NC0028827_Inspection_20190227

DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
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 I 2 IF I 3 I NCO028827 111 12 I 19/02/27 I17 18 L R J 19 L G ] 201 I
211111 I I I I I I 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 f6
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved-------------------
671 70 I, I 71 I—n I 72 I n, I 73 I I 174 751 I I I I I I I80
I—I Section B: Facility Data
I� I I i
Name and Location of Facility Inspected(For Industrial Users discharging to POTW,also include Entry Time/Date Permit Effective Date
POTW name and NPDES oermit Number) 12:15PM 19/02/27 17/08/01
Snug Harbor on Nelson Bay WWTP
272 US Hwy 70 Exit Time/Date Permit Expiration Date
Sealevel NC 28577 04:30PM 19/02/27 22/07/31
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
F Patrick Ausband//252-225-4411/2522251670
John Estep//252-225-4411 ext 223/
Mary Althouse//252-225-4411/
Patricia Davis//252-723-7528/
Patricia Taylor Davis/ORC/252-466-6787/
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
John Estep,PO Box 150 Sealevel NC 285770150/Engineering Director/252-225-4411/
Yes
Section C:Areas Evaluated During Inspection(Check only those areas evaluated)
Permit 0 Flow Measurement Operations&Maintenance 0 Self-Monitoring Program
Sludge Handling Disposal 0 Facility Site Review
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
Dean Hunkele DOCO� WIRO WQ//910-796-7215/
E3/18/2019
E1 D9294C4D3746E...
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DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Docusigned by: Date
Morelia Sanchez-King WIRO WQ//910-796-7218/ r S. J,�,,.,3,�,1�,$/ 019
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete. �""
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DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
Permit: NCO028827 Owner-Facility: Snug Harbor on Nelson Bay WWTP
Inspection Date: 02/27/2019 Inspection Type: Reconnaissance
NPDES yr/mo/day Inspection Type (Cont.) 1
31 NCO028827 I11 121 19/02/27 117 18 1 RI
Section D:Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
The visit was to determine the facility's current status and if the items/conditions noted in 2-2017 had
been addressed as no correspondence &evidence to that effect had been submitted to DWR's
regional office. It was also to meet with new& current staff while discussing the effluent data reporting
issues that occurred for most of 2018.
A long discussion and Q&A session began the visit as all of the facility staff are new within the past few
months to a year. The management and ownership (represented by Pat Ausband) need to do a better
job in overseeing the operational staff and ensuring funds are available for repairs and bills are paid in a
timely manner. Review of preliminarily revised reports &data showed the facility had monitored some
items and simply failed to report them or did so incorrectly. The last few months of 2018, it was a
matter of failing to pay the lab for their service and thus they withheld the data.
The off-site pump station (referred to as influent PS in this report) is considered part of a deemed
permitted or approved collection system per 15A NCAC 2T .0403, but certain things must be done in
accordance with the regulation. With staff being on-site daily, then complete &documented weekly
testing versus daily is okay since no telemetry is installed; telemetry monitoring of the station and plant
EQ is recommended. There are some electrical issues noted from 2017 that still need to be
addressed and the excessive solids were observed again (not sure if ever cleaned). Installation of
pump run clocks is recommended with at least weekly logging of the times to determine if a float has
gone bad, the alternating circuit has failed, or if a pump is showing signs of an issue.
Facility needs better accounting of flow and the volume of sources to the treatment plant along with
tracking rainfall and its affect on total flow. Our Public Water Supply Section staff indicated lack of a
meter or accurate readings for the water system recently. This is also important in order to determine
if half the treatment system can be taken off-line or not and if not then what size rental tankage would
be needed to control flow while each side is taken down independently for cleaning and repair.
The permit continues to list a Flow Equalization Basin as installed/active equipment, but it has not been
used as such going back to at least 3-2011 when it was noted during an inspection. Given that the
facility can receive normal domestic flow, laundry flow, cafeteria flow, and water system backwash,
then reinitializing the use of the EQ Basin is highly recommended to make the influent more
homogeneous and allow the flow to be sent through the plant at a consistent flow rate and split evenly
between the treatment trains if necessary to operate both. However, to do so will require the flow
splitter box to be repaired or replaced and the EQ Basin plumbed from the old sludge holding tank back
into it.
Observation of redworms in the filters means they are at least in the clarifiers meaning the sludge is
very old and not being properly wasted. The old sludge holding tank could be the source if not well
mixed and volume not replaced regularily. Please provide a MLSS report for each aeration basin and
the sludge holding tank and send us records regarding the last two sludge hauling events.
The exterior railings and tank walkway grating has been replaced making it much safer to get around
the plant without fear of safety; these were first noted as needing to be addressed in 3-2009. Additional
work is needed on internal railings& access stairs plus most metal electrical panels need to be
replaced along with areas of conduit around the plant which were noted in 2017. These are safety
issues for both inspectors and staff and can lead to a complaint by our staff to the NC Dept of Labor
which would inspect your entire complex.
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DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
Permit: NCO028827 Owner-Facility: Snug Harbor on Nelson Bay WWTP
Inspection Date: 02/27/2019 Inspection Type: Reconnaissance
Permit Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ 0 ❑
application?
Is the facility as described in the permit? ❑ 0 ❑ ❑
#Are there any special conditions for the permit? ❑ ❑ 0 ❑
Is access to the plant site restricted to the general public? ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? ❑ ❑ ❑
Comment: No EQ Basin in use and hasn't been since before 3-2011. The facility did indicate it was
part of their operational system in their 2017 renewal application which was apparently
inaccurate.
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? ❑ 0 ❑ ❑
Does the facility analyze process control parameters,for ex: MLSS, MCRT, Settleable ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: Exterior safety railings have been replaced, but stairs accessing plant and filters have vet to
be replaced. A viewing and access platform has been built for the filters. New
fiberglass/resin grating has been installed over tankage where needed. None of the
electrical panels/boxes have been repaired or replaced, but most if not all need complete
replacement as well as replacement of damaged conduit&fittings around the plant.
Pump Station - Influent Yes No NA NE
Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑
Is the wet well free of excessive grease? ❑ 0 ❑ ❑
Are all pumps present? 0 ❑ ❑ ❑
Are all pumps operable? ❑ ❑ ❑
Are float controls operable? ❑ ❑ ❑
Is SCADA telemetry available and operational? ❑ ❑ 0 ❑
Is audible and visual alarm available and operational? ❑ ❑ ❑
Comment: This is the off-site pump station. Need to determine what type of pumps are installed to
determine if the bar screen or basket is necessary in the wetwell as not required for grinders
with functional cutting blades. The wetwell was full of excessive solids/grease/raps that
could interfere with float/pump operation. In addition, the solids were so bad that excessive
"dung"flies were present in the station which is not acceptable from a vector control aspect.
The control panel is old with the conduit housing the lines from the wetwell into the panel not
sealed per current code which is an explosion hazard and the conduit entering the side of
the panel is not connected allowing moisture inside. The solids and electrical issues were
noted during the 2-23-2017 inspection which the facility indicated in writing would be
corrected. It is recommended that pump run times and/or advanced telemetry like a Mission
system be installed.
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DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
Permit: NCO028827 Owner-Facility: Snug Harbor on Nelson Bay WWTP
Inspection Date: 02/27/2019 Inspection Type: Reconnaissance
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? ❑ ❑ ❑
Are all pumps present? 0 ❑ ❑ ❑
Are all pumps operable? ❑ ❑ ❑
Are float controls operable? ❑ ❑ ❑
Are audible and visual alarms operable? ❑ ❑ ❑
#Is basin size/volume adequate? ❑ ❑ ❑
Comment: The EQ basin is no longer functioning as one and is operating operating strictly as an
influent pump station as was noted during the 3-2011 inspection vet the last permit issuance
indicates its existence& use as EQ. The force main trottled back by a valve (which will
shorten the pumps life)was replumbed from the concrete splittler box due to its structural
failure to the original sludge holding tank whereby it flows by gravity into at least one
treatment train in some manner. Given the nature of varying wastestreams and their
duration from the complex having an EQ basin is highly recommended, thus the flow splitter
box should be repaired or replaced with a return to EQ in place and flow routed back to it.
During the 3-2011 it was noted that the MLSS was not even between the aeration basins.
Aeration Basins Yes No NA NE
Mode of operation Ext.Air
Type of aeration system Diffused
Is the basin free of dead spots? ❑ ❑ ❑
Are surface aerators and mixers operational? ❑ ❑ 0 ❑
Are the diffusers operational? 0 ❑ ❑ ❑
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? ❑ ❑ ❑
Is the DO level acceptable?(1.0 to 3.0 mg/1) ❑ ❑ ❑
Comment: The only blower present was shut down to facilitate communication. Prior to that it
appeared that mixing was adequate, but activated sludge looked on the dark side; no MLSS
records were available nor was a decent settleometer vessel; use of a portable TSS meter
to measure MLSS on-site or periodic MLSS samples to the lab is recommended. A
replacement blower for the one missing has been supposedly ordered. If the remaining
blower fails, then the plant's biology will die.
Secondary Clarifier Yes No NA NE
Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑
Is the site free of excessive buildup of solids in center well of circular clarifier? ❑ ❑ 0 ❑
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DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
Permit: NCO028827 Owner-Facility: Snug Harbor on Nelson Bay WWTP
Inspection Date: 02/27/2019 Inspection Type: Reconnaissance
Secondary Clarifier Yes No NA NE
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? ❑ ❑ ❑
Is the site free of excessive floating sludge? 0 ❑ ❑ ❑
Is the drive unit operational? ❑ ❑ 0 ❑
Is the return rate acceptable (low turbulence)? ❑ ❑ ❑
Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑
Is the sludge blanket level acceptable? (Approximately'/of the sidewall depth) ❑ ❑ ❑
Comment: Observed through the grating
Aerobic Digester Yes No NA NE
Is the capacity adequate? 0 ❑ ❑ ❑
Is the mixing adequate? ❑ ❑ ❑
Is the site free of excessive foaming in the tank? 0 ❑ ❑ ❑
#Is the odor acceptable? 0 ❑ ❑ ❑
#Is tankage available for properly waste sludge? 0 ❑ ❑ ❑
Comment:
Filtration (High Rate Tertiary) Yes No NA NE
Type of operation: Down flow
Is the filter media present? 0 ❑ ❑ ❑
Is the filter surface free of clogging? ❑ ❑ ❑
Is the filter free of growth? ❑ ❑ ❑
Is the air scour operational? ❑ ❑ ❑
Is the scouring acceptable? ❑ ❑ ❑
Is the clear well free of excessive solids and filter media? ❑ ❑ ❑
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DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
Permit: NC0028827 Owner-Facility: Snug Harbor on Nelson Bay WWTP
Inspection Date: 02/27/2019 Inspection Type: Reconnaissance
Filtration (High Rate Tertiary) Yes No NA NE
Comment: Filters are dosed by pumps. Red worms observed on media surface which indicates a verb
old sludge; no idea when sludge last hauled. The inspection 2 years ago mentioned media
was being lost to the mudwell. It is very likely the filters have been augmented from the
original design based on appearance of the dosing frame &overflow trough. The media
level appeared to be way too high in relation to the overflow trough for scoured solids (less
than a foot) and apparent depth of the filters, thus no doubt getting media carry-over. Given
this facility's limits especially for TSS, the need for filters shouldn't exist if flows are accurate
& if facility is operated properly. Filters do provide a safety factor for effluent quality, thus if to
remain in use then they should be returned to orginal design specifications or augmented to
function better.
Disinfection-Liquid Yes No NA NE
Is there adequate reserve supply of disinfectant? ❑ ❑ ❑
(Sodium Hypochlorite) Is pump feed system operational? ❑ ❑ ❑
Is bulk storage tank containment area adequate? (free of leaks/open drains) 0 ❑ ❑ ❑
Is the level of chlorine residual acceptable? ❑ ❑ ❑
Is the contact chamber free of growth, or sludge buildup? M ❑ ❑ ❑
Is there chlorine residual prior to de-chlorination? ❑ ❑ ❑
Comment: There was discussion about replacing the liquid with tablets to match the dechlorination
method. Based on this facility's plug flow from an off-site pump station and especially with
the EQ basin functioning as a pump station too, then tablet chlorination would be a better fit
in function & likely cost. Effluent very clear but tank very dark; perhaps cleaning and painting_
would allow observation inside the unbaffled tank. Tank should not be aerated to mix as it
drives off chlorine, should be mixed with submerged pump or motorized mixer.
De-chlorination Yes No NA NE
Type of system ? Tablet
Is the feed ratio proportional to chlorine amount(1 to 1)? ❑ ❑ 0 ❑
Is storage appropriate for cylinders? ❑ ❑ ❑
#Is de-chlorination substance stored away from chlorine containers? M ❑ ❑ ❑
Comment:
Are the tablets the proper size and type? ❑ ❑ ❑
Are tablet de-chlorinators operational? ❑ ❑ ❑
Number of tubes in use?
Comment:
Flow Measurement- Effluent Yes No NA NE
#Is flow meter used for reporting? 0 ❑ ❑ ❑
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DocuSign Envelope ID: EC174CAB-3AD6-48A4-AB46-9619322F72F6
Permit: NCO028827 Owner-Facility: Snug Harbor on Nelson Bay WWTP
Inspection Date: 02/27/2019 Inspection Type: Reconnaissance
Flow Measurement- Effluent Yes No NA NE
Is flow meter calibrated annually? ❑ 0 ❑ ❑
Is the flow meter operational? ❑ ❑ ❑
(If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑
Comment: Last known calibration was in 11-2016. Apparently the vender was not paid for his last
service thus hasn't come since. The facility should not be generating the volume it has
reported at times based on the number of patients and new ORC that operates a similar
facility nearby agreed. Not keeping meters calibrated and lack of a meter on the water
system backwash makes it hard to know the volume and source plus rainfall isn't tracked to
check for its impact thru the sewer system. Based on this facility's approved flow limit over
1 OK, then a flow meter with charting should be required vet permit doesn't indicate
continuous flow measurement. Since one is available then it should be used and a
datalogger to store the data for charting at any time interval. There was a discussion about
relocating meter to effluent pump station, but would require the hole in the low baffle wall to
be plugged and this is where samples should be collected anyway.
Pump Station - Effluent Yes No NA NE
Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑
Are all pumps present? 0 ❑ ❑ ❑
Are all pumps operable? ❑ ❑ ❑
Are float controls operable? ❑ ❑ ❑
Is SCADA telemetry available and operational? ❑ ❑ 0 ❑
Is audible and visual alarm available and operational? ❑ ❑ ❑
Comment: The station has two submersible pumps whose housings were observed to be completely
out of the water, thus will shorten the life of the pumps and can lead to overheating &tripping_
of breakers or pump failure. Floats should be adjusted accordingly to keep pumps properly
submerged.
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