NC0020427_CEI NOV_20011218

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NCDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor
December 18, 2001
Mr. Monty R. Crump, City Manager
City of Rockingham
PO Box 520
Rockingham, NC 28379
SUBJECT: Notice of Violation/
Compliance Evaluation Inspection
City of Rockingham WWTP
NPDES Permit No. NC0020427
Richmond County
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William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D.
Acting Director
Division of Water Quality
Dear Mr. Crump:
Enclosed is a copy of the Compliance Evaluation Inspection conducted December 11, 2001.
As part of the inspection a tour of the Wastewater Treatment Plant was conducted. All observations
and recommendationsare in Part D. Summary of Findings/Comments of this inspection report. The
cooperation of Mr. Larry. Cobler, Grade IV ORC wasgreatlyappreciated. During the inspection a
copy of the NPDES Compliance Reminders were reviewed and left with facility staff. The following
item is addressed in this report as violation of administrative Code 15A NCAC 2B .0503-Surface
Water Monitoring: Reporting:
The City was given until March 15, 2001 to complete effluent flow proportional sampling
as outlined in a letter dated March 21, 2000 and an inspection report dated December 21,
2000.
You are asked to immediately take steps to comply with the requirement stated above. Please
respond within ten (10) days of receiving this report. The response should include why
implementing the effluent flow proportional sampling has not taken place as required as well as the
plans the City has to implement flow proportional sampling. As a reminder preservation of the
Waters of the State can only be acquired through consistent NPDES permit compliance.
Fayetteville Regional Office'
225 Green Street.- Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone] FAX: [phone] Internet: www.enr.state.nc.us/ENR
An Equal Opportunity 1 Affirmative Action Employer - 50% Recycled 110% Post Consumer Paper

Crump
Page 2
December 18, 2001
If you or your staff have any questions do not hesitate to contact me at 910-486-1541.
Sincerely,
Paul Rawls
Water Quality Regional Supervisor
/bsh
Enclosures
cc: Larry Cobler, ORC City of Rockingham, WWTP
Maurice Horsey, USEPA, Reg. IV
DWQ NPDES Compliance Unit
Shannon Langley, Compliance Unit

NPDES COMPLIANCE INSPECTION REPORT
North Carolina Division of Water Quality
Fayetteville Regional Office
Section A. National Data System Coding
Transaction Code: N NPDES NO. NC0020427 Date: 011211 Inspection Type: C
Inspector: S Facility Type: 1 Reserved:
Facility Evaluation Rating: 3 BI: N QA: N Reserved:
Section B: Facility Data
Name and Location of Facility Inspected:
City of Rockingham WWTP
Entry Time/Date: 10:10am/011211 Permit Effective Date: 990601
Exit Time/Date: 1:45pm/011211 Permit Expiration Date: 040229
Name(s), Title(s) of On -Site Representative(s):
Larry Cobler (Certified Grade IV Operator) - "ORC"
Phone Number(s): [phone]
Name, Title and Address of Responsible Official
Mr. Monty R. Crump, City Manager
PO Box 520
Rockingham, NC 28379
Contacted: no
Section C: Areas Evaluated Duringlnspection
(S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
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Crump
Page 4
December 18, 2001
Section D: Summary of Findings/Comments:
1. The incoming wastewater is made up of 85% 90% industrial. The municipality has a pretreatment
program with ten (10) Significant Industrial Users (SIUs).
2. A backup generator is on site to operate the entire plant during power failure with the exception of the
biosolids composting system.
3. An alarm system monitors pump failures, inoperable clarifiers, power failure and etc. The facility has
an efficient telemetry system which has allowed a waiver from the requirement that a certified operator
be on site 24 hours per day.
4. The City has 24 pump stations which are monitored each day as per Mr. Cobler. All main pump
stations have telemetry also.
5. Two (2) new effluent flow meters were installed September 2001 by Nix, Purser and Associates. The
meters are Milltronics OCM III.
6. The automatic bar screen and the grit removal system appeared to be operational. The grounds around
the bar screen were cleaned more efficiently as recommended in the last inspection report dated
December 21, 2000. The grit removal system has two (2) different areas which can be utilized. One
side was down for repairs and the other was operational. All screenings and grit are loaded in containers
on a daily basis and lime is added and disposal occurs through the Uwharrie Environmental Landfill
located in Montgomery County.
7 The primary clarifiers appeared to be operating adequately. Wooden flights had been installed on the
primary clarifiers since the last inspection. The trickling filter and secondary clarifiers appeared to be
operating adequately.
8. Two (2) aeration basins are operational but only.one (1) is necessary for proper treatment of wastewater.
Four (4) aerators and two (2) floating mixers are operational in the basin. The Mixed Liquor Suspended
Solids (MLSS) results were 4400 mg/L. The Dissolved Oxygen (DO) analysis is done daily in the
aeration basin. Polymer is added to the MLSS at the end of the aeration basin before it enters the
clarifiers. It is added to assist with the settling of solids in the clarifiers. A 6000 gallon polymer storage
tank is located on site.
9. The sludge depths in the final clarifiers are as follows:
Clarifier #1 - 5 feet with a tank depth of 10 feet
Clarifier #2 - 4 feet with a tank depth of 10 feet
Clarifier #3 - 5 feet with a tank depth of 12 feet.

Crump
Page 5.
• December 18, 2001
10. The chlorine contact tanks were cleaned two (2) weeks ago as per Mr. Cobler..The effluent appeared
to be free of solids. Chlorine is used to disinfect the effluent. It is added by a flow paced system called
Regal Smart Valve which doses the effluent as the flow increases. Sulfur dioxide is used to dechlorinate
the effluent . The sulfur dioxide is added in the manhole where both effluents from the two chlorine
contact tanks combine.
11. Two (2) variable and two (2) constant speed effluent pumps are located at the effluent pump station.
One pump is utilized when normal flow conditions occur.
12. Effluent sample collection is completed at the wet well area located at the effluent pump station. The
effluent discharge pipe travels directly to the Pee Dee River.
13. The influent and effluent composite samplers' temperature were 1 degrees C. The acceptable range of
samples during storage and for stored sample extracts, is 1.0 - 4.4 degrees C.
14. The biosolids handling facility appeared to be operating adequately. Biosolids travel to the belt press
at 2 - 3 % solids and at the completion of the dewateringprocess solids are 19 - 20 % solids. Thirty
(30) to forty (40) tons weekly of biosolids are wasted to the digester and then to the filter press
Biosolids are composted for a Class A Biosolids and is used by various landscaping companies and etc.
The land application permit is WQ0004477.
15. The sand drying beds have been removed with the exception of one which is utilized to dry waste
material collected from the collection system by vac trucks. The area where the drying beds were located
is now a concrete pad used to store compost while it is curing.
16. The "Backup Operator" for this facility is James Croke, NC certified Grade III Wastewater Treatment
Plant Operator.
17. The certified laboratory on site analyzes all NPDES permit required parameter with the exception of the
following: Metals, Total Nitrogen, Total Phosphorus and Chronic Toxicity which is completed by the
commercial laboratory "Similabs". The on site laboratory has implemented an approved method to
analyze ultra low chlorine residual. The facility has a NPDES permit limit for residual chlorine.
18. Laboratory bench sheets were reviewed for the months January and March 2001 and compared to
Discharge Monitoring Reports. All records reviewed appeared to be accurate and well organized.
19. A compliance evaluation analysis report for the period October 2000 through September 2001 did not
reveal any monthly violations. There were not any Notice of Violations (NOVs) sent to the facility
during this period.

Name and Signature of Inspector Agency/Office/Telephone Date
Belinda S. Henson
Name and Signature of Reviewer
Paul E. Rawls
Action Taken
DENR/Fayetteville/[phone]%- iS-0
Agency/Office/Telephone Date
DENR/F ayetteville/(9 10)4 8 6 - 15 4 1
Regulatory Office Use Only
Compliance Status
Noncompliance
_Compliance
Date

Section D: Summary of Findings/Comments
Brief Facility Description:
A 6.0 MGD WWTP consisting of influent pumps, mechanical bar screen, grit removal, magnetic
flow meter, primary clarifiers, trickling filter, secondary clarifier. dual extended aeration basins,
three final clarifiers, two chlorine contact tanks, sulfur dioxide dechlorination, aerobic sludge
digester, belt filter press, and effluent pump station.
FACILITY SITE REVIEW
es No N/A 1. Treatment units properly operated and maintained.
Yes No N/A 2. Standby power or other equivalent provision provided.
es No N/A 3. Adequate alarm system for power or equipment failure available.
4. Sludge disposal procedures appropriate:
No N/A a. Disposal of sludge according to regulations
TI`es No N/A b. State approval for sludge disposal received.
Y-e_§ No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
es No N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
Yes No N/A 7. Adequate. spare parts and supplies inventory maintained.
Yes No N/A 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
es No N/A 9. Plant is generally clean, free from open trash areas.
10. Screening:
Yes No %' a. Manual
No N/A b. Mechanical
Yes Ni N/A c. Buildup of debris
Yea No N/A d. Screenings properly disposed of.
11. Grit Removal:
Yes 6) N/A a. Excessive organic content in the grit chamber
Yes � ' N/A b. Excessive odors
Yes No N/A c. Grit properly disposed of.

Page 2
12. Primary clarifier:
Yes N/A a. Excessive gas bubbles
Yes GO N/A b. Black and odorous wastewater
Yes i'10 N/A c. Poor suspended solids removed
Yes o N/A d. Excessive buildup of solids in center well of circular clarifier
Yes Now N/A e. Weirs level
Yes N/A f Weir blockage
Yes ' N/A g. Evidence of short circuiting
Yes N/A h. Lack of adequate scum removal
Yes) N/A i. Excessive floating sludge
Yes N/A j. Broken sludge scraper.
13. Trickling Filter:
Yes N/A a. Trickling filter ponding(indicating clogged media)
Yes j) N/A b. Leak at center column of trickling filter's distribution arms
Yes N/A c. Uneven distribution of flow on trickling filter surface
Yes OM N/A d. Uneven or discolored growth
Yeses N/A e. Excessive sloughing of growth
Yes N/A f. Odor
Yes _9) N/A g. Clogging of trickling filter's distribution arm orifices
Yes N/A h. Filter flies, worms, or snails.
14. Activated Sludge Basins/Oxidation Ditches:
Yes NS, N/A a. Dead spots
Yes No N/A b. Failure of surface aerators
Yes CO N/A c.. Air rising in clumps
Yes O N/A d. Dark foam or bad color
Yes C' N/A e. Thick billows of white, sudsy foam
Yes (I "o) N/A f. Air rising unevenly
Yes No &A g. Excessive air leaks in compressed air piping.
Na15. Stabilization'Ponds/Lagoons'
Yes No / a. Excessive weeds including duckweed in stabilization ponds
Yes No N/A b. Dead fish or aquatic organisms
Yes No N/A c. Buildup of solids around influent pipe
Yes No N/A d. Excessive scum on surface.

Page 3
16. Secondary Clarifier: -
Yes CM N/A a. Excessive gas bubbles on surface
Yes No N/A b. Level overflow weirs
Yes Teo N/A c. Weir blockage
Yes N/A d. Evidence of short circuiting
Yes N/A e. Excessive buildup of solids in center well of circular clarifier
Yes N/A f Pin floc in overflow
Y s s No N/A g. Effective scum rake
Yes Q N/A h. Floating sludge on surface
Yes C N/A i. Excessive high sludge blanket
Yes 0 N/A j. Clogged sludge withdrawal ports on secondary clarifier.
17. Filtration:
Yes NoNfrw a. Filter surface clogging
Yes No N/A b. Short filter run
Yes No N/A c. Gravel .displacement of filter media.
Yes No N/A d. Loss of filter media during backwashing
Yes No N/A e. Recycled filter backwash water in excess of 5 percent
Yes No N/A f: Formation of mudballs in filter media.
Yes N/A
Yes N/A
Yes e N/A
Yes N/A
Yes No N/A
Yes No N/A
C.) No N/A
(YES) No NIA
Yes No
18. Chlorination Unit:
a. Sludge buildup in contact chamber
b. Gas bubbles
c. Floating scum and/or solids
d. Adequate ventilation of chlorine feeding room and storage area
e. NIOSH-approved 30 minute air pack
f. All standing chlorine cylinders chained in place
g. All personnel trained in the use of chlorine
h. Proper chlorine feed, storage, and reserve supply.
19. Ultraviolet radiation disinfection present and in use.
20. ` Dechlorination:
es No N/A a. Proper storage of sulfur dioxide cylinders
C No N/A b. Adequate ventilation of sulfur dioxide feeding room
he`s No N/A c. Automatic sulfur dioxide feed or feedback control operating
properly.
Yes No N/A
Yes No N/A _
Yes No _ N/A
Yes No N/A
21. Aerobic Digester:
a. Excessive foaming in tank
b. Noxious odor
c. Mechanical aeration failure
d. Clogging of diffusers.

Page 4
Yes No
Yes No N/A
22. Anaerobic Digester:
a. Floating cover tilting
b. Gas burner operative
23. Sludge Drying and/or disposal:
Yes No I a. Poor sludge distribution on drying beds
Yes No N./ b. Vegetation in drying beds
Yes No /A c. Dry sludge remaining in drying beds
Yes No (RA d. Dry sludge stored on site
Yes No iA e. Filtrate from sludge drying beds returned to front of plant
( Yes Nof Sludge disposal through county landfill.
Yes No N/A g. Sludge land applied.
24. Filter Press:
Yes C N/A a. High level of solids in filtrate from filter presses or vacuum filters
Yes N/A b. Thin filter cake caused by poor dewatering
Yes ( o N/A c. Sludge buildup on belts and/or rollers of filter press
Yes �Id N/A d. Excessive moisture in belt filter press sludge cake.
Yes N
Yes No N/A
Yes No N/A
Yes N/A
Yes O N/A
Yes No N/A
CYe No N/A
Yes No N/A
Yes CRO N/A
Yes A
Yes No
Yes N/A
Yes No N/A
25. Polishing Ponds or Tanks:
a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
b. Solids or scum accumulations in tank or at side of pond
c. Evidence of bypassed polishing ponds or tanks because of low
capacity.
26. Plant Effluent:
a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
b. Potential toxicity (dead fish, dead plant at discharge)
c. Outfall discharge line easily accessible. 3 Vg. (11Ata�
27. Flow Measurement:
a. Proper placement of flow measurement device
b. Flow meter calibrated
c. Buildup of solids in flume or weir
d. Broken or cracked flume or weir
e. Clogged or broken stilling wells
f. Weir plate edge corroded or damaged
g. Flow measurement error less than 10%.

t
Page 5
es No N/A
No N/A
e Na N/A
Yes N/A
28. Sampling:
a. Sampling and analysis completed on parameters specified by permit
b. Composite sample temperatures maintained at 4 degrees Celsius or
less (but above freezing) during sampling
c. Contract laboratory used for sample analysis
d. Effluent composite samples obtained are flow proportional.
Ye No N/A
es No N/A
No N/A
No N/A
Ea No N/A
No N/A
No . N/A
No N/A
No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
No NIA •
Yes No N/A
RECORDKEEPITG AND REPORTENG
1. Records and reports maintained as required by permit.
2. All required information available, complete, and current.
3. Records maintained for 3 years and all sludge records maintained for 5
years.
4.. Analytical results consistent with data reported on DMRs.
5 Sampling and analyses data adequate and include:.
a. Dates, times, and location of sampling
b. Name of individual performing sampling
c. Results of analyses and calibration
d. Dates of analyses
e. Name of person performing analyses.
6. Monitoring records adequate and include:
a. Monitoring charts kept for 3 years
b. Flowmeter calibration records kept for 3 years.
7 The pH meter is calibrated daily with two buffers and checked with a
third buffer and properly documented.
Expiration dates of pH buffers adequate.
9. All thermometers used in NPDES permit reporting is calibrated
annually with an NIST certified thermometer or a traceable
thermometer annually and documented.
10. The following NPDES permit required parameters are analyzed on site:
pH, Temperature, Dissolved Oxygen and Chlorine Residual.

Page 6
j) No N/A 11. The NPDES permit required parameter Total Chlorine Residual is
analyzed by approved method.
s No N/A 12. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log for every day of operation.
Ye r' No N/A 13. Fecal coliform incubator maintained at 44.5 +/-. 0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
No N/A
•Ce3 No N/A
( No N/A
es) No N/A
14. Plant records adequate and include:
a. 0 & M Manual
b. "As -built" engineering drawings
c. Schedules and dates of equipment maintenance repairs
d. Equipment data cards.
Yes No OA 15. Peimittee is meeting compliance schedule.
es No N/A 16. DMRs complete and include all NPDES permit required parameters.
Yes No N/A 17. The facility has a permitted flow greater than 5 MOD and is required
to operate seven days per week 24 hours a day.
No N/A 18. ORC visitation logs available and current.
Yes No N/A 19. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
s) No NIA 20. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
No N/A 21. - Current copy of the complete NPDES permit on site.
ye -,-)No N/A 22. Facility description verified as contained in NPDES permit.
'e No N/A 23. Facility analyzes process control parameters for example: MT SS,
MCRT, Settleable Solids and others that are applicable.
No N/A 24. Industrial Waste Surveys (IWS) sent to all possible Significant
Industrial Users (SIUs) within the last five years (especially new
industries).
Revised 7/16/01
by Belinda Henson

City of Rockingham
Wastewater Treatment Plant and
Composting Facility
311 East Franklin Street Rockingham, North Carolina 28379
January 4, 2002
Mr. Paul Rawls, WQ Regional Supervisor
N.C. Department of ENR
Fayetteville Regional Office
225 Green Street -Suite 714
Fayetteville, North Carolina 28301-5043
JEAN - .8 2002
BBC4:
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Dear Paul,
I received your letter dated December 18, 2001 yesterday concerning the
Notice of Violation for failing to implement flow proportional sampling. I
apologize for not having this in place before now. To be honest I completely
forgot about it. We purchased the attachment from ISCO for the sampler to
connect to the flow meter over a year ago, put it on a shelf and haven't thought
about it since. We were going to hook it up this week but the snow has slowed
us a bit. It will however, be in place and operating by January 11, 2002.
Again, I apologize for this deficiency and.assure you that the City of
Rockingham is committed to the preservation of the Waters of the State of North
Carolina.
Si erely,
C
a obler
PI. t OprationsDirector
City of Rockingham, WWTP