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Home My WebLink AboutNC0041696_CEI_20220712 SENT VIA ELECTRONIC MAIL ONLY: NO HARD COPY WILL BE MAILED. July 12, 2022 Greg A Padgett Town of Valdese Email: GPadgett@valdesenc.gov SUBJECT: Compliance Inspection Report Lake Rhodhiss WWTP NPDES WW Permit No. NC0041696 Burke County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Lake Rhodhiss WWTP on 6/13/2022. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0041696. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the inspection and therefore, a response to this inspection report is not required. If you should have any questions, please do not hesitate to contact me at 828-296-4500 or via email at stephanie.williams@ncdenr.gov. Sincerely, Stephanie Williams, Environmental Specialist Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS: Inspection Report Ec: Laserfiche, Christopher Bortnick (ORC, CBortnick@valdesenc.gov) DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 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 NC0041696 22/06/13 C 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) Lake Rhodhiss WWTP 2100 Lake Rhodhiss Dr Valdese NC 28690 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 09:00AM 22/06/13 21/04/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Other Facility Data 11:15AM 22/06/13 26/02/28 Name, Address of Responsible Official/Title/Phone and Fax Number Greg A Padgett,PO Box 339 Valdese NC 286900339/Director/828-879-2131/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 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 A Williams DWR/ARO WQ/828-296-4500/ 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 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 7/12/2022 7/12/2022 NPDES yr/mo/day 22/06/13 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Stephanie Williams, with the Asheville Regional Office, conducted a Compliance Evaluation Inspection of the Valdese Wastewater Treatment Plant on June 29, 2022. This inspection was conducted to determine if the system is being operated and maintained in compliance with permit no. NC0041696. Christopher Bortnick (ORC) was present during the inspection. No deficiencies were noted during the inspection. The WWTP is currently being operated under tier one of the three-tiered permit. Tier one allows for a maximum monthly average flow of 3.5 MGD. Mr. Bortnick stated that average flow is approximately 1.5-1.8 MGD. Most of the flow is comprised of industrial wastewater, which causes the influent to be various colors. Mr. Bortnick stated that this is due to the textile industries. Valdese currently has 7 industrial users permitted to discharge into the collection system. The WWTP consists of screen and grit removal equipment, an influent pump station, two primary clarifiers, two aeration basins, two secondary clarifiers, two chlorine contact basins, a de-chlorination structure, two gravity sludge thickeners, two centrifuges, a dewatering structure, and a residuals composting operation. The plant is operated by a SCADA system. Treated water discharges into the Lake Rhodhiss (Catawba River), classified as WS-IV, B, and CA waters. Aeration Basin: Settleability was 93% at the time of the inspection. This is out of range for what we would typically consider to be normal, however, the clarifiers appear to be adequately settling solids. Secondary Clarifier: The splitter box which splits flow between the two secondary clarifiers is accumulating solids. Mr. Bortnick stated that staff monitor this accumulation of solids and clean as needed. Solids Handling: The design of this plant is such that return activated sludge is not returned directly to the aeration basin but is first delivered to a holding basin. The holding basin delivers sludge to the aeration basin at the same pace that the holding basin fills. Similarly, sludge is wasted to an adjacent holding tank prior to being pumped to the sludge thickeners. Effluent Pipe: The pipe discharges below the surface of the lake and is not visible. NC0041696 17 (Cont.) Page#2 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 Permit:NC0041696 Inspection Date:06/13/2022 Owner - Facility: Inspection Type: Lake Rhodhiss WWTP 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? # 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? The permit became effective on 4/1/2021 and expires on 2/28/2026.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? Process control parameters include sludge judge, settleability, MLSS, MLVSS, pH, and alkalinity. 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? Tubing on the samplers, particularly the influent sampler, easily become stained due to dye from industrial influent. It is recommended that the tubing be kept clean. Comment: 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? Is the unit in good condition? Comment: Page#3 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 Permit:NC0041696 Inspection Date:06/13/2022 Owner - Facility: Inspection Type: Lake Rhodhiss WWTP Compliance Evaluation Bar Screens Yes No NA NE 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? The new grit removal system was built and put into operation in 2018.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? The influent pump station consists of 4 pumps. Pumps 1 and 2 are smaller and are used for normal operation. Pumps 3 and 4 are larger and are only used during high flow events. All pumps are exercised monthly. Comment: Equalization Basins Yes No NA NE 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? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? The floats in the equalization basin are manually tested every Sunday.Comment: Primary Clarifier Yes No NA NE Page#4 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 Permit:NC0041696 Inspection Date:06/13/2022 Owner - Facility: Inspection Type: Lake Rhodhiss WWTP Compliance Evaluation Primary 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 sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately ¼ of the sidewall depth) Just prior to the inspection, the sludge blanket was measured at 5 feet in clarifier 1 and 3 feet in clarifier 2. Both clarifiers are 13 feet deep. 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/l) Aeration basin 1 has not been used in many years and is not needed with the current flow rate. Settleability in basin 2 was measured at 93%. 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? Page#5 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 Permit:NC0041696 Inspection Date:06/13/2022 Owner - Facility: Inspection Type: Lake Rhodhiss WWTP Compliance Evaluation Secondary Clarifier Yes No NA NE 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) Both secondary clarifiers are 14 feet deep and at the time of the inspection the sludge blanket in both was 7 feet. Comment: Disinfection-Gas Yes No NA NE 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 lbs 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: 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? Comment: Solids Handling Equipment Yes No NA NE Is the equipment operational? Page#6 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 Permit:NC0041696 Inspection Date:06/13/2022 Owner - Facility: Inspection Type: Lake Rhodhiss WWTP 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: 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? Flow meters are calibrated every 6 months. The meter was last calibrated in May 2022 and is due in November 2022. 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)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? 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? The effluent pipe discharges below the surface of the lake and is not visible. See summary for details. Comment: Page#7 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8 Permit:NC0041696 Inspection Date:06/13/2022 Owner - Facility: Inspection Type: Lake Rhodhiss WWTP Compliance Evaluation 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? The generator is tested under load monthly.Comment: Page#8 DocuSign Envelope ID: F91C537C-B4A3-4C30-A4DD-664A6DFCF5C8