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Home My WebLink AboutNC0046728_Compliance Evaluation Inspection_20220304ROY COOPER Governor ELIZABETH S. BISER Secretary S. DANIEL SMITH Director Allison Kraft, Public Utilities Director Town of Mooresville Post Office Box 878 Mooresville, North Carolina 28115 Dear Ms. Kraft: NORTH CAROLINA Environmental Quality March 4, 2022 Subject: Compliance Evaluation Inspection Town of Mooresville/Rocky River WWTP NPDES Permit No. NC0046728 Iredell County Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on March 1, 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. 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 Dep®rlmont of Environmental Onolit Sincerely, DocuSigned by: Le14.1444i, H Nue4 F161FB69A2D84A3... 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 E PA 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 I5 21IIIIII NPDES yr/mo/day Inspection I 3 I NC0046728 111 121 22/03/01 117 Type 18 i i IIIIIIIIIII Inspector Fac Type 19 I S I 201 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 731 I 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) Rocky River WWTP 369 Johnson Dairy Rd Mooresville NC 28115 Entry Time/Date 09:10AM 22/03/01 Permit Effective Date 19/11/01 Exit Time/Date 11:56AM 22/03/01 Permit Expiration Date 24/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// James Levis/ORC/704-662-8341/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Allison Kraft,2523 Charlotte Hwy Mooresville NC 28115//704-799-4066/ 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 -Docusiyned by: DWR/MRO WQ/704-663-1699 Ext.2192/ 3/4/2022 ioer Belt '-A61696D9OCC3437... Signature of Maau61AReviewer Agency/Office/Phone and Fax Numbers Date Andrew Pitn rA4-014144, H P *'f3WR/MRO WQ/704-663-1699 Ext.2180/ 3.4.22 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 31 NPDES yr/mo/day N C0046728 111 121 22/03/01 117 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On -site Representatives: The following Town of Mooresville staff were in attendance during the inspection: Mr. Jamie Levis, Mr. Jerry Lyman and Mr. Jeff Campbell. Page# 2 Permit: NC0046728 Inspection Date: 03/01/2022 Owner - Facility: Rocky River 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 11/20/19. 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The records reviewed during the inspection were organized and well maintained. Discharge monitoring reports (eDMRs) were reviewed for the period January 2021 through December 2021. All monitoring frequencies were correct. A weekly average effluent BOD violation was reported in April 2021. The Division has previously addressed this limit violation through the issuance of a Notice of Violation (NOV). Page# 3 Permit: NC0046728 Inspection Date: 03/01/2022 Owner - Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE 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: Influent and effluent analyses (including field) are performed under the Town's Rocky River WWTP Laboratory Certification #173. Pace Analytical Services has also been contracted to provide analytical support. The facility staff must ensure to compare (and document) the LDO meter to the theoretical dissolved oxygen level prior to each effluent analysis day in accordance with the NC Wastewater/Groundwater Laboratory Certification approved procedure for the analysis/calibration of DO. The LDO meter reading should be within +/- 0.5 mg/L of the theorectical DO value. 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: The subject permit requires influent BOD and TSS composite samples. Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ 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 • El El El representative)? Page# 4 Permit: NC0046728 Inspection Date: 03/01/2022 Owner - Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE Comment: The subject permit requires composite and grab effluent samples. Upstream / Downstream Samplinq Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, MODE and sampling location)? Comment: The facility staff perform the upstream hardness sampling. The Division has conditionally waived the instream monitoring for dissolved oxygen and temperature due to the Town's participation in the Yadkin -Pee Dee River Basin Association. 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: The wastewater treatment facility appeared to be properly operated and well maintained. Facility staff incorporate a comprehensive process control program with all measurements being properly documented and maintained on -site. In-depth operation and maintenance records are also maintained on -site. The facility's SCADA system was operational and in service. 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? • ❑ ❑ ❑ 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 stations for the traditional plant (screw pumps) and package plants (submersible pumps) were operational and in service. One of the submersible pumps was in the process of being repaired. 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? Yes No NA NE Page# 5 Permit: NC0046728 Inspection Date: 03/01/2022 Owner - Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Equalization Basins Yes No NA NE Are float controls operable? • ❑ ❑ ❑ Are audible and visual alarms operable? ❑ ❑ • ❑ # Is basin size/volume adequate? • ❑ ❑ ❑ Comment. Both equalization tanks (1 MG each) were in service. 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? Comment: Screenings are disposed at a permitted landfill. Yes No NA NE • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Chemical Feed Yes No NA NE Is containment adequate? • ❑ ❑ ❑ Is storage adequate? • ❑ ❑ ❑ Are backup pumps available? • ❑ ❑ ❑ Is the site free of excessive leaking? • ❑ ❑ ❑ Comment: 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? • ❑ ❑ ❑ 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) • ❑ ❑ ❑ Page# 6 Permit: NC0046728 Inspection Date: 03/01/2022 Owner - Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Comment: The traditional plant is equipped with surface aeration and the package plants are equipped with diffused aeration. Sodium hydroxide is added to maintain appropriate alkalinity/pH levels. 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'/4 of the sidewall depth) Yes No NA NE Comment: All four (4) final clarifiers (2 — traditional plant and 2 — package plants) were in service. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Filtration (High Rate Tertiary) Type of operation: Is the filter media present? Is the filter surface free of clogging? Is the filter free of growth? Is the air scour operational? Is the scouring acceptable? Is the clear well free of excessive solids and filter media? Comment: The final clarifier effluents from the traditional plant and package prior to the tertiary filters. All four (4) disc type tertiary filter trains were in service. ❑ ❑ El El El El ❑ ❑ ❑ ❑ El El El El ❑ ❑ ❑ ❑ El El El El Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE Cross flow • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ plants are combined Page# 7 Permit: NC0046728 Inspection Date: 03/01/2022 Owner - Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Filtration (High Rate Tertiary) Yes No NA NE 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 quarterly and was last calibrated on 1/19/22 by CTS, Inc. 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? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? • ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? • El El El If effluent (diffuser pipes are required) are they operating properly? El El • El 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? • El El El Is the site free of excessive foaming in the tank? • El El El # Is the odor acceptable? • El ❑ ❑ # Is tankage available for properly waste sludge? • ❑ ❑ ❑ Comment: Both aerobic digesters were in service. Solids Handling Equipment Is the equipment operational? • Yes No NA NE ❑ ❑ ❑ Page# 8 Permit: NC0046728 Inspection Date: 03/01/2022 Owner - Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Solids Handling Equipment Yes No NA NE Is the chemical feed equipment operational? Is storage adequate? 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? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The belt press and dryer system were operational and in service. Dewatered bio-solids are conveyed to the dryer system to produce a Class A product. Dewatered bio-solids from the belt press are also disposed into a permitted landfill if the dryer system is not in service. 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The facility is equipped with four (4) backup generators. The generators are serviced on a quarterly basis by a contracted company (Power Generation & Control, Inc.). Page# 9