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Home My WebLink AboutNC0074268_Compliance Evaluation Inspection_20200218ROY COOPER Gov43'rror MICHAEL S. REGAN SrcrN-3ry S. DANIEL SMITH vhvc w NORTH CAPOLINA Emir+ronmemaf Qrsoltty February 18, 2020 Ms. Stephanie Scheringer, Division Manager Two Rivers Utilities P.O. Box 1748 Gastonia, NC 28053 Subject: Compliance Inspection Crowders Creek WWTP NPDES Permit No. NCO074268 Gaston County Dear Ms. Scheringer: Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on February 11, 2020, by Ori Tuvia and Maria Schulte. David Shellenbarger's, Kevin Greave's, and Mourice Brother's cooperation during the site visit was much appreciated. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed report. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Ori Tuvia at (704) 235-2190, or at ori. tuvia(a),ncdenr. gov. Sincerely, DocuSigned by: A wNp,ui ft F161F669A2D84A3... for W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources cc: NPDES, MRO files (Laserfiche) State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations Mooresville Regional Office 1 610 East Center Avenue, Suite 3011 Mooresville, North Carolina 28115 704 663 1699 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 NCO074268 111 12 I 20/02/11 I17 18 I S i 19 i G i 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 ------------------- 67 1.0 70Id I 71 [„ I 72 I I 73I I I74 751 I I I I I I I80 I —I I� 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 oermit Number) 01:10PM 20/02/11 17/04/01 Crowders Creek WWTP 5642 S York Rd Exit Time/Date Permit Expiration Date Gastonia NC 28052 03:20PM 20/02/11 20/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Mourice Kenith Brothers/ORC/919-494-5850/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Kevin M Graves,PO Box 1748 Gastonia INC 28053/Senior Plant Operator/704-854-6655/7048669405 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self -Monitoring Program 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 DocuSigned by: Maria Schutte DWR/Division of Water Quality/704-663-1699/ 2/17/2020 Ori A Tuvia ��-,� "� DWR/MRO WQ/704-663-1699/ IBB057A2DE017498... gocusigned by: Date Signature of Management Q A Reviewer Agency/Office/Phone and Fax Nu1�1`1611`1369AMUAI. 4•�n.t�o H ;P+ *." Andrew Pitner DWR/MRO WQ/704-663-1699 Ext.2180/ 2 .17. 2020 . EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NCO074268 I11 121 20/02/11 117 18 JCJ Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NCO074268 Owner - Facility: Crowders Creek WWTP Inspection Date: 02/11/2020 Inspection Type: Compliance Evaluation 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? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: The subject permit expires on 8/31/2020. Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ Dates, times and location of sampling Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported CM Are DMRs complete: do they include all permit parameters? ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator ❑ ❑ ❑ on each shift? Is the ORC visitation log available and current? ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? 0 ❑ ❑ ❑ Comment: The records reviewed during the inspection were organized and well maintained. DMRs, COCs, ORC logs, Calibration logs and Bench sheets were reviewed for the period Janaury 2019 throuah December 2019. Laboratory Yes No NA NE Page# 3 Permit: NCO074268 Owner - Facility: Crowders Creek WWTP Inspection Date: 02/11/2020 Inspection Type: Compliance Evaluation Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? 0 ❑ ❑ ❑ # Is the facility using a contract lab? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? 0 ❑ ❑ ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ ❑ Comment: Influent and effluent analyses (including field) are performed under the on -site laboratory certification #210. Meritech Labs Inc, (#165) and Shealy_(#329) have been contracted to Provide analytical support. Influent Sampling Yes No NA NE # Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected above side streams? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Is sampling performed according to the permit? ❑ ❑ ❑ Comment: The subject permit requires composite BOD and TSS influent sampling. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: The subject permit requires composite and grab effluent sampling. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and 0 ❑ ❑ ❑ sampling location)? Comment: Page# 4 Permit: NCO074268 Owner - Facility: Crowders Creek WWTP Inspection Date: 02/11/2020 Inspection Type: Compliance Evaluation Upstream / Downstream Sampling Yes No NA NE 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: The wastewater facilitv aDDeared to be DroDeriv operated and well maintained. The ORC and staff incorporate a comprehensive process control program (including Chem -Scan Unit) with all measurements being properly documented and maintained on-site.The facility is equipped with a SCADA system to assist the staff with the operation of the treatment units/processes. Selected plant alarms are also connected to a plant -wide audible system to notify operators out in the plant of alarm conditions. 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? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ Comment: Flow meter was calibrated on 1/2/2020 by Expert Services. Grit Removal Yes No NA NE Type of grit removal a.Manual ❑ b.Mechanical Is the grit free of excessive organic matter? ❑ ❑ 0 ❑ Is the grit free of excessive odor? ❑ ❑ 0 ❑ Page# 5 Permit: NC0074268 Inspection Date: 02/11/2020 Owner - Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Grit Removal Yes No NA NE # Is disposal of grit in compliance? ❑ ❑ 0 ❑ Comment: The grit removal treatment unit was not in service at the time of the inspection. During high rain event few days prior to the inspection the influent wet well was at high level which caused the grit pump to be underwater. The facility was at the process of repairing the pump at the time of the inspection. 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? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ ❑ ❑ Comment: Three of the four pumps or operational at the time of the inspection. Primary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? 0 ❑ ❑ ❑ Are weirs level? 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? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/ of the sidewall depth) 0 ❑ ❑ ❑ Comment: Both primaries were operational and in service. Nutrient Removal Yes No NA NE # Is total nitrogen removal required? 0 ❑ ❑ ❑ # Is total phosphorous removal required? 0 ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? 0 ❑ ❑ ❑ Page# 6 Permit: NCO074268 Inspection Date: 02/11/2020 Owner - Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Nutrient Removal Yes No NA NE Is nutrient removal process operating properly? 0 ❑ ❑ ❑ Comment: The subject permit requires a total phosphorus and total nitrogen seasonal effluent loading. Glycerin is added as a carbon source (anoxic basin). Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? 0 ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) 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? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? ❑ ❑ ❑ Is the site free of evidence of short-circuiting? ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? ❑ 0 ❑ ❑ 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'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: Both secondaries were ODerational and in service. At the time of the insDection both clarifiers had a large area of sludge at the top of the surface of the clarifiers, over half the surface area. The ORC indicated that it was due to high rain event few days prior to the inspection, which caused the solids to float to the surface. At the time of the inspection no sludge was observed going over the weir and no downstream treatment units seemed to be negatively affected. Page# 7 Permit: NCO074268 Inspection Date: 02/11/2020 Owner - Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? 0 ❑ ❑ ❑ Comment: Lagoons Yes No NA NE Type of lagoons? # Number of lagoons in operation at time of visit? 1 Are lagoons operated in? # Is a re -circulation line present? ❑ ❑ 0 ❑ Is lagoon free of excessive floating materials? 0 ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? ❑ ❑ 0 ❑ Are dike slopes clear of woody vegetation? 0 ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? 0 ❑ ❑ ❑ Are dikes free of seepage? 0 ❑ ❑ ❑ Are dikes free of erosion? 0 ❑ ❑ ❑ Are dikes free of burrowing animals? 0 ❑ ❑ ❑ # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ 0 ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ EEI Is the lagoon surface free of weeds? 0 ❑ ❑ ❑ Is the lagoon free of short circuiting? 0 ❑ ❑ ❑ Comment: The facility is equipped with two polishing ponds (both lined and operational): however, only one pond was in service. Disinfection -Gas Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de -chlorination? Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)? If yes, then is there a Risk Management Plan on site? Yes No NA NE ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ Page# 8 Permit: NCO074268 Owner - Facility: Crowders Creek WWTP Inspection Date: 02/11/2020 Inspection Type: Compliance Evaluation Disinfection -Gas Yes No NA NE If yes, then what is the EPA twelve digit ID Number? (1000- - ) 100000067321 If yes, then when was the RMP last updated? Comment: The chlorination and dechlorination systems are serviced annually. De -chlorination Yes No NA NE Type of system ? Gas Is the feed ratio proportional to chlorine amount (1 to 1)? 0 ❑ ❑ ❑ Is storage appropriate for cylinders? 0 ❑ ❑ ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ ❑ 0 ❑ Comment: Are the tablets the proper size and type? ❑ ❑ 0 ❑ Are tablet de -chlorinators operational? ❑ ❑ 0 ❑ Number of tubes in use? Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? M ❑ ❑ ❑ Comment: Flow meter was calibrated on 1/2/2020 by Expert Services. Effluent Pipe Yes No NA NE 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: Did not examine at the time of the inspection. Anaerobic Digester Yes No NA NE Type of operation: Floating cover Is the capacity adequate? ❑ ❑ ❑ # Is gas stored on site? ❑ ❑ ❑ Is the digester(s) free of tilting covers? ❑ ❑ ❑ Page# 9 Permit: NCO074268 Inspection Date: 02/11/2020 Owner - Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Anaerobic Digester Yes No NA NE Is the gas burner operational? 0 ❑ ❑ ❑ Is the digester heated? 0 ❑ ❑ ❑ Is the temperature maintained constantly? 0 ❑ ❑ ❑ Is tankage available for properly waste sludge? 0 ❑ ❑ ❑ Comment: The facility is equipped with four digesters (1-primary, 1-secondarV, 2-holding tanks). Bio-solids are land applied under Permit W00001793. Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Is the site free of sludge buildup on belts and/or rollers of filter press? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? Yes No NA NE ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ Comment: Two DAF units. The DAF units are used to thicken the WAS prior to digestion. The DAF supernate is returned to the head of the biological/nutrient removal treatment processes. Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? 0 ❑ ❑ ❑ Comment: Standby Power Yes No NA NE Is automatically activated standby power available? 0 ❑ ❑ ❑ Is the generator tested by interrupting primary power source? 0 ❑ ❑ ❑ Is the generator tested under load? 0 ❑ ❑ ❑ Was generator tested & operational during the inspection? ❑ ❑ ❑ Do the generator(s) have adequate capacity to operate the entire wastewater site? M ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up power? 0 ❑ ❑ ❑ Is the generator fuel level monitored? 0 ❑ ❑ ❑ Page# 10 Permit: NC0074268 Inspection Date: 02/11/2020 Owner - Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Standby Power Yes No NA NE Comment: All three standby -generators were operational. The generators are tested monthly under load and are serviced annually by a contracted company (CAT) Page# 11