NC0043176_Inspection_20120227

ATA
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Charles Wakild, P. E. Dee Freeman
Governor Director - Secretary
February 27, 2012
Mr. Dean Gaster
Public Utilities Director
City of Dunn
P.O. Box 1065
Dunn, NC 28335
SUBJECT: Compliance Evaluation Inspection (CEI)
City of Dunn Black River
Wastewater Treatment Plant (WWTP)
NPDES Permit No. NC0043176
Harnett County
Dear Mr. 'Gaster:
Enclosed you will find a copy of the Compliance Evaluation Inspection report for
the inspection that was conducted on February 24, 2012, that includes observations that
were made during a tour of the Wastewater Treatment Plant and a cursory review of
wastewater treatment plant records. I appreciate the professional cooperation of Donrie
Dukes (ORC), Gary Barefoot (Wastewater Treatment Plant operator), and your staff. On
the day of this CEI, the facility was found to be in compliance with NPDES permit
NC0043176. The POTW appeared to be well maintained. You and your staff are
commended for your continued success. Please keep up the good work.
If you have any questions or comments concerning this report, please feel free to
contact me at [phone].
Dale Lopez
Environmental Specialist
/dl
Enclosure: EPA Water Compliance Inspection Report -
Regional Field Inspectors Check List for Field Parameters
cc: Donrie Dukes (ORC, City of Dunn Black River WWTP)
)
225 Green Street -Suite 714—F.yetteville, North 'a':hna 28 64.:5043
Phone: [phone] FAX: [phone] Customer Service:.1-877-623-6748
Internet www.ncwaternualitv.orq
An Equal Opportunity \ Affirmative Action Employer
NoiThCarolina
!aturafli

United States Environmental Protection Agency
EPA Washington, D.C. 20460
Compliin(:A I nspArttinn Report
Form Approved.
OMB No. 2040-0057
Approval expires 8-31-98
•Water
Section A: National Data System Coding (Le., PCS)
Transaction Code NPDES yr/mo/day Inspection
1 INI 2 151 31 NC0043176 111 121 12/02/24 117
Type Inspector Fac Type
181 C I 191 S I 201 I
IIIIII166
Remarks
211III II1IIIIIIIII IIII111111II I1'IIIIII1'1II
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ----- --------- ----Reserved----------
671 2.0 169 701 41 71 I I 721 N I 731 1_,1 74 751 I I I I I I 1 80
' Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Usersdischarging to POTW, also include
POTW name and NPDES permit Number)
Dunn WWTP ' '
Susan Tart Rd
Dunn NC 28335
Entry Time/Date
11:00 AM 12/02/24
Permit Effective Date
, 07/02/01
Exit Time/Date
02:30 PM 12/02/24
Permit Expiration Date
11/09/30
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Donrie Eldridge Dukes/ORC/910-892-8162/
Other Facility Data
•
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Ronald D Autry,PO Box 1065 Dunn NC 28335//910-892-2633/ 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) a Signature(s) of Inspector(s) Agency/Office/Phone and Fax
Dale Lopezat FRO WQ//910-433-3300 Ext.712/
Numbers Date
y
qC t7 / iM / r�
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
ej— 0.30 - / ,
idt4;040
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type
sI NC0043176 111 121 12/02/24 17 181 CI
(cont.) 1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
On the day of this CEI, the facility was found to be in compliance with NPDES permit NC0043176. The
POTW appeared to be well maintained. You and your staff are commended for your continued success.
Please keep up the good work. Enclosed you will find a copy of the Compliance Evaluation Inspection report
for the inspection that was conducted on February 24, 2012, that includes observations that were made
during a tour of the Wastewater Treatment Plant and a cursory review of wastewater treatment plant
records. I appreciate the professional cooperation of Donrie Dukes (ORC), Gary Barefoot (Wastewater
Treatment Plant operator), and your staff. The new generator was a 1,000 KW Cummings that could
handle the whole WWTP with automatic switchover, and was tested under -load on every Monday. The
generator run-time was documented in a log, as was the diesel fuel level. This.facility had a written
emergency agreement with diesel fuel supplier. The old generator was a 500 KW and was still operational
and was exercised on a schedule of once -per -month. Progress Energy was the electrical supplier. All four
Gorman Rupp influent pumps were variable speed pumps; one was usually running, and the others were
run as needed depending upon the wastewater level. The SCADA was mostLy on the new equipment, and
on the drum, but it was not on all of the units yet. The audible and visual alarms were checked on
once -per -month schedule. This facility had seven operators and one laboratory technician, and was run
24-hours per day, seven -days -per -week. The cyclone grit removal was operational. The influent pump
station had an Equalization Basin. If the WWTP could not handle the influent flow, the extra amount of
influent wastewater would be diverted to the new three -million gallon Equalization Tank (up to the day of this
CEI, the EQ Tank had not been needed to handle extra influent flow). Ninety percent of the EQ tank's
capacity would be gravity fed into the aeration basin, and ten percent of the capacity would flow back into
the headworks of the POTW. The grit and bar screen dumpsters drainage was pumped to the head of the
POTW. The temperature of the Influent composite sample refrigerator was 4° Celsius. The aeration basins
had coarse diffusers. All three secondary clarifiers were on-line, no short circuiting was noticed. The
fiberglass clarifier weirs were in good condition. There was a small amount of foam present on surface of
the clarifiers that may be caused by the diffused aeration in the aeration basins. According to the ORC and
Gary Barefoot (wastewater treatment plant operator), the amount of foam that was present on the clarifiers
was normal. The clarifier weirs were routinely brushed and cleaned on a weekly or a bi-weekly schedule,
usually on Friday. Sludge blanket readings were performed every two hours around the clock. The
blankets were usually about two to three feet in the ten foot deep clarifiers, one clarifier was a 12-foot
clarifier. Fecal Coliform samples were collected after the chlorine contact chamber and after dechlorination,
before it was pumped (by means of 200-HP effluent pumps) to the discharge at the Cape Fear River,
seven -miles away. The circular effluent pump charts were changed every night at midnight. The circular
charts were easy to read because the chart attenuation and chart gridlines matched the readings of the
digital readouts. In the future, the influent flow meter will also be calibrated on an annual basis. The
chlorine and dechlor were each on flow -paced dosing. The Waste Activated Sludge (WAS) was pumped to
a rotary drum that dewatered the solids to a 5 to 7%, then the solids were pumped to the aerobic digester.
Later, Synagro hauled the 2% digested sludge for to contracted fields land application.
Page # 2

Permit: NC0043176 Owner -Facility: DunnWWTP
Inspection Date: 02/24/2012 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? ■ n n n
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ n n n
Judge, and other that are applicable?
Comment:
Permit Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new application? n n ■ n
Is the facility as described in the permit? ■ n n n
# Are there any special conditions for the permit? ■ n n n
Is access to the plant site restricted to the general public? ■ n n n
Is the inspector granted access to all areas for inspection? - ■ n n n
Comment: The new NPDES permit is presently in the process at the NCDENR
Permitting Unit. Please continue with the requirements of your NPDES permit that
expired at midnight on September 30, 2011. • -
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? ■ n n n
Is all required information readily available, complete and current? ■ ❑ n n
Are all records maintained for 3 years (lab. reg` required 5 years)? ■ n n n
Are analytical results consistent with data reported on DMRs? - ■ n n n
Is the chain -of -custody complete? ■ n n n
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? ■ .n n n
Has the facility submitted its annual compliance report to users and DWQ? ■ n n n
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? n n ■ n
Is the ORC visitation log available and current? ■ n n n
Is the ORC certified at grade equal to or higher than the facility classification? ■ n n n
Is the backup operator certified at one grade less or greater than the facility classification? ■ n n n
Page # 3

Permit: NC0043176 Owner - Facility: Dunn WWTP
Inspection Date: 02/24/2012 Inspection Type: Compliance Evaluation
Record Keeping
Is a copy of the current NPDES permit available on site?
Facility has copy of previous year's Annual Report on file for review?
Comment:
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:
Flow Measurement - Effluent
# 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: The 12-inch Parshall Flume ultrasonic flow meter was calibrated on
08/11/2011 by chadwick Instrument Service Co, Inc.
Aerobic Digester
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?
Comment:
Pump Station - Influent
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?
Yes No NA NE
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Page # 4

Permit: NC0043176 Owner - Facility: Dunn WWTP
Inspection Date: 02/24/2012 Inspection Type: Compliance Evaluation
Pump Station - Influent
Comment:
Pump Station - Effluent Yes No NA NE -
Is the pump wet well free of bypass lines or structures? ■ n n n
Are all pumps present? ■ n n n
Are all pumps operable? ■ n n n
Are float controls operable? ■ n n n
Is SCADA telemetry available and operational? ■ n n n
Is audible and visual alarm available and operational? ■ n n n
Comment:
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?
rz-
Comment:
Grit Removal
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:
Equalization Basins
Is the basin aerated?
Is the basin free of bypass lines or structures to the natural environment?
Is the basin free of excessive grease?.
Yes No NA NE
Yes No NA NE
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Yes No NA NE
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Page # 5

Permit: NC0043176 Owner - Facility: Dunn WWTP
Inspection Date: 02/24/2012 Inspection Type: Compliance Evaluation
Equalization Basins
Are all pumps present?
Are all pumps operable?
Are float controls operable?
Are audible and visual alarms operable?
# Is basin size/volume adequate?
Comment: The 3 million gallon capacity flow equilization tank was operational but has
on yet been used.
Secondary Clarifier
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 'A of the sidewall depth)
Comment:
Aeration Basins
Mode of operation
Type of aeration system
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/I)
Yes No NA NE
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Yes No NA NE
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Yes No NA NE
Ext. Air
Diffused
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Page # 6

Permit: NC0043176 Owner - Facility: Dunn WVVTP
Inspection Date: 02/24/2012 Inspection Type: Compliance Evaluation
Aeration Basins Yes No NA NE
Comment:
De -chlorination Yes No NA NE
Type of system ? Liquid
Is the feed ratio proportional to chlorine amount (1 to 1)? n n 'n •
Is storage appropriate for cylinders? n n En
# Is de -chlorination substance stored away from chlorine containers? n n ■ n
Comment:
Are the tablets the proper size and type? nnn ■
Are tablet de -chlorinators operational? n ❑ n •
Number of tubes in use?
Comment:
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?
Comment:
Pumps-RAS-WAS
Are pumps in place?
Are pumps operational?
Are there adequate spare parts and supplies on site?
Comment:
Laboratory
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)?
Yes No NA NE
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Yes No NA NE
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Page # 7

Permit: NC0043176 Owner - Facility: Dunn WWTP
Inspection Date: 02/24/2012 Inspection Type: Compliance Evaluation
Laboratory
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees?
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
Comment:
Disinfection -Liquid
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)
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?
Comment:
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?
Comment:
Effluent Sampling
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)?
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment:
Upstream / Downstream Sampling
Yes No NA NE
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Yes No NA NE
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Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ■ 0 0
Comment: This facility is a member of the Middle Cape fear River Basin Association
n
Page # 8

Regional Field Inspectors Check List for Field Parameters
Name of site to be, Inspected: Dunn WWTP Date: 02/24/2012
Field certification # (if applicable): 115 Inspector: Dale Lopez
NPDES #: NC0043176
Region: Fayetteville
I. Circle the parameter or parameters performed at this site.
'Residual Chlorine
, Settleable Solids, p�Il- , f DO, Conductivity,
II. Instrumentation:
Temperature
A. Does the facility have the equipment necessary to analyze field parameters as circled above?
1. A pH meter
Thermo Scientific Orion Dual Star'
2. A Residual Chlorine meter
3. DO meter
4. A Cone for settleable solids
5. A thermometer or meter that measures temperature.
HACH HQ30d
6. Conductivity meter
III. Calibration/Analysis:
HACH DR-4000
HACH HQ30d
1. Is the pH meter calibrated with 2 buffers and -
checked with a third buffer each day of use?
2. For Total Residual Chlorine, is a check standard
analyzed each day of use?
1Yes
[Yes
fYes
No
No
No
Yes No
fres
No
Yes No
Yes
Yes
No
No
3. Is the air calibration of the DO meter performed
each day of use? 'Yes No
4. For Settleable Solids, is 1 liter of sample
settled for 1 hour?
5. Is the temperature measuring device calibrated
annually against a certified thermometer?
6. For Conductivity, is a calibration standard
analyzed each day of use?
Yes No
Yes
No
Yes No

IV. Documentation:
1. Is the date and time that the sample was collected documented?
2. Is the sample site documented?
3. Is the sample collector documented?
4. Is the analysis date and time documented?
5. Did the analyst sign the documentation?
6. Is record of calibration documented?
7. For Settleable Solids, is sample volume and
1 hour time settling time documented?
8. For Temperature, is the annual calibration of
the measuring device documented?
f Yes
'Yes
Yes
'Yes
Yes
'Yes
Yes
Yes
No
No
No
No
No
No
No
Comments:
pH 4 buffer will expire on 01/20/2013
pH 7 buffer will expire on 01/20/2013
pH 10 buffer will expire on 09/20/2013
pH electrode check: 11.4 mV with a pH 7 buffer
The chlorine residual 5-standard curve was performed on March 8, 2011
Please submit a copy of this completed form to the Laboratory Certification Program.
DWQ Lab Certification
Chemistry Lab
Courier # 52-01-01
FIELD INSPECTOR CHECKLIST REV. 04/23/2002