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Home My WebLink AboutNC0024538_Compliance Evaluation Inspection_20220915ROY COOPER Governor ELIZABETH 5. BISER 5ecrefvey RICHARD E. ROGERS, JR. airrrror Mr. David Hux Utilities Director - Operations Town of Shelby P.O. Box 207 Shelby, NC 28151 Dear Mr. Hux: NORTH CAROL! NA Envi'ronit ertint Qualify September 15, 2022 Subject: Compliance Inspection City of Shelby/First Broad River WWTP NPDES Permit No. NC0024538 Cleveland County Enclosed is a copy of the Compliance Inspection for the inspection conducted at the subject facility on September 14, 2022, by Ori Tuvia and Maria Schutte. Steven Smith's cooperation 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: A.44tw N P4444 �F 161 FB69A2D84A3... Andrew H. Pitner P.G., Assistant Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Cc: MRO Files (Laserfiche) State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations Mooresville Regional Office 1610 East Center Avenue, Suite 301 I Mooresville, North Carolina 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 1 IN Code I 2 IL NPDES yr/mo/day Inspection Type Inspector Fac I 3 I NC0024538 111 121 22/09/14 117 1810I 191 S I 2011 Type 21 1 1 1 1 1 1 1 1 1 11 1 1 1 I I I 1 1 1 1 1 1 I I I I I I I 1 1 1 1 11 1 1 1 I 1 P6 Inspection 67I1.0 Work Days Facility Self -Monitoring I 70I4 Evaluation Rating I 71IN B1 I 72 QA I N I 73I 1 I I Reserved 74 751 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) First Broad River WWTP 1940 S Lafayette St Shelby NC 28152 Entry Time/Date 10:05AM 22/09/14 Permit Effective Date 20/03/01 Exit Time/Date 12:45PM 22/09/14 Permit Expiration Date 24/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Steven C Smith/ORC// Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Bradford Carl Greene,PO Box 207 Shelby NC 281510207//704-484-6850/ 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) Maria Schutte Ori A Tuvia of Inspector(s) ,—DocuSigned _ _— `— BB057A2DE017498... Agency/Office/Phone and Fax Numbers Date by: DWR/Division of Water Quality/704-663-1699/ 9/15/2022 DWR/Division of Water Quality/704-663-1699/ Signature of Man Andrew Pitne l ocNtAelklaviewer Agency/Office/Phone and Fax Numbers Date As"' H P OUR/MRO WQ/704-663-1699 Ext.2180/ 9/15/2022 F161 FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 NPDES yr/mo/day 31 NC0024538 111 121 22/09/14 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0024538 Inspection Date: 09/14/2022 Owner - Facility: First Broad 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? • ❑ ❑ ❑ # 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 subject permit expires on 8/31/2024. Facility has completed the process of constructing a new digester and storage building to replace the compost building. The pressed sludge is land applied, as a class B product under permit WQ0042031 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? • ❑ ❑ ❑ 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? ❑ ❑ ❑ • Comment: The permittee's records were organized and well maintained. DMRs, COCs, ORC visitation logs and calibration logs were reviewed for May 2022 - August 2022. Page# 3 Permit: NC0024538 Inspection Date: 09/14/2022 Owner - Facility: First Broad River WWTP Inspection Type: Compliance Evaluation 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: 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Effluent Sampling Yes No NA NE Is composite sampling flow proportional? • ❑ ❑ ❑ Is sample collected below all treatment units? • El El El Is proper volume collected? • El El El Is the tubing clean? • ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 ■ El El El degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type • El El El representative)? Comment: The subject permit requires composite and grab effluent samples. Aliquot verification taken at the time of the inspection pulled 125 ml. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, MEI ❑ ❑ and sampling location)? Comment: Page# 4 Permit: NC0024538 Inspection Date: 09/14/2022 Owner - Facility: First Broad River 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 ORC and staffincorporate a comprehensive process control program with all measurements beingproperly documented and maintained on -site. A SCADA system is used to assist the wastewater staff in the operation of the treatment units/processes including alarm conditions. Flow Measurement - Influent 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: The flow meter is calibrated annually and was last calibrated on 9/12/2022 by Clearwater Inc. 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? Yes No NA NE • • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Two new mechanical bar screens (12 MGD and 15 MGD) with back up Manual Screen Grit Removal 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? Yes No NA NE • • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: New Pista Grit removal unit. Screenings and grit are disposed at an approved landfill. Page# 5 Permit: NC0024538 Inspection Date: 09/14/2022 Owner - Facility: First Broad River 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? ❑ ❑ El • 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 • Comment: 4 pumps, and an influent genrator. Primary 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 sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Both primaries were operational; however, only one was used in the time of the inspection 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? El ❑ • ❑ Are the diffusers operational? • El El El Is the foam the proper color for the treatment process? • El ❑ ❑ Does the foam cover less than 25% of the basin's surface? • El El El Is the DO level acceptable? • El ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/I) • El El El Page# 6 Permit: NC0024538 Inspection Date: 09/14/2022 Owner - Facility: First Broad River WWTP Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Comment: Three aeration trains with two in operation. 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) Comment: All four secondaries were operational; however, only two were in service. 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- Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • Yes No NA NE • ❑ ❑ ❑ ▪ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ • Page# 7 Permit: NC0024538 Inspection Date: 09/14/2022 Owner - Facility: First Broad River WWTP Inspection Type: Compliance Evaluation Disinfection -Gas If yes, then when was the RMP last updated? Comment: 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)? • ❑ El El Is storage appropriate for cylinders? • El El El # Is de -chlorination substance stored away from chlorine containers? • ❑ ❑ ❑ Comment: Are the tablets the proper size and type? ❑ El • El Are tablet de -chlorinators operational? El El • ❑ Number of tubes in use? Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? • El El El Is flow meter calibrated annually? • ❑ ❑ ❑ Is the flow meter operational? • El El El (If units are separated) Does the chart recorder match the flow meter? El El El • Comment: The flow meter is calibrated annually and was last calibrated on 9/12/2022 by Clearwater Inc. 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: At the time of the inspection the effluent seemed to be clear Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ Anaerobic Digester Yes No NA NE Type of operation: Fixed cover Is the capacity adequate? • El El El # Is gas stored on site? • El El El Is the digester(s) free of tilting covers? • ❑ ❑ ❑ Page# 8 Permit: NC0024538 Inspection Date: 09/14/2022 Owner - Facility: First Broad River WWTP Inspection Type: Compliance Evaluation Anaerobic Digester Yes No NA NE Is the gas burner operational? • ❑ ❑ ❑ Is the digester heated? • ❑ ❑ ❑ Is the temperature maintained constantly? • ❑ ❑ ❑ Is tankage available for properly waste sludge? • ❑ ❑ ❑ Comment: Two anerobic digesters and 1 holding tank. Scrub methane is used to hit the boilers, excess methane is flared. 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? ❑ ❑ El • The facility has an approved sludge management plan? ■ ❑ ❑ ❑ Comment: Two belt presses , pressed sludge is land applied under permit WQ0042031. 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: Both backup generators are tested under load annually (minimum) and serviced by a contract company (CAT ) quarterly. The facility also participates in a peak shaving program. Page# 9