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Home My WebLink AboutNC0025984_CEI_20201210 December 10, 2020 Janet Mason, Town Manager Town of Forest City PO Box 728 Forest City, NC 28043-0728 SUBJECT: Compliance Inspection Report Forest City WWTP NPDES WW Permit No. NC0025984 Rutherford County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Forest City WWTP on 12/02/2020. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0025984. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the inspection and therefore, a response to this inspection report is not required. If you should have any questions, please do not hesitate to contact me at 828-296-4686 or via email at mikal.willmer@ncdenr.gov. Sincerely, Mikal Willmer, Environmental Specialist II Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS: Inspection Report Ec: LF Sonny Penson, ORC DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC EPA United States Environmental Protection Agency Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 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 N 52 NC0025984 20/12/02 C S31112171819 20 21 66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- N67707172 73 74 75 80 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Forest City WWTP 397 Riverside Dr Forest City NC 28043 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 09:30AM 20/12/02 16/04/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Other Facility Data 11:30AM 20/12/02 19/07/31 Name, Address of Responsible Official/Title/Phone and Fax Number Charles R Summey,PO Box 728 Forest City NC 280430728//828-245-4747/8282485216 Contacted No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Sludge Handling Disposal Facility Site Review Pretreatment Effluent/Receiving Waters 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 Lauren E Armeni DWR/ARO WQ/828-296-4500/ Mikal Willmer DWR/Division of Water Quality/828-296-4686/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page#1 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC 12/10/2020 12/10/2020 12/10/2020 NPDES yr/mo/day 20/12/02 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Mikal Willmer and Lauren Armeni, with the Asheville Regional Office, conducted a compliance evaluation inspection of the Town of Forest City’s WWTP on December 2, 2020. This inspection was conducted to determine whether the facility is being operated and maintained in compliance with NPDES permit NC0021039. Sonny Penson (ORC) and Jacob Hodge (pretreatment coordinator) were present and assisted in the inspection. Overall, the facility appeared to be operated and maintained in compliance. Below is a summary of the items reviewed from the last inspection and any comments/observations made at the time of this inspection. Industry changes: Everest Textiles has their DAF unit installed and operational and O&G numbers have improved significantly. ProAmpac reduced flow from their pretreatment process and are no longer an SIU. Headworks: Mechanical barscreen will be swapped with the same model and the old screen will be refurbished and kept as a backup. There is a manual barscreen immediately downstream of the mechanical screen. The mechanical screen has been able to accommodate flows of 15 MGD. The bypass barscreen is not used. Grit Chamber: plan to refurbish within the next year. Grease Removal: Grease is pumped from the headworks by Harris septic and land applied under a DWM permit. Splitter Box: Staff modified one of the splitter boxes to accommadate heavy flow during rain events. Excess flow is routed to a circular basin and, when flows subside, is pumped back to the treatment process. Aeration Basins: facility has approximately 6 aeration basins, only one is currently in use. The other basins would need to be refurbished and repaired before placed into operation. The basin in use can accommodate approximately 4 MG. DO is 1.6 to 1.8 mg/L in the summer and 4-5 mg/L in the winter, according to facility staff. Secondary Clarifiers: Clarifier #2 had a blanket of approximately 3’ out of 14.5’. Telescoping valve is still broken; however, staff adjust pump run times as needed. On for approximately 25 minutes and off for 35. Clarifier #2 receives more flow than clarifier #1. Facility staff hope to have the weirs in clarifier #1 serviced when other work is slated to be completed. Chlorine Contact Chamber/Dechlor: disinfection is still flow proportional. The Town may look at replacing dosing equipment to allow a smaller dose feed. Currently feeding approximately 12-30lbs per day of chlorine. Effluent Sampling/Outfall: The second broad breaches it's banks during heavy rains. According to the ORC, they have not seen the river overtop the contact chamber walls. Staff may wish to permanently raise the effluent sampler due to flooding immediately around the outfall. The river backs up flow on the cascading steps below the effluent weir during heavy rains. Solids Handling: The new equipment was installed and working well; however, both digesters are currently inoperable. The mixer broke within Digester 2 and a pin sheered in the smaller digester. Flow NC0025984 17 (Cont.) Page#2 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Permit:NC0025984 Inspection Date:12/02/2020 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation typically goes from digester one to the new rotary drum thickener to digester 2 and then to the belt filter press. Staff’s goal is to have the digesters operational this month. The belt press’ belts were replaced last year and the current plan is to completely revamp the rest of the belt press this coming year. Facility staff have taken measures to ensure all cake remains in the building to prevent potential runoff to stormwater outlets. Generator: It is still recommended, during future plant upgrades, the aeration basin surface aerators be connected to the generator to prevent an upset during an extended power outage. Page#3 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Permit:NC0025984 Inspection Date:12/02/2020 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation 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? Monitor MLSS and routinely check sludge blankets.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? Is access to the plant site restricted to the general public? Is the inspector granted access to all areas for inspection? Sludge dryer is no longer in use and the belt thickener has been replaced with a rotary drum thickener. Permit is currently in renewal. Comment: Record Keeping Yes No NA NE 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? (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? Page#4 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Permit:NC0025984 Inspection Date:12/02/2020 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Record Keeping Yes No NA NE Facility has copy of previous year's Annual Report on file for review? Annual Reports are generated for both the CS and WWTP and posted on the Town's website. Staff analyze most of the permit parameters in house Metals, pollutant scans and toxicity are contracted out. Comment: 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: Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? Flow meters are calibrated twice a year by KDT Service Technologies.Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? Comment: Aerobic Digester Yes No NA NE Is the capacity adequate? Is the mixing adequate? Is the site free of excessive foaming in the tank? # Is the odor acceptable? # Is tankage available for properly waste sludge? The digesters are adequately sized for the current flow and solids handling; however, both digesters were offline for repairs at the time of the inspection. Facility staff indicated they were not having difficulty managing solids with the digesters down. Plan to have digesters repaired by the end of the month. Comment: Page#5 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Permit:NC0025984 Inspection Date:12/02/2020 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Aerobic Digester Yes No NA NE 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? 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? The rotary drum thickener and belt filter press are operational. Digester one and two are offline for repairs. Sludge cake is approximately 14% TS, according to the ORC. Comment: Bar Screens Yes No NA NE Type of bar screen a.Manual b.Mechanical Are the bars adequately screening debris? Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? The step screen was going to be replaced with a rake screen; however, due to costs, the mechanical screen will be replaced with the same screen type and the old screen will be refurbished and kept as a backup. Comment: Grit Removal Yes No NA NE Type of grit removal a.Manual b.Mechanical Is the grit free of excessive organic matter? Is the grit free of excessive odor? # Is disposal of grit in compliance? Comment: Grease Removal Yes No NA NE # Is automatic grease removal present? Page#6 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Permit:NC0025984 Inspection Date:12/02/2020 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Grease Removal Yes No NA NE Is grease removal operating properly? Automatic grease removal is present, but not in use. Harris septic pumps the grease chamber as needed. Comment: Secondary Clarifier Yes No NA NE 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? 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 ¼ of the sidewall depth) Sludge blanket is running approximately 3' out of 14.5' in clarifiers 1 & 2. The weirs in clarifier #1 appear to be unlevel. Staff report they have not been worked on since the 90's. Some algal growth is beginning to block the weir teeth and should be removed before it completely blocks the weir teeth. See summary for additional details. Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface 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? Is the DO level acceptable?(1.0 to 3.0 mg/l) Comment: Disinfection-Gas Yes No NA NE Are cylinders secured adequately? Page#7 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Permit:NC0025984 Inspection Date:12/02/2020 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Disinfection-Gas Yes No NA NE 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 lbs of Chlorine (CAS No. 7782-50-5)? If yes, then is there a Risk Management Plan on site? If yes, then what is the EPA twelve digit ID Number? (1000-____-____) If yes, then when was the RMP last updated? The Town maintains approximately 2000 lbs of chlorine at one time.Comment: 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? Was generator tested & operational during the inspection? Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Is the generator fuel level monitored? Generator does not operate blower motors.Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: De-chlorination Yes No NA NE Type of system ?Gas Is the feed ratio proportional to chlorine amount (1 to 1)? Is storage appropriate for cylinders? # Is de-chlorination substance stored away from chlorine containers? Are the tablets the proper size and type? Page#8 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Permit:NC0025984 Inspection Date:12/02/2020 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation De-chlorination Yes No NA NE Sulfur dioxide containers are stored in the same building as the chlorine cylinders.Comment: Are tablet de-chlorinators operational? Number of tubes in use? Comment: Page#9 DocuSign Envelope ID: 937B75E4-3859-493A-A3A0-33ED1D46E1BC Certificate Of Completion Envelope Id: 937B75E43859493AA3A033ED1D46E1BC Status: Completed Subject: Please DocuSign: NC0025984_CEI ltr 12-10-20.docx, NC0025984_CEI.pdf Source Envelope: Document Pages: 10 Signatures: 4 Envelope Originator: Certificate Pages: 2 Initials: 0 Mikal Willmer AutoNav: Enabled EnvelopeId Stamping: Enabled Time Zone: (UTC-05:00) Eastern Time (US & Canada) 217 W. Jones Street Raleigh, NC 27699 Mikal.willmer@ncdenr.gov IP Address: 149.168.204.10 Record Tracking Status: Original Dec 10, 2020 | 14:55 Holder: Mikal Willmer Mikal.willmer@ncdenr.gov Location: DocuSign Security Appliance Status: Connected Pool: StateLocal Storage Appliance Status: Connected Pool: North Carolina Department of Environmental Quality Location: DocuSign Signer Events Signature Timestamp Mikal Willmer mikal.willmer@ncdenr.gov Environmental Specialist North Carolina Department of Environmental Quality Security Level: Email, Account Authentication (None) Signature Adoption: Pre-selected Style Using IP Address: 149.168.204.10 Sent: Dec 10, 2020 | 14:59 Viewed: Dec 10, 2020 | 14:59 Signed: Dec 10, 2020 | 14:59 Electronic Record and Signature Disclosure: Not Offered via DocuSign Lauren Armeni lauren.armeni@ncdenr.gov North Carolina Department of Environmental Quality Security Level: Email, Account Authentication (None)Signature Adoption: Pre-selected Style Using IP Address: 149.168.204.10 Sent: Dec 10, 2020 | 14:59 Viewed: Dec 10, 2020 | 15:50 Signed: Dec 10, 2020 | 15:50 Electronic Record and Signature Disclosure: Not Offered via DocuSign Daniel Boss daniel.boss@ncdenr.gov Environmental Specialist North Carolina Department of Environmental Quality Security Level: Email, Account Authentication (None) Signature Adoption: Pre-selected Style Using IP Address: 149.168.204.10 Sent: Dec 10, 2020 | 15:50 Viewed: Dec 10, 2020 | 15:51 Signed: Dec 10, 2020 | 16:07 Electronic Record and Signature Disclosure: Not Offered via DocuSign In Person Signer Events Signature Timestamp Editor Delivery Events Status Timestamp Agent Delivery Events Status Timestamp Intermediary Delivery Events Status Timestamp Certified Delivery Events Status Timestamp Carbon Copy Events Status Timestamp Witness Events Signature Timestamp Notary Events Signature Timestamp Envelope Summary Events Status Timestamps Envelope Sent Hashed/Encrypted Dec 10, 2020 | 14:59 Certified Delivered Security Checked Dec 10, 2020 | 15:51 Signing Complete Security Checked Dec 10, 2020 | 16:07 Completed Security Checked Dec 10, 2020 | 16:07 Payment Events Status Timestamps