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Home My WebLink AboutNC0042528_Compliance Evaluation Inspection Report_201707063 Watergesources Wdb6tONKS1ITAL WAUTY July 6, 2017 Carter Jordan B Everett Jordan & Son -1927 LLC PO Box 128 Saxapahaw, NC 27340-0128 Subject: Compliance Evaluation Inspection Report NPDES Permit NCO042528 Saxapahaw Plant WWTP, Alamance County Dear Mr. Jordan: ROY COOPER Govemor MICHAEL S. i`L L,.\. A secretarl S, JAY ZIMIa1 RIv AN Vilwtor RECEIVEDINCDENWR JUL 12 2017 Water Quality Permitting Section On June 22, 2017, Paul DiMatteo of the Division of Water Resources ("Division"), Winston-Salem Regional Office conducted a Compliance Evaluation Inspection of the above referenced wastewater treatment system. Mike Carson, Operator in Responsible Charge (ORC), was present for the inspection. An inspection summary follows and an inspection report is attached for your records. Site Review 1. Permit The current permit became effective on January 1, 2017 and expires on May 31, 2021. Permitted components include equalization basins, aeration basins, settling basin, aeration digester, and ultraviolet disinfection. A copy of the current permit was available for review. Facility Site Review The facility is as described in the permit. The UV system appeared to be working properly. Replacement bulbs are kept on site and a backup chlorination system is available. Operation and Maintenance The facility appeared to be generally well maintained. In response to the issues noted during the previous inspection on June 25, 2015, it was reported that an engineering firm was consulted and several changes were made which resulted in the permitted plant being better able to treat waste and eliminated the need to use any old components. 4. Effluent/Receiving Waters The effluent is discharged into the Haw River in the Cape Fear River Basin. A river -side nature trail runs directly behind the plant and acts as a path to the effluent. Effluent appeared clear with no signs of impact to the river. Operators take samples from the effluent holding tank. State of North Carolina I Environmental Quality I Water Resources AGA LT7 -, TL.«,... a.1.11 D.....! e....,. ann rn..,...,..,_e,l,..., ATP wlns e � 5. Flow Measurement Effluent flow is measured using a Badger Meter Ultrasonic Open Channel Flow Meter. It was reported that the meter's calibration was overdue because you planned to move the totalizer to reduce the possibility of wiring being cut during grounds maintenance and would need to calibrate the meter again afterwards. However, the only calibration record available during the inspection showed calibration being conducted in 2013 and no other record has been provided as of the date of this letter. Please be advised that the permit requires flow measurement devices to be calibrated at least once per year and maintained to ensure that the accuracy of measurements is consistent with the accepted capability of the device. These records must be kept for at least three years and be accessible during inspection. Documentation Review 6. Records/Reports Discharge Monitoring Reports (DMRs) and lab data are maintained according to the permit. DMRs include all permit parameters. Copies of DMRs, operator visitation logs, lab reports and Chain -of -Custody forms were available for review during the inspection. 7. Self -Monitoring Program A review of DMRs from July, 2015 through April, 2017 showed several violations which are summarized below. The last violation occurred in November, 2016. VIOLATION DATE PARAMETER VIOLATION ACTION 11/11/2016 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOD 07/02/2016 Nitrogen, Ammonia Total Proceed to NOV 07/02/2016 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOV 07/02/2016 Solids, Total Suspended - Concentration Proceed to NOV 03/31/2016 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOV 03/24/2016 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOV 01/31/2016 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOV 01/08/2016 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOV 11/06/2015 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOD 10/02/2015 Solids, Total Suspended - Concentration Proceed to NOV 08/14/2015 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to NOV 07/31/2015 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to Enforcement Case 07/31/2015 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to Enforcement Case 07/02/2015 BOD, 5 -Day (20 Deg. C) - Concentration Proceed to Enforcement Case 8. Laboratory Mr. Carson visits the plant weekly and tests the following field parameters: pH and temperature. Mr. Carson's field parameter certification number is 5195. Calibration records for Mr. Carson's meters are maintained with records and reports. Meritech, Inc. analyzes all other parameters for the facility. Sludge Handling Disposal Sludge is removed from the plant approximately twice per year McPherson's Septic Tank Cleaning Sludge removed sludge from the plant in October, 2016 and May, 2017. A receipt of the October removal was available during the inspection. State of North Carolina I Environmental Quality I Water Resources 450 West Hanes Mill Road, Suite 300, Winston-Salem, NC 27105 We appreciate your efforts in effectively operating and maintaining this treatment system. No additional response to this report is required. If you should have any questions, please do not hesitate to contact Paul DiMatteo at (336) 776-9691 or our office at (336) 776-9800. Sincerely, inncerely, Sherri V. Knight, P.E., Regional Supervisor Water Quality Regional Operations Section Winston-Salem Regional Office Division of Water Resources, NCDEQ Enclosures — Inspection Report and Summary CC: WQS Winston-Salem Regional Office - Enforcement File NPDES Compliance/Enforcement Unit - Enforcement File Central Files State of North Carolina I Environmental Quality I Water Resources 450 West Hanes Mill Road. Suite 300. Winston-Salem. NC 27105 United States Environmental Protection Agency Form Approved EPA Washington, D C 20460 OMB No 2040-0057 Water Compliance Inspection Report Approval expires 8-31-98 Section A National Data System Coding (i e, PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 IN 1 2 15 I 3 I NCO042528 I11 12 17/06/22 17 18 L C A 19 1s 201 6 211111 1 1 1 1 1 1 II I I I I I I I I I I I I I I I I I I I I I I I II I I I I I 1 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA --------------------Reserved-------------- 67 70 I_j 71 L] 72 LL N � 73 ► I 174 75III I_U80 J I I I Section B Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include Entry Time/Date Permit Effective Date POTW name and NPDES permit Number) 11 40AM 17/06/22 17/01/01 Saxapahaw Plant WWTP 1735 Saxapahaw-Bethlehem Exit Time/Date Permit Expiration Date Saxapahaw NC 27340 01 OOPM 17/06/22 21/05/31 Name(s) of Onsite Representative(s)Mtles(s)/Phone and Fax Number(s) Other Facility Data /// James M Carson/ORC/336-578-3264/ Name, Address of Responsible Official/Tifle/Phone and Fax Number Contacted Carter Jordan,PO Box 128 Saxapahaw NC 273400128//336-376-3122/ No Section C Areas Evaluated During Inspection (Check only those areas evaluated) Permit N Flow Measurement Operations & Maintenance Records/Reports Self-Monitoring Program N Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters Laboratory Section D Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Paul DiMatteo WSRO WQ//336-776-9691/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date, I,�6'1 A-6 , c C1.11, 7 l 7 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete Page# NPDES yr/mo/day Inspection Type (Cont.) 1 31 N00042528 I11 12 17/06/22 17 18 , _ , Section D Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Site Review 1 Permit The current permit became effective on January 1, 2017 and expires on May 31, 2021 Permitted components include equalization basins, aeration basins, settling basin, aeration digester, and ultraviolet disinfection A copy of the current permit was available for review. 2 Facility Site Review The facility is as described in the permit The UV system appeared to be working properly Replacement bulbs are kept on site and a backup chlorination system is available 3 Operation and Maintenance The facility appeared to be generally well maintained In response to the issues noted during the previous inspection on June 25, 2015, it was reported that an engineering firm was consulted and several changes were made which resulted In the permitted plant being better able to treat waste and eliminated the need to use any old components 4 Effluent/Receiving Waters The effluent is discharged into the Haw River in the Cape Fear River Basin A river -side nature trail runs directly behind the plant and acts as a path to the effluent Operators take samples from the effluent holding tank 5 Flow Measurement Effluent flow Is measured using a Badger Meter Ultrasonic Open Channel Flow Meter It was reported that the meter's calibration was overdue because you planned to move the totalizer to reduce the possibility of wiring being cut during grounds maintenance and would need to calibrate the meter again afterwards However, the only calibration record available during the Inspection showed calibration being conducted in 2013 and no other record has been provided as of the date of this letter Please be advised that the permit requires flow measurement devices to be calibrated at least once per year and maintained to ensure that the accuracy of measurements is consistent with the accepted capability of the device These records must be kept for at least three years and be accessible during Inspection Documentation Review 6 Records/Reports Discharge Monitoring Reports (DMRs) and lab data are maintained according to the permit DMRs include all permit parameters Copies of DMRs, operator visitation logs, lab reports and Chain -of -Custody forms were available for review during the inspection 7 Self -Monitoring Program A review of DMRs from July, 2015 through April, 2017 showed several violations The last violation occurred In November, 2016 8 Laboratory Mr Carson visits the plant weekly and tests the following field parameters pH and temperature Mr Page# Permit NCO042528 Inspection Date 06/22/2017 Owner - Facility Saxapahaw Plant VWVTP Inspection Type: ' Compliance Evaluation Carson's field parameter certification number is 5195 Calibration records for Mr Carson's meters are maintained with records and reports Meritech, Inc analyzes all other parameters for the facility 9 Sludge Handling Disposal Sludge Is removed from the plant approximately twice per year McPherson's Septic Tank Cleaning Sludge removed sludge from the plant in October, 2016 and May, 2017 A receipt of the October removal was available during the Inspection Page# L Permit- NCO042528 Owner - Facility Saxapahaw Plant WWTP Inspection Date. 06/22/2017 Inspection Type Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? M ❑ ❑ ❑ Does the facility analyze process control parameters, for ex MLSS, MCRT, Settleable M ❑ ❑ ❑ 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 ❑ ❑ M ❑ application? 0 ❑ ❑ ❑ Is the facility as described in the permit? M ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ 0 ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment - Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required Information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab reg required 5 years)? 0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? M ❑ ❑ ❑ 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 CDCs Are DMRs complete do they Include all permit parameters? 0 ❑ ❑ ❑ Has the facility submitted Its annual compliance report to users and DWQ? ❑ ❑ M ❑ (If the facility Is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator ❑ ❑ 0 ❑ on each shift? Is the ORC visitation log available and current? M ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? 0 ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? 0 ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? 0 ❑ ❑ ❑ Page# 4 Permit NCO042528 Owner -Facility- Saxapahaw Plant VWVrP Inspection Date 06/22/2017 Inspection Type Compliance Evaluation Record Keeping Yes No NA NE Facility has copy of previous year's Annual Report on file for review? 0 ❑ ❑ ❑ Comment. Records not kept on-site are stored at the owner's nearby office Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? E ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? N ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment A nature trail runs along the river behind the plant and acts as a path to the outfall Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? ❑ N ❑ ❑ Is the flow meter operational? N ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ E ❑ Comment Calibration records were not available for review durina the Inspection Records are reportedly kept at the owner's office The calibration report kept at the facility dated back to 2013 Additionally, Mr Carson said that the calibration was slightly past due, because they planned on moving the totalizer closer to the meter In the next 2 months Aerobic Digester Yes No NA NE Is the capacity adequate? E ❑ ❑ ❑ Is the mixing adequate? 0 ❑ ❑ ❑ Is the site free of excessive foaming in the tank? 0 ❑ ❑ ❑ # Is the odor acceptable? N ❑ ❑ ❑ # Is tankage available for properly waste sludge? 0 ❑ ❑ ❑ Comment. Bar Screens Yes No NA NE Type of bar screen a Manual b Mechanical ❑ Are the bars adequately screening debris? 0 ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? N ❑ ❑ ❑ Page# 5 Permit NC0042528 Owner - Facility Saxapahaw Plant VWVrP Inspection Date 06/22/2017 Inspection Type Compliance Evaluation Bar Screens Yes No NA NE Is the unit in good condition? ■ ❑ 1:11:1 Comment There are two bar screens one at the original plant Intake, and one at the Inlet of the newer package plant, which Is set Inside the old sedimentation basin Equalization Basins Yes No NA NE Is the basin aerated? 0 ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the basin free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? N ❑ ❑ ❑ Are all pumps operable? N ❑ ❑ ❑ Are float controls operable? N ❑ ❑ ❑ Are audible and visual alarms operable? 0 ❑ ❑ ❑ # Is basin size/volume adequate? 0 ❑ ❑ ❑ Comment Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? ❑ ❑ N ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? E ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/ of the sidewali depth) ❑ ❑ ❑ E Comment Aeration Basins Yes No NA NE Mode of operation Ext Air Type of aeration system Diffused Is the basin free of dead spots? 0 ❑ ❑ ❑ Page# 6 Comment Disinfection - UV Yes No NA NE Are extra UV bulbs available on site? N ❑ Permit. NCO042528 Owner - Facility: Saxapahaw Plant UWVrP Are UV bulbs clean? N ❑ Inspection Date- 06/22/2017 Inspection Type. Compliance Evaluation Is UV Intensity adequate? ❑ ❑ Aeration Basins Yes No NA NE Are surface aerators and mixers operational? ❑ ❑ M ❑ Are the diffusers operational? N ❑ ❑ ❑ Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? 0 ❑ ❑ ❑ Is the DO level acceptable? ❑ ❑ ❑ 0 Is the DO level acceptable?(1 0 to 3 0 mg/1) ❑ ❑ ❑ M Comment Disinfection - UV Yes No NA NE Are extra UV bulbs available on site? N ❑ ❑ ❑ Are UV bulbs clean? N ❑ ❑ ❑ Is UV Intensity adequate? ❑ ❑ ❑ M Is transmittance at or above designed level? ❑ ❑ ❑ N Is there a backup system on site? 0 ❑ ❑ ❑ Is effluent clear and free of solids? 0 ❑ ❑ ❑ Comment- UV Intensity and Transmittance were not measured, but assumed adequate based on fecal coliform reports Page# 7