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Home My WebLink AboutNC0020737_Compliance Evaluation Inspection_20220324ROY COOPER Governor ELIZABETH 5. 3ISER Secretary RICHARD E. ROGERS, JR. btrectar NORTH CAROLINA r iviironm. ntar Qrsoltty March 24, 2022 Mr. Ricky Duncan, Water Resources Director City of Kings Mountain P.O. Box 429 Kings Mountain, NC28086 Subject: Compliance Evaluation Inspection City of Kings Mountain NPDES Permit No. NC0020737 Cleveland County Dear Mr. Duncan: Enclosed is a copy of the Compliance Evaluation Inspection report for the inspection conducted at the subject facility on March 22, 2022, by Ori Tuvia and Michael Meilinger. The cooperation of Richelle Meek during the site visit was much appreciated. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed report. Overall, the waste treatment unit is continually improving. The facility has been effective in reducing the dead spot areas in the aeration basins, which has resulted in a significant improvement in the condition of the clarifiers. Additionally, the following items should be addressed: 1) At the time of the inspection, it was observed that the clarifier #3 weir was uneven; 2) Chlorine curve was late to be renewed for the year of 2021 and the new chlorine curve did not pass the low chlorine limit (10 ug/L). The higher level passed 50 ug/L, which is above the permit limit of 28 ug/L. The report should be self-explanatory; however, should you have any questions, please do not hesitate to contact Ori Tuvia at (704) 235-2190, or at ori.tuvia@ncdenr.gov. Sincerely, �DocuSigned by: .��1iZ�ZGG1r-�w.r A14CC681 AAF27425... cc: NPDES, MRO files (Laserfiche) �D_EQNORTH CAROLINA oay,ro�em or Environmentalw.i W. Corey Basinger Regional Supervisor Mooresville Regional Office Division of Water Resources North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1601 East Center Avenue, Suite 301 Mooresville, NC 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 L 21IIIIII NPDES yr/mo/day Inspection 3 I NC0020737 111 121 22/03/22 117 Type 18 i i IIIIIIIIIII Inspector Fac Type 19 I S I 201 IIIIIIIIIIIIIIIIII I IIIIII i66 l Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 67I1.0 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 Hermit Number) Pilot Creek WWTP 200 Potts Creek Rd Kings Mountain NC 28086 Entry Time/Date 09:50AM 22/03/22 Permit Effective Date 20/02/01 Exit Time/Date 12:30PM 22/03/22 Permit Expiration Date 23/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Kendrene Richelle Meek/ORC/704-739-7131/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Richelle Meek,PO Box 429 Kings Mtn NC 280860429/ORC/704-739-7131/ 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) Michael J Meiling Ori A Tuvia of Inspector(s) Agency/Office/Phone and Fax Numbers Date 3/24/2022 ,—DocuSigned by: DWR/MRO WQ/704-235-2183/ — DWR/MRO WQ/704-663-1699/ BB057A2DE017498... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger DWR/Division of Water Quality/704-235-2194/ EPA Fornbo 56 0 eaev 9-94) Previous editions are obsolete. 3/24/2022 �A14CC681AF27425... Page# 1 NPDES yr/mo/day 31 NC0020737 111 121 22/03/22 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0020737 Inspection Date: 03/22/2022 Owner - Facility: Pilot 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 ❑ ❑ ❑ 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: New tiered permit was issued and became effective on 2/1/2020. The new permit has removed the Arsenic limit for the tiers under 6 MGD. The City implements an approved Industrial Pretreatment Program. 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? • ❑ ❑ ❑ (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? • El El El 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? • El El El Facility has copy of previous year's Annual Report on file for review? El El El • Page# 3 Permit: NC0020737 Inspection Date: 03/22/2022 Owner - Facility: Pilot Creek WWTP Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: The records reviewed during the inspection were organized and well maintained. DMRs, COCs, ORC visitation loq, Bench sheets, and calibration logs were reviewed for the period October 2021 through December 2021. Chlorine curve was late to be renewed for the year of 2021 and the new chlorine curve did not pass the low chlorine limit (10 uq/L) the higher level passed 50 uq/L, is too high since the permit limit is 28 ug/L. 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 are performed under the City's certified laboratory #222. Pace Labs (metals, priority pollutants, total phosphorus, total nitrogen, oil & grease, Thallium), and ETT, Inc.(toxicity) have also been contracted to provide analytical support 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The subject permit requires influent composite BOD and TSS samples. The facility staff perform and document monthly aliquot verifications. Influent pH levels are continuously monitored by an in -line monitoring system. Effluent Sampling 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)? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 4 Permit: NC0020737 Inspection Date: 03/22/2022 Owner - Facility: Pilot Creek WWTP Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type • ❑ El El representative)? Comment: The subject permit requires composite and grab effluent samples. The facility staff perform and document monthly aliquot verifications. Samples taken are time proportional. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, ■ El El El and sampling location)? Comment: Operations & Maintenance 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The facility staff incorporate a comprehensive process control program with all measurements being properly documented and maintained on -site. Overall the waste treatment unit is continually improving. The facility has purchased a SCADA system and is in the process of improving it, the facility has a done good job reducing the dead spot areas in the aeration basins, and in addition greatly improved the condition of the clarifiers. However, the following items need to be adressed: 1. At the time of the inspection it was observed that the clarifier #3 weir was uneven. 2. Chlorine curve was late to be renewed for the year of 2021 and the new chlorine curve did not pass the low chlorine limit (10 ug/L) the higher level passed 50 ug/L, is above the permit limit 28 ug/L 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? ■ ❑ ❑ ❑ Are float controls operable? • ❑ ❑ ❑ Is SCADA telemetry available and operational? • ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ El • El Comment: Both screw pumps were operational and in service. Bar Screens Type of bar screen Yes No NA NE Page# 5 Permit: NC0020737 Inspection Date: 03/22/2022 Owner - Facility: Pilot Creek WWTP Inspection Type: Compliance Evaluation Bar Screens Yes No NA NE a.Manual El b.Mechanical • Are the bars adequately screening debris? • El El El Is the screen free of excessive debris? • El El El Is disposal of screening in compliance? • El El El Is the unit in good condition? • El El El Comment: Screenings are disposed at the Cleveland County Landfill. Flow Measurement - Influent # 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: The influent flow meter is calibrated annually. Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Chemical Feed Yes No NA NE Is containment adequate? • ❑ ❑ ❑ Is storage adequate? • ❑ ❑ ❑ Are backup pumps available? • El ❑ ❑ Is the site free of excessive leaking? • ❑ ❑ ❑ Comment: 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 6 Permit: NC0020737 Inspection Date: 03/22/2022 Owner - Facility: Pilot Creek WWTP Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Comment: 3 (1,3,4) clarifiers were in service. At the time of the inspection it was observed that the clarifier #3 weir was uneven. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Disinfection -Gas Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de -chlorination? Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)? If yes, then is there a Risk Management Plan on site? If yes, then what is the EPA twelve digit ID Number? (1000- - ) If yes, then when was the RMP last updated? Comment: Yes No NA NE • ❑ ❑ ❑ ❑ ❑ • ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ De -chlorination Yes No NA NE Type of system ? Gas Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ ❑ • Is storage appropriate for cylinders? • ❑ ❑ ❑ # 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? ❑ ❑ • ❑ Page# 7 Permit: NC0020737 Inspection Date: 03/22/2022 Owner - Facility: Pilot Creek WWTP Inspection Type: Compliance Evaluation De -chlorination Yes No NA NE Comment: 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 meters (end of each chlorine contact chamber) are calibrated annually 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? Comment: Did not examine the outfall Aerobic Digester 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: Solids Handling Equipment 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: Belt press appeared to be running properly at the time of the inspection Yes No NA NE ❑ ❑ ❑ • • ❑ ❑ • Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ▪ ❑ ❑ ❑ • ❑ ❑ ❑ Page# 8 Permit: NC0020737 Inspection Date: 03/22/2022 Owner - Facility: Pilot Creek WWTP Inspection Type: Compliance Evaluation 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 two backup generators. The smaller generator powers the blowers for aeration basin #3 and the larger generator powers the rest of the plant. Page# 9