NC0062855_WWTP Inspection_20101020

Beverly Eaves Perdue
Governor
ATA
NCDENR,
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins Dee Freeman
Director Secretary
October 20, 2010
Mr. George Hayfield
Town Manager
Post Office Box 296
Robbins, NC 27325
Subject: COMPLIANCE EVALUATION INSPECTION (CEI)
Town of Robbins WWTP
NPDES Permit No. NC0062855
Moore County
Dear Mr. Hayfield:
Enclosed you will find a copy of the Compliance Evaluation Inspection (CEI)
report for the inspection conducted on October 13, 2010 at the Town of Robbins
Wastewater Treatment Plant, accompanied by Rodney Kiser, Town of Robbins ORC.
As part of the inspection a tour of the Wastewater Treatment Plant was conducted. All
observations and recommendations are in Section D. Summary of Findings/Comments of
this inspection report. The wastewater treatment plant appeared to be in compliance
with the NPDES permit. Please note that the housekeeping that was performed by the
ORC was acceptable. However, the area near the entrance of the wastewater treatment
plant appeared to be a storage area for vehicles, of which included a Fire Department
trailer, a truck that was painted in a camouflaged pattern, a police vehicle, and garage
door metal parts that were stored near the fence. By November 20, 2010, please send a
letter to this office that explains the purpose of keeping the above listed items on the
premises of the wastewater treatment plant; and, please include a Plan -of -Action for the
removal of the above mentioned items. The following items listed were reported in the
November 12, 2009 Compliance Evaluation Inspection (CEI) report, and were still in the
process for future repair:
1) The audio alarms were not operational for the chlorine, sulfur dioxide, and
influent pump station,
2) The grit rake motor sounded as if it needed repair,
3) The metal parts at the grit removal unit were corroded and in need of
painting (at a minimum) to prevent further corrosion.
225 Green St., Suite 714, Fayetteville; NC 28301-5043
Phone: [phone] FAX: [phone] \ Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
)Ile
NortwhCarolina
An Equal Opportunity 1 Affirmative Action Employer

Mr. Hayfield
October 20, 2010
Page 2
You and your staff are commended for your continued efforts to comply with the
NPDES permit. If you have any questions or comments concerning this report or require
clarification on part(s) of this report, please feel free to contact me at [phone].
Sincerely,
\t„,_
Deal Lopez
Environmental Specs'
Enclosures: EPA Water Compliance Inspection Report
Facility Site Review (checklist)
cc: Rodney Kiser, Town of Robbins ORC
FRO files

•
United States Environmental Protection Agency
E P ^H 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
1 IINI 2 1 51 31 NC0062855 111 121 10/10/13 117
Type Inspector Fac Type
. 181 a 19I sl 201
I_JRemarks
I1II1III I1166
211II1I11I IIII III1I11I IIII IIII1II11I1I
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 . QA Reserved
671 2.0 1 69 70 131 711 I - 721 N 1 . 731 1 174 751 I I I 1 1 I 1 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)
Robbins WWTP
Sewer Plant Rd
Robbins NC 27325
Entry Time/Date
11:00 AM 10/10/13
• Permit Effective Date
. 06/07/01
Exit Time/Date
03:00 PM 10/10/13
Permit Expiration Date
11/03/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Rodney Lane Kiser/ORC/910-948-3063/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Rodney L Kiser, //910-948-3063/ No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement • Operations & Maintenance • Records/Reports
Self -Monitoring Program • Facility Site Review • Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) Signature(s) of Inspector(s) J Agency/Office/Phone and Fax Numbers Date
/
Dale Lopez % FRO WQ//910 433-3300 Ext.712/ fekfRe4
Signatures of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date/
i&i
Page # 1

3I
NPDES
NCOO 62855
111 121
yr/mo/day
10/10/13 117
Inspection Type
18101
(cont.) 1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
According to the description of the treatment process submitted in the NPDES application, dated September.
2, 2010: "All wastewater is conveyed to the Robbins Wastewater Treatment Plant via a permitted collection
system. The collection system consists of approximately 8.4 miles of gravity sewer, 1.5 miles of force
main, and three duplex pump stations one of which is the main headworks lift station. The Town of
Robbins Wastewater Treatment Plant is an extended aeration facility. It has a design capacity of 1.3 MGD,
however we are operating at a tier 2 reduced flow of 0.5 MGD because of low flow. Treatment is initiated at
a preliminary treatment unit (headworks), which consists of grit removal unit, semi -cylindrical fine screen,
and manual bar screen. This lift station is about a quarter mile from WWTP. De -gritted and screened
wastewater is pumped to a secondary treatment unit. Dual activated sludge treatment units are provided
with integral center -feed clarifiers. Mixing and aeration are provided by diffused aeration. Caustic soda is
added at the head of the system at a manhole right before the splitter box to add alkalinity. Aluminum
sulfate is added prior to the clarifiers to facilitate settling of the solids. Clarified effluent is disinfected by
chlorination and then wasted to an aerobic digester for further stabilization. After digestion is completed,
the stabilized sludge is land applied in liquid form onto permitted land application sites. The effluent from
the wastewater treatment plant is discharged into the Deep River, in the Cape Fear River Basin. It is
discharged through an outfall line which is about 4 miles from the plant to Deep River." Presently, the
Robbins WWrP Effluent flow was approximately 100,00 GPD, and maybe up to 150,000 GPD.
Page # 2

Permit: NC0062855 Owner - Facility: Robbins VVMIrP
Inspection Date: 10/13/2010 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? MOOD
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: The housekeeping performed by the ORC was acceptable. However, the
area near the entrance of the wastewater treatment plant appeared to be a storage area
for vehicles and garage door metal parts nears the fence.
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?
Comment: As a temporary measure, the #1 aeration basin was presently used as a
digester until the aerobic digester is repaired. According to Rodney Kiser, the Town
intends to budget the repairs in the next fiscal year. It is highly suggested that the
Town perform repairs to the aerobic digester, as this is one of the units listed in the
NPDES permit.
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 operator on each shift?
Yes No NA NE
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Page #

Permit: NC0062855 Owner - Facility: Robbins VWVTP
Inspection Date: 10/13/2010
Inspection Type: Compliance Evaluation
Record Keeping
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?
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: Calibrated on October 22, 2007, October 21, 2008, October 7, 2009, and
October 15, 2010.
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?
Comment: The influent pump station had an autodialer, and the police made routine
drive -by rounds that included checking the pump station. The influent pump station
had a 155 KW generator.
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?
Yes No NA NE
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Page # 4

Permit: NC0062855 Owner - Facility: Robbins wWTP
Inspection Date: 10/13/2010 Inspection Type: Compliance Evaluation
Bar Screens
Is the unit in good condition?
Comment: The manual bar screen had a small tree growing in it. Rodney Kiser said
that he would remove it soon.
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: The grit rake motor sounded as if it needed repair.
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'/< 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?
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 # 5

Permit: NC0062855 Owner - Facility: Robbins WNTP
Inspection Date: 10/13/2010 Inspection Type: Compliance Evaluation
Aeration Basins
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)
Comment: Aeration Basin #1 had a box on the surface that had grass growth in it.
Please remove the plant growth.
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?
Comment:
De -chlorination
Type of system ?
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?
Comment: Sulfur dioxide gas.
Are tablet de -chlorinators operational?
Number of tubes in use?
Comment:
Standby Power
Is automatically activated standby power available?
Yes No NA NE
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Yes No NA NE
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Yes No NA NE
Gas
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Page # 6

Permit: NC0062855 Owner - Facility: Robbins WWfP
Inspection Date: 10/13/2010 Inspection Type: Compliance Evaluation
Standby Power Yes No NA NE
Is the generator tested by interrupting primary power source? MOOD
Is the generator tested under load? ■ ❑ ❑ ❑
Was generator tested & operational during the inspection? ❑ ■ ❑ fl
Do the generator(s) have adequate capacity to operate the entire wastewater site? • ❑ Q fl
Is there an emergency agreement with a fuel vendor for.extended run on back-up power? Q ■ ❑ I]
Is the generator fuel level monitored? ■ ❑ ❑ ❑
Comment: When the power fails at the WWTP, plant staff will be paged. They must
go to the POTW to start all of the electric motors, because the facility was not equipped
with an automatic transfer switch. The generator handled the whole plant, the digester,
etc. The generator was tested and documented at a frequency of once per week for
two hours (not under load). The WWTP had a 400 KW generator, and the Influent
Pump station had a 155 KW generator.
Page #

Mayor Theron K. Bell
Commissioners:
Lynn M. Loy, Mayor Pro Tem
A. H. Davis Jr.
Terri Holt
Joey Boswell
Claire A. Barrow
November 4, 2010
TOWN OF ROBBINS
PO Box 296
Robbins, NC 27325
[phone]
Fax: [phone]
Mr. Dale Lopez, Environmental Specialist
NCDWQ
225 Green St, Suite 714
Fayetteville, NC 28301-5043
RE: Response to CEI Inspection, NPDES NC0062855
Dear Mr. Lopez,
Town Manager
George Hayfield
This letter is in response to the Compliance Evaluation Inspection performed by you on
October 13, 2010 at Robbins WWTP. In the report you listed several items that needed
to be addressed. All of the recommendations and requirements are listed below.
Requirement #1- Vehicle and part storage on premises. I have talked to the Town
Manager about this situation and these will be removed as soon as possible. Sometimes
vehicles are temporarily stored at WWTP that are not needed in other departments or are
in need of repair. The Town's Plan of Action includes inspecting all these vehicles and
equipment and determining what is going to be repaired and removed and the items that
will be sold as part of the Town's scrap metal program.
Recommendation #2- Audio and visual alarms for Chlorine, Sulfur Dioxide gas and
Influent pump station alarm. The leak detectors for Chlorine and Sulfur Dioxide gas have
been approved and actually already ordered. These will be installed by Piedmont
Chlorinator out of Charlotte. They are on schedule to be installed by middle/end of
November and will include both audio and visual alarms for both. At the Influent lift
station there is an auto dialer which dials ORC and others on contact list in the event of a
power failure, however the audio/visual alarm doesn't work. The Town will be getting
quotes for the repair of this right away and will be repaired as soon as possible.
Recommendation #3- Grit rake and removal unit. The grit removal system does operate,
however not as efficiently as it used to. It is much more cost effective to replace this unit
instead of repairing as parts for it would be hard to find because of its age. The Town is
dealing with a very slim budget but is working on items like this to be replaced as soon as
possible.

Other items of note- Some of the equipment is beginning to need painting and we are
planning for this. Some will be performed by Town staff but larger jobs may be
contracted out. The grass growth on one of the inlet boxes on Basin #1 has been removed
as well as the small tree in the influent bar screen. I have recently got some part time
help and this is helping me with routine maintenance as I have been working alone for the
past year. The Aeration blower for Digester #1 will be replaced at the beginning of next
fiscal year. At that time it will also be completely drained and all diffusers cleaned.
The Town of Robbins WWTP tries to operate as efficiently as possible and produce high
quality effluent despite having to operate on a very slim budget. If you have any
questions or require more information please feel free to contact us.
Sincerely
Rodney ser
WWTP Manager/ORC