NC0066516_Compliance Evaluation Inspection_20220309

March 9, 2022

Town of Fuquay-Varina
Attn: Chris Grimes
401 Old Honeycutt Road
Fuquay-Varina, NC 27526

Subject: Compliance Sampling Inspection
Terrible Creek WWTP
NPDES Permit No. NC0066516
Wake County

Dear Mr. Grimes

On February 2, 2022, Stephanie Goss and Colleen Cohn of the Raleigh Regional Office (RRO)
conducted an inspection at the subject facility. The cooperation of Adam Stephenson, operator
in responsible charge (ORC) and Troy King (back up ORC) of the facility was greatly
appreciated. Findings during the inspection were as follows:

1. The current NPDES permit was issued effective July 1, 2021 and will expire on April 30,
2026.

2. The 3.0 MGD treatment plant consists of a influent pump station, mechanical coarse bar
screen, mechanical step bar screens, manual bar rack, grit removal system, flow
distribution box, three equalization basins, two 5-stage conventional BNR basins, two
secondary clarifiers, RAS pump station, two ultrascreen disc filters, ultraviolet
disinfection, effluent flow measurement, WAS pump station, one aerated sludge holding
tank, two 3-belt filter presses with gravity thickening ability and a stand-by power
generator.

3. The plant discharges to Terrible Creek, which is classified as Class C, Nutrient Sensitive
Waters (NSW) in the Neuse River Basin.

4. The facility’s three equalization basins hold approximately one million gallons combined
and were empty during the time of the inspection.
5. The two five-stage biological BNR basins appeared to be operating satisfactorily. Foam
was observed on approximately 50% of the surface of each of the basins.

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6. Mr. Stephenson stated that both of their clarifiers are approximately twenty feet deep.
The overflow weirs appeared to be level and free of algae on Clarifier #1 and a sludge
judge showed the sludge depth to be approximately three feet deep. Clarifier #2 was
empty during the time of the inspection.

7. The facility’s two channel UV disinfection system appeared to be operating satisfactorily
and is self-cleaning. Spare bulbs are maintained on site.

8. The effluent was clear and free of excess solids. No detrimental impacts to Little Creek
were observed during the time of the inspection.

9. The influent composite sampler is programmed to collect 200 ml every 28 minutes and is
time paced. The refrigerated units were maintained at the proper temperature, < 6
degrees C.

10. The effluent composite sampler is programmed to collect 250 ml and is flow
proportionate. The refrigerated units were maintained at the proper temperature, < 6
degrees C.

11. The effluent flow meter was calibrated on October 2021 by FCX Services.

12. The facility has one aerated sludge holding tank and Mr. Stephenson stated the sludge
holding tank is approximately 15-18 feet deep. During the time of the inspection, the
aerated sludge holding tank contained approximately 11 feet of sludge and liquid.

13. The sludge is transferred to the belt filter presses where the sludge can be thickened with
a polymer or pressed.

14. Mr. Stephenson stated that their sludge is hauled three days a week (approximately
180,000 pounds) by McGill Environmental Systems which converts it into Class A
sludge.

15. Mr. Stephenson stated that the facility’s chemical feed system for alum is used daily.

16. Mr. Stephenson stated the onsite diesel generator is tested under load weekly.

17. A review of discharge monitoring report (DMR) data for the period January 2020 through
December 2021 showed all required monitoring was performed.

18. A cursory review of laboratory and DMR data for March 1, 2021 showed consistent
reporting of results. However, the DMR data for September 2021 revealed
inconsistencies in data entry. More specifically, the influent flow data was inadvertently
entered in as the effluent flow data. At the time of this letter, the September 2021 DMR
has been revised. It was recommended by RRO staff that Mr. Stevenson enact a peer
review process for DMR data entry.

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19. Mr. King performed the calibration of the pH meter, and it was observed that the probe
was not being rinsed with deionized water between solutions. RRO staff advised Mr.
Stephenson and Mr. King the probe must be rinsed in between pH solutions to ensure
consistency with calibration results.

20. Mr. Stephenson stated there is one industry in the Town of Fuquay-Varina which is John
Deere.

21. A daily operator logbook is kept online which details daily operations, problems and
when the plant conducts wasting of the sludge.

22. Composite and grab samples were taken from the influent and effluent for analysis of the
following parameters (analytical results shown below):

Influent
Parameter
Sample
Location Result Permit Limits Method
Reference
Analysis
Date Monthly
Avg.
Weekly
Avg.
BOD, 5-Day Influent 340 mg/L
G5, G7* - - SM 5210 B-2001 2/2/2022
TSS Influent 238 mg/L - - SM 2540 D-1997 2/2/2022

Effluent
Parameter
Sample
Location Result Permit Limits Method
Reference
Analysis
Date Monthly
Avg.
Weekly
Avg.
Conductivity Effluent 450 N/A N/A SM 2510 B-1997 2/ 17/ 2022
Fecal Coliform Effluent 6 CFU/100
ml 200 400 SM 9222 D-1997 2/2/2022
Nitrite-Nitrate
(NO2+NO3) Effluent 1.3 mg/L N/A N/A EPA 353.2 rev 2 2/4/2022
Total Kjeldahl
Nitrogen (TKN) Effluent 1.1 mg/L N/A N/A EPA 351.2 rev 2 2/22/2021
Total Nitrogen
TN=[NO2+NO3] + TKN Effluent 2.4 mg/L N/A N/A - -
NH3 as N Effluent 0.02 mg/L 2.0
(winter)
6.0
(winter) EPA 350.1 rev 2 2/4/22
BOD, 5-Day Effluent 5.7 mg/L;
G5*
10.0
(winter) 15.0
(winter) SM 5210 B-2001 2/2/2022
TSS Effluent 5.6 mg/L;
U, Y** 30.0 45.0 SM 2540 D-1997 2/2/2022
*G5: The Glucose/glutamic acid standard exceeded the range of 198 +/- 30.5 mg/L.
*G7: Estimated - Less than 1 mg/L DO remained for all dilutions. Reported va is greater than
the value for lowest sample dilution.
**U: Indicates that the analyte was analyzed for but not detected above the reported practical
quantitation limit.
**Y: Elevated PQL due to insufficient sample size.
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The samples collected on the influent and effluent were obtained using the subject facility’s
composite samplers and split with the facility for separate analyses. The inspector collected
a grab sample for the fecal coliform analysis.

If you have questions concerning this report, please contact Stephanie Goss at 919-791-4256 or
[e-mail].

Sincerely,

Vanessa E. Manuel, Assistant Regional Supervisor
Water Quality Regional Operations Section
Raleigh Regional Office
Division of Water Resources, NCDEQ

cc: Laserfiche
RRO files

DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
EPA
United States Environmental Protection Agency
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 Type Inspector Fac Type
1 N 52 NC0066516 22/02/02 S S31112171819 20
21 66
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved-------------------
N67707172 73 74 75 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)
Terrible Creek WWTP
NCSR 2751 Hilltop Rd
Fuquay Varina NC 27526
Entry Time/Date Permit Effective Date
Exit Time/Date Permit Expiration Date
08:30AM 22/02/02 21/07/01
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Adam Parker Stephenson/ORC//
Other Facility Data
12:30PM 22/02/02 26/04/30
Name, Address of Responsible Official/Title/Phone and Fax Number
Adam Mitchell,134 N Main St Fuquay Varina NC
275266267//919-552-1401/9195527481
Contacted
No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenance Records/Reports
Self-Monitoring Program Sludge Handling Disposal Facility Site Review Compliance Schedules
Effluent/Receiving Waters Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s)Agency/Office/Phone and Fax Numbers Date
Stephanie Goss DWR/RRO WQ/919-791-4200/
Colleen Cohn DWR/RRO WQ/919-791-4258/
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page#1
3/9/2022
DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
3/9/2022
NPDES yr/mo/day
22/02/02
Inspection Type
S3111218
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
NC0066516 17
Page#2
DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
Permit:NC0066516
Inspection Date:02/02/2022
Owner - Facility:
Inspection Type:
Terrible Creek WWTP
Compliance Sampling
Compliance Schedules Yes No NA NE
Is there a compliance schedule for this facility?
Is the facility compliant with the permit and conditions for the review period?
Comment:
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
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment:
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?
# 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:
Record Keeping Yes No NA NE
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?
Page#3
DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
Permit:NC0066516
Inspection Date:02/02/2022
Owner - Facility:
Inspection Type:
Terrible Creek WWTP
Compliance Sampling
Record Keeping Yes No NA NE
(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?
A cursory review of laboratory and DMR data for March 1, 2021 showed consistent
reporting of results. However, the DMR data for September 2021 revealed
inconsistencies in data entry. More specifically, the influent flow data was inadvertently
entered in as the effluent flow data. At the time of this letter, the September 2021 DMR
has been revised. It was recommended by RRO staff that Mr. Stevenson enact a peer
review process for DMR data entry
Comment:
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?
If effluent (diffuser pipes are required) are they operating properly?
Comment:
Flow Measurement - Effluent 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:
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?
Page#4
DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
Permit:NC0066516
Inspection Date:02/02/2022
Owner - Facility:
Inspection Type:
Terrible Creek WWTP
Compliance Sampling
Aerobic Digester Yes No NA NE
The facility has one aerated sludge holding tank and Mr. Stephenson stated the sludge
holding tank is approximately 15-18 feet deep. During the time of the inspection, the
aerated sludge holding tank contained approximately 11 feet of sludge and liquid.
Comment:
Solids Handling Equipment Yes No NA NE
Is the equipment operational?
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:
Chemical Feed Yes No NA NE
Is containment adequate?
Is storage adequate?
Are backup pumps available?
Is the site free of excessive leaking?
Comment:
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:
Bar Screens Yes No NA NE
Type of bar screen
a.Manual
Page#5
DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
Permit:NC0066516
Inspection Date:02/02/2022
Owner - Facility:
Inspection Type:
Terrible Creek WWTP
Compliance Sampling
Bar Screens Yes No NA NE
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:
Grit Removal Yes No NA NE
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:
Influent Sampling Yes No NA NE
# 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:
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)?
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DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
Permit:NC0066516
Inspection Date:02/02/2022
Owner - Facility:
Inspection Type:
Terrible Creek WWTP
Compliance Sampling
Effluent Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type
representative)?
Comment:
Laboratory Yes No NA NE
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?
Comment:
Pumps-RAS-WAS Yes No NA NE
Are pumps in place?
Are pumps operational?
Are there adequate spare parts and supplies on site?
Comment:
Standby Power Yes No NA NE
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:
Disinfection - UV Yes No NA NE
Are extra UV bulbs available on site?
Are UV bulbs clean?
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DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
Permit:NC0066516
Inspection Date:02/02/2022
Owner - Facility:
Inspection Type:
Terrible Creek WWTP
Compliance Sampling
Disinfection - UV Yes No NA NE
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:
Secondary Clarifier Yes No NA NE
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 ¼ of the sidewall depth)
Comment:
Aeration Basins Yes No NA NE
Mode of operation
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/l)
The two five-stage biological BNR basins appeared to be operating satisfactorily. Foam
was observed on approximately 50% of the surface of each of the basins.
Comment:
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DocuSign Envelope ID: 3D0A8D7A-1FCF-4BB7-A16B-7330F99190C6
Permit:NC0066516
Inspection Date:02/02/2022
Owner - Facility:
Inspection Type:
Terrible Creek WWTP
Compliance Sampling
Filtration (High Rate Tertiary)Yes No NA NE
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:
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