NC0021717_CEI_20210720

DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
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
21I I I I I
NPDES yr/mo/day Inspection
L 31 NC0021717 111 121 21/07/20 117
Type
18L.,jr,
I I I I I
Inspector Fac Type
19 I S I 201
I I I I I I I I I I I I I I I I I I I I I I I I
I I I
I I I 1 I P6
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved
671I 70 I I 711 172 I N I 73 _ I 74 71
I I
1 1 1 1 1 1 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Cub Creek WWTP
701 Snyder St
Wilkesboro NC 28697
Entry Time/Date
10:OOAM 21/07/20
Permit Effective Date
16/02/01
Exit Time/Date
01:30PM 21/07/20
Permit Expiration Date
19/09/30
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Dustin Franklin Colburn/ORC/336-927-3785/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Michael R. Testerman,PO Box 1056 Wilkesboro NC
286971056/Superintendent/336-667-2391/ 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)
Ron Boone
Patricia Lowery����65�23Y4so.
of Inscector(s) Agency/Office/Phone and Fax Numbers Date
Doc Signed y: 8/11/2021
osiaecl 13oo,ve DWR/WSRO WQ/336-776-9690/
DWR/WSRO WQ/336-776-9691/
8/11/2021
Signature of
Managemen2tia5R$keviewer Agency/Office/Phone and Fax Numbers Date
r;iDocuSigned by:
e. T. 5A,acc. 8/11/2021
145B49E225C94EA...
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page# 1

DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
3I
NPDES yr/mo/day
NC0021717 111 121 21/07/20
117
Inspection Type
18LI
(Cont.)
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
On 7/20/2021, Ron Boone and Tricia Lowery met with Dustin Colburn, ORC, to perform a Compliance
Evaluation Inspection at Cub Creek WWTP in the Town of Wilkesboro. This inspection consisted of
two parts: 1) in -office file review, and 2) on -site inspection of the treatment facility. Dustin Colburn
and Kimberly Greene (laboratory) assisted with the in -office review, and Dustin Colburn escorted
inspectors through the facility during the on -site inspection. The attached EPA inspection form detail
the areas that were evaluated with their respective comments (if needed).
Concerns noted during the inspection are outlined below:
1. Off -gassing is present in the secondary clarifiers. This condition is possibly due to de -nitrification
occuring in the clairifiers. Floating sludge was visible in clarifiers and the blanket was high. May need
to adjust return rates.
2. Composite sampling dates were being recorded incorrectly on DMR. Sample dates were marked
by the end date/time of sample, and not the start date/time of sample. Laboratory personnel was
made aware of this and will record the sample date using start date/time with future samples.
3. Significant amount of scum and sludge particles present in chamber leading to pre UV channel.
Need to keep water hose/spray on at all time to control.
4. Bar screen, grit auger/chamber and one surface aerator are still out of service. These
components were out of service during the inspection of January 2020. If possible, expedite the
repair or replacement of components as soon as possible.
Overall the facility is operating properly. The concerns mentioned are not effecting overall
performance of treatment facility, however if not address, could potentially lead to issues in the
future.
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DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Permit Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new MODE
application?
Is the facility as described in the permit? El • El El
# Are there any special conditions for the permit? • El El El
Is access to the plant site restricted to the general public? • ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? • El El El
Comment: The aeration basin listed on permit is owned, operated, and maintained by Tyson
Foods. Tyson allow the facility to use the EQ basin if needed.
Special conditions: Chronic aquatic toxicity (quarterly), effluent pollutant scan, MMP,
nutrient reopener for High Rock lake,
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? • El ❑ ❑
Is all required information readily available, complete and current? • El El El
Are all records maintained for 3 years (lab. reg. required 5 years)? • El ❑ ❑
Are analytical results consistent with data reported on DMRs? El • El El
Is the chain -of -custody complete? • El ❑ ❑
Dates, times and location of sampling •
Name of individual performing the sampling •
Results of analysis and calibration •
Dates of analysis MI
Name of person performing analyses ■
Transported COCs ■
Are DMRs complete: do they include all permit parameters? • El El El
Has the facility submitted its annual compliance report to users and DWQ? • El ❑ ❑
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified ■ El El El
operator on each shift?
Is the ORC visitation log available and current? • El ❑ ❑
Is the ORC certified at grade equal to or higher than the facility classification? • El El El
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? • El El El
Facility has copy of previous year's Annual Report on file for review? ■ El El El
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DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Comment: One significant issue found with laboratory records. There was a misunderstanding
concerning 'sample date' for composite samples. All composite samples were dated
and recorded using 'end time' date resulting in values being placed on wrong date
(note: no errors in actual values recorded). Inspector explained sample date
correlates to the date composite is started, not the date composite ends.
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)?
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees?
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
Yes No NA NE
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▪ El El El
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Comment: The on -site laboratory was very well organized and clean. No standards/reagents
found to be outdated. Incubators were kept at proper temperatures.
Contract/certified lab used is Meritech.
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 MODE
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: Facility conducts MLSS, SS, pH, DO and residuals for process controls. Suggestion
was made to include ammonia and phosphorus in testing process controls.
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? • ❑ ❑ ❑
Comment: Two points of influent into plant: municiple and Tyson operations. They calculate BOD
and TSS using "weighted average" of both influent points.
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?
Yes No NA NE
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DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Flow Measurement - Effluent Yes No NA NE
Comment: Two effluent flow meters in operation. One for sampler, one for transducer system/UV
channel/chart recorder. Both calibrated annually. Last calibration conducted
7/2/2021.
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? • ❑ El El
Are all pumps operable? • El El El
Are float controls operable? • El ❑ ❑
Is SCADA telemetry available and operational? El El • El
Is audible and visual alarm available and operational? • El El El
Comment: Influent pumpls: One belongs to Tyson (they maintain their influent pump). Plant has
3 submerisble pumps (1 large and 2 smaller ones). Plant primarily operates the 2
smaller pumps (one lead/one lag). Larger pumps is standby if needed. ORC stated
the two smaller pumps can handle daily operations.
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: Temp 6 degrees C in sampler. Average influent flow is 4 MGD
Yes No NA NE
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▪ I=1 El El
Pump Station - Effluent Yes No NA NE
Is the pump wet well free of bypass lines or structures? • ❑ ❑ ❑
Are all pumps present? • El El El
Are all pumps operable? • El El El
Are float controls operable? • El El El
Is SCADA telemetry available and operational? El El • El
Is audible and visual alarm available and operational? • El El El
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DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Pump Station - Effluent Yes No NA NE
Comment: They do not use SCADA system. System operates with a transducer float control
system. If system alarms, messages are sent through telephone system. Operators
are notified first, then ORC.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? • El El El
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 • ❑ El El
representative)?
Comment: none
Upstream / Downstream Sampling
Is the facility sampling performed as required by the permit (frequency, sampling type,
and sampling location)?
Comment: Maintains membership with the Yadkin -Pee Dee River Basin Assoc.
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?
Yes No NA NE
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Yes No NA NE
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Comment: One bar screen is out of service. Bar screens are auger/screw press. Note: bar
screen was out of service during the last inspection conducted January 2020. ORC
stated bar screen is being rebuilt.
Grit Removal
Type of grit removal
a.Manual
b.Mechanical
Yes No NA NE
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DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Grit Removal Yes No NA NE
Is the grit free of excessive organic matter? ❑ ❑ • ❑
Is the grit free of excessive odor? ❑ ❑ • ❑
# Is disposal of grit in compliance? ❑ ❑ • ❑
Comment: Grit chamber/auger is still out of service. It was out of service when last inspection was
conducted in January 2020.
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?
Are all pumps present?
Are all pumps operable?
Are float controls operable?
Are audible and visual alarms operable?
# Is basin size/volume adequate?
Yes No NA NE
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Comment: As noted earlier, Tyson owns, operates and maintains basin. The facility uses Tyson's
aerated basin when needed.
Primary 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 sludge blanket level acceptable?
Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth)
Comment: Facility does not have primary clarifiers.
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?
Yes No NA NE
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Yes No NA NE
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DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Secondary Clarifier Yes No NA NE
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'/4 of the sidewall depth) • ❑ ❑ ❑
Comment: Floating sludge was seen in clarifiers. Secondary clarifiers exhibiting 'off -gassing'.
Possible denitrification is happening in clarifiers. Inspectors asked for sludge blanket
reading during inspection. Sludge blanket was at 9 feet (should be on average 2-4
feet). Highly recommended they adjust the RAS rate.
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? El • El El
Are the diffusers operational? El El • El
Is the foam the proper color for the treatment process? ■ El El El
Does the foam cover less than 25% of the basin's surface? • El El El
Is the DO level acceptable? El El El •
Is the DO level acceptable?(1.0 to 3.0 mg/I) El El El •
Comment: 6 surface aerators total. One is out of service. ORC stated a replacement is on the
way.
Pumps-RAS-WAS
Are pumps in place?
Are pumps operational?
Are there adequate spare parts and supplies on site?
Comment: none
Yes No NA NE
Chemical Feed Yes No NA NE
Is containment adequate? • El El El
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DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Chemical Feed Yes No NA NE
Is storage adequate?
Are backup pumps available?
Is the site free of excessive leaking?
Comment. none
• ❑ ❑ ❑
Solids Handling Equipment Yes No NA NE
Is the equipment operational? • ❑ El El
Is the chemical feed equipment operational? • El El El
Is storage adequate? • El ❑ ❑
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? ■ ❑ El El
Is the site free of excessive moisture in belt filter press sludge cake? • El El El
The facility has an approved sludge management plan? • El ❑ ❑
Comment: Sludge management system consists of sludge screw press discharged to landfill.
Drying Beds
Is there adequate drying bed space?
Is the sludge distribution on drying beds appropriate?
Are the drying beds free of vegetation?
# Is the site free of dry sludge remaining in beds?
Is the site free of stockpiled sludge?
Is the filtrate from sludge drying beds returned to the front of the plant?
# Is the sludge disposed of through county landfill?
# Is the sludge land applied?
(Vacuum filters) Is polymer mixing adequate?
Comment: Sludge drying beds are out of service.
Yes No NA NE
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Aerobic Digester Yes No NA NE
Is the capacity adequate? El ❑ El El
Is the mixing adequate? El El El El
Is the site free of excessive foaming in the tank? El ❑ El El
# Is the odor acceptable? El El El El
# Is tankage available for properly waste sludge? El ❑ El El
Page# 9

DocuSign Envelope ID: 878CBB7D-7146-4C3E-9ED6-5FAD129D4B7F
Permit: NC0021717
Inspection Date: 07/20/2021
Owner - Facility: Cub Creek WWTP
Inspection Type: Compliance Evaluation
Aerobic Digester Yes No NA NE
Comment: 3 aerobic digester total. Digester #2 is out of service. With current average flow, 2
digestors are adequate to meet treatment needs. ORC stated plant will undergo
renovations and attempt an upgrade to 15 MGD (not previous 6.6 MGD expansion).
Disinfection - UV
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?
Yes No NA NE
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❑ • ❑ ❑
Comment: Total of 48 bulbs in use (24 lead/24 lag) with only 4 bulbs on hand for replacement.
The effluent is clear and free of solids, however the pre -UV channel has substantial
floating solids and scum. ORC stated water hose is continuously on and used to
control scum. Note: Water hose was not 'on' upon arrival of UV area, was turned on
once we arrived at UV.
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: none
Yes No NA NE
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