NC0025453_Compliance Evaluation Inspection_20221202

ROY COOPER
Governor
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
NORTH CAROLINA
Environmental Quality
December 2, 2022
Richard Cappola Jr., Interim Town Manager
Town of Clayton
PO Box 879
Clayton, NC 27520
Subject: Compliance Evaluation Inspection
Sam's Branch WRF
NPDES Permit: NC0025453
Johnston County
Dear Mr. Cappola:
Mitch Hayes of the Raleigh Regional Office conducted the subject inspection on November 22,
2022. The assistance of Bill Simpson WW-4 Operator in Responsible Charge (ORC) and
Michael Ratley, with this inspection was greatly appreciated. Please find attached to this letter
the Basinwide Information Management System (BIMS) check list summarizing the inspection.
Below is list of findings developed from the inspection and review of the permit:
1. The current permit became effective March 1, 2022 and will expire March 31, 2024.
2. The facility is currently permitted to discharge 2.5 MGD of treated wastewater to the
Neuse River. An amended agreement with the City of Raleigh to increase the amount of
wastewater to send to the Neuse River Resource Recovery Facility from 1.0 MGD to
1.75 MGD effective December 2021. The Town of Clayton also has an agreement with
Johnston County to send 1.4 MGD of wastewater to Central Johnston County WWTP.
3. The 2.5 MGD water reclamation facility consists of the following units: influent head
works with a biofilter odor control system; mechanical and automatic bar screens; a
vortex type grit removal system; influent pump station with three (3) 60-Hp dry pit
submersible pumps and one (1) 40-Hp pump; 9-inch Parshall flume with ultrasonic flow
meter; a 214,500 gallon anaerobic selector tank in front of the first stage anoxic tank; a
300,000 gallon first stage anoxic tank in front of oxidation basin # 2; two (2) — oxidation
basins; a 200,000 gallon first stage anoxic tank in front of oxidation basin # 1; three (3)
secondary clarifiers; Return Activated Sludge pump station; two (2) shallow bed
DAVCO traveling bridge type tertiary filters; UV disinfection, two banks, with back-up
chlorination / dechlorination; effluent pump station; one (1) 90,000 gallon aerated
digester/sludge stabilization tank; two (2) - 360,000 gallon aerated sludge holding tanks;
sludge loading station; a sludge thickening building containing two (2) rotary drum
thickeners with polymer flocculation; sludge transfer pump station; sludge drying beds;
North Carolina Department of Environmental Quality I Division of Water Resources
Raleigh Regional Office I 3800 Barrett Dnve 1 Raleigh, North Carolina 27609
919.791.4200

in -plant non -potable water system using reclaimed treated wastewater; a reclaimed water
pump station and transmission force main to the Pine Hollow Golf Course and two (2)
on -site generators and one portable generator to provide back-up power.
4. At the time of inspection, all units listed in the permit were observed and no negative
issues were found. The biofilter odor control system appeared to be operating normally.
The automatic and manual bar screens and vortex grit removal system were functioning
normally. The number 1 aerated sludge holding tank was approximately 80% full. The
number 2 aerated sludge holding tank was approximately 40% full. Sludge was being
off-loaded into a truck. Thickened sludge is taken to Beulaville, NC for land application.
Aerators in sludge holding tank number 1 and 2 were operational. Influent in the two
oxidation basins was medium brown in color with very little foam in oxidation ditch #1.
Foam covered about 20% of the surface area in ditch #2. Covers have been placed over
the anaerobic selector to prevent odor. The #1 secondary clarifier was not in service.
Effluent appeared clear flowing off the weirs in secondary clarifiers 2 and 3. Effluent in
the wet well at the tertiary filters appeared clear with no foam. The sludge drying beds
had little sludge in them.
5. Permit annual fee for the period July 1, 2022 to June 30, 2023 was due July 3, 2022. r�
Please remit the overdue amount of $3,440 as soon as possible. ►o4f e: papte.,has: 6r�� Receive-0
v57
6. The annual performance report was last issued August 2022 and is available on the
Town's website and at the Town Hall.
7. The Annual Pollutant Scan (APS) was last completed September 2021. The permit
requires the APS to be completed before the end of this year, 2022.
8. The laboratory was checked in a cursory manner. Sam's Branch WRF laboratory,
certification number 348, analyzes BOD, TSS, fecal coliform, Phosphorus, Nitrate, COD
and is field certified for TRC, pH, temperature, DO, specific conductance. Environment
1, certification number 10, Cameron Testing, certification number 654, and Meritech
Labs, certification number 027, analyses all other parameters.
9. Results for Toxicity testing for the period September 2021 to June 2022 showed
compliance with the permit.
10. Effluent and Influent flow meters were last calibrated by Chadwick Instrumentation on
May 12, 2022, and is calibrated annually.
11. Discharge Monitoring Reports (DMR' s) for the period September 2021 through
September 2022 were reviewed for compliance with permit limits and monitoring
requirements. A Notice of Violation for exceeding Quarterly Average for Total
Phosphorus for September 2022 DMR. This violation will be addressed under a separate
correspondence. There were no other monitoring or limit violations.
North Carolina Department of Environmental Quality I Division of Water Resources
512 North Salisbury Street 11611 Mall Service Center I Raleigh, North Carolina 27699-1611
919 707 9000

12. Commercial lab results, chain of custody records, and bench sheets were compared with
data submitted on the DMR for September 2022. Results for Toxicity testing percentage
was inadvertently listed as 0.2% instead of 2.0%. A revised DMR will be submitted.
I would like to thank Bill Simpson and Michael Ratley with this inspection. If there are any
questions about the inspection or this letter, please contact Mitch Hayes at 919.791.4261 or at
mitch.ha}es;a;ncdenr.gov
Laserfiche
EtEci5
a rnrra' ��..r+.+ro.rtr V
Sincerely,
Vanessa E. Manuel, Assistant Regional Supervisor
Water Quality Regional Operations Section
Raleigh Regional Office
NC DEQ
61111100"---
North Carolina Department of Environmental Quality I Division of Water Resources
512 North Salisbury Street 11611 Mail Service Center I Raleigh, North Carolina 27699-1611
919.707.9000

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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 NPDES yr/molday Inspection
1 iN i 2 U 3 I NC0025453 111 12 22/11/22 17
Type
18 I c I
II[HI
Inspector
19 I
Fac Type
s I 20l I
21111111111111111ill mill 1111111
III 11 l66
`
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA
671 I 70 �4 71 I I 72 [, l
L.J LJ
Reserved
73l I l74
L_L_J
71
1
1 1 1 I I 1 180
Section B: FacilityLData
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Sam's Branch WRF
1000 Durham St
Clayton NC 27520
Entry Time/Date
10:OOAM 22/11/22
Permit Effective Date
21/02/01
Exit Time/Date
11:30AM 22/11/22
Permit Expiration Date
24/03/31
Name(s) of Onsite Representative(stles(s)/Phone and Fax Number(s)
111
William R SimpsonlORCl919-553-1535!
William R Simpson/Superintendent WRF/919-553-1355 /9195538919
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Steven Biggs,PO Box 879 Clayton NC 275280879/Town
Manager/919-553-5866/9195531541 No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Records/Reports Self -Monitoring Progran
Sludge Handling Dispo: Facility Site Review Compliance Schedules 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) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Mitchell S Hayes DWRIRRO WQ1919-791-42001
IdalCal ) //cc
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers '� Dale
I/7/(iney04-(7 II-- *- ,,,r2-32_ er-e.--.4.-_vt 1 S 2.7.__
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page# 1

1
NPOES
NC0025453
yr/mo/day
22/11/22
117
Inspection Type
18 U
(Cont.)
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
The current permit became effective March 1, 2022 and will expire March 31, 2024.
The facility is currently permitted to discharge 2.5 MGD of treated wastewater to the Neuse River. An
amended agreement with the City of Raleigh to increase the amount of wastewater to send to the
Neuse River Resource Recovery Facility from 1.0 MGD to 1.75 MGD effective December 2021. The
Town of Clayton also has an agreement with Johnston County to send 1.4 MGD of wastewater to
Central Johnston County VWVTP.
The 2.5 MGD water reclamation facility consists of the following units: influent head works with a
biofilter odor control system; mechanical and automatic bar screens; a vortex type grit removal
system; influent pump station with three (3) 60-Hp dry pit submersible pumps and one (1) 40-Hp
pump; 9-inch Parshall flume with ultrasonic flow meter; a 214,500 gallon anaerobic selector tank in
front of the first stage anoxic tank; a 300,000 gallon first stage anoxic tank in front of oxidation basin
# 2; two (2) — oxidation basins; a 200,000 gallon first stage anoxic tank in front of oxidation basin # 1;
three (3) secondary clarifiers; Return Activated Sludge pump station; two (2) shallow bed DAVCO
traveling bridge type tertiary filters; UV disinfection, two banks, with back-up chlorination /
dechlorination; effluent pump station; one (1) 90,000 gallon aerated digester/sludge stabilization
tank; two (2) - 360,000 gallon aerated sludge holding tanks; sludge loading station; a sludge
thickening building containing two (2) rotary drum thickeners with polymer flocculation; sludge
transfer pump station; sludge drying beds; in -plant non -potable water system using reclaimed treated
wastewater; a reclaimed water pump station and transmission force main to the Pine Hollow Golf
Course and two (2) on -site generators and one portable generator to provide back-up power.
At the time of inspection, all units listed in the permit were observed and no negative issues were
found. The biofilter odor control system appeared to be operating normally. The automatic and
manual bar screens and vortex grit removal system were functioning normally. The number 1 aerated
sludge holding tank was approximately 80% full. The number 2 aerated sludge holding tank was
approximately 40% full. Sludge was being off-loaded into a truck. Thickened sludge is taken to
Beulaville, NC for land application. Aerators in sludge holding tank number 1 and 2 were operational.
Influent in the two oxidation basins was medium brown in color with very little foam in oxidation ditch
#1. Foam covered about 20% of the surface area in ditch #2. Covers have been placed over the
anaerobic selector to prevent odor. The #1 secondary clarifier was not in service. Effluent appeared
clear flowing off the weirs in secondary clarifiers 2 and 3. Effluent in the wet well at the tertiary filters
appeared clear with no foam. The sludge drying beds had little sludge in them.
Permit annual fee for the period July 1, 2022 to June 30, 2023 was due July 3, 2022. Please remit the
overdue amount of $3,440 as soon as possible.
The annual performance report was last issued August 2022 and is available on the Town's website
and at the Town Hall.
The Annual Pollutant Scan (APS) was last completed September 2021. The permit requires the APS
to be completed before the end of this year, 2022.
The laboratory was checked in a cursory manner. Sam's Branch WRF laboratory, certification
number 348, analyzes BOD, TSS, fecal coliform, Phosphorus, Nitrate, COD and is field certified for
TRC, pH, temperature, DO, specific conductance. Environment 1, certification number 10, Cameron
Testing, certification number 654, and Meritech Labs, certification number 027, analyses all other
parameters.
Results for Toxicity testing for the period September 2021 to June 2022 showed compliance with the
permit.
Page# 2

Permit: NC0025453 Owner - Facility: Sam's Branch WRF
Inspection Date: 11/22/2022 Inspection Type: Compliance Evaluation
Effluent and Influent flow meters were last calibrated by Chadwick Instrumentation on May 12, 2022,
and is calibrated annually.
Discharge Monitoring Reports (DMR's) for the period September 2021 through September 2022 were
reviewed for compliance with permit limits and monitoring requirements. A Notice of Violation for
exceeding Quarterly Average for Total Phosphorus for September 2022 DMR. This violation will be
addressed under a separate correspondence. There were no other monitoring or limit violations.
Commercial lab results, chain of custody records, and bench sheets were compared with data
submitted on the DMR for September 2022. Results for Toxicity testing percentage was inadvertently
listed as 0.2% instead of 2.0%. A revised DMR will be submitted.
Page# 3

Permit: NC0025453
Owner - Facility: Sam's Branch WRF
Inspection Date: 11/22/2022 Inspection Type: Compliance Evaluation
Compliance Schedules Yes No NA NE
Is there a compliance schedule for this facility? 0 • 0 0
Is the facility compliant with the permit and conditions for the review period? • ❑ 0 0
Comment: No compliance schedules.
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? M 0 0 ❑
# Are there any special conditions for the permit? 0 • 0 0
Is access to the plant site restricted to the general public? • ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? • ❑ ❑ ❑
Comment: No special conditons.
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? • ❑ ❑ 0
Are all records maintained for 3 years (lab. reg. required 5 years)? • 0 0 0
Are analytical results consistent with data reported on DMRs? • 0 ❑ 0
Is the chain -of -custody complete? • 0 0 ❑
Dates, times and location of sampling II
Name of individual performing the sampling •
Results of analysis and calibration li
Dates of analysis •
Name of person performing analyses •
Transported COCs •
Are DMRs complete: do they include all permit parameters? • ❑ ❑ 0
Has the facility submitted its annual compliance report to users and DWQ? • 0 0 0
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified 0 0 • ❑
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? • 0 0 ❑
Is the backup operator certified at one grade less or greater than the facility • ❑ 0 0
classification?
Is a copy of the current NPDES permit available on site? 110 ❑ ❑
Page# 4

Permit: NC0025453 Owner - Facility: Sam's Branch WRF
Inspection Date: 11/22/2022 Inspection Type: Compliance Evaluation
Record Keeping
Facility has copy of previous year's Annual Report on file for review?
Comment:
Yes No NA NE
• ❑ ❑ ❑
Flow Measurement - Influent Yes No NA NE
# Is flow meter used for reporting? ❑ ■ ❑ ❑
Is flow meter calibrated annually? • 0 0 0
Is the flow meter operational? •❑ ❑ ❑
(If units are separated) Does the chart recorder match the flow meter? • 0 0 0
Comment: Effluent flow used for reporting.
Flow Measurement - Effluent Yes No NA NE
# Is flow meter used for reporting? E 0 0 0
Is flow meter calibrated annually? •❑ ❑ ❑
Is the flow meter operational? ■ ❑ ❑ ❑
(If units are separated) Does the chart recorder match the flow meter? • 0 0 0
Comment: All meters calibrated by Chadwick Mav 12, 2022.
Aerobic Digester Yes No NA NE
Is the capacity adequate? • 0 0 0
Is the mixing adequate? ■ ❑ ❑ ❑
Is the site free of excessive foaming in the tank? • 0 0 0
# Is the odor acceptable? • 0 0 ❑
# Is tankage available for properly waste sludge? • 0 0 0
Comment: Aerobic sludge tank. Was being off-loaded into a truck at the time of inspection.
Drying Beds Yes No NA NE
Is there adequate drying bed space? • 0 0 0
Is the sludge distribution on drying beds appropriate? • 0 0 0
Are the drying beds free of vegetation? • 0 0 0
# Is the site free of dry sludge remaining in beds? ❑ • ❑ ❑
Is the site free of stockpiled sludge? • 0 0 0
Is the filtrate from sludge drying beds returned to the front of the plant? • ❑ ❑ ❑
# Is the sludge disposed of through county landfill? • 0 0 ❑
Page# 5

Permit: NC0025453
Owner - Facility: Sams Branch WRF
Inspection Date: 11/22/2022 Inspection Type: Compliance Evaluation
Drying Beds
# Is the sludge land applied?
(Vacuum filters) Is polymer mixing adequate?
Comment' 3 sludge drvina beds in use. Little to no sludge in drvina bed.
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:
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:
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)?
Is the facility sampling performed as required by the permit (frequency, sampling type
representative)?
Yes No NA NE
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Yes No NA NE
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Yes No NA NE
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Page# 6