repairs. There are gates that are used to direct flow to whichever
unit needs to be used. The gate frames are original equipment from the 1960’s and made
of carbon steel. The frames had deteriorated and were replaced with stainless steel
frames.
Filter Effluent Pump Station. The filter Effluent Pump Station (FEPS) collects all
incoming flow that has traveled through the primary clarifiers and trickling filters. It then
transfers this water on to the secondary system for further treatment. This station is
equipped with four pumps. Their pumping capacities are 2.1, 7.9, 7.9, and 9.2 million
gallons per day (MGD). Here as with the influent pump station, the smaller pump is the
“workhorse”. At this station the two 7.9 MGD pumps alternate after equal run times to
aid the 2.1 MGD pump during normal flows. The 9.2 MGD pump is the high flow pump
at this station. One of the 7.9 MGD pumps developed a vibration. To minimize damage,
-5-
wear and tear on the larger 7 MGD pumps which are needed in cases of higher flows.
They alternate based on run time hours until flows increase to a level where both are
needed together. This station is equipped with an emergency flow release valve in the
event flows from extreme weather conditions come in faster that the pumps can remove.
Without this valve catastrophic failure of the station would occur causing a long down
time for repairs. The valve is original equipment from the 1963. It is old technology
metal flap to metal seal and does not seal well allowing environmental waters to enter the
pump station placing extra unnecessary flow on the station. This valve was replaced with
an elastomer style valve that completely seals.
Rotary Distribution (Trickling Filter). Biological wastewater treatment begins at this
phase of the wastewater treatment process. There are two rotary distributors.
Wastewater from the primary clarifier enters the center column of the circular rotary
distributor. The center column splits the water equally to four distribution arms. The
arms have holes (orifices) in the top which the water passes through then down the front
of the arm. This causes the distributor to rotate. Underneath the arms is a 5’ this bed of
rock. Microorganisms grow on the rock surface and as the wastewater trickles through
(trickling filter) the bed of rock, the microorganisms start cleaning up the wastewater.
The four arms supported by 1” vertical diameter stainless steel support truss rods
connected to the center column. There are 5 per arm for a total of 20 on the distributor.
In addition, there are two half inch horizontal cables between the four arms for a total of
eight. These cables help stabilize the arms. One of these cables broke and had to be
replaced.
Primary Clarifier. Primary clarifier (primary) is a circular tank with a cone shaped
bottom. Without the cone, the tank is 12’ deep. There are two primaries. At the bottom
of the cone is a hopper attached to pipe work that leads to a pump station called the
Primary Solids Pump Station. Wastewater which contains organic solids enters the
primary. A baffle slows the velocity of the wastewater entering the primary allowing the
solids to settle to the bottom of the tank. A motorized sweeper located on the tank
bottom sweeps the settled solids into the hopper. Using the pumps in the Primary Solids
Pump Station, solids are removed from the primary at regular scheduled intervals. The
solids are transferred to another process where they are treated and stabilized. There are
two horizontal centrifugal chopping pumps located in this pump station to make this
transfer. They are used on average three times a day for approximately an hour each
time. They transfer solids which by nature are abrasive. During the course of the year
both pumps started showing signs of inefficiency. On separate occasions they were
removed for repair. A spare is available to use in the absence of a pump under repair.
These pumps are also equipped with sight glasses for observing the thickness of the
solids being transferred. Only the thickest should be transferred. One of these sight
glasses began to leak and had to be repaired. The surface of the primary is skimmed by
a motorized skimmer. Its purpose is to remove floatables, mainly grease, from incoming
flow. These floatables are deposited in a trough connected to a collection box. Each
primary has one. The floatables are transferred to the same treatment and stabilization
process as the settled solids. There are two submersible vertical centrifugal chopper
pumps that are used for this application. One of these pumps also began having problems
transferring the collected floatables. It was removed and repaired. A spare is available to
use in the absence of a pump under repafr. Due to some equipment installation in the
pump station which involved the roof and due to the age of the roof covering, the roof
covering had to be replaced.
-6-
the pump was promptly removed from service and repairs made. Afterwards the pump
was returned to service.
Secondary System. The Secondary System is a biological treatment system consisting of
three aeration basins and two secondary clarifiers. The system is operated by the use of
various valves and piping, control panels, traveling siphon bridges with valves and
skimmer arms, gear boxes, motors, pumps, and blowers. Various repairs and upgrades
were done.
Each pump has an automatic oiler to keep the internals lubricated and in working order.
In 2012 these oilers began to fail and had to be replaced. In addition, each pump has an
electrical control cabinet. These cabinets build up heat and if not removed will cause the
pump to trip out. To keep this from occurring, each cabinet is equipped with a cooling
fan. These fans began to fail and had to be replaced.
There are four blowers, two 75 horsepower (#1 & #3 and two 100 horsepower (#2 & #4).
Blower #3 had multiple repairs in 2012. Each blower has an inlet and outlet bearing. On
#3 the inlet bearing had to be replaced. Also, the motor on the #3 blower went bad. The
motor was repaired and replaced. Finally, the internals of the blower failed. The motor
and bearings repairs were done in-house. However, the internals repair is an intricate job
so it was returned to the manufacturer. The repair was completed and the blower was
returned to service. In its absence, a spare was utilized.
The electrical control system of the syphon bridges has had numerous repairs over the
years. The connection system was in a state of disrepair. The connection system was
replaced to make future repairs easier and safer.
The mix pump system is accomplished with piping where air and solids are blended and
injected. The piping is connected with flanges. In 2012 some of the flanges failed & had
to be replaced. Both secondary' clarifiers have a traveling syphon bridge driven by a
motor and gearbox with chain and sprocket and a pulley cable system. The traveling
syphon bridges had previously been retrofitted with temporary priming valves. These
valves were subject to leaking causing prime loss of the bridges. These valves were
removed and the prime of the bridges improved significantly. The traveling bridges are
equipped with a clutch system. In the event of any binding of the system, the clutch
releases to protect the system. The clutch on #2 failed and was replaced.
Each aeration basin is equipped with a mixing pump. They are piped into the basin so
that they blend basin content with blower air causing a mixing action. Each mixing pump
is controlled with a variable frequency drive (VFD). The VFD can speed up or slow
down the motor affecting the dissolved oxygen concentration in the basins. The displays
on the mix pumps that control the speed faded out and had to be replaced.
Disinfection. The final phase of the water treatment process is disinfection (pathogen
kill) and disinfection removal. Sodium Hypochlorite (bleach) is added to the wastewater
flow in sufficient amount to destroy potentially dangerous virus and bacteria. After this
process, sodium bisulfite is added to remove any remaining hypochlorite. This is
necessary because hypochlorite is hazardous to the aquatic life of the receiving stream.
This system is nearly two years old now and issues with it are beginning. The chemical
feed and transport lines and valves are PVC. Several locations along the PVC lines and
some valves had to be repaired. Cracks developed in lines and valves necessitating
replacement. Also, gaskets in several valves deteriorated which caused leaks. These
gaskets were replaced. The pumps that move the chemicals in this system are diaphragm
Removing and installing motors is difficult. The work area around them is small and the
power and motor leads are connected in a manner that disconnecting & reconnecting is
awkward because of a small electrical box. To make this easier, larger connection boxes
were installed on all four blowers and power/motor leads were fitted with quick
disconnects.
-7 -
The water that is re-circulated through the heater is a closed loop system. It is reused
over and over. With some time water may be lost because of evaporation or possibly a
slight leak. To compensate for this each heater is equipped with a replenishing water
storage tank. One tank was installed in 1963 and the other in 1983. They both were
deteriorating beyond repair. Without storage water the heater will not run. A safety
device will recognize no water and shut the heater down. To prevent this storage tanks
on both heaters was replaced. Excess heat from the heaters has to be exhausted just as in
an automobile. The heaters are forced air vented through exhaust piping with the use of a
blower. It is important to exhaust properly to prevent noxious fumes, for example carbon
monoxide, from building up in the digester building. Heater #1 had some problems with
its exhaust system. First, the motor went bad and had to be replaced. Second, the
exhaust piping deteriorated and had to be replaced. To monitor proper temperature
settings, the digesters are equipped with chart recorders. The number one chart recorder
failed and was replaced. Each heater is equipped with a solids horizontal centrifugal
recirculation pump. The pump pulls solids out of the digester and loops them through the
heater and then returns them back to the digester. This looping can be intermittent or
continuous depending on temperatures and temperature settings. The pump for number 1
digester underwent a couple of repairs. First, the pump motor failed and had to be
Digesters and Stabilization. Digesters receive solids removed from primary clarifiers.
With heat and mixing and occasional chemical addition for pH control, solids are
stabilized. There are two digestions tanks. Each is heated with its own heat exchanger.
Each heat exchanger is a two chamber piece of equipment. One side is a heat
compartment and the other a water bath. Solids are re-circulated between the two
chambers where the heat is transferred or exchanged. A byproduct of the stabilization
process is methane. It is captured and used for fuel to heat the exchanger. The heat
exchangers are also equipped to run off natural gas as well at times when methane
production may be low or temperatures are colder requiring the use of supplemental fuel.
For this operation gas valves are required for both types of fuels.
style. There are two for the hypochlorite and two for the bisulfite. On average after a
year of service, these pumps have to be rebuilt. In 2012 these pumps were started being
rebuilt with the kits supplied by the manufacturer. The tanks which house the chemicals
are under warranty. To maintain this warranty, they must be inspected annually. In
2012, their first inspection was done. The electrical control system for the chemical feed
system must be protected from electrical surges which could result from lightning. The
piece of equipment used for this protection is a transient voltage surge suppressor
(TVSS). During a lightning storm, the TVSS stopped a surge and protected all
downstream electrical equipment as it is designed to do. However, when this occurred
the TVSS was damaged. The TVSS had to be replaced to continue to protect the
electrical equipment. A separate electrical issue arose in 2012. Voltage to the
disinfection building became erratic and low. Equipment in the building could not
operate correctly. After a search it was discovered that the electrical wires from the
motor control center feeding power to the disinfection building was not a continuous run.
Wires had splices in it located in an electrical access junction manhole. The splices had
corroded causing the electrical issues. The splices were repafred using a better style
splice kit hopefully to avoid this occurrence again in the future.
All functions of the heat exchanger are controlled by one piece of equipment called the
"fire eye". It is a safety component. If it senses improper operation of any electrical part,
it will not let the heat exchanger fire. If the eye itself fails, the heat exchanger will not
start either. Heat exchanger number 2 had this type of failure and had to have a new “fire
eye” installed. Also, on number 1 heat exchanger, the gas regulation valve failed. This
part opens up as demand for gas, either methane or natural, increases or closes down as
demand decreases. This is all dependent on temperature settings. The gas regulator had
to be replaced to restore temperature control. The water bath of the heat exchangers is re­
circulated with a water pump to keep the warmest water in contact with re-circulated
solids. Without recirculation, proper solids heating will not occur. Heat exchanger
number 1 water pump failed and had to be replaced.
replaced. Second, the seal went bad causing a leak. The seal had to be replaced to stop
the leak. The tops of the digesters are unique. They are metal and float on the solids
being treated. They move up and down depending on the amount of solids in the
digester. However the tops are restricted to the “working zone” of the digester. If the top
gets too low it could crush. To high and it could fall off. To monitor this, the tops are
equipped with a level indicator with alarms. The alarm on #1 digester failed. It had to be
replaced to restore this safety feature. Because these tops are metal and exposed to the
atmosphere, they require painting to prevent deterioration. All tops were painted in 2012.
Biosolids Thickening. Excess solids from the secondary treatment process are thickened
by gravity settling tank and a drum concenfrator with the use of polymers. Polymers
when mixed with solids create a reaction which causes solids to concentrate (floc) and
water separate. The purpose is to minimize the solids removed from the treatment plant
because removal charges are based on the amount of gallons removed. Excessive solids
from the secondary system enter a pump station by gravity flow. From here the solids are
pumped to a gravity settling tank to begin the thickening process. There are two gravity
settling tanks and one drum concentrator. Current flows necessitate the use of only one
gravity settling tank. This provides back up for the tank on line. The gravity settling
tank and drum concentrator can be used separately or in series. Wastewater operations
dictate which is used but normally the series option is used with the solids first entering
the tank. The gravity setting tanks are switched regularly to ensure proper operation and
even wear and tear on equipment. The pump station is used to send solids to the gravity
settling tank.
The pump at this station became inefficient. The pump impeller or the part that actually
forces flow wears over time. If it is not completely worn out it can be adjusted to return
efficiency. However, when completely worn out it must be replaced to return efficiency.
The pump was removed and inspected. The impeller only needed adjustment to return
efficiency. From this pump station the solids are pumped to one of two gravity settling
tanks. Flow out of these tanks is by gravity. Over the years flow from tank number 2
became restricted. On several occasions the tank had been inspected for debris causing
the restriction. The drain piping was also dismantled in this search as well. Trash and
debris was found on a couple of occasions but when put to use it still would not flow
well. Tank number 2 was rotated off line again this year to cycle the tanks for equal
wear. Number 2 was also scheduled to be painted inside and out. To help accomplish
this the drain piping had to be dismantled. Another opportunity was taken to search for
the restriction. However, this time a TV camera was inserted into the lines. At this time
a plastic cap and a rubber float control cover were discovered. Previous cleaning of the
line had not removed this debris. This debris was removed and after the tank received its
paint job it was returned to service. Flow from this tank now has returned to normal.
During the year this same tank required other repairs as well. There is a motor and
gearbox attached to a mixing paddle. The paddle mixes the solids and polymer to make
good contact and aid the settling process. Both motor and gearbox wore out and had to
be replaced. Solids flowing out of the gravity tank are sent to the drum concentrator.
The concenfrator runs on a series of pillar block bearings. These bearings stabilize the
drum. Without this stabilization the solids thickening belt tracks off the concentrator.
One of these bearings wore out and had to be replaced. Before polymer can be used for
the gravity tank or concentrator systems it must be maintained. Polymer is received in
concentrated form. It must be maintained through mixing. This is accomplished with the
use of progressive cavity pump. During the year a few repairs became necessary. First,
the pump motor failed and had to be replaced. Later the pump lost efficiency. The pump
was removed and taken apart. There are two parts working together to create the
pumping. The rotor and stator are these two parts. The stator was found worn and was
replaced. This returned the pump to normal efficiency.
Lime Stabilization. Waste activated thickened solids are stabilized through the use of
lime. Time and pH’s dictate the stabilization requirement. Lime is received in dry form
and fransferred to a storage/feed silo. The dry lime is then fed to a preparation tank
where water is added creating slurry which is then added to a mixing tank containing
-8-
-9-
Even though the MGT is mixed constantly, lime still precipitates out. Over time it builds
up on the tank bottom. This reduces the effectiveness of the mixers. Approximately
once a year, the tank is emptied and cleaned to remove the built up lime. This time also
allows for the mixers to be inspected for wear and tear and an opportunity for the oil
levels to be checked. Also, the integrity of the MGT can be inspected. However, the
inspection in 2012 was due to an emergency. One of the riser pipes for solids transfer
built up pressure and blew apart at the mechanical joint near ground level. The brackets
that hold the riser pipe to the tank were lifted causing damage to the brackets and to the
tank panels. The company that consfructed the tank and does regular preventative
maintenance was called in to do an inspection and repairs. The tank was thoroughly
inspected and only minor damages found. The tank repairs were done by this contractor.
The mechanical joint of the riser pipe was repaired in house.
Generator. The plant generator is used to supply the entire plant with power in the event
utility power is interrupted. The generator is on a quarterly preventative maintenance
program with a contractor to maintain the engine. However, if the transfer switch which
transfers power from utility to generator does not function properly the generator cannot
Million Gallons Stabilization Solids Storage Tank (MGT). The MGT holds all stabilized
solids from the digester stabilization process and the lime stabilization process. It
contains five mixers that are used to keep the two different stabilized solids blended, to
help keep lime in suspension with the stabilized solids, and for odor control. One of
these mixers had to be removed for repair. A spare was used in its absence. Once
repaired, the mixer was reinstalled. Stabilized solids are removed from the bottom of the
tank through four valves located in different areas of the tank. Over the years some of the
valves had broken and others were difficult to use. This made emptying the tank slow
and difficult. To remedy this situation all four valves were replaced. When solids are
removed for land application process a pump is used by the truck drivers with the use of a
remote switch located at their loading stand. The switch went bad bringing the
application process to a halt. The switch was promptly replaced restoring the process.
Solids are removed at a cost per gallon. During the storage water will still separate from
the solids. Also the tank size, one million gallons, is like a large rain gauge. This excess
water is removed with a decent system saving thousands of dollars each year. During the
year part of the decant line and a valve burst. It was repaired so this process could
continue.
solids to be treated. The preparation tank when in use must be mixed constantly to
prevent lime from precipitating out and caking up creating a clogged discharge from the
tank. The mixing is accomplished with a paddle wheel run by a gearbox/motor combined
unit. This unit went bad and was replaced. Once the lime slurry is added to the solids
mixing tank and the proper level is reached, the treated tank is ready for transfer to a
downstream process. The levels can be monitored remotely with the use of a level
indicator called a pressure transducer. Having these indicators can allow an operator to
follow the tank levels. If a tank gets too low the mixers could cavitate causing damage to
the mixers. Also, if a tank gets to high it can overflow. The transducers failed and had to
be replaced. One of the lime/solids mixers failed and had to be rebuilt. A spare was used
in its absence. There are two wet well transfer stations associated with this process. The
first transfers stabilized solids to the holding tanks. The second transfers stabilized solids
from the holding tanks to final storage. The first wet well transfer control panel was
rebuilt in 2011. In 2012, an alarm “High” level light and horn was added. Also, in 2012
the second well transfer control panel was rebuilt. Now both stations are in good
electrical working condition. The holding tank stores lime stabilized solids until time and
pH measurements are achieved. To aid this process mixers are used. They are controlled
with a float style leveler. This was not a good application. It caused the mixers to turn
on and off repeatedly. This allowed lime to precipitate and undue wear and tear on the
mixers. To remedy this situation a different style of leveler called a multitrode was
installed. The operation now is constant. In 2012, to protect the metal integrity of the
lime silo, it was painted.
be used. The transfer switch is now also on a regular scheduled maintenance program
with an outside contractor.
The diesel tank level indicator is mechanical and prone to sticking giving a false reading
of available diesel fuel gallons. To improve this reading an electronic device was
installed in the tank with an associated LED display. The gallons indicated are now more
accurate. A federal law enacted required certain diesel powered equipment to do some
air emissions cleanup. The emergency generator fell under this umbrella. In 2012, the
generator was equipped with an exhaust filter system to help control these emissions.
12” pump installation. The 12 inch pump installed at the head-works of the plant in 2000
remains a valuable tool in preventing spills. In the event of high flows or maintenance
repairs, water can be removed to two abandoned secondary clarifiers. These clarifiers
were taken off-line in the early eighties after plant upgrades. They were originally used
for stabilized biosolids storage. The capacity was increased by extending a wall up from
where the weir overflows were when used as secondary clarifiers. This increased the
storage capacity of the two tanks to 750,000 gallons. After a dedicated biosolids tank
was constructed, the two abandoned tanks were dedicated to spill containment. Once
stored, wastewater can be returned to the plant with an existing pump station. Some pipe
work has been added to this station and depending on conditions, water could be returned
as the tanks are filled. This further increases holding capacity or downtime, during high
flows or maintenance and repairs. In 2012, 4,355,788 gallons of wastewater were stored.
Since setup in 2000, 49,732,667 gallons of wastewater have been prevented fi om spilling.
At the average flow of 3.5 MGD in 2012, this would be 14.2 days of flow.
SC ADA (Supervisor Control and Data Acquisition). SCADA is a computer-based
program. It brings site information into the central operations center. SCADA is a useful
tool by providing monitoring information to be used for more efficient plant operation. It
also brings remote site alarms into the operations center, which provides better control
over plant problems. Additional SCADA work was done in the thickening/stabilization
area of the plant. Some additional pumps and mixers were added to the computer alarm
and trend identification and tracking system. There were also some motion detection
sensors added too pieces of equipment. Also receiving some additional SCADA work
was the digester building. The pearths, manometers, and exhaust fans were added and
the heater alarm signals were expanded. Due to the size and complexity, and some parts
of the SCADA system beginning to age, several repairs were necessary throughout the
year. Also, to keep the SCADA computer working reliably and efficiently, the data from
2011 was unloaded on to an external hard drive.
The emergency generator is also used to curtail. The District is under contract with
Dominion Power. From May 16,h through September 30^ (summer curtailment) and
from December lsl through March 31st (winter curtailment), Dominion can request the
- 10-
Another means of spill control is with a backup generator. The wastewater plant must
continue to run in the event of power interruptions from the power-supply company.
Power interruption can occur from equipment failure, road accidents, and weather events,
such as ice storms, electrical storms, tornadoes, and hurricanes. A 750 kilo-watt
generator is on site for events and can supply enough generated power to run the entfre
plant. In 2012, there were five power interruptions resulting in the use of the back up
generator for power supply. This first occurred on February 1st and was due to failed line
transformer. The generator was used for 3 hours and 30 minutes and prevented 145,833
gallons from spilling. The second was on July 1st and was due to a storm blowing trees
down on service lines. The generator was used for 52 minutes to prevent 110,136 gallons
from spilling. The next three occurred on August 3rd, two separate events, and on August
6th. The generator was employed for all three events preventing 188,015 gallons (Ihour
35 minutes), 187,500 gallons (Ihour 15minutes) and 194,600 gallons (Ihour 10 minutes)
respectively. The last three events were due to blown service line fuses. In all 826,084
gallons were prevented from spilling by using the backup generator for the five events
covering approximately eight and one half hours without normal power supply.
-11 -
wastewater plant to supply its own power for parts of the day during peak demand.
These requests usually come on the hottest days of summer and the coldest days of
winter. Dominion can then send power that the District would normally use to other
places of need. Winter requests are usually from 6am to 1 lam (5 hours) but can be 5pm
to 10pm also possibly on the same day. However, each requests counts as one run.
Summer requests are from 2pm to 9pm (7 hours). The contract is limited. In the winter
requests to curtail are limited to 13 or 65 hours and summer 19 or 133 hours. In 2012 the
wastewater plant was called to run 17 times during the summer curtailment. There was 1
winter call. The District does incur the cost of diesel fuel. However, the rate structure
the wastewater plant has because of the contract off sets this cost and provides electrical
energy savings. An added benefit of this program is that it provides a means to exercise
the generator. This keeps the generator in better running condition and exposes any
potential problem. It would be better to find out a problem during a curtailment than an
actual power outage. Dominion does provide one waiver per curtailment season each
year for such cases where a mechanical issue should arise. By having the generator under
a contracted quarterly preventive maintenance program hopefully mechanical problems
will be minimized or eliminated.
Biosolids land application program. This program permitted by the Environmental
Protection Agency (EPA) ran well in 2012. In the required annual report to North
Carolina division of Water Quality (NCDWQ) and the (EPA), there were no deficiencies
or spills. In 2012 there were 208 lime stabilization events at 11,250 gallons per event for
a total of 2,477,250 gallons. This is 60 % of the days in a year. The anaerobic digestion
process produced an additional 932,400 gallons of stabilized solids. Although these
solids have met all requirements for stabilization, they are also limed. This is done solely
for the purpose of odor control. The wastewater plant has entered into agreement with
area fanners for the use of their land for biosolids application. The farmers in turn
receive the nutrient value, moisture content, soil remediation, and lime, which is a by­
product of ph control in the treatment process of the biosolids. If necessary, additional
lime can be applied. There are 3100 acres, consisting of 128 fields, available in Halifax,
Northampton, and Warren Counties. All acreage was inspected, approved, and permitted
by the State of North Carolina. Using EPA approved treatment processes, 3,379,000
gallons of stabilized biosolids were safely applied to area lands, consisting of 11 fields
and 308.4 acres, for beneficial reuse. Cost of this application process was approximately
$112,000. Cost of treatment to stabilize solids is separate. Land that grew fescue,
Bermuda, soybeans, wheat, and cotton was applied to. The amount applied in 2012 is
down 21 % from the previous year. Charges for application are based on gallons. In an
attempt to save application costs, biosolids are thickened as much as can possibly be
handled. The removed water is returned to the treatment plant. Also, once biosolids are
placed in storage for land application, water is further separated. This water along with
environmental water (rain, snow, etc) is decanted and returned to the treatment plant. In
2012, 325,384 gallons was decanted, at savings of $10,965. Although 3100 acres of land
is permitted and storage of 1,000,000 gallons is available, at times application is difficult
due to weather conditions, crop status, and crop rotation. Owning land would provide an
outlet for these times. In 2004, the District purchased a suitable land application site. It
is located in Northampton County where the District already has farmer owned land
permitted. The land has been developed for livestock (cow) operation. The area has
been split into two fields. One contains 41.8 acres of fescue and the other contains 67.2
acres of bermuda.
Since purchasing the land, investment improvements continued in 2012. Improvements
have been going on for nearly eight years. In 2012, the District over seeded the Bermuda
with annual rye. Because Bermuda goes dormant in cold weather months the rye over
seed makes the Bermuda acreage available for nutrient uptake if application to this site
becomes necessary. The District has strived to develop a model site. In 2012, in excess
of $1,500.00 was spent to maintain and enhance the application site. In 2012, the
District’s site was used for land application. This was the first time since 2008, just a few
months short of four years since previous use. In September, 471,200 gallons of
biosolids were applied over a four day period for an average 117,800 gallons per day.
The District’s Emergency Response Plan (ERP) was revised in and submitted to the state
October 9, 2012. The PERCS Unit approved the ERP revisions October 15, 2012. Each
industry was sent a revised edition.
The pretreatment annual report (PAR) was submitted to the state pretreatment unit on
February 15, 2012. A letter, dated June 7, 2012, was received stating review of the PAR
indicates the report in good order and satisfied the requirements of the North Carolina
Pretreatment Program (PERCS Unit).
The biosolids were applied to the Bermuda side of the site only. In contrast for 2008, a
total of 1,053,000 gallons was applied of which 253,500 gallons were applied to the
Bermuda side and 799,500 gallons were applied to the Fescue side for a total of
1,053,000 gallons. This application event was over an eight day period for an average of
131,625 gallons per day.
The laboratory submitted all required evaluation studies and received an acceptable rating
on all in-house study parameters. The laboratory received e-mail notification March 20,
2012 that it had satisfied its performance evaluation requirement for 2012.
- 12-
Industrial pretreatment program. In 2012 the industrial pretreatment program had
oversight of three significant industrial users. One user has a categorical discharge pipe.
Five non-significant industrial users are permitted to send flow to the wastewater plant.
Significant and non-significant status is determined in part by the volume of flow
discharged and the pollutants in the discharge. The pollutants, carried by certain
industrial wastes, determine the categorical status of an industry. Each industry whether
classified as a significant or non-significant user is issued a permit with limits and
monitoring requirements. In 2012 there were no significant industrial users in significant
non-compliance; a status based on the number and types of violations of a pennit. There
were six notices of violation sent for permit violations.
The laboratory has two full-time and one part-time technician, a laboratory supervisor,
and laboratory manager. After the laboratory obtains certification, it must complete an
annual performance evaluation study and submit the results to the state certification
section. This performance evaluation must be in the form of a “blind” study. Study
samples are ordered from a state approved vendor. The study sample values are
unknown to the laboratory. The samples are analyzed and the results are submitted back
to the supplier fro grading. If the laboratory fails to achieve an acceptable rating on a
parameter for three consecutive samples, the laboratory could loose certification for that
parameter. If certification is lost, the laboratory must go through a recertification process
as if they had never achieved certification.
Monitoring Laboratory. The District wastewater plant has an on-site monitoring
laboratory. Analysis for NPDES reporting to the Division of Water Quality must be
performed by a certified laboratory. The laboratory is certified by the North Carolina
Division of Water Quality Laboratory Certification Section. In order to become certified
the laboratory facility must meet space and equipment specifications as well as analysis
performance evaluation. The laboratory is currently certified for twelve inorganic
parameters and four Vector Attraction Reduction options for the treatment of biosolids.
The laboratory receives samples from approximately 39 sampling points that include
plant monitoring, industrial monitoring, performance evaluation studies, septage hauling,
and collection system samples.
In 2012, the pretreatment program began its five year Industrial Waste Survey as required
by state and federal pretreatment regulations. Submittal of the survey is required by
February 1, 2013.
All industrial pretreatment permits expired in 2012. Permits were renewed with an
effective date of May 1, 2012 and an expiration date of 5/31/2017.
- 13-
In 2012, there were 52 restaurants in the District database. There was one restaurant to
close during 2012. Inspections of the restaurants and updates to the database continued
in 2012.
There were no Notice of Violations or Notices to Correct sent out to any restaurant in
2012.
A requirement of the wastewater plant through its NPDES permit is quarterly chronic
toxicity testing. The test involves using a predetermined amount of effluent along with a
Fats, Oils, and Grease (FOG) Ordinance. The Roanoke Rapids Sanitary District adopted
its first Fats, Oils and Grease (FOG) Ordinance in 2005. Since then operational issues
under the ordinance arose. In 2008, the District addressed those in a revision and
subsequent adoption of new ordinance language.
FOG public education is a requirement of the wastewater collections system permit
WQCS00027. Ongoing efforts from 2011 continued in 2012 with the revision of a FOG
slide that airs on local television Channel 15 and the addition of a FOG pamphlet
enclosure with one billing cycle. The adminisfrative staff continues to distribute a FOG
ordinance package to all new Food Preparation Facilities when opening a new account.
The administrative staff also gives out industrial waste surveys to each person who
opened a commercial account that asks questions regarding food preparation and grease
traps.
National Pollutant Discharge Elimination System (NPDES) permit. The waste water
treatment plant has an NPDES permit. It is issued by the North Carolina Division of
Water Quality (NCDWQ) after final approval is granted by the Environmental Protection
Agency (EPA). The permit authorizes discharge of treated wastewater to the
Roanoke River. The current permit is valid through March 2012. However, 180 days
(6months) prior to the current permit expiration an application for renewal must be
submitted. The renewal application was submitted September 2011. A draft permit was
received on December 27, 2012. This draft is provided to the public thirty days for
review and comment. Likewise, the District has thirty days for review and comment.
Some additional requests may be made. This process has begun.
Additional requirements of the program include state inspections, quarterly in-house
blind studies, maintaining a quality control program and a chemical hygiene plan, a
chemical inventory plan, equipment calibration and certifications, and certification fee.
The laboratory also works in association with the pretreatment program and biosolids
program in that analysis of samples taken by pretreatment technicians and plant operators
are brought to the laboratory for analysis. A laboratory technician is also responsible for
entry of the resulting data into a spreadsheet that is used by the Pretreatment program for
its Long Term Monitoring Plan. Laboratory technicians are also responsible for data
entry into the plant operations spreadsheet used for NPDES permit compliance
monitoring and plant process control.
The laboratory works in coordination with the state certification branch to certify field
testing equipment for the surrounding communities with small treatment facilities who
work on limited funds. At this time, the laboratory assists six small facilities with
equipment certification.
There were no sanitary sewer overflows or blockages reported in 2012 that were
attributed to FOG, a continuance from 2011 which also had no overflows or blockages.
The District continues a more frequent cleaning schedule of collection system lines that
service high density housing areas in an effort to further prevent sanitary sewer
overflows. The District also continues to clean lines that service high FOG volume areas,
such as restaurants, before seasonal high flows.
Another testing requirement of the NPDES permit is the annual priority pollutant analysis
(APPA). As indicated, it is an annual test that checks the effluent for conventional and
non-conventional compounds, total recoverable metals, volatile organic compounds,
acid-extractable compounds, and base-neutral compounds. These substances, if found in
sufficient quantity, could be harmful to the wastewater plant, receiving stream, and the
public. To date, no substances have been found in significant quantity to cause harm.
The test is done seasonally over the term of a five year NPDES pennit.
NCDWQ also requires an Annual Performance Report (APR). The report must contain at
a minimum, general information, performance, deficiencies, violations, spills and
bypasses, any known environmental impacts, and corrective measures to address
deficiencies or violations. Also, from the APR a condensed Consumer Confidence
Report (CCR) must be distributed to the customers of the District with information on
where to obtain the APR.
The wastewater plant now has a general storm water permit. It was received through an
application process as required by the NCDWQ. A requirement of this permit is a written
storm water management plan. The plan is used to evaluate potential pollution sources
and to select and implement appropriate methods to prevent or control the discharge of
pollutants to stormwater runoff. As a part of the plan, semiannual preventative
maintenance evaluations and semiannual inspections of site runoff areas are required.
The Division of Water Quality (DWQ) conducted several inspections in 2012. The first
was on June 4,h and was a wastewater permit inspection. Areas evaluated included
permit, self-monitoring, laboratory, flow measurement, solids handling disposal,
operations and maintenance, facility site review, records/reports and effluent receiving
waters. The second was on December 4th and was a solids generation and land
application permit inspection. Areas evaluated included miscellaneous questions,
pathogen and vector attraction, recordkeeping, treatment and sampling. The third was on
December 171' and was a dual inspection. It was a wastewater permit inspection that
evaluated the same areas as the June 4th inspection. In addition, a storm water permit
inspection was conducted. Additional areas evaluated were storm water and pollution
prevention. All four inspections indicated the wastewater plant was well maintained and
deemed compliant.
macroscopic organism. The wastewater treatment plant contracts this test with a private
independent laboratory. They collect sample and run the test. Ceriodaphnia are placed in
the effluent and must survive and reproduce for a specific length of time. Results of the
test are either pass or fail. A pass indicates the absence of substances in the effluent
which may be harmful or threaten aquatic life. The wastewater plant has been required to
test for chronic toxicity since April of 1993 or nineteen and one half years. To date only
one test has received a fail result. This occurred in July 2001. This test was collected
and tested by North Carolina Division of Water Quality (DWQ). DWQ has run this test
again with all passing. The latest was conducted in March 2011.
Safety program. The safety program within the District is veiy active and assertive in its
approach to the protection of the employees and surrounding citizens. The program
consists of a safety officer, safety committee, incident/accident committee and appeals
committee. The safety officer sets up the monthly safety meetings, coordinates the
activities of the safety committee, keeps up with safety regulations, and many other
various safety activities. The safety committee prepares safety policy programs and
updates current ones. They also do site inspections and produce potential hazard punch
lists. The safety committee and safety officer also keeps up with and prepares for
updating regulations and integrating new regulations of OSHA. The incident/accident
committee reviews all potential accidents and accidents. The appeal committee follows
up the safety committee recommendation at the request of an employee. The attempt is to
minimize the seriousness of an accident and ultimately prevent accidents. As a result of
the awareness and training from the safety program, there were no loss work days in 2012
at the wastewater treatment plant. This makes the 7th straight year the wastewater plant
- 14-
Permit limit violation
1.C.S.: None
Monitoring and Reporting Violations
2012 Sanitary Sewers Overflows (SSO)
1.
2. WWTP: N/A
Bypass of Treatment Facility
- 15-
B. By month, list of the number and type of any violations of permit conditions,
environmental regulations, or environmental laws, including (but not limited to):
achieved this accomplishment. The Sanitary District was previously involved with the
Department of Labor (DOL) OSHA SHARP Program. DOL works with and inspects
companies by company’s request. After DOL requirements are met, companies are
awarded SHARP recognition. Participating in this program exempts companies from
unannounced inspections with possible fines. The District remained in this program for
several years before DOL restructured the program and removed the District from this
program. The correct program now is the STAR Program. The District began in 2011
plans for admission into the STAR Program.
In 2012 efforts were continues to be admitted into this program. One of the requirements
is to be evaluated and instructed by a mentor. This would be a facility or organization
that has been through the STAR process and gained admittance. In February, Cabarrus
County sent two representatives to do a site evaluation. A pre-plant walk through was
done. The STAR program was explained in general. Items such as what to get prepared
tor, what to expect, how to conduct and OSHA expectations plus others were discussed.
Then a site walk through produced a punch of concerns and deficiencies. Afterward a
post walk through evaluation was explained and the punch list was addressed. Much
time was used in 2012 to address all the items on the list. The most consuming was
general housekeeping. During the STAR preparation, a committee of 14 employees was
developed to implement the STAR program. This represents around 34% of District
employees. STAR program mandates employee participation strongly. Also during
2012, the star committee was given a list of eighteen points ranging from PPE, employee
participation, emergency programs/drills, self-inspections and others. Each member was
assigned one of the points and was responsible for making a presentation to be given to
OSHA at a later date. The committee met on several occasions during the year to
practice and develop a PowerPoint presentation. The presentation followed by a walk
through site preliminary evaluation early next year will determine if the District will be
allowed to continue to the next steps of STAR admittance.
C.S.: There were 9 reportable SSO in 2012.
1. 5/9/2012 - Belmont pump station. -5100 gallons
2. 7/21/2012 - Manhole 46 at 3rd and Stark Dr.-1800 gallons
3. 8/19/2012 - Belmont pump sta.-6000 gallons
4. 8/19/2012 - River Rd. G-54-75000 gallons
5. 8/19/2012 - Manhole 46 at 3rd and Stark Dr. -6000 gallons
6. 8/25/2012 - Numerous Manhole during flood - 15001 gallons
7. 9/18/2012 - Manhole 46 at 3rd and Stark Dr. -7200 gallons
8. 9/18/2012 -4th and Laurel -8400 gallons
9. 10/12/2012 - Hwy 48-Manhole A-180 - 2800 gallons
2. WWTP: None
1. C.S.: None
2. WWTP: None
C. Description of any known environmental impact of violations.
D. Description of corrective measures taken to address violations or deficiencies.
- 16-
1.
2.
RRSD performed preventative maintenance by cleaning with Jet-Vac and a root cutter
which is attached to the Jet-Vac hose for cutting roots, following with a CCTV camera to
inspect the lines after cleaning. The District also procured a new jetter which cleans the
line more effectively and proves to be more reliable than the old unit. Along with in­
house work, the District contracted services from KRG Utility Inc for further line
cleaning and CCTV.
RRSD secured a planning grant from The Rural Center in 2012 to further evaluate the
Belmont area. The District employed W. K. Dickson to conduct a study including more
smoke testing, manhole evaluations and storm water dye testing to locate sources of I&I,
which has been the root cause of many reportable spills over the past few years.
During 2012 District employees performed 5 point repairs on sewer lines.
1. 8'1 and Rapids - 8’ section of 8” sewer line
2. 817 Rapids St. -replaced 14’ of 8” sewer line
3. East 7th St. - replaced 7’ of 8” sewer line
4. Premier Blvd. - replaced 6’ of 10” sewer line
5. 628 Marshall St. - replaced 20’ of 12” sewer line
6. Installed new manhole on dead end line at 400 block of Carolina St.
MJ Price Construction cut and cleaned 16 miles of Chokyotte outfall and District
employees cut and cleaned 4.5 miles of outfall and cross country lines. KRG Utility Ic.
Cleaned and CCTV 16186.9 feet of line and District employees cleaned 70127 feet of
line for a total of 16.35 miles of line cleaned.
In October of 2012, RRSD contracted with KRG Utility and Ralph Hodge Construction
to pipe burst 372 ft. of 18” clay pipe to 21” polyethylene pipe to eliminate I&I from
several points in that line. The District replaced Manhole 180 in Hwy 48 with a new
manhole just off Hwy 48 in the right-of-way. At this time, the District also rerouted the
force main from 48 Lift Station to the new manhole. We had to bypass pump this section
of line while replacing for a period of approximately 2 weeks. We also had to pump and
haul from Hwy 48 Lift Station during this time.
C.S.: N/A
WWTP: Three
The first occurred on August 19,h. Nearly two and one half inches of rain had fell
just prior to this date. Then an additional three and one half inches fell on this date.
Much higher than normal flows tried to pass through the plant. Approximately
63,000 gallons was bypassed that received grit and rag removal with primary
clarification and first step secondary treatment. On August 25th two bypasses
occurred on the same day when Roanoke Rapids received nearly twelve inches of
rain in approximately five hours. Flows into the plant, rated at 8.34 million gallons
per day (MGD), exceeded 20 MGD. The plant was overwhelmed with flow it could
not handle. The first location bypassed approximately 1,095,000 gallons which
received grit and rag removal treatment only. This lasted for about sixteen hours.
The second location bypassed approximately 1,363,000 gallons which received grit
and rag removal, primary clarification, and first step secondary treatment. This
lasted for about nineteen hours.
1. C.S.:
1. C.S.: None
2. WWTP: None
- 17-
The hypochlorite bulk storage tanks, which came on line in 2001, are now on an annual
inspection program. The hope is to catch a problem, preventing a catastrophic spill
Training and directives have been put in place to prevent icing problems and equipment
failure that can result from the scum control spray system on the secondary clarifiers.
Low influent suspended solids can occur after rains making the 85% removal difficult.
Polymer can be fed into the secondary clarifiers aiding settlement of solids and help with
the 85% removal rate.
Secondary clarifiers can have solids washed out during periods of high flows.
Operational strategies have been put into place to minimize this.
During high flows or some maintenance repairs, influent flow can be diverted to
equalization storage tanks. Once flows lower or repairs are complete, the stored water is
returned to the plant for treatment. Flow is diverted to these tanks with the use of a 12
inch (5 MOD) pump. Proper maintenance of the pump is critical. It has been rebuilt
once and is on an annual preventative maintenance contract to ensure reliability. The
pump is started monthly and quarterly pumping is done.
Some of the work done to prevent problems is the identification of potential spill areas.
Once identified, arrangements are made to stop or minimize and contain.
During the construction of the disinfection/disinfection removal process, a truck
unloading contaimnent structure was installed. The structure is piped to a pumping
station equipped with pH alarms that are tied to the SCADA system. This provides
acknowledgement and control over a spill situation that may occur during chemical
delivery. The spill containment grating is open air. Normal rain can fill the containment
system. This would prevent collection in this system and a spill could occur. Level
indicators were installed on the contaimnent system with SCADA. Now rain water, as it
accumulates, can be removed. Also, before each chemical delivery the system is pumped
down. The system is also pumped down regularly by assignment. To further control this
area, the discharge valve is kept in the closed position and the pump turned off.
Primary clarifier influent lines have grease collection pits located on them. As the pits
collect grease and fill, the flow through the influent lines can be restricted, back up, and
cause spills, fo prevent this from occurring, a contracted vacuum truck company is
scheduled regularly to remove the excess grease and keep he lines unrestricted.
The Emergency Flood Pump Station is critical for the removal of wastewater from the
plant when river levels are high. This station is backed up with a diesel pump capable of
removing the wastewater flow in the event of pump station failure or electrical failure.
Two things were done to ensure the diesel pump preparedness. The first was an engine
heater was added to ready the diesel for immediate use. Second, an automatic starter was
added to start and run the pump weekly for a specific amount of time. This keeps the
pump ready for use also.
2. WWTP:
The WWTP is very aggressive in reacting to violations and identifying potential
deficiencies. Once identified, plans are made to upgrade or replace potential deficiencies,
which may result in violation. Modifying operations, training operators, laboratory
training, improved equipment, maintenance inventory parts and equipment and raising
awareness is also an on-going and continuous process.
- 18-
Identifying and eliminating inflow and infiltration (I&l) is an on-going and difficult task.
It is important to control I&I to take excess flows off of the treatment plant. However, it
is also important to address because excess I&I “dilutes” incoming waste. With diluted
wastewater it is more difficult to meet the percent removal requirements (85%) of the
plant’s permit. I&I also hydraulically over loads treatment processes making it harder to
meet permit limits. In addition to hydraulic overloads during these events, debris such as
sand and rock, which has built in the collection system, gets flushed to treatment plant.
On two occasions in 2012 this was a significant problem. On August 19th approximately
three and one half inches of rain fell in a relatively short period of time. Flows for the
day spiked up to 18.6 million gallons and the total for the day was 9.2 million gallons
(total plant capacity is 8.34 million gallons per day). Then on August 25th (less than one
week later) Roanoke Rapids received an additional eleven and one half inches of rain in a
very short period of time. Flows for the day spiked over 20 million gallons and the total
for the day was 14.7 million gallons. On August 19th the high flow flushed
approximately three pickup truck loads of sand and rock into the Rotomat/Grit collector
channel, basically shutting down these treatment processes. A vacuum truck has to be
brought in to vacuum all the debris out. Then less than one week later on August 25th an
additional two pickup truck loads of sand were flushed into the same area of the plant.
Again a vacuum truck was used to remove the debris. Average flow for 2012 was 3.5
million gallons per day. The month of August alone was 5.2 million gallons per day.
In 2012, more areas were identified and addressed to help resolve these problems. (See
II.D. 1, above)
The plant generator is capable of powering the entire plant in the event of power loss.
Without it, spills would occur. It is on a contracted quarterly preventative maintenance
program. Also, the transfer switch transfers incoming power to generator power is under
a preventative maintenance contract. Annually it is taken off line, disassembled,
inspected, and cleaned. Without a properly operating transfer switch, generator use is not
possible. It is also exercised monthly by the staff. And, curtailment program with the
main power supply company assures further testing and exercise of the generator.
The SCADA alarm system is an extremely valuable tool for preventing spills and other
problems. As problems arise or equipment fails, prompt attention is given to repairs so
the alarms are returned to service.
There are various pump station alarms throughout the plant. Some are equipped with
local visual lights and audible horns or sirens, and some are even equipped with remote
SCADA alarms. In an attempt to keep functioning alarms, they are tested on a monthly
basis. As more alarms are installed, they are added to the testing list.
The gravity tank wet well pump station has been a site of previous spills. The station
now has a local high level alarm horn and light. This signal has also been added to the
SCADA system to give this alarm remotely to the operations building.
lemporary pumps and hoses are used frequently. Hoses easily spring leaks. To prevent
hose leaks while pumping wastewater or biosolids, lay flat hose was replaced with
reinforced canoline hose.
The plant storm water drains are blocked and gated to help control spills that might
otherwise be released from the plant site. Although painted bright yellow, they were
struck and broken on occasion. A new design keeps the containment from being easily
struck. Also, flags on poles have been added, further increasing visibility.
A valve exercise program is now employed. It keeps valves in good working order. In
the event of routine maintenance, equipment problems, or emergencies, valves used to
address these issues are in a state of readiness. As valves are repaired or replaced, they
are added to the exercise list. There are hundreds of valves located inside and outside of
various areas. Each operator has a list of valves to exercise.
displays.
- 19-
The wastewater plant has a protective bank next to the Roanoke River, to the north,
Chockyotte Creek, to the east, and an unnamed creek, to the west. The entire length is
several thousand feet in length and over fifty feet in height in some locations. The slope
is very extreme. Several years ago the river began eroding the bank away. The District
began stabilizing the slope with a cloth bag filled with grout. The bags start at the top of
the slope and extended down into the river by several feet. The entire length was done in
sections. The next step was to stabilize the toe of the bags at the bottom of the river.
This was done with stacked storm cloth bags to secure the slope bags. After several
years, the last of the storm bags was completed in 2012.
Each year during the budget process, close scrutiny is paid to the potential of deficiencies
which could lead to violations. Any identification of potential problems is addressed
during this process so that they are remedied before problems arise.
The Fat, Oil, and Grease (FOG) program continues to be a useful tool for the prevention
of spills. A pretreatment technician oversees and implements the program. The
technician inspects restaurants to ensure grease trap maintenance. Best Management
Practices for the control of grease entrance into the collection system is also conveyed.
Part of the FOG program is public education. The technician is required to incorporate
all users of the collection system. This is accomplished through door hangers, bill
inserts, poster distribution, advertisements, public service announcement and public
The Stormwater Pollution Prevention Plan (SPPP) is a valuable tool in identifying
deficiencies. It incorporates annual awareness and training to all plant personnel. It also
requires semi-annual inspections of all plant equipment and facilities, containment, and
tanks and chemical storage. The plan also addresses chemical suppliers and contractors
through training. The plan allows for scheduled identification of deficiencies before they
become problems.
III.NOTIFICATION
IV.CERTIFICATION
eh
-20-
R. Danieley Brown, PE/
Chief Executive Offic/r
Reduce
Recycle
Satisfy
Develop
Date
A. A condensed, summarized version of this report will accompany the annual water report
which will be distributed to the users and customers of the Roanoke Rapids Sanitary
District via mail. The full report will be available at the main office upon request.
snr
A. I certify under penalty of law that this report is complete and accurate to the best of my
knowledge. I further certify that this report has been made available to the users of the
named system and that those users have been notified of its availability.
kJ
December 16, 2013
RE: November 2013 DMR for NC0024201
This is to notify you of situations that pertain to data reported on the enclosed DMR.
If you have any questions, please contact me at [phone].
Sincerely,
CC: Gregg Camp, ORC
Dan Brown, CEO
Attn: Central Files
DENR/DWQ
1617 Mail Service Center
Raleigh, NC 27699-1617
Waste Water Treatment Plant
135 Aqueduct Rd. Weldon, NC 27890 [phone] Fax [phone]
November 25, 26 - The CBOD Glucose/Glutamic Acid standard was outside of the acceptable range of
164+/- 30.7 mg/1.
Greta Glover
Laboratory Supervisor
Waste Water Treatment Plant
135 Aqueduct Rd.Weldon, NC 27890 [phone] Fax [phone]
The Roanoke Rapids Sanitary District Wastewater Plant (WWTP) has a monthly Total Suspended
Solids (TSS) limit of 30 milligrams per liter (mg/l) and an 85 % removal requirement. The WWTP
was noncompliant for November 2013 with a 34.7 TSS and an 82.2 % removal.
The WWTP has two Trickling Filters that buffers flow from the Primary Clarifiers before reaching
the Activated Sludge System. With the lower plant flows of recent one Filter with recirculation
will accomplish the buffering needed. The Filters had both Rotary Distributors replaced in the
mid to late nineties. Unlike the Distributors of the past these Distributors were built with
bottom load bearings rather than top load bearings. The WWTP has experienced much trouble
with this style of Distributor. In 2012 funding was budgeted to have both Distributors rebuilt in
2013 and retrofitted with top load bearings. The first Distributor was in the process of being
machined for retrofitting when the bearing of the Distributor still in service failed. The lack of
no buffering led to the organic over load and the resulting bulking sludge.
The bulking sludge caused three extremely high TSS results that led to the noncompliance. The
numbers were 176.0,142.0 and 186.1 mg/l. Without these anomalies the monthly average
would be 14.7 and the percent removal 93.4. The first high number was due to a pump failure
which was feeding polymer to aid in solids settling. The other two high numbers was a result of
high flow wash out due to 2.4 inches of rain in two days.
To control the loss effluent solids the WWTP did the following. Approximately $77,500 was
spent to rebuild the first distributor. It is back on line but will take some time before zoogleal
mass can be established and buffering begins. Around $5500.00 was spent on polymer to aid
settling. Over $1000.00 of spare pump parts were on hand to be able to repair the polymer
pump as quickly as possible. Extra maintenance was done to the on line Distributor to keep it in
operation. The wasting was halted to bring the F/M ratio back in balance. Extra sampling and
The WWTP is experiencing bulking sludge. Microscopic examination reveals no filamentous
organisms. The sludge is finely dispersed and will not settle and therefore easily washes out
with effluent flow. Laboratory comparison of data from this year to last at the same time
shows nearly a 50% increase in food to microorganism (F/M) ratio. Literature states a 10%
increase in F/M ratio can cause bulking sludge.
Waste Water Treatment Plant
135 Aqueduct Rd.Weldon, NC 27890 [phone] Fax [phone]
testing was done to improve the TSS weekly and monthly averages. And during high flow day's
equalization tanks were used to store flow to minimize solids wash out.
The WWTP spent approximately $84,000.00 and put in a great deal of effort to obtain
compliance.
Month 2013Year
Halifax
Date 12/6/2013
50050 00400 00610 01002 01027 01042 01051 01067 00147 01092 00300
9.7 <14.12 1.17
12.4
2.9
3.0
6.2
58
6.0
36
16
47
C
8.34
IE»I
3.5
4.1
z
m X z
mg/l
§
Q
EFFLUENT
I
Discharge No. 001
Class IV
4.0
27.4
4.8
4.9
5,5
5.4
5.4
<10.0
<10.6
<10.0
<10.0
<10.0
0800
0800
JJSOO
0800
0800~
0800
0800
0800
j800
0800
0800
0800
0800
0800^
0800
0800
0800
0800
0800
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
18.4
21.0
15.9
G
15.9
16.1
17.5
H
H
19.6
19.0
19.5
20.4
19.5
7.7
7.0
_G^
6-9
7.5
7 5
7.3
H
H
7.6_
7.5
7.5
7.5
7.4
H_
7.2
7.0
7.1
7.4
11.3
11.0
34.7
186.1
Al.
C
30
33.3
16.8
30.8
13.5
176.0
13.4
12.2
15.1
13.0
142.6'
186.1
8.3
10.2
9.0
23A
20.4
15.2
13.3
13.8
6.5
8A
7.4
9.7
6.0
12.4
2.9
C
<14.12
<14.12
<14.12
C
1.17
1.17
1.17
C
$ fl II___ _
_6_
c
—0 _
0
c
#DIV/0!
0_
6
c
0
_0_
c
0
_0
G
6
__o_
c
0
0
c
0
0_
c
0
_0_
c
#DIV/0!
0
0
c
o
R
mg/l
5J_
5.9
4.2
G
5.9
5.3
5.7
H
H
47
5.5
4.2
4.2
5.0
<10.0
<10.0
<10.0
<10.0
<10.0
^4
69
8
G
200
JI
45
8
69
49
1
2
3
4
5
6
7
8
2
10
11
12
13
J[4
15__
16
17
18
19
20__
21
22
23
24
25
26
27
28
29
30
31
Xverage ___ ______
Maximum ______ ___
Minimum __
Somp/Grab __
Monthly Limit
)WQ Form MR-1 (01-00)
Y
Y
Y
H
H
H
¥
Y
Y
Y
Flow EFF
X.INF _
MGdF"-
3.1
3.0
1_2-7
__2.7
2.8
2.8
2.9 _
'2.8__
__Z3
2.2___
2.3
2.5L_
2.1
__Z5
2.5
2.6
2,7
2^5___
Z4
2.3
2.8
^6 _
2.5
2.4
2.3
_3.0
4.7
3.8
2.8
2.7
47
2.1
J9.6
18.6’
177
1'7.’8
18.1
H
187
17.7
17.5
17.6
7.5
7.6
7.6
?7
7.7
<10.3
27.4
<2.0^
C
25
3.0
21.2
<.0
2.1
m
Q
O m
0
mg/l
Nov
______County:
Phone [phone]
g.
o
o
mg/l
©
■X
mg/l
0
c
H_
5.2
5.2
5.8
5.4
<_10.0
<10.0
10.0
H
H
H
<10.0
<10.0
<10.0’
<10.0
o
c!
<
mg/l
71900
I
ug/l
x a
Units
7.6
E
.2
E
mg/l nig/l
00720
®
re
o
mg/l
00665
i
3 f
"mg/T
RoanokeRapIds Sanitary District
A. Gregg Camp Grade:
01062
I J_
mg/l
01034
E
!
5
mg/l
31616
§
■£0
#/100ml
00010
w
C
21.0
NPDS PermipNC0d24201 ________
Facility Name: |_______
Operator In Responsible Charge (ORC)
——J... I I I
Check If ORC Has Changed__
Certified Laboratories (1) Roanoke Rapids Sanitary^DlstrlctWWTP-La'b NaYojOer^hJn^LabNoj165
Mail ORIGINAL and ONE COPY
ATTN: Central Files
Division Of Water Quality
1617 MaH Service Center
Raleigh, NC 27699-1617
50060
Sf SI E
Sz
X O
ug/l
<10.0
.2
S
X E
mg/l
00530
1 ■o
mg/l
<10.0-
10.0
<10.0
G
28
_____
■8
H Q ?i - mg/l
4.3
re 5
Ew
l- c
__O
HRS’
24_
24
24
24
24
24
’24
24
24
24
24
24
24
24
24
_24
24
24
24
24
24
~24
24
24
24
24
_Z2<
24
24
24
2 _
a-= o <
HRS
0800
0800
0800
■■0802
I 0800
0800
0800
0800
J800
0800
0800
o « g X
^pfr
00600
0 ?
A 5 S
mg/l
0.2
x co
O c _o
Y/B/N
Y
4_______________________________ I
Person(s) Collecting Samples: Lab Staff, Operators
(Signature of Operator in Responsible Charge)
By this signature, I certify that this report is I_____
accurate and complete to the best of my knowledge.
80082
Year 2013Month
Halifax
12/6/2013Date
00340 00556 70301 00900 01059 34413 34416
1
160.0
EFFLUENT
I __
Discharge No. 001__
Class IV
________________________________ ____________ _________ |
Certified Laboratories (1) Roanoke Rapids Sanitary District WWTP-Lab No. 70 (2) Meritechjnc.-Lab No. 165
Person(s) Collecting Samples: Lab Staff, Operators
#DIV/0!
___0 _
0
c
ft IIIIIIII
0 _
G “
^0
c
IIIIII
0
0
G
IIII IlliII
0
_0_
G
160.0
160.0
160.0 c
IIIIIIIIII
ZaZ_o
c
a ii ii ii n
__ o
Z o
c
IIIIIIIIII
0
d
G
IIIIIIIIII
0
0
G
NPDS Permit NC0024201 ___ ____
Facility Name:______[______ __ ___
Operator in Responsible Charge (ORC)
71900
S'
I
£
Check if ORC Has Changed _
i i r
Mail ORIGINAL and ONE COPY to:
ATTN: Central Files ___
Division Of Water Quality __ __
1617 Mail Service Center
Raleigh, NC 27699-1617
Nov
______County:
Phone [phone]
1
2
3
4
5
~~ 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Average
Maximum _
Minimum
Comp/Grab
Monthly Limi
DWq Form MR-1 (014)0)
Q
8
mg/l
z1
mg/l
2?
HII
mg/l
*1£2
Roanoke Rapids Sanitary District
A. Gregg Camp ’Grade: J 4
71900
3 e o s
ug/l ug/l
(Sipnalure of Operator in Responsible Charpa) __
By this sipnature, I cartify that this report it________
accurate and complete to the best of my knowledpe.
32730
ss
ug/l ug/l
|h
m°g/i
UJ
00 W
x *
O Qt
__o
mg/l
009000030031616000100030000900000100030071900
16.6 9.2 68.052.016.8 8.5
10.613.09.9
5 TO
Q
i $.1 0)
ra O 1§ Q
273.8
3653
19675
C
277.2
238.1
259.5
283.3
Yr.
80082
2697
301.1
IO Q
O m o
mg/l
152.0
230.0
138.0
176.0
258.0
94.0
200.0
226.0
2003^
156.0
216.0
528.0
324.0
220.0
H
111.0
3963
2203
196.0
1463
192.0
14L°
332.0
236.0
; [UPSTREAM
Roanoke River____J
308 Rollingwood Road
HRS
0800
0800
0800
0800
0800
0800__
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800”
0800
0800’
0800
0800
0800
0800
0800
0800
0800
0800
15.0
16.8
13.2
G
9.2
9.9
8.5
G
#DIV/0!
0
0
G
52.0
52.0
52.0
G
UPSTREAM
Chockoyotte Creek
US 158 Crossing
#DIV/0!
0
0_
G
0
0
G
HRS
0800
£800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
080£
0800
0800
0800
Average
Maximum__
Minimum
I
1
2
3
4
5
6
7
8
9
10
11
12
13
I4
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
14.8
16.6
13.0
G
9.9
10.6
9.’£
G
68.0
68.0
68.0
G
H
196.5
365.3
221.5
528.0
94.0
C
13-2
I
1
2
3
4
5
6
7
£
£
10
11
12
13
14
15
16
17
18
19
20
21_
22
23
24
25
26
27
28
29
30
31
Average
Maximum
Minimum
I
#DIV/0!
0
0
G
___ DOWNSTREAM
Roanoke River________
US 158 Crossing
o £
HRS
0800
£300 ’
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
2013
00530
■o
V) w
mg/l
S’
3
E o> z
ug/l
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2£
2£
23
2£
25
26
27
28
29
30
31 ____
Average
Maximum
Minimum
I
1
2
3
4
5
6
7
8
9
10
11
12
13j
14
15
J 6
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
coLU z Q o:
X CO
mg/l
00010
co
HO
c
co
LU
ZQX
x co
mg/l
co
Z
C
o £
« £
oo
mg/l
co2
z
c
u- O
#/100ml
■o
Q O
mg/lHRS
0800
0800'
0800
0800
’ 0800
0800
0800
0800 '
0800
“0800
0800
0800
0800
0800
0800
“0800
0800
£800_
0800
0800_
0800 ’
0800
0800
0800
0800
0800
0800
0800
0800
0800^’
0800
Average
Maximum
Minimum
Comp/Grab
___I _ [INFLUENT
NPDES No. NC002420lPipe No. 001
Roanoke Rapids Sanitary District WWTP
Halifax CounfMo,
____ _______ Nov
•iI. I E
O H
HRS
24
24
24
24
2£
24
24
24
24
24
24
24
24
24
24
“24
24
24
24
24
£4
24
24
24
24
24
24
24
24
24
24
■o
o S)
a 5? o o
mg/l
December 16,2013
RE: November 2013 DMR for NC0024201
This is to notify you of situations that pertain to data reported on the enclosed DMR.
If you have any questions, please contact me at [phone].
Sincerely,
CC: Gregg Camp, ORC
Dan Brown, CEO
November 25, 26 - The CBOD Glucose/Glutamic Acid standard was outside of the acceptable range of
164+/- 30.7 mg/1.
Attn: Central Files
DENR/DWQ
1617 Mail Service Center
Raleigh, NC 27699-1617
Waste Water Treatment Plant
135 Aqueduct Rd. Weldon, NC 27890 [phone] Fax [phone]
Greta Glover
Laboratory Supervisor
Waste Water Treatment Plant
135 Aqueduct Rd.Weldon, NC 27890 [phone] Fax [phone]
The WWTP is experiencing bulking sludge. Microscopic examination reveals no filamentous
organisms. The sludge is finely dispersed and will not settle and therefore easily washes out
with effluent flow. Laboratory comparison of data from this year to last at the same time
shows nearly a 50% increase in food to microorganism (F/M) ratio. Literature states a 10%
increase in F/M ratio can cause bulking sludge.
The WWTP has two Trickling Filters that buffers flow from the Primary Clarifiers before reaching
the Activated Sludge System. With the lower plant flows of recent one Filter with recirculation
will accomplish the buffering needed. The Filters had both Rotary Distributors replaced in the
mid to late nineties. Unlike the Distributors of the past these Distributors were built with
bottom load bearings rather than top load bearings. The WWTP has experienced much trouble
with this style of Distributor. In 2012 funding was budgeted to have both Distributors rebuilt in
2013 and retrofitted with top load bearings. The first Distributor was in the process of being
machined for retrofitting when the bearing of the Distributor still in service failed. The lack of
no buffering led to the organic over load and the resulting bulking sludge.
The bulking sludge caused three extremely high TSS results that led to the noncompliance. The
numbers were 176.0,142.0 and 186.1 mg/l. Without these anomalies the monthly average
would be 14.7 and the percent removal 93.4. The first high number was due to a pump failure
which was feeding polymer to aid in solids settling. The other two high numbers was a result of
high flow wash out due to 2.4 inches of rain in two days.
The Roanoke Rapids Sanitary District Wastewater Plant (WWTP) has a monthly Total Suspended
Solids (TSS) limit of 30 milligrams per liter (mg/l) and an 85 % removal requirement. The WWTP
was noncompliant for November 2013 with a 34.7 TSS and an 82.2 % removal.
To control the loss effluent solids the WWTP did the following. Approximately $77,500 was
spent to rebuild the first distributor. It is back on line but will take some time before zoogleal
mass can be established and buffering begins. Around $5500.00 was spent on polymer to aid
settling. Over $1000.00 of spare pump parts were on hand to be able to repair the polymer
pump as quickly as possible. Extra maintenance was done to the on line Distributor to keep it in
operation. The wasting was halted to bring the F/M ratio back in balance. Extra sampling and
r 0/
*/ 1
*
Waste Water Treatment Plant
135 Aqueduct Rd.Weldon, NC 27890 [phone] Fax [phone]
testing was done to improve the TSS weekly and monthly averages. And during high flow day's
equalization tanks were used to store flow to minimize solids wash out.
The WWTP spent approximately $84,000.00 and put in a great deal of effort to obtain
compliance.
” !</>
Region a ra meters
TRC pH TEMP DO SC SETT
/
Noes
No
No
Noes
Noes
Yes
---------.------------------------------------------------------------------------------------------- 4---------- y _ | y__________
‘Date and time of sample collection and analysis may be the same for in situ or on-site measurements.
^ZlYes
'gYes
Yes
0~Yes
M/es
spectors’ Checklist for Fie^P
Are the following items documented (V where applicable):
Item_____________________________
Date of sample collection*__________
Time of sample collection*__________
Sample collector’s initials or signature
Date of sample analysis*___________
Time of sample analysis*___________
Analyst initials or signature_________
Sample location
No
Nc)'
No
No
No
No
No
No
'□ No
No
^Yes
^Yes
Yes
S'Yes
Facility Name:
NPDES #: /VCO 1-0 /
Field Lab Certification #: <70_______
Lab Contact:
III. Total Residual Chlorine_____________
Total Residual Chlorine meter make and model:
Is a check standard analyzed each day of use? (Circle one: gel oOguid standi
What is the assigned/obsen/ed value of the daily check standard?^
Is a 5-point calibration verification performed? Note date of last verification:
Alternatively, does the lab construct a linear regression, using 5 standards, to calculate
results? Note date of last calibration curve constructed:
True values: gj-pg/L mg/L
Obtained values: jB-ug/L mg/L ____
What program are samples analyzed on? .'^-7
Are results reported in proper units? Check one: ^kpg/L mg/L
Are results reported between the facility’s permit limit and the compliance limit of 50 pg/L?
If value is less than the low standard, report as “<x'’, where x=low standard cone.
Are samples analyzed within 15 minutes of collection?
iv-___ph__________________________________________________
I pH meter make and model:/tea*-
I Is the pH meter calibrated with at least 2 buffers per mfg’s instructions each day of use?
Note buffers used:___________________________________________
Is the pH meter calibration checked with an additional buffer each day of use? Note checlT
buffer used:____________________________________
Does the check buffer read within ±0.1 S.U. of the known value?
Are the following items documented:
Meter calibration?_____________ _________
Check buffer reading?__________
Are samples analyzed within 15 minutes of collection?______
Are sample results reported to 0.1 pH units?"
A Y Z' 7:
II. General Laboratory (note any exceptions in section XI)_________________
Are instruments, meters, probes, photometric cells, etc, maintained in good condition?
Are standards, reagents and consumables used within manufacturer expiration dates?
[TRC gel standard is exempt.]
Regional Plant Inspector:
Regional Inspector Contact TV/-
Region:
Date: /
I- . Check the parameter(s) performed at this site for reporting purposes.
□<otal Residual Chlorine (TRC) Q^emperature (TEMP) Specific Conductivity (SC)
O-pH' QatSsblved Oxygen (DO) Settleable Residue (SETT)
t
No
NoYes
KlYes No~
Yes No
Yes No
program recommended?
XI.
X.
Yes
Yes
Yes
Yes
CZ Yes
O Yes
No
No
Q No
No
No
G No
No
No
Q No
I J No
No
Yes
G Yes
G Yes
ZJ Yes
G YesWas a paper trail (comparing contract lab and on-site data to DMR)
performed? If so, list months reviewed:
Is follow-up by the Laboratory Certification
Additional comments:
G No
G No
G No
G No
G No
G No
G No
Id Yes No,

sssu?sxsj CM"°n p'°,m *
Electronic copies may be emailed to [e-mail].
Revision 04/20/2012
^KLYes
S-Yes
0-Yes
V. Temperature ~ -------—

Is the instrument/thermometer calibration checked at least annually aqainst a NIST
traceable or NIST certified thermometer?
J^reJemperature corrections (even if zero) posted on the instrument/thermometer?
Are samples measured in situ or on-site? [REQUIREDGhere is no holdinqTimeGo?------
temperature] ____
Are sample results reported in degrees C? -------------------~
VI. Dissolved Oxygen 5 -T ¥<^'7~~ ---------------------------------
DO meter make and model: XL '~~~~ ------------
Js the air calibration of the DO meter performed each day of use?
Are the following items documented'
Meter calibration?
_Are samples analyzed within 15 minutes of collection?
Are results reported in mg/L? :-------------------- -------------------------
VII. Conductivity " ------------------------------
Conductivity meter make and model: " ---------------- --------------
?VhJ\^eter callbrat®d dai|y according to the manufacturer’s instructions? Note standard
used (this is generally a one-point calibration):
Is a daily check standard analyzed? Note value: ~ ---------------------
Are the following items documented: ------
Meter calibration? ~ ----------------------------
_Are samples analyzed within 28 days of collection? -----------------
Are resuftsreported in pmhos/cm (some meters display equivalent pS/cm units)?
viii. Settleable Residue--------- -----------------------------
Goes the laboratory have an Imhoff Cone in good condition? -------
Is the sample settled for 1 hour? ------------------------------ -—---------------------
Is the sample agitated after 45 minutes? --------------------------------
Are the following items documented: ' ---------------------------------------
—Volume of sample analyzed? Note volume analyzed:______
—Date and time of sample analysis (settling start time)?--------------------
Time of agitation after 45 minutes of settling? ------------------------------------- -—
Sample analysis completion (settling end time)? ----------
Are samples analyzed within 48 hours of collection? -------------------------------------
Are results reported in ml/L? -------------- --------------------------------------
IX.
EPA
NPDES
NC0024201
21| I I I I I I
Entry Time/Date Permit Effective Date
13/04/0110:37 AM 13/12/20Roanoke River WWTP
Exit Time/Date Permit Expiration Date
17/03/3103:17 PM 13/12/20
Other Facility Data
Alan Gregg Camp/ORC/919-536-4884/
Name, Address of Responsible Official/Title/Phone and Fax Number
Gregg Camp.PO Box 308 Roanoke Rapids NC 27870//252-536-4884/
Permit Records/Reports
Effluent/Receiving Waters
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Agency/Office/Phone and Fax Numbers Date
Mack K Wiggins RRO WQ//919-791-4200/
Page #1
12,
Self-Monitoring Program
Laboratory
Operations & Maintenance
Sludge Handling Disposal Facility Site Review
United States Environmental Protection Agency
Washington, D.C. 20460
Contacted
No
135 Aqueduct Rd
Weldon NC 27890
yr/mo/day
13/12/20
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
III
Form Approved.
OMB No. 2040-0057
Approval expires 8-31-98
Name(s) and Signature(s) of Inspector(s)
Facility Self-Monitoring Evaluation Rating
7°U
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
■I Flow Measurement
Fac Type
20U
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Inspection Type
18l£j
Inspector
19[sJ
QA72 w
EPA Form^SeO-S (Rev 9-94) Previous editions are obsolete.
3l
Inspection Work Days
671 I 69
Transaction Code
1 N 2 LI
Remarks
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 I I I I I I66
(Agency/Of^ce/Phone and Fax Numbers Date
--------Reserved------------------------
75l I I I I I I I 8073l I I74
Water Compliance Inspection Report
Section A: National Data System Coding (i.e„ PCS)
B1
71IJ
J"J17
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 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 application?
Is the facility as described in the permit?
# Are there any special conditions for the permit?
o Is access to the plant site restricted to the general public?
DOOIs the inspector granted access to all areas for inspection?
Comment:
Record Keeping Yes No NA NE
■ O 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?■
■ O(If the facility is - or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift?
■ 0Is 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?
Page #3
Permit: NC0024201
Inspection Date: 12/20/2013
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance Evaluation
Permit: NC0024201
Inspection Date: 12/20/2013
Record Keeping Yes No NA NE
■ ODOFacility has copy of previous year's Annual Report on file for review?
Comment:
Effluent Pipe Yes No NA NE
■ O 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:Effleunt was clear with little to no foam at the time of the inspection.
Bar Screens Yes No NA NE
Type of bar screen
a.Manual
b.Mechanical
■ Are the bars adequately screening debris?
■ o Is the screen free of excessive debris?
■ Is disposal of screening in compliance?
■ Is the unit in good condition?
Comment:
Yes No NA NE
Type of grit removal
a.Manual
b.Mechanical
■ oIs the grit free of excessive organic matter?
■ o o Is the grit free of excessive odor?
■ 0# Is disposal of grit in compliance?
Comment:
Yes No NA NE
■ Is the filter free of ponding?
■ Is the filter free of leaks at the center column of filter's distribution arms?
■ Is the distribution of flow even from the distribution arms?
■ Is the filter free of uneven or discolored growth?
■ Is the filter free of sloughing of excessive growth?
Page #4
Vortex Primary and Gravity grit removal as back-up system.
Trickling Filter
Has a vortex grit and rag removal system as back-up.
Grit Removal
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance Evaluation
Trickling Filter Yes No NA NE
■ Are the filter's distribution arms orifices free of clogging?
■ oIs the filter free of excessive filter flies, worms or snails?
Comment:
Aeration Basins Yes No NA NE
Ext. AirMode of operation
JetType of aeration system
■ Is the basin free of dead spots?
■ Are surface aerators and mixers operational?
■ Are the diffusers operational?
■ 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?
■ oIs the DO level acceptable?(1.0 to 3.0 mg/l)
Comment:
Secondary Clarifier Yes No NA NE
■ Is the clarifier free of black and odorous wastewater?
o ■ oIs the site free of excessive buildup of solids in center well of circular clarifier?
■ Are weirs level?
■ o o Is the site free of weir blockage?
■ Is the site free of evidence of short-circuiting?
■ Is scum removal adequate?
■ oIs the site free of excessive floating sludge?
■ Is the drive unit operational?
■ Is the return rate acceptable (low turbulence)?
■ oIs the overflow clear of excessive solids/pin floc?
■ Is the sludge blanket level acceptable? (Approximately /a of the sidewall depth)
Comment:
De-chlorination Yes No NA NE
LiquidType of system ?
■ Is the feed ratio proportional to chlorine amount (1 to 1)?
Page #5
Permit: NC0024201
Inspection Date: 12/20/2013
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance Evaluation
Permit: NC0024201
Yes No NA NEDe-chlorination
■ ODDIs storage appropriate for cylinders?
■ ODO# Is de-chlorination substance stored away from chlorine containers?
■ Are the tablets the proper size and type?
Sodium Bisulfite used to de-chlorinate.Comment:
0 0 ■ 0Are tablet de-chlorinators operational?
Number of tubes in use?
Comment:
Yes No NA NEDisinfection-Tablet
■ oAre tablet chlorinators operational?
o ■ Are the tablets the proper size and type?
Number of tubes in use?
■ oIs the level of chlorine residual acceptable?
■ Is the contact chamber free of growth, or sludge buildup?
■ o Is there chlorine residual prior to de-chlorination?
Sodium Hypochlorite used to disinfect.Comment:
Yes No NA NESolids Handling Equipment
■ O Is the equipment operational?
■ Is the chemical feed equipment operational?
■ o Is storage adequate?
■ 0Is 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?
o ■ Is the site free of excessive moisture in belt filter press sludge cake?
■ The facility has an approved sludge management plan?
Yes No NA NEAnaerobicJDigester
Floating coverType of operation:
■ Is the capacity adequate?
■ # Is gas stored on site?
■ o o Is the digester(s) free of tilting covers?
Page #6
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance Evaluation
Comment: Cynagro collects every three months on average and lad appys at farms in
Halifax, Northampton and Warren Counties.
Inspection Date: 12/20/2013
Anaerobic Digester Yes No NA NE
Is the gas burner operational?■ □00
Is the digester heated?■ 000
Is the temperature maintained constantly?■ 000
■ ODDIs tankage available for properly waste sludge?
Comment:
Chemical Feed Yes No NA NE
Is containment adequate?noon
Is storage adequate?0 0 0 0
Are backup pumps available?0 0 0
Is the site free of excessive leaking?0 0 0 0
Comment:
Drying Beds Yes No NA NE
Is there adequate drying bed space?■ 0 00
Is the sludge distribution on drying beds appropriate?■ DOO
Are the drying beds free of vegetation?■ ODO
# Is the site free of dry sludge remaining in beds?■ 000
Is the site free of stockpiled sludge?■ ODO
Is the filtrate from sludge drying beds returned to the front of the plant?■ ODD
# Is the sludge disposed of through county landfill?0 n ■
# Is the sludge land applied?■ Don
(Vacuum filters) Is polymer mixing adequate?■ DOO
Comment:
Yes No NA NE
# Is flow meter used for reporting?DDbO
Is flow meter calibrated annually?O O ■ 0
Is the flow meter operational?O 0 ■ o
(If units are separated) Does the chart recorder match the flow meter?n o ■ o
Comment:
Yes No NA NE
# Is flow meter used for reporting?■ 000
Page #7
No influent flow meter.
Flow Measurement - Effluent
14 drying beds on site. Only used fro an emergency.
Flow Measurement - Influent
Permit: NC0024201
Inspection Date: 12/20/2013
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance Evaluation
Permit: NC0024201
Inspection Date: 12/20/2013
Yes No NA NEFlow Measurement - Effluent
■ oIs flow meter calibrated annually?
■ Is the flow meter operational?
■ (If units are separated) Does the chart recorder match the flow meter?
Comment:Flow meter is an Endress & Hauser FMU 90.
Yes No NA NENutrient Removal
# Is total nitrogen removal required?
□□□# Is total phosphorous removal required?
Type
o # Is chemical feed required to sustain process?
Is nutrient removal process operating properly?
Comment:
Yes No NA NEStandby Power
■ Is automatically activated standby power available?
■ o Is the generator tested by interrupting primary power source?
■ Is the generator tested under load?
■ Was generator tested & operational during the inspection?
■ o Do the generator(s) have adequate capacity to operate the entire wastewater site?
■ □00Is there an emergency agreement with a fuel vendor for extended run on back-up power?
■ ODOIs the generator fuel level monitored?
Comment:
Yes No NA NEPumps-RAS-WAS
■ OODAre pumps in place?
■ nonAre pumps operational?
■ nonAre there adequate spare parts and supplies on site?
Comment:
Yes No NA NELaboratory
■ DOOAre field parameters performed by certified personnel or laboratory?
■ nonAre all other parameters(excluding field parameters) performed by a certified lab?
■ ODO# Is the facility using a contract lab?
■ 0 n 0# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Page #8
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance Evaluation
Laboratory Yes No NA NE
■ Incubator (Fecal Coliform) set to 44.5 degrees Celsius*/- 0.2 degrees?
■ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
Comment:
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ■DOO
Comment:
Influent Sampling Yes No NA NE
■ D O # Is composite sampling flow proportional?
■ DOOIs sample collected above side streams?
Is proper volume collected?■ ODD
Is the tubing clean?■ ODD
■ D D 0# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
■ ODDIs sampling performed according to the permit?
Comment:
Effluent Sampling Yes No NA NE
■ ODOIs composite sampling flow proportional?
■ 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)?
■
Equalization Basins Yes No NA NE
■□OIs the basin aerated?
■ o Is the basin free of bypass lines or structures to the natural environment?
Is the basin free of excessive grease?■
Are all pumps present? o ■
0 ■Are all pumps operable?
Are float controls operable? ■
Are audible and visual alarms operable? O 0 ■
Page #9
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment:
Permit: NC0024201
Inspection Date: 12/20/2013
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance Evaluation
Permit: NC0024201
Yes No NA NEEqualization Basins
■ o# Is basin size/volume adequate?
Comment:Has two old clarifiers that can be used as an equalization basin.
Yes No NA NEPrimary 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?
■ o 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?
■ o Is the drive unit operational?
■ o Is the sludge blanket level acceptable?
■ Is the sludge blanket level acceptable? (Approximately % of the sidewall depth)
Comment:
Page #10
Owner - Facility: Roanoke River WWTP
Inspection Type: Compliance EvaluationInspection Date: 12/20/2013
Month Year 2013
4
±
12/6/2013Date
50050 TPG 38010020102701042007200105171900001470109200300
Y
9.7 <14.12 1.17
12.4
2.9
3.0
6.2
58
6.0
36
16
0800 |47
0800
C
8.34
lEEli
3.5
4.1
Nov
County:
3.0
21.2
«
Q
Z
coXZ__________
mg/l mg/l mg/1
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
^800
0800
0800
0800 '
0800
0800
0800
0800 ~
0800 I
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
‘24
24
24
24
24
24
24
24
24
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Roanoke Rapids Sanitary District
A. Gregg Camp Grade:
Person(s) Collecting Samples: Lab Staff, Operators
21.0
15.9
G
15.9
16.1
17.5
H
H
j9.6
18.6
17.7
17.8
18.1
19.6
19.0
19.5
20.4
19.5
7.5
7.5
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H
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7.6
7.5
7,5
7.5
7.4
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7.2
7.0
7.1
7.4
4J
27.4
11.3
11.0
33.3
16.8
30.8
13.5
176.0
13.4
12.2
15.1
13.0
142.0
186.1
8.3
10.2
9.0
34.7
186.1
6.5
C
30
6.0
12.4
2.9
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<14.12
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4.9
5.5
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28
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<•10.0
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<10.0
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34
69
8
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200
69
49
______| 0800
Average
Maximum
minimum
3omp/Grab
Monthly Limit__________
)WQ Form MR-1 (01-00)
Mail ORIGINAL and ONE COPY
ATTN: Central Files I__
Division Of Water Quality
1617 Mall Service Center
Raleigh, NC 27699-1617
1
2
3
4
5
6
2
8
9
10
JI
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Y
Y
Y
H
H
H
Y
Y x
Y
2.7
4.7
2.1
7.7
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7.5
7.6
7.6
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27.4
<2.0
C
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mg/l
H
6.5
8.1
7.4
9.7
__________Halifax
Phone [phone]
o o
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ug/l
4.7
5.5
4.2
4.2
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<10.0
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45
8
Flow EFF
X.INF _
MGD ~
3.1
3.0
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2.7
2.8
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2.9
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2.3
2.2
2.3
2.5
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2.5
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2.7
2.5
2.4
2.3
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2.5
2.4
2.3
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4.7
3.8
2.8
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mg/l
o
mg/l
‘ 5.2
5.2
5.8
5.4
x
Units
7.6
01034
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mg/l
1 <2.0
2.1
3
3
mg/l
EFFLUENT
I
Discharge No. 001__
t I | Class IV
5.9
5.3
5.7
_H
H
23.9
20.4
15.2
13.3
13.8
5
U3 E
mg/l
.2 S’ P SA
P/F
NPDS Permit NC0024201___________
Facility Name: |
Operator in Responsible Charge (ORC)
I | | |
Check If ORC Has Changed___
Certified Laboratories (1) Roanoke Rapids Sanitary District WWTP-Lab No. 70 (2) Meritech,Inc-Lab No, 165
i ; i -
50060
X O
ug/i
<10.0
31616
g
3 =
#/100ml
CO
g -° I it
mg/l
4.3
(Signature of Operator in Responsible Charge)____
By this signature, I certify that this report is |
accurate and complete to the best of my knowledge.
00530
1
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mg/l
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18.7
17.7
17.5
17.6
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5 2
6 S
S
mg/l
00010 00400] 80082
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c
21.0
00610 00600 | 00665
JO
2013Year
12/6/2013Date
00340 00556 70301 00900 01059 34418
160.0
lESEJI
I ■! I III II II II HI III II II II 211
I j
mg/1
1
Halifax
Phone [phone] i
Class IV
___________________ ________________________________ |
Certified Laboratories (1) Roanoke Rapids Sanitary District WWTP-Lab No. 70 (2) Meritech,Inc.-Lab No. 165
Person(s) Collecting Samples: Lab Staff, Operators
0
0
c
0
0
G
0
£
C
0
0.
G
0
V
G
0
0
C
0
0
G
0
0
G
Nov
County:
Check if ORC Has Changed
i i r~ ~
Mail ORIGINAL and ONE COPY to:
ATTN: Central Files__________
Division Of Water Quality
1617 Mail Service Center______________
Raleigh, NC 27699-1617
1
2
3
J
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
160.0
160.0
C
0
0
c
NPDS Permit NC0024201____________
Facility Name: | ~___
Operator in Responsible Charge (ORC)
71900
□
<9 a
Ufl/l
71900
S'I
a
Ufl/l
<n
§
mg/1
Maximum__i
Minimum i
Comp/Grab <
Monthly Limi___
DWQ Form MR-1 (01-00)
Q
O
mg/1 llmg/1
iu
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mg/1
32730
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-1 IU
EFFLUENT
I ~
___________Discharge No. 001
Roanoke RapidsSanitary District
A. Gregg Camp Grade: | 4
(Signature of Operator in Responsible Charge) ’
By this signature. I certify that this report is |
accurate and complete Io th.e best of my knowledge.
34413
00300 009000001031616000100030000300719000090000010
68.016.6 9.28.516.8
13.0 10.613.2 9.9
Q
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Q 1 o
ro EE
24
25
26
27
28
29
30
31
I
i-
HRS
0800'
0800
0800
0800
0800
0800
0800
0800
0800
259.5
283.3
277.2
238.1
273.8
365.3
196.5
C
269.7
301.1
H
196.5
365.3
152.0
230.0
138.0
176.0
258.0
94.0
200.0
226.0
200.0
156.0
216.0
528.0
324.0
220.0
221.5
528.0
94.0
C
146.0
192.0
147.0
332.0
236.0
H
111.0
396.0
220.0
196.0
|_______| UPSTREAM
Roanoke River |
308 Rollingwood Road
1__
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17 ~
18
19
20
21
22
23
24
25
26
27
28
29
30
31
#DIV/0!
0
0
G
52.0
52.0
52.0
G
| |UPSTREAM
Chockoyotte Creek
US 158 Crossing
HRS
0800
0800
0800
0800 '
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800 '
0800
0800
0800
0800 ~
0800
0800
0800 '
0800
0800
0800
0800
0800
0800
0800_
0800
Average
Maximum__
Minimum
I
#DIV/0!
b
o
G
2.
o
G
| | DOWNSTREAM
Roanoke River
US 158 Crossing______
HRS
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
Average
Maximum
Minimum
I
14.8
16.6
13.0
G
9.9
10.6
9.2
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68.0
68.0
68.0
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2013
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1
2
3
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5
7
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10
11
12
13
14
15
16
17
18
19
1°
21
22
23
24
25
26
27
28
29
30
31
#DIV/0!
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G
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
<n
UJz
Qa:<x tn
mg/l
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
3
2 a
Z
ug/l
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80082
HRS
0800
0800
0800
0800
0800
0800
£800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800
0800'
0800
0800
Average
Maximum
Minimum
§
£ o
tnx
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u lu
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j I INFLUENT I
NPDES No. NC002420^Pipe No. 001 ~
Roanoke Rapids Sanitary District WWTP
Halifax Count] Mo.
Nov
S
L o I
HRS
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
■e
II
Q O
mg/l
- o o
mg/l
520
I
15.0
16.8
13.2
iG
aj
ro
Q__
= /
1
2
3
4
5
6
7
8
9
10 0800
11
12
13
14
15
16
17
18
19
20
21
23 | 0800
0800
0800
0800
0800
0800
0800
0800
0800
Average
Maximum
Minimum
Comp/Grab
? C
o §>
8 £•
5 o
mg/l
9.2
9.9
8.5
G_,