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Home My WebLink AboutNC0020184_Compliance Evaluation Inspection_20220901ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS. JR. D recror NORTH CAROLINA Environmental Quality September 1, 2022 Ms. Stephanie Scheringer, Division Manager Two Rivers Utilities P.O. Box 1748 Gastonia, NC 28053 Subject: Compliance Evaluation Inspection Long Creek WWTP NPDES Permit No. NC0020184 Gaston County Dear Ms. Scheringer: Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on August 30, 2022, by Ori Tuvia. The assistance and cooperation of David Shellenbarger and Maurice Brothers during the site visit was much appreciated. Please advise the staff involved with this NPDES Permit by forwarding a copy of the enclosed report. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Ori Tuvia at (704) 235-2190, or at ori.tuvia@ncdenr.gov. Sincerely, DocuSigned by: 44 44cw H P;.xa.e4 F161FB69A2D84A3... Andrew H. Pitner P.G., Assistant Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Cc: NPDES, MRO Files (Laserfiche) NC DWR — Water Quality Regional Operations Section 610 East Center Avenue, Suite 301, Mooresville, NC 28115 Mooresville Regional Office Phone: (704) 663-1699 FAX: (704)-633-6040 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 21IIIIII NPDES yr/mo/day Inspection L 3 I NC0020184 111 121 22/09/01 117 Type 18110 IIIIIIIIIII Inspector Fac Type 19 I S I 201 IIIIIIIIIIIIIIIIII I IIIIII P6 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 permit Number) Long Creek WWTP 3000 Old Spencer Mountain Rd Dallas NC 28034 Entry Time/Date 12:OOPM 22/09/01 Permit Effective Date 22/02/01 Exit Time/Date 02:30PM 22/09/01 Permit Expiration Date 27/01/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Mourice Kenith Brothers//704-214-9121 / Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Douglas E Barker,PO Box 1748 Gastonia NC 280531748/Senior Plant Operator/704-866-6991/7049220619 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 Ori A Tuvia Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date 1—DocuSigned by: _-�� DWR/Division of Water Quality/704-663-1699/ 9/1/2022 \- BB 057A2DE017'198... Signature of Ma Andrew Pit 041MReviewer Agency/Office/Phone and Fax Numbers Date rA4'44. 4 H P44.st WR/MRO WQ/704-663-1699 Ext.2180/ 9/1/2022 F161 FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 NPDES yr/mo/day 31 NC0020184 111 121 22/09/01 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long 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 El El El application? Is the facility as described in the permit? • El El El # Are there any special conditions for the permit? El • El El Is access to the plant site restricted to the general public? • ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? • El El El Comment: The subject permit expires on January 31, 2027 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ▪ El El El Comment: Records were reviewed for the period of March 2022 - June 2022, Lab results, Chain of Custody, ORC Log, and Field parameter results taken including the calibration data were complete and well organized. Page# 3 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long Creek WWTP Inspection Type: Compliance Evaluation 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: Permit requires both influent composite samples and grab sampling. 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 • ❑ ❑ ❑ representative)? Comment: Permit requires both effluent composite samples (flow proportional) and grab sampling. Aliquot verification taken during the inspection pulled 200 ml Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, MODE and sampling location)? Comment: 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? Comment: Lab instrument appeared to be well maintained and calibrated Yes No NA NE • ❑ ❑ ❑ Page# 4 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long Creek 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: The facility appeared to be properly operated and well maintained. The operations staff incorporate a comprehensive process control program with all documentation being properly documented and maintained on -site. The facility is equipped with a SCADA system to assist the operations staff with the monitoring of treatment processes and units. 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: Screenings and grit are disposed at the county landfill Grit Removal Yes No NA NE Type of grit removal a.Manual ❑ b.Mechanical • Is the grit free of excessive organic matter? • El El El Is the grit free of excessive odor? • El El El # Is disposal of grit in compliance? • ❑ ❑ ❑ Comment: Screenings and grit are disposed at the 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: Yes No NA NE Page# 5 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long Creek WWTP Inspection Type: Compliance Evaluation 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? • El El El Comment: 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'/4 of the sidewall depth) • ❑ ❑ ❑ Comment: Two of three primaries were in service (all operational). At the time of the inspection the weires were uneven Nutrient Removal Yes No NA NE # Is total nitrogen removal required? • ❑ ❑ ❑ # Is total phosphorous removal required? • ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? • ❑ El El Is nutrient removal process operating properly? • El El El Comment: The facility, combined with Eagle Road WWTP, are required to comply with a summer (April 1 - October 31) effluent total nitrogen loading limit as well as winter (November 1 — March 31) effluent total nitrogen loading limit. The combined facilities also have a year around effluent total phosphorus loading limit. Nutrient removal is performed biologically and chemically (alum) Page# 6 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long Creek WWTP Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused 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) • ❑ ❑ ❑ Comment: 3 of the 4 aeration tracks were in operation during the inspection (4th was out for maintenance) Chemical Feed Yes No NA NE Is containment adequate? • ❑ ❑ ❑ Is storage adequate? ■ ❑ ❑ ❑ Are backup pumps available? • ❑ ❑ ❑ 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? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: 3 of the 4 aeration tracks were in operation during the inspection (4th was out for maintenance) Page# 7 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long Creek WWTP Inspection Type: Compliance Evaluation Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Down flow Is the filter media present? • ❑ El El 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: 5 of 8 tertiary filters were in service 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: De -chlorination Type of system ? 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? Are the tablets the proper size and type? Comment: One ton cylinders are stored outside together under cover Are tablet de -chlorinators operational? Number of tubes in use? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • 1000-0006-7367 Yes No NA NE Gas • ❑ ❑ ❑ ▪ ❑ ❑ ❑ ❑ ❑ • ❑ Page# 8 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long Creek WWTP Inspection Type: Compliance Evaluation De -chlorination Yes No NA NE Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? 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? Comment: The influent and effluent flow meters are calibrated/verified twice per year 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE ❑ • ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ Comment: Right of way was not maintained. Effluent appeared clear with no floatable solids or foam Lagoons Yes No NA NE Type of lagoons? # Number of lagoons in operation at time of visit? 2 Are lagoons operated in? Series # Is a re -circulation line present? ❑ ❑ • ❑ Is lagoon free of excessive floating materials? • ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? ❑ ❑ • ❑ Are dike slopes clear of woody vegetation? • ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? • ❑ ❑ ❑ Are dikes free of seepage? • ❑ ❑ ❑ Are dikes free of erosion? • ❑ ❑ ❑ Are dikes free of burrowing animals? ❑ ❑ • ❑ Page# 9 Permit: NC0020184 Inspection Date: 09/01/2022 Owner - Facility: Long Creek WWTP Inspection Type: Compliance Evaluation Lagoons Yes No NA NE # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ • ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? El El El Is the lagoon surface free of weeds? ■ ❑ ❑ ❑ Is the lagoon free of short circuiting? ❑ ❑ • ❑ Comment: Anaerobic Digester Type of operation: Is the capacity adequate? # Is gas stored on site? Is the digester(s) free of tilting covers? Is the gas burner operational? Is the digester heated? Is the temperature maintained constantly? Is tankage available for properly waste sludge? Yes No NA NE Fixed cover • ❑ ❑ ❑ Comment: Waste activated sludge (WAS ) is thickened in a DAF unit prior to being pumped to thediqesters. The facility is equipped with six anaerobic digesters (4-primary, 3 in operation and 2-secondary). Bio-solids are land applied by a contracted company (EMA) under the authority of Permit No. WQ0OO1793. 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 three standby generators that are placed under load at leat once per month (peak shaving/storm events) Page# 10