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Home My WebLink AboutNC0062481_Compliance Evaluation Inspection_20220127ROY COOPER Governor ELIZABETH S. BISER Secretary S. DANIEL SMITH Director Shannon Becker, President Aqua North Carolina, Inc. 202 MacKenan Court Cary, North Carolina 27511 Dear Mr. Becker: NORTH CAROLINA Environmental Quality January 27, 2022 Subject: Compliance Evaluation Inspection Mallard Head WWTP NPDES Permit No. NC0062481 Iredell County Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on January 13, 2022, by Mr. Wes Bell of this Office. Please advise the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding a copy of the enclosed report. A majority of the bar screen is submerged in the aeration basin and ineffective at removing paper debris, etc. The ORC has to dip out screenings in the aeration basin. It is requested that a written response be submitted to this Office by February 18, 2022, addressing the actions taken to address the ineffective bar screen. In responding, please address your comments to the attention of Mr. Bell. Should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192, or via email at wes.bell@ncdenr.gov. Enclosure: Inspection Report NORTH Deparlmant of Environmental Ouallt Sincerely, Docu Signed by: �r w H P444.4 F161 FB69A2D84A3... fo r W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ North Carolina Department of Environmental Quality 1 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 IL 21IIIIII I NPDES yr/mo/day Inspection 3 I NC0062481 111 121 22/01/13 117 Type 1810I IIIIIIIIIII Inspector Fac Type 19I S I 2011 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 73I 1 74 751 I I 1 I I I I I I 180 l Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Mallard Head WWTP NCSR 1112 Stutts Rd Mooresville NC 28115 Entry Time/Date 08:53AM 22/01/13 Permit Effective Date 21/04/01 Exit Time/Date 09:43AM 22/01/13 Permit Expiration Date 25/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Dustin Joseph Dillard/ORC/828-261-6459/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Shannon V Becker,202 Mackenan Dr Cary NC 275116447/President/919-653-5570/ 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/ 1/26/2022 164- Belt '-A61696D9OCC3437... Signature of Man Andrew Pitn t?91QsQnAA�@raviewer Agency/Office/Phone and Fax Numbers Date rA."41441 H P44 A/R/MRO WQ/704-663-1699 Ext.2180/ 1.27.22 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 NPDES yr/mo/day 31 NC0062481 111 121 22/01/13 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0062481 Inspection Date: 01/13/2022 Owner - Facility: Mallard Head 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 ❑ ❑ ❑ application? Is the facility as described in the permit? • ❑ El El # 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: The last compliance evaluation inspection at this facility was performed by DWR staff on 8/1/19. 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? 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ Page# 3 Permit: NC0062481 Inspection Date: 01/13/2022 Owner - Facility: Mallard Head WWTP Inspection Type: Compliance Evaluation Record Keeping 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 December 2020 through November 2021. No effluent limit and/or monitoring violations were reported. The ORC must ensure all process control measurements (settleability tests, MLSS measurements, etc.) are documented as required by 15A NCAC 2B .0506 (c)(3) and subject NPDES Permit. 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 • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: On -site effluent field analyses (dissolved oxygen, pH, temperature and total residual chlorine) are performed under the Aqua N.C.'s field laboratory certification #5035. Water Tech Labs (Certification #50) has been contracted to provide analytical support. The ORC must ensure to report all effluent total residual chlorine (TRC) values down to the lowest standard verified (15 ug/L) on the TRC meter (annual five -point curve verification). 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)? Is the facility sampling performed as required by the permit (frequency, sampling type • ❑ ❑ ❑ representative)? Comment: The subject permit requires effluent grab samples. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, • ❑ ❑ ❑ and sampling location)? Comment: Operations & Maintenance Yes No NA NE Page# 4 Permit: NC0062481 Inspection Date: 01/13/2022 Owner - Facility: Mallard Head WWTP Inspection Type: Compliance Evaluation 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: Overall the wastewater treatment facility appeared to be properly operated and well maintained; however, concerns with the bar screen were noted and are discussed in further detail in the Bar Screens Section. Bar Screens Yes No NA NE 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? ■ ❑ El El Is the unit in good condition? El • El El Comment: A majority of the current bar screen is submerged in the aeration basin and the screenings have to be dipped out of the aeration basin. Please be advised that the permittee must properly operate and maintain the treatment facility at all times as required by the subject NPDES Permit. Screenings that are manually collected are transported and disposed into the dumpster located at the Hwy. 150/River Park WWTP. The dumpster contents are disposed at a permitted landfill. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? • El ❑ ❑ Are surface aerators and mixers operational? El El • El 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? • El El El Is the DO level acceptable? • El El El Is the DO level acceptable?(1.0 to 3.0 mg/I) • ❑ ❑ ❑ Comment: Secondary Clarifier Is the clarifier free of black and odorous wastewater? • Yes No NA NE ❑ ❑ ❑ Page# 5 Permit: NC0062481 Inspection Date: 01/13/2022 Owner - Facility: Mallard Head WWTP Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE 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'/4 of the sidewall depth) Comment: • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ • ❑ ❑ ❑ Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? • ❑ ❑ ❑ Are the tablets the proper size and type? • ❑ El El Number of tubes in use? 1 Is the level of chlorine residual acceptable? • El ❑ ❑ Is the contact chamber free of growth, or sludge buildup? ■ El El El Is there chlorine residual prior to de -chlorination? • El El El Comment: Calcium hypochlorite tablets were used for disinfection. 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The flow meter is calibrated annually and was last calibrated by Aqua NC staff on 7/14/21. De -chlorination Yes No NA NE Type of system ? Tablet Is the feed ratio proportional to chlorine amount (1 to 1)? El El • El Is storage appropriate for cylinders? El ❑ • El Page# 6 Permit: NC0062481 Inspection Date: 01/13/2022 Owner - Facility: Mallard Head WWTP Inspection Type: Compliance Evaluation De -chlorination # 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? 1 Yes No NA NE • ❑ • ❑ • ❑ ❑ ❑ Comment: Sodium Sulfite tablets were used for dechlorination. Post aeration is provided following dechlorination. 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? Yes No NA NE Comment: The effluent appeared clear with no floatable solids or foam. The receiving stream did not appear to be negatively impacted. Aerobic Digester Yes No NA NE 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: Wastewater solids are removed by a contracted company (Lake Norman Sewer & Septic Services). 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 7 Permit: NC0062481 Inspection Date: 01/13/2022 Owner - Facility: Mallard Head WWTP Inspection Type: Compliance Evaluation Standby Power Yes No NA NE Comment: The backup generator is exercised (automatically) weekly and tested under load monthly. Managed Generator Services has been contracted to service the generator quarterly. Page# 8