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Home My WebLink AboutNC0047597_Compliance Evaluation Inspection_20200713DocuSign Envelope ID: 8OB6581 F-36D4-4462-8C40-EAB5A1 C39C2A ROY COOPER Governor MICHAEL S, REGAN Secrnary S. DANIEL SMITH Dlrrcror Don Greeley, P.E. Director of Water Management 101 City Hall Plaza Durham, NC 27701 NORTH CAROLINA Environmental Quality July 13, 2020 Subject: Compliance Evaluation Inspection South Durham Water Reclamation Facility NPDES Permit No NCO047597 Durham County Dear Mr. Greeley: On July 10, 2020, Cheng Zhang of the Raleigh Regional Office (RRO) conducted a Compliance Evaluation Inspection at the subject facility. The assistance provided by Mr. Charles Cocker, Operator in Responsible Charge (ORC), Mr. John Young, Assistant Director of Water Management, and Mr. Jeremy Cartner, backup ORC, was appreciated. The inspection report is attached. Findings during the inspection were as follows: L The facility is currently permitted to discharge up to 20.0 MGD into an unnamed tributary to New Hope Creek, a Class WS-IV NSW waters in the Cape Fear River Basin. Current permit expired on April 30, 2016. The City submitted permit renewal application on October 28, 2018, which was received by the Division on October 30, 2015. 2. The plant is classified as a WW -4 wastewater facility. Mr. Charles Cocker is designated as the ORC, there are six designated backup ORCs. It was noted that the list of backup ORCs needs to be updated. Daily operation log books are detailed and are kept onsite going back at Ieast three years. 3. Due to Covid-19, cursory laboratory inspection was not conducted during the inspection. Mr. Cocker explained that the City Laboratory, which is located at South Durham WRF analyzed most parameters with a few exceptions. The inspector reminded Mr. Cocker of new rules that require field labs to have Standard Operating Procedures (SOPs) and develop and implement a documented training program. March 2020 DMR data was compared to bench sheets and lab reports; no data transcription errors were noted. Lab results, chain -of -custody forms, and DMRs were complete and organized. 4. The permit lists the following units; all were observed during the inspection, due to low flow at the time of inspection (effluent flow was 7.53 MGD at the time of inspection), some treatment �� Nonh Carolina Department of Environmental Quality ! DMision of Water Resources d :evo —,"o r DE ERaleigh Regional Office 3800 Barrett Drive - Raleigh. North Carolina 27609 �+ -W 9t9.791.4200 DocuSign Envelope ID, 80665aiF-36D44462-8NO-EA135A1C39C2A units were not in use: • Influent pump station with four pumps, each with capacity of 20 MGD. All pumps were operable, one of them needed minor repair; • Two mechanical bar screens, both were in operation; in addition to the two bar screens, three mechanical band screens were under construction; • Four mechanical grit removal units were all in operation, will be replaced with three new 25 MGD peak flow grit removal units (under construction); • The newly constructed 2 Million -gallon equalization basin was under final testing and not in use yet; • Four primary clarifiers with primary sludge pump station (two in use); • Eight aeration basins with BNR (three in use), all diffusers were replaced with new fine bubble diffusers. All aeration basin influent mixers were also replaced recently; • Five circular secondary clarifiers (two in use); a new 160-foot diameter with 18-foot side water depth secondary clarifier was under construction; • Four travelling bridge tertiary filters (three in use, one offline for media replacement); • Six UV disinfection units (five in use, one beyond repair), will be replace by one new UV system consisting of four channels with three banks each in series (under construction); • Two RAS pump stations; • One new WAS Pump Station with three 225 GPM pumps; • Four anaerobic digesters (two primary and two secondary) (all in use), for primary clarifier sludge and thickened wasted sludge; • Two gravity belt thickeners to dewater wasted sludge (both in use); three belt filter presses (one in use; one not operable and will be removed); new polymer feed facility has two set of systems, one for belt thickeners and one for belt filter presses, each has two tanks and three pumps; • The facility no longer has aerobic digesters; • 32 sludge drying beds (some were occupied by construction dirt and sludge from the City's Water Treatment Plant), about ten available to store final sludge; final sludge storage pad can hold about 6 months of cake sludge under roof, at the time of inspection, the pad was about 90% full; • Four On -Site generators, two on natural gas and two on diesel fuel, are tested under load monthly by a contractor; DocuSign Envelope ID:8OB6581F-36D4-4462-8C4o-EAB5A1C39C2A Two sidestream treatment systems (ANITA Mox) were in operation to treat belt press filtrate with high ammonia. The right of way to the outfall was properly maintained. The effluent appeared clear and free of solids. There were no visible detrimental impacts to the receiving stream. This facility was found to be compliant with NPDES permit conditions as a result of this inspection. The plant is well maintained and documentation was found to be detailed, organized, and complete. If you have any questions regarding the attached report, please contact Cheng Zhang at 919-7914200 (or email: cheng.zhang@ncdenr.gov). Sincerely, [utM Docu8lpd Oy' ml a,ssx -9, MUUAXtt H"IOEWW21"F Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources Attachments: Compliance Inspection Report Cc: Central Files wlattachment (Laserfiche) Raleigh Regional Office wlattachment Charles Cocker, ORC (electronic copy only) DocuSign Envelope ID: BOB6581F-36D4-4462-8C40-EAB5A1C39C2A 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 yrlmolday Inspection Type Inspector Fee Type 1 IN I 2 I{ I 3 NCO047597 I l l 121 20/07/10 17 18 I c i 191 S I 20L J 21 u u � - � 1=J 6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 OA Reserved 67 70 LJ J I 71 Lj 72 I N I 731 I 174 7 80 Section 8: Facility Data LJ Lt 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 permit Number) 09:OOAM 20/07/10 11111/01 South Durham WRF 6605 Farrington Rd Exit rime/Date Permit Expiration Date Chapel Hill NC 27517 11:30AM 20/07/10 16/04/30 Name(s) of Onsite Representative(s)Rtles(s)1Phone and Fax Number(s) Other Facility Data 111 Charles Cocker/Plant Superintendentl919-5604386/9195604418 Charles W CockerlORC1919-560-43361 Name, Address of Responsible OfficiallTtie/Phone and Fax Number Chores Cocker,6605 Farrington Rd Chapel Hill NC 275171Pfanl Contacted Superintendent/919-560-438619195604418 Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement N Operations & Maintenar 0 Records/Reports Self -Monitoring Progran Sludge Handling Dispo: 0 Facility Site Review N Effluent/Receiving Wate Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Cheng Zhang Doeusignedby: DWRIRRO1NQ1919-791-42001 heng Zhang 7/13/2020 EC' 11171150aElEC41F Signature of Management O A Reviewer AgencylOfficelPhone and Fax Numbers Date �oocuftnedby: i/aUt,t,SSOL . A4_ NCDWR-WQROS-Rai ei gh Regional office 919-791-4232 7/13/2020 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete Page# DocuSign Envelope to: 80B6581 F-36D4-4462-8C40-EA135A1 C39C2A NPDES yrlmolday Inspection Type 3 NCO047597 11 20/07/10 17 18 [. j Section D. Summary of FindinglComments (Attach additional sheets of narrative and checklists as necessary) See attached report. Page# DocuSign Envelope ID: BOB6581F-3BD4-4462-BC40-EAB5A1C39C2A Permit: NCO047597 Owner - Facility: South Durham WRF Inspection Date: 07/10/2020 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ■ ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The facilily analyzes MLSS MCRT settleable solids H DO sludge blankets nitrate etc. for process control Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ N ❑ application? Is the facility as described in the permit? ❑ M ❑ ❑ # Are there any special conditions for the permit? ❑ M ❑ ❑ Is access to the plant site restricted to the general public? N ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? N ❑ ❑ ❑ Comment: Current permit expired on 4/3012016. Some treatment units, such as sidestream (belt press filtrate) treatment sludge storage gad, are not listed in treatment unit list. The-facilily no longer has aerobic digesters. 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? ❑ ❑ ❑ Are all pumps operable? ❑ ❑ ❑ Are float controls operable? ❑ ❑ ❑ Is SCADA telemetry available and operational? M ❑ ❑ [] Is audible and visual alarm available and operational? ❑ ❑ ❑ Comment: Four influent pumps, each has capacity of 20 MGD. Pump #1 needs minor re air but is operable. Bar Screens Yes No NA NE Type of bar screen a.Manual ❑ b.Mechanical Are the bars adequately screening debris? N ❑ ❑ ❑ Is the screen free of excessive debris? N ❑ ❑ ❑ Is disposal of screening in compliance? M ❑ ❑ ❑ Page# 3 DocuSign Envelope ID: 80B6581F-36D4-4462-8C40-EAl35A1C39C2A Permit: NCO047597 Owner - Facility: South Durham WRF Inspection Date: 07/10/2020 Inspection type: Compliance Evaluation Bar Screens Yes No NA NE Is the unit in good condition? N ❑ ❑ ❑ Comment: In addition to the two bar screens three mechanical band screens are under construction. Flow Measurement - Influent Yes No NA NE # is flow meter used for reporting? [Is ❑ ❑ Is flow meter calibrated annually? ❑ ❑ ❑ Is the flow meter operational? ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ M ❑ Comment: Last calibration was conducted on 5/29/2020. Grit Removal Yes No NA NE Type of grit removal a.Manual ❑ b.Mechanical N Is the grit free of excessive organic matter? N ❑ ❑ ❑ Is the grit free of excessive odor? M ❑ ❑ ❑ # Is disposal of grit in compliance? M ❑ ❑ ❑ Comment: Four mechanical -grit removal units will be replaced with three 25 MGD peak flow -grit removal units under construction). Equalization Basins Yes No NA NE Is the basin aerated? ❑ M ❑ ❑ is the basin free of bypass lines or structures to the natural environment? ❑ ❑ ❑ ■ Is the basin free of excessive grease? ❑ ❑ ❑ 0 Are all pumps present? ❑ ❑ ❑ N Are all pumps operable? ❑ ❑ ❑ M Are float controls operable? ❑ ❑ ❑ 0 Are audible and visual alarms operable? ❑ ❑ ❑ N # Is basin size/volume adequate? ❑ ❑ ❑ Comment: The 2 million --gallon EQ basin was not online vet (under leak test). Primavy Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? M ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? N ❑ ❑ ❑ Page# 4 DocuSlgn Envelope ID: 8086581F-38D4-4462-8C40-EAB5AiC39C2A Permit: NG0047597 Inspection Date: 07/10/2020 Primary Clarifier Owner - Facillty: South Durham WRF Inspection Type: Compliance Evaluation Are weirs level? 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? Is the drive unit operational? Is the sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately'/ of the sidewall depth) Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ■❑❑❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Comment: Two of four Primary clarifiers were online #1 and #4 due to low flow 7.53 MGD at the time of inspection. 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? N ❑ ❑ [j Does the foam cover less than 25% of the basin's surface? E❑ ❑ ❑ Is the DO level acceptable? ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mgll) ❑ ❑ ❑ Comment: All diffusers in aeation basins were re laced with fine bubble diffusers. All aeration basin influent mixers were also replaced recently. Nutrient Removal Yes No NA NE # Is total nitrogen removal required? 0 ❑ ❑ ❑ # Is total phosphorous removal required? 0 [f [j ❑ Type # Is chemical feed required to sustain process? Is nutrient removal process operating properly? Biological ■ ❑ ❑ ❑ N ❑ ❑ ❑ Comment: Aluminate sulfate is fed into droobox between aeration basins and clarifiers Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? N ❑ ❑ ❑ Page# 5 DocuSign Envelope ID: 8086581F-36D44462-8C40-EAMA1C39C2A Permit: NCO047597 Owner - Facility: South Durham wRF inspection Date: 07110/2020 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is the site free of excessive buildup of solids in center well of circular clarifier? ■ ❑ ❑ ❑ Are weirs level? ■ ❑ ❑ ❑ 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? ■ ❑ ❑ ❑ Is the drive unit operational? ■ ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? ■ ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? ■ ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) ■ ❑ ❑ ❑ Comment: Only #5 and #6 were online due to low flow (7.53 MGM at the time of inspection. #1. #2, an #3 are only used during periods with high flow. A new clarifier (#4) is under construction. Filtration (High Rate Tertiary) Type of operation: Is the filter media present? Is the filter surface free of clogging? Is the filter free of growth? Yes No NA NE Down flow ■❑ Is the air scour operational? ■ ❑ Is the scouring acceptable? ■ ❑ Is the clear well free of excessive solids and filter media? ■ ❑ Comment: Three of four filters were online. One filter was offline for media replacement. Disinfection - UV Yes No NA NE Are extra UV bulbs available on site? ■ ❑ ❑ ❑ Are UV bulbs clean? ■ ❑ ❑ ❑ Is UV intensity adequate? ■ ❑ ❑ ❑ Is transmittance at or above designed level? ■ ❑ ❑ ❑ Is there a backup system on site? ■ ❑ ❑ ❑ Is effluent clear and free of solids? ■ ❑ ❑ ❑ Comment: One of six UV units was beyond repair. Current UV units will be replaced with a new UV system consisting of four channels with three banks each in series (under construction Page# 6 DocuSign Envelope ID: 80B6581F-36D4-4462-BC40-EAB5A1C39C2A Permit: NCO047597 Owner - Facility: South Durham WRF Inspection Date: 07/10/2020 Inspection Type: Compliance Evaluation Standby Power Yes No NA NE Is automatically activated standby power available? ❑ ❑ ❑ Is the generator tested by interrupting primary power source? ❑ ❑ ❑ Is the generator tested under load? M ❑ ❑ ❑ Was generator tested & operational during the inspection? ❑ M ❑ ❑ Do the generator(s) have adequate capacity to operate the entire wastewater site? 0 ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up power? 0 ❑ ❑ ❑ Is the generator fuel level monitored? N ❑ ❑ ❑ Comment: Four generators (two on natural gas, two on diesel fuel) have capacity to operate the entire site excei3t sludge clewatering facilily. Generators are tested under load monthly by a contractor. Anaerobic Digester Yes No NA NE Type of operation: Floating cover Is the capacity adequate? M ❑ ❑ ❑ # Is gas stored on site? 0❑ ❑ ❑ Is the digester(s) free of tilting covers? N❑ ❑ ❑ Is the gas burner operational? ❑ ❑ N ❑ Is the digester heated? N❑ ❑ ❑ Is the temperature maintained constantly? M ❑ ❑ ❑ Is tankage available for properly waste sludge? M ❑ ❑ ❑ Comment: Gas nroduced by the digesters is used to power the blowers and heat the digesters temperature was around 100 degree) Solids Handling Equipment Yes No NA NE 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? M ❑ ❑ ❑ Is the site free of sludge buildup on belts and/or rollers of filter press? 0 ❑ ❑ ❑ Is the site free of excessive moisture in belt filter press sludge cake? ❑ ❑ ❑ The facility has an approved sludge management plan? ❑ ❑ ❑ Comment: Two of three belt Dresses were operable (one was running), the other one will be removed in the future. Two gravity belt thickeners were in operation New polymer feed facility was in use. Page# 7 DocuSign Envelope ID: 80B6581F-36D4-4462-8C40-EAB5A1C39C2A Permit: NCO047597 owner - Facility: South Durham %A RF Inspection Date: 07/10/2020 Inspection Type: Compliance Evaluation Drying Beds Yes No NA NE Is there adequate drying bed space? N ❑ ❑ ❑ Is the sludge distribution on drying beds appropriate? 0 ❑ ❑ ❑ Are the drying beds free of vegetation? ❑ M ❑ ❑ # Is the site free of dry sludge remaining in beds? ❑ 0 ❑ ❑ Is the site free of stockpiled sludge? ❑ 0 ❑ ❑ Is the filtrate from sludge drying beds returned to the front of the plant? 0 ❑ ❑ ❑ # Is the sludge disposed of through county landfill? ❑ N ❑ ❑ # Is the sludge land applied? ■ ❑ ❑ ❑ (Vacuum filters) Is polymer mixing adequate? ❑ ❑ M ❑ Comment: Final sludge from belt presses are store on sludge stroa a pad with roof. At the time of ins ection, the pad had about 10% of total storage space available. if the pad is full, final sludge will be stored in drying beds. About ten out of 32 beds were availabe for sludge storage at the time of inspection some were temperarily occupied by construction dirt and sludge from the Cit 's Water Treatment Plant Chemical Feed Yes No NA NE Is containment adequate? N ❑ ❑ ❑ Is storage adequate? N ❑ ❑ ❑ Are backup pumps available? M ❑ ❑ ❑ Is the site free of excessive leaking? M ❑ ❑ ❑ Comment: Pumps-RAS WAS Yes No NA NE Are pumps in place? M ❑ ❑ ❑ Are pumps operational? ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ❑ ❑ ❑ Comment: Laboratory, Yes No NA NE Are field parameters performed by certified personnel or laboratory? N ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? ❑ ■ ❑ ❑ # Is the facility using a contract lab? N ❑ ❑ ❑ # 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? ❑ ❑ ❑ Page# 8 DocuSlgn Envelope ID: 8OB6581F-3604-4462-BC40-EA95A1C39C2A Penult: NCO047597 Owner - Facility: South Durham WRF Inspection Date: 07/10/2020 Inspoction Type: Compliance Evaluation Laboratory Yes No NA NE Incubator.(BOD) set to 20.0 degrees Celsius +1- 1.0 degrees? ❑ ❑ ❑ ■ Comment: The City lab analyzes all narameters (except for low lever mercury and cyanide for LTMP . Lab was not visited due to Covid-19. Influent Sampling Yes No NA NE # Is composite sampling flow proportional? N ❑ ❑ ❑ Is sample collected above side streams? N ❑ ❑ [] 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 N ❑ ❑ ❑ Celsius)? Is sampling performed according to the permit? ❑ ❑ ❑ Comment: Effluent Sampling Yes No NA NE Is 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 N❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type N ❑ ❑ ❑ representative)? Comment: Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? 0❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ N ❑ Comment: Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? N ❑ ❑ ❑ Is all required information readily available, complete and current? N ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? N ❑ ❑ ❑ Page# 9 DocuSlgn Envelope ID: BOB6561F-36D4-4462-BC40-EAB5A1C3gC2A Permit: NCO047597 owner - Facility: South Durham WRF Inspection Date: 07110/2020 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Are analytical results consistent with data reported on DMRs? a ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ Dates, times and location of sampling 0 Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Are DMRs complete: do they include all permit parameters? ■ ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 2417 with a certified operatc ❑ ❑ ❑ 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' 0 ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? M ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? M ❑ ❑ ❑ Comment: Need to update list of backup ORCs. Flow Measurement - Effluent Yes No NA NE # is flow meter used for reporting? ■ ❑ ❑ ❑ Is flow meter calibrated annually? N ❑ ❑ ❑ Is the flow meter operational? M ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ M ❑ Comment: Last calibration was conducted on 5/29/2020. Page# 10