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Home My WebLink AboutNC0040797_Compliance Evaluation Inspection_20210223ROY COOPER Governor MICHAEL S. REGAN Secretary S. DANIEL SMITH Director Shawn Pennell, Public Utilities Director City of Hickory Post Office Box 398 Hickory, North Carolina 28603-0398 Dear Mr. Pennell: NORTH CAROLINA Environmental Quality February 23, 2021 Subject: Compliance Evaluation Inspection Henry Fork WWTP NPDES Permit No. NC0040797 Catawba County Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on February 17, 2021, by Mr. Wes Bell of this Office. Please inform the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding a copy of the enclosed report. Should you have any questions concerning this letter, please do not hesitate to contact Mr. Bell at (704) 235- 2192, or via email at wes.bell@ncdenr.gov. Enclosure: Inspection Report D_E NORTH CAROLINA Department el EnNrumimbl Qualpy Sincerely, ,-DocuSigned by: As 4lticw H P t t F161 FB69A2D84A3... for W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1610 East Center Avenue, Suite 301 I Mooresville, North Carolina 28115 704.663.1699 United States Environmental Protection Agency EPA 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 1 IN I 2 I5 21IIIIII NPDES yr/mo/day Inspection I 3 I NC0040797 111 121 21/02/17 117 Type 18110 IIIIIIIIIII Inspector Fac Type 19 I S I 201 IIIIIIIIIIIIIIIIII I IIIIII P6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 67I2.0 I 70I4 I 71IN I 72 I N I 731 I 74 751 I I 1 I I I I I I 180 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Henry Fork WWTP 4014 River Rd Hickory NC 28602 Entry Time/Date 09:22AM 21/02/17 Permit Effective Date 18/09/01 Exit Time/Date 12:05PM 21/02/17 Permit Expiration Date 22/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Robert P Shaver/ORC/828-294-0861/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Warren Wood,PO Box 398 Hickory NC 286010398/City Manager/828-323-7412/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran Sludge Handling DispoFacility Site Review 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) Wes Bell of Inspector(s) Agency/Office/Phone and Fax Numbers Date —Docusigned by: DWR/MRO WQ/704-663-1699 Ext.2192/ 2/23/2021 ioe 73d1 "-A61696D9OCC3437... Signature of Management Q A Reviewer Agency/Office/Phone and Fax N eTSgcusigned by: Date Andrew Pitner DWR/MRO WQ/704-663-1699 Ext.2180/ 4`44H P'4.4 2.23.21 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 NPDES yr/mo/day 31 NC0040797 111 121 21/02/17 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0040797 Inspection Date: 02/17/2021 Owner - Facility: Henry Fork WWTP Inspection Type: Compliance Evaluation Permit (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? Yes No NA NE • ❑ • ❑ • ❑ ❑ ❑ Comment: The Division issued an Authorization to Construct (AtC) on 12/29/2020 that included the rehabilitation of three (3) sludge holding basins and the installation of the following: several pumps, mixers and blowers; odor control system, gravity belt thickener, two (2) belt filter presses, belt dryer system, polymer blending units, three (3) screw conveyors, storage tanks (sodium hypochlorite and sodium hydroxide), four (4) boilers, cake storage bin, sulfuric acid storage, dried product storage and a septic receiving station. The City implements a Division -approved Industrial Pretreatment Program. The last compliance evaluation inspection at this facility was performed by DWR staff on 1/17/2019. Record Keeping 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 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' Is a copy of the current NPDES permit available on site? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 3 Permit: NC0040797 Inspection Date: 02/17/2021 Owner - Facility: Henry Fork WWTP Inspection Type: Compliance Evaluation Record Keeping Facility has copy of previous year's Annual Report on file for review? • Yes No NA NE ❑ ❑ ❑ Comment: The records reviewed during the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed for the period January 2020 through December 2020. No effluent limit violations were reported and all monitoring frequencies were correct. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? • ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? • ❑ ❑ ❑ # Is the facility using a contract lab? • ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees ❑ ❑ • ❑ Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ • ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ • ❑ Comment: Influent and effluent analyses are performed under the City's municipal laboratory certification #203. Pace Analytical Services, Blue Ridge Labs and ETT Environmental have also been contracted to provide analytical support. Influent Sampling # Is composite sampling flow proportional? Is sample collected above side streams? 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 Celsius)? Is sampling performed according to the permit? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The subject permit requires influent BOD and TSS composite samples. The samplers are checked five days per week (every day sampling is performed) and calibrated monthly (at a minimum). 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 • ❑ ❑ ❑ Celsius)? Page# 4 Permit: NC0040797 Inspection Date: 02/17/2021 Owner - Facility: Henry Fork WWTP Inspection Type: Compliance Evaluation Effluent Sampling Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Yes No NA NE • ❑ ❑ ❑ Comment: The subject permit requires composite and grab effluent samples. The samplers are checked five days per week (every day sampling is performed) and calibrated monthly at a minimum). Operations & Maintenance 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The wastewater treatment facility appeared to be properly operated and well maintained. The facility staff incorporate a comprehensive process control program with all measurements being properly documented and maintained on -site. In-depth operation and maintenance records were also being maintained on -site. The operations staff also monitor treatment processes by the on -site SCADA system. One primary clarifier, aeration basin train and chlorine contact chamber train were in service due to low influent flows. Bar Screens 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? Comment: Yes No NA NE • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? • ❑ ❑ ❑ Is the wet well free of excessive grease? • ❑ ❑ ❑ Are all pumps present? • ❑ ❑ ❑ Are all pumps operable? ❑ • ❑ ❑ Are float controls operable? • ❑ ❑ ❑ Is SCADA telemetry available and operational? • ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ ❑ • ❑ Comment: One of four influent pumps was not operational and in the process of being repaired. Page# 5 Permit: NC0040797 Inspection Date: 02/17/2021 Owner - Facility: Henry Fork WWTP Inspection Type: Compliance Evaluation Pump Station - Influent Yes No NA NE 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: Screenings and grit are disposed at the County Landfill. Equalization Basins Yes No NA NE Is the basin aerated? • ❑ El El Is the basin free of bypass lines or structures to the natural environment? • El El El Is the basin free of excessive grease? • ❑ ❑ ❑ Are all pumps present? ❑ El ■ ❑ Are all pumps operable? ❑ ❑ • ❑ Are float controls operable? ❑ El • ❑ Are audible and visual alarms operable? El ❑ • El # Is basin size/volume adequate? • ❑ ❑ ❑ Comment: The influent flows by gravity to the primaries. Primary 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? • El El El Is the site free of weir blockage? • ❑ ❑ ❑ Is the site free of evidence of short-circuiting? • El El El Is scum removal adequate? • El El El 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 IA of the sidewall depth) • ❑ El El Comment: Both primaries were operational. Page# 6 Permit: NC0040797 Inspection Date: 02/17/2021 Owner - Facility: Henry Fork WWTP Inspection Type: Compliance Evaluation 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? • ❑ ❑ ❑ 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? • ❑ El El Is the DO level acceptable?(1.0 to 3.0 mg/I) • ❑ ❑ ❑ Comment: Both aeration basin trains were operational. Magnesium hydroxide is added to maintain appropriate alkalinity/pH levels. Sodium hydroxide is also available if needed. One of the three blower/motor units was not operational and in process of being repaired. Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? • ❑ El El Is the site free of excessive buildup of solids in center well of circular clarifier? • ❑ ❑ ❑ Are weirs level? • El El El Is the site free of weir blockage? • ❑ ❑ ❑ Is the site free of evidence of short-circuiting? • ❑ ❑ ❑ Is scum removal adequate? • ❑ El ❑ Is the site free of excessive floating sludge? • ❑ ❑ ❑ Is the drive unit operational? • ❑ El ❑ 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: Both secondary clarifiers were operational. Page# 7 Permit: NC0040797 Inspection Date: 02/17/2021 Owner - Facility: Henry Fork WWTP Inspection Type: Compliance Evaluation Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: 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? If yes, then what is the EPA twelve digit ID Number? (1000- If yes, then when was the RMP last updated? Yes No NA NE • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ • ❑ • ❑ Comment: The gas chlorination and dechlorination systems are serviced annually by a contracted company (Piedmont Chlorinator Sales). 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? • ❑ ❑ ❑ Comment: Are the tablets the proper size and type? ❑ ❑ • ❑ Are tablet de -chlorinators operational? ❑ ❑ • ❑ Number of tubes in use? Comment: Flow Measurement - Effluent # Is flow meter used for reporting? Is flow meter calibrated annually? Yes No NA NE Page# 8 Permit: NC0040797 Inspection Date: 02/17/2021 Owner - Facility: Henry Fork WWTP Inspection Type: Compliance Evaluation Flow Measurement - Effluent Yes No NA NE Is the flow meter operational? • ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ • ❑ Comment: The flow meter is calibrated twice per year and was last calibrated on 1/5/2021 by Diversified Integration. Effluent Pipe 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: The effluent appeared clear with no floatable solids or foam. 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 • ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ Yes No NA NE • ❑ ❑ ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ Comment: The facility is equipped with two aerated sludge storage tanks (1 - primary sludge and 1 - waste activated sludge). The primary sludge is stored in a covered tank. Sludge from the storage tanks is transported (by City personnel) to the Regional Compost facility for continued treatment and ultimate disposal. Standby Power 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Both backup generators were operational and are placed under load monthly. Clark Power Generation has been contracted for any repairs, etc. City personnel perform the routine maintenance activities. Page# 9